Wire-Fed Friction Stir Deposition With Nested Feed Path
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Solution Overview
Problem
Existing additive friction stir deposition (AFSD) and friction stir additive manufacturing (FSAM) systems face challenges in efficiently depositing and bonding materials, particularly in large-scale applications, due to limitations in material feeding and processing.
Innovation Solution
The development of a friction stir additive manufacturing system that includes a spindle, a housing, and a feeding system, where a wire is fed through a wire inlet and into a track within the housing, allowing for the deposition of softened material onto a substrate as the spindle rotates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If wire-feed systems are used for friction stir additive manufacturing, then material deposition efficiency and build quality are improved, but device complexity increases due to the need for precise wire feeding mechanisms and housing structures
Solution Approach 1:
The wire is fed through a wire inlet in the housing and guided through a track that is nested within the housing structure. The track is positioned to guide the wire into the gap between the housing and spindle, creating a nested arrangement where the wire feeding path is integrated within the existing housing and spindle structure, reducing the need for separate external feeding mechanisms
Solution Approach 2:
The housing serves multiple functions: it provides structural support, contains the wire inlet and track for material feeding, and maintains the gap with the spindle for friction stir processing. The wire inlet and track system is designed to accommodate different wire materials and feeding rates, making the system versatile for various additive manufacturing applications
2Manufacturing precision
If a track is used to guide the wire into the gap between housing and spindle, then material feeding precision is improved, but manufacturing complexity increases due to the additional track structure
Solution Approach 1:
The track is nested within the housing structure, utilizing the housing's internal space to guide the wire. The track is positioned to lead the wire from the wire inlet directly into the gap between the housing and spindle, ensuring precise material delivery without requiring external guiding structures
Solution Approach 2:
The track is designed with specific local characteristics - it is positioned at a defined depth within the housing and extends partially around the circumference to guide the wire into the gap. This localized tracking structure provides precise wire guidance only where needed, rather than requiring a complete external guiding 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
This system enhances the efficiency and quality of material deposition and bonding, enabling the creation of large metallic structures with improved build quality and consistency, while also allowing for the seamless transition between different materials.
Implementation Method 1
friction stir additive manufacturing
Implementation Method 2
the wire is fed through the wire inlet and into a gap between an interior surface of the housing and an exterior surface of the rotating spindle and rotated and softened by the spindle
Data Source
AI summary
A friction stir additive manufacturing system configured to extrude a material is provided. In one aspect, the system includes a spindle configured to rotate about a central axis, the spindle including a conical portion having a plurality of threads at a deposition end of the spindle. The system also includes a housing configured to remain stationary relative to the spindle, the housing including a wire inlet extending through a side wall of the housing, an interior surface of the side wall defining a truncated cone terminating at a material exit, the truncated cone configured to receive the conical portion of the spindle. The system also includes a feeding system configured to feed a wire through the wire inlet and into a gap between the spindle and the truncated cone of the housing.