CN105983742A

CN105983742A - Method and system for additive manufacturing using high energy source and hot-wire

Info

Publication number: CN105983742A
Application number: CN201610156940.9A
Authority: CN
Inventors: P·E·丹尼; S·R·彼得斯; B·纳拉亚南; 狄厄尼索斯·达马托; M·怀特黑德
Original assignee: Lincoln Global Inc
Current assignee: Lincoln Global Inc
Priority date: 2015-03-23
Filing date: 2016-03-18
Publication date: 2016-10-05
Also published as: DE102016003468A1; KR20160113987A; JP2016179501A

Abstract

A method and a 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 are provided.

Description

Use high-energy source and hot weld silk for increasing the method and system that material manufactures

Priority

The application be on January 24th, 2014 submit to No. 14/163,367 U.S. Patent application part continuation application simultaneously And requiring its priority, this application is combined at this with entire contents by quoting.

Technical field

Some embodiment relates to increasing material manufacture application.Fill more specifically, some embodiment relates to a kind of use combined type Welding wire is sent into and energy resource system is for increasing the system and method for material manufacture application.

Background

The use using the increasing material manufacture of various method has been developed recently.It is well known, however, that method have various Shortcoming.For example, some technique uses usual metal dust slowly and a large amount of powder can be caused to waste.Use based on electric arc The additive method of system is also slow and disapproves the high-precision goods of manufacture.Accordingly, it would be desirable to can high speed and high-accuracy water The increasing manufacture process of flat operation and system.

By this method compared with the embodiments of the invention illustrating referring to the drawings in the remainder of the application, often Further limitation and the shortcoming of rule, tradition and the method being proposed will become bright for those skilled in the art Aobvious.

Content of the invention

Embodiments of the invention include a kind of for increasing the system and method that material manufactures, and wherein, high-energy rig high energy is put Electricity irradiates the surface of workpiece thus produces molten metal bath on the workpiece surface.Welding wire is fed to molten bath by wire feeder, and And power supply supplies heating signal to welding wire, wherein, this heating signal includes multiple current impulse, and wherein, these electric current arteries and veins Each current impulse in punching produces molten droplets in the deposition of welding wire on the far-end in molten bath.Every in these current impulses Individual current impulse reaches peak current level, and this heating letter after molten bath described in wire feeder causes the distal contact of welding wire There is no electric current between the plurality of current impulse number in these current impulses.The movement of this wire feeder control welding wire, so makes The far-end of welding wire between the follow-up peak current level of these current impulses not with molten bath contact, and the control of this power supply adds Thermocurrent, so makes during these current impulses, does not produce electric arc between welding wire and workpiece.

Brief Description Of Drawings

Describe the exemplary embodiment of the present invention by referring to accompanying drawing in detail, above and/or other aspects of the present invention Will become apparent from, in the accompanying drawings:

Fig. 1 illustrates the schematic block diagram of the exemplary embodiment increasing material manufacture system of the present invention；

Fig. 2 A to Fig. 2 D illustrates the molten drop deposition process of the exemplary embodiment according to the present invention；

Fig. 3 illustrates another view of the molten drop deposition process of the exemplary embodiment according to the present invention；

The representative current waveform that can use together with embodiments of the present invention of Fig. 4 A to Fig. 4 B show；

Fig. 5 illustrates the representative embodiment of the voltage and current waveform of the present invention；

Fig. 6 A and Fig. 6 B show are adapted to assist in the utilization of the laser instrument of molten drop deposition；

Fig. 7 illustrates the exemplary embodiment of welding wire heating system according to aspects of the present invention；

Fig. 8 A illustrates the exemplary embodiment of the current waveform can being used together with the system of Fig. 7；

The current waveform of the exemplary embodiment of Fig. 8 B show present invention, voltage waveform, wire feed rate and laser power Exemplary embodiment；

Fig. 9 illustrates another exemplary embodiment of the welding wire heating system of the present invention；

Figure 10 illustrates the further exemplary embodiment of the present invention using many root wires；

Figure 11 illustrates another exemplary embodiment of the system of the present invention；

Figure 12 illustrates power-supply system according to an embodiment of the invention；

Figure 13 illustrates the embodiment of the system of the multiple consumptive material of first use；

Figure 14 illustrates another embodiment of the system in Figure 13；

Figure 15 illustrates the further exemplary embodiment of the system shown in Figure 13；

Figure 16 illustrates the exemplary embodiment that non-adhesive manufactures substrate；

Figure 17 A to Figure 17 C illustrates the further exemplary embodiment that non-adhesive manufactures substrate；

Figure 18 A illustrates the embodiment of the non-adhesive substrate with cooling system；

The exemplary embodiment of the manufacture truss structure that Figure 18 B show embodiments of the invention can use；

Figure 19 A to Figure 19 C illustrates the woollen yarn knitting can being used together with system described herein and increases material manufacture consumptive material Exemplary embodiment；

Figure 20 A to Figure 20 B show is according to the deformed exemplary woollen yarn knitting consumptive material of embodiments of the invention；

Figure 20 C illustrates the embodiment of mariages deposition contact tip assembly described herein；

Figure 20 D illustrates the further exemplary embodiment of the mariages contact tip of the present invention；

Figure 21 A and Figure 21 B show may be used to consumptive material deformation so that the present invention carrying during deposition Exemplary contact tip assembly；

Figure 22 illustrates another exemplary consumable part of the present invention；

Figure 23 illustrates the further exemplary embodiment of the consumptive material manufacturing for increasing material described herein；And

The additional exemplary that Figure 24 A to Figure 24 D illustrates the increasing material manufacture consumptive material that embodiments of the invention can use is real Execute example.

Describe in detail

Will now be described with reference to the attached figures the exemplary embodiment of the present invention.Described exemplary embodiment is intended to help Understand the present invention, and be not intended as limiting by any way the scope of the present invention.Throughout, identical reference numeral refers to phase Same element.

Term " increases material manufacture " and uses with broad sense herein and may refer to any application, including construction, structure Make or create object or parts.

Fig. 1 illustrates for performing the combined type filler wire feeder of increasing material manufacture and the exemplary of energy resource system 100 The functional schematic block diagram of embodiment.System 100 includes making laser beam 110 focus on workpiece 115 thus to workpiece 115 The laser subsystem of heating.This laser subsystem is the high intensity energy.This laser subsystem can be any kind of High energy laser sources, including but not limited to carbon dioxide, Nd:YAG, Yb-dish, YB-optical fiber, optical fiber conveying or direct diode laser Device system.Other embodiments of this system can include the electron beam as the high intensity energy, plasma arc-welding subsystem, tungsten Pole gas shield welding subsystem, gas shielded metal-arc welding subsystem, solder flux flux cored arc welding subsystem and submerged-arc welding At least one in system.Hereinafter illustrate to mention Optical Maser System, beam and power supply by repeating, however, it should be understood that this It is exemplary for quoting, because any high intensity energy can be used.For example, the high intensity energy can provide at least 500W/ cm².This laser subsystem includes laser device 120 and the laser power supply 130 being operatively connected each other.Laser instrument electricity Source 130 provides the power for operating laser device 120.

System 100 also includes providing the workpiece near at least resistance filler wire 140 and laser beam 110 The 115 hot filler wire feeder subsystems contacting.Of course it should be understood that by quoting workpiece 115 herein, molten Melting pond is considered as a part for workpiece 115, therefore to workpiece 115 contact quote and include and the contacting of molten bath.Send Silk device subsystem includes filler wire feeder the 150th, contact tube 160 and power supply 170.In operation, filler wire 140 Heated by the current resistor from the power supply 170 being operatively connected between contact tube 160 and workpiece 115.According to the present invention Embodiment, although exchange (AC) or other kinds of power supply are also possible, but power supply 170 is pulse direct current (DC) power supply. Welding wire 140 from filler wire feeder 150 by contact tube 160 by towards workpiece 115 be sent into and extend to this mouth 160 it Outward.The epitaxial part of welding wire 140 is resistively heated, so make epitaxial part before touching the molten bath on workpiece close to or Reach fusing point.Laser beam 110 for make some base metal in the base metal of workpiece 115 melt thus formed molten bath and Can be also used for making welding wire 140 be melted on workpiece 115.Power supply 170 provides the energy needed for resistance melting filler wire 140. As explained further below, in certain embodiments, power supply 170 provides required all energy, and in other embodiments In, laser instrument or other high energy thermals source can provide some energy in this energy.According to some other embodiment of the present invention, Feeder subsystem can may provide one or more welding wire simultaneously.This will discuss more fully below.

System 100 farther includes to make laser beam 110 (energy) and resistance filler wire 140 along workpiece 115 court The motion control subsystem of (at least on relative meaning) is moved in same direction 125, so makes laser beam 110 and resistance fill Welding wire 140 keeps being relatively fixed each other.According to each embodiment, the relative motion between workpiece 115 and laser/welding wire combination is permissible Realize by actual travelling workpiece 115 or by mobile laser device 120 and wire feeder subsystem.In FIG, motion control Subsystem includes the motion controller 180 being operatively connectable to robot 190.Motion controller 180 controls robot 190 Motion.Robot 190 is operatively connected (for example, mechanically fixing) to workpiece 115 so that workpiece 115 is in direction Move on 125, so make laser beam 110 and welding wire 140 effectively travel along workpiece 115.Substituting according to the present invention Embodiment, laser device 120 and contact tube 160 can be integrated in single head.This head can be via being operatively connected Move to this motion control subsystem along workpiece 115.

Typically, there are the several method that the high intensity energy/welding wire can be made to move relative to workpiece.If workpiece is round , for example, the high intensity energy/welding wire can be static, and workpiece can rotate under this high intensity energy/welding wire.Can replace Dai Di, robots arm or linear pulling machine can be parallel to round piece and move, when workpiece rotates, and the high intensity energy/welding wire Can continuously move or each circulation indexing is once so that (such as) covers the surface of round piece.If workpiece is flat Or be not at least round, then workpiece can move as shown in Figure 1 under the high intensity energy/welding wire.But, robots arm Or linear pulling machine or even install the balladeur train of beam and may be used to the high intensity energy/welding wire head and move relative to workpiece.

System 100 farther includes sensing and current control subsystem 195, this sensing and current control subsystem operability Be connected to workpiece 115 and contact tube 160 (that is, being operatively connected to the output of power supply 170) and workpiece 115 can be measured And the electrical potential difference (that is, voltage V) between welding wire 140 and by their electric current (I).Sensing and current control subsystem 195 can Can be further able to calculate resistance value (R=V/I) and/or performance number (P=V*I) from measured voltage and current.Generally, when When welding wire 140 contacts with workpiece 115, electrical potential difference between welding wire 140 and workpiece 115 is zero volt or closely zero volt Special.As a result, as herein after a while in greater detail, sensing and current control subsystem 195 can fill weldering at resistance Silk 140 contacts with workpiece 115 and is operatively connectable to sense during power supply 170, thus is further able in response to this sense Survey and control the electric current flowing by resistance filler wire 140.According to another embodiment of the invention, sensing and electric current control Subsystem 195 can be the part of power supply 170.

According to embodiments of the invention, motion controller 180 can be further operable for being connected to laser power supply 130 And/or sense and current controller 195.In this way, motion controller 180 and laser power supply 130 can communicate with one another, this Sample makes laser power supply 130 know when workpiece 115 moves, and so makes motion controller 180 know laser Whether device device 120 is movable.Similarly, in this way, motion controller 180 and sensing and current controller 195 can To communicate with one another, so make sensing and current controller 195 know when workpiece 115 moves, and so make fortune Movement controller 180 knows whether filler wire feeder subsystem is movable.This kind of communication may be used for coordination system 100 Activity between each subsystem.

As is it well known, increase material manufacture be a kind of material deposition on workpiece to create desired manufacture product Technique.In some applications, goods can be extremely complex.But, may often be such that for increasing the known method of material manufacture and system Slowly and the limited capacity that has.Embodiments of the invention are increased material manufacture method and are with high accuracy by providing at a high speed System solves those fields.

System 100 depicted in figure 1 is this kind of example system, wherein, welding wire 140 by repeated melting become molten drop and Deposition is on workpiece, thus produces desired shape.This technique of Fig. 2 A to Fig. 2 D example plot.Such as institute in these figures Show.As shown in Figure 2 A, the surface of workpiece by laser beam 110 (or other thermals source) irradiate, and welding wire 140 not with absorption surface. Beam 110 produces molten metal bath A on the surface of workpiece.In most applications, molten bath A has little area, and through-fall Flat will not be to penetrate level required by other operations (such as welding or engage).On the contrary, molten bath A is generated as making the surface of workpiece Prepare to receive from the molten drop of welding wire 140 and cause with this molten drop well-bonded.Therefore, the beam density of beam 110 makes Must only produce little molten bath on workpiece and do not cause too many heat to be input in workpiece or cause molten bath too big.Once produce molten Pond, as welding wire is advanced to molten bath A, molten drop D-shaped becomes the far-end at welding wire 140 to contact with molten bath A, sees Fig. 2 B.? After contact, (see Fig. 2 C) in molten drop D deposition to molten bath A and workpiece.Repeat this process to create desired workpiece.At figure In 2D, showing optional step, in this step, after the molten drop D of deposition separates with welding wire 140, beam 110 is guided in At the molten drop of institute's deposition.In this kind of embodiment, beam 110 may be used to surface of the work and smooths and/or add additional heat Molten drop D is allowed to be entirely integrated on workpiece.Further, this beam may be used to provide the additional shaping of workpiece.

Fig. 3 depicts the exemplary deposition process of the molten drop D from welding wire 140.Image on the left hand edge of Fig. 3 depicts Welding wire 140 contacts with workpiece.Power supply 170 detects that this contacts, and then, this power supply provides heating electric current to welding wire 140, with Just this welding wire is heated to the fusion temperature at or approximately at welding wire 140.For detecting contacting between workpiece with welding wire 140 Testing circuit can be constructed and operate as the known testing circuit used in the source of welding current, and therefore do not needs There is provided herein and this circuit operation and structure are explained in detail.Heating electric current quickly oblique ascension from power supply 170 Thus provide necessary energy end melted to make molten drop D from welding wire 140.But, careful this electric current of control, so that Electric arc is not produced between welding wire 140 and workpiece.The generation of electric arc can prove there is destructiveness to workpiece and therefore not be the phase of making us Hope.Therefore, with in order to prevent from forming this kind of mode of electric arc (being explained further below) control electric current.

Rotating back into Fig. 3, welding wire 140 contacts with workpiece and power supply 170 provides fusion current (1).Exemplary at some In embodiment, open-circuit voltage OCV can put on welding wire 140 before contact.After contact, electric current quick ramp is to make Welding wire 140 end melted thus the molten drop D that has (2) to be deposited.Electric current also causes welding wire 140 just above molten drop D Neck-shaped is shunk to allow molten drop D to separate (3) with welding wire 140.But, electric current is controlled, and so makes when welding wire 140 neck-shaped During contraction, electric current is closed or is greatly reduced, so that when welding wire 140 separates with molten drop D, between welding wire 140 and workpiece Do not produce electric arc (4).In some exemplary embodiments, during the connection between molten drop D and welding wire 140 disconnects and just at it Before, welding wire 140 can be retracted away from workpiece.Because molten drop D contacts with molten bath, the surface tension in molten bath will help to make to melt Drip from welding wire 140 dialysis.Once molten drop separates with welding wire 140, and welding wire 140 is just pushed into repeat this process, thus molten Apply another molten drop.Welding wire 140 can be advanced to same position and/or next molten drop can be deposited over any desired position Put.

