A Finite Element Study of Coil Shapes Effects on Extruder Temperature Distribution in Extrusion-Based Metal Additive Manufacturing Using Induction Heating

Induction heating finds extensive application in industrial processes such as welding, brazing, preheating, and melting. However, its use in metal additive manufacturing as a heating source has yet to be explored extensively. In induction heating, heat is generated directly inside the workpiece by restricting eddy currents. To ensure consistent material deposition in extrusion-based metal additive manufacturing, a uniform temperature must be maintained throughout the extruder to achieve a constant liquid–solid fraction ratio during extrusion. A study of induction heating, comparing the effects of different coil shapes on extruder temperature distribution, has been conducted using finite element analysis. Simulation results show that using an oval coil shape with induction heating in an extrusion-based additive manufacturing system creates more uniform heat distribution in the extruder compared to other coil shapes.