WO2019137976A1 - Procédé et appareil de fabrication d'objets en métal - Google Patents

Procédé et appareil de fabrication d'objets en métal Download PDF

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Publication number
WO2019137976A1
WO2019137976A1 PCT/EP2019/050495 EP2019050495W WO2019137976A1 WO 2019137976 A1 WO2019137976 A1 WO 2019137976A1 EP 2019050495 W EP2019050495 W EP 2019050495W WO 2019137976 A1 WO2019137976 A1 WO 2019137976A1
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WO
WIPO (PCT)
Prior art keywords
wire
electrode
metal
metal wire
channel
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Application number
PCT/EP2019/050495
Other languages
German (de)
English (en)
Inventor
Pierre Joseph SCHMITZ
Original Assignee
Schmitz Pierre Joseph
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Schmitz Pierre Joseph filed Critical Schmitz Pierre Joseph
Publication of WO2019137976A1 publication Critical patent/WO2019137976A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K11/00—Resistance welding; Severing by resistance heating
    • B23K11/0013—Resistance welding; Severing by resistance heating welding for reasons other than joining, e.g. build up welding

Definitions

  • the present invention relates generally to a method and apparatus for making articles of metal.
  • Today's metal 3D printers prove to be complex, expensive and cumbersome devices. In contrast to the plastic FDM 3D printers, which already have a large number of people at home, they are unsuitable for the masses of people.
  • the available so-called desktop 3D printers can mainly produce only plastic objects with low strength and temperature resistance compared to metals. Printing a metal object for a wide variety of applications is too expensive and cumbersome for most people and therefore out of the question.
  • An object of the present invention is therefore to provide a method and a corresponding device with easy-to-use technique that allow to produce metal objects in good quality and strength and also are inexpensive.
  • a corresponding device should be relatively small and lightweight to space, building material and thus save costs.
  • This object is achieved according to the invention in a first aspect by methods for producing an article of metal a metal wire progressively in layers by means of a wire-carrying primary electrode in the resistance welding process stretched or spot welded,
  • a channel passes through which the metal wire is guided in the solid state and led out into or directly below the mouth of this channel through which the metal wire from the wire-guiding primary electrode, laid out on an adjacent metal surface and stretched or Welded pointwise
  • metal surface is a carrier plate, or a previously attached metal wire layer
  • the method further comprises, optionally, the step of:
  • step D passing a further electric current from a secondary electrode by means of steps (a) and (b) already stretched or point welded metal wire around this at least partially in addition, preferably on the entire in one or more of the steps (b) designed length to heat up and merge with the adjacent metal surface, ie To connect stronger by resistance welding or even to merge with this possibly completely melt it.
  • the metal wire is bent laterally during laying out at the mouth of the channel of the wire-guiding primary electrode during step (b). More preferably, the metal wire is bent at a very small centerline radius, eg 0.5 * q ⁇ centerline radius ⁇ 3 * q, where q is the diameter of a round wire or the width / thickness of a different shaped wire to make it flat by sliding over the lower one Apply contact surface of the wire-guiding primary electrode below the mouth of the channel, wherein the metal wire to the adjacent Metal surface, ie the support plate, or on a previously attached metal wire layer, placed.
  • a very small centerline radius eg 0.5 * q ⁇ centerline radius ⁇ 3 * q
  • the bending of the metal wire can be done on the one hand by guiding and friction along the mouth of the wire-guiding primary electrode.
  • the mouth may comprise or consist of a different material from the body.
  • the different material is a ceramic material or a different / different from the base metal.
  • the bending of the metal wire can also be done by heating the metal wire and moving the wire-carrying primary electrode.
  • the channel of the wire-guiding primary electrode can be closed laterally, i. be tubular. In other embodiments, however, the channel may also be open and correspond to a notch attached laterally to the body through which the metal wire is passed and which terminates in an orifice to the bottom surface of the wire-carrying primary electrode.
  • the mouth of the channel of the wire-guiding primary electrode preferably comprises an annular contact surface. Under such a contact surface of the metal wire can advantageously rotate around the orders in order to apply it in any direction of a plane can.
  • the contact surface is preferably configured such that it can transmit at least a portion of the current from the wire-guiding primary electrode to the metal wire.
  • the channel of the wire-guiding primary electrode is wider (in and short) above the mouth than the remainder of the channel so as to facilitate or allow the metal wire to bend, thereby ensuring that the wire-carrying primary electrode with the lowest contact surface can rest on the wire. More preferably, the wider portion extends for a length from the lowest end of the mouth of the channel as seen along the centerline of the channel, which may be between 0 and 4 * q, where q is the wire diameter of one round wire or the width / thickness of another shaped one Wire is.
  • the wire-carrying primary electrode may also apply the metal wire without resting on the bottom surface of the top of the metal wire.
  • the metal wire is preheated by means of a wire leading primary electrode upstream, second electrode by conducting a second current (shock).
  • the second electrode is preferably arranged inside the main body of the wire-guiding primary electrode.
  • the cross section of the metal wire may be round or any other shape.
  • An embodiment sees e.g. that before the introduction of the metal wire in the wire-guiding primary electrode whose cross-section, preferably by rolling, is changed.
  • the movement of the wire-guiding primary electrode relative to the carrier plate is designed so that it can be performed in three dimensions, wherein in step (b) either only the wire-carrying primary electrode, or only the carrier plate, or both are moved.
  • the primary electrode may be movable in only one (vertical, Z) direction, in which case the carrier plate is movable in the other two (X and Y) directions.
  • the carrier plate is firmly mounted and the primary electrode can be moved in all three directions.
  • step (d) a pressure is exerted on the heated metal wire to press the underlying, in the case of at least partially melted metal wire, metal wire flat, for example.
  • the electrical opposite pole of the secondary electrode is usually the carrier plate.
  • the opposite pole can also be one or more further counter-pole secondary electrode (s) which can be placed on the metal object.
  • the mouth of the wire-guiding primary electrode, if necessary, or the tip of the secondary electrode can be reground automatically if necessary, particularly preferably by means of a grinding surface adjacent (i.e., in the vicinity of the corresponding electrode and within the range of its movement unit).
  • the method may further comprise a step of additionally shaping the article of metal during and / or after its completion, e.g. by means of a movably arranged metal-removing tool, preferably a movably arranged grinding surface or a movably arranged milling cutter.
  • a movably arranged metal-removing tool preferably a movably arranged grinding surface or a movably arranged milling cutter.
  • the metal wire is usually a wire made of a metal or a metal alloy.
  • a metal wire additionally comprises a sheath with fusible solder material, wherein the solder material has a melting temperature which is expediently below that of the metal wire.
  • the invention relates to a device for producing articles of metal by progressively layered orders and
  • the device comprises means which are suitable for carrying out the method or are adapted / configured.
  • the invention relates to a device for the production of articles of metal by progressively layered orders and
  • Resistance welding of a metal wire comprising:
  • wire-guiding primary electrode for guiding and spot-wise or section-wise resistance welding of a metal wire, wherein the wire-carrying primary electrode is connected to the power supply
  • a carrier plate for receiving the article to be made of metal, wherein the carrier plate is connected to the power supply,
  • the secondary electrode being connected to the power supply
  • one or more movement arrangements which are designed / are the wire-guiding primary, if necessary and / or secondary electrode, and to move the support plate relative to one another in three dimensions,
  • a control unit for controlling the movement arrangement (s) and the power supply, wherein the main body of the wire-guiding primary electrode, a channel through which the metal wire in the solid state can be passed through to a mouth of the channel and in or directly below this mouth to a adjacent metal surface can be designed and spot or in sections welded, and wherein the metal surface is a support plate, or on a previously attached metal wire layer.
  • the mouth of the channel of the wire-guiding primary electrode preferably comprises a different material from the base body or consists of this, preferably a ceramic material or a different metal.
  • the mouth of the channel of the wire-guiding primary electrode may comprise an annular contact surface and be configured to transmit at least a portion of the current from the wire-guiding primary electrode to the metal wire.
  • the device further advantageously comprises a wire leading primary electrode upstream, the second electrode which is designed by conducting a second Power (shock) it to preheat the metal wire, wherein preferably the second electrode is disposed within the main body of the wire-guiding primary electrode.
  • a motorized feed is designed to guide the metal wire through the channel, preferably by adhesion via rollers to support.
  • the apparatus may further comprise rollers preceding the wire-guiding primary electrode which are adapted to change the cross-section of the metal wire prior to its insertion into the wire-carrying primary electrode.
  • the moving unit is preferably designed to move either only the wire-guiding primary electrode, or only the support plate, or both.
  • the opposite electric pole of the secondary electrode, the support plate or another on the object of metal can be placed opposite polarity secondary electrode.
  • an adjacently mounted grinding surface is provided which is suitable to regrind the mouth of the wire-guiding primary electrode or possibly the tip of the secondary electrode.
  • a movably arranged metal-removing tool advantageously a movably arranged grinding surface or a movably arranged cutter, which is suitable for additional shaping of the metal object during and / or after its completion and can be used if necessary ,
  • An inventive device herein in analogy to the known plastic FDM-3D printers, also called simply 3D printer, does not need an artificial protective atmosphere, so no protective gas, for printing with steel.
  • Different wires made of different metals or alloys can be used to "print" with a described 3D printer.
