Support Bead Geometry for Stable Additive Weld Deposition
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Solution Overview
Problem
Existing methods for forming weld beads on substrates with vertical or inclined surfaces face issues such as dripping and humping due to gravity, which hinder efficient manufacturing of additively-manufactured objects.
Innovation Solution
The method involves forming support beads on the base portion with a height-to-width ratio of 0.35 or more, followed by depositing weld beads on these support beads to build the object, preventing dripping and humping by managing the influence of gravity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the welding torch moves slowly to prevent dripping on vertical or inclined surfaces, then the weld bead quality improves, but the manufacturing productivity decreases
Solution Approach 1:
A support bead structure is formed in advance on vertical or inclined surfaces before depositing the actual weld bead. This preliminary support structure prevents dripping during welding, allowing the torch to move at normal speeds without compromising weld quality, thus resolving the contradiction between precision and productivity
2Productivity
If the welding torch moves quickly to maintain productivity, then the manufacturing efficiency improves, but humping occurs that interrupts the weld bead
Solution Approach 1:
The support bead is formed beforehand to provide a stable base that prevents humping during rapid welding. This preliminary structure ensures that even at high speeds, the weld bead remains continuous and free of interruptions, maintaining both productivity and precision
3Reliability
If a support bead with height-to-width ratio of 0.35 or more is formed, then dripping and humping are prevented, but the device complexity increases
Solution Approach 1:
The invention specifies a quantitative parameter (height-to-width ratio of 0.35 or more) for the support bead geometry. By controlling this specific parameter, the process achieves reliable weld bead formation without requiring complex equipment or procedures. The ratio specification provides a simple, measurable criterion that ensures stability while avoiding excessive 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
This approach allows for the efficient formation of weld beads without dripping or humping, improving manufacturing efficiency and quality of additively-manufactured objects with overhang-shaped portions.
Implementation Method 1
a plurality of weld beads obtained by melting and solidifying a filler metal are deposited on a base portion
Implementation Method 2
a plurality of weld beads obtained by melting and solidifying a filler metal are deposited on a base portion
Data Source
AI summary
A method for manufacturing an additively-manufactured object, in which a plurality of weld beads obtained by melting and solidifying a filler metal are deposited on a base portion to build a built-up object, includes: a support bead forming step of forming a support bead on the base portion; and a depositing step of depositing a weld bead on the support bead. When the support bead is formed to be inclined from a vertical direction in the support bead forming step, a ratio H/W of a height H to a width W of the support bead is set to 0.35 or more.