Weld-Bead Additive Manufacturing for Filling Narrow Recesses
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Solution Overview
Problem
Existing methods for additively manufacturing objects using weld beads often result in torch interference and insufficient filling of narrow recesses between weld beads, leading to potential welding defects like blow holes and reduced mechanical strength, especially in complex shapes.
Innovation Solution
A method and apparatus that adjust the size and posture of new weld beads to fill recesses formed by previously deposited weld beads, ensuring complete filling and preventing torch interference by using a torch-moving mechanism and control unit to optimize bead formation based on detected profiles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If weld beads are deposited with given size in conventional overlay welding, then the welding process is simple and fast, but narrow recesses are formed between adjoining weld beads causing insufficient filling and potential blow holes
Solution Approach 1:
The invention dynamically adjusts the torch inclination angle during the welding process based on real-time detection of the weld bead profile. The control unit modifies the torch posture mid-process to ensure proper penetration into narrow recesses between adjoining weld beads, preventing blow holes while maintaining efficient deposition.
Solution Approach 2:
The system uses a detection device to measure the actual profile of deposited weld beads and feeds this information back to the control unit. Based on this feedback, the control unit adjusts the torch inclination angle and deposition parameters to ensure complete filling of narrow recesses, achieving both high productivity and manufacturing precision.
2Adaptability or versatility
If the torch is used to deposit weld beads in complex shapes, then the additively manufactured object can have complicated geometry, but the torch may interfere with other portions of the workpiece
Solution Approach 1:
The torch-moving mechanism dynamically adjusts the torch position and posture in real-time during deposition. The control unit calculates optimal torch trajectories that avoid interference with surrounding structures while maintaining proper welding parameters, enabling successful deposition in complex geometries.
Solution Approach 2:
The system applies local adjustments to the torch posture and inclination angle based on the specific local geometry being welded. Different regions of the workpiece receive customized torch positioning and deposition parameters, allowing the torch to adapt to varying local conditions without interference.
3Ease of operation
If fixed torch inclination is used in overlay welding, then the welding process is easy to control, but the penetration amount is insufficient to fill narrow recesses between weld beads
Solution Approach 1:
The invention changes the torch inclination angle parameter dynamically during the welding process based on detected weld bead profiles. The control unit adjusts this parameter in real-time to optimize penetration depth into narrow recesses, ensuring complete filling while maintaining ease of operation through automated control.
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 prevents unfilled portions and torch interference, resulting in high-quality additively manufactured objects with improved mechanical strength and reduced defects.
Implementation Method 1
a filler metal is melted with the arc and solidified to form weld beads
Implementation Method 2
a filler metal is melted with the arc and solidified to form weld beads
Data Source
AI summary
A method for producing an additively manufactured object includes melting and solidifying a filler metal to form weld beads and depositing the weld beads adjoining each other, thereby forming a weld-bead layer, and repeatedly depositing a next weld-bead layer on the formed weld-bead layer to conduct additive manufacturing. The method includes a bead formation step of forming a new weld bead so as to fill a recess formed by at least three of the already formed weld beads, in a cross-section perpendicular to a longitudinal direction of the weld beads.