Rocket Connection Ring Additive Bonding With Electromagnetic Pulses
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Solution Overview
Problem
Traditional manufacturing processes for high-strength aluminum alloy connection rings of heavy-lift carrier rockets face challenges such as pores and composition segregation, affecting mechanical properties, and existing additive manufacturing methods like impact welding are inefficient.
Innovation Solution
An electromagnetic pulse additive device and method that includes a gear disk, lifting modules, and an electromagnetic head with a coil connected to a capacitor and discharge circuit, which generates a high-speed collision between an additive thin sheet and the base body to form a metallurgical bond, followed by rotational friction and extrusion to eliminate defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional manufacturing processes are used for high-strength aluminum alloy connection rings, then manufacturing complexity is reduced, but manufacturing defects such as pores and composition segregation occur, affecting mechanical properties
Solution Approach 1:
The patent replaces traditional mechanical manufacturing processes with electromagnetic pulse additive manufacturing technology. The electromagnetic pulse system uses electromagnetic fields to drive the additive manufacturing process, eliminating mechanical contact and associated defects like pores and composition segregation, thereby improving mechanical properties while managing manufacturing complexity through automated electromagnetic control.
Solution Approach 2:
The patent changes the fundamental manufacturing parameters from traditional mechanical subtraction or addition methods to electromagnetic pulse-driven solid-phase connection. This parameter change enables direct formation of high-strength aluminum alloy connection rings with controlled microstructure, avoiding defects while achieving reliable mechanical properties through precise electromagnetic parameter control.
2Productivity
If electric arc fuse three-dimensional (3D) printing technology is used, then additive manufacturing capability is achieved, but manufacturing defects such as pores and composition segregation are easily emerged, directly affecting the mechanical properties of additive components
Solution Approach 1:
The patent substitutes electric arc fuse 3D printing with electromagnetic pulse additive manufacturing. The electromagnetic pulse technology uses non-contact electromagnetic fields to drive material connection, eliminating the thermal processes that cause pores and composition segregation in electric arc methods, thereby maintaining additive manufacturing capability while significantly improving mechanical properties.
Solution Approach 2:
The patent utilizes solid-phase connection through electromagnetic pulse impact, avoiding the melting and solidification phase transitions that occur in electric arc 3D printing. This solid-phase approach prevents pore formation and composition segregation associated with thermal processing, achieving defect-free additive components with superior mechanical properties.
3Reliability
If impact welding method is used in additive manufacturing process, then manufacturing defects are eliminated, but manufacturing efficiency is low
Solution Approach 1:
The patent employs periodic electromagnetic pulse impacts in the additive manufacturing process. By applying series of controlled electromagnetic pulses at optimized intervals, the system achieves thorough defect elimination through repeated solid-phase connection cycles while maintaining high manufacturing efficiency through automated rapid pulsing sequences.
Solution Approach 2:
The patent implements continuous electromagnetic pulse additive manufacturing with automated material feeding and sequential layer construction. The process maintains continuous useful action by eliminating idle time between operations, with electromagnetic pulses continuously driving material deposition and connection, thereby achieving both defect elimination and high manufacturing efficiency.
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
Improves the compactness and mechanical properties of the additive parts by forming strong bonds and eliminating defects like pores and cracks, enhancing the structural integrity of the connection ring.
Implementation Method 1
an electromagnetic head with a coil connected to a capacitor and discharge circuit, which generates a high-speed collision between an additive thin sheet and the base body
Implementation Method 2
followed by rotational friction and extrusion to eliminate defects
Data Source
AI summary
An electromagnetic pulse additive device for a connection ring of a heavy-lift carrier rocket is provided. The device includes brackets, a gear disk rotatably matched with the annular ground rail through a plurality of rolls arranged in a circumferential direction of the gear disk, a first drive motor, an annular ground rail, and a guide rail in a semicircular shape arranged at top ends of the brackets. An output shaft of a first drive motor is fixedly provided with a first drive gear engaged with the gear disk. The guide rail is slidably provided with three lifting modules which respectively drive a bending module, an electromagnetic head arranged electromagnetic coil electrically connected with a capacitor and a discharge circuit, and a rotational friction and extrusion module including a second drive motor and a friction bar fixedly connected to an output shaft of the second drive motor to rise and fall.