Deposition Head Geometry for Consistent Friction Stir Weld Profiles

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Solution Overview

Problem

Existing friction stir additive manufacturing tools produce inconsistent and rough welds, leading to structural deformities and material degradation, and traditional riveting methods introduce additional structural issues.

Innovation Solution

A friction stir additive manufacturing device with a deposition head that includes semi-cylindrical portions with controlled weld profiles, allowing for high-quality welds and the formation of integrated stiffeners and in-situ rivets, minimizing material waste and post-processing needs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional friction stir additive manufacturing tools are used, then the joining process can be completed, but the weld profiles are inconstant, rough, and uncontrolled

Engineering Contradiction:

Improveweld profile consistencyVSAvoidweld quality control

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The deposition head is pre-configured with semi-cylindrical portions having specific radii (inner radius and outer radius) that define the desired weld profile geometry before the joining process begins. This preliminary geometric configuration ensures consistent weld profiles are formed as the tool advances, eliminating the rough and uncontrolled welds produced by traditional tools.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention introduces specific geometric parameters (inner radius and outer radius of the semi-cylindrical portions) that control the weld profile formation. By carefully selecting and maintaining these radius parameters, the weld profile consistency is improved while keeping the manufacturing process feasible.

Inventive Principle:

Principle #35Parameter changes

2Strength

If traditional riveting methods are used to join parts, then structural connection can be achieved, but structural deformities are created in parts

Engineering Contradiction:

Improveconnection strengthVSAvoidstructural deformities

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The invention merges the joining function with the stiffening function into a single integrated process. The deposition head simultaneously forms the weld connection and creates integrated stiffeners that strengthen the structure without causing deformities. This combines multiple functions (joining and stiffening) that would otherwise require separate operations like riveting.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The filler material itself serves dual purposes: it creates the weld connection between parts and simultaneously forms the integrated stiffeners. The material performs the service of both joining and structurally reinforcing the assembly, eliminating the need for separate riveting operations that cause deformities.

Inventive Principle:

Principle #25Self-service

3Productivity

If integrated stiffeners and rivets are formed concurrently, then manufacturing efficiency is improved, but device complexity increases

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoiddeposition head structure

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The deposition head is designed with semi-cylindrical portions that perform multiple functions simultaneously: guiding filler material deposition, defining weld profile geometry, and forming integrated stiffeners. This multi-functionality improves productivity by combining joining and stiffening operations while the modular semi-cylindrical design keeps the complexity manageable.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 device achieves consistent, high-quality welds with reduced defects, lowers manufacturing costs, and enhances structural integrity by forming integrated stiffeners and rivets concurrently, improving material utilization and reducing lead times.

Implementation Method 1

friction stir additive manufacturing

Methodology Applied

Scientific EffectFriction: Friction

Implementation Method 2

Friction stir additive manufacturing tools are used to manufacture or join parts

Methodology Applied

Scientific EffectFriction heating: Viscous Heating

Implementation Method 3

The inner curved surface of the second semi-cylindrical portion is configured to define a weld profile

Methodology Applied

Scientific EffectPlastic deformation: Plasticity

Data Source

PatentUS20250242431A1Deposition head for friction stir additive manufacturing devices and methods

Publication Date: 2025.07.31 BLUE ORIGIN LLC

AI summary

A friction stir additive manufacturing device configured to join a first work-piece and a second work-piece is provided. In one aspect, the device includes a rotating spindle configured to deposit a filler material over a weld line as the device is advanced along an interface between the first work-piece and the second work-piece. The device also includes a deposition head configured to receive at least a portion of the spindle, the deposition head configured to remain stationary relative to the rotating spindle. The deposition head includes a first semi-cylindrical portion having an inner radius and an outer radius relative to a first axis, and a second semi-cylindrical portion having an inner radius and an outer radius relative to a second axis that is perpendicular to the first axis. The second semi-cylindrical portion can include a chamfered inner surface configured to define a weld profile.