Pin Support Mounting for DED Substrate Distortion Mitigation
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Solution Overview
Problem
Directed Energy Deposition (DED) processes in additive manufacturing often result in residual stresses and distortion in metal workpieces, particularly in titanium and titanium alloys, due to thermal expansion and contraction, leading to geometric inaccuracies and potential failure.
Innovation Solution
A system and method for DED that involves pre-bending a metallic substrate to form a plastically pre-bent substrate, which is then supported by a mount system with a reduced substrate contact interface to minimize heat transfer and residual stress, thereby reducing distortion and improving material quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If DED process is used to manufacture metal workpieces, then manufacturing freedom and material utilization are improved, but residual stress and distortion increase
Solution Approach 1:
The substrate is pre-bent to a predetermined curvature before the DED process begins. This preliminary action creates a pre-stressed state that compensates for the thermal stresses and distortion that will occur during additive manufacturing, allowing the workpiece to achieve the desired final geometry despite the inherent distortion tendencies of the DED process
2Productivity
If DED process deposits metal layers, then near-net-shape products are produced, but welding-induced residual stress accumulates
Solution Approach 1:
A mount system with localized support points is used instead of full-surface contact. The support points are strategically positioned to provide necessary mechanical support while minimizing the contact area between the substrate and mounting structure. This reduces the overall residual stress accumulation by limiting the regions where thermal gradients and constraint-induced stresses develop
3Stress or pressure
If substrate contact interface is reduced to minimize heat transfer, then residual stress is reduced, but support stability may be compromised
Solution Approach 1:
The substrate is pre-bent to a predetermined curvature before mounting. This pre-curving creates an inherent geometric constraint that provides stability during the DED process even with minimal contact points. The pre-formed curvature acts as a built-in stabilizing feature that reduces reliance on extensive mechanical support
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
The approach effectively reduces residual stress and distortion in DED-manufactured products, leading to increased strength, fatigue resistance, and durability, while also improving manufacturing efficiency and reducing material waste.
Implementation Method 1
a mount system with a reduced substrate contact interface to minimize heat transfer
Implementation Method 2
a thermal source to melt a source of metal into metallic molten material that is deposited on a surface of a base material
Implementation Method 3
a cooling gas jet device to direct a cooling gas to impinge upon the as-solidified material adjacent to the liquid-solid boundary of the liquid molten pool
Data Source
Figure 1A
Figure 1B~1C
Figure 1D~1F
AI summary
The present application relates to a mount system (100) and systems and methods using the mount system (100) for manufacturing objects on a substrate (300), especially titanium and titanium alloy objects, by directed energy deposition. The method includes thermally pre-bending the substrate (300) onto which the object is to be manufactured to form a pre-bent substrate (300), attaching the pre- bent substrate (300) to a jig using the mount system (100) as an underlying support, preheating the substrate (300), and forming the object on the p re-heated, pre-bent substrate (300) using a directed energy deposition technique.