  • the price and geometrical dimensions of a device according to the 3D printing process described herein is only a fraction of a common model available on the market. Relatively large objects in comparison to the size of the 3D printer can be produced with the so-called 3D printing process according to the invention from metal wire.
  • the method in principle, involves the process of making an object layer by layer of wire of metal in an automated process.
  • the wire is passed through a primary electrode of a three-dimensional printer and placed on a platform (support plate) or an already created layer or part of an object and connected by electrical current in the resistance welding process.
  • the Electrode leading the wire, the wire and the carrier plate or build platform close a circuit when the wire makes contact between the electrode and the build platform.
  • the electrode has a channel through which the wire is passed. At the lower end of the electrode, where the wire is led out, there is a contact surface, which in principle is mostly directed parallel to the layer to be created.
  • the wire makes a bend through an angle, which in the ideal case is, for example, about 90 °.
  • the wire is then bent directly out of the mouth.
  • the lower, preferably annular contact surface of the wire-guiding primary electrode slides over the wire and delivers surges and preferably exerts additional pressure on the wire.
  • the electrode preferably does not rotate around itself in the manufacturing process, but only moves in the direction of the planes, for example.
  • the wire often forms the highest electrical resistance portion in the closed circuit during welding and is heated by the flow of current therethrough and can thereby make a metallic connection at the point of contact with the metal on which it is abutting.
  • the wire By moving, for example, the electrode to the build platform (or vice versa), the wire is placed below the mouth of the wire-guiding primary electrode in the plane of the layer to be created.
  • a channel in the wire-guiding primary electrode which is advantageously perpendicular to the plane of the layer to be created and thus the bend of the wire in the mouth of this electrode, for example, an angle of 90 °, the wire can in all directions in the plane of a layer as it were can be applied without the need for a self-rotating electrode driving the wire.
  • the wire with the primary electrode leading the wire through a channel and directly bending it can be easily applied in any way without the wire being pinned on top of other adjacent wire paths and blocking further jobs.
  • the wire webs can be completely melted and melt together to produce more isotropic objects. Strong connections can thus be made everywhere between the wire paths applied with the primary electrode.
  • the wire paths of, for example, standardized round wires can flatten through the secondary electrodes are melted and flattened to a flat plane on which in turn round wires can be accurately applied to the primary electrode. By such a fusion of the wire webs together disappears the pronounced groove pattern that would otherwise be present in cross-section almost unchanged stacked wires. The shape of the sheets of wire is thus changed by the welding process with the secondary electrodes.
  • the electrodes are attached to a printhead. At this cooling is preferably also attached, which consists for example of cooling fins to cool the electrodes.
  • the secondary electrodes generally use up in the welding operations and their lower contact surface can therefore be advantageously ground down step by step by sliding over a grinding surface which is fastened to the printer. This ensures a clean electrode surface at all times.
  • the electrodes are preferably interchangeable and advantageously there are various types of electrodes that can be used.
  • various metals and alloys can be "printed".
  • items made of steel, stainless steel or aluminum can be produced.
  • wire-guiding primary electrode With the wire-guiding primary electrode, very thin wires with a diameter of e.g. 0.1 mm can be applied precisely. By simply changing the primary electrode, other wires can be printed quickly and easily and there is a large variation in the diameter of the wires that can be printed with a printer device.
  • the primary electrode is particularly suitable for attaching the wire only slightly and applying it in a form-fitting manner.
  • the primary wire-guiding electrode may be stationary, that is to say rigidly connected to the frame of the 3D printer, or it may be movable. If the electrode is movably attached to the device, it is preferably driven by motors and sets the way back to apply the wire on the required lanes can. If the electrode is rigidly mounted, the build platform / carrier plate moves to apply the wire to the desired locations. Both the electrode and the build platform can be made as self-moving parts.
  • a material for the electrodes is a hard good electrically conductive material such as forged copper or a copper alloy or an electrode of a plurality of materials, which consists for example mainly of copper and the tip with the contact surface to the wire made of tungsten.
  • the copper provides better electrical and thermal conductivity properties and the harder material such as tungsten at the contact surface for a hard lower wear surface. It is good if the electrode pad has a high melting point to better withstand high heat, and a material where the wire is applied will not stick too much to the electrode when transferring current.
  • the controller (or control unit) of the 3D printer controls the so-called printing operation and gives the power supply the signals for current delivery.
  • the power supply of the primary wire-guiding electrode can also be separated from the motion control and operated independently, but this usually brings disadvantages. Also, the power supply of the primary wire-guiding electrode may be controlled partly by the overall control unit of the printer via the software and partly by hand-operated regulators on the printer with which one can easily change parameters such as the current during the printing process.
  • a round cross-section is suitable for the channel in the wire-carrying electrode through which the metal wire, the material is passed, so that a rotation of the wire in the channel of the electrode is possible.
  • Other cross sections are also possible.
  • the channel must be at least as wide as the wire being used and the channel should have a smooth surface and be as straight as possible so that the wire can be moved easily.
  • the wire coming out of it directly outside the wire-guiding electrode has a small cross section in relation to the rest of the circuit and a very high electrical resistance. Therefore, when strong electric current is conducted through the wire from the wire-carrying electrode, the wire directly under the primary electrode heats up strongly. By the resulting heat in the wire, the wire can melt locally or completely, or with the contact surface of the metal on which the wire is applied a punctiform or intermittent metallic compound received and thus connect with adjacent tracks of metal wire.
  • Particularly suitable is a round wire, because of its small point or line-wise contact surface facilitates the resistance welding.
  • the wire may also be fused at positions with the primary electrode at locations throughout the cross-section and fused with the layer to make solid connections.
  • the force pushing the wire through the wire-carrying electrode presses the wire against the surface on which it is applied.
  • the resting of the wire-guiding electrode on the wire is easily possible at the location of the lower mouth of the channel of the wire-guiding electrode should be enough space in which the bending of the wire, which is necessary to lay the wire flat in the plane , can be done.
  • the channel in the wire-carrying electrode is preferably wider than the width of the wire and in principle wide enough to allow the bend or the area at and just above the mouth of the channel is wider than the rest of the channel and shaped so that the bending of the wire can take place.
  • a push device which presses the wire through the wire-carrying electrode is also suitable.
  • Such a compressive force pushing the wire through the channel allows for smaller bending radii of the wire and thus more accurate application and less wear of the wire-carrying electrode because it does not have to exert lateral pressure on the wire to pull the wire out by relative movement of the electrode to the object to be created got to.
  • the electrode does not have to rest with the lowest surface at the level of the layer to be created.
  • the invention therefore also relates to a method which makes it possible to produce metal objects in an automated process by the layered orders of a metal wire with a wire-carrying primary electrode through which a channel passes through which the wire is passed and in or directly Below the mouth of this channel, where the wire is led out of the electrode, is bent at an angle which is approximately 90 ° in the ideal case so that it can be designed flat on a metal surface where it is applied by the current transmitted to it from the primary electrode in the resistance welding process for the most part cross-sectionally unmodified and is usually only slightly tacked.
  • the wire is applied by the layer-wise printing with the primary wire-guiding electrode in the correct locations according to the pattern of the respective cross-section of the object to be created.
  • Secondary electrodes continue to drive after a layer has been applied from adjacent mainly cross-sectionally unmodified wire webs, the layer automatically on, put on her in places and further weld the wire webs in the resistance welding process to make tighter connections.
  • the secondary electrodes can melt the wire paths under their contact surface completely to a flat, flat portion of fused together wires and flattening.
  • the contact surfaces of the secondary electrodes after a number of welding operations, due to wear of the contact surface by pressure welding, can be automatically abraded or abraded by a tool so that the contact surface maintains a good quality for the welding operations that it must perform.
  • the invention also preferably relates to a device, namely a so-called 3D printer, for producing objects made of metal, wherein the device comprises at least one primary wire-carrying electrode through which a channel passes, through which a metallic wire is passed in the solid state can emerge from the mouth of the channel and after a process of bending under the lowest surface of the primary wire-guiding electrode is pressed against the surface on which it is applied and by current transfer from the wire-carrying electrode to the wire in the resistance welding process with the metal surface which the wire is applied is connected.
  • the device preferably also has at least one secondary electrode, which put on the applied with the primary wire-guiding electrode webs of wire and these together with each other stronger in the resistance welding process.
  • the mainly cross-sectionally changed already designed with the primary wire-guiding electrode on adjacent tracks wire in cross-section can be changed by the plate-melting with the secondary electrode, so that the wire loses height and with the surrounding tracks of wire and the existing metal material of the piece which the wire is piled up can be fused.
  • the device can be operated with the following (replaceable) types of the electrode, or include the following further features: - With a wire-guiding primary electrode in which the lowermost surface is an annular contact surface which rests on the bent, out of the mouth of the channel of the electrode out, part of the wire and transmits most of the current from the wire-carrying electrode to the wire to weld it.
  • a wire-guiding primary electrode with a channel which is wider just above the mouth of the channel to space for the deflection of the wire in each direction in the plane as it allows to and so as to reliably apply the wire can.
  • wire-carrying primary electrode having an inner second electrode which can preheat the wire through the line of a second current flow therethrough.
  • Electrode pushes through and helps to bend the wire in or below the mouth of the channel.
  • roller wheel electrode as a secondary electrode whose contact surface for
  • Welding is continuously or automatically reground step by step.
