Additive-Manufactured Solid Welding Wire for Custom Chemistry
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Solution Overview
Problem
Current manufacturing methods for solid and tubular welding wires face challenges in producing custom chemistry or composition wires, particularly in smaller lot sizes, due to cost and consistency issues, with tubular wires experiencing ballooning, non-uniform heating, and reduced columnar strength, while solid wires have limitations in custom production and economies of scale.
Innovation Solution
The use of additive manufacturing techniques, such as 3D printing and laser metal deposition, to produce solid welding wires with custom chemistry or composition, involving sintering or melting powders onto a metal strip substrate, allowing for near-net shape formation and subsequent drawing into final product form, reducing the need for extensive hardening and annealing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If tubular wire is used to produce custom chemistry wires in smaller lot sizes, then cost flexibility and custom composition capability are improved, but manufacturing consistency and welding performance are worsened due to ballooning, non-uniform heating, and reduced columnar strength
Solution Approach 1:
The wire is segmented into a solid outer sheath and a powder-filled core, combining the advantages of both solid wire (consistent outer diameter, good feedability) and tubular wire (custom powder composition). The solid sheath provides structural integrity while the powder core enables custom chemistry.
Solution Approach 2:
The wire uses a composite structure with a metal sheath and powder core, allowing different materials to be combined. The sheath provides mechanical strength and consistent geometry, while the powder core provides custom chemistry and controlled melt-off characteristics.
2Manufacturing precision
If solid wire is produced using traditional methods, then manufacturing consistency and welding performance are improved, but cost flexibility and custom composition capability are worsened due to economies of scale requirements
Solution Approach 1:
The desired wire geometry and composition are prepared in advance through additive manufacturing, creating a near-net shape that requires minimal subsequent processing. This allows custom compositions to be produced without extensive hardening and annealing processes.
Solution Approach 2:
The manufacturing process parameters are changed from traditional subtractive or forming methods to additive manufacturing, enabling custom chemistry while maintaining consistency. The laser metal deposition process allows precise control of material composition and geometry.
3Adaptability or versatility
If additive manufacturing is used to produce custom chemistry wires, then cost flexibility and custom composition capability are improved, but manufacturing complexity is worsened
Solution Approach 1:
The additive manufacturing system performs multiple functions: it creates the wire geometry, controls the composition, and produces the near-net shape in a single integrated process. This multi-functionality reduces the need for separate manufacturing steps.
Solution Approach 2:
Traditional mechanical forming and assembly processes are replaced with laser metal deposition and sintering. The laser energy field substitutes for mechanical forces, enabling more precise and flexible manufacturing of custom chemistry wires.
4Productivity
If traditional solid wire manufacturing is used, then economies of scale are achieved, but production flexibility and custom lot sizes are worsened
Solution Approach 1:
The manufacturing system is made dynamic and adaptable, allowing production parameters such as lot size, composition, and geometry to be changed quickly between runs. This enables efficient production of custom lot sizes without sacrificing productivity.
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
This method enables the economical production of custom chemistry or composition solid wires, improving manufacturability and reducing wire breakage, especially for high carbon equivalent and small diameter wires, while maintaining consistency and precision, thus combining the benefits of both solid and tubular wires.
Implementation Method 1
additive manufacturing of solid wire with laser metal deposition (LMD)
Implementation Method 2
depositing a layer of material on the metal substrate during each pass through or by the material source system; building via sintering or melting the layer of a deposited material
Implementation Method 3
building via sintering or melting the layer of a deposited material on the metal substrate after each pass through or by the material source system
Data Source
AI summary
Systems and methods for the manufacture of a solid wire using additive manufacturing techniques are disclosed. In one embodiment, a fine powdery material is sintered or melted or soldered or metallurgically bonded onto a metal strip substrate in a compacted solid form or a near-net shape (e.g., a near-net solid wire shape) before being turned into a final product through forming or drawing dies.