Hybrid Wire Arc Processing Head for Precision Large-Part Deposition
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Solution Overview
Problem
Existing additive manufacturing techniques face challenges in producing large-scale, complex parts with high precision and low porosity, as wire arc methods suffer from deformations and residual stresses, while powder-based methods have low deposition rates and high costs.
Innovation Solution
A hybrid system combining wire arc and powder-based additive manufacturing, utilizing a processing head assembly with multiple feedstocks and a closed loop electrical circuit to protect CNC machines from electrical discharges, enabling high deposition rates and precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If wire arc additive manufacturing is used, then deposition rate increases and cost decreases, but manufacturing precision deteriorates and porosity increases
Solution Approach 1:
The patent combines wire arc additive manufacturing and powder-based additive manufacturing into a hybrid system. The processing head assembly includes both wire feedstock mechanisms and powder feedstock mechanisms, allowing simultaneous or alternating operation of both processes to achieve high deposition rates while maintaining geometrical accuracy and low porosity.
2Volume of moving object
If wire arc additive manufacturing is used, then large-scale parts can be produced, but deformations and residual stresses increase
Solution Approach 1:
The hybrid system merges wire arc and powder-based additive manufacturing processes. The powder-based process contributes to reducing heat input and minimizing deformations and residual stresses, while the wire arc process maintains high deposition rates for large-scale part production.
3Manufacturing precision
If powder-based additive manufacturing is used, then geometrical accuracy improves, but deposition rate decreases and cost increases
Solution Approach 1:
The patent integrates powder-based additive manufacturing with wire arc additive manufacturing. The powder-based process provides high geometrical accuracy, while the wire arc process compensates for the low deposition rate, achieving both precision and productivity.
Solution Approach 2:
The processing head assembly applies different feedstock types (wire and powder) to different regions or layers of the workpiece based on specific requirements. Wire arc is used for areas requiring high deposition rates, while powder-based manufacturing is used for areas requiring high geometrical accuracy.
4Manufacturing precision
If hybrid system with multiple feedstocks is used, then manufacturing precision and deposition rate improve, but device complexity increases
Solution Approach 1:
The processing head assembly is designed as a multi-functional device that can handle both wire feedstock and powder feedstock. It includes wire feed mechanisms, powder feed mechanisms, and a single processing head that can operate with both types of feedstocks, reducing the need for separate machines and simplifying the overall system.
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 quick and cheap production of large-scale, complex parts with high geometrical accuracy and low porosity, while integrating additive and subtractive manufacturing processes to achieve precision net-shape components.
Implementation Method 1
a machine tool coupled to a processing head assembly wherein the substrate is electrically connected to a wire feedstock, thereby forming a closed loop electrical circuit
Implementation Method 2
a fabrication energy source including the wire feedstock surrounded by the shield. The fabrication energy source may include the wire feedstock surrounded by the shield
Data Source
AI summary
A processing head assembly is disclosed. In some examples, the processing head assembly comprises a fabrication energy source; a wire feedstock surrounded by a shield and one or more filler feedstocks surrounded by one or more nozzles. In some examples, the fabrication energy source includes the wire feedstock surrounded by the shield. A method of depositing material on a substrate using a processing head assembly for use with a fabrication energy source; a wire feedstock surrounded by a shield and one or more filler feedstocks surrounded by one or more nozzles is disclosed. In some examples, the method comprises projecting a fabrication energy beam from the fabrication energy source onto the substrate at a spot, projecting the wire feedstock surrounded by the shield onto the substrate at the spot and projecting the one or more filler feedstocks surrounded by the one or more nozzles onto the substrate close to the spot.