Valve Element Hybrid Build for Hardwearing Complex Surfaces
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Solution Overview
Problem
Additive manufacturing components may not be sufficiently hard for certain applications, and forming hardwearing surfaces using methods like PTA can be challenging, especially when access is limited, requiring costly bespoke processes.
Innovation Solution
A method involving additive manufacturing of a first component followed by the addition and securement of a second component with different material properties, which can be harder, using various manufacturing processes, including additive and non-additive methods, and heat treatment to enhance material properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If additive manufacturing is used to create components, then complex shapes and design freedom are achieved, but the hardness and wear resistance of the component surfaces are insufficient
Solution Approach 1:
The patent combines additive manufacturing with post-processing hardfacing techniques to create composite structures where the base component provides complex geometry and the hardfacing layer provides wear resistance. This allows the final product to exhibit properties of both manufacturing methods simultaneously.
Solution Approach 2:
The patent modifies the surface properties of additive manufactured components by applying hardfacing processes that change the material parameters (hardness, wear resistance) of the surface layer without altering the overall component geometry or base material properties.
2Strength
If hardwearing surfaces are deposited using welding processes like PTA, then surface hardness is improved, but the process becomes difficult when access to the surface is limited and requires costly bespoke automated equipment
Solution Approach 1:
The patent incorporates hardfacing considerations during the initial additive manufacturing design phase, preparing surfaces and geometries that will facilitate subsequent hardfacing operations. This preliminary preparation reduces the complexity of later hardfacing processes.
Solution Approach 2:
The patent uses the additive manufactured component itself as an intermediary structure that provides both the base geometry and a prepared surface for hardfacing, eliminating the need for separate fixtures or complex automated positioning systems.
3Strength
If hardwearing surfaces are deposited using welding processes like PTA, then surface hardness is improved, but the process requires costly bespoke automated processes and equipment
Solution Approach 1:
The patent merges the additive manufacturing process with hardfacing operations, allowing both processes to be performed using the same equipment platform. This integration eliminates the need for separate bespoke automated equipment for hardfacing.
Solution Approach 2:
The patent makes the additive manufacturing equipment multi-functional by enabling it to perform both base component fabrication and subsequent hardfacing operations, reducing the need for specialized equipment and lowering overall system complexity.
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
Enables the creation of valves or valve elements with improved hardness and complex shapes, combining the benefits of additive manufacturing with the material properties of different processes, reducing the risk of cracking and enhancing durability.
Implementation Method 1
additive manufacturing the inner wall and the lattice structure together by depositing a solidifiable material in a predetermined pattern to create a three-dimensional integrated body
Implementation Method 2
a hardwearing surface may be deposited using a welding process such as a Plasma Transferred Arc (PTA) process
Implementation Method 3
a laser/electron beam melting/sintering process
Implementation Method 4
a laser/electron beam melting/sintering process
Implementation Method 5
a powder bed fusion process
Implementation Method 6
a direct laser deposition process
Implementation Method 7
a Hot Isostatically Pressing (HIP) process
Data Source
Figure 1
Figure 2~5C
Figure 6~8
AI summary
A method of manufacturing a valve or an element used to form a valve, the method comprising forming a first part of a first component using additive manufacturing, adding a second component to the first part of the first component and forming a second part of the first component using additive manufacturing.