Laser-Swept Wire Deposition for Stable High-Speed Metal AM
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Solution Overview
Problem
Existing additive manufacturing techniques using Directed Energy Deposition-Wire (DED-Wire) face challenges with unstable and non-constant local material deposition conditions, leading to geometric or metallurgical defects and weak points due to speed variations and wire alignment issues during the manufacturing of large workpieces.
Innovation Solution
A method involving a laser beam focused on a metallic wire supply head, with controlled 2-axis modulation of the laser beam's movement along a main path and transverse to it, dynamically adjusting parameters based on local characteristics to ensure consistent energy deposition and fusion, allowing for preheating and optimized material deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a laser beam is used to melt and deposit metallic wire in DED-Wire additive manufacturing, then material deposition and layer formation are achieved, but speed variations and wire alignment issues lead to unstable local deposition conditions and defects
Solution Approach 1:
The patent applies dynamics by making the laser beam path modifiable through real-time adjustments. The beam path is dynamically adjusted based on feedback from sensors that monitor deposition conditions, allowing the system to adapt to speed variations and wire alignment issues during high-speed construction, thereby maintaining deposition regularity despite varying construction speeds
Solution Approach 2:
The patent implements feedback control by using sensors to monitor local deposition conditions and wire position in real-time. This feedback information is used to automatically adjust laser beam parameters and wire feed rate, creating a closed-loop control system that maintains stable deposition conditions even at high construction speeds, thus resolving the contradiction between productivity and manufacturing precision
2Ease of operation
If the laser beam path is fixed along a main path, then the manufacturing process is simple to control, but wire alignment issues and speed variations cause geometric or metallurgical defects
Solution Approach 1:
The system maintains ease of operation by keeping the main beam path fixed and programmable, while introducing dynamic modifications through controlled deviations from this path. The modulation allows the beam to adjust its position relative to the wire based on real-time conditions, improving reliability without complicating the overall control structure, as the deviations are automated responses to sensor feedback
3Productivity
If high construction speeds are used to improve productivity, then manufacturing efficiency increases, but deposition regularity and quality deteriorate due to unstable local conditions
Solution Approach 1:
The patent uses feedback control to maintain deposition regularity at high construction speeds. Sensors continuously monitor the deposition process and provide real-time information about wire position and material flow. This feedback enables automatic adjustments to laser power and beam path modulation to compensate for the instability inherent in high-speed operation, allowing high productivity without sacrificing layer regularity
Solution Approach 2:
The patent applies periodic modulation to the laser beam path to maintain stable deposition at high speeds. By introducing controlled periodic variations in the beam path that synchronize with the wire feed and deposition cycle, the system creates consistent local deposition conditions even during high-speed operation, thereby maintaining layer regularity while achieving high construction speeds
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 the stable and efficient manufacturing of large workpieces with high construction speeds, maintaining regularity and quality of deposition layers, reducing defects, and allowing for the use of various metal alloys and wire configurations, enhancing the robustness and reproducibility of the process.
Implementation Method 1
a laser beam (WLAM method for 'Wire Laser Additive Manufacturing') locally melts the wire
Implementation Method 2
melting a metallic material in wire form using a concentrated thermal energy (laser, electron beam or electric arc)
Implementation Method 3
the movement of the zone of interaction is modulated by 2-axis modulation in a longitudinal direction parallel to the speed vector of the main path and a transverse direction normal to the speed vector in the focal plane, the deviation defining a curve swept at a speed greater than the speed of travel along the main path
Implementation Method 4
depositing the raw material on a substrate as molten pool deposit
Data Source
AI summary
An additive manufacturing method involves commanding movement across the surface of a workpiece of an equipment item comprising a laser, of which the beam is focused on the outlet of a supply head that delivers a metallic wire. The equipment item is caused to move the zone of interaction of the laser beam with the wire along a main path representative of the geometry of the workpiece being manufactured. The movement of the zone of interaction is modulated by 2-axis modulation in a longitudinal direction parallel to the main path and a transverse direction normal to the main path in the focal plane. The deviation defines a curve swept at a speed greater than a speed of travel along the main path. The 2-axis modulation is controlled by a control system comprising means for entering the parameters, for each manufacture, of the control law used for the 2-axis modulation.