Additive Welding Shell-Core Strategy for Surface Accuracy

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Solution Overview

Problem

The existing additive manufacturing method can result in sagging or waviness on the side surface of manufactured objects and deteriorates surface accuracy.

Innovation Solution

The method involves a shell portion forming step using weaving welding to create a shell portion bead and a core portion forming step using straight welding to form a core portion bead, with an additive manufacturing system that includes a welding head and a control device to manage these processes, ensuring improved surface accuracy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional additive manufacturing method is used, then manufacturing process is simple, but surface accuracy deteriorates due to sagging or waviness on side surface

Engineering Contradiction:

Improvesurface accuracyVSAvoidmanufacturing process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The additive manufacturing process is segmented into two distinct phases: shell portion forming using weaving welding for high surface accuracy, and core portion forming using conventional welding for structural bulk. This segmentation allows each phase to be optimized independently, with the shell phase prioritizing surface quality and the core phase prioritizing manufacturing efficiency.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different welding methods are applied to different regions of the manufactured object: weaving welding is used specifically for the shell portion where surface accuracy is critical, while conventional welding is used for the core portion where structural integrity is paramount. This local quality approach ensures that resources are allocated efficiently to where they are most needed.

Inventive Principle:

Principle #3Local quality

2Manufacturing precision

If weaving welding is used for shell portion, then surface accuracy is improved, but manufacturing time increases

Engineering Contradiction:

Improvesurface accuracyVSAvoidmanufacturing efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The manufacturing process is divided into shell portion forming and core portion forming, allowing the time-consuming weaving welding to be applied only to the shell portion where surface accuracy matters, while the faster conventional welding handles the bulk core portion.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Weaving welding is applied partially only to the shell portion rather than the entire object. This partial action provides sufficient surface accuracy improvement for the visible exterior while avoiding the excessive time cost of applying the same method to the hidden core portion.

Inventive Principle:

Principle #16Partial or excessive action

3Productivity

If conventional welding is used for entire object, then manufacturing efficiency is maintained, but side surface exhibits sagging or waviness

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidside surface accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The object is segmented into shell and core portions, with the shell portion formed by weaving welding to prevent sagging and waviness on the visible surface, while the core portion uses conventional welding for efficient bulk material deposition.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The shell portion receives specialized weaving welding treatment to ensure high surface accuracy and prevent defects, while the core portion uses standard welding processes. This local quality differentiation ensures surface accuracy where it matters most without sacrificing overall manufacturing efficiency.

Inventive Principle:

Principle #3Local quality

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 approach enhances the surface accuracy of additive manufactured objects by densely forming the shell portion with weaving welding, reducing variations, and supporting the core portion to prevent sagging, thereby improving the overall manufacturing efficiency and reducing finishing processing time.

Implementation Method 1

a shell portion forming step of additively forming a shell portion corresponding to an outer portion of an addictive manufactured object by a shell portion bead formed by weaving welding

Methodology Applied

Scientific EffectWelding: Welding

Implementation Method 2

shell portion bead formed by weaving welding

Methodology Applied

Scientific EffectWeaving welding: Welding

Data Source

PatentUS20240359264A1Addictive manufactured object manufacturing method and additive manufacturing system

Publication Date: 2024.10.31 MITSUBISHI HEAVY IND LTD

AI summary

An addictive manufactured object manufacturing method includes: a shell portion forming step of additively forming a shell portion corresponding to an outer portion of an addictive manufactured object by a shell portion beads formed by weaving welding; and a core portion forming step of additively forming a core portion corresponding to an inner portion of the addictive manufactured object by a core portion bead formed by welding.