Electromagnetic Granule Deposition for Stronger Additive Components
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Solution Overview
Problem
Existing additive manufacturing methods, such as Selective Laser Sintering and Electron Beam Melting, face challenges in achieving desired component properties like engineering strength due to issues like cracking, cavitation, and discontinuities, particularly in nickel-based components, and lack precise control over material feeding and temperature.
Innovation Solution
The use of electromagnetic fields to control the movement and path of granules and electron beams in a vacuum environment for direct material deposition, allowing for precise control over granule speed, temperature, and chemistry, reducing energy consumption and improving component strength by forming fine crystalline structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If selective laser sintering or electron beam melting is used to form components from fusible powder material, then the component can be manufactured layer by layer, but the engineering strength is low due to cracking, cavitation and discontinuities
Solution Approach 1:
The patent changes the thermal parameters by preheating granules to temperatures close to the melting point before deposition, and by controlling the bath melt temperature and cooling rate. This results in fine crystalline structures with high strength values, resolving the contradiction between manufacturability and strength
Solution Approach 2:
The patent utilizes controlled phase transitions of material between solid, liquid, and crystalline states. Granules are heated to melt, deposited into a liquid bath, then rapidly cooled to form fine crystalline structures. This controlled phase transition process eliminates defects and enhances strength while maintaining additive manufacturing capabilities
2Strength
If the whole granule volume is remelted to ensure complete fusion, then the component strength increases, but the energy consumption and bath melt volume increase considerably
Solution Approach 1:
The patent applies partial melting by preheating only the outer layer of granules to melting point before deposition, rather than remelting the entire granule volume. The granules are heated to T2>T1 where T1 is internal temperature and T2 is external temperature, achieving sufficient fusion with reduced energy consumption
Solution Approach 2:
The patent performs preliminary heating of granules external layers to melting point before they enter the bath melt. This pre-heating action reduces the thermal energy required during deposition and minimizes bath melt volume while ensuring complete fusion and high component strength
3Ease of operation
If a nozzle with gas flow is used to feed powder into the bath melt, then material delivery is enabled, but the amount of powder is excess and control over feeding speed, path, and temperature is limited
Solution Approach 1:
The patent replaces the mechanical gas-flow-based nozzle delivery system with an electromagnetic field-based control system. Electromagnetic fields precisely control granule acceleration, trajectory, and positioning, enabling accurate control of powder amount, speed, path, and temperature without excess material
Solution Approach 2:
The patent changes the control mechanism from gas flow parameters to electromagnetic field parameters, allowing independent and precise control of granule velocity, trajectory, and temperature. This enables exact delivery of required powder amounts with controlled feeding speed and path
4Productivity
If coarse powder or granules of 200÷300 μm are used instead of fine powder of 20÷30 μm, then power production cost decreases and additive equipment efficiency increases, but the manufacturing precision and surface quality may be affected
Solution Approach 1:
The patent changes the thermal and mechanical parameters during deposition, including preheating granules to melting point and controlling bath melt temperature, enabling successful use of coarse granules (200-300 μm) while maintaining high surface quality and manufacturing precision
Solution Approach 2:
The patent applies different treatments to different parts of the granule: external layers are heated to melting point while internal layers are heated to lower temperatures. This local quality approach allows use of coarse granules while ensuring complete fusion and high surface quality
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 enhances the efficiency and accuracy of material deposition, reduces energy consumption, and increases the strength of components by enabling precise control over granule movement and temperature, leading to improved additive manufacturing processes.
Implementation Method 1
The use of electromagnetic fields to control the movement and path of granules and electron beams in a vacuum environment for direct material deposition, allowing for precise control over granule speed, temperature, and chemistry
Implementation Method 2
for which beam 2 preliminary forms a bath melt 3 at the body of component 4 top face
Implementation Method 3
beam 2 of photons or electrons with the bath melt 3 generation
Implementation Method 4
The granule approaching the bath melt is melted at the surface, at that the solid sphere with the temperature of T3 remains inside and a liquid shell with the temperature T4 is on the surface
Implementation Method 5
When getting into the bath melt the powder or granules capture the heat energy causing formation of fine crystalline structure in the body of component formation area
Data Source
AI summary
The invention relates to the field of the additive manufacturing of components, which are formed by the direct deposition of a substance, in the form of granules of a metal or non-metal, which passes from a reservoir into a melt bath, produced by the thermal energy of a laser or electron beam, and subsequently crystallizes. The granules enter the melt bath without the intervention of a gas stream, the path and rate of travel of said granules changing while they are in flight under the effect of an electromagnetic field. The granules travel within a chamber, falling into the melt bath from above from a reservoir, from which they are fed at a set speed by the rotation of an adjustable screw feed, and passing through a system of electromagnetic devices, which control the path of the granules by means of electromagnetic fields. The coordinates of this path are tracked by sensors, which transmit a signal to a computer, wherein the flight path of the granules is adjusted by control via the electronic devices and the delivery speed and volume of the substance is adjusted by adjusting the rotation of the screw feed. The invention increases the efficiency of the production cycle, reduces the dimensions of the equipment and increases the accuracy and speed with which material is delivered for the manufacture of a component, while enabling adjustment of the amount, temperature, path and fraction of said material and increasing the strength of the component.