Metal Frame Assembly Using Hot Pressed 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, and subjecting it to a hot pressing process at specific pressure and temperature to form a strong metal frame with low residual stresses and high density, using techniques like hot isostatic pressing to reduce porosity and achieve near-net shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If machining-from-solid is used to manufacture metal frames, then structural strength is improved, but material waste increases and manufacturing cost increases
Solution Approach 1:
The frame structure is divided into multiple separate components (first element, second element, third element, closing member) that are manufactured independently and then assembled. This allows each component to be optimized separately and reduces the need for subtractive machining of a single solid block, thereby reducing material waste while maintaining structural integrity through proper design of individual segments.
Solution Approach 2:
The invention changes the manufacturing parameters from traditional machining or welding to a hot pressing process that bonds pre-formed components together. This parameter change allows for near-net-shape manufacturing of each component, minimizing material removal and waste while achieving strong joints without the defects associated with welding.
2Adaptability or versatility
If welding is used to manufacture frame structures, then assembly flexibility is improved, but structural defects increase due to cracks, porosity, and residual stresses
Solution Approach 1:
The invention replaces the welding process (thermal-chemical joining) with a hot pressing process that uses controlled pressure and temperature to bond components. This substitution eliminates the harmful effects of welding such as cracks, porosity, and residual stresses, while still achieving strong, flexible assemblies through the bonding of pre-formed components.
3Device complexity
If additive manufacturing is used to manufacture frame structures, then manufacturing complexity is reduced, but residual stresses increase leading to bending and cracking
Solution Approach 1:
The individual frame components are pre-formed using appropriate manufacturing processes to achieve near-net-shape geometry before assembly. This preliminary action allows for controlled material placement and minimizes the need for post-assembly machining, while the hot pressing bonding process avoids the residual stress problems of additive manufacturing by using controlled pressure and temperature rather than layer-by-layer deposition.
4Weight of moving object
If frame structures are manufactured with cavities to reduce weight, then weight is reduced, but structural strength decreases
Solution Approach 1:
The frame is segmented into multiple components with strategically placed cavities and walls. This segmentation allows for weight reduction through hollow sections while maintaining strength through the distributed structure and bonding interfaces. The hot pressing process ensures strong bonds at the joints, compensating for the reduced material volume from cavities.
Solution Approach 2:
The invention uses composite construction with different materials or material densities in different parts of the frame structure. By combining materials with different properties and using hollow sections strategically, the frame achieves optimal weight-strength ratio, with the hot pressing process ensuring strong integration of the composite components.
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 reduced material waste and minimal subtractive removal, allowing for complex structures and lower post-treatment needs, while minimizing defects and residual stresses.
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
Implementation Method 2
a hot pressing process, e.g. a hot isostatic pressing process
Implementation Method 3
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
Implementation Method 4
using techniques like hot isostatic pressing to reduce porosity and achieve near-net shape
Implementation Method 5
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
Data Source
Figure 1
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Figure 4~5a
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.