Internal Passage Agitators for Additive Powder Removal
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Solution Overview
Problem
Current methods for removing conglomerated powder from internal passages of additively manufactured components, such as those with complex geometries, are inefficient, as they often require repeated and labor-intensive processes like accelerated media blast and mechanical scraping.
Innovation Solution
Incorporating multiple agitators of varying sizes and shapes within the internal passage during the additive manufacturing process, which are designed to resonate at specific frequencies, allowing for controlled vibration to loosen and remove the conglomerated powder through increased flowability and mechanical displacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional methods like accelerated media blast and mechanical scraping are used to remove conglomerated powder from internal passages, then some powder removal is achieved, but the process is labor-intensive, time-consuming, and inefficient
Solution Approach 1:
Agitators are co-built into the internal passages during the additive manufacturing process itself, before the component is completed. This preliminary placement of agitators enables subsequent efficient powder removal without requiring manual intervention during or after the manufacturing process
Solution Approach 2:
The patent employs vibratory excitation at resonant frequencies to loosen and break up conglomerated powder within internal passages. The agitators, when vibrated, mechanically disrupt the powder aggregates, enabling their removal through improved flowability rather than labor-intensive scraping or blasting
2Quantity of substance
If repeated accelerated media blast and mechanical scraping are performed to remove powder, then more powder is removed, but the process becomes increasingly labor-intensive and complex
Solution Approach 1:
The agitators are designed to be removed along with the conglomerated powder they helped loosen. The vibratory action causes both the powder and the agitators to be ejected from the internal passages together, eliminating the need for separate agitator removal steps and simplifying the overall process
Solution Approach 2:
By using resonant vibration frequencies, the system achieves effective powder removal with a single application rather than repeated blasting and scraping cycles. This reduces both the complexity of the removal process and the manual labor required
3Ease of operation
If ultra sonic or ultrasonic vibratory methods are used to liberate powder particles, then some powder is loosened, but removal from within internal passages remains inefficient
Solution Approach 1:
The agitators serve as intermediaries that are placed within the internal passages during manufacturing. These agitators resonate with ultrasonic vibrations to amplify the loosening effect on conglomerated powder, making the powder more accessible for removal while maintaining operational simplicity
Solution Approach 2:
The patent combines ultrasonic vibratory methods with mechanically co-built agitators that resonate at specific frequencies. This combination enhances the liberation of powder particles from internal passages, achieving both ease of operation and effective removal by addressing the limitations of ultrasonic methods alone
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
Facilitates direct and rapid removal of conglomerated powder with minimal manual operation, enabling efficient cleaning of internal passages and reducing surface roughness, thus improving the manufacturing process efficiency and automation potential.
Implementation Method 1
designed to resonate at specific frequencies, allowing for controlled vibration to loosen and remove the conglomerated powder
Implementation Method 2
controlled vibration to loosen and remove the conglomerated powder through increased flowability and mechanical displacement
Data Source
Figure 1~3
Figure 2
Figure 4~5
AI summary
A component includes an additively manufactured component with an internal passage; and a multiple of agitators additively manufactured within the internal passage. A method of additively manufacturing a component including additively manufacturing a component with an internal passage and additively manufacturing a multiple of agitators within the internal passage concurrent with additively manufacturing the component.