Differential-Rotation Stirring Tool for Solid-State Alloy Coating
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Solution Overview
Problem
Existing solid state additive manufacturing technologies face challenges in achieving high temperature alloy manufacturing due to excessive downward pressure requirements, difficulty in temperature control, limited parameter ranges, and inefficient consumable rod length, leading to poor performance and accuracy of coating layers.
Innovation Solution
A method involving differential rotation speeds between the consumable rod and the hollow stirring tool, combined with heating and cooling mechanisms, to generate a plastic deformation flow without excessive pressure, optimizing temperature control, and enhancing the efficiency and mechanical performance of coating layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If large downward pressure is applied to the consumable rod to generate violent friction and heat, then heat generation and plastic deformation are achieved, but the downward pressure becomes excessively large making it difficult to manufacture high temperature alloys
Solution Approach 1:
The patent replaces the conventional mechanical friction-based heating system with a laser heating system. The laser beam directly heats the consumable rod and base material to achieve plastic deformation and coating formation without requiring violent mechanical friction. This substitution of mechanical energy with optical energy resolves the contradiction by eliminating the need for excessive downward pressure while maintaining effective heat generation for material deformation.
2Ease of operation
If the rotation speed of the consumable rod is kept consistent with the hollow stirring tool, then the process is simple to control, but the parameter range is limited and not optimal for the stirring process
Solution Approach 1:
The patent implements independent, dynamic control of rotation speeds for the consumable rod and hollow stirring tool. The consumable rod can rotate at a first rotation speed while the hollow stirring tool rotates at a second rotation speed, allowing both parameters to be independently optimized for different material properties and process requirements. This dynamic parameter control expands the adaptable parameter range while maintaining operational simplicity through automated control systems.
3Ease of operation
If the consumable rod length is kept short for easy handling, then the rod can be easily manipulated, but it must be changed frequently reducing working efficiency
Solution Approach 1:
The patent extracts the consumable rod from the hollow stirring tool during the additive manufacturing process. This allows the consumable rod to be fed continuously or in longer segments without requiring frequent tool changes. The extraction mechanism enables longer consumable rods to be used, reducing the frequency of changes and improving working efficiency while maintaining ease of operation through automated feeding and replacement systems.
4Manufacturing precision
If downward pressure is increased to achieve violent friction, then coating formation is enabled, but the length of the consumable rod is limited
Solution Approach 1:
The patent replaces mechanical pressure-based coating formation with laser-heated plastic deformation. The laser beam provides localized heating that enables material flow and coating formation without requiring excessive downward pressure. This allows longer consumable rods to be used since the coating quality is determined by thermal and rotational parameters rather than mechanical pressure, thus extending the usable rod length while maintaining manufacturing precision.
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
Reduces the need for large downward pressure, improves the mechanical performance of high temperature alloys, and enhances the efficiency and accuracy of coating layer formation by optimizing rotation speeds and temperature control.
Implementation Method 1
the consumable rod rubs against an inner wall of the hollow stirring tool to generate thermal deformation so as to obtain a plastic deformation flow
Implementation Method 2
heating the hollow stirring tool and/or the consumable rod in the hollow stirring tool to enable the consumable rod to generate the plastic deformation flow
Implementation Method 3
cooling a bottom surface of the hollow stirring tool to adjust the temperature of the plastic deformation flow
Data Source
AI summary
A solid state additive method includes: disposing a round consumable rod in a hollow stirring tool; based on a coating layer height, setting a gap between a bottom surface of the hollow stirring tool and a base surface; driving the hollow stirring tool to rotate at a first rotation speed; driving the consumable rod to rotate at a second rotation speed, where the second rotation speed and the first rotation speed are different in angular speed to form a differential, such that the consumable rod rubs against an inner wall of the hollow stirring tool to generate thermal deformation so as to obtain a plastic deformation flow in the hollow stirring tool; pressing the consumable rod downward to enable the plastic deformation flow to be in friction contact with the base surface; translating the hollow stirring tool and stirring the base surface.