Additive Manufacturing Device and Method with Interlayer Ultrasonic Rolling Assisted Through in-situ Electromagnetic Induction Heating

Patent metadata

Field	Value
Publication number	US-2026061492-A1
Application number	US-202519316820-A
Country	US
Kind code	A1
Filing date	Sep 2, 2025
Priority date	Sep 2, 2024
Publication date	Mar 5, 2026
Grant date	—

Abstract

An additive manufacturing device and method with interlayer ultrasonic rolling coupled in-situ electromagnetic induction heating, the device includes an additive manufacturing equipment, a substrate turntable for supporting and adjusting a component's position, an ultrasonic rolling device and an electromagnetic induction heating device cooperated with a top of the component; an ultrasonic controller connected to the ultrasonic rolling device to set rolling parameters required, and an electromagnetic controller connected to the electromagnetic induction heating device to set a current intensity and an induction frequency required. The device and method utilize eddy currents generated by an alternating electromagnetic field to regulate component surface temperature, which can significantly reduce ultrasonic rolling resistance, improve interlayer strengthening efficiency, reduce interlayer strengthening costs, broaden the range of materials suitable for interlayer strengthening, close defects in AM metal components and improve component forming quality and density, and has a positive impact on AM metal materials.

First claim

What is claimed is:

1 . An additive manufacturing device with interlayer ultrasonic rolling and in-situ electromagnetic induction heating, characterized in that, comprising:
an additive manufacturing equipment ( 1 ) arranged for printing a component ( 3 ); a substrate turntable ( 2 ), communicating and controlled through said additive manufacturing equipment ( 1 ), supporting the component ( 3 ) to adjust the position of the component ( 3 ); an ultrasonic rolling device ( 6 ) and an electromagnetic induction heating device ( 4 ) cooperated with a top ( 32 ) of the component ( 3 ), an ultrasonic controller ( 7 ) connected to said ultrasonic rolling device ( 6 ) to set rolling parameters required for said ultrasonic rolling device ( 6 ), wherein the rolling parameters include ultrasonic power, ultrasonic frequency and static load; and an electromagnetic controller ( 5 ) connected to said electromagnetic induction heating device ( 4 ) to set a current intensity and an induction frequency required for said electromagnetic induction heating device ( 4 ).

2 . The additive manufacturing device with interlayer ultrasonic rolling coupled in-situ electromagnetic induction heating according to claim 1 , said additive manufacturing equipment ( 1 ) is an arc fuse additive manufacturing device, a laser directed energy deposition device, or an electron beam directed energy deposition device.

3 . The additive manufacturing device with interlayer ultrasonic rolling coupled in-situ electromagnetic induction heating according to claim 2 , characterized in that, said electromagnetic induction heating device ( 4 ) is a disc-shaped electromagnetic induction copper tube.

4 . The additive manufacturing device with interlayer ultrasonic rolling coupled in-situ electromagnetic induction heating according to claim 2 , characterized in that, said electromagnetic induction heating device ( 4 ) and said ultrasonic rolling device ( 6 ) are coaxially installed.

5 . An additive manufacturing method by said additive manufacturing device with interlayer ultrasonic rolling coupled in-situ electromagnetic induction heating according to claim 1 , characterized in that, said method comprises the steps of:
step (a): creating a 3D model of a component by using a computer CAD software, and performing slicing, layering and path planning of the 3D model of the component through an additive manufacturing system software to obtain a preset printing path; step (b): printing the component along the preset path by a print head of said additive manufacturing equipment, and adjust a position of the component through said substrate turntable to achieve printing of the component, which may be of any shape; step (c): after printing one layer, regulating a current and an induction frequency of said electromagnetic induction heating device by said electromagnetic controller so that said electromagnetic induction heating device introduces a heating temperature required to an interlayer rolling area of the component; and setting an ultrasonic power and frequency of said ultrasonic rolling device ( 6 ) by said ultrasonic controller ( 7 ) so that said ultrasonic rolling device introduces a plastic deformation zone of a desired depth in the interlayer; after the parameters are set, turning on said electromagnetic induction heating device and said ultrasonic rolling device simultaneously to perform ultrasonic rolling on the latest printed layer; step (d): performing step (c) by adjusting the parameters of said ultrasonic controller and said electromagnetic controller for the printed layer if a depth of the printed layer is less than the required range, and performing steps (b) to (c) to print subsequent layers if the depth of the printed layer reaches the required range; and step (e): performing steps (b) to (d) until the entire component ( 3 ) is printed.