As previously discussed, it is also possible to utilize laser beam 110 after molten drop D has been deposited on workpiece after deposition Make workpiece smooth or otherwise shape.Furthermore, it is possible to further with beam 110 during deposition.It is, one In a little exemplary embodiments, beam 110 may be used for adding heat to welding wire 140 thus help to cause molten drop formation and/or Molten drop D separates with welding wire 140.This will be discussed further below.

Turning now to Fig. 4 A and Fig. 4 B, each plot depicts the utilizable exemplary electrical of exemplary embodiment of the present invention Stream waveform.In Figure 4 A, as can be seen, waveform 400 has multiple pulse 401, and wherein each pulse represents from welding wire The transfer of the molten drop D of 140.Current impulse 401 starts when welding wire 140 contacts.Then, electric current uses ramp up portion 402 to increase To peak current level 401, this peak current level just occurred before welding wire 140 separates with molten drop D.In this embodiment In, during ramp up portion 402, electric current is continuously increased thus causes molten drop to be formed and receive with welding wire generation neck-shaped before separation Contracting.Before molten drop D separates, electric current quickly reduces during oblique deascension part 404, so that when occurring to separate, do not produce Raw electric arc.In the waveform 400 of Fig. 4 A, electric current is cut-off and drops to zero.But, in other exemplary enforcements of the present invention In example, electric current can drop to relatively low discrete level without being completely severed, until separating.In this kind of embodiment In, continuation is added heat to welding wire 140 by relatively low separation current level, thus helps to disconnect molten drop D.

Fig. 4 B depicts another exemplary embodiment of current waveform 410.But, in the present embodiment, pulse 411 has Have and utilize the ramp up portion 402-of multiple different ramp rate section as shown.In the embodiment shown, it is separated at molten drop D Before, ramp up portion 402 utilizes three different ramp rate 402A, 402B and 402C.First ramp rate 402A is very steep simultaneously And electric current quickly increases quickly to heat welding wire 140, thus start fusion process as early as possible.Reach the first level 405 at electric current Afterwards, current ramp speed becomes second ramp rate 402B less than the first ramp rate.In some exemplary embodiments In, the first current level is in the range of the 35% to 60% of the peak current level 413 of pulse.Ramp rate 402B is less than just Beginning ramp rate 402A is to help to control electric current and preventing from forming electric arc or micro-electric arc.In the embodiment shown, the second slope Speed is maintained until molten drop D starts to be formed at the far-end of welding wire 140.In the embodiment shown, once molten drop D starts shape Becoming, current ramp speed just becomes less than the 3rd ramp rate 402C of the second ramp rate 402B again.Again, ramp rate Minimizing allow to tighten control electric current to prevent from not noting producing electric arc.If electric current increase is too fast, when separation being detected Can be difficult to (because various problems, such as system inductance) quickly reduce electric current and be difficult to prevent electric arc.Exemplary at some In embodiment, transition point 407 between the second ramp rate and the 3rd ramp rate is in the peak current level 413 of pulse 411 50% to 80% in the range of.Same with the pulsion phase in Fig. 4 A, when detecting that molten drop separates, electric current substantially reduces, and this will Explaining more fully below.It should also be noted that other embodiments of the present invention can use different ramp rate special Levy curve without deviating from the scope of the present invention or spirit.For example, these pulses can have two different ramp rate sections Or can have more than three ramp rate section.Additionally, these pulses can utilize the oblique ascension being continually changing.For example, electricity Stream can be followed anti-parabolic curve and be reached peak current level, or can utilize different configuration of combination, wherein, and constant slope Speed can begin to use until the first current level 405 from welding wire contact, and then can begin to use anti-throwing from that Thing curve.

As explained herein, the peak current level of pulse 401/411 will be less than electric arc generation level, but at each Be enough to during pulse melt away molten drop D.The exemplary embodiment of the present invention can utilize different control methods for peak electricity Stream level.In some exemplary embodiments, peak current level can be by the different use increasing input before material manufactures Peak current threshold determined by family input parameter.This kind of parameter includes solder wire material type, gage of wire, wire types (medicine The real core of core v.) and per inch molten drop number (DPI).It is, of course, also possible to utilize other parameters.When receiving this input information, electricity Source 170 and/or controller 195 can utilize different control methods, such as look-up table, and determine the peak point current for operation Value.Alternately, power supply 170 can monitor output electric current, voltage and/or the power of power supply 170 to determine when to occur Separate and correspondingly control electric current.For example, it is possible to monitoring (using pre-inductive circuit etc.) dv/dt, di/dt and/dp/dt, and And when determining that separation is to be occurred, close or reduce electric current.This is by explanation in further detail below.

It is discussed below purposes and the operation of the exemplary embodiment of the present invention.When increasing material manufacture process starts, power supply 170 can apply to sense voltage via power supply 170 between welding wire 140 and workpiece 115.Power supply 170 can be according to sensing and electricity The order of stream controller 195 applies to sense voltage.In certain embodiments, the sensing voltage being applied does not provides enough energy Amount heats welding wire 140 significantly.In the case of applying sensing voltage condition, the far-end of welding wire 140 is pushed into workpiece 115. Then, laser instrument 120 sends beam 110 and comes the surface of heated parts 115 and produce molten bath thus receive welding wire 140.Wire feed Device 150 performs this propelling, and when first the far-end of welding wire 140 contacts with workpiece 115, senses and the contacting of workpiece.Example As controller 195 can provide the low-down current level (for example, 3 to 5 amperes) by welding wire 140 by order power supply 170. This sensing can be measured between welding wire 140 (for example, via contact tube 160) and workpiece 115 by sensing and current controller 195 The electrical potential difference of about zero volt (for example, 0.4V) complete.When the far end short of filler wire 140 be connected to workpiece 115 (that is, with Absorption surface) when, may not there is significant voltage level (being higher than zero volt) between filler wire 140 and workpiece 115.

After contact, power supply 170 can be in response to this sensing in the time interval limiting (for example, some milliseconds) It is closed.Then, power supply 170 can return at the end of the time interval limiting and be opened, thus is applied through welding wire 140 Heating current flows.Further, after sensing contact, beam 110 can be turned off so that and do not adds to molten bath or workpiece 115 Add too many heat.In certain embodiments, laser beam 110 can persistently remain, thus helps heating and the separation of molten drop D. This is by discussion in further detail below.

In some exemplary embodiments of the present invention, this process can include stopping propulsion solder wire in response to this sensing 140th, restart to advance (i.e., again advancing) welding wire 140 at the end of the time interval limiting and verify in applying heating Electric current flowing before or apply heating electric current with and molten drop D-shaped become after filler wire 140 far-end still with workpiece 115 contacts.Sensing and current controller 195 can order wire feeder 150 stop be sent into and order system 100 wait (for example, Some milliseconds).In this kind of embodiment, sensing and current controller 195 are operatively connectable to wire feeder 150 so that order is sent Silk device 150 starts and stops.Sensing and current controller 195 can order power supply 170 apply heating current impulse thus as above Described heating welding wire 140, and this process can be repeated so as on workpiece the multiple molten drop of deposition.

In operation, the high intensity energy (for example, laser device 120) and welding wire 140 can move along workpiece 115 Move thus molten drop is provided as desired.Motion controller 180 order robot 190 is relative to laser beam 110 and weldering Silk 140 travelling workpieces 115.Laser power supply 130 provides for operating the power that laser device 120 forms laser beam 110.? In further embodiment, laser device 120 includes optics, and these optics can be adjusted to for changing sharp Shape on the shock surface of workpiece for the light beam 110.Embodiment can use beam shape to control the shape of deposition process, also It is through using the beam of rectangle, ellipse or oval shape, the deposit of opposite, narrow can be formed, thus form relatively thin enclosing Wall construction.Further, beam shape may be used for making deposit shape after molten drop separates with consumptive material.

As discussed above, determine will occur between welding wire 140 and molten drop D fracture when, to close or be greatly reduced arteries and veins Rush electric current.This can be completed by various ways.For example, this kind of sensing can be by sensing and current controller 195 Premonition circuit measuring welding wire 140 and workpiece 115 between electrical potential difference (dv/dt), by their electric current (di/dt), they Between resistance (dr/dt) or completed by the rate of change of the one in their power (dp/dt).When rate of change surpasses When crossing predefined value, sensing and current controller 195 formally predict that contact loss will occur.This kind of pre-inductive circuit is for arc-welding For be well known in the art, and its 26S Proteasome Structure and Function does not needs herein to be described in.

When the far-end of welding wire 140 becomes high melting due to heating, far-end will start from welding wire 140 hoop break to On workpiece 115.For example, at that time, because when the far-end hoop of welding wire breaks, its cross section quickly reduces, so electrical potential difference or voltage increase Add.Therefore, by this kind of rate of change of measurement, system 100 will be it is anticipated that when far-end will bind round disconnected and depart from workpiece 115 Contact.

As explained before, when sensing molten drop and separating, power supply 170 can be closed or be greatly reduced electric current.For example, exist In some exemplary embodiments, in the range of electric current is reduced to the 95% to 85% of the peak current value of pulse.Exemplary In embodiment, the reduction of this electric current occurs before separating between welding wire with molten bath.

For example, Fig. 5 illustrates a pair voltage and current waveform 510 being associated respectively with the increasing manufacture process of the application With 520 exemplary embodiment.Voltage waveform 510 be by sensing and current controller 195 contact tube 160 and workpiece 115 it Between measurement.Current waveform 520 is measured with workpiece 115 by welding wire 140 by sensing and current controller 195.

No matter when welding wire 140 disengage with workpiece 115, and the rate of change (that is, dv/dt) of voltage waveform 510 will Exceed predetermined threshold, thus indicating band is disconnected that (slope see at the point 511 of waveform 510) will occur.As an alternative, pass through The rate of change of the electric current (di/dt) of filler wire 140 and workpiece 115, the resistance (dr/dt) between them rate of change, Or will be able to be occurred alternatively for indicating band is short by the rate of change of their power (dp/dt).This kind of rate of change Premonition technology is well known in the art.At that time point, sensing and current controller 195 are by order power supply 170 Close (or being at least greatly reduced) electric current flowing by welding wire 140.

It is spaced 530 (for example, electricity when sensing and current controller 195 sense the far-end of filler wire 140 sometime Voltage level falls back to about zero volt putting at 512s) after when again forming good contact with workpiece 115, sensing and electric current control Device 195 order power supply 170 processed makes by the electric current flowing of resistance filler wire 140 towards predetermined output current level 550 oblique ascension (see slope 525).Time interval 530 can be predetermined time interval.According to embodiments of the invention, oblique ascension is from set-point value 540 start.When the energy 120 and welding wire 140 move relative to workpiece 115 and when welding wire 140 due to wire feeder 150 towards work Part 115 advances thus when desired position deposition molten drop, this process repeats.In this way, prevent at welding wire 140 Far-end and workpiece 115 between formed electric arc.The slope of heating electric current helps prevent unintentionally will when there is not this kind of situation Voltage changing rate is explained to be become the short situation of hoop or forms arcing condition.Any big curent change may be due to heater circuit Inductance and cause use mistake voltage readings.When electric current gradually oblique ascension, reduce inductive effect.

As explained before, power supply 170 provides heating electric current to filler wire 140.Electric current flows to weldering from contact tip 160 Silk 140 and then flow in workpiece.This resistance heating current causes the welding wire 140 between most advanced and sophisticated 160 and workpiece to reach place In or close to the temperature of the fusion temperature of filler wire 140 being used.Certainly, the fusion temperature institute of filler wire 140 is reached The heat needing will depend upon which the size of welding wire 140 and chemical composition and different.Correspondingly, the molten of welding wire is reached in the fabrication process The heat changing temperature will depend upon which welding wire 140 and different.As will be further discussed, the desired operation temperature of filler wire The data in system can be enter into, so that maintain desired welding wire temperature in the fabrication process.Under any circumstance, The temperature of welding wire should make the welding wire 140 can be by molten drop deposition to molten bath.

In an exemplary embodiment of the present invention, power supply 170 supply causes at least a portion of the far-end of welding wire 140 to be in In its fusion temperature or higher than its electric current at a temperature of 90%.For example, when use has about 2, filling out of 000 °F of fusion temperature When filling welding wire 140, welding wire temperature during welding wire contact can be substantially 1,800 °F.Of course it should be understood that corresponding fusing Temperature and desired operation temperature be not by according at least to the alloy of filler wire 140, constituent, diameter and feed rate and With.In still further illustrative embodiments, the some of welding wire is maintained at and is in the fusion temperature of welding wire or is higher than it At a temperature of the welding wire of 95%.Certainly, in certain embodiments, the far-end of welding wire is heated electric current and is heated to its fusion temperature extremely Few 99%.Therefore, when the molten drop after heating contacts with the molten metal bath that laser produces, the heat from molten bath can be to welding wire 140 interpolation heats thus produce molten droplets completely at the end of welding wire 140 so that when welding wire 140 is drawn back into, molten drop Adhere to molten bath and keep together with it.By filler wire 140 being maintained close in or being in its fusion temperature Temperature, welding wire 140 is easily melted and enters or be consumed in the molten bath that entrance thermal source/laser instrument 120 produces.It is, welding wire 140 are in and do not cause, when welding wire 140 and molten bath contact, the temperature making molten bath significantly quench.Because the high temperature of welding wire 140, when with During molten bath contact, welding wire rapid melting.In other exemplary embodiments, welding wire can be heated to be in its fusion temperature or Higher than its fusion temperature 75%.But, when be heated to close to 75% temperature when, will be it is likely that additional heat will be needed Amount makes the droplet transitions significantly melting.

As previously described, in some exemplary embodiments, can only be entered by welding wire 140 molten bath promotes weldering Silk 140 is completely melt.But, in other exemplary embodiments, welding wire 140 can be heated electric current, molten bath and impact in weldering The combination of the laser beam 110 in a part for silk 140 is completely melt.It is, the heat/melting of welding wire 140 can be by laser Bundle 110 helps, and so makes beam 110 contribute to the heating of welding wire 140.But, because many filler wires 140 are by can Making with the material of reflection, if using reflection type of laser, the temperature that welding wire 140 should be heated to makes its surface reflect Rate reduces, thus allows beam 110 to contribute to heat/melting welding wire 140.In the exemplary embodiment of this configuration, welding wire 140 and beam 110 welding wire 140 enter at the point in molten bath intersect.Fig. 6 A and Fig. 6 B shows this situation.

As shown in FIG, in some exemplary embodiments, beam 110 may be used for helping molten drop D deposition to workpiece On 115.It is, beam 110 may be used for adding heat to the far-end of welding wire 140 thus produces molten droplets.In this kind of reality Executing in example, the heating electric current from power supply may remain under the level far below electric arc generation level, so that it is guaranteed that will not Produce electric arc but correct droplet transitions can be realized.In this kind of embodiment, it can be so made only to impact with beams directed Molten drop D, or in other embodiments, beam 110 is sufficiently large, be formed or rasterize, and its mode is this beam impact molten drop At least a portion and at least certain part in molten bath thus contribute to adding heat to molten bath to receive molten drop D.At beam 110 Energy density exemplary embodiment in, in this phase process of this process, when this beam on workpiece 115 produce During raw molten bath, the typically smaller than energy density of this beam.

Fig. 6 B depicts other exemplary embodiment of the present invention, and wherein, the beam 110 at welding wire 140s is just at molten drop Top thus help it to separate with welding wire.In this kind of embodiment, when sense or determine welding wire 140 above molten drop neck-shaped receive Contracting, beam 110 is directed to welding wire, is positioned at the junction between molten drop D and welding wire 140, so makes beam 110 help to make two Person separates.This kind of embodiment helps prevent generation electric arc, because not needing to use heating electric current to control this separation.Show at some In example embodiment, beam 110 can come from for the initial same laser instrument 120 producing molten bath.But, in other embodiments In, the beam in Fig. 6 B can also be from also being sent by the second single laser instrument that controller 195 controls.Therefore, in this kind of reality Execute in example, when controller and/or power detecting will separate to molten drop formation or molten drop D, be guided to welding wire at laser beam 140 with cause desired separate while, the output electric current of power supply 170 can decline.