  • the invention has one or more of the following advantages:
  • Heat for melting together which first passes at the contact points, accumulates particularly quickly in the material at the contact surfaces, so that they can merge together. Thus, several layers can be applied one above the other with the wire-guiding electrode and be fused in a welding process with the secondary electrodes.
  • the wire can be applied in any desired way in a layer that is created without the wire on other laterally adjacent wires with the center line above the the side-by-side wires are applied and welded thereto, which would hinder the wire application process and would most likely cause the rotation of the rolling wheel electrode to break because the spot weld is not directly below the axis of the rolling wheel electrode and therefore the unwanted one Welded on a laterally adjacent wire web would have to be torn to the rolling wheel electrode to apply the wire in another direction on.
  • the wire is not led into a molten bath where it then melts, but is line or layer by side or superimposed to create the geometry of an object in layers and is in the resistance welding procedure ß ⁇ on the contact surface to the surrounding wires interconnected, either with or without handling the liquid phase of the wire.
  • Fig. 1 shows an embodiment of a 3D printer with a primary wire-guiding electrode, with three secondary electrodes, with a build platform on which an object is stacked and with a attached to the printer housing grinding surface on which the contact surface of the secondary electrodes can be ground ,
  • Fig. 2 shows an embodiment of a printhead in applying wire to the primary wire-carrying electrode.
  • FIG. 3 shows an embodiment of a perpendicular channel primary lead wire electrode to the surface to which it applies a metal wire.
  • Fig. 4 shows an enlargement of the mouth of the channel of a primary wire-guiding electrode during the application of wire.
  • FIG. 5 shows a general embodiment of a primary wire-guiding electrode.
  • Fig. 6 shows an embodiment of a primary wire-guiding electrode having a lower portion with a contact surface for welding the wire, which is intended to be worn down and worn away during the printing process.
  • Fig. 7 shows an embodiment of a primary wire-guiding electrode with an inner second electrode for preheating the wire in the channel of the electrode.
  • Fig. 8 shows an embodiment of a primary wire-guiding electrode which, when applying a wire, does not rest on the wire with the lowest surface and does not exert downward pressure on the wire.
  • FIG. 9 shows an embodiment of a primary lead-wire electrode with a ceramic tip.
  • Fig. 10 shows an embodiment of a block in which secondary electrodes are mounted.
  • FIG. 11 shows an embodiment of a replaceable tip secondary electrode.
  • Fig. 12 shows another embodiment of a secondary electrode.
  • Fig. 13 shows an embodiment of a secondary electrode having a different contact material as the main part of the electrode.
  • Fig. 14 exemplifies the process of mounting and welding with a secondary electrode.
  • Fig. 15 exemplifies the process of welding with a secondary electrode in cross section.
  • Fig. 16 shows an example of a structure created from round in cross-section unchanged metal wires which were applied with a primary wire-guiding electrode.
  • Fig. 17 shows an example of a structure of metal wires fused together by the combination of the printing operation with the application of wire paths to a primary wire-guiding electrode and subsequent flat-melting with a secondary electrode.
  • Fig. 18 shows an embodiment four secondary bonded together
  • Electrodes for resistance welding with more focused heat development in the metal to be welded are Electrodes for resistance welding with more focused heat development in the metal to be welded.
  • Fig. 19 shows two opposed interconnected and electrically isolated electrodes for resistance welding with more focused heat development in the metal to be welded.
  • Fig. 20 shows a secondary electrode with a raster-shaped contact surface.
  • FIG. 1 shows an embodiment of an automated device, also referred to herein as a 3D printer, with the implementation of the following main components: the printhead 105 to which the primary lead-and-wire electrode 103 is attached, and the power cable 106 of the electrodes, the block 130 with the secondary electrodes 132, 133 and 109, the grinding surface 1 14, the build platform 101 with the attached to it power cable 107, and the housing 1 17 with built-in control unit and with integrated movement mechanism.
  • an article 102 is manufactured on the build platform 101 by the layer-wise deposition of the metal wire 104, which is thus the fabrication material.
  • the wire 104 for example a wire of stainless steel with a round cross-section, is unwound from a roll and moved by a stepping motor whose axis 1 12 drives a roll 1 10 mounted thereon between which and an opposing roll 1 1 1 the wire 104 is driven and is conveyed by the channel 302 of the primary lead-and-wire electrode 103 shown in FIG.
  • the wire-carrying electrode 103 is screwed into the printhead 105 moving in a plane parallel to the build platform 101 and is perpendicular to the channel 302 to the build platform 101.
  • the wire 104 will be partially within the channel or entirely outward below the mouth of the wirewound electrode channel 302 103 bent at a substantially right angle, in a very small bending radius, so that it is pressed flat against the surface of the previous layer and by means of electricity between the primary electrode 103 and the building platform 101 and the object 102, through the part of the wire 104 flows below the electrode 103, applied by resistance welding and welded.
  • webs of wire according to the pattern of the respective layer of the cross section of the object 102, are juxtaposed side by side for the most part with short current impulses only slightly attached.
  • the metal wire 104 is connected pointwise or in sections only in the fixed, mostly uninterrupted, state with the metal surface resting against it.
  • the wire webs applied with the primary wire-guiding electrode 103 are thus usually only weakly connected to one another and to the surface on which they are applied, and can easily be torn off from this surface without being torn.
  • the wire can be patterned as quickly, accurately and with great certainty and with little wear on the electrode 103.
  • Metal articles of only successive layers of coated round wire webs have lower strength and inferior mechanical properties in most directions, as compared to articles of isotropic and homogeneous structure, for example cast articles.
  • the secondary electrodes 132, 133 and 109 housed in the metal block 130 connected to the printhead 105 can locally approach the new layer consisting of wire paths Put on their surface and transfer pressure and current to the layer around the layer step by step continue to process in the resistance welding process, thereby substantially improving the properties of the object 102.
  • the secondary electrodes can fuse the wire webs of a layer, which are applied with the primary wire-applying electrode 103, in cross-section entirely unchanged, flatten them and allow them to fuse together to form a unitary part of the article 102 in which the secondary electrodes carry a strong local current flow guide them through.
  • the secondary electrodes wear off during the printing process.
  • the mostly existing standardized wires have a round cross section, this cross section is particularly suitable for printing by means of the primary and secondary electrodes, because the wire through the circular shape of the cross section has an increased electrical resistance in the direction perpendicular to the plane on which the wire is applied flat.
  • the round wire is located only with a very small area, so that the resistance welding process, the current flow and the heat generation is concentrated at the point where the wire rests, which allows the creation of a compound with relatively low current flow.
  • the round wires already deposited can easily be melted and deformed under the secondary electrodes because of their usually higher electrical resistance compared to the rest of the circuit and much less heat transfer from the wire to the electrode and the surface on which it is made rests, because of the very small contact surface. This, in turn, causes a lot of heat to quickly build up in the wire instead of being quickly drained, in which case the necessary melting temperature would not be achieved.
  • the wire can be changed and, if necessary, the support material can be removed, in addition, parts can be introduced to the objects created at locations which are no longer accessible after the printing operation. In addition, it can be determined via a sensor whether there is still wire on the coil.
  • the build platform 101 is linearly mounted on the rails 124 and is moved up and down by the stepper motor 128 which drives a spindle. Power to the build platform 101 could also be transferred via contact on an electrically conductive rail.
  • a display 1 19 and a knob 1 18 on the printer housing, can operate the device. The printer is connected to a power outlet.
  • Fig. 2 Printhead during printing - whole unit
  • Fig. 2 shows the part of the print head 105 of Fig. 1 with the wire 104 applying electrode 103 during the printing process of an object 205, a screw-on angle, with the wire-applying electrode 103, which moves relative to the build platform 206 and doing the wire 104 applies.
  • the print head 105 in FIG. 1 is mounted linearly on the guide rails 122. It is driven by stepper motors 127 via pulleys 126 moving belts 125, so that the position of the print head 105 can be adjusted to the build platform 101.
  • the roller 1 1 1 by a spring 204 which transmits a force to the Flebel 203, which in turn transmits a force on the roller 1 1 1, pressed against the wire 104.
  • the wire 104 is also pressed against the roller 1 10.
  • the force of the spring 204 on the Flebel 203 could be adjustable with a set screw.
  • the channel 302 of FIG. 3 inside the electrode 103, through which the wire 104 is passed, is substantially perpendicular to the building platform 206 and so also the wire-carrying electrode 103 in order to apply the wire 104 in all directions as it can.
  • the wire 104 is bent over, as here, by the angle of typically 90 ° so that it can be applied parallel to a layer and parallel to the surface of the build platform 206.
  • the construction platform is connected to the power cable 207 opposite to the wire-guiding electrode 103.
  • the rollers are arranged so that the wire driven between them is led directly into the channel 302 of the wire-guiding electrode 103. Therefore, the upper part 303 of FIG. 3, the wire-guiding electrode 103 is advantageously tapered and conically shaped.
  • the distance between the channel and the rollers is also properly adjusted.
  • the wire could also be passed into a thin channel and tapered tip portion which would be mounted between the wire-guiding electrode and the rollers, with any shape of the upper portion of the electrode 103.
  • the electrode 202 connected to the power cable 131 is an optional complement to the printhead 105 for preheating or preheating the wire 104 by passing a precisely adjustable current set by the system controller directs the wire 104.
