Hybrid Wire Arc Processing Head for Low-Porosity Precision Deposition
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Solution Overview
Problem
Current additive manufacturing techniques face challenges in producing large-scale parts with high precision and low porosity, as powder-based methods are limited by low deposition rates and porosity issues, while wire arc methods suffer from deformations and residual stresses. Additionally, there is a need to integrate additive and subtractive manufacturing processes to create complex parts efficiently.
Innovation Solution
A hybrid system combining wire arc and powder-based additive manufacturing using a processing head assembly with multiple feedstocks, including wire and powder, to enhance deposition rates and precision, and integrating a 3D printing tool with a CNC machine to form a closed loop electrical circuit protected by an insulator to prevent damage from electrical discharges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If powder-based additive manufacturing is used, then high geometrical accuracy can be achieved, but deposition rate is very low and porosity issues occur
Solution Approach 1:
The patent combines wire arc additive manufacturing and powder-based additive manufacturing into a hybrid system. The wire arc process provides high deposition rates while the powder process contributes high geometrical accuracy. The processing head assembly integrates both wire feed mechanisms and powder delivery systems, allowing simultaneous or alternating operation to achieve both high productivity and high precision.
2Productivity
If wire arc additive manufacturing is used, then high deposition rates can be achieved, but deformations and residual stresses occur
Solution Approach 1:
The hybrid system merges wire arc and powder-based additive manufacturing. The powder-based process is used to create precise reference surfaces or features that compensate for deformations caused by the wire arc process. The combination allows the system to achieve high deposition rates while maintaining dimensional accuracy through the complementary strengths of both processes.
3Manufacturing precision
If a hybrid system combining wire arc and powder-based additive manufacturing is used, then deposition rates and precision can be enhanced, but device complexity increases
Solution Approach 1:
The processing head assembly is designed as a multi-functional device that can perform both wire arc additive manufacturing and powder-based additive manufacturing. The system uses a single processing head that can switch between or simultaneously execute both processes, reducing the need for separate machines and minimizing overall system complexity despite the advanced capabilities required.
4Productivity
If additive and subtractive manufacturing processes are integrated, then complex parts can be created efficiently, but electrical discharge damage risk increases
Solution Approach 1:
The system introduces an insulator as an intermediary component between the wire arc additive manufacturing process and the CNC subtractive manufacturing process. This insulator prevents electrical discharge from the arc process from damaging the CNC machine's sensitive electronics, allowing the hybrid system to operate safely and efficiently without compromising either process.
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 quick and cheap production of large-scale complex parts with high geometrical accuracy and low porosity, while managing stress build-up and achieving precision net-shape components by leveraging the advantages of both wire arc and powder-based methods, and protecting CNC machine electronics from electrical discharges.
Implementation Method 1
A hybrid system combining wire arc and powder-based additive manufacturing using a processing head assembly with multiple feedstocks, including wire and powder, to enhance deposition rates and precision
Implementation Method 2
A processing head assembly can include a fabrication energy source, a wire feedstock surrounded by a shield and one or more filler feedstocks surrounded by one or more nozzles
Implementation Method 3
a wire feedstock surrounded by a shield and one or more filler feedstocks surrounded by one or more nozzles
Data Source
AI summary
A processing head assembly is disclosed. In some examples, the processing head assembly comprises a fabrication energy source; a wire feedstock surrounded by a shield and one or more filler feedstocks surrounded by one or more nozzles. In some examples, the fabrication energy source includes the wire feedstock surrounded by the shield. A method of depositing material on a substrate using a processing head assembly for use with a fabrication energy source; a wire feedstock surrounded by a shield and one or more filler feedstocks surrounded by one or more nozzles is disclosed. In some examples, the method comprises projecting a fabrication energy beam from the fabrication energy source onto the substrate at a spot, projecting the wire feedstock surrounded by the shield onto the substrate at the spot and projecting the one or more filler feedstocks surrounded by the one or more nozzles onto the substrate close to the spot.