Metal manufacturing systems and methods using mechanical oscillation

Patent metadata

Field	Value
Publication number	US-12145223-B2
Application number	US-202017064345-A
Country	US
Kind code	B2
Filing date	Oct 6, 2020
Priority date	Oct 2, 2017
Publication date	Nov 19, 2024
Grant date	Nov 19, 2024

Abstract

An example system includes an additive manufacturing tool configured to receive a wire from a wire feeder, to receive current from a power source, and to supply the wire to a workpiece during an additive manufacturing process, and a mechanical oscillation system configured to mechanically oscillate a structural component toward and away from the workpiece, wherein the structural component is external to the wire feeder and the power source.

First claim

What is claimed is:

1. A system comprising:
an additive manufacturing tool configured to receive a wire from a wire drive assembly of a wire feeder, to receive current from a power source, and to supply the wire to a workpiece during an additive manufacturing process; and
a mechanical oscillation system configured to mechanically oscillate a structural component toward and away from the workpiece, wherein the structural component is external to the wire feeder and the power source.

2. The system of claim 1 , wherein the structural component is at least partially disposed within the additive manufacturing tool.

3. The system of claim 1 , wherein the additive manufacturing tool comprises the mechanical oscillation system and the structural component.

4. The system of claim 1 , wherein the additive manufacturing tool is a handheld additive manufacturing tool.

5. The system of claim 1 , wherein the additive manufacturing tool is a robotic additive manufacturing tool.

6. The system of claim 1 , wherein the structural component comprises a liner.

7. The system of claim 1 , wherein the welding wire extends through the structural component.

8. The system of claim 1 , wherein mechanical oscillation of the structural component has a substantially fixed travel distance.

9. The system of claim 1 , wherein mechanical oscillation of the structural component has a substantially fixed frequency.

10. The system of claim 1 , wherein the mechanical oscillation system comprises a motor and a mechanical linkage assembly coupled to the motor, wherein the mechanical linkage assembly is fixedly attached to the structural component.

11. The system of claim 10 , wherein the additive manufacturing tool comprises a liner extending into the structural component, the wire extends through the liner, and the structural component is directly coupled to the liner.

12. The system of claim 10 , wherein the mechanical linkage assembly comprises a cam coupled to the motor, and a piston coupled to the cam, wherein the piston is fixedly attached to the structural component.

13. A system comprising:
an additive manufacturing tool configured to receive a wire from a wire drive assembly of a wire feeder, to receive current from a power source, and to supply the wire to a workpiece during an additive manufacturing process;
a mechanical oscillation system configured to mechanically oscillate a structural component toward and away from the workpiece, wherein the structural component is external to the wire feeder and the power source; and
control circuitry configured to control the current based on feedback relating to the additive manufacturing process.

14. The system of claim 13 , wherein the control circuitry is configured to control the current based at least in part on feedback relating to timing of a short circuit that occurs between the wire and the workpiece during the additive manufacturing process.

15. The system of claim 14 , wherein the control circuitry is configured to determine when the short circuit occurs based at least in part on feedback received from a sensor that detects a voltage level corresponding to the current.

16. The system of claim 14 , wherein the control circuitry is configured to hold the current substantially constant for a time period of between 100-300 milliseconds after the short circuit ends before increasing the current.

17. The system of claim 14 , wherein the control circuitry is configured to increase the current to a peak current level after the short circuit ends.

18. The system of claim 17 , wherein the control circuitry is configured to increase the current to the peak current level using a current-controlled ramp.

19. The system of claim 17 , wherein the control circuitry is configured to determine a rate of increase of the current to the peak current level based on at least one of a diameter of the wire or an average wire feed speed of the wire.

20. The system of claim 17 , wherein the control circuitry is configured to increase the current to the peak current level in an asymptotic manner.

Assignees

• Illinois Tool Works
• Illinois Tool Works

Inventors

• Holverson Todd Earl
• Hsu Christopher

Classifications

• B22F10/85

  for controlling or regulating additive manufacturing processes · CPC title

• B22F10/38

  to achieve specific product aspects, e.g. surface smoothness, density, porosity or hollow structures · CPC title

• B22F10/36

  of energy beam parameters · CPC title

• B22F12/90

  Means for process control, e.g. cameras or sensors · CPC title

• B22F12/58

  for changing the material composition, e.g. by mixing · CPC title