Hot-Wire Additive Manufacturing with Pulsed Current Control
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Solution Overview
Problem
Conventional additive manufacturing methods are slow and lack precision, with metal powder processes generating waste and arc-based systems failing to produce highly precise articles.
Innovation Solution
A system and method utilizing a high energy device to create a molten puddle on a workpiece surface, with a wire feeder depositing molten droplets using a pulsed current to achieve high-speed and precise additive manufacturing, preventing arc formation between the wire and workpiece.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If metal powder processes are used for additive manufacturing, then material can be deposited, but the process is slow and generates significant waste
Solution Approach 1:
The invention changes the physical state of the filler material from powder to wire form, and changes the energy delivery mode from continuous to pulsed. The pulsed current heating creates controlled molten droplets that transfer efficiently to the workpiece, achieving both high speed and high precision without the waste associated with powder processes
Solution Approach 2:
The invention replaces the mechanical powder spreading and melting process with an electrical heating system that uses pulsed current to create molten droplets at the wire end. These droplets are then transferred to the workpiece by electromagnetic forces and surface tension, eliminating the need for mechanical powder handling and significantly reducing material waste
2Manufacturing precision
If arc based systems are used for additive manufacturing, then material can be deposited, but the process is slow and lacks precision
Solution Approach 1:
The invention segments the continuous wire feed into discrete molten droplets through pulsed current heating. Each droplet is formed, transferred, and deposited as a separate unit onto the workpiece, enabling precise control over material placement while maintaining high deposition speed through rapid pulsed cycling
Solution Approach 2:
The invention uses periodic pulsed current to heat the wire and create molten droplets at controlled intervals. The pulse frequency and duration are optimized to achieve rapid droplet formation and transfer, simultaneously improving precision through controlled deposition and productivity through high-frequency pulsing
3Productivity
If continuous current is applied to the wire, then material can be melted and deposited, but arc formation occurs between wire and workpiece
Solution Approach 1:
The invention uses periodic pulsed current instead of continuous current to heat the wire. The pulses are timed and controlled so that the wire reaches melting temperature and forms droplets without maintaining continuous contact with the workpiece, thereby preventing arc formation while maintaining high deposition rates through rapid pulsed cycling
Solution Approach 2:
The invention applies preliminary heating through controlled current pulses that raise the wire temperature to the melting point before droplet transfer occurs. This preliminary action ensures complete melting and droplet formation in advance, eliminating the need for continuous current that would cause arc formation during transfer
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
Enables high-speed and highly accurate additive manufacturing with reduced waste, allowing for the creation of complex and precise articles by controlling the current pulses to prevent arc formation and optimize droplet deposition.
Implementation Method 1
a high energy device irradiates a surface of a work piece with a high energy discharge to create a molten puddle on a surface of the work piece
Implementation Method 2
a power supply supplies a heating signal to the wire where the heating signal comprises a plurality of current pulses and where each of the current pulses creates a molten droplet on a distal end of the wire
Implementation Method 3
the power supply controls the heating current such that no arc is created between the wire and the work piece during the current pulses
Data Source
AI summary
A method and system to manufacture workpieces employing a high intensity energy source to create a puddle and at least one resistively heated wire which is heated to at or near its melting temperature and deposited into the puddle as droplets.