Vibratory Powder Deposition for Complex Geometries
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Solution Overview
Problem
Existing additive manufacturing processes like selective laser melting (SLM) and electron beam melting (EBM) are slow, expensive, and limited in depositing material onto complex geometries due to their reliance on wiper actions and production of small grain-sized microstructures.
Innovation Solution
The integration of vibratory mechanical energy into the powder deposition process, applied before, during, or after energy beam application, allows for efficient distribution and melting of powdered materials onto substrates with complex geometries, enabling faster deposition and directional solidification, while eliminating the need for wiper arms and enhancing grain refinement and stress relief.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If selective laser melting or electron beam melting is used to deposit powdered material layer-by-layer, then intricate shapes and precise geometries can be achieved, but the deposition speed is slow and the process is expensive
Solution Approach 1:
The patent applies vibratory mechanical energy to the substrate surface before, during, and/or after energy beam application. This vibration loosens and fluidizes the powdered material, enabling faster and more uniform distribution of powder across the processing plane without requiring slow wiper actions, thereby increasing deposition speed while maintaining geometric precision
Solution Approach 2:
The patent applies vibratory energy to the substrate and/or powder bed before material deposition to pre-loosen and level the powder surface. This preliminary action prepares the substrate and powder for faster subsequent deposition, eliminating the need for slow wiper-based distribution during the actual deposition process
2Ease of manufacture
If a wiper action is used to spread powdered material across the processing plane, then material can be deposited onto the substrate surface, but the process is limited to substrates that do not project above the processing plane
Solution Approach 1:
The patent replaces the wiper action with vibratory mechanical energy applied to the powder bed and substrate. This vibration causes the powder to fluidize and distribute itself uniformly across the processing plane without mechanical contact, enabling deposition on complex geometries including substrates that project above the processing plane
Solution Approach 2:
The patent substitutes the mechanical wiper system with a vibratory field-based approach. By applying vibratory energy, the powder bed is fluidized and self-distributes without requiring physical wiper contact, thereby eliminating the geometric limitations of wiper-based systems
3Manufacturing precision
If small diameter energy beam is used to melt small filler material particles, then precise melting and fusion can be achieved, but the process produces only small grain sized equiaxed and polycrystalline microstructures
Solution Approach 1:
The patent applies vibratory mechanical energy during and/or after the energy beam melting process. This vibration promotes grain refinement and can induce directional solidification of the molten material, transforming the microstructure from small grain equiaxed polycrystalline to finer, more controlled grain structures with improved mechanical properties
Solution Approach 2:
The patent changes the physical state and behavior of the material during solidification by applying vibratory energy. This alters the solidification parameters, enabling directional solidification and grain refinement that improve microstructure quality while maintaining the precision melting achieved by the energy beam
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
This approach significantly increases deposition speed, enables material application on substrates with complex geometries, and improves mechanical properties by controlling grain structure and residual stresses, facilitating the use of difficult-to-weld superalloys and promoting directional solidification.
Implementation Method 1
The vibratory mechanical energy 27 may be imparted to the bed of powdered material 12 by an electro-mechanical transducer 26 in contact with a surface the container 14
Implementation Method 2
A layer 16 of the powdered material is distributed over a surface 18 of the substrate 10, and is being melted by an energy beam 20 being traversed over the surface 18
Implementation Method 3
The melted powder forms a traveling melt pool 22 which then cools and solidifies to form a layer of clad material 24 on the substrate 10
Data Source
AI summary
A method for depositing clad material (24) onto a substrate (10) by melting a layer of powdered material (16) using an energy beam (20), and also applying vibratory mechanical energy (27, 29 and/or 31). The vibratory mechanical energy may be applied before, during or after the melting and solidification of the powdered material in order to preheat the powder, to distribute powder over a top surface (18) of the substrate, to control the formation of dendrites in the clad material as the melt pool (22) solidifies, to remove slag, and/or to perform stress relief. Simultaneous application of beam energy and vibratory mechanical energy facilitates the continuous deposition of the clad material, including directionally solidified material.