Flow-Formed AM Preforms for Chamber-Limited Aerospace Parts
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Solution Overview
Problem
Additive manufacturing of high refractory metal products is constrained by the size limitations of the manufacturing chamber, limiting the production of larger objects, particularly those made from alloys like Niobium Super C103, which are essential for aerospace components.
Innovation Solution
A method involving forming a hollow preform using additive manufacturing, depositing excess material along the walls, inserting a mandrel, and using flow forming rollers to elongate the preform on a turning machine, allowing for the production of elongated objects by compressing and rotating the preform.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If additive manufacturing is used to form products layer by layer in a chamber, then products can be manufactured with complex geometries and material efficiency, but the chamber size limits the maximum height and length of producible objects
Solution Approach 1:
The manufacturing process is divided into two distinct stages: first, additive manufacturing creates a hollow preform with excess material deposited on the walls; second, flow forming elongates the preform to achieve the final extended dimensions. This segmentation allows the chamber size limitation to be overcome by performing the elongation operation after the preform is removed from the chamber.
Solution Approach 2:
The additive manufacturing process performs preliminary action by creating a hollow preform structure with excess material strategically deposited on the walls. This preform serves as the starting material for the subsequent flow forming operation, preparing the workpiece in advance for elongation without requiring the final extended dimensions to fit within the chamber.
2Length of moving object
If flow forming rollers compress and rotate the preform to elongate it, then the object length increases, but the material must be maintained at elevated temperatures to facilitate the process
Solution Approach 1:
The flow forming process utilizes parameter changes by maintaining the preform at elevated temperatures (up to about 800° F.) during elongation. This temperature increase modifies the material properties to facilitate plastic deformation and elongation, allowing the preform to be stretched to the desired final dimensions without excessive force or damage to the structure.
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
Enables the production of elongated high refractory alloy objects, such as those made from Niobium Super C103, Rhenium, and Tantalum, suitable for aerospace applications, by leveraging the excess material to achieve greater size and shape without welding, at ambient or elevated temperatures.
Implementation Method 1
flow forming rollers then engage the walls of the object and as the rollers rotate and compress the preform and traverse the length of the preform, it is thereby elongated
Data Source
AI summary
A method for elongating an additive manufactured object is achieved through the use of flow forming rollers. A preform is additive manufactured with excess material which is used to elongate the preform on as turning machine, as flow forming rollers apply pressure to the preform as it is turning. A mandrel conforming to the object of the preform is positioned within the interior thereof to ensure that proper conformation is achieved. The present invention has particular utility in the additive manufacturing of aerospace components from high temperature alloys.