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

VSEngineering 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

Engineering Contradiction:

Improvemanufacturing flexibilityVSAvoidcomposition uniformity

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent applies preliminary homogenization heat treatment to the stacked foils before final bonding. This preliminary action redistributes alloying elements throughout the foil stack, ensuring uniform composition before the bonding process occurs, thereby preventing composition gradients in the final part

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent changes the temperature parameter during processing by applying elevated temperature heat treatment to the foil stack. This parameter change enables solid-state diffusion of alloying elements, transforming the non-uniform composition into a uniform homogeneous composition throughout the bonded regions

Inventive Principle:

Principle #35Parameter changes

2Adaptability or versatility

If foils with different compositions are stacked to achieve target alloy composition, then material versatility is improved, but composition homogeneity deteriorates due to bonded regions having different compositions

Engineering Contradiction:

Improvematerial versatilityVSAvoidcomposition homogeneity

Core Design Contradiction:

Adaptability or versatilityVSStability of the object's composition

Solution Approach 1:

The patent applies temperature as a changing parameter by heating the foil stack to elevated temperatures during homogenization. This parameter change activates solid-state diffusion, allowing alloying elements to migrate and redistribute uniformly across the interfaces of differently composed foils, achieving homogeneous composition while maintaining material versatility

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent applies local quality by targeting the bonded regions and interfaces of the foil stack with homogenization heat treatment. The treatment specifically addresses the composition non-uniformity at foil interfaces and bonded regions, ensuring uniform alloy composition throughout the entire part while preserving the ability to use different foil materials

Inventive Principle:

Principle #3Local quality

3Manufacturing precision

If heat treatment is applied to homogenize the stack, then composition uniformity is improved, but energy consumption and processing time increase

Engineering Contradiction:

Improvecomposition uniformityVSAvoidenergy consumption

Core Design Contradiction:

Manufacturing precisionVSUse of energy by moving object

Solution Approach 1:

The patent applies preliminary homogenization heat treatment to the foil stack before final bonding and part completion. This preliminary action ensures uniform composition is achieved early in the process, preventing the need for extended or repeated heat treatment cycles later, thereby optimizing overall energy consumption while achieving composition uniformity

Inventive Principle:

Principle #10Preliminary action

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 matching a target alloy composition, similar to commercially available aluminum alloys, by promoting interdiffusion of alloying elements throughout the part, thereby improving the consistency and strength of the laminated object.

Implementation Method 1

bonding the foils together to yield a solid object

Methodology Applied

Scientific EffectDiffusion bonding: Diffusion Welding

Implementation Method 2

bonding the foils together to yield a solid object

Methodology Applied

Scientific EffectTransient liquid phase diffusion bonding: Diffusion Welding

Implementation Method 3

applying heat to the stack at a second temperature to homogenize the composition of the stack

Methodology Applied

Scientific EffectSolid-state diffusion: Diffusion

Data Source

PatentUS12043878B2Homogenizing heterogeneous foils for light alloy metal parts

Publication Date: 2024.07.23 ALLOY ENTERPRISES INC

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.