Additive Manufacturing of Welding Wire

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Solution Overview

Problem

Conventional methods for manufacturing welding wires from special materials like superalloys with desired geometric properties, such as small diameters, are complex and costly.

Innovation Solution

The method employs additive manufacturing processes, including selective electron beam melting or selective laser melting, to fabricate welding wires with customized geometric and structural properties, using materials like Nickel-based superalloys, allowing for precise control over dimensions and properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional metalworking processes like wire drawing are used to manufacture welding wires from special materials with small diameters, then the manufacturing process becomes complex and costly, but the geometric precision and material integrity can be maintained

Engineering Contradiction:

Improvegeometric precisionVSAvoidprocess complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent changes the fundamental manufacturing parameter from subtractive (wire drawing) to additive (layer-by-layer deposition). This parameter change enables direct manufacturing of complex geometries without the complexity of conventional multi-step metalworking processes, while maintaining geometric precision through controlled deposition parameters

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The additive manufacturing process allows different sections of the welding wire to have locally optimized properties. The process can vary deposition parameters, material composition, and structural characteristics at different locations along the wire, enabling customized geometric properties and material distribution without requiring complex post-processing

Inventive Principle:

Principle #3Local quality

2Adaptability or versatility

If conventional metalworking processes are used to manufacture welding wires from special materials, then the material processing capability is limited, but the process simplicity can be maintained

Engineering Contradiction:

Improvematerial processabilityVSAvoidprocess complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent employs parameter changes by transitioning to additive manufacturing, which fundamentally alters how special materials are processed. The layer-by-layer deposition approach with controlled energy input (laser or electron beam) enables processing of materials that are difficult or impossible to process using conventional metalworking, including superalloys and functionally graded materials

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The additive manufacturing process enables the creation of composite structures and functionally graded materials within the welding wire. Different materials can be deposited in sequence or mixed during the manufacturing process, allowing complex material compositions and gradients that would be extremely difficult to achieve with conventional wire drawing methods

Inventive Principle:

Principle #40Composite materials

3Manufacturing precision

If additive manufacturing processes are used to manufacture welding wires with small diameters, then the geometric precision and material versatility improve, but the manufacturing time may increase

Engineering Contradiction:

Improvedimensional accuracyVSAvoidmanufacturing speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The additive manufacturing process for welding wires employs continuous layer-by-layer deposition without the need for intermediate stopping, machining, or assembly operations. The wire is manufactured in a single continuous process from raw material to finished product, eliminating downtime and maintaining continuous useful action throughout the manufacturing cycle

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The additive manufacturing process performs preliminary actions by directly creating the final wire geometry and internal structure during deposition. Features such as hollow sections, variable cross-sections, and material gradients are built-in during manufacturing rather than requiring subsequent post-processing operations, thereby improving overall manufacturing efficiency

Inventive Principle:

Principle #10Preliminary action

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 enables the reliable and high-quality manufacturing of welding wires with precise geometric properties, such as small diameters, from challenging materials like Nickel-based superalloys, improving process efficiency and reducing costs.

Implementation Method 1

additively manufacturing the at least one part of the welding wire base body by means of successive layerwise selective irradiation and consolidation of, particularly powdery, build material layers by means of at least one energy beam, particularly an electron beam or a laser beam

Methodology Applied

Scientific EffectSelective electron beam melting: Electron Beam

Implementation Method 2

Methodology Applied

Scientific EffectSelective laser melting: Laser

Data Source

PatentEP3702067A1Method for manufacturing a welding wire

Publication Date: 2020.09.02 CONCEPT LASER

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AI summary

Method for manufacturing a welding wire, the welding wire (10) comprising a welding wire base body (11), comprising manufacturing at least one part of the welding wire base body (11), particularly the complete welding wire base body (11), via at least one additive manufacturing process.