Variable Orifice Torch for Solid Free Form Fabrication
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current solid free-form fabrication (SFF) processes, particularly ion fusion formation (IFF) and direct metal deposition (DMD), face challenges in achieving high deposition accuracy and varying deposition rates due to the limitations of gaseous systems, such as arc-based torches, which require manual orifice size changes, leading to inefficiencies and reduced accuracy.
Innovation Solution
A variable orifice torch nozzle with moveable components, such as partial disc members, allows for continuous adjustment of the orifice size to match heat demand during the fabrication process, enabling precise control of heat delivery without physical replacement, thereby enhancing deposition accuracy and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the orifice size is decreased to improve deposition accuracy, then the heat flow is restricted and gas velocity increases, but the deposition rate is reduced and splatter is created
Solution Approach 1:
The patent implements a variable orifice mechanism that allows the orifice size to be dynamically adjusted during the deposition process. The orifice can change size based on real-time process conditions, enabling the system to optimize between deposition accuracy and deposition rate by selecting appropriate orifice sizes for different operational requirements.
Solution Approach 2:
The patent changes the physical parameter of orifice size to resolve the contradiction. By providing multiple orifice sizes and the ability to switch between them, the system can adjust gas flow rate and heat delivery parameters to match the specific requirements of different deposition scenarios, thereby balancing accuracy and productivity.
2Productivity
If the orifice size is increased to improve deposition rate, then more heat is supplied, but the deposition accuracy is reduced
Solution Approach 1:
The variable orifice mechanism enables dynamic adjustment of orifice size to match heat demand. When high deposition rates are required, larger orifices can be selected to supply more heat and material. When high precision is needed, smaller orifices provide better control over heat delivery and material placement.
Solution Approach 2:
The system utilizes parameter changes by selecting different orifice sizes based on the specific deposition requirements. This allows optimization of the balance between heat flow rate and deposition precision, enabling the system to achieve high deposition rates when accuracy requirements are moderate and high precision when accuracy requirements are stringent.
3Use of energy by moving object
If manual orifice size changes are implemented to adjust heat delivery, then heat flow can be varied, but the process efficiency is reduced and deposition accuracy is compromised
Solution Approach 1:
The variable orifice mechanism is designed to be self-adjusting based on process requirements. The system can automatically select or switch between different orifice sizes without requiring manual intervention, thereby maintaining efficient heat delivery control while preserving process productivity and deposition accuracy.
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 variable orifice torch enables continuous adjustment of heat delivery, improving deposition accuracy and rate, reducing the need for manual orifice changes, and minimizing erosion, thus enhancing the economic viability of SFF processes by allowing for net-shape or near-net-shape part creation with reduced subsequent machining.
Implementation Method 1
an arc electrode and a variable orifice defined in the torch nozzle. The torch structure includes a torch nozzle comprised of a bulk material and having a gas flow channel defined therein. The arc electrode is disposed within the gas flow channel formed in the torch nozzle
Data Source
AI summary
A variable orifice torch for use in a solid free form fabrication system for manufacturing a component from successive layers of metal feedstock material. The variable orifice torch includes a torch structure defining a torch nozzle formed of a highly conductive bulk material. The variable orifice torch further includes a gas flow channel and a variable orifice defined therein. An arc electrode is disposed within the gas flow channel. The variable orifice is defined in the torch nozzle and in alignment with the arc electrode. The variable orifice is coupled to the torch structure in a manner operable to control a flow gas therethrough by varying the size of an aperture defined by the variable orifice.