Turning now to Fig. 7, show heating system 700 and the exemplary embodiment of contact tip assembly 707.Generally should note Meaning, embodiments of the invention can utilize with regard to contact tip 160 and resistance known to hot weld silk or some welding systems Heating system, without departing from the spirit or scope of the present invention.But, in other exemplary embodiments, it is possible to use such as Fig. 7 Shown in system 700.In this system 700, contact tip assembly is made up of two current-carrying parts 701 and 703, and these are led Electricity part is electrically isolated from each other by insulated part 705, and this insulated part can be made up of any dielectric substance.Certainly, at it In his embodiment, if tip portion 701 and 703 with electrically isolated from one, avoid the need for there is insulated part.System 700 is also wrapped Including switching circuit 710, the power supply 170/ that current path is switched between tip portion 701 and workpiece 115 by this switching circuit is cut Change and leave this power supply.In some embodiments, it may be possible to be desirable to manufacturing when welding wire 140 does not contacts with workpiece 115 During welding wire 140 is maintained certain threshold temperature.(for example, again determining when welding wire 140 contacts with workpiece 115 During Wei), do not have electric current and flow through welding wire 140, and such resistance heating will stop.Certainly, amount of residual heat will still Exist, but can rapid decline.This embodiment allows welding wire 140 to be heated continuously, even if it does not contacts with workpiece 115.As institute Showing, a lead-in wire from power supply is attached to the upper part 703 of contact tip assembly 707.In operation, welding wire is worked as 140 with absorption surface when, switch 710 be positioned such that current path from the beginning of upper part 703, pass through welding wire 140 and Workpiece, thus return to power supply 170 (dotted line in switch 710).But, when molten drop D separates and and workpiece with welding wire 140 When the contact of 115 disconnects, switch 710 is switched to so that current path is from contact tip part 703 to contact tip part 701 and return to power supply 170.This allows at least some heating electric current to flow through workpiece thus continues under a certain background heating level Resistance heats welding wire.Because this kind of configuration, welding wire can be heated to its desired deposition level more quickly.If molten drop melts Having had long duration between application, during this duration, welding wire may cool down, then especially this situation.Therefore, In the exemplary embodiment, when switch 710 is in the primary importance directing current through workpiece (the first current path) When, power supply 170 provides one or more current impulse (as broadly described herein), and then, when this switch is in Direct current through two parts 701/703 of contact tip thus in the middle of droplet transitions, keep heating the second of welding wire When putting (the second current path), power supply 170 provides background current or heating electric current (it can be such as constant current).One In a little embodiments, switch can switch between each droplet transitions pulse, and in other embodiments, switch can With switching after multiple droplet transitions pulses.In the exemplary embodiment, background current level/heating current level is chosen Become welding wire is maintained at desired-non-melt-at a temperature of level.If temperature is too high, then can become to be difficult to shift welding wire onto Molten bath.In some exemplary embodiments, the peak point current electricity that background current/heating electric current reaches during droplet transitions pulse In the range of flat 10% to 70%.

It should be noted that in the figure 7, it is outside that switch 710 is shown in power supply 170.But, this description be only for Clear and switch can inside power supply 170.Alternately, switch can also be inside contact tip assembly 707. Insulated part 705 can be made up of any type of insulation material or can be only between the isolation between parts 701 and 703 Gap.This switch can be controlled or depended on by controller 195 (as shown) desired configuration and can be directly by power supply 170 Control.

In other exemplary embodiments, welding wire preheating apparatus can be positioned in the upstream of assembly 707, and this welding wire is pre- Welding wire 140 was preheated before welding wire enters most advanced and sophisticated 707 by heater.For example, this preheating apparatus can be sensing Heater, it does not needs electric current and flows through welding wire 140 to heat welding wire 140.It is of course also possible to use resistive heating system.This Individual preheating apparatus may be used for maintaining welding wire at a temperature of as mentioned above.Further, preheating apparatus may be used for Before welding wire is by deposition, from welding wire 140, also remove any less desirable moisture (when using Ti, this particular importance).This kind of Preheating system is well-known and does not needs to be described in detail.Preheating apparatus can be arranged at welding wire Before 140 entrance tip assemblies 707, this welding wire is heated to predetermined temperature, thus allows the electric current from power supply 170 to be used for defeated Send enough electric currents to complete deposition process.It should be noted that welding wire 140 should be heated to destroy welding wire 140 by preheating apparatus Level, so make welding wire 140 can be correctly pushed through most advanced and sophisticated 707.If it is, welding wire 140 is too boiling hot, then its Can become excessively soft, when pushed, this can destroy the response of welding wire 140.

Fig. 8 A depicts the exemplary manufacture current waveform 800 that the system 700 in Fig. 7 can use.In fig. 8 a, substantially Current waveform 800 is shown as including two components, segment pulse 801 and background portion 803.Segment pulse is by being used for making such as this The current impulse composition of the molten drop deposition discussed in Wen.During these pulses, electric current is conducted through from tip portion 703 Workpiece 115.But, during background portion, electric current be directed to part 701 from tip portion 703 thus when welding wire 140 not with Workpiece 115 heats this welding wire when contacting.It should be noted, of course, that contact tip part 701/703 is to as shown in Figure 7 just Power supply terminal is exemplary with the connection of negative power source terminal, and these connect and can arrange and property based on desired system Can and be reversed.As previously explained, the background current level 803 between pulse 801 melts for welding wire is maintained at molten drop The temperature being maintained between application.In some exemplary embodiments of the present invention, welding wire 140 is maintained at place by background current Temperature in the range of the 40% to 90% of the fusion temperature of welding wire 140.In other exemplary embodiments, electric current 803 will Welding wire 140 is maintained at temperature in the range of the 50% to 80% of the fusion temperature of welding wire 140.

It should further be appreciated that may not expect or need not constantly be switched to background electricity between each pulse 801 Stream.In high molten drop deposition rate process, may be especially such.It is, in high molten drop deposition rate process, welding wire 140 will be maintained at high temperature level between molten drop.Therefore, in some exemplary embodiments, only in the duration menstrual period Full or just occur to background when the duration between molten drop pulse exceedes threshold time and heat electric current (as mentioned above) Switching.For example, in certain embodiments, if the time between pulse was more than 1 second, then system 700 will use as above Switching and background heat electric current.If it is, the manufacture method being utilized have be higher than determined by the pulse of threshold frequency Frequency, then will use above switching.In an exemplary embodiment of the present invention, this threshold value between the pulses 0.5 second is to 2.5 In the range of Miao.In other embodiments, system 700 can utilize the timer of the time between monitoring pulse (at controller 195 And/or power supply 170 is internal), and if this time exceed threshold quantity, then will utilize above-mentioned switching and background heating electric current.Example As if system 700 determines that the stand-by period between pulse alreadys more than threshold time limit (for example, 1 second), then will be utilized this Welding wire 140 is maintained at desired temperature by end heating electric current.This kind of embodiment can be used in set threshold time In embodiment through expiring, it is, determine in system 700 and use in real time when time restriction has been expired, or can be System 700 predicts when next pulse will not occur before time restriction is expired and uses.For example, if system 700 (for example, Controller 195) determine that next pulse will not occur (for example, due to workpiece 115 and/or welding wire before time restriction is expired The movement of 140), then system 700 can initiate above-mentioned switching and background heating electric current immediately.Exemplary embodiment in the present invention In, this duration threshold is in the range of 0.5 second to 2.5 seconds.

Fig. 8 B depicts the example that the exemplary embodiment of the present invention may be used for deposition molten drop as described in this article Property waveform.These example waveform are the transfers for single according to an embodiment of the invention molten drop.Shown in waveform be for The 820th, laser power the 810th, wire feed rate increases material welding wire and heats electric current 830 and voltage 840.It will be appreciated that, described waveform purport It is being exemplary, and other embodiments of the present invention can use and have and shown herein or described different characteristic Other waveforms.As indicated, the droplet transitions cycle is drawn towards 811 beginnings of workpiece in laser power, and increase by 812 to peak value Laser power level 813.After duration T p, at point 814, laser produces molten bath on workpiece.When this, wire feed Device starts to drive towards molten bath to increase material welding wire.After being 814 generation molten baths, wire feed rate increases by 821 and arrives peak value wire feed rate 822.In an exemplary embodiment of the present invention, wire feed rate substantially same a period of time when contacting with molten bath 821 ' with the far-end of welding wire Between reach its peak level 822.But, in other exemplary embodiments, wire feed rate can reach before welding wire contact Its peak level 822.As indicated, while wire feed process starts, open-circuit voltage puts on welding wire 841, so that this weldering Silk certain point before welding wire with molten bath contact reaches peak voltage level 842.Further, when welding wire and molten bath contact, add Thermocurrent 830 starts flowing (at point 831), and voltage 840 begins to decline 843.Voltage drops below arc-detection voltage The level 844 of 848, during higher than this arc-detection voltage, determines and will produce electric arc.

After welding wire with molten bath contact, it is respective that laser power the 810th, wire feed rate 820 and electric current 830 are maintained at it Peak level duration section Ta, during this time period, in the molten drop deposition of welding wire to molten bath.Expire at deposition time period Ta After (815), scheduled time that this deposition time period can be controlled with continuous heating power supply (for example, use timer circuit) Section, laser power is with wire feed rate 823 oblique deascension 816.After time period Ta (summit 834) expires and in laser power and When wire feed rate reduces, heating electric current 830 is maintained at its peak level 833 section of continuing for some time.This helps molten drop and welding wire Separate.After molten drop adds phase Ta, welding wire retraction phase Tr starts.Start its oblique deascension 835 (in point 834 beginning) at electric current 830 Afterwards, wire feed rate be reduced to zero (at point 827) and wire feeder is controlled so as to retract welding wire 824 with peak value retraction speed 825. Further, during the retraction phase, electric current 830 is reduced to the current level 836 that flashes back, and this current level that flashes back is for when welding wire is from molten bath In flashing back of welding wire is provided when being drawn out of.During welding wire retraction phase Tr, it is straight that electric current 830 is maintained at the current level 836 that flashes back Meeting or exceeding arc-detection voltage level 848 to voltage at some 845s, this arc-detection voltage level is due to welding wire and to melt Pond separates (cause electric current to decline and voltage increases) causing.When reaching voltage level 848, initiate extinguishing arc routine 847 thus Prevent electric arc.During this time, voltage climbs peak level 846.

Arc-detection voltage level 848 is that power supply and/or system controller are for guaranteeing to withdraw between welding wire and workpiece not Produce the predetermined level of electric arc.Arc-detection voltage level 848 is inputted based on every user by power supply and/or system controller Set, including but not limited to wire types, gage of wire, workpiece material type, the per inch molten drop number of input, every point of input Clock molten drop number etc..

When reaching arc-detection voltage level 848 (at point 845), electric current 830 is stopped by dump (837) and welding wire Non-return contracts (826), and when electric current 830 and wire feed rate 820 each reach 0, the droplet transitions cycle is in point 817 end.? In illustrated embodiment, laser power 810 be also shown in a little 817 end cycle when cut-off.In other exemplary embodiments In, when reaching arc voltage threshold value 848 (at point 845), laser power 810 is cut off.Then, come for repeatedly molten drop deposition Repeat this cycle.

In some exemplary embodiments, (not shown) can be initiated between the droplet transitions cycle (as seen in fig. 8b) Laser power pulse thus help in the middle of the droplet transitions to make workpiece smooth or otherwise add energy to workpiece.For example, Can initiate laser power pulse in the middle of each in droplet transitions cycle, or in other embodiments, as required, Ke Yi Laser power pulse is initiated after n droplet transitions cycle.

Fig. 9 depicts another example system 900 of the present invention.System 900 includes background power supply 170 ' and pulse electricity Source 170.In addition to except background heating, electric current supplied by single power supply 170 ', the operation of this system with discussed above Operate closely similar.Therefore, in certain embodiments, background power supply 170 ' can provide constant heating electric current in the fabrication process And there is no need to provide switching discussed above.Except the peak anode current of the pulse power 170 is due to power supply 170 ' offer Extra heating/electric current and beyond can reducing, this pulse power is according to operation as additionally describing herein.In this kind of reality Executing in example, the control of the pulse power 170 or the level of precision can be improved.It is, due to the electricity to power supply 170 demand Flowing less, the pulse power 170 can reach its peak pulse level quickly.Certainly, also will so when reducing electric current.Power supply Each power supply in 170/170 ' can be controlled by controller 195, or can configure by master-slave relationship, and this is many institute's weeks Know.Although additionally, in order to clear and show separately these power supplys, but they may be accommodated in individual unit and do not take off From the spirit or scope of the present invention.

Further, Fig. 9 shows another contact tip assembly 900, there is current-carrying part 901 and 905 and insulation division Divide 903.In this embodiment, current-carrying part 905 is configured so that heating electric current is transmitted as far as possible near welding wire 140 Exposed distal end.This kind of configuration assistant guarantees that the heating of welding wire keeps as far as possible near this far-end, thus optimizes the effect of background heating Really.In a further embodiment, the far-end of welding wire 140 remains minimum range from the overhang X of contact tip 910.If Overhang X keeps oversize, then the heating effect that background heating electric current produces can affect adversely.Therefore, exemplary at some In embodiment, overhang X is maintained at 0.1 inch in 0.5 inch range.In other exemplary embodiments, overhang keeps In 0.2 inch to 0.4 inch range.Further, in additional exemplary embodiment, add thermogenetic to obtain background Further benefit, between molten drop pulse, welding wire 140 is completely or almost completely retracted back in contact tip 910, so makes Obtain overhang X in 0 inch to 0.15 inch range.The far-end of welding wire 140 can be maintained at desired by this kind of embodiment Background heating-up temperature and do not make other parts not close to far-end of welding wire 140 overheated.In other exemplary embodiments, stretch out Distance can be bigger, particularly when using the consumptive material of larger diameter.For example, in some exemplary embodiments, outreach Can be in 0.75 inch to 2 inch range.Certainly, in some other embodiments, it is possible to use longer overhang.

Turning now to Figure 10, depict another example system 1000, within the system, contact tip assembly 1010 energy Enough not only one root wire 140/140 ' is transported to workpiece 115.Increase in material manufacture operation at some, it would be desirable to for not Same manufacture part utilizes different welding wires.System 1000 allows to depend on manufacturing desired and carrying out between different welding wires Switching.Although it is not shown, but every root wire 140/140 ' could be attached to the wire feeding device of their own thus in manufacture process In advance as required, corresponding welding wire 140/140 ' of retracting.Therefore, in the fabrication process, controller 195 can be by contact point End assembly 1010 is located so that suitable welding wire for manufacturing.For example, it may be desired to be the using and there is the first characteristic One consumptive material 140 builds base, and then has, to the interpolation use of that base, the layer that the welding wire 140 ' of different qualities makes, from And realize desired manufacture result.For example, based on desired Fabrication parameter, welding wire 140/140 ' can have different big Little, shape and/or constituent.Although it should also be noted that contact tip assembly is shown as having only two root wires 140/ 140 ', but the enforcement of the present invention can utilize contact tip assembly or by contact tip separately thus provide any amount of not Same consumptive material.Embodiments of the invention are not limited in this respect.

