Multi-Wire Metal Deposition for Faster Weld Pool 3D Printing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current 3D metal printing technologies face limitations in printing speed and size due to the physical constraints of the deposition process, which restrict the rate at which metal wires can be fed into the weld pool and energy added, thereby limiting the size and speed of printed structures.
Innovation Solution
The implementation of an additive manufacturing system that uses multiple feed wires, where a second wire is fed into the weld pool at a controlled rate, positioned either ahead or behind the electrode wire, to optimize energy injection and deposition, with a print controller determining feed rates based on power and travel speed to achieve superior visual characteristics, uniform deposition, and maximized material deposition rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single feed wire is used to maintain a stable weld pool, then deposition quality is maintained, but printing speed and material deposition rate are limited
Solution Approach 1:
The single feed wire is segmented into multiple feed wires (first feed wire and second feed wire), each delivering material to different regions of the weld pool. This allows independent control of material input rates, enabling higher overall deposition rates while maintaining weld pool stability through coordinated feeding from multiple sources.
Solution Approach 2:
The patent transitions from a single-point material delivery approach to a multi-point spatial distribution approach. Multiple feed wires are positioned at different locations relative to the weld pool (e.g., leading edge, trailing edge, or sides), adding a spatial dimension to material delivery that increases total deposition capacity while maintaining process control.
2Productivity
If the feed wire is fed into the weld pool at a higher rate, then material deposition rate increases, but weld pool stability and deposition quality deteriorate
Solution Approach 1:
The total material deposition requirement is segmented across multiple feed wires, allowing each wire to operate at optimized feed rates that maintain weld pool stability. The first feed wire and second feed wire can be fed at different rates, enabling the system to achieve high overall deposition rates while each individual wire contributes to a stable, controlled weld pool.
Solution Approach 2:
Different regions of the weld pool receive material from different feed wires at different rates, optimizing local deposition quality. For example, one feed wire may target the leading edge while another targets the trailing edge, ensuring uniform material distribution and consistent deposition quality across the entire weld pool area.
3Productivity
If energy is added to the weld pool at a higher rate, then printing speed increases, but control over the weld pool and deposition precision are reduced
Solution Approach 1:
Energy input is segmented and distributed through multiple feed wires, each potentially receiving controlled electrical energy in addition to mechanical feeding. This allows the total energy input to the weld pool to be increased for higher printing speeds while maintaining precise control over the distribution and timing of energy delivery through multiple independent channels.
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 enhances printing speed and size capabilities by optimizing energy injection and deposition, resulting in improved material deposition rates and reduced defects, allowing for larger and more complex structures to be printed efficiently.
Implementation Method 1
an electric power source configured to provide an input electric power through an electrode wire including Inconel to create a weld pool on a workpiece
Implementation Method 2
an electrode end of the electrode wire melts into the weld pool; a second wire end of the second wire melts into the weld pool
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
A 3D printer can print a structure by depositing material into a weld pool that is moving relative to a workpiece. A multi-wire process may be utilized to increase the deposition rate of the 3D printer. 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. Different materials may benefit from different orientations of the electrode wire and the second wire.