Methods and systems for additive tool manufacturing

Patent metadata

Field	Value
Publication number	US-2019160594-A1
Application number	US-201816025020-A
Country	US
Kind code	A1
Filing date	Jul 2, 2018
Priority date	Nov 29, 2017
Publication date	May 30, 2019
Grant date	—

Abstract

An additive manufacturing system includes an electrode head comprising an array of electrodes for depositing material to form a three-dimensional part. The array includes a first plurality of electrodes formed from a first metallic material having a first ductility and a first hardness, and a second plurality of electrodes formed from a second metallic material having a second ductility and a second hardness, wherein the first ductility is greater than the second ductility and the second hardness is greater than the first hardness. A power source provides electrical power for establishing a welding arc for each electrode. A drive roll system drives each electrode. A controller is connected to the power source to control operations of the additive manufacturing system to form an interior portion of the part using the first plurality of electrodes, and control the operations of the additive manufacturing system to form an exterior portion of the part using the second plurality of electrodes, such that ductility of the interior portion of the part is greater than ductility of the exterior portion of the part.

First claim

1 . An additive manufacturing system, comprising:
an electrode head comprising an array of multiple electrodes for depositing material layer by layer to form a three-dimensional (3D) part, wherein the array of multiple electrodes includes a first plurality of electrodes formed from a first metallic material having a first ductility and a first hardness, and a second plurality of electrodes formed from a second metallic material having a second ductility and a second hardness, wherein the first ductility is greater than the second ductility and the second hardness is greater than the first hardness; a power source configured to provide power for heating each electrode of the array of multiple electrodes; a drive roll system configured to drive each electrode of the array of multiple electrodes; and a controller operatively connected to the power source and configured to:
control operations of the additive manufacturing system to form an interior portion of the part using the first plurality of electrodes, and
control the operations of the additive manufacturing system to form an exterior portion of the part, surrounding the interior portion of the part, using the second plurality of electrodes, such that ductility of the interior portion of the part is greater than ductility of the exterior portion of the part.

2 . The additive manufacturing system of claim 1 , wherein the electrodes of the array of multiple electrodes are consumable welding wires.

3 . The additive manufacturing system of claim 1 , wherein the controller is programmed to operate the additive manufacturing system to deposit the material at areas defined by a computer aided design (CAD) model of the part.

4 . The additive manufacturing system of claim 1 , further comprising a thermal spray subsystem operatively connected to the controller, wherein the controller is configured to control operations of the thermal spray subsystem to apply a metallic coating on the part.

5 . The additive manufacturing system of claim 1 , further comprising a blown powder laser subsystem operatively connected to the controller, wherein the controller is configured to control operations of the blown powder laser subsystem to form a high resolution portion of the part having a higher resolution than said interior portion and said exterior portion.

6 . The additive manufacturing system of claim 1 , wherein the controller is configured to control the operations of the additive manufacturing system to form a transition portion of the part, extending between the interior portion and the exterior portion, using both of the first plurality of electrodes and the second plurality of electrodes such that the transition portion is an alloy formed from the first metallic material and the second metallic material.

7 . The additive manufacturing system of claim 6 , wherein a proportion of the first metallic material to the second metallic material decreases through the transition portion from the interior portion to the exterior portion.

8 . An additive manufacturing system, comprising:
an electrode head comprising an array of multiple electrodes for depositing material layer by layer to form a three-dimensional (3D) part, wherein the array of multiple electrodes includes a first plurality of electrodes formed from a first metallic composition, and a second plurality of electrodes formed from a second metallic composition different from the first metallic composition; a power source configured to provide power for heating each electrode of the array of multiple electrodes; a drive roll system configured to drive each electrode of the array of multiple electrodes; and a controller operatively connected to the power source and configured to:
control operations of the additive manufacturing system to form an interior portion of the part using the first plurality of electrodes but not the second plurality of electrodes,
control the operations of the additive manufacturing system to form an exterior portion of the part using the second plurality of electrodes but not the first plurality of electrodes, and
control the operations of the additive manufacturing system to form a transition portion of the part, extending between the interior portion and the exterior portion, using both of the first plurality of electrodes and the second plurality of electrodes such that the transition portion is an alloy formed from the first metallic composition and the second metallic composition.

9 . The additive manufacturing system of claim 8 , wherein the electrodes of the array of multiple electrodes are consumable welding wires.

10 . The additive manufacturing system of claim 8 , wherein the controller is programmed to operate the additive manufacturing system to deposit the material at areas defined by a computer aided design (CAD) model of the part.

11 . The additive manufacturing system of claim 8 , further comprising a thermal spray subsystem operatively connected to the controller, wherein the controller is configured to control operations of the thermal spray subsystem to apply a metallic coating on the part.

12 . The additive manufacturing system of claim 8 , further comprising a blown powder laser subsystem operatively connected to the controller, wherein the controller is configured to control operations of the blown powder laser subsystem to form a high resolution portion of the part having a higher resolution than said interior portion and said exterior portion.

13 . The additive manufacturing system of claim 8 , wherein a proportion of the first metallic composition to the second metallic composition decreases through the transition portion from the interior portion to the exterior portion.

14 . The additive manufacturing system of claim 13 , wherein the first metallic composition is a carbon steel and the second metallic composition is a stainless steel.

15 . A method of additively manufacturing a part to limit crack propagation through the part, comprising the steps of:
providing an additive manufacturing system comprising:
an electrode head comprising an array of multiple electrodes for depositing material layer by layer to form the part, wherein the array of multiple electrodes includes a first plurality of electrodes formed from a first metallic material having a first ductility and a first hardness, and a second plurality of electrodes formed from a second metallic material having a second ductility and a second hardness, wherein the first ductility is greater than the second ductility and the second hardness is greater than the first hardness;
a power source configured to provide electrical power for establishing an electric arc for each electrode of the array of multiple electrodes;
a drive roll system configured to drive each electrode of the array of multiple electrodes; and
a controller operatively connected to the power source;
additively manufacturing the part from at least the first plurality of electrodes and the second plurality of electrodes, including:
forming an interior portion of the part using the first plurality of electrodes; and
forming an exterior portion of the part, surrounding the interior portion of the part, using the second plurality of electrodes, wherein ductility of the interior portion of the part is greater than ductility of the exterior portion of the part.

16 . The method of claim 15 , further comprising the step of forming a transition portion of the part, extending between the interior portion and the exterior portion, using both of the first plurality of electrodes and the second plurality of electrode

Assignees

• Lincoln Global Inc

Inventors

• Flamm Jason K
• Matthews William T
• Kottman Michael A

Classifications

• B22F7/06

  of composite workpieces or articles from parts, e.g. to form tipped tools {(B22F7/002 takes precedence)} · CPC title

• B22F12/57

  Metering means · CPC title

• B22F10/22

  Direct deposition of molten metal · CPC title

• B22F12/55

  Two or more means for feeding material · CPC title

• B23K26/34 Primary

  Laser welding for purposes other than joining · CPC title