Solid-State Composite Additive Manufacturing for Poor-Weldability Metals
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Solution Overview
Problem
Existing additive manufacturing methods face challenges with materials of poor weldability, leading to metallurgical defects like inhomogeneity, hot cracks, and residual thermal stress, which reduce the mechanical properties of structural components, especially due to severe friction and inclusion issues in solid additive manufacturing techniques.
Innovation Solution
A solid composite additive manufacturing method involving extrusion and rolling pressure connection after pretreatment at the material's melting temperature, where the cast metal is formed into a structural component with thermal mechanical processing, refining grains and breaking oxide films to enhance bonding strength and interlayer connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If existing additive manufacturing methods are used for materials with poor weldability, then the manufacturing process can be applied, but metallurgical defects such as tissue inhomogeneity, hot cracks, and holes are produced, resulting in unacceptable mechanical properties
Solution Approach 1:
The invention changes the fundamental parameter of the additive manufacturing process from melting and solidification to solid-state deformation and connection. By operating below the melting point of the material, the process avoids the metallurgical defects associated with phase transitions, enabling reliable manufacturing of components from materials with poor weldability while maintaining excellent mechanical properties
Solution Approach 2:
The invention replaces the thermal field-based melting and solidification mechanism with a mechanical field-based solid-state deformation and connection mechanism. This substitution eliminates the formation of dendrites, hot cracks, and tissue inhomogeneity, achieving both broad material adaptability and high component reliability
2Adaptability or versatility
If friction stir additive manufacturing is used to achieve solid-state deformation and connection, then the process is applicable to all kinds of metal materials, but severe friction causes severe wear of the mixing head and introduces hard inclusions that reduce mechanical properties
Solution Approach 1:
The invention extracts and eliminates the mixing head component from the additive manufacturing process. By using direct solid-state extrusion and rolling pressure connection without a rotating mixing head, the process avoids the severe friction and wear that generate hard inclusions, while still achieving solid-state deformation and connection applicable to all metal materials
Solution Approach 2:
The invention introduces an extrusion die and rolling rollers as intermediary components that replace the direct contact between a rotating mixing head and the material. These intermediaries enable solid-state deformation and connection with minimal friction and wear, eliminating the source of hard inclusions while maintaining broad material applicability
3Object-affected harmful factors
If ultrasonic additive manufacturing is used to connect layers with low environmental requirements, then the process is environmentally friendly, but the manufacturing efficiency is affected by the weldable thickness of each layer
Solution Approach 1:
The invention changes the connection mechanism from ultrasonic welding to solid-state extrusion and rolling pressure connection. This parameter change allows for thicker layer deposition without compromising connection quality, significantly improving manufacturing efficiency while maintaining the environmentally friendly characteristic of solid-state processing without harmful emissions
4Reliability
If additive manufacturing under solid conditions is used to avoid metallurgical defects, then the thermal temperature gradient during solidification is reduced, but severe friction between the mixing head and material causes severe wear and introduces inclusions
Solution Approach 1:
The invention extracts the mixing head from the solid-state additive manufacturing process and replaces it with an extrusion die and rolling rollers. This elimination of the rotating mixing head removes the source of severe friction and wear, allowing solid-state processing to achieve both metallurgical defect avoidance and inclusion-free components
Solution Approach 2:
The invention substitutes the high-friction mixing head deformation mechanism with a low-friction extrusion and rolling pressure connection mechanism. This mechanical substitution maintains the benefits of solid-state processing (avoidance of metallurgical defects) while eliminating the harmful friction wear that introduces inclusions
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 method eliminates metallurgical defects, improves mechanical properties such as strength, plasticity, and fatigue resistance, and is suitable for difficult-to-weld materials by achieving uniform thermal mechanical processing and refined microstructures, reducing the introduction of high-density inclusions.
Implementation Method 1
The cast rod-shaped raw material of the solid composite additive is heated to the solid solution temperature
Implementation Method 2
The rod-shaped raw material of the solid composite additive after solid solution is loaded into the extrusion die and extruded into a set shape
Implementation Method 3
The raw materials of the extruded solid composite additive are laid on the base plate layer by layer according to the track by rolling method to form a prefabricated billet
Data Source
AI summary
A solid composite additive manufacturing method for high-performance structural component includes: the rod-shaped raw material of solid composite additive is heated to a solid solution temperature, wherein the rod-shaped raw material is prepared by casting method; the rod-shaped raw material of the solid composite additive after solid solution is loaded into the extrusion die and extruded into a set shape; The raw materials of the extruded solid composite additive are laid on the base plate layer by layer according to the track by rolling or other pressure connection methods to form the prefabricated billet of the solid composite additive. The prefabricated billet is processed by numerical control to obtain metal part. The solid composite additive manufacturing method refines the grain, breaks the oxide film, and improves the mechanical properties of the structural component.