High Energy Additive Manufacturing with Resistive Wire Droplet Control
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Solution Overview
Problem
Conventional additive manufacturing methods are slow and lack precision, with metal powder processes generating significant waste and arc-based systems being inefficient for producing complex, precise articles.
Innovation Solution
A system and method utilizing a high energy device to create a molten puddle on a workpiece surface, with a wire feeder depositing molten droplets using a pulsed current to achieve high-speed and precise additive manufacturing, avoiding the formation of arcs between the wire and workpiece.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If metal powder processes are used for additive manufacturing, then manufacturing capability is achieved, but manufacturing speed is slow and material waste increases
Solution Approach 1:
The patent changes the physical state of the filler material from powder to wire form, and the energy delivery from continuous to pulsed. This parameter change enables faster material deposition rates while maintaining manufacturing precision through controlled droplet formation and placement into the molten pool.
Solution Approach 2:
The patent employs periodic pulsed current to the wire feeder, creating discrete molten droplets at controlled intervals. This periodic action allows for precise timing and placement of material deposits, increasing manufacturing speed while maintaining precision through rhythmic, controlled droplet formation and transfer.
2Manufacturing precision
If arc based systems are used for additive manufacturing, then manufacturing capability is achieved, but manufacturing speed is slow and precision is reduced
Solution Approach 1:
The patent extracts the harmful arc phenomenon from the process by using non-contactive pulsed current heating of the wire. Instead of creating an arc between wire and workpiece, the system heats the wire tip to form controlled droplets that are deposited into the molten pool, eliminating arc-related precision and speed limitations.
Solution Approach 2:
The patent replaces the arc-based thermal field with a controlled resistive heating field in the wire. This substitution allows for more precise control of heat input and material melting, enabling faster and more precise manufacturing without the instability and speed limitations of arc-based systems.
3Productivity
If continuous current is applied to wire feeder, then material deposition is continuous, but arc formation occurs between wire and workpiece
Solution Approach 1:
The patent uses periodic pulsed current instead of continuous current, creating discrete heating cycles that form and deposit droplets before the wire contacts the workpiece. This periodic action maintains material deposition continuity through rhythmic droplet transfer while preventing sustained arc formation by interrupting current flow between pulses.
Solution Approach 2:
The patent applies current pulses to pre-heat and melt the wire tip before contact with the workpiece, forming a droplet that is then deposited into the molten pool. This preliminary action ensures material is ready for transfer without requiring continuous current that would cause arcing upon contact.
4Productivity
If wire contacts workpiece continuously, then material transfer is efficient, but precision control is lost
Solution Approach 1:
The patent employs periodic pulsed current to create discrete droplets at controlled intervals, with the wire contacting the workpiece only at specific moments for droplet deposition. This periodic action maintains precision control through timed, discrete material placement while achieving efficient transfer through continuous rhythmic cycling of droplet formation and deposition.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables high-speed, precise additive manufacturing with reduced waste and improved precision, allowing for the creation of complex articles by controlling the deposition of molten droplets onto the workpiece surface without arc formation.
Implementation Method 1
a high energy device irradiates a surface of a work piece with a high energy discharge to create a molten puddle on a surface of the work piece
Implementation Method 2
a power supply supplies a heating signal to the wire where the heating signal comprises a plurality of current pulses and where each of the current pulses creates a molten droplet on a distal end of the wire
Data Source
AI summary
A method and system to manufacture workpieces employing a high intensity energy source to create a puddle and at least one resistively heated wire which is heated to at or near its melting temperature and deposited into the puddle as droplets.