Kimme, J.; Gruner, J.; Hälsig, A.; Hensel, J. Droplet Formation and Energy Input during Induction Wire Melting with Pulsed and Constant Generator Power. J. Manuf. Mater. Process.2024, 8, 80.
Kimme, J.; Gruner, J.; Hälsig, A.; Hensel, J. Droplet Formation and Energy Input during Induction Wire Melting with Pulsed and Constant Generator Power. J. Manuf. Mater. Process. 2024, 8, 80.
Kimme, J.; Gruner, J.; Hälsig, A.; Hensel, J. Droplet Formation and Energy Input during Induction Wire Melting with Pulsed and Constant Generator Power. J. Manuf. Mater. Process.2024, 8, 80.
Kimme, J.; Gruner, J.; Hälsig, A.; Hensel, J. Droplet Formation and Energy Input during Induction Wire Melting with Pulsed and Constant Generator Power. J. Manuf. Mater. Process. 2024, 8, 80.
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 sluggish response to the excitation voltage, resulting in a lag in the coil current. The process is captured using a high-speed camera, revealing regular droplet formation and uniform size and shape 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 overall efficiency.
Keywords
additive manufacturing; directed energy deposition; 3D printing; induction heating; calorimetry; mild steel; wire feedstock; pulsed power; process monitoring
Subject
Engineering, Industrial and Manufacturing Engineering
Copyright:
This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.