Additionally, the contact tip assembly 1010 in Figure 10 is shown as so that welding wire 140/140 ' is on-insulated each other.At this In class embodiment, suitable welding wire is advanced to workpiece 115 so that deposition, and so, the electric current from power supply 170 will be drawn Turn on that root wire-thus cause deposition.When welding wire is to be changed, while another root wire is contracted, advance another root Welding wire, so makes current path now by another root wire.In other exemplary embodiments, contact tip assembly 1010 Can be constructed such that welding wire 140/140 ' is electrically isolated from one.In this kind of embodiment, it is possible to use as being discussed with regard to Fig. 7 Switching.In some exemplary embodiments, laser beam (not shown in Figure 10) can be by being scanned between two root wires The Energy distribution affecting or otherwise changing between welding wire 140 and 140 ' in molten bath.

Contact tip assembly 1010 can be come real relative to the positioning of workpiece 115 and movement by any amount of device Existing.Definitely, it is possible to use any of robot or kinetic control system are without deviating from the spirit or scope of the present invention.Also It is exactly, it is possible to use any of device or method (including robot system) position suitable welding wire 140/140 ', and And it can be controlled by controller 195.For example, contact tip assembly 1010 can include three or more different welding wires And can be similar to be rotated and be positioned to allow for utilize known computer numerical control (CNC) the machining head of proper implements Construction and utilization.This kind of system and control logic can be with in an embodiment of the present invention to provide institute's phase of desired welding wire The positioning hoped.

The welding wire that embodiments of the invention use has the concrete size manufacturing operation needs and chemical composition.Typically, Welding wire has circular cross-section, and other embodiments are not limited in this respect.Other exemplary embodiments can be based on manufacture method Utilize the welding wire with noncircular cross section with manufacture process.For example, welding wire can have polygon, avette or oval shape Shape thus realize desired manufacturer's standard.Circular cross section welding wire can have in 0.010 inch to 0.045 inch range Diameter.Certainly, if it is desired to, it is possible to use bigger scope (for example, up to 5mm), but as diameter increases, molten drop controls May become more difficult.Owing to using laser instrument described herein and method for heating and controlling, embodiments of the invention can To provide point-device manufacture.The embodiment utilizing smaller diameter welding wire is especially true, as at 0.010 inch to 0.020 English In the range of very little.By using this kind of minor diameter, it is possible to achieve big DPI (per inch molten drop number) ratio, thus provide pin-point accuracy and Detailed manufacture.The chemical composition of welding wire is selected to provide manufactured parts desired characteristic.Further, utilized Welding wire can have real core or metal-cored configuration.Flux-cored wire may be used for producing composite material structure.It is, for example possible to use tool Have aluminium sheath and the flux-cored wire of aluminum oxide core.

It should further be noted that because technique described herein does not use electric arc, the great majority of the present invention should With any kind of protective gas will do not needed.But, in some applications it can be desirable to be use protective gas prevent Oxidation, or for other purposes.

Figure 11 depicts the still another example embodiment of the present invention.Figure 11 shows embodiment class as shown in Figure 1 As embodiment.But, in order to clearly, not describe some parts and connection.Fig. 1 depicts system 1100, wherein, heat sensing Device 1110 is for monitoring the temperature of welding wire 140.Heat sensor 1110 can be temperature any known that can detect welding wire 140 Type.Sensor 1110 can contact or could be attached to most advanced and sophisticated 160 to detect the temperature of welding wire with welding wire 140.At this Invention further exemplary embodiment in, sensor 1110 be use can detect wisp (such as the diameter of filler wire, And do not contact welding wire 140) the laser beam of temperature or the type of infrared beam.In this kind of embodiment, sensor 1110 is positioned Become the temperature stretching out place's detection welding wire 140 allowing at welding wire 140, it is, between the end and molten bath at tip 160 Certain point.Sensor 1110 also should be positioned such that not sense bath temperature for the sensor 1110 of welding wire 140.

Sensor 1110 is attached to sensing and control unit 195 (being discussed with regard to Fig. 1), so makes temperature feedback believe Breath can be provided to power supply 170 and/or laser power supply 130, so that optimize the control to system 1100.Example As power or the output electric current of power supply 170 can be adjusted at least based on the feedback from sensor 1110.It is, at this In inventive embodiment, user can input desired temperature arrange (for given manufacture operation and/or welding wire 140) or Sensing and control unit 195 can set desired temperature and then based on other user input datas (electrode type etc.) Sensing and control unit 195 will at least control power supply 170 to maintain that desired temperature.

In this kind of embodiment, can explain before welding wire 140 enters molten bath owing to impacting the laser beam 110 of this welding wire And it may happen that welding wire 140 heat.In an embodiment of the present invention, the temperature of welding wire 140 only passes through control via power supply 170 Electric current in welding wire 140 controls.But, as explained above, in other embodiments, the heating of welding wire 140 at least certain Part can come from impinging upon the laser beam 110 at least a portion of welding wire 140.So, electric current or the work(from power supply 170 Rate cannot individually represent the temperature of welding wire 140.So, utilize sensor 1110 can help by control power supply 170 and/or Laser power supply 130 regulates the temperature of welding wire 140.

In further exemplary embodiment (also figure 11 illustrates), temperature sensor 1120 can be directed to sense Survey the temperature in molten bath.In this embodiment, the temperature in molten bath is also coupled to sensing and control unit 195.But, at another In exemplary embodiment, sensor 1120 can be attached directly to laser power supply 130.Feedback from sensor 1120 is used for The output of control laser power supply 130/ laser instrument 120.It is, the energy density of laser beam 110 can be corrected to guarantee Realize desired bath temperature.

It in the exemplary embodiment further of the present invention, not that sensor 1120 is guided to molten bath, this sensing Device can be guided to the region adjacent with molten bath of workpiece 115.Definitely, it would be desirable to guarantee to be input to and deposition position The heat putting adjacent workpiece 115 is minimized.Sensor 1120 can be positioned so that this thermally sensitive region of monitoring, So make at deposition position adjacent, be less than threshold temperature.For example, sensor 1120 can with monitoring workpiece temperature and based on Sense temperature and reduce the energy density of beam 110.This kind of configuration will ensure that the heat input at deposition position adjacent does not surpasses Cross desired threshold value.This kind of embodiment can be used in the very important accurate manufacture operation of the heat being input in workpiece.

In another exemplary embodiment of the present invention, sensing and control unit 195 could be attached to feeding force detection Unit (not shown), this feeding force detector unit is attached to wire feeder (not shown, but see 150 in Fig. 1).Feeding force detects Unit is known and detects the feeding force putting on this welding wire when making welding wire 140 be sent into workpiece 115.For example, this kind of Detector unit can monitor the moment of torsion that wire feeding motor in wire feeder 150 applies, and therefore monitoring and welding wire 140 far-end and The parameter that the contact of workpiece 115 is related to.In conjunction with electric current and/or voltage monitoring, this may be used for stopping after touching molten bath Wire feed, thus allow molten drop D to separate.Certainly, as previously indicated, controller 195 can only use voltage and/or electric current sense Survey and detect contacting and (if desired) can be used alone this information when contacting between welding wire 140 and molten bath Stop wire feed.

In still further illustrative embodiments, sensor 1120 may be used for the big of the molten bath area on detection workpiece Little.In this kind of embodiment, sensor 1120 can be heat sensor or vision sensor and for monitoring the limit in molten bath Edge, thus monitor size and/or the position in molten bath.Then, controller 195 uses the weld pool resonance detecting to control as above institute The operation of the system stated.

It is further that herein below provides with regard to the control to the heating pulse that various embodiments of the present invention can use Discuss.As previously mentioned, when the far-end of welding wire 140 contacts with molten bath/workpiece 115, voltage between the two may be at Or close to 0 volt.But, in other exemplary embodiment of the present invention, it is provided that be in the electric current of this kind of level, thus The voltage level obtaining higher than 0 volt is made not produce electric arc.By utilizing higher current value, can make welding wire 140 with Faster speed reaches a high temperature, closer to the fusion temperature of welding rod.This allows to carry out more quickly manufacture process.In the present invention Exemplary embodiment in, power supply 170 monitoring voltage, and when voltage reaches or close to voltage higher than 0 volt at certain point During value, power supply 170 stops electric current flowing to welding wire 140 to guarantee not produce electric arc.At least partially due to the welding wire being used The type of 140, threshold voltage level generally will change.For example, in some exemplary embodiments of the present invention, threshold voltage Level is at or below 6 volts.In another exemplary embodiment, threshold level is at or below 9 volts.Further In exemplary embodiment, threshold level is at or below 14 volts, and in additional exemplary embodiment；Threshold level is in Or it is less than 16 volts.For example, when using mild steel weldinmg rod, the threshold level of voltage will be relatively low type, and be used for stainless steel The welding wire manufacturing can deal with higher voltage before producing electric arc.Therefore, this kind of system can be with monitoring voltage and pass through Voltage and voltage set point are compared to control heating electric current, so make to exceed electricity when voltage exceedes or predicts During pressure set point, cut off or reduce electric current.

In still further illustrative embodiments, not being maintained below the voltage level such as upper threshold value, voltage maintains behaviour In the range of work.In this kind of embodiment, it may be desirable to voltage is maintained above minimum, so that it is guaranteed that sufficiently high electric current comes Welding wire is maintained or close to its fusion temperature, but less than making certain voltage level, so make not produce electric arc.For example, Voltage can be maintained in 1 to 16 volt range.In still further illustrative embodiments, voltage is maintained at 6 to 9 volts In the range of.In another example, voltage can be maintained between 12 to 16 volts.Certainly, desired opereating specification can To be affected by the welding wire 140 for manufacturing operation, so make to be at least partially based on for the scope (or threshold value) of operation The feature of the welding wire being used or the welding wire being used selects.When utilizing this kind of scope, the lowest limit of scope is set to weldering Silk can fully be deposited over the voltage at place in molten bath, and the upper limit of scope is set to avoid the electricity of generation electric arc Pressure.

As previously described, when voltage exceedes desired threshold voltage, heating electric current is cut off by power supply 170, so Make not produce electric arc.Therefore, in this kind of embodiment, can be based on ramp rate that is predetermined or that select (or multiple slope speed Rate) drive electric current, until reaching voltage threshold and then electric current is cut-off or reduces to prevent from forming electric arc.

In above-mentioned many embodiments, power supply 170 comprises the circuit for monitoring and maintaining voltage described above.This species The construction of the circuit of type is known for industry personnel.But, traditionally, this kind of circuit has been used to tie up voltage Hold higher than a certain threshold value for arc-welding.

As explained before, heat electric current to be monitored by power supply 170 and/or regulate.As an alternative, except prison Surveying beyond a certain level/amperage feature of voltage, power or voltage, this also can complete.It is, electric current can be driven To or maintain desired level guaranteeing that welding wire 140 is maintained at suitable temperature to be correctly deposited in molten bath, but Again below electric arc generation current level.For example, in this kind of embodiment, voltage and/or electric current are monitored to guarantee any one Or both within the specified range or be less than desired threshold value.Then, power supply 170 regulates supplied electric current to guarantee not produce electricity Arc, but maintain desired operating parameter.

In the exemplary embodiment further of the present invention, heating power (V × I) also can be monitored by power supply 170 And regulation.Definitely, in this kind of embodiment, the voltage and current for heating power is monitored thus maintains desired electricity Put down or in desired scope.Therefore, power supply not only regulates voltage or the electric current reaching welding wire, but also can regulate electric current With voltage.In this kind of embodiment, upper threshold level or Optimum Operation can be set to the heating power of welding wire Scope, so makes power be maintained below threshold level or (be similar to above with respect to voltage discussion in desired scope Scope).Again, threshold value or scope are arranged the feature based on welding wire and the manufacture being carrying out, and can be at least part of To based on selected filler wire.For example, it may be determined that have 0.045 " optimal power of the mild steel arc welding electrode of diameter arranges In the range of 1950 to 2,050 watts.Power supply will regulate voltage and current, so make power be driven to this operation model Enclose.Similarly, if power threshold is set at 2,000 watt, then power supply will regulate voltage and current, so that power water Put down and be less than but close to this threshold value.

In the further embodiment of the present invention, power supply 170 comprises monitoring heating voltage (dv/dt), electric current (di/dt) And/or the circuit of the rate of change of power (dp/dt).This kind of circuit is commonly referred to as pre-inductive circuit, and its ordinary construction is Known.In this kind of embodiment, the rate of change of voltage, electric current and/or power is monitored, if so making rate of change Exceed a certain threshold value, then the heating electric current to welding wire 140 is closed.

In other exemplary embodiment of the present invention, go back monitoring resistor change (dr/dt).In this kind of embodiment, monitoring The resistance of the welding wire between contact tip and molten bath.As explained before, with welding wire heating, it starts neck-shaped and shrinks and this Can produce formed electric arc trend, at this moment between period, the resistance of welding wire exponentially increases.When detecting that this increases, As described above, the output of power supply is turned off to guarantee not produce electric arc.Embodiment regulation voltage, electric current, or both with guarantee weldering The resistance of silk is maintained at desired level.

Figure 12 depicts the example system 1200 that may be used for providing heating electric current to welding wire 140.(it should be noted that In order to clearly, be shown without Optical Maser System).System 1200 be shown with power supply 1210 (this power supply can be with such as Fig. 1 Shown in the similar type of power supply 170).Power supply 1210 can have known welding/heating power supply construction, such as converter type Power supply.It because known when the design of this kind of power supply, operation and construction, is not discussed in detail them herein.Power supply 1210 wraps Containing user input 1220, this user input allows user input data, including but not limited to: wire types, gage of wire, Desired power level, desired welding wire temperature, voltage and/or current level.Of course, it is possible to utilize other to input as required Parameter.User interface 1220 is attached to receive user input data and uses this information to be that power model 1250 produces required behaviour Make the CPU/ controller 1230 of set point or scope.Power model 1250 can be any of type or construction, including inverse Become device formula or transformer type module.It should be noted that certain parts can also found out on controller 195 in these parts, Such as user input 1220.

CPU/ controller 1230 can determine desired operating parameter by any amount of mode, searches including use Table.In this kind of embodiment, CPU/ controller 1230 utilizes input data (for example, gage of wire and wire types) to determine defeated Go out the desired current level (suitably heat welding wire 140) of end and threshold voltage or power level (or voltage or power can The opereating specification accepting).Will be at least based on input parameter this is because welding wire 140 is heated to the electric current needed for proper temperature. It is, aluminium welding wire 140 may have a lower fusion temperature than mild steel arc welding electrode, and it is thus desirable to less electric current/work( Rate carrys out filler wire 140.Additionally, the less welding wire 140 of diameter is by current/power less for the welding wire that needs diameter group bigger. Further, as manufacturing speed increases (and correspondingly deposition speed), the current/power level needed for filler wire may be more High.

Similarly, CPU/ controller 1230 use is entered data to determine be used for operation voltage/power threshold and/or Scope, so makes to avoid producing electric arc.For example, for the mild steel arc welding electrode with 0.045 inch, can have 6 to 9 volts Voltage range, wherein power model 1250 is driven thus is maintained voltage between 6 to 9 volts.In this kind of embodiment, Electric current, voltage and/or power are driven thus are maintained 6 volts of minimum of a values, and it guarantees that current/power is sufficiently high thus suitably adds Hot weld bar, and voltage is kept at or below 9 volts to guarantee not produce electric arc and the fusing temperature less than welding wire 140 Degree.Certainly, other set point parameter (voltage, electric current, power or the change of resistance speed) also can be according to expectation cause CPU/ control Device 1230 processed sets.

As indicated, the positive terminal 1221 of power supply 1210 is attached to the contact tip 160 of system, and the negative terminal of power supply It is attached to workpiece W.Therefore, heat electric current be provided to welding wire 140 by positive terminal 1221 and pass through negative terminal 1222 Return.This kind of configuration is well-known.