  • the electrical opposite pole to the electrode 202 may be, for example, the build platform 206, the rollers 110 and 11 or the wire-carrying electrode 103.
  • preheating the wire 104 it becomes more ductile, less rigid, and may be softened, thereby making the wire more easily bent and the mechanical stress on the surface of the wire-applying electrode 103 is lower.
  • the electrical resistance of the metal wire 104 is higher with higher temperature, which has a positive effect on the welding process.
  • the wire between the rollers 1 10 and 1 11 could be rolled to achieve a different cross section of the wire.
  • additional rollers may be provided to allow the wire 104 to be pulled apart or rolled so that it becomes thinner.
  • the pressure on the wire 104 between the rollers could also be controlled by an attached motor to cause the wire to change its cross-section during printing with the wire-carrying electrode 103, for example to change the layer height, or to make layers of the wire 104 in places adapted to produce a rectangular cross-section which is not melted with the secondary electrodes in order to make the surface of the first layers freestanding, supported by support material sections cleaner and more easily separable from the lower support layer.
  • a wire-carrying electrode 103 may be used whose channel is coated with a flow and heat-insulating ceramic or glass layer. By annealing the wire tensions can be solved because of the winding of the wire on the coil, so the wire can be applied more easily.
  • wire-carrying electrode 103 Due to the small size and complexity of the wire-carrying electrode 103, it is very easy to grow several such electrodes on a print head with wire feed mechanism, so you can print with several different wires in a printing process, for example, to print faster in the places to be able to where the precision is not so important and instead can be filled with a thicker wire.
  • the wire-carrying electrode 103 is screwed into the metal block of the print head 105, which is made of aluminum, for example, and can well dissipate the heat in the electrode 103 formed in the welds from the electrode 103 and the current for welding the attached to the print head 105 power cable 106 into the wire-carrying electrode 103 well conducts.
  • the metal block of the printhead 105 which conducts current to the electrode 103 should be electrically isolated from the guide rails, for example by a layer of plastic between the linear bearings mounted on the printhead 105 in the holes 201 and supporting it on the guide rails 122.
  • the power cable 106 is bolted to the movable printhead 105.
  • the insulated power cable 106 is advantageously made of many individual thin wires so that it has a great deal of flexibility and comes in a long arc coming from the power supply unit, which is installed in the printer housing 1 17, to the print head 105 so that it easily in the direction of the plane in the he can move back and forth.
  • the guide tube 120 through which the metal wire 104 is guided from a spool to the printhead 105 is made of flexible plastic, for example, and extends in an arc from the print head 105 to an attachment to the printer housing 1 17.
  • the guide tube 120 performs the function especially with thin wires of, for example, 0.2 mm, the wire can not get tangled and is not kinked by the movements of the printhead 105 or is exposed and dragged behind the printhead, thus hindering the printing process.
  • the wire is so isolated.
  • the printhead 105 preferably also cooling fins 1 13 are mounted which ensure that absorbed heat from the printhead 105 can be released quickly to the ambient air and the printhead and thus also screwed to it the wire-carrying electrode 103 is cooled.
  • the cooling of the wire-guiding electrode 103 increases its life.
  • a fan 121 allows the air to flow to the cooling fins.
  • the stepper motor which drives the roller 1 10 is preferably screwed to the print head 105 and moves with it.
  • the tip of the primary wire-applying electrode 103 with which the electrode 103 makes the lowest contact with the wire 104 and with which it transfers the welding current to it, may be made of a different metal, for example tungsten or stainless steel for printing with a wire of aluminum.
  • a heat-insulating layer with small current-carrying contacts which conduct the current from the upper bulk material into the tip, so that the tip of the wire-carrying electrode 103 becomes very hot and when fresh on the lead bent wire piece during the welding process with the contact surface transfers heat to the wire and not or much less derived from this, which supports the welding process.
  • Suitable materials for the electrodes are copper alloys, which bring about the conductive properties of copper with a promoted tardability and strength, for example copper alloy with zirconium, beryllium or tungsten.
  • the wire-leading Electrode 103 Current through the part of the wire 104 which emerges from the channel of the electrode 103 and usually has the largest electrical resistance in the circuit.
  • the wire 104 is resistance welded together with the surface of the previous layer of the object 205 to which the wire is applied and fixed by fusing in spots or in sections because of the strong heat generated by the flow of current in the wire 104 Metallic connection is received at the point where the surface of the wire 104 contacts the metal surface on which the wire 104 rests or bears laterally and which dissipates the current.
  • This may be the surface of the already created object 205, the build platform 206 or a metal surface on which a structure of wire is to be applied.
  • the wire can melt in places over the entire cross section and fuse with the surrounding wires.
  • the cross-section of the wire 104 is not substantially changed and the wire 104 is only tacked on laying and adhering to the primary wire-guiding electrode 103, so that the electrode 103 is less loaded and stronger connections thereafter are made, if necessary, with secondary electrodes.
  • the wire is bent during the orders in the form of the wire paths, which then pretend side by side the shape of the layer.
  • the wire 104 can be applied by the wire-carrying electrode 103 over a large area without interruption.
  • the resulting applied wire sections can abut directly against each other and they can be applied adjacent to each other regardless of the direction in which a wire section points to the wire section to which it is applied and partially welded, without the wire applied to the above directly adjacent wire part above rests and without cutting through the wire with subsequent re-placement during the printing process with the primary electrode 103.
  • This is a great advantage over the methods that apply the wire directly by means of a rolling wheel electrode.
  • the power comes from the housed in the housing 1 17 welding power supply and is transmitted through the thick power cable 106 in the block of the print head 105, which passes the power to the screwed in it wire-applying electrode 103, which then passes the current through the part of the wire 104 which has left directly the mouth of the channel of the electrode.
  • This part of the wire which is thereby highly heated, can thereby produce the connections to the metal surface which is produced by the object 205 or the building platform 206 on which the wire 104 is applied.
  • the current then flows through the wire 104 through the already created part of the object 205 on the he is applied and the build platform 206, on which the object 205 rests and is pinned through.
  • the wire-carrying electrode 103 forms the electrical opposite pole to the building platform 206 and the part of the object 205 applied thereon with the support material.
  • the current flow may be bidirectional and may be DC or AC.
  • the electrical voltage between the wire-guiding electrode 103 and the building platform 206 is very small and harmless to humans.
  • the welding power supply may consist of a simple transformer with electronic control, of low voltage capacitors or of high voltage capacitors with electronic control, which conduct electricity through a transformer to reach very high currents of several thousand amperes in the output. This is useful for producing extremely high, short power to create pulsed, stronger, and faster welds. Pulsed welding is important for lower resistivity metal wires and results in shorter layup times of the secondary electrodes with less heat transfer, causing the secondary electrodes to overheat less rapidly.
  • the first layer of the object is applied directly to the surface of the build platform 206.
  • the wire tracks of the first layer are only tacked with less intense current surges and are not fused by the secondary electrodes to the surface of the build platform 206.
  • the object is fixed stably enough so that it does not become detached, and thus the lower layer does not bend or bulge due to tensions in the part of the object created thereupon, which may arise as the metal cools after the welding operations.
  • a contact layer of adjacent wire paths can be created which has a larger area than the first layer of the object 205 or the first layer of the object 205 can be applied directly to the build platform 206 with additional Wire webs abutting the edges of the contours of the first layer. This establishes a stronger connection to the build platform 206.
  • the object 205 is thus only weakly connected to the build platform 206, so that it can be removed easily without damaging it, for example, by pushing a thin spatula under the first layer and trying to lift the object from the build platform 206.
  • the build platform 206 may consist of a thick reinforced aluminum sheet, can be placed on the thinner removable panels 129 and clamped or screwed, on which then the objects to be printed are printed.
  • the wire 104 is connected by means of current pulses from the electrode 103 to the metal surface on which it is applied. These current pulses, with a duration of usually a few milliseconds and up to several hundred amperes, are controlled by the system controller, which accesses a stored machine code, which specifies the printing operation of one or more objects. Multiple objects can be created side by side in one printing process.
  • the machine code is e.g.
  • a file created by a layering software that uses as input a three-dimensional CAD file of the three-dimensional object to be printed and determines therefrom the required movements of the parts in conjunction of the printhead 105 and the build platform 206 with the timed stream pulses Consequence of respective layers corresponding to the cross-section of an object, which are possible or necessary by the application and welding of wire to print a three-dimensional object.
  • FIG. 2 Printhead, printing
  • the wire-carrying electrode 103 is interchangeable and there are various types of the wire-guiding electrodes 103 that are suitable for printing differently and with different materials.
  • Fig. 2 shows the operation of the print head 105, in which the wire 104 in layers according to the pattern suitable for the cross section of an object 205, a screw-on angle, is applied.
  • the wire 10 and 11 In order that the wire is not pulled by the movement of the print head 105 relative to the build platform 206 through the wire-carrying electrode 103, the wire 10 and 11, the wire through the electrode 103 at the appropriate speed with which the wire 104 is applied pushed.
  • the rollers 1 10 and 1 11, can be made of steel, have a smooth surface and they move the wire through the existing between them traction.
  • the engine speed can be set slightly higher than it actually has to be to apply the wire on a web.
