Additively Manufactured Metal Joint With Resistive Heating Welds
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Solution Overview
Problem
Current additive manufacturing techniques face limitations in producing large-scale aerospace components due to size constraints and high operational costs, particularly with titanium-based metals, which are difficult to machine and require costly dies.
Innovation Solution
The method involves additively manufacturing metal portions and joining them with a resistive heating material at a welded joint, using a different material than the portions, to produce heat for welding, thereby eliminating the need for large-scale machines and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If additive manufacturing is used to form large-scale parts, then manufacturing cost and time are reduced, but the available machine volume limits the maximum part size
Solution Approach 1:
The patent divides a large-scale part into multiple smaller sub-components that can be additively manufactured within the volume constraints of available machines. These sub-components are then joined together through welding to form the complete large-scale assembly, thereby overcoming the machine volume limitation while maintaining the productivity benefits of additive manufacturing.
2Reliability
If titanium-based materials are used for high temperature and pressure operation, then operational reliability is improved, but machining difficulty and tooling cost increase
Solution Approach 1:
The patent replaces traditional mechanical machining processes with additive manufacturing for producing titanium-based components. By building parts layer-by-layer through additive manufacturing, the difficult-to-machine titanium materials can be formed without requiring costly specialized tooling and machining operations, while maintaining the material's operational reliability for high temperature and pressure applications.
3Length of stationary object
If large-scale additive manufacturing machines are used, then part size capability is improved, but operational cost increases
Solution Approach 1:
The patent segments large-scale part production into multiple smaller sub-components manufactured on standard-size additive manufacturing equipment. This approach enables production of large-scale parts using readily available, cost-effective machines rather than requiring expensive large-scale additive manufacturing equipment, thereby reducing operational costs while achieving the needed part size through subsequent welding assembly.
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 approach enables the efficient and cost-effective manufacturing of large-scale aerospace components with complex geometries, reducing manufacturing time and complexity, and supporting on-demand production without the need for large-scale machines or expensive tooling.
Implementation Method 1
a resistive heating material disposed within an interior of the welded joint... directing electric current through the resistive heating material to produce heat via the resistive heating material
Data Source
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AI summary
An article comprising additively manufactured metal portions is described. The article comprises a first additively manufactured metal portion, and a second additively manufactured metal portion coupled to the first additively manufactured metal portion at a welded joint. The article further comprises a resistive heating material disposed within an interior of the welded joint, the resistive heating material comprising a different material than the first additively manufactured metal portion and the second additively manufactured metal portion.