Laminate Shaping Component Joining via Built-Up Weld Joints

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Solution Overview

Problem

Existing methods for additively manufacturing metal components are limited by the size and complexity of the manufacturing apparatus, making it difficult to produce large or intricately shaped objects in a single step without compromising quality or increasing the number of processing steps.

Innovation Solution

A joining method that welds multiple additively manufactured components via a weld joint built during the additive manufacturing process, allowing for the creation of larger and more complex structures by depositing weld bead layers with shifts and using backing strips to enhance weld strength and reduce processing steps.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If the size of the additively-manufactured object is increased beyond the range of movement of the manufacturing apparatus, then the manufacturability is improved, but the object cannot be fabricated due to apparatus size limitations

Engineering Contradiction:

Improvesize of additively-manufactured objectVSAvoidmanufacturability

Core Design Contradiction:

Volume of moving objectVSEase of manufacture

Solution Approach 1:

The patent divides a large-scale structure into multiple additively-manufactured components that can be fabricated within the range of movement of the manufacturing apparatus. These components are then joined together through welding to form the complete large-scale structure, thereby overcoming the size limitations of the apparatus while maintaining manufacturability

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent performs preliminary additive manufacturing of individual components within the apparatus's movement range, then prepares them for subsequent welding assembly. This preliminary fabrication approach allows the components to be manufactured with high precision before being joined to form the final large-scale structure

Inventive Principle:

Principle #10Preliminary action

2Productivity

If the structure is fabricated in one manufacturing step, then high-efficiency manufacture with reduced processing steps is achieved, but structures with large size or complicated shape cannot be manufactured

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidability to manufacture large or complex structures

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The patent segments complex structures into multiple manageable components that can be additively manufactured separately within the apparatus's capabilities, then joined through welding. This segmentation enables the manufacturing of large or complex structures that would otherwise be impossible to fabricate in a single step

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent combines additive manufacturing with welding processes to create a hybrid manufacturing approach. Multiple additively-manufactured components are merged through weld joints to form the final structure, achieving both the efficiency of additive manufacturing and the capability to produce large or complex structures

Inventive Principle:

Principle #5Merging (Combining)

3Ease of manufacture

If post-processing such as cutting is used to form weld joints, then the structure can be assembled, but the number of processing steps increases

Engineering Contradiction:

Improveassembly capabilityVSAvoidnumber of processing steps

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent merges the additive manufacturing process with the weld joint formation process. The weld joints are built up simultaneously with the additive manufacturing of the components, eliminating the need for separate post-processing steps such as cutting or machining, thereby reducing the total number of processing steps while maintaining assembly capability

Inventive Principle:

Principle #5Merging (Combining)

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 the fabrication of larger and more complex structures with high quality without size or shape limitations, reducing the number of processing steps and improving weld strength by integrating weld joints and backing strips within the additive manufacturing process.

Implementation Method 1

the additively-manufactured components are built by repeatedly depositing a weld bead layer of a next layer on a weld bead layer formed of a weld bead obtained by melting and solidifying a filler metal by use of an arc

Methodology Applied

Scientific EffectArc: Electric Arc

Implementation Method 2

welding a plurality of additively-manufactured components via a weld joint to fabricate an integral structure

Methodology Applied

Scientific EffectWelding: Welding

Data Source

PatentUS11654500B2Joining method and structure for laminate shaping component, and laminate shaping component

Publication Date: 2023.05.23 KOBE STEEL LTD

AI summary

A method for joining an additively-manufactured component includes welding a plurality of additively-manufactured components via a weld joint to fabricate an integral structure. The additively-manufactured components are built by repeatedly depositing a weld bead layer of a next layer on a weld bead layer formed of a weld bead obtained by melting and solidifying a filler metal by use of an arc, and the weld joint is built along with the deposition.