The Ohio State University

Other

Gm Global Technolgoy Operations, Inc.

Honda Motor Co., Ltd.

Medtronic, Inc.

Whirlpool Corporation

Glenn S Daehn

Vincent J Vohnout

Anupam Vivek

John Robert Bradley

Lawrence DuBois

Steven John Kuehl

Guolian Wu

James Gregory Schroth

Jason R Johnson

Timothy A Abke

John C Lippold

Linda M Johnson-Morke

Geoffrey A Taber

Edward A Herman

Amit A Tamhane

Ryan Carl Brune

Ali Nassiri

A metallic product is produced by an additive manufacturing method. A device for practicing has a controller with a stored instruction set for implementing the manufacturing of the metallic product. The metallic product is manufactured in a piece-wise or layer-wise manner on a target platform by a print head that is in two-way communication with the controller. The print head operates on a momentum transfer technique in which pulsed energy from an impulse source is used to launch pieces of metal toward the target platform, the pieces of metal bonding at the target platform to manufacture the metallic product.

Additive manufacturing using a momentum transfer method

A multiple spot vaporizing foil actuator weld (VFAW) system includes a target sheet layer secured relative to a stabilizing component, such that standoff components may be arranged sandwichably between the target and a flier sheet layer. An electrically insulating layer separates the flier from a vaporizing component sheet layer, which may comprise at least two vaporizing subsections configured to have less conductive material than at least three dividing subsections that separate the vaporizing subsections. The geometry and/or other features of the vaporizing subsections may be varied to optimize the vaporization. A second electrically insulated stabilizing component may sandwichably secure the above components between the first stabilizing component in order to control the forces generated in the VFAW process. The method involves loading the vaporizable component sheet layer with electrons via applied voltage such that the vaporizing subsections sublimate. The rapidly expanding gas particles accelerate the flier, completing the weld.

Device and methods of multiple spot welding for automotive applications using vaporizing foil actuator welding

A system and method for joining dissimilar metals. In one embodiment, a method comprises providing a first metal plate, a second metal plate, and an intermediate body that is positioned between the first metal plate and the second metal plate. The first metal plate is then driven into the intermediate body, which causes at least a portion of the intermediate body to collide with the second metal plate. As a result, the material of the intermediate body joins the first metal plate to the second plate. In another embodiment, a method for joining dissimilar metals comprises providing a first metal that is not amenable to welding, a second metal that is joinable to the first metal, and an intermediate body that is not joinable to at least the first metal. The intermediate body may have at least one hole such that the first metal and the second metal are positioned over and on opposite sides of the hole(s). At least a portion of the second metal may then be driven into the hole(s) to be joined to first metal.

Joining of dissimilar materials using impact welding

An elongate tape () acts as a vaporizing actuator for impulse metalworking. It has an electrically-insulative base layer (), an electrically-conductive layer (), and an electrically-insulative top layer (). In it, the base layer is characterized by the length of the tape and a first width W, as measured between a pair of side edges. The conductive layer is characterized by the length of the tape and a second width W, as measured between a pair of side edges; and the top layer is characterized by the length of the tape and a third width W, as measured between a pair of side edges. The layers are joined to each other to form the elongate tape with the electrically-conductive layer interposed between the electrically-insulative base and top layers.

Vaporizing foil actuator configured as consumable tape

A method of forming a refrigeration heat exchanger comprising a suction line and a capillary line includes juxtaposing at least a portion of the suction and capillary lines to form a juxtaposed portion, at least partially enveloping the juxtaposed portion with a metal material, and encapsulating the capillary line to the suction line along at least a portion of the juxtaposed portion.

Method of forming a refrigeration heat exchanger

A method for forming a piece of a sheet metal is performed by positioning a consumable body, made of metal, proximate to the piece of the sheet metal. The consumable body is rapidly vaporized, and the gas pressure generated thereby is directed into the piece of the sheet metal. This results in acceleration of the piece of sheet metal, and it is collided into a stationary body at a velocity, generally in excess of 200 m/s. Depending upon the type of stationary body, the piece of sheet metal is deformed into a predetermined shape or is welded onto the stationary body. The vaporization is accomplished by passing a high current of electricity into the consumable body. The effect of the vaporized metal may be augmented by additional components in the consumable body.

Electrically driven rapidly vaporizing foils, wires and strips used for collision welding and sheet metal forming

Methods and devices provide for high velocity forming of medical device casings. The high velocity forming may be produced by creating a pressure wave within a liquid contained by an enclosure. A die and a workpiece adjacent to the die are in the path of the pressure wave within the enclosure and the pressure wave forces the workpiece to conform to the contours of the die. Objects may be adhered to the die to provide for customized contours. Trimming features may be included within the enclosure to trim excess material from a formed workpiece as an integral part of the forming process. Various other features may also be provided within the enclosure including a diffuser to disperse the pressure wave. The workpiece may be of various forms including flat sheet stock.

