WIRE-FEED FRICTION STIR ADDITIVE MANUFACTURING SYSTEMS, DEVICES, AND METHODS
A friction stir additive manufacturing system configured to extrude a material is provided. In one aspect, the system includes a spindle configured to rotate about a central axis, the spindle including a conical portion having a plurality of threads at a deposition end of the spindle. The system also includes a housing configured to remain stationary relative to the spindle, the housing including a wire inlet extending through a side wall of the housing, an interior surface of the side wall defining a truncated cone terminating at a material exit, the truncated cone configured to receive the conical portion of the spindle. The system also includes a feeding system configured to feed a wire through the wire inlet and into a gap between the spindle and the truncated cone of the housing.
1 . A friction stir additive manufacturing system configured to extrude a material, the system comprising:
a spindle configured to rotate about a central axis, the spindle comprising a conical portion having a plurality of threads at a deposition end of the spindle;
a housing configured to remain stationary relative to the spindle, the housing comprising a wire inlet extending through a side wall of the housing, an interior surface of the side wall defining a truncated cone terminating at a material exit, the truncated cone configured to receive the conical portion of the spindle; and
a feeding system configured to feed a wire through the wire inlet and into a gap between the spindle and the truncated cone of the housing.
2 . The friction stir additive manufacturing system of claim 1 , wherein the conical portion of the spindle comprises a plurality of notches comprising cutting edges, the plurality of notches circumferentially spaced about the conical portion of the spindle.
3 . The friction stir additive manufacturing system of claim 2 , wherein the plurality of notches each comprise a smooth surface.
4 . The friction stir additive manufacturing system of claim 2 , wherein sets of the plurality of threads are positioned between adjacent notches.
5 . The friction stir additive manufacturing system of claim 2 , wherein sets of the plurality of threads are positioned adjacent at least three edges of each notch.
6 . The friction stir additive manufacturing system of claim 1 , wherein the conical portion comprises a twisting helical shape.
7 . The friction stir additive manufacturing system of claim 1 , wherein the conical portion comprises a plurality of indentations defining a spiral pattern, each indentation defined on a first side by an abrupt edge and on a second side by a curved edge.
8 . The friction stir additive manufacturing system of claim 7 , wherein sets of the plurality of threads are positioned on the abrupt edges.
9 . The friction stir additive manufacturing system of claim 1 , wherein the spindle is configured to move along the central axis between a flush position, a retracted position, and a protruding position during use.
10 . The friction stir additive manufacturing system of claim 9 , wherein, when the spindle is in the flush position, a tip of the spindle is substantially coplanar with the material exit of the truncated cone.
11 . The friction stir additive manufacturing system of claim 9 , wherein, when the spindle is in the retracked position, a tip of the spindle is retracted within the truncated cone.
12 . The friction stir additive manufacturing system of claim 9 , wherein, when the spindle is in the protruding position, a tip of the spindle protrudes through the truncated cone and through the material exit.
13 . The friction stir additive manufacturing system of claim 1 , wherein the housing comprises a deposition surface surrounding the material exit, the deposition surface configured to contact one or more work surfaces as material is extruded from the material exit.
14 . The friction stir additive manufacturing system of claim 13 , wherein the deposition surface is configured to contact a surface of a single work-piece.
15 . The friction stir additive manufacturing system of claim 13 , wherein the deposition surface is configured to contact a previously deposited layer of material when depositing an additional layer of material.
16 . The friction stir additive manufacturing system of claim 13 , wherein the deposition surface is configured to contact surfaces of two adjacent work-pieces.
17 . The friction stir additive manufacturing system of claim 1 , wherein the housing comprises one or more cooling channels.
18 . A method comprising:
feeding a wire through a wire inlet extending through a side wall of a housing of a friction stir additive manufacturing device, the side wall defining a truncated cone terminating at a material exit;
rotating a spindle positioned within the housing about a central axis, the spindle comprising a conical portion having a plurality of threads;
feeding the wire into a gap between an interior surface of the housing and an exterior surface of the spindle;
cutting the wire with the plurality of threads;
softening the wire; and
depositing softened material on to a substrate as it exits the material exit.
19 . The method of claim 18 , further comprising advancing the friction stir additive manufacturing device across the substrate as the softened material is deposited.
20 . The method of claim 18 , further comprising moving a tip of the spindle from a first position within the housing to a second position where the tip extends out of the housing.
21 . The method of claim 18 , wherein feeding the wire through the wire inlet further comprises feeding the wire through a roller configured to guide the wire into a wire sleeve aligned with the wire inlet and preheating the wire when passing through the wire sleeve.
22 . A system comprising:
a friction stir additive manufacturing device comprising:
a spindle configured to rotate about a central axis and move along the central axis from a first position to a second position;
a housing configured to receive at least a portion of the spindle, the housing configured to remain stationary relative to the spindle, the housing comprising a wire inlet extending through a side wall of the housing; and
a feeding system configured to feed a wire through the wire inlet and into a gap between the spindle and the housing; and
a control system configured to move the friction stir additive manufacturing device during use.
23 . The system of claim 22 , wherein the control system comprises a robotic arm configured to move the friction stir additive manufacturing device during use.
24 . The system of claim 22 , wherein the control system comprises a gantry-based based platform configured to move the friction stir additive manufacturing device during use.
25 . The system of claim 22 , wherein the friction stir additive manufacturing device is configured to deposit material in a direction opposite a direction of gravity.
26 . The system of claim 22 , wherein the friction stir additive manufacturing device further comprises one or more thermocouples configured to collect temperature data for a closed loop control of printing parameters.
27 . The system of claim 22 , further comprising a tooling system configured to move a part or structure being formed by the friction stir additive manufacturing device during use.