Movable Oven Lid Build Chamber for AM Stress Relief Heating

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Solution Overview

Problem

Additive manufacturing processes face challenges in managing residual stresses and distortion in large or less ductile materials, leading to potential cracking and warping of three-dimensional objects during the build process.

Innovation Solution

An additive manufacturing apparatus with a heated build chamber, facilitated by an oven comprising a furnace body and a movable oven lid, allows for controlled heating and stress relief by enclosing the build area, and optionally using an autoclave for pressurization to perform hot isostatic pressing treatments.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If additive manufacturing is used to fabricate large or less ductile workpieces, then manufacturing capability is improved, but residual stresses and distortion increase leading to cracking and warping

Engineering Contradiction:
Improvemanufacturing capabilityVSAvoidworkpiece integrity
Core Design Contradiction:
Ease of manufactureVSReliability

Solution Approach 1:

The patent applies preliminary action by implementing stress relief heating during the additive manufacturing process before the workpiece is complete. The system periodically heats the workpiece to elevated temperatures to relieve residual stresses as they accumulate during building, preventing cracking and warping before they occur. This proactive approach allows the fabrication of large or less ductile workpieces that would otherwise be prone to failure.

Inventive Principle:
Principle #10Preliminary action

2Reliability

If stress relief heating is applied during additive manufacturing, then residual stresses are reduced, but process time increases

Engineering Contradiction:
Improveworkpiece integrityVSAvoidbuild process time
Core Design Contradiction:
ReliabilityVSLoss of time

Solution Approach 1:

The patent implements periodic action by applying stress relief heating at intervals during the additive manufacturing process rather than continuously. The system monitors residual stresses and applies heating only when thresholds are exceeded, allowing the build process to continue otherwise. This periodic intervention reduces total process time compared to continuous heating while still preventing cracking and warping.

Inventive Principle:
Principle #19Periodic action

3Temperature

If an enclosed heated build chamber is used, then temperature control is improved, but device complexity increases

Engineering Contradiction:
Improvetemperature controlVSAvoidapparatus structure
Core Design Contradiction:
TemperatureVSDevice complexity

Solution Approach 1:

The patent applies universality by designing the build chamber to serve multiple functions: it provides structural enclosure for the additive manufacturing process, acts as a heating furnace for stress relief treatments, and enables temperature control during building. By making the build chamber multi-functional, the system achieves improved temperature control without proportionally increasing device complexity, as the same hardware structure supports multiple operations.

Inventive Principle:
Principle #6Universality (Multi-functionality)

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 solution enables the construction of larger and less ductile workpieces by alleviating residual stresses, reducing distortion, and preventing cracking, while improving heating efficiency and reducing the need for subsequent processing steps.

Implementation Method 1

an energy source configured to apply an energy beam to the deposited material to melt the deposited material at the build surface

Methodology Applied
Scientific EffectEnergy beam melting: Laser Beam Welding

Implementation Method 2

heating the deposited material with an oven after the layer is deposited on the build surface

Methodology Applied
Scientific EffectThermal heating: Heating

Implementation Method 3

heating the workpiece to a temperature sufficient to relieve residual stresses in the workpiece

Methodology Applied
Scientific EffectStress relief heating: Annealing

Implementation Method 4

pressurizing the deposited material in the cavity after heating

Methodology Applied
Scientific EffectIsostatic pressing: Hot Isostatic Pressing

Data Source

PatentUS20240227022A1Apparatus and method to manage temperature and stress in a part during additive manufacturing
Publication Date: 2024.07.11 GENERAL ELECTRIC CO
  • US20240227022A1 patent drawing
  • US20240227022A1 patent drawing
  • US20240227022A1 patent drawing

AI summary

A method of additively manufacturing a workpiece may include depositing and melting a material on a build plate by translating a deposition head of an additive manufacturing apparatus over the build plate to form a layer of deposited material; and heating the deposited material with an oven after the layer is deposited on the build plate, wherein the oven comprises a furnace body and an oven lid movable with the deposition head and disposable on the furnace body to enclose a heated build chamber of the oven.