Amorphous Additive Manufacturing Using Pulsed Laser Cooling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional additive manufacturing methods produce polycrystalline or equiaxed microstructures with defects and inhomogeneity, requiring post-processing that leads to grain growth, which affects yield strength and fatigue resistance.
Innovation Solution
An additive manufacturing system using a pulsed laser and ultrasonic transducers to create an amorphous structure with a high cooling rate and nanocrystal grains, allowing for the formation of an amorphous matrix with controlled vibration during the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional additive manufacturing methods are used to produce polycrystalline structures, then manufacturing process is simple, but the structure contains defects and inhomogeneity requiring post-processing that causes grain growth
Solution Approach 1:
The patent changes the cooling rate parameter from conventional slow cooling to extremely high cooling rates (10^5 to 10^6 K/s) achieved through selective laser melting. This parameter change transforms the microstructure formation process, enabling amorphous structure creation without post-processing while maintaining manufacturing simplicity.
Solution Approach 2:
The patent utilizes phase transition from crystalline to amorphous state by controlling the cooling rate during additive manufacturing. The rapid cooling prevents crystal nucleation and growth, directly forming amorphous structures that eliminate the need for post-processing heat treatment and avoid grain growth.
2Reliability
If post-processing heat treatment is applied to polycrystalline structures, then defects are reduced, but grain growth occurs affecting yield strength and fatigue resistance
Solution Approach 1:
The patent performs preliminary action by forming the desired amorphous microstructure directly during the additive manufacturing process itself, eliminating the need for subsequent post-processing heat treatment. This prevents grain growth before it can occur, preserving both defect reduction and mechanical strength properties.
Solution Approach 2:
The patent converts the typically harmful rapid cooling (which causes inhomogeneity) into a beneficial effect by using it to form the desired amorphous structure directly. The rapid cooling rate, normally a challenge, becomes the mechanism for creating the superior microstructure without post-processing.
3Ease of manufacture
If amorphous structure is formed with high cooling rate, then post-processing is eliminated, but process control complexity increases
Solution Approach 1:
The patent makes the laser serving multiple functions: it both melts the powder and controls the cooling rate to form amorphous structures. This multi-functionality eliminates the need for separate post-processing equipment and operations, reducing overall system complexity despite the advanced process control requirements.
Solution Approach 2:
The patent replaces mechanical post-processing systems (heat treatment furnaces, HIP equipment) with a controlled energy field approach using the laser. The process control shifts from mechanical manipulation to precise thermal field management, eliminating complex post-processing machinery.
4Strength
If ultrasonic vibration is applied during additive manufacturing, then nanocrystal grains form in amorphous matrix improving mechanical properties, but device complexity increases
Solution Approach 1:
The patent merges the ultrasonic vibration system with the existing additive manufacturing setup, integrating it into the build platform. This combination allows nanocrystal grain formation in the amorphous matrix without requiring entirely separate equipment, managing device complexity while achieving superior mechanical properties.
Solution Approach 2:
The patent applies mechanical vibration at ultrasonic frequencies during the additive manufacturing process to promote nanocrystal grain formation within the amorphous matrix. This vibration mechanism, when integrated with the build platform, enhances fatigue resistance and elastic strain without requiring complex external processing equipment.
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 system produces a hybrid structure with nanocrystalline grains in an amorphous matrix, enhancing fatigue resistance and elastic strain while minimizing brittleness, thereby improving the mechanical properties of the manufactured articles.
Implementation Method 1
The energy applicator can include a laser. The control module can be configured to pulse the laser.
Implementation Method 2
The control module can be configured to control the laser to cause an amorphous matrix formation cooling rate to form an amorphous matrix.
Implementation Method 3
The energy applicator can include one or more acoustic transducers disposed on or in the build platform to provide vibration during additive manufacturing to the article and/or a portion thereof to cause formation of nanocrystal grains in the amorphous matrix.
Data Source
AI summary
An additive manufacturing system configured to additively build an article can include an energy applicator, a build platform, and a powder nozzle configured to eject powder toward the build platform to be acted on by the energy applicator. The system can include a control module configured to control the energy applicator to create an amorphous structure forming at least a portion of the article.