Pulsed Wire Additive Manufacturing for Precision and Speed
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Solution Overview
Problem
Conventional additive manufacturing methods are slow and lack precision, with metal powder processes generating significant waste and arc-based systems being inefficient for producing complex, precise articles.
Innovation Solution
A system and method utilizing a high energy device to create a molten puddle on a workpiece surface, with a wire feeder depositing molten droplets using a pulsed current to achieve high-speed and precise additive manufacturing, preventing arc formation between the wire and workpiece.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If metal powder processes are used for additive manufacturing, then material can be deposited, but the process is slow and generates significant waste
Solution Approach 1:
The patent changes the physical state of the filler material from powder to wire form, and changes the energy delivery mode from continuous to pulsed. This allows for more efficient material deposition with less waste and higher manufacturing speed, directly resolving the contradiction between productivity and material waste
Solution Approach 2:
The patent replaces the traditional arc-based thermal system with a pulsed current system that creates controlled molten droplets. This substitution enables precise material placement and reduces material waste while increasing manufacturing speed
2Manufacturing precision
If arc based systems are used for additive manufacturing, then material can be deposited, but the process is slow and lacks precision
Solution Approach 1:
The patent segments the continuous wire feed into discrete molten droplets through pulsed current application. Each droplet is precisely controlled and deposited separately, enabling high precision manufacturing while maintaining high deposition speed through rapid pulsing
Solution Approach 2:
The patent uses periodic pulsed current to create molten droplets at controlled intervals. This periodic action allows for precise material placement with each pulse while maintaining high overall manufacturing speed through rapid repetition of the pulse cycle
3Productivity
If continuous current is applied to the wire, then material can be fed continuously, but arc formation occurs between wire and workpiece
Solution Approach 1:
The patent applies periodic pulsed current instead of continuous current. The pulsed nature allows the wire to be fed continuously while the intermittent current application prevents sustained arc formation, resolving the contradiction between productivity and harmful arc effects
Solution Approach 2:
The patent uses the pulsed current timing to prevent arc formation before it can occur. By controlling the current pulse duration and frequency, the system anticipates and prevents the harmful arc effect while maintaining continuous material deposition
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
Enables high-speed, highly accurate additive manufacturing with reduced waste and improved precision, allowing for the creation of complex products efficiently.
Implementation Method 1
a high energy device irradiates a surface of a work piece with a high energy discharge to create a molten puddle on a surface of the work piece
Implementation Method 2
a power supply supplies a heating signal to the wire where the heating signal comprises a plurality of current pulses and where each of the current pulses creates a molten droplet on a distal end of the wire
Data Source
AI summary
A method and system to manufacture workpieces employing a high intensity energy source to create a puddle and at least one resistively heated wire which is heated to at or near its melting temperature and deposited into the puddle as droplets.