Wire Feed Additive Manufacturing With Pulsed Magnetic Distortion Control

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Solution Overview

Problem

Wire feed additive manufacturing introduces distortion and residual stresses in metal structures due to solidifying and cooling effects, leading to potential cracks and inaccuracies in the manufacturing process.

Innovation Solution

Applying a pulsed magnetic field during the cooling process of wire feed additive manufacturing to induce Lorentz forces, causing plastic deformation and reducing residual stresses, which can be controlled by varying discharge parameters of capacitor banks, including discharge current, frequency, and pulse length.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If wire feed additive manufacturing is used to manufacture parts quickly and cost-effectively, then productivity is improved, but distortion and residual stresses occur due to solidifying and cooling effects

Engineering Contradiction:

Improvemanufacturing speedVSAvoiddimensional accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent applies pulsed magnetic fields to convert the harmful residual stresses and distortion caused by rapid cooling into beneficial plastic deformation. The magnetic pulses induce Lorentz forces that plastically deform the build-up material, counteracting the shrinking processes and reducing distortion while maintaining the productivity benefits of wire feed additive manufacturing

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Manufacturing precision

If conventional forming techniques such as milling, forging or casting are used instead of wire feed additive manufacturing, then manufacturing precision is improved, but productivity deteriorates due to longer processing times

Engineering Contradiction:

Improvedimensional accuracyVSAvoidprocessing time

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent merges wire feed additive manufacturing with pulsed magnetic field treatment in a single integrated process. The magnetic field apparatus is positioned to treat the build-up material immediately after deposition, combining the advantages of rapid additive manufacturing with the precision benefits of controlled deformation, eliminating the need for separate forming operations

Inventive Principle:

Principle #5Merging (Combining)

3Manufacturing precision

If rolling treatment is applied to refine distorted microstructures, then manufacturing precision is improved, but device complexity increases due to requiring rolling devices capable of withstanding forces up to 100 kN

Engineering Contradiction:

Improvedimensional accuracyVSAvoidrolling device requirements

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent replaces the complex mechanical rolling system with an electromagnetic field-based solution. Instead of using heavy rolling devices capable of withstanding 100 kN forces, the invention uses pulsed magnetic fields to generate Lorentz forces that achieve the same plastic deformation effect, significantly reducing device complexity and eliminating mechanical contact

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 method significantly reduces residual stresses and distortion in metal structures, allowing for more accurate and flexible formation of complex geometries with reduced material waste and increased equipment lifespan, while maintaining grain refining effects.

Implementation Method 1

This at least one magnetic pulse causes Lorentz forces resulting from an opposite-directed interaction of the magnetic field caused by the magnetic pulse with currents being induced in the material

Methodology Applied

Scientific EffectLorentz forces: Lorentz Force

Implementation Method 2

Lorentz forces resulting from an opposite-directed interaction of the magnetic field caused by the magnetic pulse with currents being induced in the material

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS10987755B2Method and apparatus for distortion control on additively manufactured parts using wire feed and magnetic pulses

Publication Date: 2021.04.27 AIRBUS OPERATIONS LTD

AI summary

The invention provides a method and apparatus for forming a freeform metal structure by wire feed additive manufacturing. In accordance with the method, a holding structure is moved in at least one moving direction, the holding structure holding the metal structure. A metal wire end is fed along an area of deposition on the metal structure in the at least one moving direction. The metal wire end is heated to a melting temperature using a heat source, with the metal wire end as melted being deposited on the metal structure as a metallic build-up material. The metallic build-up material after heating and during the cooling is subjected in the at least one moving direction behind the area of deposition to at least one pulsed magnetic field using a magnetic coil arranged after the heat source, the at least one pulsed magnetic field effecting plastic deformation of the build-up material.