Functionally Graded Titanium Wire Deposition for Large High-Strength Parts
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Solution Overview
Problem
Existing wire feedstocks for titanium alloys used in additive manufacturing are costly and have reduced tensile and fatigue strength compared to wrought processed materials, making them unsuitable for producing large aerospace components with high structural demands.
Innovation Solution
A functionally graded monolithic structure is created using a heat-treated wire drawn from a sintered billet of powdered metals, comprising titanium, iron, vanadium, and aluminum, which is then integrated with a base plate through additive manufacturing, allowing for the production of large titanium alloy components with enhanced strength and reduced segregation issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If existing wire feedstocks are used for titanium alloy additive manufacturing, then large parts can be produced, but the tensile and fatigue strength are reduced compared to wrought processed material
Solution Approach 1:
The patent applies parameter changes by modifying the material composition parameters of the wire feedstock. Specifically, it uses titanium alloys with controlled compositions (including Ti-6Al-4V and other alpha-beta or beta titanium alloys) to achieve both large part production and high strength properties, resolving the contradiction between part size and mechanical strength
Solution Approach 2:
The patent employs composite materials by creating functionally graded structures that combine different titanium alloy compositions within a single monolithic component. This allows different regions of the large part to have optimized material properties for their specific functional requirements, achieving both large scale and high strength simultaneously
2Volume of moving object
If existing wire feedstocks are used for titanium alloy additive manufacturing, then large parts can be produced, but the material cost increases
Solution Approach 1:
The patent changes the material composition parameters to use cost-effective titanium alloy formulations. By controlling the alloying elements (Al, V, and other additives within specified ranges) and using powder metallurgy processes, it achieves large part production at reduced material costs compared to conventional wire feedstocks
Solution Approach 2:
The patent adopts a disposable wire feedstock approach where cost-effective titanium alloy wires are used for additive manufacturing. The wire is consumed during the manufacturing process, and by using economically viable material compositions and processing methods, the overall cost of producing large titanium parts is reduced
3Shape
If powder bed additive manufacturing is used for titanium alloy components, then complex geometries can be achieved, but large parts cannot be produced
Solution Approach 1:
The patent applies segmentation by dividing the manufacturing process into manageable stages. Wire deposited additive manufacturing allows for the construction of large parts through incremental material deposition, enabling both complex geometries and large dimensions to be achieved by building up the structure layer by layer or section by section
4Volume of moving object
If wire deposition additive manufacturing is used with conventional wire feedstocks, then large parts can be produced, but macro segregation issues occur
Solution Approach 1:
The patent changes the material parameters by using carefully controlled alloy compositions with specific ranges of alloying elements. This compositional control, combined with optimized processing parameters, prevents macro segregation during wire deposition, ensuring uniform material composition throughout large parts while maintaining the ability to produce large dimensions
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 material costs and enhances the tensile and fatigue strength of titanium alloy components, overcoming macro segregation issues and enabling the production of large, high-strength aerospace parts with tailored material compositions for specific engineering loads.
Implementation Method 1
the wire feedstock comprising a heat treated wire drawn from a sintered billet of powdered metals
Implementation Method 2
The heat treated wire may undergo at least one of a beta phase transformation, a beta anneal, or an alpha-beta anneal during the at least one of annealing, solutionizing, or aging
Implementation Method 3
Wire deposition additive manufacturing techniques may be used to form large parts
Data Source
AI summary
A metallic part is disclosed. The part may comprise a functionally graded monolithic structure characterized by a variation between a first material composition of a first structural element and a second material composition of at least one of a second structural element. The first material composition may comprise an alpha-beta titanium alloy. The second material composition may comprise a beta titanium alloy.