CN110524891A - Continuous ultrasonic increasing material manufacturing - Google Patents
Continuous ultrasonic increasing material manufacturing Download PDFInfo
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- CN110524891A CN110524891A CN201910419350.4A CN201910419350A CN110524891A CN 110524891 A CN110524891 A CN 110524891A CN 201910419350 A CN201910419350 A CN 201910419350A CN 110524891 A CN110524891 A CN 110524891A
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/10—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating making use of vibrations, e.g. ultrasonic welding
- B23K20/103—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating making use of vibrations, e.g. ultrasonic welding using a roller
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/26—Auxiliary equipment
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
- B23K37/04—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups for holding or positioning work
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
- B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
- B29C65/083—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations using a rotary sonotrode or a rotary anvil
- B29C65/086—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations using a rotary sonotrode or a rotary anvil using a rotary anvil
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
- B29C65/7841—Holding or clamping means for handling purposes
- B29C65/785—Holding or clamping means for handling purposes using magnetic forces to hold at least one of the parts to be joined
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
- B29C65/7858—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus characterised by the feeding movement of the parts to be joined
- B29C65/7861—In-line machines, i.e. feeding, joining and discharging are in one production line
- B29C65/787—In-line machines, i.e. feeding, joining and discharging are in one production line using conveyor belts or conveyor chains
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
- B29C66/721—Fibre-reinforced materials
- B29C66/7214—Fibre-reinforced materials characterised by the length of the fibres
- B29C66/72141—Fibres of continuous length
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/74—Joining plastics material to non-plastics material
- B29C66/742—Joining plastics material to non-plastics material to metals or their alloys
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/16—Composite materials, e.g. fibre reinforced
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/16—Composite materials, e.g. fibre reinforced
- B23K2103/166—Multilayered materials
- B23K2103/172—Multilayered materials wherein at least one of the layers is non-metallic
Abstract
The present invention relates to continuous ultrasonic increasing material manufacturings.According on one side, the present invention provides a kind of for manufacturing the manufacture system of transition structure, which includes the fiber line being embedded into metal component.The system may include metal substrate source of supply.The system may include conveyer, and conveyer is supported on multiple rollers and is configured to move metal substrate along production mode reform.The system may include multiple grades along production mode reform arrangement.Each grade may include: passage fforming device, be configured to form channel in metal substrate；Fiber insertion apparatus is configured to for being inserted into channel few fibers material；And one or more ultrasonic welders, it is configured to for metal foil layer being fixedly arranged on fiber.The present invention includes the method using above system production transition structure and enhancing component.
Description
According to the priority claim of 35U.S.C. § 119
Entitled " the CONTINUOUS ULTRASONIC ADDITIVE that patent application claims are submitted on May 24th, 2018
Provisional application 62/676,191 priority of MANUFACTURING ", the provisional application are assigned to assigning for the application
People, and entire contents are herein incorporated by reference.
Background technique
The composite materials such as carbon fiber reinforced polymer provide high-intensitive or rigidity and weight ratio, and can be used for replacing
For the conventional metal member in various applications, such as automobile and aerospace applications.However, in same application, metal for
It may be preferred for other components.Therefore, it is necessary to composite component is bound to metal component.
The conventional method that composite component is bound to metal component is used to the combination of adhesive and Mechanical bonding techniques.Example
Such as, using adhesive by polymer-bonded to metal, then machanical fastener is driven to pass through composite component and mechanical component.It is this
Conventional method may destroy reinforcing material and generate the connector weaker than component.For example, using continuous fiber material,
Machanical fastener may destroy continuous fiber, to form weak spot.
In view of foregoing teachings, need to be modified to the technology in conjunction with metal and continuous fiber material.Particularly, it may be necessary to
The technology that can effectively produce.According to the content being provided below, more advantages be will become obvious.
Summary of the invention
The content of present invention is provided for introducing a series of designs in simplified form, these conceive specific embodiment parties below
It is further described in formula.The content of present invention is not intended to identify the key feature of claimed theme, is also not intended for auxiliary
Help the range for determining claimed theme.
