Water-Soluble Sacrificial Material for UAM Internal Channels
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Solution Overview
Problem
Existing ultrasonic additive manufacturing (UAM) processes face challenges in maintaining the geometry and mechanical properties of internal features like chambers and channels due to deformation of added foil layers, and the removal of traditional sacrificial materials is difficult and hazardous.
Innovation Solution
A sacrificial material comprising a water-soluble solid, such as salt, and a water-soluble binding agent like polyvinyl alcohol (PVA) is used, which is cured to form a stiff substrate that can be easily removed by dissolution in water after the build, ensuring the integrity of internal features and safe removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional sacrificial materials (powdered metals or low melting point metals) are used to support internal features during UAM, then the geometry and mechanical properties of chambers and channels are maintained, but the removal of these materials is difficult and hazardous
Solution Approach 1:
The patent changes the chemical composition parameters of the sacrificial material from traditional metals to a water-soluble composite consisting of salt particles (5-50 micrometers) suspended in a PVA binder solution. This parameter change transforms the material from difficult-to-remove metal particles to water-soluble compounds that can be easily dissolved and removed through washing, completely resolving the removal difficulty and hazard issues while maintaining geometric support functionality
Solution Approach 2:
The patent creates a composite sacrificial material by combining salt particles (sodium chloride, potassium chloride, or calcium chloride) with a polyvinyl alcohol binder in a specific ratio (salt particles: 0.5-5 grams, PVA binder: 0.1-1 gram). This composite structure provides both the structural support needed during manufacturing and the water-solubility required for easy removal, simultaneously addressing both the reliability and ease of manufacture requirements
2Productivity
If additional metal foils are applied to complete the component, then the component structure is completed, but the foil layers bow or deform into the chambers and channels, changing the geometry and adversely affecting mechanical properties and fluid flow
Solution Approach 1:
The patent applies the sacrificial material to the internal surfaces of chambers and channels before completing the UAM process with additional metal foils. This preliminary action creates a protective coating that prevents the subsequent foil layers from bowing into or deforming the internal features, thereby maintaining manufacturing precision while allowing productivity to proceed with complete component structure formation
Solution Approach 2:
The sacrificial material acts as an intermediary layer between the chamber/channel walls and the additional metal foils. This intermediary prevents direct contact and deformation of the internal features by the foil layers, maintaining geometric precision. The intermediary is later removed through water dissolution, leaving no residual effect on the final component
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 sacrificial material maintains the geometry and mechanical properties of internal features by preventing deformation during UAM and allows safe, complete removal without residual material, enhancing the process's efficiency and safety.
Implementation Method 1
a water-soluble binding agent like polyvinyl alcohol (PVA) is used, which is cured to form a stiff substrate that can be easily removed by dissolution in water after the build
Implementation Method 2
High-frequency ultrasonic vibrations are locally applied to the metal foils (to break oxide layers found thereon), which are held together under high pressure, to create a solid-state weld
Implementation Method 3
the at least one water-soluble solid is mixed with the at least one water-soluble binding agent and cured at a predetermined temperature for a predetermined period of time prior to use in ultrasonic additive manufacturing
Data Source
AI summary
A sacrificial material for use in ultrasonic additive manufacturing processes that includes at least one water-soluble solid; and at least one water-soluble binding agent, wherein the at least one water-soluble solid is partially dissolved or suspended in the at least one water-soluble binding agent and cured at a predetermined temperature for a predetermined period of time prior to use in ultrasonic additive manufacturing.