6 . An additive manufacturing method by said additive manufacturing device with interlayer ultrasonic rolling coupled in-situ electromagnetic induction heating according to claim 2 , characterized in that, said method comprises the steps of:
step (a): creating a 3D model of a component by using a computer CAD software, and performing slicing, layering and path planning of the 3D model of the component through an additive manufacturing system software to obtain a preset printing path; step (b): printing the component along the preset path by a print head of said additive manufacturing equipment, and adjust a position of the component through said substrate turntable to achieve printing of the component, which may be of any shape; step (c): after printing one layer, regulating a current and an induction frequency of said electromagnetic induction heating device by said electromagnetic controller so that said electromagnetic induction heating device introduces a heating temperature required to an interlayer rolling area of the component; and setting an ultrasonic power and frequency of said ultrasonic rolling device ( 6 ) by said ultrasonic controller ( 7 ) so that said ultrasonic rolling device introduces a plastic deformation zone of a desired depth in the interlayer; after the parameters are set, turning on said electromagnetic induction heating device and said ultrasonic rolling device simultaneously to perform ultrasonic rolling on the latest printed layer; step (d): performing step (c) by adjusting the parameters of said ultrasonic controller and said electromagnetic controller for the printed layer if a depth of the printed layer is less than the required range, and performing steps (b) to (c) to print subsequent layers if the depth of the printed layer reaches the required range; and step (e): performing steps (b) to (d) until the entire component ( 3 ) is printed.

7 . An additive manufacturing method by said additive manufacturing device with interlayer ultrasonic rolling coupled in-situ electromagnetic induction heating according to claim 3 , characterized in that, said method comprises the steps of:
step (a): creating a 3D model of a component by using a computer CAD software, and performing slicing, layering and path planning of the 3D model of the component through an additive manufacturing system software to obtain a preset printing path; step (b): printing the component along the preset path by a print head of said additive manufacturing equipment, and adjust a position of the component through said substrate turntable to achieve printing of the component, which may be of any shape; step (c): after printing one layer, regulating a current and an induction frequency of said electromagnetic induction heating device by said electromagnetic controller so that said electromagnetic induction heating device introduces a heating temperature required to an interlayer rolling area of the component; and setting an ultrasonic power and frequency of said ultrasonic rolling device ( 6 ) by said ultrasonic controller ( 7 ) so that said ultrasonic rolling device introduces a plastic deformation zone of a desired depth in the interlayer; after the parameters are set, turning on said electromagnetic induction heating device and said ultrasonic rolling device simultaneously to perform ultrasonic rolling on the latest printed layer; step (d): performing step (c) by adjusting the parameters of said ultrasonic controller and said electromagnetic controller for the printed layer if a depth of the printed layer is less than the required range, and performing steps (b) to (c) to print subsequent layers if the depth of the printed layer reaches the required range; and step (e): performing steps (b) to (d) until the entire component ( 3 ) is printed.

8 . An additive manufacturing method by said additive manufacturing device with interlayer ultrasonic rolli

Assignees

• Univ Xi An Jiaotong

Inventors

• Huang Ke
• Li Xinzhi
• Zhang Mugong
• Fang Xuewei
• Lu Bingheng

Classifications

• B22F12/10 Primary

  Auxiliary heating means · CPC title

• B22F10/50 Primary

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

• B33Y40/00

  Auxiliary operations or equipment, e.g. for material handling · CPC title

• B22F10/25

  Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS] · CPC title

• B22F10/38

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