Feedback sense lead-in wire 1223 is also attached to power supply 1210.This feedback sense lead-in wire can be with monitoring voltage and by inspection The voltage measuring is transported to voltage detecting circuit 1240.Voltage detecting circuit 1240 is by the voltage that detects and/or detects Voltage changing rate conveys to the CPU/ controller 1230 of the operation of correspondingly control module 1250.For example, if be detected that Voltage be less than desired opereating specification, then CPU/ controller 1230 instruction module 1250 increase its output (electric current, voltage and/or Power), until the voltage detecting is in desired opereating specification.Similarly, if be detected that voltage at or greater than Desired threshold value, then CPU/ controller 1230 instruction module 1250 is cut to the electric current flowing of most advanced and sophisticated 160, so that do not produce Electric arc.If voltage drops below desired threshold value, then CPU/ controller 1230 instruction module 1250 supply curtage, Or both to proceed manufacture process.Certainly, CPU/ controller 1230 can maintain with instruction module 1250 or supply expectation Power level.Of course it is possible to use similar current detection circuit, and in order to clearly be shown without.This kind of testing circuit is Well-known.

It should be noted that testing circuit 1240 and CPU/ controller 1230 can have and the controller 195 shown in Fig. 1 Similar construction and operation.In an exemplary embodiment of the present invention, sampling/detection rates is at least 10KHz.In other examples In property embodiment, detection/sampling rate is in the range of 100KHz to 200KHz.

In each figure in Fig. 1 and Figure 11, in order to clearly, show separately laser power supply the 130th, power supply 170 and Sensing and control unit 195.But, in an embodiment of the present invention, these parts can be integrated in individual system.This Bright each side does not needs the parts that maintain individually discussion the same with independent physical location or stand-alone configuration.

In some exemplary embodiments above-mentioned, system can be used for combining cladding as above by this kind of mode and melt Drip melt applies.It is, in construction workpiece fabrication, can not require that there is high accuracy construction, for example, support lining creating always At at the end.At this construction phase, it is possible to use hot weld silk cladding process.This kind of technique (and system) is in the U.S. the 13/th Being described in 212, No. 025 applications, this application is incorporated by with it by quoting herein.More properly, the application is complete Entirely being incorporated herein, its degree uses hot weld silk system to melt for This application describes in cladding or other kinds of overlay-operation The system of compress material, using method, control method etc..Then, when expecting that more accurate cladding method constructs workpiece, control Device 195 is switched to molten drop cladding method as above.Controller 195 can control system described herein to be come according to need Molten drop deposition to be utilized and cladding deposition techniques realize desired construction.

Above-described embodiment can realize high speed molten drop deposition.For example, embodiments of the invention can be at 10Hz to 200Hz model Enclose and realize molten drop deposition.Certainly, operating parameter is depended on, it is possible to achieve other scopes.In certain embodiments, operation is depended on Some parameters in parameter, molten drop deposition frequency can be higher than 200Hz.For example, the welding wire being relatively large in diameter will generally use and be less than The deposition frequency of 200Hz, and welding wire as less in the diameter in 0.010 inch to 0.020 inch range can realize faster Frequency.Other factors affecting molten drop deposition frequency include laser power, workpiece size and shape, welding wire size, welding wire class Type, gait of march etc..

Figure 13 depicts another exemplary embodiment of the present invention, and wherein, multiple consumptive materials can be simultaneously by deposition.Institute Showing in embodiment, four consumptive materials are by deposition.But, embodiment is not limited in this respect, because any number can be utilized Amount.In this kind of embodiment, owing to single pass can accelerate the construction of workpiece with the multiple consumptive material of deposition.As retouched further below State, it is possible to obtain other advantages of this kind of configuration.

As shown in example system 1300, contact tip assembly 1305 accommodate multiple contact tip the 1303rd, 1303 ', 1303 ", 1303 " ', wherein each by consumptive material the 140th, 140 ', 140 ", 140 " (difference) be transported to the workpiece created.Institute Showing in embodiment, each contact tip in these contact tips is electrically isolated from one, so makes each contact tip to connect Receiving has the independent current waveform being ready to use in deposition.For example, as shown in example system 1300, power supply is electrically coupled to each contact Most advanced and sophisticated, in order to be provided separately and control the current waveform for each consumptive material.As noted, system is not shown in this drawing Controller 195.But, system 1300 can include such as aforementioned controllers 195 herein, and this controller controls the behaviour of each power supply Make and this operation.In the embodiment shown, power-supply system 1310 is shown with different independent power module P.S.#1 To P.S.#4 (the 1311st, the 1312nd, 1313 and 1314), wherein each power-supply system can export different electric currents and carrys out deposition consumptive material. Each electric current in these electric currents can be similar to example waveform described herein, has different parameters etc..Enter one Step ground, the mode that each power supply in power supply 1311-1314 can be similar with the power supply being discussed herein in connection with Fig. 1 to Figure 12 It is constructed and operate.In some exemplary embodiments, each power supply in power supply 1311-1314 can be single power-supply system Single power module in 1310, for example, in single housing.In other exemplary embodiments, in power supply 1311-1314 Each power supply can be independent and different power supplys, these power supplys can link each other so that its operation synchronization and its other party Formula controls its operation.

In operation, system 1300 can be passed through the multiple layer of single pass deposition thus create workpiece in substrate S.At figure In the embodiment of 13, each consumptive material 140-140 " ' creating individual course L#1, L#2, L#3, L#4, wherein each consumption below Material is just being to create layer on the top of layer above.This is by making most advanced and sophisticated 1303-1303 " ' on as directed direction with each other one Cause to complete.During deposition, leading consumptive material 140 is deposited in substrate S, thus creates ground floor L#1, and consumptive material below 140 ' depositions are on previous layer L#1, thus create second layer L#2, etc..In order to allow to create these layers, contact tip group Part 1305 can deposition at various height, these contact tips are relative to substrate S surface at various height.Such as institute in Figure 13 Showing, these contact tips have staggered or step form, thus allow to stack these layers.In other exemplary embodiments, These contact tips can be in same level relative to this surface, but the outreach of consumptive material can be appropriately adjusted to realize Desired layer stack is folded.

In an exemplary embodiment of the present invention, the spacing between consumptive material (on direct of travel) is for making succeeding layer permissible It is configured appropriately on the layer of deposition before.In the exemplary embodiment, this spacing is so that consumptive material is not deposited over same melting Chi Zhong.It is, consumptive material below not with molten bath contact above.But, corresponding molten bath on workpiece with adjacent one another are.Also Be exactly, in the exemplary embodiment, although molten bath is adjacent one another are or close, but its puddle not with contact with each other.Certainly, melt Pond can be in different elevation levels (for example, seeing Figure 13), and the temperature of the deposit between molten bath can be very high, but melted Part does not contacts each other.

Although it should be noted that not figure 13 illustrates, but system 1300 can also use foregoing exemplary such as to implement Described in laser instrument or heat input system.Definitely, system 1300 can use laser instrument to create molten metal bath and/ Or help to melt consumptive material.In some exemplary embodiments, single beam can be directed to each single consumptive material deposition Process, and can be independently controlled for each corresponding deposition process.These single beams can be by single laser Emitter produces, or can come from single laser beam emitting device, but is divided into via optics and laser beam splitter etc. A plurality of single beam.Each single consumptive material 140 to 140 " ' deposition can be controlled as aforementioned.Alternately, exist In other exemplary embodiments, it is possible to use during deposition between consumptive material rasterized thus be each consumptive material deposition mistake Journey provides the single laser/calorie source of desired heat input.For example, the rasterized arrival of laser beam each consumptive material 140- 140 " deposit ', and be controlled in the interaction time of each consumptive material position to realize for the operation of each deposition Desired heat inputs.

In an exemplary embodiment of the present invention, the type of consumptive material 140-140 " ', size and constituent are based on institute's phase The characteristic hoped selects.In certain embodiments, in these consumptive materials 140-140 " ', each consumptive material is identical, has phase Same diameter and constituent.But, in other exemplary embodiments, these consumptive materials can have different characteristics.For example, Consumptive material 140-140 " ' can have different diameters, so makes by using different diameter consumptive materials, and layer L#1-L#4 is permissible It is fabricated to that there is different width.And, these consumptive materials can have different constituent thus allow to create differently Side has the workpiece of different physics/composition characteristics.In this kind of embodiment, the constituent of the workpiece being manufactured is permissible " at a gallop " change.It is, the first material may be used for making some contact tips-of some part-use of workpiece and Then not making system stop can be according to expectation deposition difference or additional materials.

For example, the exemplary embodiment of the present invention is used for the mixture of stainless steel and mild steel to manufacture structure Or workpiece.It is possible to further build this class formation with interpolation nickel material.Certainly, these are merely exemplary, and this Inventive embodiment allows the mixture of multiple material to build desired structure.In other exemplary embodiments, for various Reason, including the measurement of workpiece, nonmagnetic substance/metal tape or layer can add on workpiece.Different materials also can be used In by material Zhuan Bianchengshi body stainless steel.

In addition to the different qualities/type of consumptive material, embodiments of the invention can be by different wire feed rate conveying consumptions Material 140-140 " '.It is, in certain embodiments, the wire feed rate of all consumptive materials is identical.But, implement at other In example, it would be desirable to change wire feed rate.This can via controller 195 and consumptive material corresponding wire feed system (in order to Clearly, not shown) complete.By changing corresponding wire feed rate, the physical characteristic of the workpiece created can be affected. For example, it may be desired to be at least one layer thinner than other layer having in layer L#1 to L#4.In this kind of embodiment, more The wire feed rate of the corresponding consumptive material of thin layer can be slowed, thus produces thinner layer.

And, in the exemplary embodiment, different current waveforms can be provided to consumptive material 140-140 " '.In shown system In system 1300, there is the multiple single power module 1311-1314 that corresponding deposition electric current is provided to consumptive material.Implement at some In example, in these electric currents, each electric current can be identical, and in other embodiments, current waveform can different-have different Frequency, peak current level etc..When using different wires feed rate and/or different consumptive materials to guarantee correct deposition, meeting It is this situation.

By changing consumptive material 140-140 " ' in the deposition aspect of arbitrary consumptive material, the creation that system 1300 is layer L#1-L#4 carries Supply notable flexibility.It is, in the exemplary embodiment, types of consumables, constituent, wire feed rate and deposition electric current Any one or a combination thereof in waveform can be different relative to another consumptive material, in order to realize the desired of layer or deposition process Characteristic.Therefore, embodiments of the invention allow sizable flexibility and precision with the construction of any overlay of consumptive material Fast Construction or construction workpiece.It is, based on using different deposition/consumptive material characteristics, different layers can have different Thickness, width, shape etc..

Figure 14 depicts another view of the system 1300 shown in Figure 13.As shown with discussed above, contact point End 1303 and 1303 ' is installed to orient according to expectation, hold and contact tip assembly 1305 that moving contact is most advanced and sophisticated.Further Ground, as discussed above, contact tip is retained under staggered or step pattern to allow self to create layer-such as institute Show.In this kind of embodiment, the overhang X of corresponding consumptive material the 140th, each consumptive material in 140 ' be maintained in totally identical away from From.But, in other embodiments, this needs not be this situation.It is, each consumptive material the 140th, 140 ' outreach X Can be different to realize that desired deposition shows.In fact, in certain embodiments, the 1303rd, contact tip 1303 ' can be consolidated Determine into and make its corresponding distal face coplanar with each other relative to the surface of substrate S.In this kind of embodiment, when layer L#1, L#2 press During according to shown being constructed, the outreach X of consumptive material (for example, 140 ') below is by less than the consumptive material before each (for example, 140)。

Further, as indicated, in certain embodiments, contact tip is the 1303rd, 1303 ' in contact tip assembly 1305 It is moveable.In this kind of embodiment, actuator mechanism 1320 (such as roller, actuator etc.) may be used for contact tip 1303rd, 1303 ' be movable into and out contact tip assembly 1305 in case provide the desired overhang of workpiece being constructed and/ Or geometry.Actuator 1320 can also be controlled (not having in Figure 14) by controller 195, so makes the contact tip can be Move " at a gallop " during deposition.For example, during deposition, the relative altitude of contact tip and/or the swinging radius of consumptive material The desired geometry of the workpiece being manufactured can be adjusted to achieve from X.Various ways as above can be used Produce this movement.For example, servo control mechanism, motor control roller, linear actuators etc. may be used for desirably moving contact point End.This kind of control enhances the flexibility of the manufacturing capacity of system 1300.

It should be noted, although Figure 13 and Figure 14 depicts contact tip assembly 1305, so make consumptive material and advance/molten Applying direction consistent, contact tip assembly 1305 can also be oriented to laterally configure, in the configuration, contact tip with and row Enter on the vertical line in direction.It is, these contact tips can be side by side to provide wide material deposition.In this kind of embodiment, Consumptive material is adjacent one another are rather than self deposition as shown in figure 13 and figure 14.Certainly, in other exemplary embodiments In, contact tip assembly 1305 may be oriented so that these contact tips are angularly oriented relative to direct of travel.This Inventive embodiment is not limited in this respect.

Figure 15 depicts another exemplary embodiment, and wherein, contact tip assembly 1305 is relative to the row of deposition process It is also rotatable for entering direction.As shown in this top-down view, in primary importance A, such as institute in Figure 13 and Figure 14 Show, consumptive material deposition in line.As contact tip assembly 1305 continues on, it is rotated to new position B, so makes The deposition of layer changes shape, as shown.Contact tip assembly 1305 can be controlled by any known devices and method and revolve Turn, as (for example, robot welding being used for controlling/promoting by using stepper motor, motor or any other known system Those systems that are mobile and that rotate).Controller 195 may be used for control contact tip assembly 1305 relative to substrate S rotation/ Mobile.By making assembly 1305 rotatable, the shape of workpiece can be created as required.For example, the wall thickness of workpiece can basis Need to increase/reduce.Further, in assembly 1305 rotary course, for the wire feed rate of any consumptive material, current waveform, Any one or a combination thereof in overhang and/or contact tip position can be adjusted.For example, as shown in Figure 15, in place Before putting A, in consumptive material, only one of which consumptive material is created a layer L#1 by deposition, as shown.This can be the leading consumptive material in assembly. When assembly 1305 turns to, the second consumptive material 140 ' starts by deposition for second layer L#2, so makes deposit L#2 be attached to And add on ground floor L#1.This can fall, and is not to add less desirable height, but only increases and created The width of workpiece.Similarly, when assembly 1305 rotates to desired position B, follow-up consumptive material 140 " and 140 " ' class can be used Like mode with start deposition in order.Similarly, this motion may be used for creating lug on workpiece or overhangs, without For outer outstanding additional support.In this kind of embodiment, the rotation of assembly 1305 and to consumptive material arbitrary in consumptive material or all consumptions The adjustment (as mentioned above) of the deposition of material can allow relatively easily to create overhangs.For example, to feed rate and/or overhang/ The adjustment of contact tip depth localization can allow relatively simply to create lug.

Therefore, system 1300 substantially increases the manufacture flexibility of increasing manufacture process described herein and system.

Figure 16, Figure 17 A-C and Figure 18 A depicts the substrate 1600 that method and system described herein can use Exemplary embodiment.Substrate 1600 is conduction, in order to provides current path for deposition electric current/waveform, but also has non-adherent Property surface 1610, so make after completing manufacture process, workpiece removed from substrate 1600 relatively easy.

Typically, in increasing material manufacture, the workpiece constructing is placed on substrate or the surface of conduction, in order to be consumptive material Heating electric current provides correct current path.But, because substrate is conduction (that is, metal), workpiece becomes to glue with substrate Knot.It is, in the initial fabrication processes of workpiece, the layer initially created becomes to adhere on substrate via deposition process.Cause For this, need additional process step to remove workpiece from substrate and some substrate materials may be removed from final workpiece Material.Which add the additional potential risk processed and produce and damage workpiece.Those skilled in the art it should be understood that , between workpiece and substrate, generally there is generation when fusing, so make from workpiece in the bonding between workpiece and substrate Adulterant district on substrate of the material of material and substrate in mix, consistent with joining technique.Embodiments of the invention solve This problem.

