Methods, systems, and apparatus for component manufacturing

Patent metadata

Field	Value
Publication number	US-12138708-B2
Application number	US-202217678869-A
Country	US
Kind code	B2
Filing date	Feb 23, 2022
Priority date	Feb 23, 2022
Publication date	Nov 12, 2024
Grant date	Nov 12, 2024

Abstract

Methods, systems, and apparatuses for component manufacturing are provided. A component may be manufactured via an extrusion of loose substrate material into a unitary tubing. Features may be added to the tubing via friction stir additive manufacturing to manufacture a component. In this manner, a component may be manufactured from titanium alloys while processing challenges such as iron segregation or material loss through machining are ameliorated. Such a component may replace steel or other high strength components and further exhibits corrosion resistance.

First claim

What is claimed:

1. A method of forming an additively manufactured component comprising:
rotating a die;
extending a mandrel through a sleeve and toward the rotating die while the die is rotating;
compressing, by the mandrel, a first loose substrate material disposed within the sleeve against the rotating die;
extruding a unitary tubing made of the first loose substrate material from the rotating die in response to the compressing, by the mandrel, the first loose substrate material disposed within the sleeve against the rotating die, wherein the extruded unitary tubing comprises a first body of the additively manufactured component;
rotating a first billet material;
pressing a tip of the first billet material against the first body while the first billet material is rotating;
bonding at least a portion of the first billet material to the first body in response to the pressing and the rotating of the first billet material;
translating the first billet material relative to the first body; and
forming a boss from the at least the portion of the first billet material on the first body in response to the translating.

2. The method according to claim 1 , wherein the additively manufactured component is a metal.

3. The method according to claim 1 , wherein the additively manufactured component is a titanium alloy.

4. The method according to claim 1 , wherein the additively manufactured component is a Ti-8V-5Fe-1Al (Ti185) metastable β-titanium alloy.

5. The method according to claim 1 , wherein the first billet material comprises a ⅜ inch (0.95 cm) diameter rod.

6. The method according to claim 1 , wherein the first body and the boss are of a same material.

7. The method according to claim 1 , wherein the additively manufactured component comprises an aircraft landing gear component.

8. The method according to claim 1 , wherein the first loose substrate material comprises an elemental mixture of titanium hydride (TiH2) powder, iron, and a V—Al master alloy.

9. The method according to claim 1 , wherein the first body and the boss exhibit homogeneous grains.

10. An apparatus for forming an additively manufactured component comprising:
a rotatable die;
a mandrel extendible toward the rotatable die while the rotatable die is rotating;
a sleeve defining a space through which the mandrel extends, wherein the mandrel extends through the sleeve and compresses a first loose substrate material disposed within the sleeve against the rotatable die, wherein a unitary tubing made of the first loose substrate material is extruded from the rotatable die in response to the compressing, by the mandrel, the first loose substrate material disposed within the sleeve against the rotatable die, wherein the extruded unitary tubing comprises a first body of the additively manufactured component; and
a friction stir additive manufacturing machine configured to rotate and press a first billet material against the first body while the first billet material is rotating and to bond at least a portion of the first billet material to the first body in response to the pressing and the rotating of the first billet material.

11. The apparatus of claim 10 , wherein the friction stir additive manufacturing machine translates the first billet material relative to the first body, and
wherein a boss formed from the at least the portion of the first billet material is additively manufactured on the first body in response to the translating.

12. The apparatus of claim 11 , wherein the additively manufactured component is a metal.

13. The apparatus of claim 11 , wherein the additively manufactured component is a titanium alloy.

14. The apparatus of claim 11 , wherein the additively manufactured component is a Ti-8V-5Fe-1Al (Ti185) metastable β-titanium alloy.

15. The apparatus of claim 11 , wherein the first billet material comprises a ⅜ inch (0.95 cm) diameter rod.

16. The apparatus of claim 11 , wherein the first body and the boss are of a same material.

17. The apparatus of claim 11 , wherein the additively manufactured component comprises an aircraft landing gear component.

18. The apparatus of claim 11 , wherein the first loose substrate material comprises an elemental mixture of titanium hydride (TiH2) powder, iron, and a V—Al master alloy.

Assignees

• Goodrich Corp

Inventors

• Mironets Sergey
• El-Wardany Tahany Ibrahim

Classifications

• B23K20/126

  Workpiece support, i.e. backing or clamping · CPC title

• B23K20/125

  Rotary tool drive mechanism · CPC title

• B23K2101/006

  Vehicles · CPC title

• B23K2103/14

  Titanium or alloys thereof · CPC title

• B33Y80/00

  Products made by additive manufacturing · CPC title