Field-assisted friction stir additive manufacturing

Patent metadata

Field	Value
Publication number	US-12269110-B2
Application number	US-202318160223-A
Country	US
Kind code	B2
Filing date	Jan 26, 2023
Priority date	Jan 26, 2023
Publication date	Apr 8, 2025
Grant date	Apr 8, 2025

Abstract

A method of forming a metal workpiece is disclosed herein. The method includes applying an electrical current through a feedstock material, applying a vertical axis force to the feedstock material; applying a rotational force to the feedstock material, and producing a metallic component from the feedstock material based on the electric current, the vertical axis force, and the rotational force.

First claim

What is claimed is:

1. A method for forming a metal workpiece, comprising:
applying an electrical current to a feedstock material;
applying a vertical axial force to a first end of the feedstock material, wherein the axial force is provided via a press mechanism;
applying a rotational force to the feedstock material; and
producing a metallic component from a second end of the feedstock material based on the electrical current, the vertical axial force, and the rotational force,
wherein a first end of an electrical current circuit supplying the electrical current is applied to the first end of the feedstock material and a second end of the electrical current circuit is applied to a substrate.

2. The method of claim 1 , wherein the electrical current is at least one of a direct electrical current or an alternating electrical current.

3. The method of claim 1 , wherein the substrate is comprised of a first material and the feedstock material is comprised of a second material and wherein the first material is the same as the second material.

4. The method of claim 1 , wherein the substrate is comprised of a first material and the feedstock material is comprised of a second material and wherein the first material is different material than the second material.

5. The method of claim 1 , wherein the feedstock material is a metal alloy with a hardness at or above a 4 hardness (Mohs).

6. The method of claim 1 , wherein producing the metallic component from the feedstock material further comprises:
preforming a first deposition process to form a first layer on a substrate; and
preforming a second deposition process to form a second layer over the first layer.

7. The method of claim 6 , wherein the first layer is formed to a first thickness and the second layer is formed to a second thickness.

8. The method of claim 6 , wherein the first deposition process is a stir friction welding process.

9. A system, comprising:
an electric current source;
a force mechanism;
a rotating tool;
a controller; and
a tangible, non-transitory memory configured to communicate with the controller, the tangible, non-transitory memory having instructions stored thereon that, in response to execution by the controller, cause the controller to perform operations comprising:
commanding the electric current source to apply an electrical current to a feedstock material;
commanding the force mechanism to apply a vertical axial force to a first end of the feedstock material, wherein the axial force is provided via a press mechanism;
commanding the rotating tool to apply a rotational force to the feedstock material; and
producing a metallic component from a second end of the feedstock material based on the electrical current, the vertical axial force, and the rotational force,
wherein a first end of an electrical current circuit supplying the electrical current from the electric current source is applied to the first end of the feedstock material and a second end of the electrical current circuit is applied to a substrate on which the metallic component is produced.

10. The system of claim 9 , wherein the electrical current is at least one of a direct electrical current or an alternating electrical current.

11. The system of claim 9 , wherein the substrate is comprised of a first material and the feedstock material is comprised of a second material and wherein the first material is the same as the second material.

12. The system of claim 9 , wherein the substrate is comprised of a first material and the feedstock material is comprised of a second material and wherein the first material is different material than the second material.

13. The system of claim 9 , wherein the feedstock material is a metal alloy with a hardness at or above a 4 hardness (Mohs).

14. A method of forming a metal workpiece, comprising:
receiving a feedstock material comprising a first material;
applying an electrical current to the feedstock material to heat the feedstock material to a first temperature;
applying a vertical axial force to a first end of the feedstock material, wherein the axial force is provided via a press mechanism;
applying a rotational force to the feedstock material, wherein an application of the vertical axial force and the rotational force causes a second end of the feedstock material to heat to a second temperature, wherein the second temperature is higher than the first temperature; and
producing a metallic component from the second end the feedstock material,
wherein a first end of an electrical current circuit supplying the electrical current from an electric current source is applied to the first end of the feedstock material and a second end of the electrical current circuit is applied to a substrate on which the metallic component is produced.

15. The method of claim 14 , wherein the electrical current is at least one of a direct electrical current or an alternating electrical current.

16. The method of claim 14 , wherein the substrate is comprised of a second material and wherein the first material is the same as the second material.

17. The method of claim 14 , wherein the substrate is comprised of a second material and wherein the first material is different material than the second material.

Assignees

• Goodrich Corp

Inventors

• Mironets Sergey
• El-Wardany Tahany

Classifications

• B23K20/128

  making use of additional material · CPC title

• B23K20/1235

  with temperature control during joining · CPC title

• B33Y50/02

  for controlling or regulating additive manufacturing processes · CPC title

• B33Y30/00

  Apparatus for additive manufacturing; Details thereof or accessories therefor · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title