In-Situ Laser Peening for Thin-Wall Additive Manufacturing
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Solution Overview
Problem
Existing additive manufacturing techniques face limitations in post-processing complex geometries due to the requirement for line of sight access, which restricts the control of surface finish, hardness, and residual stress, especially for interior surfaces.
Innovation Solution
Integrating peening processes, such as laser peening or shot peening, into the additive manufacturing process to induce plastic deformation and control surface finish, hardness, and residual stress throughout the part, including inaccessible regions, by alternately or repeatedly performing additive manufacturing and peening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If post-processing techniques (electropolishing, sand blasting) are used to control surface finish, then surface quality is improved, but line of sight access is required which limits applicability to complex geometries
Solution Approach 1:
The patent combines the additive manufacturing process with in-situ peening processes (laser peening, shot peening) to perform surface treatment during manufacturing rather than as a separate post-processing step. This merging allows interior surfaces and complex geometries to be treated without requiring line of sight access, as the peening media can reach areas inaccessible to traditional post-processing methods
Solution Approach 2:
The peening process is performed preliminarily during the additive manufacturing process, before the part is complete. This allows surface treatment to be applied to interior surfaces and complex geometries that would be inaccessible for post-processing, effectively performing the surface finish control action in advance before geometric constraints prevent further access
2Adaptability or versatility
If additive manufacturing is used to create complex geometries, then design flexibility is improved, but minimum wall thickness limits are imposed by machine resolution
Solution Approach 1:
The patent uses peening-induced plastic deformation to change the physical parameters of the wall structure. By applying controlled deformation, the effective thickness and density of thin walls are modified, allowing walls to be made thinner than the machine's minimum resolution limit while maintaining structural integrity and eliminating porosity
3Manufacturing precision
If in-situ peening is performed during additive manufacturing, then surface finish and residual stress control is improved throughout the part, but process complexity increases
Solution Approach 1:
The additive manufacturing system is designed with multi-functionality, incorporating peening capabilities (laser or shot peening) directly into the manufacturing machine. This allows the same equipment to perform both additive manufacturing and surface treatment functions, reducing the need for separate dedicated equipment and optimizing resource utilization
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 improved fatigue life and stress corrosion resistance by controlling surface finish and residual stress throughout the part, including interior surfaces, and achieves thinner wall thicknesses below the resolution limits of conventional additive manufacturing.
Implementation Method 1
The peening may include laser peening, with a laser impulse system, the at least a portion of the wall
Implementation Method 2
The laser peening may include directing a laser beam through a confining medium between the at least a portion of the wall and the laser impulse system
Implementation Method 3
The shot may be configured to sublime at a temperature and a pressure inside the additive manufacturing machine
Data Source
AI summary
A method of manufacturing a part includes additively manufacturing, with an additive manufacturing machine, at least one wall of the part having a first thickness from powder in a powder bed, and peening, with a peening system, at least a portion of the wall of the part. The peening induces plastic deformation in the portion of the wall. The portion of the wall that is peened has a second thickness less than the first thickness of the wall prior to peening. The second thickness of the portion of the wall may be less than a minimum thickness limit achievable by the additive manufacturing machine.