How to Control Arc Voltage Fluctuation in Submerged Arc

Overview of Technical Issues:

The arc zone exhibits insufficient stability in converting electrical energy to heat during submerged arc welding, and the flux layer provides insufficient constraint on arc geometry, causing voltage fluctuations that result in inconsistent heat input to the molten pool and produce weld defects including irregular penetration depth, porosity, and inconsistent bead appearance; the goal is to achieve stable arc voltage control for consistent weld quality.

Solution directions generated for this problem

Problem Direction 1 :

ImproveFlux constraint capacity on arc
VS
ConstraintFlux consumption rate

Inspiration 1 : Cross-domain reference

Application Principle: #35 Parameter changes
Cross-domain applicability Assess applicability
Carbon materials, methods for manufacturing carbon materials, and non-aqueous secondary batteries using carbon materials.
Innovative Solution Refine solution

Temperature-responsive flux with phase-transition constraint mechanism

Flux transitions from low to high viscosity at arc temperature
How to solve :
  • Incorporate phase-change materials (PCM) into flux formulation that undergo reversible solid-liquid or viscosity transitions at 1200–1400°C arc temperature range, providing strong geometric constraint only when arc instability raises local temperature
  • Formulate flux with 15–25% sodium fluoroaluminate and 8–12% calcium fluoride as temperature-sensitive viscosity modifiers, remaining inert at base metal temperature (≤800°C) but forming high-viscosity melt (≥200 Pa·s) above 1200°C to confine arc column within 0.6mm diameter tolerance
  • Deploy standard flux consumption rate (0.8–1.2 kg flux per kg wire) while achieving constraint force equivalent to 1.5× density systems through adaptive rheological response — quality control via viscosity measurement at 1250°C (target 180–220 Pa·s) and arc voltage monitoring (±2V stability window)
Expected Effect : Constraint force +60%, flux consumption unchanged, voltage stability ±1.5V
Risk Control :
  • PCM decomposition temperature drift
  • viscosity transition hysteresis
  • fluoride vapor emission control

Problem Direction 2 :

ImproveFlux constraint capacity on arc
VS
ConstraintSlag detachability

Inspiration 1 : Cross-domain reference

Application Principle: #2 Taking out (Extraction)
Cross-domain applicability Assess applicability
Method for removing magnesium impurity element in waste aluminum regeneration
Innovative Solution Refine solution

Dual-phase flux system with vaporizing arc constraint layer

Separate arc constraint from slag formation using dual-phase flux
How to solve :
  • Deploy bottom vaporizing constraint layer (5-8mm depth) containing fluoride-rich fine particles (≤100μm) that provide arc confinement through gas-phase interaction then vaporize at arc temperature (≥2500°C), leaving minimal residue
  • Apply upper silicate-based protective layer (15-20mm depth) with standard composition (SiO₂ 45-55%, CaO 20-30%, MgO 5-10%) that forms conventional easily-removable slag without contacting arc directly
  • Control bottom layer particle size distribution (80% within 80-120μm range) and fluoride content (12-18% CaF₂ + AlF₃) to ensure complete vaporization while maintaining arc geometry constraint force ≥85% of solid-phase constraint
Expected Effect : Arc voltage stability ±2V; slag removal force reduced 60%; constraint effectiveness maintained
Risk Control :
  • bottom layer vaporization incomplete causing residue
  • layer interface mixing during welding
  • fluoride vapor emission control

Problem Direction 3 :

ImproveArc voltage stability
VS
ConstraintFlux consumption rate

Inspiration 1 : Cross-domain reference

Application Principle: #35 Parameter changes
Cross-domain applicability Assess applicability
Apparatus and method for configuring control message in broadcasting system
Innovative Solution Refine solution

Temperature-responsive flux with adaptive viscosity control for arc stabilization

Flux adapts constraint force by temperature
How to solve :
  • Formulate flux with thermally-activated viscosity modifiers (15–25 wt% sodium silicate + 3–5 wt% bentonite clay) that increase melt viscosity from 0.8 Pa·s at 1400°C to 2.5 Pa·s at 1600°C, automatically constraining arc during voltage spikes without continuous high-density coverage
  • Deploy dual-phase flux system: 8–12 mm base layer of standard flux (consumption 0.8 kg/m) provides thermal insulation, while 2–3 mm active top layer contains phase-change additives (calcium fluoride-lithium carbonate eutectic, melting point 1450°C) that liquefy and increase electrical conductivity by 40% during arc instability, self-correcting voltage deviations
  • Implement real-time voltage monitoring (sampling rate ≥1 kHz) triggering auxiliary flux feeder that dispenses constraint-enhancing powder (magnesium oxide + potassium titanate, particle size 50–100 μm) at 5–8 g/min only when voltage deviation exceeds ±3V threshold, reducing specialized flux consumption by 55–65%
Expected Effect : Voltage stability ±2V, flux consumption +8% only, penetration uniformity 92%
Risk Control :
  • viscosity modifier decomposition at high current
  • dual-layer separation during transport
  • sensor fouling in flux environment

Problem Direction 4 :

ImproveArc voltage stability
VS
ConstraintSlag detachability

Inspiration 1 : Cross-domain reference

Application Principle: #19 Periodic action
Cross-domain applicability Assess applicability
Pixel driving method, display driving method and display substrate
Innovative Solution Refine solution

Pulsed flux injection system with voltage-triggered constraint delivery

Pulsed flux delivery stabilizes arc without continuous high-constraint slag
How to solve :
  • Install voltage-sensing flux injector that monitors arc voltage at 1 kHz sampling rate and injects high-constraint flux (15–25% fluoride content) only when voltage deviation exceeds ±2V threshold, reducing specialized flux use by 60%
  • Base flux layer uses standard silicate composition (SiO₂ 35%, CaO 25%, MgO 15%) with water-soluble binder (5% sodium silicate) that forms easily-removable slag during stable welding phases
  • Injection nozzle delivers 0.3–0.5 g/pulse of constraint flux within 50 ms response time, positioned 20 mm ahead of electrode tip, creating localized arc stabilization zone that vaporizes during welding without forming tenacious slag residue
Expected Effect : Voltage stability ±1.5V, slag removal time −70%, constraint flux cost −60%
Risk Control :
  • injection timing synchronization accuracy
  • nozzle clogging under flux dust
  • voltage sensor interference from electromagnetic field
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