Additive Bead Closure Control for Overhang Weld Quality
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Solution Overview
Problem
In additive manufacturing using welding beads, variations in bead size and shape lead to inconsistent space amounts in closing paths, affecting strength and quality control, particularly in horizontal or overhang structures.
Innovation Solution
A control method and device that measures and adjusts welding conditions in real-time to ensure appropriate space amounts for closing paths by acquiring design values, specifying shape profiles, determining closure feasibility, and correcting additive conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If welding beads are deposited in horizontal direction or overhang shape, then building complexity is increased, but manufacturing precision deteriorates due to burn-through and size variation
Solution Approach 1:
The system performs preliminary measurement of the opening portion shape profile before executing the closing path welding. This allows the control device to predict the actual space amount and adjust welding conditions in advance, preventing burn-through and size variation before they occur during the actual welding process.
Solution Approach 2:
The system measures the actual shape profile of the opening portion and feeds this information back to the control device, which then adjusts the closing path welding conditions based on the measured space amount. This closed-loop feedback ensures consistent bead size even when building complex horizontal or overhang structures.
2Manufacturing precision
If welding conditions are adjusted for each location, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The control device changes welding parameters (current, speed, etc.) based on the measured space amount of the opening portion. By dynamically adjusting these parameters according to actual measurements rather than using fixed conditions, the system achieves consistent joint quality without requiring complex hardware modifications.
3Productivity
If closing path welding is performed without space amount management, then productivity is maintained, but manufacturing precision deteriorates due to quality variation
Solution Approach 1:
The system replaces complex mechanical adjustments with automated optical measurement and computational control. A measurement unit captures the opening portion shape, and a control device calculates and applies the appropriate welding conditions, maintaining high welding speed while ensuring consistent joint quality through intelligent automation rather than manual intervention.
Data Source
AI summary
A control method for an additive manufacturing device includes specifying a space amount indicating a size of a space of an opening portion and a representative position of the opening portion according to a shape profile, determining whether the opening portion is closed based on at least one of a comparison between the space amount and a design value of a bead shape, a comparison between information on the representative position and a target position of a welding bead included in a additive condition, and whether a penetration bead is formed, for a closing path for closing the opening portion with a welding bead to be formed based on the additive condition, and correcting the additive condition of the closing path when it is determined that the opening portion is not capable of being closed by the closing path.