Mechanical Electrode Oscillation for Dissimilar Metal Joint Deposition
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Solution Overview
Problem
Current metal manufacturing processes, such as additive manufacturing and welding, are complex and expensive due to the need for precise control of energy application and material composition, especially when joining components with different materials, which often results in increased weight and complexity from fasteners or geometries.
Innovation Solution
A system utilizing mechanical oscillation of an electrode in a manufacturing tool that controls the deposition of droplets with varying compositions and energies to form joints between workpieces of different materials, reducing the need for additional weight and complexity by precisely applying energy through controlled short circuit welding processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional welding or additive manufacturing processes are used to join components of different materials, then the joint can be formed, but the system complexity and cost increase due to the need for fasteners or complementary geometries
Solution Approach 1:
The patent merges multiple manufacturing operations (welding, additive manufacturing, heat treatment) into a single integrated tool head that can perform all operations sequentially on the same joint without repositioning workpieces. This consolidation eliminates the need for separate fastening operations and reduces system complexity while maintaining joint reliability through continuous process control.
Solution Approach 2:
The tool head is designed with universal multi-functionality, incorporating welding electrodes, additive manufacturing nozzles, and heating elements that can be selectively activated. This multi-functional design allows the same apparatus to perform different manufacturing operations on dissimilar materials without requiring separate specialized equipment, thereby reducing overall system complexity.
2Reliability
If fasteners or complementary geometries are added to join different materials, then the joint can be formed, but the weight and complexity of the assembly increase
Solution Approach 1:
The invention extracts the need for separate fastening elements by directly fusing dissimilar materials through controlled welding and additive manufacturing processes. By removing the requirement for fasteners, brackets, or complementary geometries, the design achieves joint formation through material fusion alone, significantly reducing assembly weight while maintaining structural integrity.
3Manufacturing precision
If precise control of energy application is implemented in metal manufacturing, then manufacturing precision improves, but process complexity and cost increase
Solution Approach 1:
The system maintains continuous useful action by performing welding, additive manufacturing, and heat treatment in an uninterrupted sequence within the same tool head. This continuous process eliminates the need for separate setup and control systems for each operation, achieving high deposition precision through consistent process parameters while reducing overall process complexity.
Solution Approach 2:
The invention utilizes parameter changes by dynamically adjusting welding current, wire feed speed, and heating temperature based on real-time process conditions. These controlled parameter variations enable precise material deposition and microstructure control without requiring complex external control systems, as the adjustments are made through integrated sensors and actuators within the tool head.
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 simplifies the manufacturing process, reduces costs, and enhances the precision and durability of joints by directly depositing material with controlled microstructure and heat application, minimizing the heat-affected zone and improving the properties of the final product.
Implementation Method 1
a manufacturing tool (20) that mechanically oscillates an electrode (28) toward and away from a workpiece (16, 18)
Implementation Method 2
controls the deposition of droplets with varying compositions and energies to form joints between workpieces
Implementation Method 3
enhances the precision and durability of joints by directly depositing material with controlled microstructure and heat application
Data Source
Figure 1~2
Figure 3~4
Figure 5~6B
AI summary
The present application relates to a system (10) that includes a welding tool (20) configured to receive a welding wire (28) from a wire feeder (24), to receive welding power from a power source (54), and to supply the welding wire (28) to a workpiece (16, 18, 40) during a welding process. The system (10) also includes a mechanical oscillation system configured to mechanically oscillate a structural component toward and away from the workpiece (16, 18, 40). The structural component is external to the wire feeder (24) and the power source (54). The system (10) further comprises control circuitry (42) configured to control the welding power based on feedback relating to the welding process.