According on one side, the present invention provides a kind of transition knot for manufacturing including the fiber line in insertion metal component
The system of structure.System may include metal substrate source of supply.System may include conveyer, and conveyer is supported on multiple rollers simultaneously
And it is configured to move metal substrate along production mode reform.System may include multiple grades along production mode reform arrangement.Each grade can be with
Include: passage fforming device, is configured to form channel in metal substrate；Fiber insertion apparatus is configured to part is fine
It ties up in material insertion channel；And one or more ultrasonic welders, it is configured to for metal foil layer being fixedly arranged on fiber.
The present invention provides a kind of transition knot for manufacturing including the fiber line in insertion metal component according to another aspect,
The method of structure.This method may include the reception metal-based layer at conveyer.This method may include being formed in metal-based layer
Channel.This method may include that few fibers material is inserted into channel.This method may include along conveyer in multiple ultrasounds
Each of bonding head place receives metal foil.This method may include will at each of multiple ultrasonic bonding heads place
Metal foil is ultrasonically welded to metal-based layer, with the new metal-based layer of the few fibers material formed in encapsulating channel.It should
Method may include promoting metal-based layer along conveyer.
The present invention provides a kind of method for manufacturing the component of metal enhancing according to another aspect,.This method can wrap
Include the reception substrate at conveyer.This method may include receiving along conveyer at each of multiple ultrasonic bonding heads place
Reinforcing material.This method may include that reinforcing material is ultrasonically welded to base at each of multiple ultrasonic bonding heads place
The strengthening part of material.This method may include that the strengthening part of substrate is promoted along conveyer.
On the other hand, transition structure includes metal part and multi-layer fiber part, and multi-layer fiber is partly comprised in difference
The multiple tow for being embedded in metal part at layer and being stretched out from the metal part for forming fabric.
Detailed description of the invention
List in detail in the claims be considered as speciality of the present invention novel feature.In the following description, like
Respectively with identical appended drawing reference in the whole instruction and attached drawing.The drawings are not necessarily drawn to scale, and is clear and letter
For the sake of clean, certain attached drawings can be shown in the form of amplification or outline.But when read in conjunction with the accompanying drawings, by reference to sheet
Invention illustrative aspect following specific embodiments, can be best understood the present invention itself and its it is preferable to use mode,
Further purpose and development, in the accompanying drawings:
Fig. 1 shows the exemplary transition structure of one aspect according to the present invention.
Fig. 2 shows one aspect according to the present invention for continuously manufacturing the example system of transition structure.
Fig. 3 shows another example system for continuously manufacture transition structure of one aspect according to the present invention.
Fig. 4 A shows the side view of the example roll-type anvil block of one aspect according to the present invention.
Fig. 4 B shows the front view of the example roll-type anvil block of Fig. 4 A.
Fig. 5 shows the example UAM enhancing component of one aspect according to the present invention comprising basal component and metal enhancing
Part.
Fig. 6 shows the example UAM enhancing component of one aspect according to the present invention comprising basal component and multiple metals increase
Strong part.
Fig. 7 shows the example system for continuously manufacture UAM enhancing component of one aspect according to the present invention.
Fig. 8 shows the top view of the example system of Fig. 7.
Fig. 9 shows the flow chart of the exemplary method for continuously manufacturing transition structure of one aspect according to the present invention.
Figure 10 shows the process of the exemplary method for continuously manufacturing UAM enhancing component of one aspect according to the present invention
Figure.
Specific embodiment
The definition of selected term used herein included below.Definition includes that within the scope of term and can be used for implementing
Component various examples and/or form.Example is simultaneously non-limiting.
Herein, " vehicle " is to refer to mobile and provide someone of power or unmanned by any form of energy
Structure.Term " vehicle " includes but is not limited to: automobile, truck, cargo, buggy, SUV, bicycle, motorcycle, pedal
Motorcycle, ship, personal watercraft, submarine, boat, canoe, aircraft and spacecraft.In some cases, motor vehicles packet
Include one or more engines.
