Multi-Diameter Wire Deposition for Faster Additive Manufacturing
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Solution Overview
Problem
The existing additive manufacturing processes for titanium parts, such as reactor mast components, result in significant material waste due to the need for large wire diameters to maintain production rate, leading to substantial grinding material removal and reduced efficiency.
Innovation Solution
The process involves using a combination of large-diameter and reduced-diameter wires in additive manufacturing under focused energy, with specific parameters for each, to maintain high production rates while minimizing surface undulations and material loss during the manufacturing of titanium parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If large-diameter wires (greater than 1 mm) are used to maintain high production rate, then productivity is improved, but manufacturing precision deteriorates due to large surface undulations requiring substantial grinding material removal
Solution Approach 1:
The patent applies local quality by using different wire diameters for different zones of the same part. Large-diameter wires (≥1 mm) are used for the main zone where high deposition rate is critical, while small-diameter wires (≤0.8× the large wire diameter) are used for peripheral zones where surface quality is critical. This allows each zone to have the material properties optimized for its specific function, resolving the contradiction between productivity and surface precision.
2Manufacturing precision
If small-diameter wires are used to reduce surface undulations, then manufacturing precision is improved, but productivity deteriorates due to reduced material deposition rate
Solution Approach 1:
The patent segments the part into distinct zones (main zone and peripheral zones) that are manufactured using different wire diameters. The main zone is built with large-diameter wires for high productivity, while peripheral zones are built with small-diameter wires for high precision. This segmentation allows the system to achieve both high overall productivity and high local surface precision simultaneously.
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 allows for a high production rate while reducing the amplitude of surface undulations and material waste, enabling more efficient production of titanium parts with reduced material removal during grinding.
Implementation Method 1
melting a material using a focused energy source, such as a laser beam or an electron beam
Implementation Method 2
focused energy source, such as a laser beam or an electron beam
Implementation Method 3
focused energy source, such as a laser beam or an electron beam
Data Source
Figure 1~3
AI summary
The invention relates to an additive manufacturing process, by deposition of material under focused energy, for obtaining a part (20) by melting wires (24, 24') using a focused energy source. The part (20) comprises at least one main zone (30) made from at least one first wire (24) having a first cross-section with a diameter greater than or equal to 2 mm, and at least one peripheral zone (32) made from at least one second wire (24') having a second cross-section that is different from and smaller than the first cross-section of the first wire (24). The peripheral zone (32) at least partially covers a free surface (S20) of the part (20). This process makes it possible to maintain a high production rate while reducing the amplitude of the waviness of the free surface (S20) of the part (20) covered by the peripheral zone (32).