Consumable Wire Arc Welding Current Lowering for Arc Stability
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Solution Overview
Problem
Existing arc welding methods face instability and reduced weld quality due to thermal overload of the welding wire stickout when transitioning to processes with increased mean wire conveying speed and/or welding current, leading to arc length variations and spatter formation.
Innovation Solution
Implementing a lowering phase with reduced welding current during the transition to a process with increased mean wire conveying speed and/or welding current, accompanied by a delay time or predefined path length, to stabilize the arc and maintain consistent temperature distribution in the stickout.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the welding process is changed to a welding process with an increased mean wire conveying speed and/or an increased mean welding current, then the productivity and penetration depth of the welding process is improved, but the risk of thermal overload of the stickout increases leading to arc length variations and spatter formation
Solution Approach 1:
The method initiates a lowering phase with reduced welding current before the full increased current is applied when changing to a new welding process. This preliminary action prevents thermal overload of the stickout by gradually preparing the system, allowing the wire to be conveyed at higher speeds and current to be increased without causing sudden thermal overload, arc length variations, or spatter formation.
2Power
If the welding current is increased to improve penetration depth, then the welding process efficiency is improved, but the temperature in the stickout increases causing sudden melting of the welding wire end
Solution Approach 1:
The method employs periodic modulation of the welding current through distinct phases: a lowering phase with reduced current, a transition phase with increasing current, and a target phase with full current. This periodic action allows the welding current to be increased for better penetration while preventing excessive temperature buildup in the stickout by cycling through current levels that allow thermal management.
3Productivity
If the wire conveying speed is increased to improve productivity, then the welding efficiency is improved, but the welding process stability deteriorates due to thermal overload
Solution Approach 1:
The method initiates a lowering phase with reduced welding current before the full increased current is applied when changing to a new welding process. This preliminary action prevents thermal overload of the stickout by gradually preparing the system, allowing the wire to be conveyed at higher speeds and current to be increased without causing sudden thermal overload, arc length variations, or spatter formation.
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
Stabilizes the arc and maintains consistent weld quality by preventing thermal overload of the welding wire stickout, ensuring a stable welding process even with changes in welding parameters.
Implementation Method 1
the consumable welding wire is contacted in the contact tube of the welding torch and has a welding voltage and a welding current applied to it, so that an electric arc is formed from the free end of the welding wire to the workpiece, which melts the end of the welding wire
Implementation Method 2
an electric arc is formed from the free end of the welding wire to the workpiece, which melts the end of the welding wire, leading to a material transfer from the welding wire to the workpiece
Data Source
AI summary
The invention relates to an arc welding method using a consumable welding wire (1), wherein in successive welding cycles (SZ) during a welding process (Pi) a certain welding current (I(t)) is applied to the welding wire (1) and the welding wire is moved with a certain wire conveying speed (v(t)) towards a workpiece (2) to be processed. The aim of the invention is to further improve the stability of the welding method. The aim is achieved, according to the invention, in that in the event of a change of the welding process (P1) to a welding process (P2) with an increased mean wire conveying speed (vmean) during a welding cycle (SZ) and/or with an increased mean welding current (Imean) during a welding cycle (SZ), a lowering phase (AP) is initiated, wherein in the lowering phase (AP) the welding current (IA(t)) is lowered for a specified duration (ΔtA).