Impact Welding Wire Segments Additive Manufacturing
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Solution Overview
Problem
Challenging to join difficult-to-weld materials like dissimilar metals and nickel-based superalloys in additive manufacturing due to issues such as precipitation of brittle phases, segregation, solidification cracking, and strain age cracking, especially in high heat input fusion techniques.
Innovation Solution
A method involving a wire with a powder filler metal core within a sheath, where an energy pulse interacts with the sheath to pinch off segments, propelling them toward a substrate at high velocity to form an impact weld, using electromagnetic, laser, or high electric current pulses, mimicking explosion welding for solid-state bonding with minimal melting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high heat input fusion techniques (arc welding, laser welding) are used for additive manufacturing, then deposition capability is improved, but precipitation of brittle phases, segregation formation, and solidification cracking occur
Solution Approach 1:
The patent replaces thermal fusion processes (arc welding, laser welding) with a mechanical impact welding process. Wire segments are propelled at high velocity to impact the substrate, creating solid-state welds through plastic deformation and metallurgical bonding without melting. This substitution eliminates the harmful thermal effects while maintaining deposition capability.
Solution Approach 2:
The patent fundamentally changes the welding parameters from high temperature/heat input to high velocity/kinetic energy. By propelling wire segments at velocities sufficient to create impact welds, the process achieves deposition without the thermal cycles that cause brittle phase precipitation, segregation, and cracking.
2Speed
If high heat input fusion techniques are used, then welding speed is improved, but strain age cracking occurs upon post weld heat treatment
Solution Approach 1:
The patent replaces thermal welding processes with mechanical impact welding. Wire segments are accelerated and impacted against the substrate at high velocity, creating solid-state bonds through plastic deformation rather than fusion. This eliminates the heat-affected zone and residual stresses that lead to strain age cracking during post-weld heat treatment.
Solution Approach 2:
The patent changes the welding mechanism from thermal fusion to kinetic energy impact. By using high velocity propulsion to create impact welds, the process achieves rapid deposition speeds while avoiding the thermal cycles and residual stresses that cause strain age cracking in conventional welding.
3Ease of manufacture
If conventional welding methods are used to join dissimilar metals and nickel-based superalloys, then deposition is achieved, but precipitation of brittle phases and segregation formation occur
Solution Approach 1:
The patent replaces thermal fusion processes with mechanical impact welding. Wire segments are propelled at high velocity to impact the substrate, creating solid-state welds through plastic deformation and direct metallurgical bonding. This avoids melting and solidification, preventing the formation of brittle phases and segregation that occur in conventional welding of dissimilar metals and superalloys.
Solution Approach 2:
The patent fundamentally changes the welding parameters from high temperature to high velocity. By using kinetic energy to create impact welds, the process achieves deposition of dissimilar metals and nickel-based superalloys without the thermal cycles that cause brittle phase precipitation and segregation, maintaining microstructure stability.
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
Enables controlled, low heat input welding of challenging materials, reducing defects like precipitation and cracking, and allowing for continuous layer formation in additive manufacturing processes, suitable for repairing high-temperature components like turbine engine parts.
Implementation Method 1
the energy pulse may be an electromagnetic pulse
Implementation Method 2
the energy pulse may be an electromagnetic pulse, a laser energy pulse
Implementation Method 3
the energy pulse may be an electromagnetic pulse, a laser energy pulse or a high electric current pulse
Implementation Method 4
causes propulsion of the segment toward a substrate with sufficient velocity to form an impact weld
Data Source
Figure 1~2B
Figure 3A~3B
Figure 4A~4B
AI summary
A method for forming an impact weld used in an additive manufacturing process. The method includes providing a wire 12 having a powder filler metal core 14 located within a sheath 16. The wire 12 is then inserted within a conduit 18 having an opening 20. Further, the method includes providing at least one energy pulse that interacts with the sheath 16 to pinch off at least one segment 40 of the wire 12, wherein the energy pulse causes propulsion of the segment 40 toward a substrate 34 with sufficient velocity to form an impact weld for welding the metal core 14 to the substrate 34. In particular, the energy pulse is an electromagnetic pulse, a laser energy pulse or a high electric current pulse.