Hybrid Multi-Wire Additive Manufacturing for Fast Dense 3D Builds
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Solution Overview
Problem
Conventional additive manufacturing processes face challenges with long build times and defects like lack-of-fusion due to low heat inputs, particularly in applications requiring fully dense structures under dynamic loading conditions.
Innovation Solution
A multi-wire welding system is employed, using a combination of low and high deposition rate processes to create contour and fill portions of a part, respectively, with the low deposition rate process forming high-resolution outlines and the high deposition rate process filling in using a submerged arc welding technique, allowing for variable width and length control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a low deposition rate process is used to ensure high resolution and proper fusion, then manufacturing precision is improved, but productivity deteriorates due to long build times
Solution Approach 1:
The additive manufacturing process is divided into two distinct stages: a first metal deposition process that creates high-resolution contours and a second metal deposition process that performs high-speed filling. This segmentation allows each process to be optimized independently - the first process ensures proper fusion and resolution while the second process maximizes deposition rate, thereby resolving the contradiction between manufacturing precision and productivity
Solution Approach 2:
The first metal deposition process deposits only enough material to create the contour or shell of each layer, rather than filling the entire layer. This partial action approach ensures high resolution and proper fusion at the critical interface regions while significantly reducing the total deposition time compared to complete layer filling at high resolution
2Productivity
If a high deposition rate process is used to reduce build time, then productivity is improved, but manufacturing precision deteriorates due to low resolution and potential lack-of-fusion defects
Solution Approach 1:
The process separates the high-resolution contour deposition from the high-speed filling operation. The second metal deposition process using parallel multi-wire electrodes is specifically optimized for high deposition rates and is applied only after the first process has established the structural framework, allowing high productivity without sacrificing the resolution quality established in the first stage
Solution Approach 2:
The first metal deposition process performs preliminary action by creating the contour and shell structure of each layer before the second process begins filling. This preliminary high-resolution framework ensures proper fusion pathways exist before high-speed deposition begins, preventing lack-of-fusion defects even though the second process operates at lower resolution
3Productivity
If partial filling with grid or hatch pattern is used to reduce weight and build time, then productivity is improved, but reliability deteriorates due to insufficient density for dynamic loading conditions
Solution Approach 1:
The patent applies different filling strategies to different regions of the part based on local requirements. The first metal deposition process creates high-resolution contours that define the precise boundaries and critical structural features. The second process then fills the interior regions at high speed. This local quality approach ensures that critical interface regions have proper fusion and density while interior regions can use efficient filling patterns, achieving both reliability and productivity
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 significantly reduces build times, achieves high final density, and improves mechanical properties by iteratively creating skeletons and filling them, suitable for dynamic loading conditions.
Implementation Method 1
a power source configured to provide electrical power for establishing a welding arc for each electrode of the array of multiple electrodes
Implementation Method 2
The second metal deposition process may employ a parallel multi-wire welding system configured to deposit weld metal material via, for example, a submerged arc welding (SAW) technique
Data Source
AI summary
Embodiments of additive manufacturing systems are disclosed. In one embodiment, an additive manufacturing system includes an array of multiple electrodes for sequentially depositing material layer-by-layer to form a three-dimensional (3D) part. The system includes a power source to provide electrical power for establishing a welding arc for each electrode. The system includes a drive roll to drive each electrode. The system also includes a controller to operate the system at a first deposition rate to form first resolution contour portions of a layer of the part. The controller also operates the system at a second deposition rate to form second resolution fill portions of the layer of the part. The system provides variable width deposition at the second deposition rate using a variable number of the electrodes. The first deposition rate is lower than the second deposition rate, and the first resolution is higher than the second resolution.