Arc Welding Current Control for Fused Portion Adhesion
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Solution Overview
Problem
Conventional arc welding methods, such as TIG welding, often experience separated fusion defects where base metals fail to fuse properly due to vertical steps or poor contact with ground electrodes, leading to incomplete joining.
Innovation Solution
The method involves using a non-consumable welding electrode with a control unit that adjusts the welding current to change the position of fused portions, allowing them to bridge and adhere to each other, minimizing separated fusion by controlling the current through specific waveform steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional arc welding is performed on horizontally butted work pieces, then welding can be completed, but separated fusion occurs where base metals do not fuse properly
Solution Approach 1:
The welding current is dynamically changed during the welding process. The control unit decreases the welding current after an initial period, causing the fused portion to move toward the other work piece for adhesion. This dynamic current adjustment resolves the contradiction by adapting the welding parameters in real-time to achieve complete fusion and prevent separated fusion defects.
Solution Approach 2:
The welding current parameter is changed during the welding process. By decreasing the welding current after an initial welding period, the fused portion is caused to move and adhere to the other work piece. This parameter change enables complete fusion and eliminates separated fusion while maintaining welding quality.
2Manufacturing precision
If welding current is increased to ensure complete fusion, then fusion completeness improves, but excessive heat input causes defects
Solution Approach 1:
The welding current is applied in a periodic manner with two distinct phases: an initial welding period with higher current to create the fused portion, followed by a current decrease phase to move the fused portion for adhesion. This periodic action ensures complete fusion while avoiding excessive heat input that would cause defects.
Solution Approach 2:
The welding current is applied at a level sufficient to create the fused portion during the initial period, then decreased to the extent needed to move the fused portion for adhesion. This partial action approach achieves complete fusion without applying excessive heat throughout the entire process, preventing heat-related defects.
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 effectively reduces the occurrence of separated fusion by ensuring proper adhesion and fusion between work pieces, maintaining a strong bond while avoiding excessive heat input that could cause defects.
Implementation Method 1
a welding electrode which is a non-consumable type electrode used for performing arc welding
Implementation Method 2
applying welding current to the welding electrode so as to have the two work pieces welded
Data Source
AI summary
A method for performing arc welding includes steps of: preparing two work pieces each having fused portion, being butted against one another; preparing a welding electrode which is a non-consumable type electrode used for performing arc welding to the two work pieces, the welding electrode being disposed to face the two work pieces; applying welding current to the welding electrode so as to have the two work pieces welded; and performing a current changing step to change an amount of the welding current to be decreased so as to have a fused portion of at least one of the two work pieces move toward the other work piece for adhesion to the fused portion of the other work piece or for adhesion to the other work piece itself.