Foil-Based Additive Manufacturing for Amorphous Alloys
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Solution Overview
Problem
Current additive manufacturing techniques face challenges in producing metal parts with material properties comparable to traditional metal machining, particularly in achieving amorphous microstructures for components thicker than a few millimeters and with complex geometries, due to limitations in cooling rates and residual stresses.
Innovation Solution
A method involving the sequential stacking and laser joining of alloy foil sheets, with controlled material removal to shape, using a focused laser beam to weld and cut the sheets in a cooling chamber below -50°C, allowing for rapid quenching and preserving amorphous microstructures in thicker components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If powder-based additive manufacturing processes are used, then a wide range of materials can be used, but the manufacturing tolerance is limited by particle size and mechanical strength is far below raw material
Solution Approach 1:
The patent changes the fundamental parameter of material form from powder to foil sheets, enabling both wide material compatibility and high manufacturing precision. The foil-based approach allows laser joining with controlled heat input, achieving tight tolerances while maintaining versatility across metal alloys.
Solution Approach 2:
The patent replaces the mechanical powder deposition and sintering system with a laser-based foil joining system. This substitution eliminates particle-size limitations on tolerance while maintaining material versatility through laser-compatible foil materials.
2Adaptability or versatility
If powder melting techniques are used, then many materials can be processed, but uneven heating and cooling introduce residual stresses and poor surface quality
Solution Approach 1:
The patent changes the material form from powder to foil, enabling more uniform heat distribution during laser joining. This reduces thermal gradients and minimizes residual stresses while maintaining material versatility.
Solution Approach 2:
The patent replaces the powder melting process with a foil joining process using laser. This substitution provides more controlled and uniform heating, reducing thermal shock and residual stress formation.
3Ease of manufacture
If laminated object manufacturing with foil sheets is used, then low cost per part and low material deformation are achieved, but material removal processes produce large waste and mechanical strength is directional
Solution Approach 1:
The patent applies preliminary shaping to foil sheets before joining, allowing near-net-shape manufacturing. This reduces or eliminates subsequent material removal operations, minimizing waste while maintaining low cost per part.
Solution Approach 2:
The patent changes the manufacturing approach from subtractive (milling/trimming) to additive with preliminary shaping. This parameter change eliminates material waste associated with traditional post-processing while maintaining the cost advantages of foil-based manufacturing.
4Strength
If traditional rapid quenching is used to create amorphous microstructure, then superior material properties are achieved, but component thickness is limited to a few millimeters
Solution Approach 1:
The patent segments the component into thin foil layers that are joined sequentially. Each foil maintains the rapid quenching characteristics necessary for amorphous microstructure, while the stacked configuration achieves greater overall thickness. This segmentation resolves the contradiction between thickness and microstructure quality.
Solution Approach 2:
The patent uses a nested structure where multiple thin foils are stacked and joined together. Each foil retains its amorphous microstructure, and the nested arrangement enables thick components while preserving the rapid cooling characteristics of thin materials.
5Strength
If amorphous alloy foils are used, then greater hardness and strength are achieved, but the foils must be kept thin to maintain rapid quenching rates
Solution Approach 1:
The patent segments the thick component into multiple thin foil layers. Each foil maintains the thickness necessary for rapid quenching and amorphous microstructure, while the stacked configuration achieves the desired overall thickness. This segmentation allows thin foils to provide both strength and thickness.
Solution Approach 2:
The patent employs nested thin foils that are joined together. Each foil retains its amorphous structure and high strength properties, while the nested arrangement of multiple foils achieves the required component thickness without sacrificing material properties.
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 enables the production of metal alloy components with improved microhardness and tensile strength, independent of directional dependence, and facilitates the manufacture of thick, complex amorphous alloy parts with uniform microstructure, overcoming previous limitations in size and geometry.
Implementation Method 1
joining each of the n alloy foil sheets to the respective underlying layer using a material joining laser after each respective sheet is stacked on the respective underlying layer by striking a focused laser beam of the laser on a free, unobstructed surface of the foil sheet to melt and weld each alloy foil sheet to its respective underlying layer
Implementation Method 2
A method involving the sequential stacking and laser joining of alloy foil sheets, with controlled material removal to shape, using a focused laser beam to weld and cut the sheets in a cooling chamber below -50°C, allowing for rapid quenching and preserving amorphous microstructures in thicker components
Data Source
AI summary
An additive manufacturing system, method of manufacturing, and fabricated part. The system uses a material joining laser system to join together foil sheets to form a metal part. The material joining laser system can be configured to join adjacent foil sheets together in a substantially uniform manner. The manufacturing system also includes a material removal system that removes material from selected locations of the foil sheets to shape the foil sheets to correspond with selective slices of the part. The material removal system can be a laser system, such as a laser system configured to remove material from a foil sheet without removing material from an underlying layer. One embodiment involves the manufacture of amorphous alloy components.