  • the rollers slip a little over the smooth surface of the wire 104, thereby ensuring that the wire is always pushed through the electrode 103.
  • the motor force on the wire 104 must be sufficient to overcome the frictional friction between the rollers 1 10 and the wire 104, so that the motor 208, the roller 1 10th drives, not blocked.
  • the spring force on the roller 1 1 1 will be advantageously chosen so that the static friction between roller 1 10 and wire 104 is neither too big nor too small.
  • the wear of the wire-carrying electrode 103 is reduced because otherwise the wire would be pulled through the electrode 103 causing more pressure on the inside of the channel in the mouth of the channel wire guiding electrode 103 and thus could cut into the material of the electrode 103, if it is made of a material such as copper with low hardness.
  • it allows firmer welds through the wire-bonding electrode 103, because there are no or less tensile forces in the wire part between the wire-applying electrode 103 and the object 205, which can tear the wire 104 at stronger surges, which are necessary to make tighter connections to the Place where the wire heats up strongly and thus weakens during welding.
  • a non-advancing lead wire electrode 103 which wire is pulled toward the build platform 206 by the relative movement of the wire leading electrode 103, but which makes printing more difficult to control to successfully produce objects and requires more power Printhead 105 to move.
  • pressing the wire 104 through the wire-carrying electrode 103 can more easily achieve greater precision. Stronger connections, for example, by spot-welding the applied wires, can also be performed with the wire-guiding electrode 103 when printing without pushing the wire, with the lower surface of the wire-guiding electrode 103 resting on the upper surface of the wire paths created in the layer will lie and with the interruption of the relative movement of the wire applying electrode 103 to the build platform 206 during the process of resistance welding.
  • Fig. 5 the wire-carrying electrode 103 is shown individually.
  • Fig. 3 shows a section along the channel 302 of the wire-carrying electrode 103 when applying a wire.
  • the wire 301 is passed until it comes out in the funnel portion 401 of the channel 302 shown in FIG. 5 - the part of the mouth of the channel 302.
  • Fig. 4 shows a enlarged illustration of the area of the section of the wire-carrying electrode 103 with the bent in the mouth of the channel portion of the wire with its radius of the center line R.
  • the center line radius R is always greater than the radius of the wire, for a wire with a circular circular cross-section.
  • the smaller the center line radius R the larger must be the force F acting on top of the wire 301, which moves the wire through the electrode 103 and ensures the bending of the wire 301, this being true to the smallest possible center line radius to be printed can.
  • the path traveled by the wire-carrying electrode 103 should be programmed so that the design of the wire under the annular surface of the electrode 103 is on the correct tracks to make the layer more faithful. If the electrode 103 moves only with the main axis, that of the channel 302, the tracks on which the wire should be located afterwards, then the wire from the wire-guiding electrode 103 is not always applied to the correct tracks, because the mouth of the channel in which the wire can reverberate when orders are wider than the wire, then the wire is applied to more rounded corners and shorter curves than the descends the main axis.
  • the channel 302 has a circular cross section and the diameter d which is slightly larger than the diameter q of the wire, for a wire of circular circular cross section and which is slightly larger than the widest point of the cross section of a wire having a different shaped cross section , For example, a flattened wire, which had a round cross-section before a rolling process and subsequently has a rectangular-shaped cross-section.
  • Electrode 103 Much heat is transmitted from the welding point through the wire into the part of the wire which, because of the small centerline radius R and because of the small distance D, is very close to the welding point and bent in the mouth of the channel of the wire-guiding and wire-applying ones Electrode 103. This can significantly reduce the stiffness of the wire, thus ensuring that a wire-carrying electrode 103 can be set to a very small bend radius and centerline radius R around the wire 301 easily and precisely.
  • FIG. 5 The contact surface 402 with which the wire-carrying electrode 103 rests on the upper surface of the wire webs of the layer that is being created is located in a continuous annular manner around the mouth of the channel 302 and is in parallel printing position over the build platform 206, FIG. so that the wire can be applied in all directions of the plane, as it were, without rotation of the electrode 103 around itself.
  • the electrode 103 rests on the build platform 206, it contacts it on an annular surface.
  • the wire-carrying electrode 103 exerts a pressure on the bent wire on which it rests and presses the wire 104 against the surface on which the wire is applied, so that the welded connections are made as directly as possible on the newly bent part.
  • the bending of the wire 104, as in this case, the perpendicular electrode 103 to the surface of the layer is created with a perpendicular to this channel 302 of the wire-carrying electrode 103, for example, the angle of 90 ° takes place in the end of the channel 302, in the closing area to the mouth of the channel is wider by the rounding 401.
  • This funnel-shaped rounding 401 provides sufficient space in the interior of the electrode 103 so that the wire can be bent directly by an angle, for example of 90 ° and the contact surface for welding 402 of the electrode 103 can rest on the bent wire.
  • the annular contact surface 402 resting on the bent portion of the wire 301 and applying pressure to the wire generally conducts most of the current through the wire 301 so that it can be welded well in the portion below the location where the contact surface rests and has, for example, a width corresponding to the diameter of the wire 301 and an inner diameter D which is between twice and four times the diameter of the round wire 301.
  • the contact surface 402 slides over the surface of the applied wires and is only on very low, minimal pressure on the wire in the general printing process, so that it is less stressed and does not wear too quickly.
  • a width b of the ring of the annular contact surface lying 402 which is preferably not greater than the width of the wire and an inner diameter D which is preferably not greater than twice the diameter of the wire, for a wire with a round cross section so that the Electrode rests on as few adjacent wire paths as possible and unnecessarily transfers power to them.
  • the width b is set too large, it is not ensured that enough current for welding is passed through the part of the wire currently being conveyed out of the channel 302 of the electrode 103.
  • the wire-carrying electrode 103 may also apply wire without resting on the wire 402 on the wire, where less severe surges are passed through the free-standing portion of the wire between electrode 103 and the surface on which the wire is being applied.
  • the positive force F acting on the wire 301 from above, the wire 301 passing through the channel 302 of the electrode 103 should be large enough for the wire 301 to move Wire on a smooth flat metal surface with no connections to this, with the positive force S in another, rotated in this case an angle of 90 ° direction, can be pushed with the low pressure electrode, with its contact surface 402 on the bent wire section. Where the wire is nothing in the way.
  • the circular outer edge of the current transmitting annular bottom contact surface 402 is configured by the fillet 404 to allow the electrode 103 to more easily slide over bumps, such as small pieces of wire protruding out of the layer that have not been cleanly applied, rather than tangling or applied structures to damage.
  • bumps such as small pieces of wire protruding out of the layer that have not been cleanly applied, rather than tangling or applied structures to damage.
  • a slightly spring-acting suspension of the wire-guiding electrode 103 or the building platform 206 is also suitable.
  • Fig. 5 shows the thread 502 and the nut-shaped portion 501 with the wire-carrying electrode 103 is screwed into the print head 105.
  • a wire-carrying electrode 103 can also be attached differently to the print head, for example by a plug connection.
  • the wire can also be transported backwards through the wire-carrying electrode to support, for example, the separation of the wire.
  • the electrode 103 can be a stronger current pulse on the coming out of the electrode 103 and directly bent below the contact surface of the electrode 103 located piece of wire with simultaneous backward thrust of the motor 208 with the roller 1 10 transmitted.
  • the wire is severed with a current pulse with the simultaneous or subsequent movement of the electrode 103 from the point where it rests on the piece of wire, for example, by a small movement of the electrode 103 upwards, away from the layer.
  • the part of the wire which has already been attached between the channel of the electrode 103 and the flat part of the layer is heated by a short current pulse to such an extent that it melts or becomes very hot and is torn by tensile forces exerted on the wire becomes.
  • This process should be set so that no or as little as possible sparks or flashes of light, otherwise contamination by oxidation or air bubbles can occur on the wire. Due to the possibility of sparks, flashes of light or metal spatter, the space should be sealed from the environment, however, it does not have to be airtight for the use of metals that do not ignite in the air during printing and release any pollutants. Through a door one then gains access to the interior of the printer. On the housing 1 17 windows can be mounted through which one can observe the printing process.
  • Objects with free-standing sections can be created in the support material is applied below them layer by layer.
  • the support material abuts against the lower surfaces of an object and consists of metallic wire which has been applied to the primary electrode and has also been post-processed with the secondary electrodes.
  • wire may be pinned to the object that is to be created.
  • the first layers of freestanding parts of an article to be created, which are applied to layers of support material, are subjected to less intensive welding operations, but the farther they are from the layers of support material, the stronger the welding operations are performed to allow the support material to pass through easily remove subsequent tearing off.
  • the support material usually consists of the same wire as the object being created.
  • the 3D printer of FIG. 1 can also be in the printing process with another variant of the 3D printer of FIG. 1 made of a different material, which is applied with a second attached to the print head 105 primary wire-applying electrode.
  • the aluminum wire support material for an article may be made of steel, or vice versa, so that the wire paths of the first layer on the support material may be fused together by the secondary electrodes without the support material forming too strong a connection.
  • the support material can then also be made of two different wires. With a 3D printer from FIG. 1 with two wire-applying electrodes composites can also be created by the alternation of the material of the adjacent wire paths of a layer.
  • the support material made of metal is also necessary for power conduction.
