Additive manufacturing heating control systems and methods

Patent metadata

Field	Value
Publication number	US-12083633-B2
Application number	US-202017135688-A
Country	US
Kind code	B2
Filing date	Dec 28, 2020
Priority date	Jul 16, 2013
Publication date	Sep 10, 2024
Grant date	Sep 10, 2024

Abstract

An additive manufacturing system includes an additive manufacturing tool configured to supply a plurality of droplets to a part, a temperature control device configured to control a temperature of the part, and a controller configured to control the composition, formation, and application of each droplet to the plurality of droplets to the part independent from control of the temperature of the part via the temperature control device. The plurality of droplets is configured to build up the part. Each droplet of the plurality of droplets includes at least one metallic anchoring material.

First claim

The invention claimed is:

1. An additive manufacturing system for joining a first work piece to a second work piece that is composed of a different material than the first work piece, the additive manufacturing system comprising:
an additive manufacturing tool configured to receive one or more metallic anchoring materials;
a power source configured to provide electrical power to the one or more metallic anchoring materials to melt the one or more metallic anchoring materials into a plurality of droplets, the additive manufacturing tool being configured to deposit the plurality of droplets; and
a controller configured to control the additive manufacturing tool or the power source to fasten, via the plurality of droplets, a first work piece to a second work piece, wherein the controller is configured to:
control the additive manufacturing tool or the power source to apply the plurality of droplets at a surface of a first work piece via an opening formed in the second work piece to build up a part that is shaped to join the first work piece and the second work piece without melting the second work piece, and
control the power source to provide DC or AC power in the form of a pulsed welding current waveform.

2. The additive manufacturing system of claim 1 , wherein the controller is configured to control the additive manufacturing tool or the power source to build up the part to form a mating geometry with an edge of the second work piece.

3. The additive manufacturing system of claim 1 , wherein the controller is configured to control the additive manufacturing tool or the power source to build the part to extend through the opening formed in the second work piece.

4. The additive manufacturing system of claim 1 , wherein the controller is configured to control the additive manufacturing tool or the power source to apply the plurality of droplets to a recess located at the surface upon which the plurality of droplets are applied.

5. The additive manufacturing system of claim 3 , wherein the part forms a mating geometry to interface with the opening of the second work piece.

6. The additive manufacturing system of claim 1 , wherein the controller is further configured to control the additive manufacturing tool or the power source to form a cap on the part to resists separation of the second work piece from the first work piece.

7. The additive manufacturing system of claim 6 , wherein the cap comprises a flange.

8. The additive manufacturing system of claim 1 , wherein the one or more metallic anchoring materials and the first work piece are composed of a compatible material.

9. The additive manufacturing system of claim 1 , wherein the one or more metallic anchoring materials and the first work piece are composed of the same material.

10. The additive manufacturing system of claim 1 , wherein the power source is in electrical communication with the one or more metallic anchoring materials.

11. The additive manufacturing system of claim 1 , wherein the additive manufacturing tool further comprises a heater configured to preheat the one or more metallic anchoring materials.

12. The additive manufacturing system of claim 1 , wherein the controller is further configured to control the power source to provide DC or AC power in the form of a short circuit welding waveform, or a controlled short circuit welding waveform.

13. An additive manufacturing system for joining a first work piece to a second work piece that is composed of a different material than the first work piece, the additive manufacturing system, the additive manufacturing system comprising:
an additive manufacturing tool configured to receive one or more metallic anchoring materials;
a robotic system configured to move the additive manufacturing tool;
a sensor configured to determine a position of the additive manufacturing tool relative to the first work piece or the second work piece;
a power source configured to provide electrical power to the one or more metallic anchoring materials to melt the one or more metallic anchoring materials into a plurality of droplets, the additive manufacturing tool being configured to deposit the plurality of droplets; and
a controller configured to control the additive manufacturing tool or the power source to fasten the first work piece to the second work piece via the plurality of droplets, the controller configured to:
move, via the robotic system, the additive manufacturing tool to a deposition position to apply, through an opening formed in the second work piece, the plurality of droplets to a surface of the first work piece,
apply, via the additive manufacturing tool, the plurality of droplets through the opening to build up a part that joins the first work piece and the second work piece without melting the second work piece, and
control the power source to provide electric power in the form of a pulsed welding current waveform, a short circuit welding waveform, or a controlled short circuit welding waveform.

14. The additive manufacturing system of claim 13 , wherein the controller is configured to control the additive manufacturing tool or the power source to build the part to extend through the opening formed in the second work piece.

15. The additive manufacturing system of claim 13 , wherein the controller is further configured to control the additive manufacturing tool or the power source to form a cap on the part to resists separation of the second work piece from the first work piece.

16. The additive manufacturing system of claim 15 , wherein the cap comprises a flange.

17. The additive manufacturing system of claim 13 , wherein the one or more metallic anchoring materials and the first work piece are composed of the same material.

18. The additive manufacturing system of claim 13 , wherein the additive manufacturing tool further comprises a heater configured to preheat the one or more metallic anchoring materials.

19. An additive manufacturing system for joining a first work piece to a second work piece that is composed of a different material than the first work piece, the additive manufacturing system comprising:
an additive manufacturing tool configured to receive one or more metallic anchoring materials;
a power source configured to provide electrical power to the one or more metallic anchoring materials to melt the one or more metallic anchoring materials into a plurality of droplets, the additive manufacturing tool being configured to deposit the plurality of droplets; and
a controller configured to control the additive manufacturing tool or the power source to fasten, via the plurality of droplets, a first work piece to a second work piece, wherein the controller is configured to:
control the additive manufacturing tool or the power source to apply the plurality of droplets at a surface of a first work piece via an opening formed in the second work piece to build up a part that is shaped to join the first work piece and the second work piece without melting the second work piece, and
control the power source to provide DC or AC power in the form of a short circuit welding waveform or a controlled short circuit welding waveform.

Assignees

• Illinois Tool Works

Inventors

• Albrecht Bruce Patrick
• Hsu Christopher

Classifications

• B23K31/12

  relating to investigating the properties, e.g. the weldability, of materials · CPC title

• B23K31/02

  relating to soldering or welding · CPC title

• B23K20/00

  Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating · CPC title

• B23K9/232

  of different metals · CPC title

• B22F10/50

  Treatment of workpieces or articles during build-up, e.g. treatments applied to fused layers during build-up · CPC title