System and method for controlling welding parameters in welding-based deposition processes

Logic encoded in media for controlling operational weld parameters of a welding-based deposition process, the logic operable to:

• generate a solid model representing a three-dimensional part on a computer;
• generate a plurality of electronic two-dimensional layers based on the solid model;
• identify a path of material deposition based on the electronic two-dimensional layers, the path comprising a plurality of deposition points;
• determine a geometrical factor for each deposition point, the geometrical factor defined by a ratio of an actual volume of material around each deposition point to a theoretical volume of material around each deposition point;
• and
• automatically adjust, during material deposition for a respective deposition point, one or more parameters of the welding-based deposition process based on the geometrical factor for the respective deposition point.

A method for controlling operational weld parameters of a welding-based deposition process, comprising:

• generating a solid CAD model representing a three-dimensional part on a computer;
• electronically slicing the solid CAD model into a plurality of electronic two-dimensional layers;
• identifying a path of material deposition based on the electronic two-dimensional layers, the path comprising a plurality of deposition points;
• digitizing a volume of the solid CAD model to represent the solid CAD model as a three dimensional matrix of volumetric points;
• assigning each volumetric point a first value if material exists at that volumetric point or a second value if material does not exist at that volumetric point;
• identifying an actual volume of material around each deposition point based on the matrix;
• identifying a theoretical volume of material based on a theoretical hemisphere defined by a predetermined heat affected zone that is based on an initial set of parameters for the welding-based deposition process;
• determining a geometrical factor for each deposition point, the geometrical factor defined by a ratio of the actual volume of material to the theoretical volume of material;
• and
• automatically adjusting, during material deposition for a respective deposition point, one or more parameters of the welding-based deposition process based on the geometrical factor for the respective deposition point.

A system for controlling operational weld parameters of a welding-based deposition process, comprising:

• means for generating a solid model representing a three-dimensional part;
• means for generating a plurality of electronic two-dimensional layers based on the solid model;
• means for identifying a path of material deposition based on the electronic two-dimensional layers, the path comprising a plurality of deposition points;
• means for determining a geometrical factor for each deposition point, the geometrical factor defined by a ratio of an actual volume of material around each deposition point to a theoretical volume of material around each deposition point;
• and
• means for automatically adjusting, during material deposition for a respective deposition point, one or more parameters of the welding-based deposition process based on the geometrical factor for the respective deposition point.