Hybrid Structural Component Joining With Insert Parts and Wire Welding
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Solution Overview
Problem
Additive manufacturing methods for structural components are slow and costly, leading to high production times and anisotropic mechanical properties, limiting their use to low volumes and requiring additional profiles for fastening.
Innovation Solution
A hybrid method combining prefabricated insert parts with wire-based welding to form a main body, integrating balance body portions layer-by-layer, eliminating the need for a base plate and reducing additive manufacturing proportion, thus combining cost-effectiveness with design flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If additive manufacturing methods are used for producing structural components, then design flexibility and component geometry freedom are improved, but manufacturing time and production costs increase significantly
Solution Approach 1:
The structural component is divided into two distinct parts: an insert part manufactured by conventional methods and a balance body portion manufactured by additive manufacturing. This segmentation allows each part to be optimized by the most suitable manufacturing method, reducing overall production time while maintaining design flexibility for the complex balance body portion.
Solution Approach 2:
The insert part is manufactured in advance using conventional, faster methods, and then serves as a pre-prepared base for the subsequent additive manufacturing of the balance body portion. This preliminary action reduces the total manufacturing time by avoiding the need to additively manufacture the entire component.
2Adaptability or versatility
If additive manufacturing methods are used for producing structural components, then design flexibility is improved, but mechanical properties become anisotropic
Solution Approach 1:
The component is segmented such that the insert part, manufactured by conventional methods with superior mechanical properties,承担 the primary mechanical loads. The additively manufactured balance body portion provides design flexibility but does not need to bear the same mechanical demands, thus resolving the anisotropy issue.
Solution Approach 2:
Different regions of the structural component have different quality requirements. The insert part region has high mechanical strength requirements and is manufactured accordingly, while the balance body portion prioritizes geometric flexibility. Each region's manufacturing method is optimized for its specific quality requirements.
3Productivity
If conventional manufacturing methods are used for producing structural components, then manufacturing speed and cost-effectiveness are improved, but design flexibility and modification ability decrease
Solution Approach 1:
The structural component is divided into an insert part and a balance body portion. The insert part is manufactured using conventional, fast, and cost-effective methods, while the balance body portion is manufactured additively to provide design flexibility and easy modifiability. This segmentation allows the overall system to benefit from both manufacturing approaches.
Solution Approach 2:
The invention merges two different manufacturing approaches: conventional manufacturing for the insert part and additive manufacturing for the balance body portion. The two parts are then integrated into a single structural component, combining the advantages of both methods in one product.
4Adaptability or versatility
If additive manufacturing is used for the entire structural component, then design flexibility is maximized, but production costs increase
Solution Approach 1:
The component is segmented into an insert part and a balance body portion, with each part manufactured by the most cost-effective method for its specific requirements. This reduces the proportion of expensive additive manufacturing to only where it is necessary for design flexibility.
Solution Approach 2:
Instead of applying additive manufacturing to the entire component (excessive action), the method applies it only to the balance body portion where design flexibility is needed (partial action), while using more cost-effective conventional methods for the insert part.
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 significantly reduces manufacturing time and costs while enhancing mechanical stability and flexibility, allowing for rapid production of structurally sound components.
Implementation Method 1
The automated, wire-based welding device (120) is specified to geometrically extend the at least one insert part (16) to form the main body (2A) by the layered construction of at least one balance body portion (24) on the at least one insert part (16)
Data Source
AI summary
A method for producing a structural component is provided. The structural component is formed by a base element. The method includes providing at least one insert part as part of the base element, and geometrically widening the at least one insert part to form the base element with the layered construction of at least one remaining element section on the at least one insert part by way of wire-based welding.