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

1. An additive manufacturing system, comprising:

a high energy device which irradiates a surface of a work piece with a high energy discharge to create a molten puddle on a surface of said work piece; and

a power supply which supplies 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;

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;

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; and

wherein said consumable comprises a plurality of individual wires which are directed to said work piece at the same time.

2. The system of claim 1 , wherein said plurality of individual wires are surrounded by a sheath.

3. The system of claim 1 , wherein said plurality of individual wires create a void at a center of said consumable.

4. The system of claim 3 , wherein the void has a diameter which is in the range of 5 to 40% of the effective diameter of the consumable.

5. The system of claim 1 , wherein said plurality of individual wires has a first number of wires with a first diameter and a second number of wires with a second diameter which is different than said first diameter.

6. The system of claim 1 , wherein said plurality of individual wires has a first number of wires with a first composition and a second number of wires with a second composition which is different than said first composition.

7. The system of claim 1 , wherein said plurality of individual wires has a first number of wires with a first melting temperature and a second number of wires with a second melting temperature which is different than said first melting temperature.

8. The system of claim 3 , further comprising a consumable delivery assembly which changes a shape of said consumable deposition of said consumable.

9. The system of claim 2 , wherein said sheath has a lower melting temperature than said plurality of individual wires.

10. An additive manufacturing system, comprising:

a high energy device which irradiates a surface of a work piece with a high energy discharge to create a molten puddle on a surface of said work piece; and

a power supply which supplies 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;

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;

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; and

wherein said consumable comprises a plurality of braided individual wires which are directed to said work piece at the same time.

11. The system of claim 10 , wherein said plurality of individual wires are surrounded by a sheath.

12. The system of claim 10 , wherein said plurality of individual wires create a void at a center of said consumable.

13. The system of claim 12 , wherein the void has a diameter which is in the range of 5 to 40% of the effective diameter of the consumable.

14. The system of claim 10 , wherein said plurality of individual wires has a first number of wires with a first diameter and a second number of wires with a second diameter which is different than said first diameter.

15. The system of claim 10 , wherein said plurality of individual wires has a first number of wires with a first composition and a second number of wires with a second composition which is different than said first composition.

16. The system of claim 10 , wherein said plurality of individual wires has a first number of wires with a first melting temperature and a second number of wires with a second melting temperature which is different than said first melting temperature.

17. The system of claim 10 , further comprising a consumable delivery assembly which changes a shape of said consumable deposition of said consumable.

18. The system of claim 11 , wherein said sheath has a lower melting temperature than said plurality of individual wires.

19. An additive manufacturing system, comprising:

a high energy device which irradiates a surface of a work piece with a high energy discharge to create a molten puddle on a surface of said work piece; and

a power supply which supplies a heating signal to a plurality of consumables where said heating signal comprises a plurality of current pulses and where each of said current pulses creates at least one molten droplet on distal ends of said consumables which is deposited into said puddle;

wherein each of said current pulses reaches a peak current level after said distal ends of said consumables contacts said puddle,

wherein said heating signal has no current in between said plurality of said current pulses;

wherein said distal ends of said consumables are not in contact with said puddle between subsequent peak current levels of said current pulses;

wherein said power supply controls said heating current such that no arc is created between said consumables and said work piece during said current pulses; and

wherein an orientation of said consumables relative to a travel direction of said consumables can be rotated during deposition.