Methods, systems, and apparatus for component manufacturing

Patent metadata

Field	Value
Publication number	US-2023264289-A1
Application number	US-202217678869-A
Country	US
Kind code	A1
Filing date	Feb 23, 2022
Priority date	Feb 23, 2022
Publication date	Aug 24, 2023
Grant date	—

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 is:

1 . A method of forming an additively manufactured component comprising:
rotating a die; extending a mandrel toward the die and through a sleeve while the die is rotating; compressing a first loose substrate material disposed within the sleeve against the rotating die by the extending mandrel; extruding a unitary tubing made of the first loose substrate material from the rotating die in response to the compressing, 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 high-strength titanium alloy.

4 . The method according to claim 1 , wherein the additively manufactured component is a Ti-8V-5Fe-1A1 (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 (TiH 2 ) 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; and a sleeve defining a space through which the mandrel extends, wherein the mandrel compresses a first loose substrate material disposed within the sleeve against the rotatable die by the extending mandrel, wherein a unitary tubing made of the first loose substrate material is extruded from the rotatable die in response to the compressing, wherein the extruded unitary tubing comprises a first body of the additively manufactured component.

11 . The apparatus of claim 10 , further comprising 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.

12 . The apparatus of claim 11 ,
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.

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

14 . The apparatus of claim 12 , wherein the additively manufactured component is a high-strength titanium alloy.

15 . The apparatus of claim 12 , wherein the additively manufactured component is a Ti-8V-5Fe-1A1 (Ti185) metastable β-titanium alloy.

16 . The apparatus of claim 12 , wherein the first billet material comprises a ⅜ inch (0.95 cm) diameter rod.

17 . The apparatus of claim 12 , wherein the first body and the boss are of a same material.

18 . The apparatus of claim 12 , wherein the additively manufactured component comprises an aircraft landing gear component.

19 . The apparatus of claim 12 , wherein the first loose substrate material comprises an elemental mixture of titanium hydride (TiH 2 ) powder, iron, and a V—Al master alloy.

20 . A method of forming an additively manufactured component comprising an extruded unitary tubing, the method comprising:
rotating a die; extending a mandrel toward the die and through a sleeve while the die is rotating; compressing a first loose substrate material disposed within the sleeve against the rotating die by the extending mandrel; and extruding the unitary tubing made of the first loose substrate material from the rotating die in response to the compressing, wherein the extruded unitary tubing comprises a component of an aircraft landing gear.

Assignees

• Goodrich Corp

Inventors

• Mironets Sergey
• El-Wardany Tahany Ibrahim

Classifications

• B23K2103/24

  Ferrous alloys and titanium or alloys thereof · CPC title

• B23K20/1215 Primary

  for other purposes than joining, e.g. built-up welding · CPC title

• B23K20/125

  Rotary tool drive mechanism · CPC title

• B23K20/126

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

• B33Y10/00

  Processes of additive manufacturing · CPC title