Method and system for additive manufacturing using high energy source and hot-wire

An method of additive manufacturing, comprising:

• irradiating a surface of a work piece with a high energy discharge to create a molten puddle on a surface of said work piece;
• supplying a heating signal to a consumable where said heating signal comprises a plurality of current pulses and where each of said current pulses creates a molten droplet on a distal end of said consumable which is deposited into said puddle;
• passing said consumable through a passage in a contact tip assembly;
• changing a shape of said consumable within said passage of said contact tip assembly;
• and
• delivering said consumable to said work piece;
• wherein each of said current pulses reaches a peak current level after said distal end of said consumable contacts said puddle,
• wherein said heating signal has no current in between said plurality of said current pulses;
• wherein said distal end of said consumable is not in contact with said puddle between subsequent peak current levels of said current pulses;
• and
• wherein said power supply controls said heating current such that no arc is created between said wire and said work piece during said current pulses.

An additive manufacturing system, comprising:

• a high energy device which irradiates a surface of a workpiece with a high energy discharge to create at least one molten puddle on a surface of said workpiece;
• a contact tip assembly which can direct a first wire and a second wire to said work piece at the same time;
• and
• a first power supply which supplies a first heating signal to at least said first wire where said first heating signal comprises a plurality of first current pulses and where each of said first current pulses of said first heating signal creates a molten droplet on a distal end of at least said first wire which is deposited into said at least one puddle;
• and
• wherein each of said first current pulses reaches a peak current level after a distal end of said first wire contacts said at least one puddle,
• wherein said first heating signal has no current in between said plurality of said first current pulses;
• wherein said distal end of said first wire is not in contact with said at least one puddle between subsequent peak current levels of said first current pulses;
• and
• wherein said first power supply controls said first heating current such that no arc is created between said first wire and said work piece during said first current pulses.