Method for producing a variable flow of melted material and articles therefrom
AssigneeFord Global Technologies, LLC
InventorsDavid Collins, Allen Roche
Life of this patent
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Abstract
A method for generating a variable flow of melted material is disclosed. The method includes providing first and second members having a potential energy difference between them. One or more members is extended at a first average extension rate for a first period while producing an electrical arc. One or more members is extended at a second average extension rate for a second period while producing an electrical arc. One or more members is extended at a third average extension rate for a third period while producing an electrical arc. A transport medium is flowed across one or more members during one or more of the extending steps.
Claims17
A method for generating a variable flow of melted material, the method comprising:
- (a) providing first and second members, the members having a potential energy difference between them, and the first and second members including first and second consumable ends, respectively;
- (b) extending the first member at a first average extension rate for a first period, and extending the second member during at least a portion of the first period while producing an electrical arc between the first and second members to consume the first and second consumable ends followed by producing a sufficient gap between the first and second consumable ends to allow for dissipation of the electrical arc;
- (c) extending one or more of the first and second members at a second average extension rate for a second period while producing the electrical arc followed by dissipation of the electrical arc;
- and
- (d) flowing a transport medium in contact with the first and second members during the extending step (b), subsequent to extending step (b) and during extending step (c).
A method for depositing on a surface, the method comprising:
- (a) creating a variable flow of melted material by providing first and second members, the members having a potential energy difference between them, and the first and second members including first and second consumable ends, respectively;
- (b) extending the first member at a first average extension rate for a first period and extending the second member during at least a portion of the first period while producing an electrical arc to generate melted material and to consume a portion of the first member at a first average consumption rate, the first average extension rate being less than the first average consumption rate such that dissipation of the electrical arc occurs;
- (c) flowing a transport medium in contact with the first and second members during extension step (b);
- (d) atomizing the variable flow of melted material;
- and
- (e) directing the variable flow to the surface of a substrate.
A method for generating a variable flow of melted material from first and second wires, the method comprising:
- (a) providing first and second wires having a potential energy difference between them, the first and second wires having first and second consumable ends, respectively;
- (b) extending the first and second wires while generating an electrical arc between the first and second wires so as to consume the first and second consumable ends to produce melted material during a first extension period;
- (c) adjusting the average extension rate of the first wire relative to the average extension rate of the second wire such that a sufficient gap is produced between the first and second consumable ends to allow the electrical arc to dissipate and to produce melted material during a dissipation period;
- (d) subsequent to the adjusting step (c), readjusting the average extension rate of the first wire relative to the average extension rate of the second wire such that a sufficient proximity is produced between the first and second consumable ends to allow the electrical arc to regenerate so as to consume the first and second consumable ends to produce melted material during a second extension period;
- and
- (e) contacting the first and second wires with a transport medium during the first extension period, the dissipation period and the second extension period to transport the melted material away from the first and second consumable ends.
Dependencies are inferred from the claim text.