Joined Parts With Joint Material Filling Uneven Surfaces
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Solution Overview
Problem
Additive manufacturing techniques, such as binder jetting, face challenges in joining parts with uneven surfaces, leading to porosity at the joint interface and reduced joint strength, especially when forming complex or large-sized objects.
Innovation Solution
Incorporating a joint material with a powder having a particle size distribution of 1 μm to 50 μm, which fills the uneven surfaces, and optionally including a binder with reactive monomers and a thickening agent, to create a seamless joint and enhance the strength of the joined part.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If binder jetting is used to join parts with uneven surfaces, then complex or large-sized objects can be formed, but porosity occurs at the joint interface resulting in reduced joint strength
Solution Approach 1:
The patent applies preliminary action by pre-coating the uneven surfaces of green parts with a slurry material before joining. This slurry coating fills the surface irregularities and creates a flat, uniform interface that enables strong bonding when parts are joined, preventing porosity at the joint interface while maintaining the ability to form complex or large-sized objects through binder jetting
Solution Approach 2:
The slurry material acts as an intermediary substance between the uneven surfaces of green parts. This intermediate layer fills voids and surface irregularities, providing a uniform bonding interface that enhances joint strength while allowing the binder jetting process to successfully join complex or large-sized objects without direct contact between irregular surfaces
2Volume of moving object
If binder jetting is used to join parts, then objects of large size or complex shape can be obtained, but the joining process suffers from porosity at the joint interface
Solution Approach 1:
The slurry coating is applied in advance to fill surface irregularities before the joining operation. This preliminary action ensures that when large-sized or complex-shaped objects are joined, the interface is free of porosity and defects, improving joint interface quality while maintaining the capability to produce objects of large volume or complex geometry
Solution Approach 2:
The patent applies local quality by treating only the joint interface regions with slurry coating, rather than the entire part. This localized treatment fills surface irregularities at the critical bonding interface, eliminating porosity and improving joint interface quality, while allowing the rest of the large-sized or complex-shaped object to maintain its intended structure and volume
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
The solution results in improved joint strength and a seamless interface, reducing the likelihood of mechanical failure and enhancing the overall strength of the part by filling voids and providing a strong bond between the joined components.
Implementation Method 1
a joint material with a powder having a particle size distribution greater than or equal to 1 μm and less than or equal to 50 μm, which fills the uneven surfaces of joined green portions
Implementation Method 2
binder jetting is an additive manufacturing technique based on the use of a binder to join particles of a powder to form a 3D object. In particular, the binder is jetted onto successive layers of the powder in a build volume, where layers of the powder and the binder adhere to one another
Implementation Method 3
the binder further comprises a thickening agent
Data Source
AI summary
A green body part comprises a first green portion, a second green portion, an interfacial joint between the first green portion and the second green portion, and a joint material disposed within the interfacial joint. The joint material comprises a powder having a particle size distribution than or equal to 1 μm and less than or equal to 50 μm. A method of manufacturing a joined part includes applying a joint material on a face of the first green portion and contacting the second green portion to the joint material on the face of the first green portion to form a joined green body part.