In general, the present invention is provided to execute ultrasonic wave increasing material manufacturing (UAM) in continuous process to improve big rule
The system and method for mould manufacture efficiency.Example product includes UAM transition structure comprising in insertion metal master and stretches out metal
The fibrous material of main body.In U.S. Patent application 15/479,953 that example UAM transition structure was submitted on April 5th, 2017
Description, the patent application are herein incorporated by reference.Another example product includes UAM enhancing component, wherein surpasses metal layer
Sound wave is soldered to the strengthening part of component.
Referring to attached drawing, similar members are identified with like reference numerals in attached drawing.Fig. 1 shows exemplary transition structure 100,
Including metal part 102 and fiber composite part 104.Metal part 102 can be by any metal of compatible processes described herein
Or metallic combination is formed.For example, metal part 102 can by steel, aluminium, magnesium, titanium, cobalt, beryllium, nickel, columbium, tantalum, tungsten and its alloy or
Other structures alloy is formed.Fiber composite part 104 may include one or more layers fibre bundle (tows) or fibre plate.Example
Such as, fibre bundle may include carbon fiber bundle (bundles), glass fiber bundle, aramid fibre beam, the conjunction of other high-performance
At fibre bundle and/or natural or biological fiber beam.Fibre bundle can be woven to form pad or fabric.In one aspect, fine
The edge of dimension fabric may include fibre bundle, and fibre bundle forms ring along the edge of fabric.Ring can be embedded in metal portion
Divide in 102, and the rest part of fabric can stretch out metal part 102 to form fiber composite part 104.
In one aspect, metal part 102 can have the size for influencing manufacture system and method.Metal part 102 can
With thickness 110.Thickness 110 can be related with the thickness of the metal foil of ultrasonic bonding and the number of plies.Metal part 102 can be with
With width 120.In one aspect, device for ultrasonic welding can have restriction maximum width.For example, UAM equipment can have
There is the maximum width of 1 inch or about 25mm, band is fixedly arranged in layer.In one aspect, metal part 102 can have width
120, width 120 is limited to the maximum width of UAM equipment.On the other hand, it can be arranged as consolidation parallel band by multiple UAM,
To generate the width 120 for being greater than single UAM of maximum width.On the other hand, the single spool positioned at the first before UAM
It can deposit broadband (for example, 50mm-100mm), and multiple UAM can consolidate broadband to width greater than single UAM head
Metal part 102.It can be fixed by vacuum pressure, magnetic field or the mechanical clamp between deposition fraction and solidified portion
Band.Metal part 102 can have length 130.Length 130 select based on transition structure 100.
Fig. 2 shows the example systems 200 for manufacturing UAM product.System 200 may include conveyer 210, substrate 222
Source of supply 220 and collection device 230.Conveyer 210 may include for along one or more of 202 mobile product of production mode reform
A device.For example, as shown, conveyer 210 can be conveyer belt.Conveyer belt can be supported on multiple rollers.Roller can wrap
Include electromagnetism roller 212 and/or steel rider 214.Electromagnetism roller 212 can promote conveyer 210 along production mode reform.When executing operation to substrate
When, electromagnetism roller 212 can also attract substrate 222 and prevent substrate 222 mobile.Steel rider 214 can provide mechanical branch for substrate 222
Support and underway work.In one aspect, roller 212,214 can be set in each position for executing operation to substrate 222
Place.In one aspect, roller 212,214 can have flat surface, to provide support or pressure for executing operation.It is such as following
It is discussed in further detail, conveyer 210 can be discontinuous at the position for executing operation.For example, supersonic welding is hinged with
Substrate 222 can be received from the first part of conveyer and deposit reinforcing material on the second part of conveyer by setting.Although figure
In conveyer belt is shown, but it is to be understood that, conveyer 210 may include other technologies for moving substrate.For example, transmission
Machine 210 can use UAM or execute the mechanical action moving substrate of other machines of operation to substrate.It extraly, can be right
The part thereof being previously completed applies tension, to pull substrate along production mode reform 202.On the contrary, substrate source of supply can be passed through
220 apply pressure to substrate 222, to push substrate 222 along production mode reform 202.Substrate can also be moved magnetically or using packet
Pickup and placement technique containing the mechanical arm for being applicable in end effector with material are mobile.
