Abstract: Embodiments of an integrated laser hot wire deposition head are disclosed. In one embodiment, the deposition head includes a structural frame, a laser process sub-system, a wire feeding device, and a contact tube. The laser process sub-system is mounted within the structural frame to deliver a single beam path laser beam in a longitudinally-oriented direction toward a substrate or a part to be additively manufactured. The wire feeding device and contact tube are mounted within the frame to feed a consumable filler wire toward the substrate or part at an angle with respect to the longitudinally-oriented direction. The deposition head can be moved omni-directionally with respect to the substrate or the part, under the guidance of a motion control system, to additively manufacture the part without having to angularly change an orientation of the single beam path laser beam from the longitudinally-oriented direction or rotate the deposition head.

Abstract: The disclosed technology generally relates to welding, and more particularly to welding multi-layered structures. In an aspect, a method of welding multi-layered metallic workpieces comprises providing a pair of multi-layered workpieces. Each of the workpieces has a base layer and an cladding layer, where the cladding layer comprises a corrosion resistant element adapted to suppress corrosion in a ferrous alloy. The method additionally comprises forming a root pass weld bead to join cladding layers of the workpieces using a first filler wire comprising the corrosion resistant element and focusing a first laser beam on the cladding layers. The method additionally comprises forming one or more weld beads to join base layers of the workpieces by resistively heating a second filler wire and directing a second laser beam over the root pass weld bead.

Abstract: Embodiments of an integrated laser hot wire deposition head are disclosed. In one embodiment, the deposition head includes a structural frame, a laser process sub-system, a wire feeding device, and a contact tube. The laser process sub-system is mounted within the structural frame to deliver a single beam path laser beam in a longitudinally-oriented direction toward a substrate or a part to be additively manufactured. The wire feeding device and contact tube are mounted within the frame to feed a consumable filler wire toward the substrate or part at an angle with respect to the longitudinally-oriented direction. The deposition head can be moved omni-directionally with respect to the substrate or the part, under the guidance of a motion control system, to additively manufacture the part without having to angularly change an orientation of the single beam path laser beam from the longitudinally-oriented direction or rotate the deposition head.

Abstract: The disclosed technology generally relates to welding, and more particularly to welding multi-layered structures. In an aspect, a method of welding multi-layered metallic workpieces comprises providing a pair of multi-layered workpieces. Each of the workpieces has a base layer and an cladding layer, where the cladding layer comprises a corrosion resistant element adapted to suppress corrosion in a ferrous alloy. The method additionally comprises forming a root pass weld bead to join cladding layers of the workpieces using a first filler wire comprising the corrosion resistant element and focusing a first laser beam on the cladding layers. The method additionally comprises forming one or more weld beads to join base layers of the workpieces by resistively heating a second filler wire and directing a second laser beam over the root pass weld bead.

Abstract: A method and system to weld or join workpieces employing a high intensity energy source to create a weld puddle and at least one resistive filler wire which is heated to at or near its melting temperature and deposited into the weld puddle.

Abstract: A hot-wire and arc welding system and method. The system includes an arc welding power supply to supply a welding waveform. The welding waveform includes a plurality of welding pulses, with each welding pulse having a peak welding current level. The system also includes a hot-wire power supply to supply a heating waveform. The heating waveform includes a plurality of heating pulses, with each heating pulse having a peak heating current level. A controller, which is operatively connected to the arc welding power supply and the hot-wire power supply, synchronizes the plurality of welding pulses and the plurality of heating pulses such that at least a portion of the peak welding current level overlaps with at least a portion of the peak heating current level.

Abstract: A system and method of welding stainless steel to copper is provided. The method includes providing a first workpiece composed of stainless steel and providing a second workpiece composed of copper. The method also includes heating by using a laser a root area of a joint created by the workpieces. The heating by the laser creates a keyhole in at least one of the first workpiece and the second workpiece. The method also includes providing a consumable electrode that is composed of nickel to the joint and creating an arc between the consumable electrode and the joint using a welding current. The preheating of the arc using the keyhole eliminates the need to preheat the second workpiece.

Abstract: A method and system to weld or join workpieces employing a high intensity energy source to create a weld puddle and at least one resistive filler wire which is heated to at or near its melting temperature and deposited into the weld puddle.