Dual Plasma Wire Arc Printing With In-Situ Surface Smoothing
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Solution Overview
Problem
Current wire arc additive manufacturing (WAAM) processes face challenges in achieving efficient surface finishing and high deposition rates, often requiring additional post-processing steps like machining or laser cleaning, and struggle with defects due to high electrical currents and burn-off limitations.
Innovation Solution
The implementation of a dual plasma wire arc additive manufacturing system that uses a dual plasma torch combining MIG and TIG components to create a plasma arc for surface smoothing and improve deposition rates by using multiple feed wires, including a hot wire and cold wires, to enhance the weld pool's temperature distribution and shielding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional wire arc additive manufacturing is used to build structures quickly, then productivity increases, but surface finish quality deteriorates requiring additional post-processing steps
Solution Approach 1:
The patent combines the additive manufacturing process and surface smoothing process into a single integrated operation using one print head. The print head alternates between depositing material layers and smoothing surfaces in real-time, eliminating the need for separate post-processing steps and maintaining high productivity while improving surface finish quality
Solution Approach 2:
The smoothing action is performed immediately after material deposition while the material is still warm and pliable. This preliminary smoothing prevents surface defects from setting and eliminates the need for later corrective post-processing operations
2Productivity
If high electrical currents are used to increase deposition rates, then productivity improves, but harmful factors increase due to burn-off limitations and defects
Solution Approach 1:
The patent divides the single arc into two separate plasma arcs: a primary arc for material deposition and a secondary arc for surface smoothing. This segmentation allows each arc to operate at optimized current levels without causing burn-off defects, enabling high deposition rates while maintaining surface quality
Solution Approach 2:
The secondary plasma arc acts as an intermediary that processes the deposited material surface without directly involving the feed wire. This intermediary arc smooths the surface and removes defects without causing the burn-off problems associated with high-current primary arcs
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 improved surface finish quality by reducing parasitic mass and defects, increases deposition rates up to 30 pounds per hour, and eliminates the need for post-processing steps like machining and laser cleaning, while maintaining the structural integrity of the printed parts.
Implementation Method 1
a first plasma arc between a first electrode and a workpiece to melt a surface of the workpiece
Implementation Method 2
a second plasma arc between a second electrode and the workpiece to smooth the surface of the workpiece
Implementation Method 3
The shielding gas can protect the weld pool from corrosive gases and moisture
Implementation Method 4
applying an electrical arc to melt the feed wire to form the first layer of the additively manufactured article
Implementation Method 5
applying, via the additive print head, electrical energy through an electrode separate from the feed wire to a gas to form a plasma arc to shield the additively manufactured article
Data Source
AI summary
A plasma arc torch assembly is capable of additively manufacturing articles. A device may additively manufacture at least a portion of an article using the plasma arc torch assembly. A device may deactivate at least one plasma arc associated with the plasma arc torch assembly. A device may perform plasma arc surface smoothing of the article using the plasma arc torch assembly.