WO2022231423A1 - Appareil pour des applications de friction-malaxage et procédé de fabrication d'un tel appareil - Google Patents

Appareil pour des applications de friction-malaxage et procédé de fabrication d'un tel appareil Download PDF

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Publication number
WO2022231423A1
WO2022231423A1 PCT/NL2022/050223 NL2022050223W WO2022231423A1 WO 2022231423 A1 WO2022231423 A1 WO 2022231423A1 NL 2022050223 W NL2022050223 W NL 2022050223W WO 2022231423 A1 WO2022231423 A1 WO 2022231423A1
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WO
WIPO (PCT)
Prior art keywords
cavity
output opening
transport screw
opening
wall
Prior art date
Application number
PCT/NL2022/050223
Other languages
English (en)
Inventor
Teunis Cornelis Bor
Jesper Bernard LIND
Original Assignee
Universiteit Twente
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Universiteit Twente filed Critical Universiteit Twente
Publication of WO2022231423A1 publication Critical patent/WO2022231423A1/fr

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Classifications

    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/02—Small extruding apparatus, e.g. handheld, toy or laboratory extruders
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B22F10/22—Direct deposition of molten metal
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/50—Means for feeding of material, e.g. heads
    • 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
    • B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
    • B23K20/1215—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding for other purposes than joining, e.g. built-up welding
    • 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
    • B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
    • B23K20/122—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding
    • B23K20/1245—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding characterised by the apparatus
    • B23K20/1255—Tools therefor, e.g. characterised by the shape of the probe
    • 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
    • B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
    • B23K20/122—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding
    • B23K20/128—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding making use of additional material
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/266—Means for allowing relative movements between the apparatus parts, e.g. for twisting the extruded article or for moving the die along a surface to be coated
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
    • B29C48/395—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die using screws surrounded by a cooperating barrel, e.g. single screw extruders
    • B29C48/397—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die using screws surrounded by a cooperating barrel, e.g. single screw extruders using a single screw
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
    • B29C48/50—Details of extruders
    • B29C48/505—Screws
    • B29C48/52—Screws with an outer diameter varying along the longitudinal axis, e.g. for obtaining different thread clearance
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/20—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces by extruding
    • B22F2003/208—Warm or hot extruding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
    • B29C48/50—Details of extruders
    • B29C48/68—Barrels or cylinders
    • B29C48/681—Barrels or cylinders for single screws
    • 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
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material