The source of supply 220 of substrate 222 can be any distributor or formative factor of substrate 222.In one aspect, substrate
222 be sheet metal, can be used as volume, band, foil, single piece, bar or extruded product and provides.Substrate source of supply 220 can incite somebody to action
Substrate is assigned on conveyer 210 as continuous sheet or as cyclic dispersion sheet material.
Collection device 230 can be for collecting any device for completing product 232.In one aspect, collection device 230
It can be the spool for collecting the substrate 222 of UAM transition or UAM enhancing including addition.On the other hand, completing product 232 can
To be separated near the end of conveyer 210 and encapsulate in a reservoir or be transferred to another conveyer.
System 200 may include the various machines that operation is executed to the substrate 222 or UAM product of traveling.Machine can group
It is made into grade 240,250,260, these grades may include the repetition machine for executing similar operations.For example, the first order 240 may include
Passage fforming device 242.In one aspect, passage fforming device 242 may include the roller that channel is formed in substrate 222.It is logical
It can also include cutter, laser or other passage fforming devices that road, which forms device 242,.The first order 240 can also include fibre
Tie up insertion apparatus 244.For example, fiber insertion apparatus 244, which can be, is transferred to substrate 222 for fiber supply, especially it is transferred to
It is formed in the roller in the channel in substrate 222.The first order 240 can also include one or more ultrasonic brazing units 246.Each
Ultrasonic brazing unit 246 can be by the band consolidation of metal foil 248 to substrate 222.In one aspect, when substrate 222 is transmitting
When passing through below the ultrasonic brazing unit 246 on machine 210, ultrasonic brazing unit 246 can be remain stationary.Ultrasonic bonding
Device 246 can be with high-frequency vibration the tape welding of metal foil 248 is connected to metal base 222.As shown, multiple supersonic weldings
Connection device 246 can be arranged sequentially in the layer that metal foil 248 is constructed in grade, while along 202 moving substrate 222 of production mode reform.
For transition structure 100 shown in FIG. 1, system 200 may include three grades 240,250,260.Each grade 240,
250,260 can be similar to grade 240, and it is super including passage fforming device 242, fiber insertion apparatus 244 and one or more
Sound wave welder 246.Therefore, example system 200 can produce the exemplary transition structure 100 including three embedded fiber layers.
System 200 may include the additional machine for executing other operations in transition structure 100.For example, system 200
It may include for one or more computer numerical control (CNC) machine of processing channel or other feature, formed for consolidating
The system of creation feature, cutting or element, laser, heating and/or cold are eliminated in material or raw material (stock material)
But device, bonding exposure mask, application and cleaning systems, coating exposure mask, application and cleaning systems, vacuum aspirator, air blast are mechanical, electrical
And/or magnetic field generator, additional welding or combination system and the feed mechanism for continuously or discontinuously raw material.
Extraly, continuous UAM process may include the movement periodically or interrupted.For example, conveyer 210 can be along production
Direction 202 promotes substrate 222, suspends when executing one or more operations, is then pushed further into substrate along production mode reform
222。
In one aspect, there may be difficulties for continuously manufacturing for certain machines.For example, conventional ultrasonic wave welder can
To include substrate, the workpiece that substrate holding is just being ultrasonically welded.Substrate can be below supersonic generator (sonotrode)
Move back and forth, to weld multilayer foil in desired locations.Continuous operation can use multiple ultrasonic bonding heads raising layers and be welded
The speed connect, and increased simultaneously by eliminating workpiece relative to the demand for needing the supersonic generator of multilayer to move backward
The piece count of manufacture.However, workpiece positioning may be difficult in a substrate during continuous operation.In addition, if not
Pay attention to that workpiece is isolated, workpiece may be fused to conveyer system by ultrasonic bonding.Therefore, one or more components of system can
To be suitable for continuous manufacture.
