Multi-source Sound Beam Additive Manufacturing
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Solution Overview
Problem
Current additive manufacturing methods for aluminum and titanium alloys face challenges in residual stress reduction, leading to deformation and cracking due to complex temperature variations and inefficient stress homogenization, with existing methods being either inefficient, costly, or requiring significant modifications to the manufacturing system.
Innovation Solution
A multi-source self-adaptive low-stress additive manufacturing method that uses high-energy sound beams to synchronously reduce and homogenize residual stress during the manufacturing process by formulating an arrangement scheme for sound beam excitation units, monitoring molten pool positions, and adjusting energy parameters in real-time to control stress distribution and temperature, employing titanium alloy special adiabatic amplitude transformers for efficient energy transfer and stress regulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If natural aging method is used to reduce residual stress, then residual stress can be eliminated, but it occupies large field space and takes long time
Solution Approach 1:
The patent replaces the traditional mechanical/natural aging process with high-energy sound beam excitation. The sound beam excitation units generate acoustic energy that directly作用于 the metal workpiece to reduce residual stress, eliminating the need for long-duration natural aging processes and significantly reducing the time required for stress elimination.
Solution Approach 2:
The patent employs periodic high-energy sound beam excitation to reduce residual stress. The sound beams are applied in controlled periodic cycles during and after additive manufacturing, creating repeated stress cycles that progressively reduce residual stress accumulation without requiring extended continuous aging time.
2Reliability
If vibration aging method is used to eliminate residual stress, then residual stress can be reduced, but it is difficult to find resonant frequency and produces large noise
Solution Approach 1:
The system incorporates real-time monitoring of molten pool position and high-energy sound beam excitation unit position, with automatic adjustment of sound beam parameters. The system self-regulates the excitation process based on feedback from position sensors, eliminating the need for manual resonant frequency identification and reducing operational complexity.
Solution Approach 2:
The patent implements a feedback control system that continuously monitors the positions of the molten pool and sound beam excitation units, and adjusts the sound beam parameters accordingly. This closed-loop control ensures optimal stress reduction effectiveness without requiring manual intervention to find resonant frequencies, while also controlling noise through precise parameter management.
3Reliability
If heat treatment method is used to reduce residual stress, then residual stress can be eliminated, but it has strict process requirements, may introduce additional residual stress, and consumes high energy
Solution Approach 1:
The patent replaces thermal heat treatment with high-energy sound beam excitation. Instead of using thermal energy to reduce residual stress, the system uses acoustic energy from sound beam excitation units to directly作用于 the metal workpiece, achieving stress reduction without the high energy consumption and additional residual stress risks associated with heat treatment processes.
Solution Approach 2:
The patent changes the fundamental parameter used for stress reduction from thermal parameters (temperature, heating rate) to acoustic parameters (sound energy, frequency, intensity). This parameter transformation allows for more precise control of the stress reduction process, avoiding the strict process requirements and energy consumption issues of heat treatment while maintaining effectiveness.
4Reliability
If existing stress reduction methods are used, then residual stress can be reduced, but they require significant modifications to the additive manufacturing system and have high manufacturing cost
Solution Approach 1:
The patent integrates high-energy sound beam excitation units into the existing additive manufacturing platform, creating a multi-functional system that can both manufacture parts and reduce residual stress without requiring separate equipment. The sound beam units are positioned to work synergistically with the additive manufacturing process, eliminating the need for additional modifications or separate treatment steps.
Solution Approach 2:
The patent combines the additive manufacturing process with residual stress reduction by integrating sound beam excitation units into the manufacturing platform. The stress reduction function is merged with the manufacturing process, allowing both operations to occur in the same system without requiring significant modifications or adding complex separate equipment.
5Reliability
If existing stress reduction methods are used, then residual stress can be reduced, but they are suitable only for post-manufacturing stress regulation and cannot synchronously reduce stress during additive manufacturing
Solution Approach 1:
The patent applies high-energy sound beam excitation during the additive manufacturing process itself, performing stress reduction as a preliminary action before the workpiece is completed. This prevents residual stress from accumulating in the first place, rather than addressing it after manufacturing, thereby eliminating the need for separate post-processing time.
Solution Approach 2:
The patent maintains continuous high-energy sound beam excitation throughout the additive manufacturing process, ensuring uninterrupted stress reduction. The sound beams continuously作用于 the metal workpiece as it is being manufactured, providing ongoing stress management without interruption, and enabling synchronous stress reduction without extending the overall manufacturing time.
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 effectively reduces and homogenizes residual stress in real-time, improving the mechanical properties and internal quality of the metal workpiece without affecting the standard manufacturing process, ensuring higher strength and reliability with reduced porosity and energy consumption.
Implementation Method 1
a step of A of formulating an arrangement scheme of a high-energy sound beam excitation unit based on a size and a structure of a metal workpiece to be prepared
Implementation Method 2
generate high-energy sound beam(s) which transmitted to the metal workpiece according to a time and/or space control sequence
Implementation Method 3
the enabling condition and power parameters of the high-energy sound beam unit are continuously regulated based on the relative distance, ensuring the on-going reduction and homogenization to the residual stress
Data Source
AI summary
A multi-source self-adaptive low-stress additive manufacturing method that includes arranging one or more high-energy sound beam excitation units on an additive manufacturing platform according to a size and a structure of a metal workpiece; planning an additive path according to the size and the structure of the workpiece; fixing a substrate on a self-adaptive additive manufacturing workbench; conducting additive manufacturing of the workpiece and starting a high-energy sound beam regulation system synchronously to generate high-energy sound beam(s) that are transmitted to the workpiece according to a control sequence; acquiring position information of molten pool(s) and position information of the one or more high-energy sound beam excitation units in the additive manufacturing process; continuously monitoring a surface temperature of the workpiece; and closing the high-energy sound beam regulation system when the additive manufacturing of the workpiece is finished and the surface temperature of the metal workpiece is reduced to room temperature.