Definitions

  • the present invention relates to a friction stir extrusion apparatus for extruding material. Also, the invention relates to a printing apparatus for printing solid-state material. Furthermore, the invention relates to a method for extruding material.
  • additive manufacturing (AM) or 3D printing provides new routes to manufacturing of parts with complex shapes, new and/or integrated functionalities, with short time to market, and adaptable to individual needs/requirements.
  • a feed material is deposited layer-by-layer on a substrate to create a 3D object.
  • powders or wires As feed material, it is known to use either powders or wires as feed material.
  • deposition may take place by a fusion process, in which the powder is controllably melted locally and fused with the substrate.
  • a high energy beam laser beam or electron beam
  • Powder based additive manufacturing allows complex and highly detailed designs. Porosity and microstructure are however difficult to control. Also, due to melting, alloying elements may be lost due to evaporation from the melt pool which affects application for metal alloys such as a number of high strength Al alloys.
  • Patent application US2010/0285165 describes a screw extruder for continuous extrusion of materials with high viscosity.
  • Patent US 8,875,976 describes a system for continuous feeding of filler material for friction stir welding, processing and fabrication. Such a system includes friction-based fabrication tooling comprising a non consumable member with a throat and a consumable member disposed in the throat, wherein consumable filler material is capable of being introduced to the throat in a continuous manner during deposition using frictional heating and compressive/shear loading of the filer material onto the substrate.
  • a friction stir apparatus for extruding material comprising a stationary housing, a transport screw and a feeder, the housing comprising a body provided with a round cavity defined by an inner wall and extending along a rotational axis and having an input opening to the cavity for a material feed and an output opening for extruded material;
  • the transport screw being provided with one or more helical ridges along its length and at least partially arranged within the cavity with a longitudinal axis of the transport screw coinciding with the rotational axis of the cavity and adapted for rotating inside the cavity;
  • the feeder adapted for feeding the material feed to the input opening, wherein at least a first portion of the cavity is tapered towards the output opening and the transport screw is tapered along at least the first portion of the cavity and a gap between a major diameter of the at least one helical ridge of the transport screw and the inner wall of the cavity is constant and non-zero along at least the first portion and the gap defining a space in the cavity outside of a volume between the housing
  • (metallic) material is entered through the feeder in the cavity between the inner wall thereof and the transport screw.
  • the material enters in a space where it is exposed to plastic deformation and brought in softened state (i.e. , the material is brought to a temperature above its recrystallisation temperature) while transported towards the output opening. Due to the work on the material while passing the housing, the temperature of the material is high enough for deposition, no additional friction heating on the substrate is required during the deposition. Since the plastic deformation is predominantly controlled by the rotation of the transport screw, the deposition process is highly reproducible.
  • the non-zero gap is constructed larger than the minimal required clearance between the transport screw and the inner wall to avoid wear of the transport screw and/or inner wall of the cavity.
  • a diameter of an end of the transport screw at the output opening is smaller than an opening diameter of the output opening.
  • the apparatus comprises a die that is either integrated with or mounted on the output opening of the stationary housing, the die having an opening smaller than the opening of the output opening.
  • the opening of the die may have any shape, for example, circular, rectangular, elliptical, etc.
  • the arrangement of the friction stir apparatus with a die provides an advantageous setup for extrusion of the softened material.
  • the invention relates to a printing apparatus for printing solid-state material, comprising a print head consisting of a friction stir extrusion apparatus as described above.
  • the invention relates to a method for extruding material by a friction stir extrusion apparatus as described above, comprising: feeding material into the input opening by the feeder; forcing the material from the feed to the output opening by rotating the transport screw inside the cavity so as to bring the material in a softened state while passing between the transport screw and the inner wall of the cavity, and outputting the material in the softened state at the output, wherein the plastic deformation comprises forcing the material to propagate through a first portion of the cavity between the inner wall and the transport screw in which the inner wall of the cavity is tapered towards the output opening and the transport screw within the cavity is tapered along at least the first portion of the cavity in such a manner that the material is plastically deformed while passing between the transport screw and the inner wall of the cavity, and wherein a gap between a major diameter of the at least one helical ridge of the transport screw and the inner wall of the cavity is constant and non-zero along at least the first portion of the cavity.
