Additively Manufactured Welding Torch for Compact Function Integration
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Solution Overview
Problem
Existing welding torches for complex geometries and miniaturized applications are expensive to manufacture and have limited options for integrating multiple functions such as cooling, gas supply, instrumentation, and remote vision.
Innovation Solution
A welding torch manufactured using additive manufacturing techniques, featuring a body made from electrically conductive metal, integrated wire guide with insulating sheath, and components such as a carrier and base also produced by additive manufacturing, allowing for compact integration of multiple functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional manufacturing methods (machining, assembling parts from different materials) are used, then the welding torch can be manufactured with multiple materials, but the manufacturing cost is high and miniaturization options are limited
Solution Approach 1:
The patent merges multiple functions (cooling channels, gas passages, electrical connections, structural support) into a single monoblock body manufactured by additive manufacturing. This eliminates the need to assemble multiple parts from different materials, reducing manufacturing cost and enabling miniaturization while maintaining adaptability.
Solution Approach 2:
The monoblock body serves multiple functions simultaneously: it provides structural support, contains cooling channels, guides protective gas, conducts electricity to the electrode, and integrates the wire guide. This multi-functionality reduces the number of components needed, enabling miniaturization without sacrificing versatility.
2Volume of moving object
If the torch is miniaturized to access confined areas, then accessibility to repair areas is improved, but integrating multiple functions (cooling, gas supply, instrumentation) becomes more difficult
Solution Approach 1:
The patent nests multiple functional elements within the monoblock body: cooling channels are nested within the body structure, gas passages are integrated into the same volume, and the wire guide is positioned within the compact head assembly. This nesting approach allows multiple functions to coexist in a miniaturized configuration.
Solution Approach 2:
The additive manufacturing process enables three-dimensional optimization of the monoblock body, allowing complex internal channels and passages to be created in multiple dimensions. This dimensional freedom allows efficient packing of multiple functions within a small volume, overcoming the limitations of traditional miniaturization.
3Adaptability or versatility
If complex geometries are required for welding operations, then adaptability to different welding situations is improved, but traditional manufacturing methods become more expensive
Solution Approach 1:
The patent changes the manufacturing parameter from traditional subtractive machining to additive manufacturing. This parameter change enables the production of complex geometries at lower cost, as additive manufacturing builds structures layer by layer without the tooling and assembly costs associated with traditional methods for complex shapes.
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
The additive manufacturing approach enables the cost-effective production of miniaturized welding torches with complex geometries, effectively integrating multiple functions into a compact design, suitable for challenging applications like nuclear industry repairs.
Implementation Method 1
the body being obtained by additive manufacturing from an electrically conductive metal, the electrode being electrically connected to the electric power source by the metal constituting the body
Implementation Method 2
the wire guide comprising an insulating sheath inside which the filler metal wire moves, the filler metal wire being electrically insulated from the potential of the body by the insulating sheath
Data Source
AI summary
A welding torch includes a head (3) having a body (11) bearing an electrode (13); an electric power source (27); and a filler metal wire (17) and a wire guide (19) guiding the filler metal wire (17) to the electrode (13). The body (11) is obtained by additive manufacturing from an electrically conductive metal, and the electrode (13) is electrically connected to the electric power source (27) by the metal constituting the body (11). The wire guide (19) includes an insulating sheath (29) inside which the filler metal wire (17) moves, and the filler metal wire (17) is electrically insulated from the potential of the body (11) by the insulating sheath (29).