Additive Manufacturing Pure Metal Eutectics Latent Heat

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Solution Overview

Problem

Existing additive manufacturing techniques are limited to printing non-eutectic alloys with thermodynamically stable semi-solid states over a range of temperatures, whereas pure metal and eutectic alloys can only exist at a single temperature, restricting the production of non-thermodynamically stable semi-solid states.

Innovation Solution

The development of a dispensing system with an axial temperature gradient that targets the metal's melting point at the nozzle tip, allowing for the control of solids fraction during solidification, using a reservoir for melting and a long heated tube for extruding semi-solid metals or eutectic alloys through a nozzle.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If prior art techniques are used to print metal alloys, then non-eutectic alloys with thermodynamically stable semi-solid states can be produced, but pure metal and eutectic alloys cannot be processed because they only exist at a single temperature

Engineering Contradiction:

Improverange of materials that can be processedVSAvoidtemperature control range

Core Design Contradiction:

Adaptability or versatilityVSTemperature

Solution Approach 1:

The invention changes the temperature parameter dynamically along the extrusion path, creating a temperature gradient that allows pure metal and eutectic alloys to maintain a semi-solid state during extrusion. By controlling heat flow into the alloy and maintaining specific temperature zones, the system enables processing of materials that previously could not be printed due to their narrow temperature window for semi-solid existence.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The system dynamically adjusts temperature distribution along the extrusion path rather than maintaining a uniform temperature. The temperature profile is optimized to keep the material in a semi-solid state during extrusion, with different zones having different temperatures to control solidification and maintain flowability.

Inventive Principle:

Principle #15Dynamics

2Ease of manufacture

If a long heated tube is used to maintain semi-solid state during extrusion, then pure metal and eutectic alloys can be extruded, but the device complexity increases

Engineering Contradiction:

Improveability to extrude semi-solid metalsVSAvoidstructure of dispensing system

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The extrusion system is divided into distinct thermal zones along the extrusion path, with each zone serving a specific function (melting, holding, extrusion). This segmentation allows precise control of temperature distribution and enables the long heated tube to be managed as a series of controlled zones rather than a single complex component.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The long heated tube acts as an intermediary component that bridges the melting zone and the extrusion nozzle, maintaining the semi-solid state of the material during transport. This intermediary element allows the system to process pure metal and eutectic alloys without requiring direct contact between the heat source and the extrusion point.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If heat flow is controlled over distance to extrude semi-solid metal, then non-thermodynamically stable semi-solid states can be produced, but energy consumption increases

Engineering Contradiction:

Improveproduction of semi-solid metalVSAvoidheat flow control energy

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The invention exploits the phase transition of metal from solid to semi-solid state during extrusion by controlling heat flow. The latent heat of fusion is utilized to maintain the semi-solid state, and the temperature gradient is designed to facilitate controlled solidification after extrusion, reducing the overall energy required to maintain the semi-solid state throughout the entire system.

Inventive Principle:

Principle #36Phase transitions

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

Enables the additive manufacturing of pure metal and eutectic alloys by maintaining a semi-solid state during extrusion, allowing for the production of metal parts with varying solids fractions, which enhances the range of materials that can be processed and improves the manufacturing flexibility.

Implementation Method 1

a reservoir for melting and a long heated tube for conditioning the alloy for extrusion in the semi-solid state

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 2

controlling heat flow into the alloy... controlling solids fraction during solidification

Methodology Applied

Scientific EffectSolidification: Freezing

Implementation Method 3

by controlling heat flow into the alloy... exploiting the metal's latent heat during solidification

Methodology Applied

Scientific EffectLatent heat: Latent Heat

Implementation Method 4

a long heated tube for conditioning the alloy for extrusion in the semi-solid state through a nozzle

Methodology Applied

Scientific EffectExtrusion: Extrusion

Data Source

PatentUS10189081B2Additive manufacturing via direct writing of pure metal and eutectics through latent heat position control

Publication Date: 2019.01.29 LAWRENCE LIVERMORE NAT SECURITY LLC

AI summary

An additive manufacturing system for producing metal parts from pure metal or eutectic alloys. The system includes an additive manufacturing print head, a print head heater system, an agitation system, a nozzle in the additive manufacturing print head, a reservoir for melting the metal, and a long heated tube for conditioning the alloy for extrusion in the semi-solid state through a nozzle.