Valve Insert Assembly for Hardwearing Additive Manufacturing
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Solution Overview
Problem
Components manufactured using additive manufacturing may not be sufficiently hard for certain applications, and forming hardwearing surfaces on these components can be challenging, especially when access is limited, requiring costly bespoke automated processes.
Innovation Solution
A method of manufacturing a valve or valve element using additive manufacturing, where a first component is formed using additive processes, and a second component, which can be harder and formed using different processes such as casting or machining, is integrated with the first component, either by being placed in contact, secured, or encapsulated within it.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If additive manufacturing is used to create valve components, then manufacturing flexibility and complexity are improved, but material hardness is insufficient for certain applications
Solution Approach 1:
The patent applies composite materials by combining additive-manufactured valve bodies with separately manufactured hardwearing surfaces or inserts made from harder materials. This allows the valve to benefit from both the manufacturing flexibility of additive processes and the hardness of traditional hard materials, resolving the contradiction between adaptability and strength.
2Strength
If hardwearing surfaces are deposited using welding processes, then material hardness is improved, but process complexity and cost increase due to limited access requirements
Solution Approach 1:
The patent segments the valve manufacturing process into separate stages: first creating the valve body using additive manufacturing, then separately manufacturing hardwearing surfaces or inserts, and finally assembling them together. This segmentation eliminates the need for complex automated welding processes on hard-to-reach surfaces, reducing device complexity while maintaining surface hardness.
Solution Approach 2:
The patent applies preliminary action by pre-manufacturing hardwearing surfaces or inserts before assembling them to the valve body. This allows the hard surfaces to be created under optimal conditions with full access, avoiding the need for complex in-situ welding processes during valve assembly, thereby reducing process complexity.
Data Source
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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.