  • Figure 1C shows a detail of a friction stir apparatus according to an embodiment of the invention
  • Figure 2 shows a cross-sectional view of a friction stir apparatus according to an embodiment of the invention
  • Figure 3 shows a cross-sectional view of a friction stir apparatus according to an embodiment of the invention
  • Figure 4 shows a cross-sectional view of a friction stir apparatus according to an embodiment of the invention
  • Figures 5A, 5B show a perspective view of an output opening according to an embodiment of the apparatus.
  • Figures 6A, 6B show a top cross-sectional view of a friction stir apparatus according to an embodiment of the invention.
  • Figure 1A, 1B show a cross-sectional view of a friction stir apparatus according to an embodiment of the invention.
  • the friction stir apparatus 100 comprises a stationary housing 110, a feeder 120 and a transport screw 130.
  • the housing 110 is a body provided with a round cavity defined by an inner wall 112, internal in the body, and which extends in the body along a rotational axis R. At least a first portion of the cavity is tapered along the rotational axis.
  • the housing 110 is provided with an input opening 114 for entry of feed material, which is positioned substantially perpendicular to the rotational axis, and is in communication with an entry portion of the cavity.
  • the housing has an output opening 116 that is positioned at an end face of the housing and centred with the location of the rotational axis R.
  • the feeder 120 is connected to the input opening and adapted for feeding the material feed to the input opening 114 of the housing 110.
  • the feeder comprises a tube with one end configured for receiving the feed material and the other end connected to the input opening.
  • the feeder is configured for feeding material having a shape of wires, granules, chips (turnings, filings, shavings) and/or fines.
  • the transport screw 130 is at least partially arranged within the cavity with a longitudinal axis of the transport screw coinciding with the rotational axis R of the cavity such that the transport screw can rotate inside the wall 112 of the cavity.
  • the transport screw is coupled with a drive (not shown) preferably having a controllable rotational speed.
  • the transport screw 130 is provided with one or more helical ridges 132 along its length which during operation engage with feed material entered at the input opening 114 and drive it towards a tip end 131 at the level of the output opening 116.
  • the transport screw 130 is tapered conformally with the shape of the cavity, in a manner that at least in the tapered region of the cavity, a non-zero and preferably constant gap is present between the inner wall and the transport screw; i.e. set-up by a first gap g 1 , 134 perpendicular to the rotational axis R and a second gap g2,136 parallel to the rotational axis R between a major diameter D of the at least one helical ridge 132 of the transport screw 130 and the inner wall 112 of the cavity.
  • the transport screw is not an Archimedes screw which provides transport of material within the space in between the helical ridges, but is a tool that is adapted to transport material and at the same time deform the material.
  • a space 138 is created in the cavity for material outside of the helical ridge (i.e. outside of the space between the helical ridges and the central body of the screw): the apparatus is provided with a volume within the cavity in which material from the feeder is plastically deformed while it is transported towards the output opening. As a result, the material can be brought into the softened state when reaching the output opening.
  • the material can be deposited on a substrate substantially without additional frictional heating on that substrate.
  • the created space 138 provides optionally some backflow of the softened material, but it is observed that comparatively a reduction of generated heat occurs, which allows more control of the material feed through the apparatus. Also this measure allows extrusion of material to be stopped substantially instantaneously which reduces the presence of spilled material on a work piece.
  • the apparatus comprises means for adjusting the size of the gap by adapting the axial position of the transport screw relative to the cavity.
  • a diameter of the tip end 131 of the transport screw at the output opening is smaller than an opening diameter 118 of the output opening. This allows an unhindered flow of the softened material from the output opening on a substrate below the output opening. As explained below in more detail the arrangement of Figure 1A is suitable for additive manufacturing to create a 3D structure from the softened material.
  • the apparatus comprises a sample table 140 on which a substrate 150 can be placed.