  • the channel of a wire-carrying and - Cultureendem electrode must be large enough in principle, so that the wire once within the channel about its own axis can be rotated so that the wire can be laid in a single plane in all directions without cutting through the wire.
  • the channel of the electrode should not be so wide that the wire forms a spiral-like shape in the channel or kinked by the push conveyance and so could block the printing process.
  • the wire-carrying electrode 103 may be mounted in a resilient suspension and / or the build platform 101 may be resiliently mounted, so that the pressure with which the wire-carrying electrode 103 rests when applying the wire, by the positioning of the electrode 103 to the build platform 101, can be easily controlled, so that the pressure in small position deviations not too large and the wire-applying electrode is not damaged.
  • Fig. 6 shows the wire-carrying electrode 601 when applying wire 606 on a metal piece 607 with a section in the region of the mouth of the channel 605. It has a nut-shaped portion 602 with which it can be screwed into the print head 105. Below this subregion, it passes into the intermediate part 603, which tapers in the end region 604 of the electrode 601.
  • the channel 605, which preferably passes right through the electrode 601, is wider than the wire 606 which is passed through this channel.
  • the channel 605 provides sufficient space for the deflection of the wire 606 in the lowermost part, just above the mouth, of the channel 605. This allows the electrode 601 to rest directly on the bent portion of the wire lying flat on the layer to which it is applied.
  • the lower part 604 of the electrode 601 is an area intended to be worn during the printing operation. Therefore, if the region 604 has a new flaw T when the electrode 601 is not changed, the lower annular contact surface 608 which is worn by the wire welding, with which the electrode 601 rests on the wire, may degrade during printing without impairing the function and the effect of the electrode. By applying wire in all different directions in one plane, the contact surface of the electrode 601 is uniformly worn.
  • the lower part of the electrode may also be ground automatically by the printer by moving the electrode 601 back and forth on the contact surface on the grinding surface 14. It is also conceivable a printer in which the electrode anirri a cutter or grindstone to be worked up so that the quality of the welds does not deteriorate.
  • This primary electrode 601 is particularly suitable for applying wires which are intended to be directly fixed together, for example for printing without the use of secondary electrodes.
  • it is suitable for applying wires with a rectangle-like cross-section, the thicker ones Electricity or stronger, longer lasting current pulses need to make a connection, because the wire-carrying electrode 601 is much more stressed and the lower contact surface wears quickly.
  • the electrode 601 can be charged much more.
  • FIG. 7 shows a section of a wire-carrying electrode 703, which consists of two electrically insulated electrodes, another variant of the wire-carrying electrode 103.
  • the wire-carrying electrode 703 which consists of two electrically insulated electrodes, another variant of the wire-carrying electrode 103.
  • the wire-carrying electrode 703 Through the inner tubular electrode 702, the wire
  • an electrically insulating layer 704 which is heat-resistant, for example made of a ceramic material or of a heat-resistant plastic such as Teflon.
  • the electrode 703 terminates above the lower contact surface of the electrode 703 with which the welds are made.
  • the electrical opposite pole of the electrode 703 may be either the lower wire layer 706, the build platform on which the wire 701 is applied, or the lower electrode 705.
  • preheating or preheating the wire 701 it becomes more ductile, loses rigidity and is more easily bent, and the electrical resistance of the metal wire increases with increasing temperature, which in turn aids in the process of welding to the contact electrode 705.
  • the entire electrode 703 may be designed so as to be able to produce firmer connections in the continuous printing process without pushing the wire through the electrode 703 and with the design of the wire 701 from the electrode 703 by pulling the wire through, in which the electrode 703 Wire 701 adheres only with weaker current pulses and the electrode 705 can then perform the stronger welds without causing the wire is cut, because between the part of the wire to which the welded connection is created and the wire-brushing electrode 703, a piece of wire is present is attached to the layer 706 and this can forward the tensile forces to the layer 706, without causing the coming out of the electrode 702 wire 701 is severed.
  • the electrode 705 has a lower partial section which can wear without the contour shape of the contact surface changing, that is to say the cross section of the lowermost partial section remains unchanged over a certain height.
  • This form is particularly suitable for thicker wires (0.4-1 mm) which are characterized by the reduction of the Flex the stiffness with lower force to smaller bending radii due to the higher temperature.
  • the electrode 703 after mounting on the printhead of the printer, makes electrical contact with an extra power cable, thinner than the cable 106, which carries current from the welding power supply and is driven by the controller.
  • Fig. 8 shows a wire-carrying electrode 801 which does not rest with the lowest surface on the surface of the layer created during the printing process.
  • the channel inside the electrode 801, through which the wire 802 is routed, need only be shaped so wide that the wire can be easily passed.
  • the wire is bent underneath the bottom surface of the electrode 801 so that it can be laid flat in the plane of the layer to be created.
  • current pulses which are passed through the wire, the wire on the lower structure 803 is pressed on this and rests attached. These current pulses heat the wire 802 in the freestanding portion between the end of the channel of the electrode 801 and the surface of the structure 803 on which the wire 802 is applied and make it very ductile so that it can be easily shaped.
  • the printing process with the electrode 801 which does not rest on the layer being made is very gentle to the wire-applying electrode 801.
  • Suitable for thicker wires and wires coated with solder material in which the inner main wire does not melt and during printing for the accurate shaping of the structure to be created while the solder material melts around the wire 802, by the heat generated by the current in the portion of the wire between the electrode and the surface on which the wire 802 is applied, and at the small contact point to the below or next to it already applied wire web can melt with the existing solder material there and so fills gaps between the wire webs, when the structures on which the wire is applied are thin enough so that they are hot enough.
  • Wires may be clad with brazing to make air and water proof surfaces, and stronger connections between the wire paths easier, using only the wire-carrying electrode and avoiding excessive wear of this electrode.
  • a large part of the solder material always sticks to the wire so that it is applied with the wire.
  • An advantage of the wire application process with this non-overlying electrode 801 is that it ensures that the current is transmitted integrally through the portion of the wire 802 leaving the channel of the electrode 801, and thus the welds are made thereto only. It allows the application of wire with little or no wear of the wire-carrying electrode.
  • the electrode 902 which applies the wire 901 to a metal part 904.
  • the electrode 902 differs substantially from the electrode 103 of FIG. 5 and FIG. 3 in that the lower part, the tip with which it rests on the fleas of the upper surface of the layer to be applied, consists of a non-electrically conductive, hard and nonconductive material 903, preferably a ceramic. It is basically suitable for thicker wires depending on the material.
  • a contact of sheet metal, or brushes, for example, small wires of copper may be mounted inside the channel of the electrode 902 and press against the wire 901, especially at the end of the channel to ensure that the current passes over a larger, better defined surface is transferred to the wire 901 and thus can provide more constant conditions and welds.
  • this generally causes the wire 901 to make electrical contact on a very small area alternating during the printing process Electrode 902 has. This may cause the welds to be less constant because of the amount of current flowing through the alternate length of the wire member and the variable resistance of the wire member.
  • the electrode 902 ensures that the current is transmitted entirely through the wire and thus the welds are performed only on this wire 901.
  • the electrode 902 absorbs the lateral pressure exerted by the wire 901 at the end of the channel and, during separation, can lay flatly protruding pieces of wire flat against the lower layer during flinching.
  • the ceramic tip 903 may be attached, glued or screwed to the electrode 902 with a press fit.
  • Abrasive surface Fig. 1 On the printer housing 1 17, a bar 1 16 is mounted on a Abschleif Structure 1 14 is mounted parallel to the building platform by means of a clamp 1 15.
  • the abrading surface 114 may be a piece of sandpaper that can be easily replaced, or even a grindstone or a file.
  • the lower surface of the secondary electrodes wears off during the printing process. Therefore, after a certain degree of wear, it can be sanded off advantageously on the grinding surface 14, so that the lowest contact surface is again suitable for performing welds.
  • Several attached grinding surfaces of different roughness are also possible.
  • a brush may be mounted on the printhead 105, sweeping away the particles removed from the electrode on the grinding surface 14, or a fan doing this with an air jet.
  • Block 130 includes the secondary electrodes. It is attached to the movable printhead 105 in FIG. 1 and is shown in more detail in FIG.
  • the secondary electrodes 132, 133 and 109 are linearly movably installed in the block 130.
  • a good flow and heat conductive material such as copper or aluminum is suitable.
  • a camshaft 1003 is introduced which is driven by a stepper motor 1001 which is connected to the block 130 by an insulating connector 1010. As the camshaft 1003 rotates, depending on the position of the shaft, the secondary electrodes 132, 133 and 109 move up and down.
  • the cams of the camshaft 1003 are here offset by an angle of 120 ° about the axis of the shaft.
  • a plurality of secondary, here three, electrodes can be controlled individually, so that they can be put on individually and perform a resistance welding process.
  • the current for welding with the secondary electrodes is conducted from the welding power supply via the power cable 106 of FIG. 1 via a connecting part 123 to the metal block 130 and via contact in the secondary electrodes.
  • the electrical opposite pole to the secondary electrodes is the build platform 101, from which the current through the power cable 107 leads back into the welding power supply, where then closes the circuit for welding.
  • three secondary electrodes are built in to print faster and to extend the life of the printer without renewing the secondary electrodes.
  • the compression springs 1005 push the electrodes into the block 130 and against the surface of the cams of the camshaft 1003.
