Metal Frame Assembly Using HIP-Bonded Wrought Material
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Solution Overview
Problem
Current manufacturing technologies for metal frames, such as machining-from-solid and welding, are costly and prone to defects like cracks, porosity, and residual stresses, while additive manufacturing results in high residual stresses and bending issues due to all-weld-solidified structures.
Innovation Solution
A method involving creating an intermediate space between elements, filling it with wrought material, sealing, and subjecting it to a hot pressing process to form a strong metal frame with low residual stresses and reduced material wastage, using techniques like hot isostatic pressing to achieve high density and complex structure fabrication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If machining-from-solid is used to manufacture metal frames, then manufacturing precision can be achieved, but material waste increases and manufacturing cost increases
Solution Approach 1:
The patent changes the manufacturing parameters from subtractive machining to a formative process using hot isostatic pressing (HIP) technology. By controlling temperature, pressure, and time parameters during the HIP process, the wrought material pieces are metallurgically bonded to form the final frame structure with precise geometry, eliminating the need for material removal while achieving high manufacturing precision.
Solution Approach 2:
The patent utilizes phase transitions of materials during the hot isostatic pressing process. The wrought material pieces are heated to high temperatures where metallurgical bonding occurs, transforming from separate pieces to a unified structure. This phase transition enables precise formation of the frame geometry without subtractive machining, thereby reducing material waste while maintaining manufacturing precision.
2Ease of manufacture
If welding is used to manufacture metal frames, then structural assembly can be achieved, but defects such as cracks, porosity, and residual stresses increase
Solution Approach 1:
The patent replaces the welding process (a mechanical/thermal joining method) with hot isostatic pressing, which uses controlled temperature and pressure fields to achieve metallurgical bonding. This substitution eliminates the harmful effects of welding such as cracks, porosity, and residual stresses, while still achieving reliable structural assembly of the frame components.
Solution Approach 2:
The patent changes the process parameters from welding (high localized heat, rapid cooling) to hot isostatic pressing (controlled high temperature, sustained high pressure). This parameter change transforms the joining mechanism from one that creates defects to one that produces defect-free metallurgical bonding, thereby improving reliability while maintaining ease of manufacture.
3Adaptability or versatility
If additive manufacturing is used to manufacture metal frames, then complex geometries can be achieved, but residual stresses and bending issues increase
Solution Approach 1:
The patent divides the frame structure into separate wrought material pieces that are arranged to form the desired complex geometry. These segmented pieces are then bonded together using hot isostatic pressing. This segmentation approach allows for complex geometries to be achieved while avoiding the residual stresses and bending issues associated with additive manufacturing, as each piece is separately processed and then uniformly bonded.
Solution Approach 2:
The patent replaces additive manufacturing (which builds structures layer-by-layer with inherent residual stresses) with a cold-forming assembly approach followed by hot isostatic pressing. This substitution eliminates the layer-by-layer deposition process that causes residual stresses and bending, while still enabling complex geometries through the arrangement and bonding of pre-formed wrought material pieces.
4Strength
If wrought material pieces are bonded using hot pressing, then metallurgical bonding strength can be achieved, but process complexity increases
Solution Approach 1:
The patent employs hot isostatic pressing as a multi-functional process that simultaneously achieves metallurgical bonding, density consolidation, and defect elimination. This universal process replaces multiple separate operations (such as welding, heat treatment, and quality inspection) with a single integrated process, thereby achieving high bonding strength while actually simplifying the overall manufacturing process rather than increasing complexity.
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 enables the production of strong, lightweight metal frames with low residual stresses and reduced material waste, facilitating complex geometries and minimizing post-treatment reshaping needs, thereby improving manufacturing efficiency and product quality.
Implementation Method 1
subjecting the assembled frame arrangement to a hot pressing process, e.g. a hot isostatic pressing process, for a predetermined time at a predetermined pressure and a predetermined temperature, such that at least the plurality of pieces of a wrought material bond metallurgically to each other
Data Source
AI summary
The inventive concept relates to a method for manufacturing a metal based frame comprising the steps of: providing a first element (202) comprising a first element inner enveloping wall (204) surrounding an interior volume; providing a second element (210) having a second element outer wall (212), a second element inner wall (213), and a third element (220) having a third element outer wall (222), a third element inner wall, wherein the second element inner wall (213) and the third element inner wall each surrounds a free space (215); arranging the second element (210) and the third element (220) in the interior volume (208) such that an intermediate space (230) having an access opening (232) is formed between the first element inner enveloping wall (204) and the second element outer wall (212) and the third element outer wall (222) in a predetermined pattern; arranging a plurality of pieces of a wrought material (250) in the intermediate space (230); providing a closing member (240) arranged such that it covers at least the access opening (232) of the intermediate space (230), whereby the first element (202), the second element (210), the third element (220), the plurality of pieces of a wrought material (250), and the closing member (240) form an assembled frame arrangement (200); removing gas from the intermediate space; subjecting the assembled frame arrangement to a hot pressing process for a predetermined time at a predetermined pressure and a predetermined temperature such that at least the plurality of pieces of a wrought material bond metallurgically to each other, to form the metal based frame.