Ultrasonic Micro-Forging Roller for AM Grain Refinement
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Solution Overview
Problem
Current metal additive manufacturing techniques face limitations in producing large-scale complex metal components due to microstructure defects, residual stress, and poor mechanical properties, such as toughness and strength, which hinder the technology's application and popularization.
Innovation Solution
A combined ultrasonic micro-forging device that integrates a transducer, pneumatic sliding table, amplitude transformer, tool head, and roller to apply high-frequency ultrasonic energy and mechanical rolling for each layer during additive manufacturing, refining grains, eliminating defects, and reducing residual stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-energy beam additive manufacturing technology is used to manufacture large-scale complex metal components, then the manufacturing capability is improved, but microstructure defects and residual stress increase, degrading mechanical properties
Solution Approach 1:
The patent applies ultrasonic vibration treatment during the additive manufacturing process itself, before the component is completed. The ultrasonic vibration is applied to the molten pool and deposited layers in real-time during manufacturing, preventing defect formation and residual stress accumulation as they occur, rather than treating them after manufacturing is complete.
Solution Approach 2:
The patent utilizes ultrasonic vibration (mechanical vibration at high frequency) to interact with the molten pool and deposited metal layers. The ultrasonic vibration breaks dendritic structures, promotes uniform grain distribution, eliminates gas bubbles, and reduces residual stress through vibrational energy input during the manufacturing process.
2Reliability
If post-treatment techniques such as hot isostatic pressing and heat treatment are applied, then microstructure and mechanical properties are improved, but manufacturing efficiency decreases and cost increases
Solution Approach 1:
The patent combines the additive manufacturing process with ultrasonic vibration treatment into a single integrated process. The ultrasonic vibration device is incorporated into the additive manufacturing system, allowing simultaneous manufacturing and microstructure optimization without requiring separate post-treatment steps, thereby maintaining manufacturing efficiency while improving mechanical properties.
Solution Approach 2:
The ultrasonic treatment is applied during the manufacturing process itself to prevent defect formation and optimize microstructure in real-time, eliminating the need for subsequent post-treatment operations like hot isostatic pressing or heat treatment that would reduce manufacturing efficiency.
3Manufacturing precision
If ultrasonic interference technique is used to refine grains, then microstructure is improved, but the effect diminishes with increasing deposition height, limiting large-size component manufacturing
Solution Approach 1:
The patent designs the ultrasonic vibration system with multiple vibration sources that can be applied at different locations and depths within the component. This allows the ultrasonic treatment to be effective throughout the entire component volume, from the base to the top surface, enabling grain refinement and defect elimination in large-size components regardless of deposition height.
4Measurement precision
If traditional ultrasonic impact device is used, then frequency is maintained, but the impact pin is not directly connected to amplitude transformer, reducing treatment effectiveness
Solution Approach 1:
The patent integrates the ultrasonic vibration source directly with the additive manufacturing deposition system. The amplitude transformer is directly connected to the deposition head or molten pool region, ensuring that ultrasonic vibration is applied at the point of material deposition with maximum effectiveness, while maintaining precise frequency control through the transducer system.
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 device significantly improves microstructure and mechanical properties by refining grains, curing defects, and converting tensile stress to compressive stress, enhancing the performance of additive manufactured metal parts, making them comparable to forged pieces.
Implementation Method 1
an ultrasonic energy field is applied from the bottom of the workpiece to the high-temperature liquid molten pool
Implementation Method 2
breaking the dendrites in the molten pool and increasing the nucleation rate
Implementation Method 3
it will produce plastic deformation and recrystallization
Implementation Method 4
converting tensile stress to compressive stress
Data Source
AI summary
A combined ultrasonic micro-forging device and a related additive manufacturing method for improving the microstructure and mechanical properties of additive manufactured metal part. The device comprises a transducer, a pneumatic sliding table, a pneumatic sliding table connecting frame, an amplitude transformer, a tool head and a roller, wherein the transducer is provided in a transducer housing, a socket connector and a pipeline connector are provided on the transducer housing, the amplitude transformer is connected under the transducer, the tool head is connected under the transducer, the roller is located between the tool head and workpiece, and the pneumatic sliding table is connected to the transducer housing and the amplitude transformer via the pneumatic sliding table connecting frame. The ultrasonic micro-forging device of high frequency ultrasonic impact and larger deformation produced by mechanical rolling, thereby generating a composite action of ultrasonic impact and continuous rolling micro-forging.