FSAM Nosecone Wire-Feed Layout for Large-Scale Deposition
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Solution Overview
Problem
Existing additive friction stir deposition (AFSD) and friction stir additive manufacturing (FSAM) systems face challenges in efficiently depositing and bonding materials, particularly in large-scale applications, due to limitations in material feeding and processing.
Innovation Solution
The development of a friction stir additive manufacturing system that uses a wire-feed mechanism, where a wire is fed through a stationary housing and into a gap between the housing and a rotating spindle, allowing for continuous material deposition and bonding without the need for gravity-assisted feeding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If powder or bar fed systems are used for FSAM, then material can be received and softened in a channel, but the systems face challenges in efficiently depositing and bonding materials in large-scale applications
Solution Approach 1:
The patent changes the physical state and form of the feed material from powder or bar to wire form, enabling continuous feeding through a wire feed mechanism. This parameter change in material form fundamentally improves deposition efficiency while simplifying the feeding system architecture for large-scale applications
Solution Approach 2:
The patent replaces gravity-assisted feeding mechanisms with a wire feed system that uses controlled mechanical feeding through a stationary housing. This substitution eliminates reliance on gravity and enables precise material delivery for large-scale additive manufacturing operations
2Reliability
If wire is fed through a stationary housing into a gap between housing and rotating spindle, then continuous material deposition is enabled, but the wire must be precisely guided through the housing structure
Solution Approach 1:
The housing structure is segmented into functional zones: a wire inlet portion for material entry, a tracking portion for guided wire movement, and a deposition zone for material placement. This segmentation allows each section to be optimized independently, ensuring reliable wire guidance while maintaining overall structural simplicity
Solution Approach 2:
The wire itself acts as an intermediary element that bridges the stationary housing and the rotating spindle. By feeding wire through the housing gap, the system creates a controlled material delivery path that ensures consistent deposition without requiring complex internal housing structures
3Ease of manufacture
If material is softened within the channel as it travels to deposition end, then material can be deposited in softened state, but the channel design must accommodate material softening process
Solution Approach 1:
The patent transitions from a longitudinal channel design where material travels the length of the housing to a compact gap configuration between the stationary housing and rotating spindle. This dimensional change allows material softening to occur in a compact volume while maintaining effective deposition capability
Solution Approach 2:
The wire feed system is nested within the housing structure, with the wire passing through a gap that is formed by the housing and spindle arrangement. This nesting allows the softening process to occur within the confined space of the gap region, reducing the overall housing volume required for material 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 enables efficient, high-quality material deposition and bonding, allowing for the creation of large metallic structures with improved build quality and consistency, and the ability to seamlessly transition between different materials.
Implementation Method 1
a wire is fed through a stationary housing and into a gap between the housing and a rotating spindle
Implementation Method 2
The rotation of the spindle within the housing can assist in pulling the wire into any of the systems according to the present disclosure
Implementation Method 3
The rotation of the spindle within the housing can assist in pulling the wire into any of the systems according to the present disclosure
Implementation Method 4
depositing softened material on to a substrate as it exits a deposition end of the housing
Implementation Method 5
Friction stir additive welding devices, systems, and methods
Data Source
AI summary
A friction stir additive welding device configured to join a first work-piece and second work-piece is provided. In one aspect, the device includes a nosecone having a sidewall extending from a first end to a second end, a channel extending from the first end to the second end along a longitudinal axis of the nosecone, and a screw positioned within the channel. The first end is configured to couple the nosecone to a robotic arm and the second end has a surface configured to be advanced along a weld line between the first and second work-pieces. A central axis of the screw defines an angle that is less than 90 degrees relative to a plane that is perpendicular to surfaces of the first and second work-pieces as the surface of the nosecone advances along the weld line.