In an example, as shown in figure 3, double welding machines 340 may include on the first side of workpiece (for example, with gold
Belong to foil 248 contact) the first ultrasonic brazing unit 342 and in second side of workpiece with the first ultrasonic brazing unit
Second ultrasonic brazing unit 344 of 342 directly opposite (for example, being contacted with substrate 222).Substrate 222 (for example, input blank)
Can between the first ultrasonic brazing unit 342 and the second ultrasonic brazing unit 344 continuous feeding.For example, such as Fig. 3 institute
Show, input blank can be moved to double welding machines 346 by conveyer 210, and workpiece can be transported to the second biography by double welding machines 346
Send machine.In one aspect, ultrasonic brazing unit 342,344 can be with driven out-of-phase (in terms of amplitude).The each ultrasound of driven out-of-phase
Wave soldering connection device 342,344 can potentially use the more small-power of each plumb joint.Double welding machines 340 may include multiple groups first
Ultrasonic brazing unit 342 and the second ultrasonic brazing unit 344, for example, to generate wider or thicker layer.
On the other hand, roll-type anvil block 350 can be oppositely arranged with ultrasonic brazing unit 352.Ultrasonic brazing unit
Coating can be applied on 352 roll-type anvil block and/or supersonic generator, to prevent workpiece adherency (for example, becoming to weld) extremely
Roll-type anvil block 350.Thicker material, such as thicker substrate for foil will allow bigger ultrasonic energy to pass through body
(bulk) shear stress dissipates, it means that a possibility that being soldered to anvil block is less than a possibility that being soldered to supersonic generator.
Biggish anvil faces area can also make a possibility that being soldered to anvil block be less than a possibility that being soldered to supersonic generator.Example
Such as, if the bottom of composite articles is aluminium and reinforcing material is steel, uncoated steel rider anvil block may not be soldered to workpiece
Bottom, but steel amplitude transformer (horn)/supersonic generator may need coating to prevent from being soldered to steel reinforcement.
Coating can be surface treatment, the surface treatment include with the supersonic generator of ultrasonic brazing unit 352 not
Same material.Coating can be solid layer of the thickness between 5 microns -500 microns.Coating can by physical vapour deposition (PVD),
Chemical vapor deposition, thermal spraying, cold spraying, sputtering, electro-deposition or other methods apply.Coating may include ceramics, metal, gold
Belong to ceramics or metal matrix composite, containing hard material, such as cubic boron nitride, tungsten carbide, diamond, TiN, TiAlN,
TiCN, CrN or other suitable hard materials that there is low-affinity for being combined material.As an alternative, ultrasonic wave is sent out
Raw device can be hardened by carburizing or nitridation.
Example roll-type anvil block 350 is illustrated in figures 4A and 4 B.Roll-type anvil block 350 may include: median plane 354, against
Supersonic generator (amplitude transformer) supporting base material of ultrasonic brazing unit 352；And side constraint portion 356, bound base bottom
Movement of the raw material transverse to production mode reform (into the direction of Fig. 4 B page).It should be understood that system 200 may include transmission
Any combination of band, double welding machines and roll-type anvil block.
Fig. 5 shows example UAM enhancing component 500 comprising basal component 502 and metal reinforcements 504.Basal component
502 and metal reinforcements 504 can be formed by any metal compatible with presently disclosed technology or metallic combination, such as
Steel, aluminium, magnesium, titanium, cobalt, beryllium, nickel, columbium, tantalum, tungsten and its alloy or other structures alloy.In the example shown, basal component 302
It can be the metal stock for staying in that enhancing post-processing is more specific component.However, UAM enhancing can be used for other components, such as
Component with flat metal surface.
Metal reinforcements 504 can have the size for influencing manufacture system and method.Metal reinforcements 504 can have thickness
Degree 510.Thickness 510 can be related with the thickness of the metal foil of ultrasonic bonding and the number of plies.Metal reinforcements 504 can have width
Degree 520.In one aspect, metal reinforcements 504 can have width 520, and width 520 is limited to the maximum width of UAM equipment.In
On the other hand, multiple UAM heads can be used in metal reinforcements 504, and multiple UAM are arranged as consolidation parallel band and are greater than list to generate
The width 520 of a UAM of maximum width.Metal reinforcements 504 can have length 530.Length 530 can be increased based on UAM
Strong component 500 select.
Fig. 6 shows another example UAM enhancing component 600.It may include basal component 602 and two that UAM, which enhances component 600,
And the above metal reinforcements 604,606.It is discussed in further detail in as follows, multiple metal reinforcements 604,606 can lead to
It crosses along production mode reform is parallel or the first-born production of multiple UAM of interlaced arrangement.
