FSAM Structures With Integrated Passages and Secured Tubes
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The formation of parts and structures with integrated passages is costly, labor-intensive, and prone to quality issues due to the large number of manufacturing steps required.
Innovation Solution
The method involves forming near net shape parts using friction stir additive manufacturing (FSAM), machining inner and outer surfaces to create smooth surfaces and grooves for tubes or wires, joining the parts to form a structure, and securing tubes or wires within the grooves using additional material deposited by the friction stir tool.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If passages are attached to the exterior of a part after formation, then the manufacturing process is simpler, but the structural integrity and reliability are reduced
Solution Approach 1:
The patent merges the passage formation process with the part formation process by using friction stir additive manufacturing to create integrated passages within the part structure itself, eliminating the need for separate attachment operations and ensuring structural integrity throughout the passage system
2Reliability
If integral passages are formed during part formation, then structural integrity is improved, but the number of manufacturing steps and complexity increase
Solution Approach 1:
The friction stir additive manufacturing tool serves multiple functions: it deposits filler material to build the part structure, simultaneously forms the passage cavities, and secures tubes or wires in place, consolidating what would traditionally require multiple separate operations into a single multi-functional process
3Reliability
If multiple manufacturing steps are used to form integrated passages, then passage integration is achieved, but manufacturing cost and time increase
Solution Approach 1:
The patent performs preliminary actions by forming the passage cavities and positioning tubes or wires during the additive manufacturing process itself, before final part completion, which eliminates the need for subsequent separate operations to create passages and integrates them seamlessly into the part 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
This approach reduces manufacturing costs and steps, simplifies quality control, and enhances the structural reliability and integrity of parts and structures with integrated passages by allowing for the integration of dissimilar materials and improved heat transfer efficiencies.
Implementation Method 1
friction stir additive manufacturing (FSAM)
Implementation Method 2
forming near net shape parts using friction stir additive manufacturing (FSAM), machining inner and outer surfaces to create smooth surfaces and grooves for tubes or wires, joining the parts to form a structure
Data Source
AI summary
A method of additive manufacturing a structure having integrated passages is provided. In one aspect, the method includes forming first and second parts, each part having a near net shape. The first and second parts are formed by moving a friction stir tool configured to deposit a filler material. An inner surface of each part can be machined to form a generally smooth surface. The first and the second parts are joined to form a structure. The structure is machined to form a generally smooth outer surface. The method includes machining a plurality of grooves extending into the generally smooth outer surface of the structure. A tube is placed into each of the plurality of grooves and a layer of material is deposited to secure the tubes within the plurality of grooves. The method can include machining the outer surface to a predetermined shape.