Laser-Welded Metal Sheet Additive Manufacturing Without Powder Beds

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Solution Overview

Problem

Conventional additive manufacturing techniques using powder beds face issues with non-uniform material properties due to particle size distribution and high surface area, leading to increased oxygen content and environmental, health, and safety hazards, as well as labor-intensive powder removal.

Innovation Solution

The process employs a metallic sheet or layer as the raw material source, where a metallic layer is positioned beneath a substrate and welded using laser energy, either directly to the substrate or by ablating a non-metallic substrate to propel the metal layer, allowing for the advancement of subsequent layers to build components, such as those for aerospace applications.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If powder bed is used as raw material source, then additive manufacturing can be performed, but material uniformity deteriorates due to particle size distribution variation

Engineering Contradiction:

Improvematerial uniformityVSAvoidparticle size distribution

Core Design Contradiction:

Manufacturing precisionVSStability of the object's composition

Solution Approach 1:

The patent changes the physical state and form of the raw material from powder to sheet/foil form. This parameter change eliminates particle size distribution issues while maintaining the additive manufacturing capability through layer-by-layer deposition of metallic sheets.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs disposable metallic sheets or foils as the raw material source. These sheets are consumed layer by layer during the additive manufacturing process, eliminating the need for powder handling and storage while ensuring consistent material properties.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Manufacturing precision

If powder bed is used as raw material source, then additive manufacturing can be performed, but oxygen content increases due to high surface area

Engineering Contradiction:

Improvematerial consistencyVSAvoidoxygen content

Core Design Contradiction:

Manufacturing precisionVSQuantity of substance

Solution Approach 1:

The patent changes the raw material form from high-surface-area powder to low-surface-area sheet/foil form. This parameter change significantly reduces the total surface area exposed to oxygen, thereby minimizing oxidation and improving material consistency.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If powder bed is used as raw material source, then additive manufacturing can be performed, but environmental and health hazards increase

Engineering Contradiction:

Improveadditive manufacturing capabilityVSAvoidenvironmental and health hazards

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent extracts and eliminates the powder bed component from the additive manufacturing system. By using metallic sheets as the raw material source, the process removes the sources of environmental and health hazards associated with powder handling, storage, and disposal.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent converts the handling complexity and hazard of powder materials into the simplicity and safety of sheet material handling. The metallic sheets are easier to handle, store, and process safely, transforming a harmful process into a beneficial one.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

4Ease of manufacture

If powder bed is used as raw material source, then additive manufacturing can be performed, but labor-intensive powder removal is required

Engineering Contradiction:

Improveadditive manufacturing processVSAvoidpowder management

Core Design Contradiction:

Ease of manufactureVSEase of operation

Solution Approach 1:

The patent extracts and eliminates the powder removal step from the manufacturing process. By using metallic sheets instead of powder, the process eliminates the need for labor-intensive powder removal, sifting, and disposal operations.

Inventive Principle:

Principle #2Taking out (Extraction)

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 eliminates the need for powder beds, reducing environmental and health hazards, and simplifies the manufacturing process by using uniform metallic sheets, enhancing material properties and reducing labor-intensive powder management.

Implementation Method 1

the step of welding the metallic layer to the component substrate involves using laser energy to promote fusion welding between the metallic layer and the component substrate

Methodology Applied

Scientific EffectLaser welding: Laser Beam Welding

Implementation Method 2

using laser energy to promote fusion welding between the metallic layer and the component substrate

Methodology Applied

Scientific EffectFusion welding: Welding

Implementation Method 3

the step of welding the metallic layer to the component substrate involves using laser energy to ablate the non-metallic substrate and propel the metallic layer towards the component substrate to create a weld joint

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Data Source

PatentUS11458570B2Lean optimized additive manufacturing process

Publication Date: 2022.10.04 HAMILTON SUNDSTRAND CORP

AI summary

An additive manufacturing process is disclosed that involves positioning a metallic layer beneath a component substrate and welding the metallic layer to the component substrate using laser energy.