  • the electrode 132 With the cam 1003 of the camshaft 1003, for example, the electrode 132 can be moved deeper than the other electrodes so as to be ground individually by slipping on the grinding surface 14 can be placed individually on a layer of applied with a primary electrode 103 wire webs to melt them and to weld.
  • the stepper motor 1001 could drive the camshaft via a transmission, for example, via a self-locking worm gear to boost the force of the cams on the electrodes.
  • a pressure sensor may be attached to the printhead 105 to measure the force with which the electrodes are placed to be considered as a size in the printing process. For this, the machine can determine whether the electrode touches down by the electrical contact of the secondary electrodes with a layer of an object or the build platform. This also applies to the primary electrode 103. Due to the rectangular shape of the electrodes, they can be placed several times on a layer and cover all areas without having to put them in the same place several times. The secondary electrodes heat up strongly during the welding process and therefore have to be cooled. Therefore, a large radiator 1008 with cooling fins is preferably attached to block 130 which is cooled by fan 1009.
  • Smaller electrode pads are suitable for thin spots where you do not want to heat too much or the already with the primary electrode applied wire paths are close together.
  • the larger ones are intended to weld places where little material has been applied, for example, the inner space of objects that are printed with little fill, that is, filling the interior of the items with a lattice-like structure with a lot of void space.
  • Fig. 12 shows a secondary electrode 1201 having a lower portion in which the cross section is equal to the lower contact area everywhere, which when grinding on the grinding surface is machined out of the base of the electrode having a much larger cross section and above Area with the same cross-section as the contact surface is located.
  • the electrode 1201 may have a higher wear-out portion with which the welds can be made without the electrode overheating during welding operations. Due to the larger cross-section, the heat is better dissipated, as well as the electrical resistance is smaller, so less heat in the electrode caused by the flow of current.
  • Fig. 1 1 shows a secondary electrode 1 101 with exchangeable lower tip 1 102 of the Contact material.
  • the replaceable tip 1102 is pyramid-shaped so that it has less heat. In principle, it requires different grinding surfaces, which are parallel to respective surfaces of the electrode tip 1 102 at which they can be reground.
  • Fig. 13 shows a lower part electrode 1301, the tip of the electrode, the contact material 1302 of a metal other than the base.
  • the adaptation of the contact material 1302 to the material, metal or alloy from which the wire is made, allows for better welding operations and may provide less adhesion of the electrode 1301 to the wire material during welding.
  • a tip made of tungsten or stainless steel, for the welds of aluminum wire for the welds of aluminum wire.
  • Some types of stainless steels are particularly suitable for aluminum, because they heat up strongly due to the high resistivity due to the strong flow of current during resistance welding, thereby directing the resulting flash further into the aluminum, which makes it much easier and faster to melt.
  • the tip 1302 can also be made of several materials, for example the lowermost part, with the contact material of tungsten, and between the main material and the tungsten, a layer of stainless steel, with a particularly high electrical resistance, which heats up strongly during welding and heat on which transmits tungsten, which, although very hot, has even more flannability than the stainless steel above would have at the temperature setting.
  • the tip 1302 can also be abraded on the grinding surfaces.
  • holes are formed through which air can circulate and increase the surface so that the bulk material of the electrode 1301 is better cooled and the thermal conductivity between the hot tip 1302 and the main material is lower the electrode block receives less heat.
  • the transition between the tip 1302 and the bulk material of the electrode 1301 is realized in a small area so that the heat flow between both materials is less.
  • Fig. 14 The principle of the welding process with the secondary electrodes of the printer of Fig. 1 is shown in Fig. 14. After a new shift, after printing is occupied with the wire-carrying electrode 103 on the metal part 1404, with only slightly connected to the lower surface lying wire webs, set the secondary electrodes individually on the surface of this layer of wire webs, in which the wire web 1403 is on, exert a pressure Depending on the location and settings, they conduct a strong current through the wire paths for a certain time. They heat up so much because they represent a section in the circuit with relatively high electrical resistance, allowing them to melt, melt and melt together and with the surrounding applied material.
  • a wire 104 with a round cross-section which is applied when applying with a wire-guiding electrode 103 only by small point connections on the surface on which it is applied with a non-changing cross-section, is particularly suitable as the input material.
  • the wire webs thus applied have a high electrical resistance in the direction of current flow perpendicular to the plane in which the wire webs lie compared to the rest of the circuit.
  • the newly applied layer can be selectively heated at the point at which the secondary electrode 132 rests in this case.
  • a wire with a rectangular or rectangular cross-section is also suitable for printing with primary and later with secondary electrodes that fuse the wire.
  • the welding current can be AC or DC.
  • the structure of the wire paths applied with the primary electrode 103 changes with the secondary electrodes when reflowed.
  • the goal is to create an object with non-directional, isotropic material properties to produce stable objects.
  • the secondary electrode 132 has a flat surface 1402 which, when housed in the block, rests in parallel against a flat surface in the block 130 so that it is not twisted in the block 130.
  • the upper part 1401 may be narrower because it does not have to carry heat and no current, and around it a spring 1005 may also be mounted.
  • the secondary electrodes may be placed on the uppermost layer and the plurality of layers applied only to the primary electrode 103 may be applied to each other and weld the surface on which they rest. Due to the multiple stacked layers of wires, which are unchanged in cross-section and only very slightly welded, the electrical resistance of the point to be welded is higher, which favors the resistance welding process. The layers become less frequent heated, resulting in less oxidation, less wear of the secondary electrodes and less power consumption. Likewise, this can be faster.
  • the cross-section of a coated and adhered web of wire 1403, seen in FIG. 15, may change completely during the welding process with the secondary electrode 132 as the wires completely dissipate and become an isotropic, homogeneous portion of the article 1404 upon cooling.
  • the finished articles have a large tensile strength corresponding to the metal in the direction perpendicular to the layers.
  • the voids and gaps between the overlying webs of wire in the merger of the adjacent wires can be closed when the wires are close enough together.
  • the final height of the layer thickness H can be adjusted, unlike the layer thickness of a layer consisting of sheets of wire which are only attached and unchanged in cross section. This makes it possible to achieve smaller layer thicknesses than the thickness of the wires. Also, different layer thicknesses can be made using the same wire, as well as within the print of an article. Thin layers are possible, for example with a 0.2 mm diameter round wire, which is flattened to a height of 0.1 mm or 0.05 mm. In Fig. 15, the height A of the lower welding intended part of the secondary electrode 132 is shown. This part is equal over the height A in cross section and thus ensures after the removal of the lowest contact layer for a constant welding result, until the height A is completely removed.
  • the flat surface created with the secondary electrodes allows the wire webs of the next layer to be easily applied thereon.
  • the layer height for each layer can be varied, unlike the stratification of wires which remain unchanged in cross section where the height of the sections is always a plurality is the constant height of a layer.
  • areas of an article to be printed can be created faster, which have to comply with a certain tolerance of the height.
  • the wire paths applied with the primary wire-guiding electrode 103 may overlap in a layer or be applied in places twice, for example, to quickly create an internal lattice structure from a continuous wire section.
  • the secondary electrodes compress and fuse the applied wire webs into a uniform flat surface.
  • the points where wire paths overlap and abut one another become fixed fused nodes.
  • the juxtaposed wire webs are strongly interconnected by the Swissmanschmelzen. It is therefore usually not as important as precisely the wire paths are applied next to each other, as this way any space can be filled inside.
  • the volume of wire material can be more rapidly applied by the wire-carrying electrode 103 using a thicker round wire which is thereafter melted and flattened than with a thinner round wire having the diameter of the thickness of the layer.
  • the electrodes could also be water cooled and have channels in the interior through which cooled water is circulated.
  • the support material applied to the wire-carrying electrode 103 can also be reworked with the secondary electrodes.
  • the machine can automatically take breaks when overheating. A moving air exchange between interior and ambient air ensures cooling. The parts are ready after printing immediately.
  • An oxide layer can form on the contact surface for welding, which conducts the current very poorly.
  • the surface may become rougher, smoother and degrade due to the welds, resulting in ever poorer conditions for the quality of the welds. Therefore, and so as not to be adhered after contamination of the contact surface by welding, the contact surface for welding the secondary electrodes can be ground off automatically.
  • a printer similar to that in Fig. 1 with an advanced mechanism for displacing the secondary electrodes in vibration and / or rotation is conceivable so that the electrodes do not adhere during welding. By grinding, the contact surface is smoothed and remains flat and even.
  • the life of the electrodes is considerably extended.
  • the lower contact surface is suitable for an average of 1000 welds
  • the height of the lower abrasion foreseen region is 15 mm
  • the electrode can be worn 25 times per millimeter to be suitable for welding
  • the electrode is sufficient for 375,000 welds before it needs to be replaced.
  • the wear of the electrode may be predicted by the number of welds, the amount of wire under the electrode at the welds, the flow of current through them, the temperature of the electrode or the time interval between welds, and the pressure with which it is applied during welding become.
  • a stainless steel cube 100 mm wide, with a square contact electrode for welding 5 mm wide and with a layer height of 0.2 mm, by flattening and melting a round wire of 0.4 mm is created to print, it needs at least 100 * 10 * 10 * 5 * 4 200000 individual welds.
  • FIG. 16 shows a structure 1601 made of round wires which were not changed in cross-section during and after the layered deposition. Therefore, the surface of the structure viewed from the side of the layers has a pronounced groove pattern.