  • the table 140 is moveable relative to the output opening of the apparatus, which allows the printing of extruded material on the substrate according to a pattern imposed by the movement of the table.
  • the movement of the table is in at least a direction parallel to the rotation axis R and a direction perpendicular to the rotation axis.
  • the movement can be controlled by a suitable drive mechanism coupled to the table 140 (not shown).
  • the vertical distance between the output opening and a surface of the substrate 140 can be set such that it substantially corresponds with a thickness of the layer 150 that is to be printed/deposited on the surface.
  • FIG. 1B an alternative embodiment is shown in which a die 116 is provided that is either integrated with or mounted on the output opening 118 of the stationary housing.
  • the die 116 has an opening area smaller than the area of the opening of the output opening.
  • the apparatus is suitable for extrusion of the softened material.
  • the opening area of the die 116 can have any shape: for example, circular, elliptical, rectangular, etc.
  • Figure 2 shows a cross-sectional view of a friction stir apparatus according to an embodiment of the invention.
  • the cavity comprises a first exit portion 1101 that is adjacent to, and tapered towards, the output opening, similar as described above with reference to Figures 1 A, 1 B. Additionally, at the side of the input opening the cavity comprises a second entry portion 1102 that is substantially cylindrical.
  • the transport screw is positioned in the cavity and has at least one helical ridge which preferably extends along the entering and end portions.
  • the shape of the transport screw 130 is conformal with the shape of the cavity, with a cylindrically shaped portion 1302 that extends in the cylindrical portion 1102 of the cavity and a tapered portion 1301 that extends in the tapered portion 1101 of the cavity, such that at least in the tapered region of the cavity, the non-zero and constant gap is present between the inner wall and the transport screw.
  • the transport screw 130 has a length of 23.5 mm with a cylindrical and a conical section with lengths of 7 mm and 16.50 mm, respectively.
  • the helical ridge is manufactured according to ISO metric screw thread of a 20 mm bolt with a 2.5 mm pitch.
  • the helical ridge from the cylindrical section 1302 is continued on the conical section 1301.
  • the conical section 1301 has a total taper angle a of 40 degrees.
  • the inner wall 112 of the cavity comprises a cylindrical section with a diameter of 21 mm and a tapered/conical section that conforms with the shape of the transport screw.
  • the current setup is designed with a vertical gap 136, g2 that can be set between 0 mm and 15 mm.
  • the vertical gap is set between about 3 and 4 mm, which corresponds to a first horizontal gap 134, g1 between the inner wall and the major diameter of the screw of about 1 to 1.5 m (perpendicular to the rotation axis) while the vertical gap 136, g2 is between 3 and 4 mm, see fig 1C.
  • Figure 3 shows a cross-sectional view of a transport screw 135 according to a further embodiment of the invention.
  • the transport screw 135 is similar to the transport screw as shown in Figure 2, in which the transport screw 135 has a cylindrically shaped portion 1302 that extends in the cylindrical portion of the cavity and a tapered portion 1301 that extends in the tapered portion of the cavity. Additionally, the transport screw is provided at the tip end 131 which is on level with the opening of the output opening 118 of the cavity 110, with a protruding portion 1303 mounted on the tip end and which protrudes outside the output opening.
  • the protruding portion 1303 can have a same diameter as the tip end 131 of the tapered portion 1301, but alternatively the diameter of the protruding portion is smaller.
  • the protruding portion 1303 can be either cylindrical or tapered.
  • the protruding portion 1303 is provided with a thread along at least a portion of its length, which thread can have a same pitch as used on the cylindrical and tapered portions 1301, 1302. Alternatively, the pitch of the thread on the protruding portion 1303 can be different, preferably smaller.
  • the protruding portion is configured to contact or penetrate the surface of the substrate which causes local deformation and softening of the substrate material, similar to the prior art stir welding mechanism. Also, any surface layer on the substrate such as an oxide layer will be removed by the interaction between the protruding portion and the surface. As a result, the local deformation and softening causes an improved adhesion and mixing of the extruded material with the substrate.
  • FIG 4 shows a cross-sectional view of a friction stir apparatus according to an embodiment of the invention.
  • the feeder 120 is shown in some detail.
  • the feeder comprises a feeder tube (or channel) through which the feed material, preferably as wire, is transported to the input opening 114 of the cavity.
  • the feeder is positioned substantially horizontal, but may show a downward slope towards the cavity.
  • the inclination angle may vary between 0° and about 90°.
