Diffusion Bonded Foil Preform Structures
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional methods for forming objects are limited by the size and weight of ingots, leading to material wastage, contamination risks, and the inability to create complex shapes efficiently.
Innovation Solution
A method involving wrapping foil around a preform to create a multi-layered structure, followed by diffusion bonding to form the object, allowing for the direct formation of the final shape without discarding material and enabling the use of high-quality, expensive materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional ingot-based methods are used to form objects, then material availability is constrained by ingot size and weight, but this leads to material wastage and inability to create complex shapes efficiently
Solution Approach 1:
The object is formed by wrapping multiple thin foil layers around a preform, dividing the final structure into segmented layers that can be independently controlled and bonded, enabling complex shapes without material wastage
Solution Approach 2:
The material state is changed from bulk ingot to thin foil form, and the bonding process uses diffusion bonding parameters (temperature, pressure, time) to join layers, enabling efficient formation of complex shapes with minimal material loss
2Manufacturing precision
If traditional machining methods are used after object formation, then material can be removed to achieve final shape, but this increases material wastage and requires subsequent processing steps
Solution Approach 1:
The final shape is preliminarily formed by wrapping foil layers around a preform that defines the desired geometry, so that diffusion bonding directly creates the final shape without requiring subsequent material removal
Solution Approach 2:
Traditional mechanical machining is replaced with diffusion bonding process that directly forms the final shape through controlled material deposition and bonding, eliminating the need for subtractive manufacturing
3Reliability
If expensive high-quality materials are used, then object quality and performance are improved, but material cost increases
Solution Approach 1:
Thin foil layers of expensive high-quality material are used instead of bulk material, reducing the total amount of expensive material required while maintaining object quality and performance through the multi-layer structure
Solution Approach 2:
Multiple foil layers may be composed of different materials with complementary properties, creating a composite structure that achieves high reliability while optimizing material cost by using expensive materials only where necessary
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
This approach reduces material wastage, decreases the need for subsequent machining, and allows for the creation of objects of any size and complex shapes, providing cost savings and improved efficiency.
Implementation Method 1
diffusion bonding the plurality of layers and the preform together to form the object
Implementation Method 2
diffusion bonding can include a hot isostatic pressing process
Data Source
AI summary
A first method of forming an object (400) includes wrapping foil around a preform (305) to provide a multi-layered structure including a plurality of layers of wrapped foil, and diffusion bonding the plurality of layers and the preform (305) together to form the object (400). A second method of forming an object includes wrapping foil around a preform (305) to provide a multi-layered structure comprising a plurality of layers of wrapped foil, removing the preform (305) from the multi-layered structure, and diffusion bonding the plurality of layers together to form the object (400). A third method of forming an object includes stacking a plurality of layers of foil to provide a multi-layered structure, diffusion bonding the plurality of layers together, and shaping the diffusion bonded multi-layered structure to form the object (400).