A 3D printer can print a structure by depositing material into a weld pool that is moving relative to a workpiece. A multi-wire process may be utilized to increase the deposition rate of the 3D printer. An electrode wire can supply energy to the weld pool while being fed at a first feed rate into the weld pool. A second wire can be fed into the weld pool at a second feed rate to deposit additional material and thereby speed up the overall material deposition rate. All of the energy in the weld pool may be supplied by the electrode wire. Different materials may benefit from different orientations of the electrode wire and the second wire.

A method of build-up welding a powdery or wire-shaped material onto a workpiece, which is preferably a flat substrate, by means of a device which comprises a substantially rod-shaped electrode, the electrode having at least one material feed channel extending in its interior, the device comprising a nozzle surrounding the electrode, the method comprising the following steps: forming the arc as a transferred arc between the electrode and the workpiece or as a free-standing arc between the electrode and the nozzle, flooding the working gas area with a working gas to constrict the arc in the direction of the workpiece, feeding the powdery or wire-shaped material into the constricted arc and moving the device across the workpiece as the powdery or wire-shaped material is being fed into the constricted arc.

The present disclosure provides a wire and arc additive manufacturing (WAAM) method for a magnesium alloy. The method includes the following steps: step 1: performing a WAAM process assisted by cooling and rolling; step 2: milling side and top surfaces of an additive part; step 3: performing, by friction stir processing (FSP) equipment, an FSP process on the additive part, and applying cooling and rolling to a side wall of the additive part through a cooling and rolling device during the FSP process; step 4: finish-milling the top surface of the additive part for a WAAM process in the next step; and step 5: repeating the above steps cyclically until final forming of the part is finished. The present disclosure completely breaks dendritic structures and refines grains in the WAAM process of the magnesium alloy, thereby effectively repairing defects such as pores and cracks.

Disclosed is a welding system configured to perform additive manufacturing using a controlled short circuit welding process to apply a plurality of droplets of a wire to create a multilayer part comprised of the droplets. Operational parameters of the additive manufacturing system are dynamically adjusted based on data representing a temperature value and/or a geometric characteristic of the part. Based on the data, the controller can adjust one or more operational parameters to control application of droplets to build up the part.

An electronically controlled apparatus for the manufacture of fused overlay plate including a conveyor assembly, a ground assembly, two hopper assemblies, a number of wire feeder assemblies, and a perforated cooling drum to produce a metal plate with a fused weld overlay that is harder, more impact resistant, and demonstrates a longer lifespan with respect to abrasion than known in the prior art.

Cladding strip feeders having independent pressure rollers and strip cladding systems with cladding strip feeders having independent pressure rollers are disclosed. A disclosed example cladding strip feeder for a strip cladding system includes: a drive roller to advance a cladding strip along a strip feed path through contact plates; a first pressure roller positioned along the strip feed path opposite a first section of the drive roller; a second pressure roller positioned along the strip feed path opposite a second section of the drive roller; a third pressure roller positioned along the strip feed path opposite a third section of the drive roller; a first pressure adjuster to set a first pressure applied to the cladding strip by the first pressure roller and the first section of the drive roller; a second pressure adjuster to set a second pressure applied to the cladding strip by the second pressure roller and the second section of the drive roller; and a third pressure adjuster to set a third pressure applied to the cladding strip by the third pressure roller and the third section of the drive roller, the first pressure roller, the second pressure roller, and the third pressure roller being configured to apply symmetric pressure across a width of the cladding strip by selectively setting at least one of the second pressure adjuster to apply the second pressure or the third pressure adjuster to apply the third pressure based on the cladding strip having one of at least three incremental strip widths.

A method for rapidly forming a part using combination of arc deposition and laser shock forging, including: 1) dividing a preforming part model into one or more simple forming units by the simulation system and determining a forming order of the forming unit; 2) controlling, by the numerical control device, an arc welding device to perform a melting deposition forming of a processing material layer by layer on a processing substrate of a motion platform to form a melting deposition layer; 3) controlling, by the computer, a movement of the motion platform to keep a fusion zone always in a horizontal state, at the same time, a pulse laser beam of a laser device to perform a synchronous shock forging on an arc deposition region at a plastic deformation temperature. A device for implementing the method.

Disclosed are systems and methods to plan a path to form a part using an additive manufacturing system. The additive manufacturing system may include one or more additive manufacturing tools. The additive manufacturing tools may include arc welding tools and non-arc welding tools. The system may also manufacture the part based on the planned path.

The present invention relates to a device and a method for DED or WAAM, comprising a welding torch configured to generate an arc for generating a melt pool on a surface of a workpiece, and a wire feeder configured to feed a wire towards the melt pool to generate a weld seam on said surface, and an enclosure enclosing at least part of the workpiece and comprising a process atmosphere with a process gas, wherein a sucking device sucks part of the process gas out of the enclosure and thereafter re-introduces the process gas into the process atmosphere, and wherein the enclosure comprises or consists of a flexible housing or a tent and in the sucking device is connected to a buffer volume or a pressure stabilizing unit.

Systems and methods for localized work return path of additive manufacturing systems are described. Localized grounding connects the printed surface directly to the work return, and shortens the length of grounding and/or the return cables compared to substrate-based grounding.