Additive Friction Stir Fabrication for Thin Metal Ribs

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Solution Overview

Problem

Conventional additive manufacturing techniques for creating complex metal structures with thin ribs lack finer resolution and through-thickness properties, making them unsuitable for efficiently manufacturing very thin ribs or repairing inaccessible surfaces.

Innovation Solution

The method employs localized seam extrusion using an additive friction stir process with a forming die, where a rotating friction-stir tool interacts with a metallic substrate to generate plastic deformation and bond with a consumable filler material, forming ribs with excellent through-thickness properties and allowing for repair of worn or interior surfaces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional additive manufacturing techniques are used to create thin ribs, then manufacturing capability is provided, but resolution and through-thickness properties are insufficient

Engineering Contradiction:

Improverib resolution and through-thickness propertiesVSAvoidsuitability for thin ribs and inaccessible surfaces

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent changes the fundamental process parameters from melting-based deposition to solid-state friction stir processing. This involves using a rotating tool that generates frictional heat to locally soften and plasticize the substrate material, allowing for precise material deposition and rib formation with superior resolution and through-thickness properties that conventional additive manufacturing cannot achieve

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention replaces the thermal-melting mechanism of conventional additive manufacturing with a mechanical friction-stir mechanism. A rotating friction-stir tool applies mechanical energy to locally plasticize the substrate material, enabling precise material placement and rib formation with excellent mechanical interlocking and through-thickness properties

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Strength

If preformed ribs are joined using friction stir welding, then joining capability is provided, but the process is limited to seam joining rather than additive fabrication

Engineering Contradiction:

Improvebond strengthVSAvoidprocess flexibility for complex structures

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The patent merges the joining function of friction stir welding with the additive fabrication capability. The friction stir tool not only joins materials but also deposits and forms rib structures by controlling material flow and plasticization, enabling both joining and complex structure fabrication in a single integrated process

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The friction stir tool is designed to perform multiple functions: it can join preformed ribs, fabricate ribs additively, and repair surfaces. By controlling tool parameters, feed rate, and material delivery, the same tool system adapts to different manufacturing needs, providing universal capability for complex metal structure fabrication

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 ribs with various geometries that are integral to the substrate, providing enhanced corrosion and wear resistance, and allows for efficient repair of complex metallic structures, including those with internal cavities, by forming ribs that are mechanically interlocked with the substrate.

Implementation Method 1

Frictional heating occurs at the filler/substrate interface due to the rotational motion of the filler material, such as a rod, and the downward force applied

Methodology Applied

Scientific EffectFrictional heating: Friction

Implementation Method 2

Additive friction-stir fabrication (FSF) processes use shear-induced interfacial heating and plastic deformation to deposit metallic coatings onto metal substrates

Methodology Applied

Scientific EffectShear-induced interfacial heating: Friction

Implementation Method 3

The mechanical shearing that occurs at the interface acts to disperse any oxides or boundary layers, resulting in a metallurgical bond between the substrate and coating

Methodology Applied

Scientific EffectMechanical shearing: Deformation

Implementation Method 4

interaction of the rotating friction-stir tool with the substrate generates a plastic deformation at an interface between the rotating friction-stir tool and the metallic substrate

Methodology Applied

Scientific EffectPlastic deformation: Plasticity

Data Source

PatentUS10500674B2Additive friction-stir fabrication system for forming substrates with ribs

Publication Date: 2019.12.10 MELD MANUFACTURING CORP

AI summary

An additive friction stir fabrication method and system is described which may be used to fabricate and join a rib to a metallic substrate or to repair a defect in a metallic substrate through extrusion. The method may be carried out with or without the addition of preformed ribs. One such method involves feeding a friction-stir tool with a consumable filler material such that interaction of the friction-stir tool with the substrate generates plastic deformation at an interface between the friction-stir tool and a metallic substrate to bond the plasticized filler and substrate together and extrude this material through a forming cavity to form a rib joined to the metallic substrate. Further described is a system for fabricating a rib joined to a metallic substrate through extrusion.