Inclined Metal Structure Build-Up for Any-Direction Overhangs

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Solution Overview

Problem

Existing methods for manufacturing inclined structures without a supporting body are limited to angles of 57° or less, restricting the ability to produce inclined structures with any inclination direction.

Innovation Solution

A method involving the formation of a base portion with a reference surface inclined relative to the base metal surface, followed by the stacking of build-up layers on this reference surface to create a projecting portion extending in an oblique direction, using techniques like laser metal deposition to achieve high creep strength and minimize heat affected zones.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the inclined structure is manufactured by stacking build-up layers directly on the base metal surface with conventional welding, then the manufacturing process is simple, but the crystal grains form columnar shape along the stacking direction (vertical to base metal surface) resulting in low creep strength in the build direction

Engineering Contradiction:

Improvecreep strengthVSAvoidmanufacturing process complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent applies preliminary action by first forming a base portion with a reference surface that is inclined relative to the base metal surface before stacking the build-up layers. This preliminary inclination of the reference surface ensures that when layers are stacked vertically, the crystal grains form columnar structures along the oblique build direction of the final inclined structure, thereby achieving high creep strength in the build direction without requiring complex process changes

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent introduces a dimensional change by creating a base portion that tilts the reference surface relative to the base metal surface. This angular offset in the intermediate dimension allows the vertical stacking of layers to translate into oblique crystal grain formation in the final structure, resolving the contradiction between simple stacking process and desired creep strength orientation

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Ease of manufacture

If MIG welding is used to manufacture the inclined structure, then the process is straightforward, but the heat input to the base metal is large creating a large heat affected zone

Engineering Contradiction:

Improveease of weldingVSAvoidheat affected zone

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the conventional MIG welding process with laser metal deposition technology. This substitution transitions from a mechanical arc-based welding system to a laser-based energy system, enabling precise control of heat input and minimizing the heat affected zone while maintaining manufacturing feasibility

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Adaptability or versatility

If the inclined structure is manufactured without a supporting body at angles greater than 57°, then the structure can be self-supported, but it is not feasible to manufacture inclined structures with any inclination direction

Engineering Contradiction:

Improveinclination direction flexibilityVSAvoidstructural stability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent applies preliminary action by first creating a base portion with an inclined reference surface that is stable and self-supported. This preliminary structure provides a reliable foundation that enables subsequent build-up layers to be stacked at any oblique direction without requiring external supporting bodies, thus achieving both structural stability and inclination flexibility

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 method enables the manufacture of inclined structures with any inclination direction without a supporting body, while achieving high creep strength in the build direction due to columnar crystal grain formation.

Implementation Method 1

Stacking of the plurality of build-up layers on the surface of the base metal and stacking of the plurality of build-up layers on the reference surface of the base portion may be performed by laser metal deposition

Methodology Applied

Scientific EffectLaser metal deposition: Laser Beam Welding

Data Source

PatentUS12214445B2Inclined structure and method of manufacturing same

Publication Date: 2025.02.04 KAWASAKI JUKOGYO KK

AI summary

A method of manufacturing an inclined structure extending in an oblique direction from a surface of a base metal includes: forming a base portion by stacking a plurality of build-up layers on the surface of the base metal, each of the plurality of build-up layers being formed by a plurality of beads, the base portion including a reference surface inclined at an opposite side of the oblique direction across a perpendicular line of the surface of the base metal; and forming a projecting portion by stacking a plurality of build-up layers on the reference surface of the base portion, each of the plurality of build-up layers being formed by a plurality of beads, the projecting portion extending in the oblique direction from the base portion.