  • a selection is made with respect to the location where the feeder brings the material into contact with the transport screw. Hence, when during operation the feed material comes in contact with the tapered portion, more or less constant conditions occur over time, which is a preferred situation.
  • the feeder tube should be oriented substantially towards the tapered portion of the cavity.
  • the feeder tube 120 is provided with cooling means 122.
  • the cooling means are arranged in proximity to the housing 110, in order to absorb any heat that is generated by the work performed by the apparatus on the feed material in the cavity.
  • the feeder is provided with mechanical means for feeding material towards the cavity in the housing, for example, such means comprise a hydraulic cylinder. If the temperature near the feeder tube exit towards the housing becomes too high, plastic deformation of the feed material inside the feeder tube may cause such high frictional forces with the feed tube wall that the feed material gets stuck inside. To avoid this, the cooling prevents local overheating of the feed material close to the entry (i.e., the input opening 114) of the feeder tube.
  • the cooling means comprises a cooling channel that is in contact with the feeder tube and in which a cooling fluid is circulated.
  • the apparatus may comprise one or more thermal devices 115, 117 that locally heat or locally cool the housing (and/or if present the die).
  • a cooling device 115 may be arranged in proximity to the output opening or output opening 116 to prevent that the temperature of the softened material at the output opening becomes too high.
  • a heating device 117 may be arranged closer to the input opening for pre-heating. Other arrangements of cooling and/or heating devices are conceivable as well.
  • Figures 5A, 5B show a perspective view of an output opening according to an embodiment of the apparatus.
  • Figure 5A shows an output opening in a “flat” arrangement 160.
  • extruded or printed material from the output opening is deposited on a substrate that is positioned under the output opening.
  • the printed material can spread out freely without lateral geometrical restrictions based on the ability of the material to deform under the local thermo-mechanical conditions employed.
  • Figure 5B shows an output opening in an arrangement 162 with two guiding elongated ridges 164 extending parallel on opposite sides of the output opening 116.
  • the guiding ridges 164 create a printing/extrusion channel 1161 into which material from the output opening is extruded/printed on a substrate during operation.
  • the guiding ridges limit the spread of the printed material on the substrate to substantially the width between the guiding ridges. This arrangement allows printing/deposition of line shaped layers with substantially a same width as the width between the guiding ridges.
  • the output opening is arranged with a single guiding ridge to provide a guiding edge along which softened material can be deposited.
  • Figures 6A, 6B show a top view of a friction stir apparatus according to an embodiment of the invention.
  • the feed of material into the cavity is guided through the feeder tube 120 of the friction stir apparatus.
  • the feeder tube 120 is extending along a radial of the transport screw 130; 135 as shown in Figure 6A.
  • the feeder tube 120 can be oriented off axis relative to the rotation axis of the transport screw, or more preferably along a tangential direction relative to the transport screw ( Figure 6B). In the latter embodiment during operation the rotating motion of the screw assists to pull the feed material in, instead of forcing the material through the feed tube by additional external means.
  • the friction stir apparatus according to the invention as described above can be used for additive manufacturing (3D printing) of materials that can undergo plastic deformation within the volume between the transport screw and the inner cavity.
  • 3D printing additive manufacturing
  • many metals, metal alloys and metal matrix composites can be printed. Wthout any limitation such materials comprise at least light metal alloys, aluminium and aluminium-based alloys, magnesium and magnesium alloys, and soft metal alloys such as copper-based alloys but the skilled in the art will appreciate that other metals or alloys can be printed depending their material properties and the characteristics of the apparatus, in particular the materials of which the apparatus is constructed.
  • feeder tube allows the use of metal wire or metal rod in a (semi)continuous fashion, next to the use of metal-based chips, grains or fines.
  • the invention envisages the application of two (or more) feeders connected to the cavity in the housing which would allow a mixing of two (or more) materials shortly before the extrusion process.
  • the invention has been described with reference to some embodiments. Obvious modifications and alterations will occur to others upon reading and understanding the preceding detailed description. It is intended that the invention be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Health & Medical Sciences (AREA)
  • Clinical Laboratory Science (AREA)
  • Extrusion Moulding Of Plastics Or The Like (AREA)