Figure 16 depicts the illustrative substrate 1600 being made of an electrically conducting material, and this conductive material allows electric current to flow through this lining The end, but prevent workpiece 110 to be bonded on this substrate.For example, in some exemplary embodiments, this substrate can be by copper or graphite Make, copper or graphite but will not bond with aluminium or steel workpiece.In the exemplary embodiment, substrate 1600 can be made into For having the matrix of multiple different materials.For example, substrate 1600 can be made up of non-conductive pottery or clay matrix of materials material, This host material has and is distributed in pottery or the intramatrical conduction of clay (for example, metal) material thus creates conductive path. As shown in Figure 16, non-conductive matrix 1603 has the conductive particle 1605 spreading all over this non-conductive matrix, can be formed from surface 1610 to the current path-can be connected to this earth point from the lead-in wire of power supply of earth point 1625.In some exemplary enforcement In example, substrate 1600 can be mainly pottery, and wherein copper particle 1605 spreads all over distribution, and having enough copper amounts provides permission electricity Stream is delivered to the copper density of another position of substrate from the surface of the work of substrate, and ground connection or current cable are fixed to this another Position.Can be the conductive material 1605 of copper can be powder, granular, string-like or belt shape.But, conductive material should be distributed Become conductive path is formed as from surface 1600 to earth point 1625.Earth point 1625 can be positioned at appointing on substrate 1600 Where square.It should be noted that in some exemplary embodiments, conductive material there is no need to be evenly distributed on whole substrat structure In 1600, but it should fully be distributed on whole surface of the work 1610 thus provide current path, from the beginning of this current path, Workpiece is positioned on substrate surface 1610 or starts on it.Host material 1603 can be any material or will not Combination with the material of workpiece bonding.These materials can be nonconducting and have high melting temperature, so that at table During forming workpiece on face, the surface of matrix 1603 will not be melted.As indicated above, host material can be glutinous Any one in soil, pottery or a combination thereof.Other materials can include cast iron that carbon content is high or ought increase from the teeth outwards Become any other fragile alloy during material process.As described above, increase material process there is relatively low (if any) admixture, Therefore alloy would is that minimum from substrate to the propagation built body.But, propagate so that the ground floor building body becomes Obtain fragile, and still conduct electricity simultaneously.When building body and completing, fragile interface then can be bent and fracture by user easily Thus construction body and substrate are separated.As indicated above, ceramic material may be used for substrate.This kind of pottery should have Gao Rong Change temperature, such as Al₂O₃, or other similar potteries.In another example, aluminum or alloy can serve as mild steel and build body Substrate.

In still further illustrative embodiments, substrate can be made up of metal dust, the density that this metal dust has Substrate is made to provide desired conductance and physical support for building body workpiece.In this kind of embodiment, once complete, it is possible to Knock out powder from building body part easily.In further exemplary embodiment, substrate can be by being placed on electrically non-conductive material Conductive layer on (such as pottery, it can have in submount material or can not have conductive material) base (for example, copper, carbon, Iron etc.) composition.By using thin layer in submount material, can make to be reduced to minimum to the degree of penetrating of substrate, so that it is guaranteed that not It is bonded to substrate.

As shown in Figure 16, in some exemplary embodiments, substrate 1600 can have contact zone 1620, conductive material It is present in this contact zone, and outside this contact zone, there is not conductive material, or the scope existing is less, so makes substrate 1600 outside contact zone 1620 less conductive or non-conductive.In this kind of embodiment, workpiece 110 originates in or is placed in surface On 1610, so make this workpiece contact so that it is guaranteed that sufficiently make electrical contact with contact zone 1620 because in contact zone 1620 it Outer will exist minimum conductance or there is not conductance.In this kind of embodiment, the area that contact zone 1620 has is less than surface The area of 1610.Further, contact zone 1620 can be shaped as any desired shape.Therefore, in the exemplary embodiment, In order to start to increase material manufacture process, this process starts in the contact zone 1620 on surface 1610 to guarantee to there is the electric current for workpiece Path.When constructing workpiece 110, as long as workpiece is made into as one integral piece (therefore having constant current path), workpiece multiple Part just can be formed on surface 1610 outside contact zone 1620.Therefore, current path will be provided for manufacture process always, And workpiece 110 can be fabricated on the conductive surface 1610 not bondd with workpiece 110, thus allow to easily remove and process Workpiece.

Figure 17 A depicts another exemplary embodiment, and wherein substrate 1600 has the lattice 1630 of conductive material, this crystalline substance Lattice create network on the surface 1610 of substrate 1600.Lattice 1630 is made of an electrically conducting material, such as copper, is embedded into In the material of substrate 1600 (it can be pottery, clay or other electrically non-conductive materials).Lattice 1630 can be formed to make Must form network on surface 1610, so such that regardless of the size having workpiece 110 to be formed or orientation how, workpiece By at least certain part of contact lattice 1630 to provide required conductive path.Lattice 1630 width of mesh to be had is to be The size staying in the workpiece made on substrate 1600 is had to provide required spacing.In certain embodiments, lattice 1630 can have Having a degree of depth penetrating substrate 1600, and in other embodiments, the degree of depth of lattice 1630 differs the saturating substrate of direct puncture 1600.Further Ground, lattice structure 1630 is formed so that this structure is conduction all over, so such that regardless of workpiece where with lattice Structure 1630 contacts, and has the power path to earth point 1625.Further, in the exemplary embodiment, lattice structure 1630 Can be only present in the contact zone similar with regard to the contact zone described by Figure 16 in substrate 1600.It is, be exposed to Lattice structure under surface 1610 is only in the zone of dispersion on surface 1610 (that is, contact zone) and this lattice is attached to earth point 1625.In this kind of embodiment, as long as certain part of workpiece and contacts with a part for lattice 1630 in contact zone, then deposit At current path thus allow manufacture workpiece.But, again, because surface 1610 major part is nonconducting and non-adhesive , compared with known substrate, the removal of workpiece and processing are easy.

Figure 17 B shows another exemplary embodiment of the substrate 1600 can being used together with device herein. In this embodiment, substrate 1600 includes the multiple discrete earth point 1651/ being distributed on whole substrate 1600 region 1652/1653 etc..These points can be distributed in pattern, such as lattice pattern, so makes the control of the system of any this substrate of use Its corresponding position known by device processed.These earth points are made of an electrically conducting material, and can be electric wire, pin etc., and permissible Through substrate 1600, each of which is so made also to be exposed on another surface of substrate 1600.Reality shown in Figure 17 B Executing in example, these earth points pass through substrate 1600, and other the ends exposed that so makes them is on the basal surface of substrate 1600. In other embodiments if desired, other ends can come from side.Earth point the 1651st, the 1652nd, every in 1653 etc. Individual earth point is electrically coupled to switching circuit 1660, and this switching circuit is also electrically coupled to the power supply of system and is electrically coupled to control Device, this controller controls the operation of the earthed switch in circuit 1660 as described below.Because the position of earth point is known , increasing material process can start on one of these earth points (for example, 1651), and this point is used as to increase the initial ground of material process Path.Once this process starts, and can move molten bath along surface 1610 until this molten bath reaches next earth point 1652.Cut Changing circuit 1660 can allow controller to be switched to the earth point of building course from ongoing increasing nearest the connecing of material process Place.It is, when the contact tip of this process moves, earth point can be switched to provide apart from nearest the connecing of this operation Path, ground.Further, in other exemplary embodiments, switching circuit 1660 can open more than one grounding path, logical Cross multiple earth point, thus increase the magnitude of current that may be used for this process.Further, in the exemplary embodiment, switching electricity Road 1660 may be used for Ground current path redirecting to different positions to control deposition process.For example, when building course connects During the edge of nearly substrate 1600, switch 1660 can be switched to from the center of substrate 1600 closer to earth point to help control Deposition process and molten bath.This can be also used for the direction helping to control electric arc, and its degree is for causing any electricity during deposition Arc.

Figure 17 C shows the further exemplary embodiment of the present invention, and wherein substrate 1600 farther includes to electrically connect All earth points the 1651st, the 1652nd, 1653 etc. wire 1670, and wire 1670 is attached to power supply, makes the ground connection of deposition electric current Path is complete.In this kind of embodiment, it is not necessary to use switching circuit 1660 as above.In the embodiment shown, wire Conductive plate on 1670 surfaces being mounted to substrate 1600 or conductive layer, all earth points are attached to this conductive plate or conduction Layer.Certainly, wire 1670 does not needs on the bottom, it is also possible on another surface of substrate 1600.In the process of use In, when construction structure contact more than one earth point 1651 grade, guiding line 1670 provides additional ground path, thus again permits Permitted to use in this process more current.In any embodiment in the embodiment above, for the controller/electricity of deposition process Source can control deposition current level, in order to less than the acceptable current level of arbitrary earth point.It is, building When journey starts, if only using an earth point 1651, then electric current is controlled such that current level is less than single earth point The acceptable level of 1651.To this end, earth point may be damaged.But, when building body and proceeding to additional ground point, Since the additional ground point of contact-and because the grounding path quantity to wire 1670 increases, controller can cause current level Rise.Therefore, in this kind of embodiment, because the position of each earth point known by controller, when utilizing multiple earth point, in It is that controller can increase electric current.In this kind of embodiment, with contacting each corresponding earth point, deposition electric current can be with increment Ground increases, or when contacting appropriate number of earth point, deposition electric current can increase in a single step.For example, for 200 The deposition electric current of ampere, controller may determine that (information using storage) this kind of current level needs minimum 4 earth points.Control Device/power supply processed can utilize the first relatively low current level (for example, 50 amperes) until at least 4 earth points of contact, now, molten Deposited electric current increases to optimal level.In other embodiments, when contacting each new earth point, electric current can incrementally increase Add, until the earth point that contact is needed for minimum.For example, for each follow-up earth point, electric current can increase by 50 amperes, until Reach desired deposition current level./ pre-programmed electric current increase step can be made a reservation in the controller of system.

In an exemplary embodiment of the present invention, earth point is electric wire or pin, and these electric wires or pin have more than institute The average diameter of the average diameter of the gage of wire using.In the exemplary embodiment, earth point is to have ratio to be used The pin of the average diameter of big gage of wire big at least 20%.In some exemplary embodiments, diameter is in diameter group maximum The diameter of welding wire big 20% to 80% in the range of.Further, as shown in fig. 17 c, pin can have bigger head Region, as indicated, be used for and workpiece supplementary contact.It is, these pins have bigger head in the contact surface of substrate Region (for example, as nail etc.), sees such as Figure 17 C.In the sense that pin 1651 etc. has shape as shown in fig. 17 c, When considering the average diameter of pin as discussed above, do not account for bigger head zone.

In still further illustrative embodiments, earth point 1651 grade (for example, pin, electric wire, bar etc.) is at substrate 1600 In be removable and interchangeable.For example, as shown in fig. 17 c, these pins only reside in the hole in substrate and fill When above-mentioned earth point.By admixture, these pins are fixed on workpiece, build body as it, and then after completing, Workpiece is removed together with these fixed piece on earpieces.It is then possible to remove these pin/bars etc. via machining process, and newly Pin can be placed in substrate 1600, for next process.Removable pin 1651 etc. should have enough length Degree, thus contact with the workpiece being built on substrate and with contact plate 1670, so that form correct ground connection electricity Flow path.

Figure 18 A depicts the exemplary embodiment of the present invention, and wherein, substrate 1600 comprises at least one cooling duct 1640, by this at least one cooling duct, in manufacturing workpiece fabrication, or at least in workpiece initial fabrication processes, can To transmit cooling medium.Cooling medium can be gas or liquid and for substrate is maintained at uniform temperature, so makes All parts of substrate 1610 do not melt, or are otherwise adhered on workpiece.By via cooling manifold/passage 1640 make for cooling down substrate 1600, it is cool that substrate 1610 can be kept, and on surface 1610 any conduction material Can to be kept be cool to material (for example, lattice structure, conductive particle etc.), the workpiece so making to be formed on surface 1610 Any layer will not melt, or otherwise bonds with the conductive component on surface 1610.Other embodiments can use Other cooling means/techniques are without deviating from the scope of the present invention or spirit.It is, for example possible to use passive heat pipe.

Therefore, in the exemplary embodiment, providing substrate, this substrate provides required conductance, but also provides non-stick Knot property surface, so makes workpiece be easier to after the fabrication remove and processing.

Figure 18 B depicts another structure again that exemplary increasing manufacture process described herein can use.This The manufacture process that increases described in Wen may be used for manufacturing complicated and exquisite workpiece.The simple system of parts (such as these parts) Making can be by starting manufacture process from non-level conventional substrate or operation surface and getting help.For example, it may be possible to it is favourable It is the workpiece manufacturing suspension arrangements.It is, workpiece can be more easily manufactured, wherein, the initiation layer/deposition of workpiece layer is to hang , so make them start from the bottom of substrate to extend, contrary with tradition bottom-up flat surfaces substrate.In Figure 18 B Shown embodiment depicts the exemplary truss structure 1800 that can use in these cases.Truss structure 1800 can have Having multiple support member 1810 and 1820, these support members electrically connect each other, thus allow electric current to flow.Truss structure 1800 It is configured so that according to expectation, workpiece can start at any point in structure 1800 for given workpiece.For example, If upside down or manufacturing workpiece from technique from top to bottom to be easier to, then this part can be at component 1810 and 1820 Point on one of is started and is built downwards by technique described herein.Certainly, the truss structure being currently in use and weldering Lamp/contact tip should be designed such that these tips are properly positioned on truss structure 1800.Then, as required, this portion Divide the surface that can be built into downwards substrate 1600 from structure 1810/1820.As indicated, truss structure 1800 can have it certainly Oneself ground connection contact point 1825, or can be simply and conduct electricity all over.Further, in some exemplary embodiments In, truss structure can have the contact protrusion 1830 starting to build operation, and a part of beginning of workpiece is fixed to these and connects Synapses rises.These projections 1830 serve as the contact node that the beginning of workpiece is fixed to the upper.These projections are so that more Easily start manufacture process and so that be easier to separate last part and truss structure, and manufactured by not destroying Part.These projections 1830 can be formed integrally with these parts 1810/1820 of structure 1800.In other embodiments, this A little projections 1830 can be made from a variety of materials and/or can easily separate with structure.For example, projection 1830 can be to have head The pin of portion or jut or other fastener type parts, a part can be fixed on this head or jut and open Begin to be used for manufacture process.After completing, these pins can be removed from truss structure, thus allow to easily remove manufactured Part.Truss structure 1800 can use any desired shape or be configured to the manufacture process giving.

In the exemplary embodiment, truss structure 1800 can be the metal structure allowing electric current to be delivered to substrate 1600, This can be any embodiment in above-described embodiment.In other exemplary embodiments, truss structure can be closed by such as above The non-adhesive that is broadly described in Figure 16 and Figure 17 but the material of conduction are made.Under any circumstance, structure 1800 should be constructed Become it can be provided to the current path of substrate 1600 or earth point 1825, thus allow correct heating current flows.