  • the structure of Fig. 16 is printed using only the wire-carrying electrode 103 with weak current pulses and welds. The wires stacked on each other only touch one another linewise or pointwise.
  • the structure 1702 in FIG. Fig. 17 shows the result of the respective wire-applied electrode deposition 103 and fusion with the secondary electrode 132 of the respective wires of the structure 1601 with the wires surrounding the respective wires.
  • connection between the walls of an object and the inner material which is so easy to create, by merging the adjacent wire paths into a continuous area.
  • the connecting portion 1701 from the externally rounded appearing welds connections is shown in Fig. 17. These soft transitions make the objects much more stable, because the internal forces are transmitted more uniformly over wider areas or areas, in contrast to the connection between round wires, which are unchanged in cross-section, as shown in FIG. 16.
  • contours or edges of a layer which later become the surfaces of the objects to be created, can be applied with the wire-guiding electrode from longer, uninterrupted pieces of wire, which are directly thereafter connected to a secondary electrode with a larger contact surface, for example electrode 109, fused with the lower layer, so that the surface of the objects to be created smoother and level.
  • the layers fused together by means of the secondary electrodes give objects whose properties are very close to those of cast parts and require little post-processing.
  • a torsion spring 1006 is attached, which allows a secondary electrode to abut on a layer of non-decreasing pressure when the electrode is melted by the wire webs under it, with a movement of the stepper motor 1001, not must be exactly tuned sinks.
  • the torsion spring 1006 can also be replaced by a flexible intermediate piece.
  • the torsion spring 1006 is not mandatory.
  • the secondary electrode 132 is the one with the smallest bottom contact area. It is suitable for merging areas which thereafter have a continuous area equal to the area of the surface of the contact area 1007 of the electrode 132.
  • the contact surface of the secondary electrodes is preferably rectangular, so that the electrodes can cover the entire surface of a layer by multiples approach and placing the electrodes on individual partial surfaces of the layer, without causing overlapping areas exist on which the electrode with a portion of the contact surface several times.
  • One or more wheeled electrodes may also be attached as secondary electrodes to the printhead.
  • On each of these a grindstone can be mounted which is pressed with a spring against the contact surface of the electrode and slowly abrades the top contact surface as soon as the rolling wheel electrode rotates.
  • the Rollradelektrode can sit on a layer with applied wire paths, roll over them, transfer electricity to them and they weld more, and if necessary, they melt and flattening.
  • a rolling wheel electrode can also be moved over the camshaft.
  • a grinding surface can also be approached at their welding contact point is removed in order to achieve significantly longer operating times can.
  • the welding current and its flow time is adjusted to the secondary electrodes, the respective amount, thickness, shape and composition of the wire webs as well as the required final height of the layer. If a secondary electrode does not drop enough during a welding operation, then this can be felt by a pressure sensor, for example, and it can transmit more current to the location that it wants to weld.
  • the 3D printer apparatus may also be constructed such that one or more cutters may be mounted on the printhead 105, which after printing with the primary electrode (s), or with the primary and secondary electrodes, may recreate the contours of the new milled layer to achieve improved precision and surface finish.
  • an attached router on the printhead which is driven by a motor, may be oriented perpendicular to the build platform 101, and so may be accurate by the printhead movement mechanism Depart ways.
  • the milling cutter then only needs to mill a very small amount of material, which means that it can hold for a long time, quickly cut off the contours, and with a thicker wire to print better precision can be achieved.
  • the mounted on the print head 105 milling head could also be made multi-axis.
  • Fig. 19 shows a part consisting of two opposite-pole electrodes 1901 and 1903 which are very close to each other and are electrically insulated from each other. Between the electrodes 1901 and 1903 is an insulating layer 1902 which separates the two electrodes from each other.
  • the layer 1902 may be, for example, Teflon or a ceramic material.
  • the two electrodes have a rectangular contact surface for welding, when placed on a metal layer, current flows between the electrodes during welding through the underlying metal which closes the circuit, causing the metal to heat up directly below the electrodes.
  • the advantage here is that only the area of the metal to be welded located directly under and between the electrodes is heated so that more heat can accumulate more quickly and precisely so that the welding is improved.
  • the lower contact area of the electrodes can wear down and be ground down over a certain fleas, so that the electrodes last long.
  • One of the electrodes 1901 and 1903 could also be mounted on the opposite electrode so that it can move towards it and be pressed by a spring in the resistance welding process against the surface at which the welds are made so that both electrodes are always in contact with that surface to have.
  • the electrodes can be moved back and forth over the surface on which the welds are made until both electrodes have electrical contact, say, for example to ascertain that the determined electrical resistance between the electrodes approaches zero.
  • FIG. 18 shows a part consisting of a plurality of electrodes 1801, 1802,
  • the electrodes 1802 and 1805 are separated from each other and insulated from the electrodes 1801 and 1806 by the insulating layer 1803.
  • the principle is the same as in the part of Fig. 19. However, in the part having the two rectangular electrodes of Fig. 19, two parts are generally required to be seen as shown in Fig. 19, preferably rotated by 90 ° from each other mounted on the printer to weld any underlying structures equally.
  • the electrodes 1801 and 1806 together result in a part that can be moved in a block and via which the welding current is transmitted to the respective electrodes via mutually insulated contacts.
  • the electrodes 1801 and 1806 are externally insulated 1804 surrounded to be electrically isolated from it in block 130. Power cables could also be connected directly to the electrodes.
  • the electrodes of FIG. 18 can approach and weld virtually any location of a layer of wire webs coated with a wire-guiding electrode 103. Also conceivable is a double Rollradelektrode as a secondary electrode consisting of two opposing each opposite polarity separate and insulated Rollradelektroden for resistance welding according to the principle of the electrodes of FIG. 19.
  • Fig. 20 shows a secondary electrode having a contact surface with a raster pattern. It is suitable for carrying out pointwise merging on wires that are still lying on one another with a cross section, thus reliably producing small areas that are fused together.
  • the position with which the electrode 2001 touches should alternate for each successive layer, so that directly on areas of pointwise two fused wires of an overlying layer of the wire applied thereto is not fused at this point in this layer with the underlying layer and site, but only in the following layer above this point.
  • wire-applying electrode wire-applying electrode
  • Stepper motor 1201 Secondary electrode
  • Construction platform 1803 Insulating layer
  • stepper motor 1805 electrode

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Wire Processing (AREA)
  • Electrical Discharge Machining, Electrochemical Machining, And Combined Machining (AREA)

Abstract

L'invention concerne un procédé, notamment un appareil destiné à fabriquer un objet en métal, un fil métallique étant soudé, par points ou par sections, au cours du procédé de soudage par résistance, progressivement par couches, au moyen d'une électrode principale guide-fil, un canal s'étendant à travers le corps de base de l'électrode principale guide-fil, à travers lequel le fil métallique est guidé à l'état solide et est courbé, dans ou directement sous l'embouchure dudit canal à travers laquelle le fil métallique est sorti de l'électrode principale guide-fil, dans un rayon de courbure très petit, afin de l'amener à plat à travers le coulissement, sur ce dernier, de la surface de contact inférieure de l'électrode principale guide-fil sous l'embouchure du canal, le fil métallique étant ainsi déposé et soudé par points sur une surface métallique adjacente, la surface métallique étant une plaque de support, notamment sur une couche de fil métallique précédemment appliquée, le procédé comprenant les étapes suivantes : a) pour effectuer le soudage par résistance par points et par sections, faire passer une impulsion de courant électrique à partir de l'électrode principale guide-fil à travers le fil métallique vers la surface métallique adjacente, b) déplacer l'électrode principale guide-fil par rapport à la surface métallique et déposer simultanément une longueur correspondant au déplacement de fil métallique sur la surface métallique adjacente, c) répéter les étapes a) et b) pour former l'objet en métal par couches à travers des soudages et des déplacements successifs ; et, en plus desdites étapes, le procédé comprenant en outre éventuellement l'étape suivante : d) faire passer un autre courant électrique à partir d'une électrode secondaire à travers le fil métallique déjà soudé par points et par sections au moyen des étapes a) et b), pour chauffer ce dernier au moins partiellement en supplément, de préférence sur la totalité de la longueur déposée au cours de l'étape b) et pour relier ce dernier plus solidement à la surface métallique adjacente, voire pour le souder avec cette dernière, éventuellement pour le faire fondre complètement.
PCT/EP2019/050495 2018-01-10 2019-01-10 Procédé et appareil de fabrication d'objets en métal WO2019137976A1 (fr)

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102020215531A1 (de) 2020-12-09 2022-06-09 Continental Teves Ag & Co. Ohg Metalldruckvorrichtung und -Verfahren zur Erzeugung eines schichtweisen aufgebauten metallischen Werkstücks

Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6443352B1 (en) 1999-09-27 2002-09-03 Solidica, Inc. Electrical resistance based object consolidation

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6443352B1 (en) 1999-09-27 2002-09-03 Solidica, Inc. Electrical resistance based object consolidation

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102020215531A1 (de) 2020-12-09 2022-06-09 Continental Teves Ag & Co. Ohg Metalldruckvorrichtung und -Verfahren zur Erzeugung eines schichtweisen aufgebauten metallischen Werkstücks

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