Abstract

L'invention concerne un appareil d'extrusion par friction-malaxage pour extruder un matériau, comprenant une enveloppe, une vis de transport et un dispositif d'alimentation, l'enveloppe comprenant un corps comportant une cavité ronde et s'étendant le long d'un axe de rotation et ayant une ouverture d'entrée pour une alimentation en matériau et une ouverture de sortie pour le matériau extrudé ; la vis de transport ayant des nervures hélicoïdales le long de sa longueur est disposée à l'intérieur de la cavité et conçue pour tourner à l'intérieur de la cavité ; le dispositif d'alimentation est conçu pour fournir l'alimentation en matériau à l'ouverture d'entrée, une première partie de la cavité étant effilée vers l'ouverture de sortie et la vis de transport étant effilée le long de la première partie de la cavité, et un espace entre un diamètre extérieur de la nervure hélicoïdale de la vis de transport et la paroi intérieure de la cavité est constant et non nul le long de la première partie.
PCT/NL2022/050223 2021-04-26 2022-04-26 Appareil pour des applications de friction-malaxage et procédé de fabrication d'un tel appareil WO2022231423A1 (fr)

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NL2028068A NL2028068B1 (en) 2021-04-26 2021-04-26 Apparatus for friction stir applications and method for manufacturing such an apparatus

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US20220281005A1 (en) * 2021-03-04 2022-09-08 Kumar Kandasamy Processes and/or Machines for Producing Continuous Plastic Deformation, and/or Compositions and/or Manufactures Produced Thereby
US20230264289A1 (en) * 2022-02-23 2023-08-24 Goodrich Corporation Methods, systems, and apparatus for component manufacturing

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US20100285165A1 (en) 2006-11-20 2010-11-11 Jens Christofer Werenskiold Screw extruder for continuous extrusion of materials with high viscosity
US8875976B2 (en) 2005-09-26 2014-11-04 Aeroprobe Corporation System for continuous feeding of filler material for friction stir welding, processing and fabrication
WO2017075396A1 (fr) * 2015-10-30 2017-05-04 Stratasys, Inc. Pompe pour fluides visqueux à réglage de remplissage et de débit et procédés s'y rapportant
EP3251768A1 (fr) * 2016-05-31 2017-12-06 LKR Leichtmetallkompetenzzentrum Ranshofen GmbH Procédé de fabrication d'un profilé en alliage métallique
DE102016113289A1 (de) * 2016-07-19 2018-01-25 Kuka Industries Gmbh FSW-Werkzeug mit fester Schulter
DE102019106873A1 (de) * 2019-03-18 2020-09-24 Universität Stuttgart Extruder

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US8875976B2 (en) 2005-09-26 2014-11-04 Aeroprobe Corporation System for continuous feeding of filler material for friction stir welding, processing and fabrication
US20100285165A1 (en) 2006-11-20 2010-11-11 Jens Christofer Werenskiold Screw extruder for continuous extrusion of materials with high viscosity
WO2017075396A1 (fr) * 2015-10-30 2017-05-04 Stratasys, Inc. Pompe pour fluides visqueux à réglage de remplissage et de débit et procédés s'y rapportant
EP3251768A1 (fr) * 2016-05-31 2017-12-06 LKR Leichtmetallkompetenzzentrum Ranshofen GmbH Procédé de fabrication d'un profilé en alliage métallique
DE102016113289A1 (de) * 2016-07-19 2018-01-25 Kuka Industries Gmbh FSW-Werkzeug mit fester Schulter
DE102019106873A1 (de) * 2019-03-18 2020-09-24 Universität Stuttgart Extruder

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20220281005A1 (en) * 2021-03-04 2022-09-08 Kumar Kandasamy Processes and/or Machines for Producing Continuous Plastic Deformation, and/or Compositions and/or Manufactures Produced Thereby
US11691201B2 (en) * 2021-03-04 2023-07-04 Kumar Kandasamy Processes and/or machines for producing continuous plastic deformation, and/or compositions and/or manufactures produced thereby
US20230264289A1 (en) * 2022-02-23 2023-08-24 Goodrich Corporation Methods, systems, and apparatus for component manufacturing

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