Powder-in-Tube Titanium Deposition Wire With Fewer Drawing Steps
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing deposition wires for additive manufacturing, particularly those made of titanium or titanium alloys, are complex and expensive to manufacture due to multiple diameter reduction steps and intermediate heat treatments, which are not compatible with the stringent requirements of modern deposition techniques like direct energy deposition (DED).
Innovation Solution
A powder-in-tube deposition wire with a hollow tubular portion of titanium and a core portion filled with compacted elongated powders, where the core portion occupies between 25% and 85% of the wire's volume, primarily comprising titanium and optionally other elements like aluminum, vanadium, and boron, which reduces the need for intermediate heat treatments and diameter reduction steps through cold welding or laser welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple diameter reduction steps and intermediate heat treatments are used to manufacture deposition wires, then the wire quality and structural integrity are improved, but the manufacturing complexity and production cost increase significantly
Solution Approach 1:
The patent applies preliminary action by pre-compacting the powder core into elongated shapes before the final drawing process. This pre-compaction prepares the powder for better integration during subsequent drawing steps, reducing the need for multiple intermediate heat treatments and complex processing steps while maintaining wire quality
Solution Approach 2:
The patent changes the physical state and shape parameters of the powder from spherical to elongated forms, and controls the volume percentage of powder in the core (25-85%). These parameter changes allow the powder to better withstand drawing processes and integrate with the tubular structure, simplifying the manufacturing process by reducing intermediate treatments
2Manufacturing precision
If multiple diameter reduction steps are used to manufacture deposition wires, then the wire dimensional precision is improved, but the production time and energy consumption increase
Solution Approach 1:
The powder is pre-compacted into elongated shapes with controlled dimensions before being placed in the tube and subjected to drawing. This preliminary shaping reduces the number of drawing steps needed to achieve final dimensional precision, thereby improving production efficiency while maintaining dimensional accuracy
Solution Approach 2:
The patent creates a composite structure with powder particles embedded in a metallic matrix (tubular portion). This composite architecture allows for better dimensional stability during drawing processes, enabling fewer reduction steps while maintaining precision, thus improving productivity
3Productivity
If a high volume percentage of powder is used in the core portion, then the deposition rate for additive manufacturing is improved, but the wire tensile strength and structural integrity may be compromised
Solution Approach 1:
The patent optimizes the volume percentage of powder in the core to a specific range (25-85%), balancing the competing requirements. This parameter optimization ensures sufficient powder content for high deposition rates while maintaining enough metallic matrix for structural integrity and tensile strength
Solution Approach 2:
The composite structure of powder particles distributed within a metallic tubular matrix allows simultaneous achievement of high deposition rate (through adequate powder content) and sufficient tensile strength (through the load-bearing metallic framework). The interfacial bonding between powder and matrix provides structural coherence
4Ease of manufacture
If intermediate heat treatments are applied during wire manufacturing, then the powder compaction and material ductility are improved, but the manufacturing cost and energy consumption increase
Solution Approach 1:
The powder is pre-compacted into elongated shapes with improved density and orientation before final wire drawing. This preliminary compaction enhances material ductility and workability for subsequent processing, reducing or eliminating the need for intermediate heat treatments and associated energy consumption
Solution Approach 2:
The patent controls the compaction parameters of the powder (density, particle arrangement, elongation) to achieve optimal ductility without requiring thermal treatments. By adjusting physical parameters of the powder core, the material becomes sufficiently ductile for drawing processes, avoiding energy-intensive heat treatment steps
Data Source
AI summary
A deposition wire of the powder-in-tube type comprises a hollow tubular portion of titanium and a core portion filling the tubular portion. The core portion occupies between (30) volume % and (80) volume % of the deposition wire. The core portion comprises compacted elongated powders of titanium and possibly also comprises other compacted powders selected from the group consisting of aluminium, vanadium, aluminium-vanadium, chromium, molybdenum, boron, niobium, tantalum, nickel, zirconium, silicon, copper, tin, iron and palladium. Due to the high volume of the core portion, the process of making the wire is less complex.