A New Head for Friction Stir 3D Printing Metals

This patent describes a specialized part, called a deposition head, for a machine that 3D prints metal by stirring and fusing materials together, creating strong joints.

What it covers

This patent describes a device for joining two metal work-pieces using a process called friction stir additive manufacturing. The device includes a rotating spindle that deposits a filler material along a weld line as the machine moves. A key component is the deposition head, which surrounds part of the spindle but remains stationary while the spindle rotates. This head has a specific design: it features a first semi-cylindrical portion and a second semi-cylindrical portion positioned perpendicular to the first. The second portion includes a chamfered inner surface, which is designed to precisely shape the final weld, controlling how the material is laid down and fused. For example, this device could be used to add new material onto an existing metal structure or join two plates together with a strong, precisely formed seam.

What it doesn't cover

• —Does not cover friction stir manufacturing devices that do not include a deposition head with both a first and second semi-cylindrical portion.
• —Does not cover deposition heads where the second semi-cylindrical portion lacks a chamfered inner surface.
• —Does not cover additive manufacturing methods that do not rely on friction stir principles.
• —Does not cover devices where the deposition head rotates relative to the spindle.
• —Does not cover joining work-pieces without depositing a filler material.

The clever bit

The clever bit is the specific design of the deposition head, featuring two perpendicular semi-cylindrical portions and a chamfered inner surface. This geometry is intended to precisely guide and shape the filler material as it's deposited by the rotating spindle, allowing for better control over the final weld profile and material properties.

Why it matters

Friction stir additive manufacturing is a crucial technology for creating strong, high-quality metal parts, especially for industries like aerospace and automotive. It allows for joining dissimilar materials and building complex geometries with minimal distortion. This patent aims to improve the precision and control of the material deposition process, which can lead to even better weld quality and expanded applications for this manufacturing technique.

Real-world examples

• 1.Aerospace components like aircraft fuselage panels
• 2.Automotive parts for lightweight vehicles
• 3.Shipbuilding structures
• 4.Repairing metal components
• 5.Building custom metal prototypes