Multi-Wire Weld Pool Feeding for Faster Metal 3D Deposition
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Solution Overview
Problem
The physical limitations of the deposition process in 3D metal printing, such as high currents leading to welding defects, restrict the speed at which large structures can be printed, necessitating a need for improved material deposition rates.
Innovation Solution
Utilizing multiple feed wires with controlled feed rates and power adjustments to maximize material deposition without introducing defects, employing mathematical models and sensors to optimize the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the feed rate of the electrode wire is increased to improve productivity, then the deposition rate increases, but welding defects occur due to excessive current
Solution Approach 1:
The single wire feed system is segmented into multiple wire feeders (first wire feeder, second wire feeder, third wire feeder) that operate independently. Each wire feeder contributes to the total deposition rate without requiring excessive current from a single wire, thereby maintaining welding quality while improving overall productivity through parallel material deposition channels.
Solution Approach 2:
The system transitions from a single-wire deposition approach to a multi-wire spatial arrangement, utilizing different spatial dimensions and positions around the weld pool. The wires can be positioned at different angles and locations (e.g., trailing wire, leading wire, side wires), distributing the thermal and electrical loads across multiple entry points into the weld pool.
2Productivity
If the current is increased to increase the deposition rate, then more material is deposited, but harmful factors such as welding defects are introduced
Solution Approach 1:
The total current requirement is segmented across multiple wire feeders, each operating at lower, safer current levels. The first wire feeder operates at a first current, the second wire feeder at a second current, and the third wire feeder at a third current, with the sum of these currents achieving the total power needed for high deposition rates without any single wire experiencing harmful current densities.
Solution Approach 2:
The system changes multiple parameters simultaneously: feed rates of individual wires, currents through each wire, positions of wire entry points, and travel speed. By dynamically adjusting these parameters, the system achieves high deposition rates while maintaining current densities within safe operating ranges for each individual wire, preventing welding defects.
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
Enhances the material deposition rate, allowing faster printing of large structures by doubling the deposition speed while maintaining quality and minimizing defects.
Implementation Method 1
an electrode wire feeder to feed an electrode wire at a first feed rate into a weld pool on a workpiece while an electrode end of the electrode wire melts input into the weld pool
Implementation Method 2
a second wire feeder to feed a second wire at a second feed rate into the weld pool while a second wire end of the second wire melts into the weld pool
Data Source
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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.