Foil Stack Homogenization for Uniform Light Alloy Parts
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Solution Overview
Problem
Laminated object manufacturing (LOM) techniques often result in composition gradients within assembled parts, leading to mechanical properties that do not match those predicted by the average alloy composition, due to differences in bonded regions and structural parts.
Innovation Solution
A method involving the stacking of foils with different compositions, followed by heat treatment at specific temperatures to bond and homogenize the foils, achieving a desired alloy composition through solid-state diffusion without adding material, using techniques like diffusion bonding, transient liquid phase diffusion bonding, or brazing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If LOM techniques are used to manufacture parts from stacked foils, then manufacturing flexibility and design freedom are improved, but composition gradients occur in bonded regions causing mechanical properties to deviate from predicted values
Solution Approach 1:
The patent applies heat treatment at controlled temperatures to change the physical state and diffusion characteristics of alloying elements in the bonded regions. By adjusting temperature parameters during heat treatment, the composition gradients are reduced and the material properties are homogenized, resolving the contradiction between manufacturing flexibility and composition uniformity.
2Adaptability or versatility
If foils with different compositions are stacked to achieve desired alloy composition, then material versatility is improved, but composition gradients in bonded regions cause mechanical property deviations
Solution Approach 1:
Heat treatment parameters (temperature, time, atmosphere) are changed and optimized to control the diffusion process of alloying elements across bonded interfaces. This ensures that even when foils with different compositions are stacked, the final mechanical properties are consistent and reliable by eliminating composition gradients through controlled thermal processing.
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 ensures that the final product has mechanical properties similar to commercially available alloys, with improved homogeneity and consistency, overcoming the limitations of existing LOM methods by achieving a uniform composition that matches the target alloy.
Implementation Method 1
applying heat to the stack at a first temperature to bond the plurality of foils to each other
Implementation Method 2
using techniques like diffusion bonding, transient liquid phase diffusion bonding, or brazing
Implementation Method 3
using techniques like diffusion bonding, transient liquid phase diffusion bonding, or brazing
Implementation Method 4
applying heat to the stack at a second temperature to homogenize the composition of the stack, wherein the homogenized stack has the desired alloy composition
Data Source
AI summary
A method for the manufacturing of an object. The method includes receiving a desired alloy composition for the object, depositing a plurality of foils in a stack to form the object, applying heat to the stack at a first temperature to bond the plurality of foils to each other, and applying heat to the stack at a second temperature to homogenize the composition of the stack. The homogenized stack has the desired alloy composition.