Friction stir additive manufacturing systems

Patent metadata

Field	Value
Publication number	US-11117213-B2
Application number	US-201816220346-A
Country	US
Kind code	B2
Filing date	Dec 14, 2018
Priority date	Dec 14, 2018
Publication date	Sep 14, 2021
Grant date	Sep 14, 2021

Abstract

An additive manufacturing system for depositing an extrudate onto a substrate comprises a deposition head. The deposition head comprises a stirring tool, rotatable about an axis of rotation AR and comprising a tool distal end and a tool proximal end, axially opposing the tool distal end along the axis of rotation AR. The stirring tool defines a bore, extending from the tool proximal end to the tool distal end. The bore is configured to receive feedstock, biased toward the tool distal end. The deposition head also comprises a die, which is positioned adjacent to the stirring tool, defines a die axis AD1, and comprises a die distal end and a die proximal end, axially opposing the die distal end along the die axis AD1. The die axis AD1 is parallel with the axis of rotation AR of the stirring tool.

First claim

What is claimed is:

1. An additive manufacturing system for depositing an extrudate onto a substrate, the additive manufacturing system comprising a deposition head that comprises:
a stirring tool, rotatable about an axis of rotation A R and comprising a tool distal end and a tool proximal end, axially opposing the tool distal end along the axis of rotation A R , wherein the stirring tool defines a bore, extending from the tool proximal end to the tool distal end, and the bore is configured to receive feedstock, biased toward the tool distal end; and
a die, which is positioned adjacent to the stirring tool, defines a die axis A D1 , and comprises a die distal end and a die proximal end, axially opposing the die distal end along the die axis A D1 , wherein the die axis A D1 is parallel to the axis of rotation A R of the stirring tool, and the stirring tool is rotatable relative to the die about the axis of rotation A R .

2. The additive manufacturing system according to claim 1 , wherein the die distal end axially protrudes a distance D beyond the tool distal end.

3. The additive manufacturing system according to claim 1 , wherein:
the die is moveable relative to the stirring tool along the die axis A D1 between, inclusively, at least a retracted position and an engaged position, and
the die distal end protrudes axially outward a distance D beyond the tool distal end when the die is in the engaged position.

4. The additive manufacturing system according to claim 3 , further comprising a die force applicator, operatively connected to the die to selectively move the die along the die axis A D1 between at least the retracted position and the engaged position.

5. The additive manufacturing system according to claim 1 , further comprising a stirring-tool force applicator, configured to urge the deposition head against the substrate.

6. The additive manufacturing system according to claim 5 , further comprising a stirring-tool rotation device, configured to rotate the stirring tool about the axis of rotation A R while the stirring-tool force applicator urges the deposition head against the substrate.

7. The additive manufacturing system according to claim 1 , further comprising a feed-stock force applicator that biases the feedstock toward the tool distal end.

8. The additive manufacturing system according to claim 1 , further comprising a carriage, connected to the deposition head, and wherein the carriage moves the deposition head relative to the substrate.

9. The additive manufacturing system according to claim 1 , wherein the die comprises an engagement surface that defines at least one shaping feature.

10. The additive manufacturing system according to claim 1 , wherein the die is rotatable about the die axis A D1 .

11. The additive manufacturing system according to claim 10 , further comprising a die-rotation device, operatively connected to the die to rotate the die about the die axis A D1 .

12. The additive manufacturing system according to claim 10 , further comprising a second die, which is positioned adjacent to the stirring tool, defines a second-die axis A D2 , and comprises a second-die distal end and a second-die proximal end, axially opposing the second-die distal end along the second-die axis A D2 , and wherein the second-die axis A D2 is parallel with the axis of rotation A R of the stirring tool.

13. The additive manufacturing system according to claim 12 , wherein the second die is rotatable about the second-die axis A D2 .

14. The additive manufacturing system according to claim 13 , wherein:
the die is rotatable in a first direction R 1 about the die axis A D1 and the second die is rotatable in a second direction R 2 about the second-die axis A D2 ; and
the first direction R 1 and the second direction R 2 are opposite to each other.

15. The additive manufacturing system according to claim 1 , wherein:
the stirring tool comprises an outer surface, and
a shortest distance between the die and the outer surface is at most 3 millimeters.

16. The additive manufacturing system according to claim 1 , wherein:
the stirring tool comprises an outer surface, and
a shortest distance between the die and the outer surface is at most 1 millimeter.

17. The additive manufacturing system according to claim 1 , wherein the feedstock is received in the bore such that rotation of the stirring tool causes corresponding rotation of the feedstock.

18. The additive manufacturing system according to claim 1 , wherein the feedstock comprises a metal or a metal alloy.

19. The additive manufacturing system according to claim 1 , wherein:
the die is formed of a first metallic material, having a first composition;
the stirring tool is formed of a second metallic material, having a second composition; and
the first composition and the second composition are equivalent to each other.

20. An additive manufacturing system for depositing an extrudate onto a substrate, the additive manufacturing system comprising a deposition head that comprises:
a stirring tool, rotatable about an axis of rotation A R and comprising a tool distal end and a tool proximal end, axially opposing the tool distal end along the axis of rotation A R , wherein the stirring tool comprises a bore, extending from the tool proximal end to the tool distal end, and the bore is configured to receive feedstock, biased toward the tool distal end; and
a die, which is positioned adjacent to the stirring tool, defines a die axis A D1 , and comprises a die distal end and a die proximal end, axially opposing the die distal end along the die axis A D1 , wherein the die axis A D1 is parallel to the axis of rotation A R of the stirring tool, and the die distal end axially protrudes a distance D beyond the tool distal end.

Assignees

• Boeing Co

Inventors

• Rodriguez Rogie I
• Senderos Bruno Zamorano

Classifications

• B33Y40/00

  Auxiliary operations or equipment, e.g. for material handling · CPC title

• B23K20/122

  using a non-consumable tool, e.g. friction stir welding · CPC title

• B23K20/129

  specially adapted for particular articles or work · CPC title

• B23K20/1205 Primary

  using translation movement · CPC title

• B23K20/128

  making use of additional material · CPC title