Systems and Methods for Dual Plasma Wire Arc Additive Manufacturing

A method comprising:

• emitting an outer shielding gas from a torch assembly toward a substrate;
• emitting an ionizing gas from the torch assembly toward the substrate, wherein the ionizing gas is substantially surrounded by the outer shielding gas;
• extending a consumable electrode wire from the torch assembly toward the substrate, wherein the consumable electrode wire is substantially surrounded by the ionizing gas and the outer shielding gas;
• retracting the consumable electrode wire away from the substrate;
• attempting to establish a second electrical current between a nonconsumable electrode and the substrate, wherein a successful establishment at least partially ionizes the ionizing gas into a plasma;
• if the attempting is not successful, then repeating the extending, retracting, and attempting until the attempting is successful;
• and
• if the attempting is successful, then establishing a first electrical current between the consumable electrode wire and the substrate, wherein the first electrical current melts an end of the consumable electrode wire for deposition upon the substrate while the consumable electrode wire is substantially surrounded by the plasma and the outer shielding gas.

A method comprising:

• feeding a feed wire through a main channel of a torch assembly, wherein a distal end of the feed wire is in proximity to a substrate;
• supplying an inner shielding gas along the feed wire;
• supplying a middle shielding gas, wherein the inner shielding gas mixes with the middle shielding gas near a distal end of the main channel;
• applying a second electrical current through an electrode disposed at the distal end of the main channel to the distal end of the feed wire such that the second electrical current is configured to start an arc that is configured to ionize a mixture of the inner and middle shielding gases to form a plasma arc surrounding the feed wire;
• retracting the feed wire away from the distal end of the main channel;
• and
• applying a first electrical current through the feed wire, wherein the first electrical current is configured to create an electric arc to melt the feed wire to be deposited onto the substrate.

A method comprising:

• supplying an inner shielding gas along a feed wire, wherein the feed wire is fed through a main channel of a torch assembly;
• supplying a middle shielding gas, wherein the inner shielding gas mixes with the middle shielding gas near a distal end of the main channel;
• positioning a distal end of the feed wire in contact with a substrate;
• retracting the feed wire away from the substrate;
• applying a second electrical current through an electrode disposed at the distal end of the main channel to the distal end of the feed wire, wherein the second electrical current is configured to ignite an arc;
• determining if the arc is ignited:
• if not ignited, repeating the positioning, retracting, applying the second electrical current, and determining steps until the arc is ignited;
• wherein the arc is configured to ionize a mixture of the inner and middle shielding gases to form a plasma arc surrounding the feed wire;
• and
• applying a first electrical current through the feed wire, wherein the first electrical current is configured to create an electric arc to melt the feed wire to be deposited onto the substrate.