Multi-Layer Weld Bead Deposition with Dual Heat Input Control
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Solution Overview
Problem
Existing methods for manufacturing additively-manufactured objects face challenges in achieving high precision while preventing the occurrence of unwelded portions, despite improvements in manufacturing efficiency through specific filling patterns.
Innovation Solution
A method involving two welding control modes is employed: the first mode uses forward and reverse feeding control with synchronized current waveform for precise weld bead formation with low heat input, and the second mode uses constant voltage or pulse power supply for higher heat input to ensure complete filling without gaps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a filling pattern with a specific wavelength is used to reduce the number of start parts and end parts of beads, then manufacturing efficiency is improved, but unwelded portions may occur
Solution Approach 1:
The invention changes the welding parameters by switching between two distinct welding control modes (first mode with lower heat input and second mode with higher heat input) depending on the position and shape of the workpiece. This allows optimization of both manufacturing efficiency and weld quality by selecting appropriate parameters for different regions
Solution Approach 2:
The invention dynamically switches between two welding control modes during the additive manufacturing process. The control mode is changed based on the position (front/rear sides) and shape (protruding/ recessed portions) of the workpiece, enabling adaptive adjustment of welding parameters to prevent unwelded portions while maintaining efficiency
2Manufacturing precision
If a single welding control mode is used throughout the manufacturing process, then the process is simple, but both precision and efficiency cannot be optimized simultaneously
Solution Approach 1:
The invention segments the welding process into two distinct control modes: a first welding control mode for positions requiring precision (front sides and protruding portions) and a second welding control mode for positions requiring efficiency (rear sides and recessed portions). This segmentation allows each mode to be optimized for its specific purpose while managing overall system 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 enables the efficient manufacturing of additively-manufactured objects with high precision and prevents unwelded portions, improving overall productivity by selecting appropriate welding control modes based on the object's shape and location.
Implementation Method 1
a current waveform of a power supplied from a power source to the filler metal is synchronized with the forward and reverse feeding of the filler metal
Implementation Method 2
A 3D printer using a metal material uses a heat source such as a laser arc to melt metal powder or a metal wire, and deposits the molten metal to manufacture an additively-manufactured object
Data Source
AI summary
A method for manufacturing an additively-manufactured object includes forming a plurality of weld beads obtained by melting and solidifying a filler metal sent out from a torch and depositing each weld bead. The method includes forming and depositing a first weld bead of the plurality of weld beads in a first welding control mode, and forming and depositing a second weld bead of the plurality of weld beads in a second welding control mode with a higher heat input than in the first welding control mode. The first welding control mode is a forward and reverse feeding control in which, while the filler metal is fed sequentially in a forward direction and a reverse direction, a current waveform of a power supplied to the filler metal from a power source is synchronized with the forward and reverse feeding of the filler metal.