Figure 19 A, Figure 19 B and Figure 19 C illustrate the increasing material system that embodiments of the invention described herein can use Make the exemplary embodiment of consumptive material 1900.Should summarize and be understood by, the big real core consumptive material of diameter needs more electric current/energy Fusing consumptive material.But, the less consumptive material of diameter needs less electric current/energy to melt, so make to need less electric current/ Energy fluence melts collective and has the less consumption of many diameters of the area of section identical with the single solid core welding wire being relatively large in diameter Material.Therefore, the volume that the consumptive material used in some exemplary embodiments of the present invention is made up of the welding wire 1903 of many woollen yarn knittings Knot consumptive material 1900.In certain embodiments, these welding wires 1903 are identical, have identical diameter and constituent.But, at it In his exemplary embodiment, welding wire 1903 can be different from each other.For example, in certain embodiments, two kinds of different wire types May be used for making woollen yarn knitting consumptive material 1900.In this kind of embodiment, these welding wires can based on diameter and/or constituent not With.For example, middle cored welding wire can have the first diameter and the first constituent, and periphery welding wire 1903 has Second bobbin diameter and Two constituents, Second bobbin diameter and the second constituent both of which are different from this first diameter and the first constituent.This allows The consumptive material 1900 with customization characteristic is used to come for special manufacture process.It should be noted that described herein for The method and system of the real core of deposition or medicine core consumptive material may be used for deposition woollen yarn knitting consumptive material, woollen yarn knitting consumptive material as shown in figure 19.

Further, in shown in fig. 19 a embodiment, middle cored welding wire 1903 ' is non-woollen yarn knitting welding wire, and neighboring weldering Silk 1903 woollen yarn knitting is around middle cored welding wire 1903 '.Can the length with spirality pattern generally, along consumptive material 1900 compile Knot.

In some exemplary embodiments, the woollen yarn knitting of consumptive material 1900 may be used for increasing the relative wire feed speed of types of consumables Degree.For example, as shown in figure 19, middle cored welding wire 1903 ' can be the first kind/material, and welding wire 1903 around can be Different type/materials.Because cored welding wire is longer, for the given length of consumptive material 1900 in the length ratio of (outside) welding wire around Degree, effective deposition speed of every corresponding wire types is different.The effectively relative deposition speed of different wire types is also Can be affected by the relative populations of wire types in given molten bath.Therefore, embodiments of the invention allow to improve deposition chemistry The flexibility of composition.

Figure 19 B to Figure 19 C depicts another exemplary embodiment of the consumptive material that embodiments of the invention can use.So And, different from the consumptive material 1900 in Figure 19 A, the consumptive material 1900 in Figure 19 B and Figure 19 C has space 1910 at the core of consumptive material, In this space, core 1910 is surrounded by many woollen yarn knitting welding wires 1903.This hollow consumptive material construction allows consumptive material 1900 in deposition mistake Journey is extruded and " shaping ", in order to allow deposition process to be customizable.This is by explanation in further detail below.

The woollen yarn knitting of the welding wire 1903 forming the exterior section of consumptive material 1900 completes with spirality pattern generally, is similar to The welding wire braiding method known, but space 1910 maintains at the core of consumptive material 1900.Identical with Figure 19 A, in certain embodiments, Welding wire 1903 can have identical diameter and part, and in other embodiments, welding wire 1903 can have different Characteristic.Depicting this example in Figure 19 C, wherein, woollen yarn knitting includes the first welding wire class with the first diameter and constituent Type 1903 and second wire types 1905 with Second bobbin diameter and constituent.Certainly, in certain embodiments, even if welding The diameter of silk 1903/1905 is different, and constituent also can be identical.As shown in figure 19 c, different welding wires 1903/ 1905 replace around the cross-sectional perimeter of consumptive material 1900.In still further illustrative embodiments, these welding wires 1903/1905 can To have different fusion temperatures, different fusion temperatures can provide customization deposition profile and layering as required.

The size in space 1910 should be determined so that consumptive material 1900 ' keeps relative stability during deposition.If it is empty Gap is too big, and consumptive material can become unstable and will not maintain its integrality during deposition.In the exemplary embodiment, space The diameter of 1910 is in the range of the 5% to 40% of the effective diameter of consumptive material 1900 '." diameter in space 1910 " is to assemble The diameter of the greatest circle tee section in space 1910, as shown in broken circle in Figure 19 C." effective diameter " of consumptive material 1900 ' is Have and circle straight of area of section that the combined type area of section of all welding wires 1903/1905 of composition consumptive material 1900 ' is identical Footpath.

As indicated above, the consumptive material 1900 with center gap 1910 is shaped as permission change consumption during deposition The deposition characteristic of material.This has carried out general depiction in Figure 20 A and Figure 20 B, and wherein, consumptive material 1900 is relative to the traveling side of consumptive material To being extruded toward the direction, thus realize desired deposition width.As described in this article, the technique of the present invention and System may be used for being formed the shape of complexity via increasing material manufacture.Therefore, it can form workpiece and the shape with different-thickness Shape etc..Due to space, the consumptive material 1900 shown in Figure 19 B and Figure 19 C allows to form the shape of these complexity and different thickness. In Figure 20 A, consumptive material is extruded towards the direction vertical with direct of travel, and this makes consumptive material 1900 narrow relative to direct of travel. By doing so it is possible, the deposition producing is by more narrower than the green diameter of consumptive material.Similarly, Figure 20 B depicts same consumptive material 1900 court Being extruded along the direction of direct of travel, this causes makes consumptive material 1900 widen relative to direct of travel.So, this kind of squeezing is used Pressure, can form wider deposit as required.As set forth above, the size/diameter that space 1910 should have allows consumption Material 1900 deforms thus changes its relative width compared with its non-compressed state.

In some exemplary embodiments, space 1910 can be filled with the weldering of the desired chemical composition required for deposition Agent or powder.This can help to be not easily formed welding wire or the expectation can transmitted by filler wire to construction body conveying Material.For example, wear-resisting powder can be added as solder flux.

Figure 20 C depicts the contact tip assembly 2000 that embodiments of the invention can use and consumptive material induction system and side Another exemplary embodiment of method.In this embodiment, at least two consumptive material 2010 and 2020 is directed to contact tip Assembly 2000 and contact tip 2040, this contact tip has the hole 2030 allowing two consumptive materials to pass through.With above example not With consumptive material 2010 and 2020 is not knitted.They can be fed from same consumptive material source (bobbin, spool etc.) or can be defeated Send from single source.Further, they can be identical consumptive material, is of the same size and constituent, or root Desired according to given manufacture operation, can differ.In still further illustrative embodiments, can be at a different rate It is sent into consumptive material 2010 and 2020, and in certain embodiments, during deposition, feed rate can " at a gallop " change. This kind of embodiment allows customization during deposition to build the alloy of body.For example, during the Part I of this process, permissible It is sent into consumptive material 2010 and 2020 by identical speed, but in the different phase of building course, consumptive material 2010 slows down as desired Or accelerate, thus create desired deposit chemical composition.

Further, although show two consumptive materials, but as required, other embodiments can use three or more Consumptive material.In the embodiment shown, as known consumptive material induction system, consumptive material 2010 and 2020 is transported to hole 2030 (should Hole can be any other shape that is oval or that accommodate consumptive material) and it is then channeled to workpiece.In deposition process In, contact tip 2040 is oriented such that consumptive material provides desired deposition profile.Further, contact tip 2040 is can (as above-described embodiment) of rotating thus allow consumptive material to be directed and make shape or the profile of deposition process according to design Change according to expectation.For example, as indicated, the orientation on the left side shows the orientation being in line, this orientation will carry on workpiece For narrow deposit, but owing to consumptive material is in line towards direct of travel, height is increased.Then, as required, contact tip 2040 can be rotated to the position shown in the right.This rotation can be realized by controller 195 and motor etc., and can melt Apply in the change procedure of direction and use, without the orientation changing blowtorch.Being expert on direction when expectation increases the width of deposit When spending, it is possible to use positioning on the right.It should also be noted that in some embodiments, it may be possible to there is no need to be sent into two simultaneously Individual consumptive material 2010 and 2020.In this kind of embodiment, consumptive material 2010 and 2020 will be sent by single wire feeder (not shown) Enter, and controller 195 can control which consumptive material being sent in these consumptive materials, or whether they are sent into simultaneously.At this In class embodiment, the consumptive material not being sent to does not needs to draw back and therefore may be used for maintain the consumption being sent to from hole 2030 The positioning of material.In this kind of embodiment, the feeding of consumptive material can be controlled by controller 195, and this controller is by giving during the course Regularly carve any one consumptive material being sent into as required in these consumptive materials or two consumptive materials.

Further, in the embodiment shown in Figure 20 C, each consumptive material in consumptive material 2010 and 2020 shares same electricity Stream, because they are directed by single hole 2030.In this kind of embodiment, electric current can come from single power supply, and each Consumptive material shares electric current.But, Figure 20 D depicts a different exemplary embodiment.In embodiment shown in Figure 20 D, Contact tip assembly 2000 comprises two contact tip parts that can electrically insulate 2015 and 2025.Tip portion 2015 and 2025 points Shu Song consumptive material 2010 and 2020.But, assembly 2000 comprises can be by opening that tip portion 2015 and 2025 electrically connects each other Close device or mechanism 2050, so make these partial sharing electric currents, or can be by electrically isolated from one for these tip portions.? In exemplary embodiment, each tip portion in these tip portions 2015 and 2025 be attached to single power supply (PS#1 and PS#2).When switching 2050 and being in open position, each corresponding power supply can provide independent and different to corresponding consumptive material Heating electric current.In this kind of embodiment, consumptive material can carry out deposition according to different speed, and/or in size and constituent On can be different.This can be controlled and be used as the similar embodiment of the multiple consumptive material of above-mentioned use.But, in this embodiment In, as required, controller 195 can select switch, and now, contact tip part 2015 and 2025 electrically connects and can be total to Enjoy the single current signal from one of these power supplys P.S.#1 or P.S.#2.In this kind of embodiment, for given operation, can Can only need single power supply, thus reduce power and use and/or eliminate the needs to synchronizing signal.In this kind of embodiment, Switch 2050 can close, and so makes each tip portion in tip portion 2015 and 2025 can be coupled to each other now, So that consumptive material 2010 and 2020 shares the same signal from single source.When switching 2050 disconnection, these points Divide (via dielectric substance or other suitable means) electrically isolated from one, and if want two consumptive materials of deposition, then they will Receive single signal from single power supply.Alternately, certain point in deposition operating process, may be only it is desirable that need Want the single consumptive material of deposition.Therefore, only operate a power supply, but for safety purposes, switch 2050 is disconnected to consume another Material is isolated.Switching mechanism 2050 can be any construction of switch that can isolate and connect tip portion 2015 and 2025, and It is desirably integrated into tip assembly 2000, or according to expectation, may be located remotely from assembly 2000.

Turning now to Figure 21 A and Figure 21 B, show the representative contact tip assembly of the consumptive material 1900 using Figure 19 B The sketch of 1950.Figure 21 A and Figure 21 B shows the view that the exit portion at contact tip assembly 1950 looks up, Qi Zhongtu 21A is depicted at the consumptive material of non-compressed state, and Figure 21 B is depicted at the consumptive material 1900 of compressive state.It should be noted that Hereinafter the description of contact tip assembly 1950 is intended to exemplary, and those skilled in the art it will be appreciated that, its He configures and design may be used to consumptive material 1900 and shapes according to desired, thus realizes institute's phase in increasing material manufacture process The deposition hoped.

As indicated, contact tip assembly 1950 has consumptive material opening 1951, consumptive material passes through this opening.Although opening 1951 quilt Be illustrated as foursquare, but embodiments of the invention be not limited in this respect, as long as and consumptive material 1900 its compression and All can pass through under both non-compressed states, it is possible to use other shapes.In the embodiment shown, to have two right for assembly 1950 Contact piston 1953 and 1955.These pistons can move relative to opening 1951, as indicated, so make them extend to Opening is interior and therefore applies compression stress on consumptive material 1900.Contact piston 1953 and 1955 is oriented such that pair of pistons 1953 move towards the direction vertical with the moving direction of another group piston 1955.Therefore, as shown in figure 21b, piston 1953/ 1955 can towards desired direction extruding consumptive material 1900 thus realize desired shape.Often organizing piston can be via known Actuation means 1956 moves, such as linear actuators etc., and can be controlled by controller 195 (not illustrating in these figures).Enter One step ground, each piston 1953/1955 is configured for providing heating current waveform to consumptive material 1900, so makes heating electricity Flow through and these pistons are transported to consumptive material 1900.Although it should be noted that showing an actuator 1956 and partially in the drawings Pressure 1957, but for each piston, parts that exemplary embodiment will have like.

As shown in figure 21 a, during non-compressed state, each piston 1953/1955 contacts thus defeated with consumptive material 1900 Send heating electric current.Piston 1953/1955 is held in place relative to opening 1951, so that it is guaranteed that consumptive material 1900 maintains its nature Under state.Then, during deposition, determine that the width of (for example, passing through controller) consumptive material should change to realize desired Deposition configures, and as required, consumptive material should be made wider or narrower.Based on this information, controller 195 causes these pistons 1955 (via actuators 1956) activated and move inward thus compress consumptive material 1900 as shown in figure 21b.Additionally, in order to Adapting to the change in shape of consumptive material 1900, piston 1953 is drawn back into, thus allows the change in shape of consumptive material.But, in exemplary reality Execute the piston 1953 in example, being drawn back into still to contact with consumptive material 1900 thus consumptive material 1900 is retained on correct position and defeated Send heating electric current.

During deposition, the shape of consumptive material 1900 can move " by leaps and bounds " change by making piston, thus realizes Desired shape.For example, controller 195 can during deposition as desired to control piston 1953/1955 retract and Extending thus changing the shape of consumptive material 1900, leniently deposition to narrow deposition and returns again to, and does not stop deposition process.

As set forth above, the movement/actuating of piston 1953/1955 can be by realizing any known of desired motion Actuator, mobile device realize.In some exemplary embodiments, each of (not shown herein) corresponding piston pair is lived Plug can mechanically to each other link, and so makes its relative motion remain consistent each other.It in this kind of embodiment, not for each Piston has single actuator, and single actuator may be used for that each is corresponding right, and because mechanical linkage, each piston To suitably move.

Further, as indicated above, controller 195 can control piston based on there being intended shape to be constructed Activate.In still further illustrative embodiments, in deposition operating process, assembly 1950 can desirably carry out rotating with Realize desired shape.It is, assembly 1950 could be attached to electric rotating machine and/or robots arm, (or other are similar Telecontrol equipment) and controller 195 (or other system controller) assembly can be caused as required to rotate, and by these pistons In any activating piston thus realize desired consumptive material and therefore deposition, shape.

Figure 22 depicts another exemplary embodiment of the consumptive material 2000 that embodiments of the invention can use.Consumptive material The 2000 similar braided construction including welding wire 2003, have space 2010 as above, but also include sheath 2015.Protect Set 2015 can be constructed and be formed similarly to the known jacket structure for welding or brazing consumptive material.As indicated, at this In embodiment, sheath 2015 surrounds welding wire 2003 completely and has seam 2017, and it is abutment joint.Sheath 2015 can be by the phase Hope that any material being deposited on workpiece is made.In certain embodiments, sheath 2015 can be the material identical with welding wire 2003 Material, and in other embodiments, sheath can be made from a variety of materials/have different constituents.Sheath 2015 also may be used To help consumptive material 2000 to maintain its shape after it is re-formed by the piston in the contact tip assembly in Figure 21 A and Figure 21 B Shape.Definitely, welding wire is extruded sheath 2015 will be caused to be plastically deformed by hole 1951, thus causes consumptive material 2000 to be easier to protect Handle desired shape.This can allow the overhang of consumptive material 2000 to increase during deposition.