High velocity forming of medical device casings

A laser, aimed at a flyer plate tab, causes optical energy to be directed at the tab, specifically, at a top surface thereof. Energy impacting the tab accelerates the tab out of an initial bent position, straightening it into an impact with a target sheet. The impact occurs in excess of 100 m/s, resulting in a metallurgical bond between the tab and the target sheet. The laser preferably strikes the top surface in a normal direction, based upon an initial angularity of the tab relative to the target. The laser emission, preferably in the range of 1 to 100 Joules delivered in a microsecond, may be augmented by an ablative layer on the top surface or a transparent covering on the top surface that reacts against the expanding gas from ablative activity on the top surface. The weld is formed without physical contact between the welding device and the tab.

Low-temperature laser spot impact welding driven without contact

A multi-layer driver plate is disclosed for use in electromagnetic sheet metal forming operations. In one embodiment, the driver plate comprises a first layer characterized by low electrical resistivity and thickness for inducement and application of a suitable electromagnetic forming force, a second layer comprising an elastomeric material for compressing a sheet metal workpiece against a die surface and then regaining its original pre-forming structure, and a third layer interposed between the first layer and the second layer to protect the EMF force providing layer and to provide overall strength and durability to the EMF driver plate.

Driver plate for electromagnetic forming of sheet metal

A scheme for electromagnetic formation of fuel cell plates is provided. In accordance with one embodiment of the present invention, a method of forming a flow field plate is provided where an electromagnetic actuator is arranged opposite a profiled surface of a die portion. The profiled surface of the die portion is configured to at least partially define a network of flow field plate flow passages. The electromagnetic actuator is configured to generate a magnetic field upon activation and a sheet of material is positioned between the electromagnetic actuator and the profiled die surface. The sheet of material is characterized by an electrical conductivity sufficient to yield a repulsive electromagnetic force between the actuator and the sheet upon activation of the actuator. The passages are formed by driving the electromagnetic actuator such that the repulsive force is of sufficient intensity to deform the sheet against the profiled die surface.

Electromagnetic formation of fuel cell plates

A scheme for deforming a sheet of material is provided. In accordance with one embodiment of the present invention, an apparatus for deforming a sheet of material is provided. The apparatus comprises a die portion, an electromagnetic actuator, and a conductive frame. The die portion defines a profiled surface. The electromagnetic actuator is arranged opposite the profiled surface of the die portion. The conductive frame is configured to (i) secure the sheet of material in electrical contact with the conductive frame in a position between the electromagnetic actuator and the profiled die surface, (ii) permit deformation of the sheet of material against the profiled die surface upon activation of the electromagnetic actuator, and (iii) define a return path for eddy currents induced in the sheet of material upon activation of the electromagnetic actuator.

Electromagnetic metal forming

A system and method for accomplishing localized feature forming in a sheet of material and/or the localized joining of multiple sheets of material. The system and method may also be used to attach a secondary component to a sheet of material. The system and method of the present invention employs a die having a shaped cavity for receiving a portion of the sheet material. A projectile is propelled from a projectile firing device to impact the sheet or sheets of material in the area overlying the subjacent die cavity. The projectile forces a portion of the sheet material into the die cavity, imparting a shape thereto. The kinetic energy transferred from the projectile to the sheet material may be used to form a metallurgical bond between multiple sheets of material. The metallurgical bond can be used alone to join the sheets, or may be used in conjunction with an interlocking shape to provide extra strength.

High velocity forming of local features using a projectile

The present invention includes a method of forming a metal work piece into a target shape, said method comprising the steps: (a) obtaining a metal work piece, said work piece having an original shape; and (b) forming said metal work piece by mechanical action while simultaneously subjecting said work piece to hydraulic forming, so as to deform said metal work piece from an original shape to a target shape. The present invention includes a method of forming a metal work piece into a target shape, the method comprising the steps: (a) obtaining a metal work piece, the work piece having an original shape; (b) disposing the metal work piece in a mold comprising at least one hydraulic actuator, the mold comprising: (i) an male mold portion having a mold side and a back side; (ii) a female mold portion having a mold side and a back side; the mold side of the male mold portion and the mold side of the female mold portion adapted to mate so as to deform a work piece disposed therebetween; (iii) at least one of the mold portions comprising at least one hydraulic actuator; and (iv) a hydraulic power source adapted to produce at least one hydraulic pulse through the at least one hydraulic actuator, so as to be capable of deforming the work piece; (c) closing the mold sides upon the metal work piece while causing at least one hydraulic pulse to pass through the actuator, so as to deform the metal work piece from the original shape to the target shape both by direct molding contact and hydraulic pulse forming. Preferably, the at least one hydraulic pulse comprises a series of hydraulic pulses.

Growing community of inventors

Columbus, OH, United States of America

Glenn S Daehn