Titanium Alloy Component Manufacturing With Friction Stir Extrusion

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Solution Overview

Problem

Conventional machining of aircraft components results in significant material waste and manufacturing challenges with alternative materials like titanium alloys due to iron segregation, leading to inadequate mechanical properties and increased costs.

Innovation Solution

The method involves using a friction stir additive manufacturing process that combines shear-assisted processing and extrusion to produce additively manufactured components with homogeneous grain structures, specifically using a Ti-8V-5Fe-1Al titanium alloy, which reduces material waste and enhances strength and anti-corrosion properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of substance

If conventional machining of steel billet material is used, then aircraft components can be manufactured, but significant amounts of material are removed leading to significant cost and waste

Engineering Contradiction:

Improvematerial wasteVSAvoidmanufacturing process

Core Design Contradiction:

Loss of substanceVSEase of manufacture

Solution Approach 1:

The patent changes the fundamental manufacturing parameter from subtractive machining to additive friction stir processing. Loose substrate material is transformed into a densified, homogeneous structure through controlled friction stir processing and extrusion, eliminating material removal and achieving near-net-shape manufacturing with minimal waste

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent utilizes phase transition of substrate material from loose powder state to densified solid structure through friction stir processing. The material undergoes transformation from particulate to homogeneous metallic structure, enabling additive manufacturing without traditional melting and solidification

Inventive Principle:

Principle #36Phase transitions

2Weight of moving object

If alternative materials such as titanium alloys are used, then weight can be reduced, but manufacturing challenges arise due to iron segregation during material processing

Engineering Contradiction:

Improvecomponent weightVSAvoidmechanical properties

Core Design Contradiction:

Weight of moving objectVSReliability

Solution Approach 1:

The patent achieves homogeneous distribution of alloying elements including iron in titanium alloys through friction stir processing. The intense mechanical mixing and plastic deformation eliminate segregation and ensure uniform microstructure, producing reliable mechanical properties in lightweight titanium alloy components

Inventive Principle:

Principle #33Homogeneity

Solution Approach 2:

The patent creates homogeneous composite structures by thoroughly mixing different alloying elements (titanium, iron, aluminum, vanadium) at the atomic level through friction stir processing. This produces a uniform multi-element alloy structure that maintains lightweight properties while ensuring consistent mechanical performance

Inventive Principle:

Principle #40Composite materials

3Ease of manufacture

If conventional machining processes are used, then manufacturing is straightforward, but significant material removal leads to increased costs

Engineering Contradiction:

Improvemanufacturing processVSAvoidmaterial waste

Core Design Contradiction:

Ease of manufactureVSLoss of substance

Solution Approach 1:

The patent inverts the conventional manufacturing approach by building components through additive friction stir processing rather than removing material through machining. Loose substrate material is progressively densified and shaped into the final component form, eliminating the need for material removal and associated costs

Inventive Principle:

Principle #13The other way round (Inversion)

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 approach minimizes material waste, improves mechanical properties, and reduces manufacturing costs while providing high-strength, lightweight components suitable for aircraft landing gear assemblies, enhancing fuel efficiency and performance.

Implementation Method 1

friction stir additive manufacturing process

Methodology Applied

Scientific EffectFriction: Friction

Implementation Method 2

compressing a first loose substrate material disposed within the sleeve against the rotating die by the extending mandrel

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 3

bonding at least a portion of the first billet material to the first body in response to the pressing and the rotating of the first billet material

Methodology Applied

Scientific EffectFriction welding: Friction Welding

Implementation Method 4

friction stir additive manufacturing process

Methodology Applied

Scientific EffectHeat generation through friction: Viscous Heating

Implementation Method 5

combines shear-assisted processing and extrusion to produce additively manufactured components with homogeneous grain structures

Methodology Applied

Scientific EffectShear stress: Shear Stress

Data Source

PatentUS12138708B2Methods, systems, and apparatus for component manufacturing

Publication Date: 2024.11.12 GOODRICH CORP

AI summary

Methods, systems, and apparatuses for component manufacturing are provided. A component may be manufactured via an extrusion of loose substrate material into a unitary tubing. Features may be added to the tubing via friction stir additive manufacturing to manufacture a component. In this manner, a component may be manufactured from titanium alloys while processing challenges such as iron segregation or material loss through machining are ameliorated. Such a component may replace steel or other high strength components and further exhibits corrosion resistance.