Fig. 7 is shown for manufacturing UAM product, such as the example system 700 of UAM enhancing component 500,600.System 700 can be with
Including conveyer 710, for promoting substrate along production mode reform 702.System 700 can also include substrate source of supply 720 and collect
Device 730.Conveyer 710 can be similar with conveyer 210, and including multiple rollers 712, multiple rollers 712 include electromagnetism roller and/
Or steel rider.Substrate source of supply 720 can be similar with substrate source of supply 220, and can supply basal component 502.For example, substrate
Source of supply 720 basal component 502 can be arranged on conveyer 710.Collection device 730 can be similar with collection device 230,
And the UAM enhancing component 500,600 of completion can be collected.Similar to system 200, system 700 may include being arranged as grade
740,750,760 machine, for executing operation on basal component 502,602.For example, as shown, the first order 740 can be with
Including multiple UAM heads 746, for consolidating metallic foil to basal component 502,602.
Fig. 8 shows the top view of the example system 700 for producing UAM enhancing component 600.Each UAM head 746 can wrap
Include amplitude transformer 770 and one or more energy converters 772.Amplitude transformer 770 can contact metal tape consolidating metal tape to substrate
Component 602.Energy converter 772 can be laterally extended from amplitude transformer.Therefore, when UAM enhancing component 600 includes multiple metal reinforcements
604,606 when, UAM head 746 can along production mode reform 702 in each grade 740,750,760 interlaced arrangement.Similarly, work as UAM
When the width 120 of transition structure 100 is greater than the maximum width of UAM head 746, UAM can be with interlaced arrangement to utilize adjacent metal
Band generates broader transition structure.
Fig. 9 is the flow chart for manufacturing the exemplary method 900 of transition structure.Method 900 can be executed by system 200.
In block 910, method 900 may include the reception metal-based layer at conveyer.In one aspect, for example, transmission
Machine 210 can receive substrate 222 from substrate source of supply 220.
In block 920, method 900 may include that channel is formed in metal-based layer.On the one hand, for example, channel is formed
Device 242 can form channel in substrate 222.Forming channel may include cutting, machining, molding or ablation substrate 222
To form channel.For example, cutting or machining channel can be completed with slotting cutter and CNC processing head.If channel size very little
And/or with the geometrical characteristic for needing CNC not transverse movements on the direction of conveyer system, this may be most slow behaviour
Make.As another example, forming channel can be completed with mold, which, which has, is processed as the shape opposite with expectation passage shape
Shape.Mold can be cylinder, to allow its surface scrolls along workpiece, continuously press when workpiece moves on the conveyor
Print channel geometries.This method can be very fast, its advantage is that any clast or old metal bits will not be generated, and can draw
The cold working for playing part, to improve its intensity.Molding may be not suitable for the higher substrate of certain harder or intensity.As another
Example can be used laser and substrate melted or distilled along planning path, so that ablation workpiece is to form channel.This may be to list
Method in it is most fast and a bit insensitive to geometrical characteristic.The significant challenge of ablation is to be formed fat pipe without mistake
Deep ground cutting material.
In block 930, method 900 may include that few fibers material is inserted into channel.In one aspect, for example, it is fine
Tieing up insertion apparatus 244 can be inserted into few fibers material in channel.
In block 940, method 900 may include receiving gold at each of multiple ultrasonic bonding heads place along conveyer
Belong to foil.On the one hand, for example, each of multiple ultrasonic brazing units 246 can receive metal foil 248.For example, metal
Foil 248 can be via roll-fed to ultrasonic bonding head.
In block 950, method 900 may include at each of multiple ultrasonic bonding heads place by metal foil ultrasonic wave
It is soldered to metal-based layer, with the new metal-based layer of the few fibers material formed in encapsulating channel.In one aspect, example
Such as, when substrate 222 is moved along conveyer 210, each of multiple ultrasonic brazing units 246 can be by corresponding metal
Foil 248 is ultrasonically welded to substrate 222, thus in the channel by few fibers material encapsulating.
