Oscillating Wire Feed Head for Stable Directed Energy Deposition
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Solution Overview
Problem
In directed energy deposition, the inconsistent position of the feed wire due to variations in wire diameter, straightness, residual stress, and annealing during deposition/retraction leads to inconsistent melt characteristics and material properties.
Innovation Solution
A wire feed head with an integrated oscillator that oscillates either the feed wire or the energy source relative to each other, improving the average positional accuracy and power absorption by maintaining consistent wire exposure to the energy source.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If wire feed head operates without oscillation, then device complexity is low, but manufacturing precision deteriorates due to inconsistent wire position
Solution Approach 1:
The patent applies mechanical oscillation to the wire feed head assembly, causing it to vibrate at controlled frequencies and amplitudes. This vibration agitates the melt zone and promotes more uniform material deposition, thereby improving manufacturing precision without requiring complex multi-component systems
Solution Approach 2:
The wire feed head is transformed from a static component to a dynamic one capable of oscillatory motion. By introducing controlled movement to the wire feed head assembly, the system adapts to variations in wire properties and maintains consistent deposition quality, resolving the contradiction between simplicity and precision
2Ease of manufacture
If wire diameter varies, then ease of manufacture is improved, but manufacturing precision deteriorates due to inconsistent melt characteristics
Solution Approach 1:
The oscillation of the wire feed head creates agitation in the melt zone that compensates for variations in wire diameter. The vibrational energy promotes more uniform melting and material flow, ensuring consistent melt characteristics even when wire dimensions vary within acceptable tolerances
Solution Approach 2:
The system changes the operational parameters of the wire feed head by introducing oscillatory motion. This dynamic parameter change allows the system to accommodate variations in wire diameter while maintaining consistent deposition quality, as the vibration frequency and amplitude can be adjusted to match different wire specifications
3Ease of manufacture
If wire straightness varies, then ease of manufacture is improved, but manufacturing precision deteriorates due to inconsistent wire location relative to energy source
Solution Approach 1:
The oscillating wire feed head agitates the wire and melt zone, promoting more consistent material delivery to the energy source despite variations in wire straightness. The vibrational motion helps maintain stable arc attachment and uniform deposition patterns
Solution Approach 2:
By making the wire feed head dynamic through oscillation, the system compensates for wire straightness variations in real-time. The controlled movement creates a more stable interaction between the wire, energy source, and substrate, maintaining consistent wire location relative to the energy source
4Manufacturing precision
If oscillation is added to wire feed head, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The oscillation mechanism is integrated into the wire feed head assembly in a way that uses the existing structural components. The vibration is generated through the interaction of the oscillating coil with the magnetic field, causing the entire wire feed head assembly to vibrate without requiring separate actuation mechanisms for each component
Solution Approach 2:
The oscillation function is merged with the wire feed head assembly itself. The coil and magnetic field system are integrated into the existing wire feed head structure, and the oscillatory motion is generated as a property of the assembly rather than through separate moving parts, thereby minimizing the increase in device complexity
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
The oscillation enhances the average positional accuracy of the feed wire, improves melt properties, agitates the melt zone, and results in improved mechanical properties of the deposited three-dimensional component.
Implementation Method 1
one or both of the feed wire or the energy source is oscillated
Implementation Method 2
a focused energy source, such as a laser, plasma arc, or electron beam, to melt and fuse a feedstock
Implementation Method 3
the oscillator includes a magnet connected to the collet and a coil connected to the housing
Data Source
AI summary
A wire feed head for directed energy deposition, a system including a wire feed head, and methods of directed energy deposition. The wire feed head includes a collet connected to a housing, an energy emitter connected to the housing, and an energy pathway defined in the housing connected to the energy emitter. The wire feed head also includes a wire feed pathway defined in the collet and an oscillator coupled to at least one of the collet, the energy emitter, and the energy pathway. The method includes feeding a feed wire through a feed pathway in a wire feed head, emitting energy from an energy source, directing the emitting energy towards the feed wire exiting the feed pathway, and oscillating at least one of the feed wire and the emitted energy relative to the other.