Multi-Wire Weld Pool Control for Faster 3D Metal Deposition
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Solution Overview
Problem
The physics of the deposition process in 3D metal printing limits the rate at which material can be fed into the weld pool and energy added, restricting the speed at which large structures can be printed, leading to long printing times and potential welding defects.
Innovation Solution
A system and method that dynamically control the feed rates of multiple wires into the weld pool based on input power and travel speed, using a print controller to optimize the material deposition rate while preventing defects, by determining the second feed rate using a mathematical model that considers power value, travel speed, and first feed rate, and employing edge sensors and defect detectors to adjust process parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the feed rate of material into the weld pool is increased to improve printing speed, then productivity increases, but the physics of the deposition process limits the maximum feed rate and causes welding defects
Solution Approach 1:
The patent divides the single wire feed system into multiple independent wire feeders (first wire feeder, second wire feeder, etc.), each feeding wire into the weld pool separately. This segmentation allows the system to overcome the deposition rate limit of a single wire by combining the material input from multiple wires, thereby increasing printing speed without sacrificing weld quality.
Solution Approach 2:
The patent combines multiple wire feeds and multiple energy sources (laser and electric current) into a unified deposition system. The material from multiple wires merges in the weld pool, and the energy from multiple sources combines to melt and deposit the material. This merging enables the system to achieve higher deposition rates while maintaining process control and weld quality.
2Productivity
If the energy input to the weld pool is increased to melt more material, then the material deposition rate increases, but excessive energy input causes welding defects
Solution Approach 1:
The patent combines multiple energy sources (laser energy and electric current from multiple wire feeders) to provide the total energy needed to melt and deposit material at high rates. By distributing the energy input across multiple sources, the system achieves high deposition rates while maintaining better control over the thermal process, preventing excessive energy concentration that would cause defects.
Solution Approach 2:
The patent dynamically adjusts process parameters including energy input levels, wire feed rates, and travel speed based on real-time conditions. The controller modifies these parameters to optimize the deposition rate while staying within the safe operating window that prevents welding defects, allowing the system to operate at maximum productivity without compromising quality.
3Productivity
If multiple wire feeders and energy sources are added to increase deposition rate, then productivity improves, but device complexity increases
Solution Approach 1:
The patent designs the system with multi-functional components that perform multiple roles. For example, the multiple wire feeders serve both as material delivery mechanisms and as independent energy delivery paths. The controller integrates control of multiple wires and energy sources into a unified system that manages complexity through coordinated operation, allowing the system to achieve high deposition rates while managing device complexity through functional integration.
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 increases the material deposition rate without introducing defects, allowing for faster printing of large structures by optimizing the feed rates of multiple wires and adjusting power and travel speeds in real-time, thereby improving the efficiency and quality of the 3D metal printing process.
Implementation Method 1
Some systems use electricity to add energy to the weld pool. The systems that use electricity can be similar to welders that pass an electric current through the feed wire and into the weld pool. The electric current adds energy to the weld pool as the feed wire is fed into the weld pool.
Implementation Method 2
an electrode wire feeder configured to feed the electrode wire into the weld pool at a first feed rate while the electrode end melts into the weld pool
Data Source
AI summary
A 3D printer can print a structure by depositing material into a weld pool that is moving relative to a workpiece. An electrode wire can supply energy to the weld pool while being fed at a first feed rate into the weld pool. A second wire can be fed into the weld pool at a second feed rate to deposit additional material and thereby speed up the overall material deposition rate. All of the energy in the weld pool may be supplied by the electrode wire. The printer can dynamically control the first feed rate and the second feed rate during printing. A mathematical model can be used to determine the second feed rate as a function of the first feed rate, the energy put into the weld pool, and the print head travel speed. The second feed rate may optimize the material deposition rate according to the model.