Figure 23 depicts another exemplary consumable part 2100 that embodiments of the invention can use.Consumptive material 2100 comprises to protect Set 2110 and core 2120, wherein, sheath 2110 has the fusion temperature lower than core 2120.By having this different fusing Temperature, the embodiment of consumptive material 2100 can provide the enhancing control manufacturing parts.At consumptive material from start to finish totally identical In temperature melting embodiment, the dynamic of the molten metal bath of generation plays an important role in deposition and building course.At certain Under a little situations, the control to molten bath can be difficult, particularly in high accuracy manufacturing process, or the workpiece in orthotectonics When thickness is very thin.In this type of application, weld pool dynamics can be difficult to control to and explain.But, when using consumptive material 2100, sheath 2110 melted before core 2120.Melted sheath material adheres to core material on workpiece in being to provide melted matrix.At this In class application, the importance in molten bath reduces, and in some cases, molten bath can be eliminated.Further, in substituting reality Execute in example, as molten bath and melted sheath material will work together to adhere on workpiece by core material, the size in molten bath and/or The degree of depth can reduce.So, when use consumptive material 2100 when, molten bath dynamically can be less important.

In the exemplary embodiment, core 2120 can be real core, and in other embodiments, core 2120 can be desired The powder of material or particle.In this kind of embodiment, it is desired that consumptive material 2100 can be shaped as (as discussed above) realization Deposition.It is, because core 2120 can be powder or granular, the exterior section of consumptive material 2100 can be formed and squeeze Pressure is to realize desired consumptive material profile.In an additional embodiment, consumptive material can be configured to and that at least shown in Figure 22 Individual identical, wherein, sheath is around many single welding wires, and wherein, and at least some (or all) in these welding wires 2003 Welding wire has the higher fusion temperature than sheath 2015.In fact, in some embodiments in this kind of embodiment, welding wire 2003 Relative to each other can have different fusion temperatures.For example, the root wire more than first in welding wire 2003 can have first melt Change temperature (being higher than sheath fusion temperature), and the root wire more than second in welding wire 2003 can have than these in welding wire 2003 The higher or lower fusion temperature of the fusion temperature of the first welding wire.This kind of embodiment can carry for the profile of fusing and construction consumptive material For the flexibility increasing.Further, in certain embodiments, thermal source (for example, laser instrument) and/or electric current are controlled, so At least certain part making core 2120 is also melted during deposition.But, in other embodiments, the material of core 2120 It is not melted during deposition.It is, sheath 2110 is melted, and liquid sheath material is for by unfused core Material is fixed on workpiece.In this kind of embodiment, create workpiece in a hierarchical manner, between melted sheath material and core material Alternately.Although it should be noted that Figure 23 depicts consumptive material 2100 has circular cross-section, but embodiments of the invention are in this regard not Restricted.Consumptive material 2100 can also have any desired shape desirably making the construction of workpiece be benefited.For example, consumptive material 2100 can have square, rectangle, polygon or elliptic cross-section.It is of course also possible to use other shapes.

In the exemplary embodiment, the material of sheath 2110 and core 2120 is selected such that sheath 2110 compares core being in Melt at a temperature in the range of the temperature low 5% to 45% of material.In still further illustrative embodiments, sheath 2110 is molten Change temperature in the range of the 10% to 35% of the fusion temperature of core material.Certainly, the material of each one definite in sheath and core Constituent should select based on the desired constituent of the workpiece built and construction.

Figure 24 A depicts another exemplary embodiment, and wherein, consumptive material 2200 has noncircular cross section, and sheath material Material 2210 not consumptive material 2200 whole around the periphery of extend.It is, consumptive material 2200 has asymmetric cross section.For example, In the embodiment shown, the position of sheath material 2210 is only in the side of core material 2220 of consumptive material.Figure 24 B depicts another This kind of exemplary embodiment, wherein, the overall shape of consumptive material is hexagon, and sheath material 2210 ' only covers core 2220 ' 5 limits of hexagonal cross-section.Certainly, desired performance and the deposition characteristic based on consumptive material, it is possible to use other shapes and covering Scope.Figure 24 C is another exemplary embodiment, it illustrates the consumptive material 2200 with symmetrical section ", but sheath material 2210 " and core material 2220 " distribution be not symmetrical.This configuration allows to use contact tip and is designed to typical The equipment of symmetrical consumptive material uses consumptive material, but consumptive material itself is asymmetric.In this kind of embodiment, sheath material 2210 melts And the core segment 2220 for consumptive material provides and adheres to, but not from surrounding's fusing of consumptive material.In this kind of embodiment, in deposition process Period, before adhering to, consumptive material can desirably be directed.Sheath material serves as core material combination or is bonded on workpiece Adhesion material.Further, in this kind of embodiment, electric current/heat input is controlled to ensure that reservation is desired and protects Cover material melts and not exclusively melts core material.

Figure 24 D is the consumptive material 2200 that embodiments of the invention can use " ' further exemplary embodiment.Except Restrictive coating 2210 " ' have beyond layered structure, consumptive material 2200 " ' it is similar to those discussed above consumptive material.In this kind of embodiment In, restrictive coating 2210 " ' can be solid material or can be solder flux.In fact, any in embodiment discussed above In embodiment, restrictive coating can be solder flux, rather than solid metal sheath.In those embodiments, in some applications, may In (or making fusing minimize) the solder flux sheath should not being melted during expecting material is placed at deposition process.In order to realize This situation, some embodiments use layering sheath/solder flux 2210 " group of the solder flux of the surface S of ', wherein, against core 2220 " ' Become composition different from the chemical composition of the outer peripheral solder flux at this solder flux.This is shown as layer A and layer B, wherein, layer A by Figure 24 D There is the first constituent, and layer B has the second constituent.The creation of these layers can be used without discussing in the text Known deposition technology.Such construction allows the material in layer B away from core 2220 " ' in direct heat, this will be with it Part in his mode melting zone B.For example, it may be desired to, tungsten carbide is deposited in molten bath, if they and core 2220 " ' directly contact, then it may easily melt.In this embodiment, layer A serves as heat buffering area, thus allows a layer B Material deposition and seldom melt or non-fusible.It should be understood, of course, that arrive, the division between two layer A and B needs not be clearly Precise linear, but can be from a kind of constituent to the transfer of another kind of constituent.Further, layer B is relative to layer A's Shape and relative cross-section area can determine based on the expectation constituent of this application.Figure 24 D is shown as exemplary enforcement Example, and other shapes and configuration can be used, without departing from the spirit or scope of the present invention.

Being attached to the user interface presentation one of computer can for support system and method described herein Can hardware configuration, including controller 195 or for controlling and/or operating the similar system of system described herein.In order to Different aspect for the present invention provides additional context, and following discussion aims to provide brief, summary to suitable computing environment and retouches State, the different aspect of the present invention can be realized in the computing environment.Those skilled in the art is it will be recognized that the present invention also may be used Realize to combine other program modules and/or the combination as hardware and software.It is said that in general, program module includes performing tool Body task or realize the routine of concrete abstract data type, program, parts, data structure etc..

And, those skilled in the art is it will be recognized that the inventive method can be come real by other computer system configurations Trample, including uniprocessor or multiprocessor computer system, microcomputer, mainframe computer and personal computer, hand-held Formula computing device, based on microprocessor or programmable consumption electronic product etc., wherein each can operatively couple To one or more devices being associated.The each aspect of the present invention shown can also be by passing through communication network in some task Practice in the DCE that the remote processing device of network link performs.In a distributed computing environment, program module was both May be located in local memory storage device and may be located at again in remote memory storage device.

Controller 195 can utilize exemplary environments for realizing the different aspect of the present invention, including computer, wherein, This computer includes processing unit, system storage and system bus.System unit is linked up by system bus, including but not It is limited to system storage is attached to processing unit.This processing unit can be any process in different commercially available processors Device.Dual micro processor and other multiple processor structures can also be used as processing unit.

If this system bus can be any one of bus structures of dry type, including memory bus or memory Controller, peripheral bus and the local bus using various commercially available bus architecture.System storage can include Read-only storage (ROM) and random access memory (RAM).Comprise to help as during start-up between the element in computer The basic input/output (BIOS) of the basic routine of transmission information is stored in ROM.

Controller 195 may further include hard disk drive, disc driver (for example, for reading from removable disk Take or be written to wherein) and CD drive (for example, be used for reading CD-ROM disk or read from other light media or write To wherein).Controller 195 can include the computer-readable medium of at least a certain form.Computer-readable medium can be Any available medium that can be accessed by computer.For example, but unrestrictedly, computer-readable medium can include calculating Machine storage medium and communication media.Computer-readable storage medium include where method in office or technology realize for storing information The volatibility of (such as computer-readable instruction, data structure, program module or other data) and non-volatile, removable and not Removable media.Computer-readable storage medium includes but is not limited to RAM, ROM, EEPROM, flash memory or other memory technologies, CD- ROM, digital versatile disc (DVD) or other light storage devices or may be used for stores desired information and can be by joining It is connected to any other medium that the user interface of controller 195 accesses.

Communication media generally implements computer-readable instruction, data structure, program module or at modulated data-signal Other data in (such as carrier wave or other transport mechanism) simultaneously include any information delivery media.Term " believe by modulated data Number " refer to the letter that makes one or more characteristics in its characteristic be set or changed in this mode encoding the information in signal Number.For example and without limitation, communication media includes wire medium (such as cable network or direct wired connection) and wireless Medium (such as acoustics, RF, infrared ray and other wireless mediums).The combination of any of the above described content also should include depositing at computer-readable In the scope of storage media.

Multiple program modules can be stored in driver and RAM, including operating system, one or more application journey Sequence, other program modules and routine data.Operating system in computer or user interface 300 can be multiple commercially available operations Any one operating system in system.

Additionally, user can be input to order and information in computer by keyboard and fixed-point apparatus (such as mouse). Other input units can include microphone, IR remote control, tracking ball, pen-based input device, control stick, cribbage-board, digitlization Flat board, satellite dish, scanner etc..These and other input units are frequently by the string being attached on system bus Row port interface is connected on processing unit, but (bus structures (such as parallel port, game port, are led to can to pass through other interfaces With universal serial bus (" USB "), IR interface) and/or different wireless technologys connect.Monitor or other kinds of display device Also system bus can be connected to via interface (such as video adapter).Can also be by long-range display procotol (long-range table Face agreement, VNC, X-Window system etc.) complete visual output.In addition to visual output, computer generally includes other Peripheral output devices, such as loudspeaker, printer etc..

Display can be received electronically by from processing unit for presenting together with being attached to the user interface of controller 195 Data.For example, display can be to present the monitors such as the LCD formula of data, plasma type, CRT formula electronically.Alternative Ground or additionally, display can present the reception data of hard copy format, such as printer, fax, plotter etc..Display is permissible Present data by any color and can to receive number from user interface via any wireless or rigid line agreement and/or standard According to.

Computer can use logically and/or physically connecting to one or more remote computers (such as remote computer) Operate under the networked environment connecing.Remote computer can be work station, server computer, router, personal computer, based on The entertainment electronic appliances of microprocessor, peer device or other common network nodes, and generally include with regard to computer description Many or all elements in element.The logic described connects and includes LAN (LAN) and wide area network (WAN).This kind of Net environment is quotidian in office, the computer network of enterprise-wide, intranet and internet.

When used in a lan networking environment, computer is connected to LAN by network interface or adapter.When being used for When in WAN networked environment, computer generally includes modem, or the communication server being connected on LAN, or has For at upper other devices setting up connection of WAN (such as internet).In networked environment, retouch with regard to computer or its some The program module painted can be stored in remote memory storage device.It it will be recognized that network described herein connects is Exemplary and other devices setting up communication link between the computers can be used.

Although the present invention of being described with reference to certain embodiments, but those of ordinary skill in the art it will be appreciated that Can make without departing from the scope of the invention and various change and replace equivalent.Furthermore, it is possible to carry out it is many Modification so that particular situation or material adapt to the present invention teach content without deviating from its scope.Therefore, the present invention is not intended to It is confined to disclosed specific embodiment, but the present invention will include all enforcements falling within the scope of appended claims Example.

Claims

1. one kind increases material manufacture system, comprising:

One high-energy rig, this high-energy rig irradiates a surface of a workpiece thus at the one of described workpiece with high-energy discharge A molten metal bath is produced on individual surface；And

One power supply, this power supply is to consumptive material welding wire one heating signal of supply, and wherein, described heating signal includes multiple electricity Stream pulse, and wherein, each current impulse in the plurality of current impulse in the deposition of described consumptive material in described molten bath Far-end on produce a molten droplets；

Wherein, each current impulse in the plurality of current impulse the described distal contact of described consumptive material to described molten bath it After reach a peak current level,

Wherein, there is no electric current between the plurality of current impulse in the plurality of current impulse for the described heating signal；

Wherein, the described far-end of described consumptive material between follow-up multiple peak current level of the plurality of current impulse not with institute State molten bath contact；

Wherein, described power supply control described heating electric current, so makes during the plurality of current impulse, described welding wire and institute State and between workpiece, do not produce electric arc；And

Wherein, described consumptive material has each in a jacket portions and a core segment, and wherein, described jacket portions has Fusion temperature less than the fusion temperature of described core segment.

2. the system as claimed in claim 1, wherein, described core segment is a real core.

3. the system as claimed in claim 1, wherein, described core segment includes in many root wires, and described many root wires At least some welding wire has the fusion temperature of the fusion temperature higher than described sheath.

4. the system as claimed in claim 1, wherein, described core includes in many single welding wires, and described many root wires Root wire more than first there is the fusion temperature of the described fusion temperature higher than described sheath, and in described many root wires Root wire more than two has the fusion temperature less than described sheath.

5. the system as claimed in claim 1, wherein, described core includes solder flux.

6. the system as claimed in claim 1, wherein, the described fusion temperature of described core is so that at least a certain portion of described core Divide non-fusible during the deposition of described consumptive material.

7. the system as claimed in claim 1, the described fusion temperature of described sheath is lower than the described fusion temperature of described core In the range of 5% to 45%.

8. the system as claimed in claim 1, the described fusion temperature of described sheath is lower than the described fusion temperature of described core In the range of 10% to 35%.

9. the system as claimed in claim 1, wherein, described consumptive material does not have circular cross-section.

10. the system as claimed in claim 1, wherein, described sheath not described core whole around the periphery of extend.

11. the system as claimed in claim 1, wherein, described consumptive material is asymmetric.

12. the system as claimed in claim 1, wherein, described sheath includes solder flux.

13. the system as claimed in claim 1, wherein, described sheath at least has a ground floor and a second layer, its In, described ground floor and described core direct neighbor, and described ground floor has the chemical composition different from the described second layer.

14. consumptive materials as claimed in claim 13, wherein, the described second layer includes tungsten carbide.

15. 1 kinds increase material and manufacture consumptive material, comprising:

One jacket portions；And

One core segment, this core segment is covered by described jacket portions at least in part,

Wherein, described jacket portions has the fusion temperature of the fusion temperature less than described core segment.

16. consumptive materials as claimed in claim 15, wherein, the one in described jacket portions and described core segment includes solder flux.

17. consumptive materials as claimed in claim 15, wherein, described consumptive material is asymmetric.

18. consumptive materials as claimed in claim 15, wherein, described jacket portions not described core segment whole around the periphery of Extend.

19. consumptive materials as claimed in claim 15, the described fusion temperature of described jacket portions is at ratio described in described core segment Fusion temperature low 5% to 45% in the range of.

20. consumptive materials as claimed in claim 15, the described fusion temperature of described jacket portions is at ratio described in described core segment Fusion temperature low 10% to 35% in the range of.

21. consumptive materials as claimed in claim 15, wherein, described core segment includes in many root wires, and described many root wires At least some welding wire there is the fusion temperature of the fusion temperature higher than described jacket portions.

22. consumptive materials as claimed in claim 15, wherein, described jacket portions at least has a ground floor and one second Layer, wherein, described ground floor and described core segment direct neighbor, and described ground floor to have a kind of and described second layer different Chemical composition.

23. consumptive materials as claimed in claim 22, wherein, the described second layer includes tungsten carbide.