Arc-Weld Metal Lamination With Layerwise Impurity Removal
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Solution Overview
Problem
The existing metal laminating and molding methods using arc welding often result in weld defects such as impurities, sputter, slag, and fume, which can lead to reduced rigidity and accuracy in the final molded objects due to the accumulation of these defects during the lamination process.
Innovation Solution
A method that involves repeatedly laminating metal layers after removing impurities, measuring and adjusting the temperature, and performing mechanical machining to ensure accurate shape formation, while cooling the surface to prevent weld defects and improve the welding quality, thereby minimizing the presence of weld defects in the final product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If arc welding is used to laminate metal layers continuously, then productivity is improved, but weld defects such as impurities, sputter, slag, and fume accumulate reducing manufacturing precision
Solution Approach 1:
The continuous lamination process is segmented into discrete units, each consisting of metal layer deposition followed by impurity removal. This segmentation allows the system to maintain continuous production while systematically eliminating weld defects at each stage, preventing defect accumulation that would occur in fully continuous processes.
Solution Approach 2:
Impurity removal is performed as a preliminary action before the next metal layer is deposited. By removing impurities, sputter, slag, and fume immediately after each layer is formed and before subsequent layers are added, the process prevents defect accumulation while maintaining high productivity through continuous operation.
2Manufacturing precision
If impurities are removed after each metal layer deposition, then manufacturing precision is improved, but the process complexity increases
Solution Approach 1:
The impurity removal process is merged with the metal layer deposition cycle, where each deposition-removal cycle forms a complete unit. This merging integrates the additional impurity removal step into the existing lamination workflow without requiring separate, standalone processing stages, thereby limiting the increase in overall process complexity.
Solution Approach 2:
The system performs impurity removal automatically as part of its own operation cycle without requiring external intervention or separate processing equipment. The welding system itself provides the impurity removal function through integrated processing, reducing the need for additional complex external devices.
3Manufacturing precision
If multiple processing steps are added to remove impurities and control temperature, then manufacturing precision is improved, but productivity decreases
Solution Approach 1:
The processing steps for impurity removal and temperature control are implemented in a continuous cyclic manner rather than as interruptive batch operations. Each metal layer deposition is immediately followed by impurity removal and temperature management, maintaining continuous useful action that minimizes idle time and preserves productivity while ensuring high weld quality.
Solution Approach 2:
The processing follows a periodic cycle where impurity removal and temperature control are performed at regular intervals corresponding to each metal layer deposition. This periodic action structure allows the system to balance multiple processing steps with production pace, achieving high manufacturing precision through consistent periodic intervention without excessive productivity loss.
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 manufacture of molded objects with reduced weld defects, improved strength, and enhanced accuracy by ensuring the removal of impurities and precise temperature control, resulting in higher quality and more reliable metal laminating and molding processes.
Implementation Method 1
a technology of melting and fixing metals through arc discharge used in arc welding
Implementation Method 2
a metal powder sintering method of melting and fixing metal powders through laser radiation
Data Source
AI summary
A metal laminating and molding method molds a 3-dimensional molded object formed by sequentially laminating a plurality of metal layers. The metal laminating and molding method is accomplished by repeatedly performing a unit process including a metal layer laminating process of laminating the metal layer constituted by welding beads formed through arc welding and a removal process of removing impurities from a surface of the metal layer laminated in the metal layer laminating process. When the unit process is repeated, the metal layer laminating process is performed again such that a new metal layer is laminated on the surface of the metal layer from which impurities have been removed in the removal process.