{"title":"脉冲和恒定发电机功率下感应线材熔化过程中的液滴形成和能量输入","authors":"J. Kimme, Jonas Gruner, A. Hälsig, Jonas Hensel","doi":"10.3390/jmmp8020080","DOIUrl":null,"url":null,"abstract":"Induction heating is a fast, reproducible, and efficient heating method used in various manufacturing processes. However, there is no established additive manufacturing (AM) process based on induction heating using wire as feedstock. This study investigates a novel approach to AM based on inductive heating, where a steel wire is melted and droplets are detached periodically using a two-winding induction coil. The process parameters and energy input into the droplets are characterized. The induction generator exhibits a sluggish response to the excitation voltage, resulting in a lag in the coil current. The process is captured using a high-speed camera, revealing a regular droplet formation of 14 Hz and uniform shapes and sizes between 2.11 and 2.65 mm in diameter when operated within an appropriate process window. Larger drops and increased spatter formation occur outside this window. The proposed method allows for the production of droplets with almost spherical shapes. Further analysis and characterization of droplet formation and energy input provide insights into process optimization and indicate an overall efficiency of approximately 10%.","PeriodicalId":16319,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":null,"pages":null},"PeriodicalIF":3.3000,"publicationDate":"2024-04-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":"0","resultStr":"{\"title\":\"Droplet Formation and Energy Input during Induction Wire Melting with Pulsed and Constant Generator Power\",\"authors\":\"J. Kimme, Jonas Gruner, A. Hälsig, Jonas Hensel\",\"doi\":\"10.3390/jmmp8020080\",\"DOIUrl\":null,\"url\":null,\"abstract\":\"Induction heating is a fast, reproducible, and efficient heating method used in various manufacturing processes. However, there is no established additive manufacturing (AM) process based on induction heating using wire as feedstock. This study investigates a novel approach to AM based on inductive heating, where a steel wire is melted and droplets are detached periodically using a two-winding induction coil. The process parameters and energy input into the droplets are characterized. The induction generator exhibits a sluggish response to the excitation voltage, resulting in a lag in the coil current. The process is captured using a high-speed camera, revealing a regular droplet formation of 14 Hz and uniform shapes and sizes between 2.11 and 2.65 mm in diameter when operated within an appropriate process window. Larger drops and increased spatter formation occur outside this window. The proposed method allows for the production of droplets with almost spherical shapes. Further analysis and characterization of droplet formation and energy input provide insights into process optimization and indicate an overall efficiency of approximately 10%.\",\"PeriodicalId\":16319,\"journal\":{\"name\":\"Journal of Manufacturing and Materials Processing\",\"volume\":null,\"pages\":null},\"PeriodicalIF\":3.3000,\"publicationDate\":\"2024-04-18\",\"publicationTypes\":\"Journal Article\",\"fieldsOfStudy\":null,\"isOpenAccess\":false,\"openAccessPdf\":\"\",\"citationCount\":\"0\",\"resultStr\":null,\"platform\":\"Semanticscholar\",\"paperid\":null,\"PeriodicalName\":\"Journal of Manufacturing and Materials Processing\",\"FirstCategoryId\":\"1085\",\"ListUrlMain\":\"https://doi.org/10.3390/jmmp8020080\",\"RegionNum\":0,\"RegionCategory\":null,\"ArticlePicture\":[],\"TitleCN\":null,\"AbstractTextCN\":null,\"PMCID\":null,\"EPubDate\":\"\",\"PubModel\":\"\",\"JCR\":\"Q2\",\"JCRName\":\"ENGINEERING, MANUFACTURING\",\"Score\":null,\"Total\":0}","platform":"Semanticscholar","paperid":null,"PeriodicalName":"Journal of Manufacturing and Materials Processing","FirstCategoryId":"1085","ListUrlMain":"https://doi.org/10.3390/jmmp8020080","RegionNum":0,"RegionCategory":null,"ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"","PubModel":"","JCR":"Q2","JCRName":"ENGINEERING, MANUFACTURING","Score":null,"Total":0}
引用次数: 0
摘要
感应加热是一种快速、可重复、高效的加热方法,可用于各种制造工艺。然而,目前还没有基于感应加热、以钢丝为原料的增材制造(AM)工艺。本研究探讨了一种基于感应加热的新型 AM 方法,即使用双绕组感应线圈定期熔化钢丝并分离液滴。研究对工艺参数和输入液滴的能量进行了表征。感应发生器对激励电压的反应迟缓,导致线圈电流滞后。使用高速照相机拍摄的过程显示,在适当的过程窗口内操作时,液滴形成的频率为 14 赫兹,形状和大小均匀,直径在 2.11 至 2.65 毫米之间。在此窗口之外,液滴会变大,飞溅物也会增多。所提出的方法可以生产出几乎呈球形的液滴。对液滴形成和能量输入的进一步分析和表征为工艺优化提供了启示,并表明总体效率约为 10%。
Droplet Formation and Energy Input during Induction Wire Melting with Pulsed and Constant Generator Power
Induction heating is a fast, reproducible, and efficient heating method used in various manufacturing processes. However, there is no established additive manufacturing (AM) process based on induction heating using wire as feedstock. This study investigates a novel approach to AM based on inductive heating, where a steel wire is melted and droplets are detached periodically using a two-winding induction coil. The process parameters and energy input into the droplets are characterized. The induction generator exhibits a sluggish response to the excitation voltage, resulting in a lag in the coil current. The process is captured using a high-speed camera, revealing a regular droplet formation of 14 Hz and uniform shapes and sizes between 2.11 and 2.65 mm in diameter when operated within an appropriate process window. Larger drops and increased spatter formation occur outside this window. The proposed method allows for the production of droplets with almost spherical shapes. Further analysis and characterization of droplet formation and energy input provide insights into process optimization and indicate an overall efficiency of approximately 10%.