Wire-Feed Friction Stir Head for Precise Deposition
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Solution Overview
Problem
Existing additive friction stir deposition (AFSD) and friction stir additive manufacturing (FSAM) systems face limitations in material feeding and deposition efficiency, particularly in wire-feed systems, which affect the quality and consistency of large-scale manufacturing of metallic structures.
Innovation Solution
The introduction of a wire-feed system with a non-rotating shoulder and rotating pin configuration, along with a housing that includes a wire inlet and track, allows for precise feeding and softening of wires, enabling seamless material deposition and welding of work-pieces, including the use of different materials and gauges, with improved energy efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a wire-feed system is used in AFSD/FSAM, then material deposition efficiency is improved, but material feeding precision deteriorates
Solution Approach 1:
A wire guide channel is introduced as an intermediary component between the wire feed source and the deposition zone. The channel includes a wire inlet extending through the housing sidewall and a wire guide surface that directs the wire into the gap between the housing and rotating pin, ensuring precise material positioning while maintaining efficient wire feed deposition
2Manufacturing precision
If material is softened within the channel during travel, then deposition quality is improved, but energy consumption increases
Solution Approach 1:
The wire is pre-positioned and guided through the wire inlet and along the wire guide surface before reaching the deposition zone. This preliminary guidance action ensures the wire is correctly positioned for softening by friction between the rotating pin and the wire, improving deposition quality while optimizing energy use by preventing unnecessary heating during material travel
Solution Approach 2:
Friction, which typically represents energy loss, is converted into a beneficial heating mechanism. The friction between the rotating pin and the wire in the gap between the housing and pin softens the wire material right at the deposition point, improving material quality while using the friction that would otherwise be considered wasted energy
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 configuration enhances build quality, consistency, and energy efficiency in large-scale additive manufacturing, allowing for seamless transitions between materials and efficient deposition of metallic and metal matrix composites.
Implementation Method 1
wire-feed systems that feed wires through a non-rotating shoulder and into a space between an inner wall of the non-rotating shoulder and a rotating pin
Implementation Method 2
The material is softened within the channel as it travels to a deposition end
Data Source
AI summary
A friction stir additive manufacturing system is provided. In one aspect, the system includes a spindle configured to rotate about a central axis, and a housing configured to receive at least a portion of the spindle, the housing configured to remain stationary relative to the spindle. The housing includes a wire inlet extending between an exterior surface of the housing and an interior surface of the housing, and a track extending from the wire inlet and partially around a circumference of an interior surface of the housing. The system also includes a feeding system configured to receive a wire from a roller and feed the wire through the wire inlet and into the track of the housing.