Heterogeneous Foil Homogenization for Consistent 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 leading to mechanical properties that do not match predicted average alloy composition

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 stack, ensuring uniform composition in the final part while maintaining the manufacturing flexibility of LOM techniques

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent changes the temperature parameter during processing by applying elevated temperature heat treatment to the stacked foils. This parameter change enables solid-state diffusion of alloying elements, transforming the composition from heterogeneous to homogeneous while preserving design freedom

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

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

Engineering Contradiction:

Improvecomposition homogeneityVSAvoidprocessing time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent merges the homogenization heat treatment with the bonding process by applying heat treatment at the same time as or immediately before bonding. This combination achieves composition uniformity and structural bonding simultaneously, reducing total processing time and energy consumption

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If multiple foils with different compositions are stacked to create complex parts, then design versatility is improved, but composition gradients in bonded regions cause mechanical properties to deviate from predictions

Engineering Contradiction:

Improvedesign versatilityVSAvoidmechanical property consistency

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent applies preliminary homogenization heat treatment to redistribute alloying elements from regions of high concentration to low concentration. This preliminary action ensures that when multiple foils with different compositions are bonded, the final part achieves uniform composition and consistent mechanical properties matching design predictions

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 similar to commercially available alloys, with improved homogeneity and consistency, overcoming the limitations of existing LOM methods by achieving a uniform composition that matches the target alloy.

Implementation Method 1

applying heat to the stack at a first temperature to bond the plurality of foils to each other

Methodology Applied

Scientific EffectDiffusion bonding: Diffusion Welding

Implementation Method 2

using techniques like diffusion bonding, transient liquid phase diffusion bonding, or brazing

Methodology Applied

Scientific EffectTransient liquid phase diffusion bonding: Diffusion Welding

Implementation Method 3

using techniques like diffusion bonding, transient liquid phase diffusion bonding, or brazing

Methodology Applied

Scientific EffectBrazing: Brazing

Implementation Method 4

applying heat to the stack at a second temperature to homogenize the composition of the stack, wherein the homogenized stack has the desired alloy composition

Methodology Applied

Scientific EffectSolid-state diffusion: Diffusion

Data Source

PatentUS11859261B2Homogenizing heterogeneous foils for light alloy metal parts

Publication Date: 2024.01.02 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.