METHOD AND SYSTEM FOR ADDITIVE MANUFACTURING USING HIGH ENERGY SOURCE AND HOT-WIRE
First Claim
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1. An additive manufacturing system, comprising:
- a high energy device which irradiates a surface of a work piece with a high energy discharge to create a molten puddle on a surface of said work piece; and
a power supply which supplies a heating signal to a consumable wire where said heating signal comprises a plurality of current pulses and where each of said current pulses creates a molten droplet on a distal end of said consumable which is deposited into said puddle;
wherein each of said current pulses reaches a peak current level after said distal end of said consumable contacts said puddle,wherein said heating signal has no current in between said plurality of said current pulses;
wherein said distal end of said consumable is not in contact with said puddle between subsequent peak current levels of said current pulses;
wherein said power supply controls said heating current such that no arc is created between said wire and said work piece during said current pulses; and
wherein said consumable has each of a sheath portion and a core portion, where said sheath portion has a melting temperature less than a melting temperature of said core portion.
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Abstract
A method and system to manufacture workpieces employing a high intensity energy source to create a puddle and at least one resistively heated wire which is heated to at or near its melting temperature and deposited into the puddle as droplets.
46 Citations
23 Claims
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1. An additive manufacturing system, comprising:
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a high energy device which irradiates a surface of a work piece with a high energy discharge to create a molten puddle on a surface of said work piece; and a power supply which supplies a heating signal to a consumable wire where said heating signal comprises a plurality of current pulses and where each of said current pulses creates a molten droplet on a distal end of said consumable which is deposited into said puddle; wherein each of said current pulses reaches a peak current level after said distal end of said consumable contacts said puddle, wherein said heating signal has no current in between said plurality of said current pulses; wherein said distal end of said consumable is not in contact with said puddle between subsequent peak current levels of said current pulses; wherein said power supply controls said heating current such that no arc is created between said wire and said work piece during said current pulses; and wherein said consumable has each of a sheath portion and a core portion, where said sheath portion has a melting temperature less than a melting temperature of said core portion. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14)
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15. An additive manufacturing consumable, comprising:
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a sheath portion; and a core portion which is at least partially covered by said sheath portion, wherein said sheath portion has a melting temperature less than a melting temperature of said core portion. - View Dependent Claims (16, 17, 18, 19, 20, 21, 22, 23)
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Specification