Arc Welding Wire Feed Control for Crater Recess Reduction
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Solution Overview
Problem
Conventional arc welding methods face challenges in achieving low spatter, a small crater portion, and a recess-free crater portion, leading to potential defects and increased after-treatment needs, particularly due to high heat input causing large recesses during welding termination.
Innovation Solution
The method involves maintaining a constant wire feed speed during steady-state welding and switching to an alternating forward and backward wire feed speed at welding termination or after a predetermined period, reducing heat input and preventing short circuits, thereby controlling spatter and crater size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional arc welding methods are used with continuous wire feed, then welding can be performed efficiently, but large crater portions with recesses are created due to high heat input during welding termination
Solution Approach 1:
The wire feed speed is dynamically changed during welding termination from a constant speed to an alternating forward and backward speed pattern. This dynamic adjustment allows the wire to be fed forward during arc welding and backward during crater filling, optimizing both welding efficiency and crater portion control without requiring separate operations
Solution Approach 2:
The wire feed speed is changed to an alternating periodic pattern during the welding end period, switching between forward feed (during arc welding) and backward feed (during crater filling). This periodic action enables the system to achieve both efficient welding and precise crater control through rhythmic speed variations
2Manufacturing precision
If wire feed speed is reduced to minimize crater portion, then heat input is reduced, but short circuits may occur during pulse welding
Solution Approach 1:
The wire feed speed is dynamically adjusted based on the welding state, switching between forward feed during arc welding and backward feed during crater filling. This dynamic control prevents short circuits by maintaining appropriate wire feed speed during pulse welding while still minimizing crater portion through backward feeding
Solution Approach 2:
The welding end period is segmented into distinct phases: arc welding phase with forward wire feed and crater filling phase with backward wire feed. This segmentation allows independent optimization of each phase, preventing short circuits during arc welding while minimizing crater portion during filling
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 results in reduced spatter, smaller crater portions, and elimination of recesses, minimizing the need for after-treatments and improving weld quality by preventing defects, thus enhancing production efficiency.
Implementation Method 1
switches the wire feed speed from the predetermined constant speed to a wire feed speed at which the welding wire is fed in alternating forward and backward directions
Implementation Method 2
arc welding where an arc is generated between a welding wire as a consumable electrode and an object to be welded
Data Source
AI summary
Disclosed is a method for controlling arc welding where an arc is generated between a welding wire as a consumable electrode and an object to be welded. The method includes: keeping a wire feed speed at a predetermined constant speed in a steady-state welding period; and at a time point when welding termination is ordered, either switching the wire feed speed from the predetermined constant speed to a wire feed speed at which the welding wire is fed in alternating forward and backward directions, or decreasing the wire feed speed from the predetermined constant speed with time, and then switching the wire feed speed to the wire feed speed at which the welding wire is fed in alternating forward and backward directions at a time point when a predetermined time period has passed since when welding termination was ordered.