In block 960, method 900 may include promoting metal-based layer along conveyer.In one aspect, for example, conveyer
210 can promote substrate 222 along conveyer 210.
Figure 10 is the flow chart for manufacturing the exemplary method 1000 of UAM enhancing component (for example, UAM enhances component 500,600).
Method 1000 can be executed by system 700.
In block 1010, method 1000 may include the reception substrate at conveyer.In one aspect, for example, conveyer
710 can receive substrate (for example, basal component 502,602) from substrate source of supply 720.
In block 1020, method 1000 may include receiving along conveyer at each of multiple ultrasonic bonding heads place
Reinforcing material.In one aspect, for example, each UAM head 746 can receive reinforcing material.Reinforcing material can be, for example, golden
Belong to, metallic fiber compound, or any other high-strength material that can be welded with UAM technique.It in one aspect, can be for not
Different reinforcing materials are provided with ultrasonic bonding head.Different reinforcing materials can be applied to different strengthening parts, or can be with
Different reinforcing materials are fixedly arranged in the different layers of identical strengthening part.
At block 1030, method 1000 may include surpassing reinforcing material at each of multiple ultrasonic bonding heads place
Sound wave is soldered to part thereof to form strengthening part.In one aspect, for example, each UAM head 746 can surpass reinforcing material
Sound wave is soldered to part thereof to form strengthening part.
At block 1040, method 1000 may include that the strengthening part of substrate is promoted along conveyer.In one aspect, example
Such as, conveyer 710 can promote the strengthening part of substrate along conveyer.
It should be understood that above-mentioned various embodiments and other feature and function or its substitution or modification can be according to need
It is incorporated into a number of other systems or application.Similarly, those skilled in the art may be then made as at present it is unforeseeable or
Various substitutions, modification, modification or the improvement that do not expected, these should also be included in claims.
Claims (21)
1. a kind of system for manufacturing the transition structure including the fiber line in insertion metal component, the system comprises:
Metal substrate source of supply；And
Conveyer, the conveyer are supported on multiple rollers and are configured to move the Metal Substrate along production mode reform
Piece；
Along multiple grades of production mode reform arrangement, each grade includes:
Passage fforming device is configured to form channel in the metal substrate；
Fiber insertion apparatus is configured to for being inserted into the channel few fibers material；And
One or more ultrasonic welders, be configured to for metal foil layer to be fixedly arranged at the few fibers material it
On.
2. system according to claim 1, wherein roller and one or more of ultrasonic bonding in the multiple roller
Each of device is relatively positioned along the conveyer.
3. system according to claim 2, wherein the roller includes central supported surface and side constraint portion, the side
Face constriction constrains the metal substrate transverse to the movement of the production mode reform.
4. system according to claim 1, wherein one or more of ultrasonic welders include and the metal foil
First ultrasonic welder of layer contact, and the second ultrasonic bonding with the first ultrasonic welder relative positioning
Device, wherein second ultrasonic welder is driven out of phase in terms of amplitude relative to first ultrasonic welder.
5. system according to claim 1, wherein at least one of the multiple grade grade is configured to insertion section
Point fibrous material or consolidated metal layers of foil, the fibrous material or metal foil layer have with the metal substrate or are before inserted into
Fibrous material or the different component of the metal layer of consolidation.
6. a kind of method that manufacture includes the transition structure of the fiber line in insertion metal component, which comprises
Metal-based layer is received at conveyer；
Channel is formed in the metal-based layer；
Few fibers material is inserted into the channel；
Metal foil is received at each of multiple ultrasonic bonding heads place along the conveyer；
The metal foil is ultrasonically welded to the metal-based layer at each of the multiple ultrasonic bonding head place, with
Form the new metal-based layer for encapsulating the few fibers material in the channel；And
The metal-based layer is promoted along the conveyer.
7. according to the method described in claim 6, further comprising:
Second channel is formed in the new metal-based layer；
Second part fibrous material is inserted into the second channel；
The second metal foil is received at each of multiple second ultrasonic bonding heads place along the conveyer；
Second metal foil is ultrasonically welded to the Metal Substrate at each of the multiple ultrasonic bonding head place
Layer, to form the new metal-based layer for encapsulating the few fibers material in the channel；And
The metal-based layer is promoted along the conveyer.
