DED Component Repair With Local Forging for Crack-Resistant Microstructure
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Solution Overview
Problem
Current additive manufacturing (AM) technologies struggle to modify components made from materials with high melting points or those that are difficult to weld, such as Waspaloy®, Alloy 59, Alloy 625, Alloy 718, Alloy 939, and Alloy 247, due to issues like cracking, high temperatures, and changes in material properties during welding, which result in differing crystalline structures and compromised performance.
Innovation Solution
A method using Directed Energy Deposition (DED) with local forging techniques and controlled strain and temperature to create a fully recrystallized microstructure that matches the original component's properties, employing a bead region fusion process to ensure the modified area has the same crystalline structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional welding or additive manufacturing is used on high melting point materials, then material deposition and fusion are achieved, but cracking and changes in material properties occur due to high temperatures and differing crystalline structures
Solution Approach 1:
The patent applies parameter changes by precisely controlling temperature, strain rate, and deposition parameters during the DED process. The system modifies process parameters to maintain the deposited material in the beta phase field, then uses controlled cooling to achieve transformation to alpha phase, thereby preventing cracking and maintaining material reliability while enabling manufacturing of high melting point alloys
Solution Approach 2:
The patent implements local quality by applying localized deformation and heat treatment only to the deposited bead region. The system uses localized forging or rolling during deposition, and applies heat treatment specifically to the weld zone, preserving the original component properties while modifying only the necessary areas to achieve desired crystalline structure and prevent cracking
2Strength
If high temperatures are applied to fuse materials, then material bonding is achieved, but the crystalline structure changes and material properties are compromised
Solution Approach 1:
The patent exploits phase transitions by controlling the thermal cycle to maintain material in the beta phase during deposition, then using controlled cooling to transform to alpha phase. This phase transition control ensures proper crystalline structure formation, maintaining both material bonding strength and compositional stability in the deposited region
Solution Approach 2:
The patent applies preliminary action by pre-heating the substrate and controlling the thermal gradient before material deposition. The system also applies preliminary deformation or forging during the deposition process, preparing the material structure in advance to achieve desired crystalline configuration and prevent unwanted phase transformations that would compromise material properties
3Adaptability or versatility
If Directed Energy Deposition is used to deposit material, then component modification is enabled, but the deposited material has different crystalline structure from the original component
Solution Approach 1:
The patent uses an intermediary approach by introducing controlled deformation or forging as a mediating process between deposition and final structure formation. This intermediate step facilitates grain refinement and crystalline structure alignment, enabling the deposited material to achieve the same crystalline structure as the original component while maintaining modification versatility
Solution Approach 2:
The patent applies parameter changes by controlling cooling rate, deformation parameters, and heat treatment conditions to transform the deposited material's crystalline structure. By adjusting these parameters, the system ensures the deposited region achieves uniform crystalline structure matching the base material, maintaining compositional stability while enabling versatile component modification
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method ensures the modified component maintains the same crystalline structure and material properties as the original, reducing the risk of cracking and improving mechanical performance by aligning grain size with the component's requirements.
Implementation Method 1
Directed Energy Deposition (DED) to deposit the material alongside the heat input simultaneously. DED allows for the modification of 3D objects by melting the material in powder or as a wire with a focused energy source as it is deposited by the nozzle of the AM device.
Implementation Method 2
melting the material in powder or as a wire with a focused energy source as it is deposited by the nozzle
Implementation Method 3
A method using Directed Energy Deposition (DED) with local forging techniques and controlled strain and temperature to create a fully recrystallized microstructure
Implementation Method 4
create a fully recrystallized microstructure that matches the original component's properties
Implementation Method 5
To modify components, a precise area of the component is heated and fused together, with or without a filler material
Data Source
AI summary
Systems, apparatus, articles of manufacture, and methods are disclosed to build and/or modify components. An additive manufacturing apparatus comprising: at least one memory; machine-readable instructions; and processor circuitry to execute machine-readable instructions to: deposit a first layer of material, the first layer of material at a first temperature; compress the first layer of material to form a first compressed layer; deposit a second layer of material, the second layer of material at a second temperature, the first compressed layer to include a first crystalline structure; compress the second layer of material into the first layer of material to form a second compressed layer; deposit a third layer of material, the third layer of material at a third temperature, the second compressed layer to include the first crystalline structure; and compress the third layer of material into the second compressed layer to form a third compressed layer.