3D Metal Structure Welding With Sequential Dual Additives
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Solution Overview
Problem
Existing welding methods face limitations in welding speed, precision of electric arc guidance, and flexibility in choosing filler metal materials, which restricts the efficiency and accuracy of three-dimensional metal structure production.
Innovation Solution
The method involves sequentially supplying two different metal additives to a welding point, where they are fused using separate electric arcs, with a laser beam providing additional heat input. This allows for the construction of three-dimensional metal structures with high flexibility in material composition and geometry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a single welding method (GSMAW or laser welding) is used, then the process is simple and easy to operate, but the welding speed and precision are limited
Solution Approach 1:
The patent combines GSMAW and laser welding into a hybrid welding system where both welding methods work simultaneously on the same workpiece. The laser beam provides high-speed melting and precise heat input, while the GSMAW process adds filler material and ensures stable welding. This merging of two welding methods resolves the contradiction by achieving high welding speed (from laser) while maintaining ease of operation (from GSMAW's robust process characteristics).
Solution Approach 2:
The patent uses composite welding technology that integrates two different welding processes (arc welding and laser welding) into a unified hybrid system. This composite approach allows the system to leverage the advantages of both methods: the high speed and precision of laser welding combined with the operational simplicity and filler material deposition capability of GSMAW, thereby resolving the contradiction between ease of operation and welding speed.
2Device complexity
If a single welding method is used, then the equipment is simple, but the precision of electric arc guidance and material selection flexibility are limited
Solution Approach 1:
The hybrid welding system merges laser guidance technology with arc welding execution. The laser beam provides precise positioning and guidance for the welding process, while the GSMAW component handles the actual material deposition. This combination resolves the contradiction by achieving high manufacturing precision through laser guidance while keeping the overall equipment complexity manageable through integrated control systems.
3Device complexity
If traditional single-wire welding is used, then the process is simple, but the flexibility in choosing filler metal materials is limited
Solution Approach 1:
The hybrid welding system dynamically switches between laser-only mode and combined laser-GSMAW mode depending on the specific welding requirements and material selection needs. This dynamic capability allows the system to maintain process simplicity for standard applications while providing enhanced material flexibility when needed, resolving the contradiction between process simplicity and adaptability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enhances the flexibility and efficiency of three-dimensional metal structure production by allowing for the use of different materials, improving precision, and accommodating complex geometries, thereby reducing production time and costs.
Implementation Method 1
a first electric arc produced between a first electrode and the metal base material
Implementation Method 2
a laser beam is supplied to the welding point
Implementation Method 3
The shielding gas is used to shield the electric arc and the region of the melt from the atmosphere, substantially to avoid oxidation
Data Source
AI summary
In order to provide an improved method for producing metal structures which allows a high level of flexibility in respect of process speed of production, material composition of the metal structure, production accuracy, and the quality of the produced metal structure, according to the invention, a second metal additive is supplied to a welding point on a metal base material, which second metal additive is fused at least by a second electric arc produced between a second electrode and the metal base material in order to produce a second weld seam at the welding point, wherein different materials are used as the first metal additive and as the second metal additive, and wherein the first metal additive and the second metal additive are supplied to the welding point sequentially in time and are fused in the region of the welding point in whichever of the first and second electric arcs is burning, in order to form the three-dimensional metal structure.