8. a kind of method for the component that manufacture is enhanced with reinforcing material, which comprises
Substrate is received at conveyer；
Reinforcing material is received at each of multiple ultrasonic bonding heads place along the conveyer；
The reinforcing material is ultrasonically welded to the part substrate at each of the multiple ultrasonic bonding head place
To form the strengthening part of the substrate；And
The strengthening part of the substrate is promoted along the conveyer.
9. according to the method described in claim 8, further comprising:
Channel is formed in the substrate；And
Few fibers material is inserted into the channel, wherein the reinforcing material is ultrasonically welded in the fibrous material
On.
10. a kind of system for manufacturing enhancing structure, the system comprises:
First enhancing source, the first enhancement layer is supplied on metal substrate；
First ultrasonic welder is located in the downstream in first enhancing source, for first enhancement layer to be fixed to
The metal substrate；
Second enhancing source, is located in the downstream in first enhancing source, increases for the second enhancement layer to be supplied to described first
On strong layer；And
Second ultrasonic welder is located in the downstream in second enhancing source, for second enhancement layer to be fixed to
First enhancement layer.
11. system according to claim 10, further comprises:
First passage forms device, is located in the upstream in first enhancing source, is configured in the metal substrate
Middle formation channel, wherein first enhancing source includes: the first fiber insertion apparatus, and the first fiber insertion apparatus is by structure
It causes few fibers material can be inserted into the channel；And metallic coil, the metallic coil are configured to metal
Layers of foil is supplied on the few fibers material, is at least partially formed first enhancement layer.
12. system according to claim 11, further comprises:
Second channel forms device, is located in the upstream in second enhancing source, and is configured to described first
Channel is formed in enhancement layer；Wherein, second enhancing source includes: the second fiber insertion apparatus, the second fiber insertion dress
It sets to be configured to for being inserted into second part fibrous material and be formed in the channel that device is formed by the second channel；With
And metallic coil, the metallic coil are configured to be supplied to metal foil layer on the second part fibrous material, so that
It is at least partially formed second enhancement layer.
13. system according to claim 10 further comprises conveyer, the conveyer is supported on multiple rollers,
In, the conveyer is configured to move the metal substrate along production mode reform.
14. system according to claim 13, wherein the first roller is along the conveyer and first ultrasonic welder
Relative positioning, and the second roller is along the conveyer and the second ultrasonic welder relative positioning.
15. system according to claim 14, wherein during at least one of first roller and second roller include
Heart support surface and side constraint portion, the side constraint portion constrain the metal substrate transverse to the shifting of the production mode reform
It is dynamic.
16. system according to claim 10 further comprises with the first ultrasonic welder relative positioning
Three ultrasonic welders, wherein the third ultrasonic welder is relative to first ultrasonic welder in terms of amplitude
It is driven out of phase.
17. system according to claim 10, further comprises:
Third enhances source, feeds third enhancement layer away from the first distance with first enhancement layer on metal substrate；And
Third ultrasonic welder is located in the downstream in third enhancing source, for the third enhancement layer to be fixed to
The metal substrate.
18. system according to claim 10, wherein first enhancement layer includes being different from second enhancement layer
Component.
19. system according to claim 10, wherein the metal foil of first enhancement layer is to be different from described second to increase
The component of the metal foil of strong layer.
20. system according to claim 12, wherein the fibrous material of first enhancement layer includes being different from described the
The component of the fibrous material of two enhancement layers.
21. system according to claim 17, wherein first enhancement layer includes being different from the third enhancement layer
Component.
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US201862676191P | 2018-05-24 | 2018-05-24 | |
| US62/676,191 | 2018-05-24 | ||
| US16/156,532 US11298775B2 (en) | 2018-05-24 | 2018-10-10 | Continuous ultrasonic additive manufacturing |
| US16/156,532 | 2018-10-10 |
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| Publication Number | Publication Date |
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| CN110524891A true CN110524891A (en) | 2019-12-03 |
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| CN201910419350.4A Pending CN110524891A (en) | 2018-05-24 | 2019-05-20 | Continuous ultrasonic increasing material manufacturing |
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