Arc Welding Plating Layer Removal and Brazing
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Solution Overview
Problem
Conventional arc welding methods face challenges when welding base materials with plating layers, as setting peak current to melt the filler wire either leaves a weak joint due to remaining plating or evaporates the filler metal, which is not properly welded.
Innovation Solution
An arc welding method that alternates between a plating layer removal process using a higher current to expose the metal and a brazing filler metal welding process using a lower current to prevent filler metal evaporation, ensuring the plating layer is removed before welding, and the filler metal is fed to the exposed area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the peak current is set to a temperature to melt the filler wire, then the filler wire can be welded, but the plating layer remains on the joint interface causing weak joint strength
Solution Approach 1:
The welding process is segmented into two distinct phases: a plating layer removal process using higher current to eliminate the plating layer, and a filler wire welding process using lower current to melt and weld the filler wire. This segmentation allows each phase to be optimized independently, ensuring complete plating layer removal while maintaining proper filler wire welding.
Solution Approach 2:
The welding process employs periodic action by alternately applying different current values in a controlled sequence. The current is first increased to a higher value for plating layer removal, then reduced to a lower value for filler wire welding. This periodic variation in current enables both the plating layer to be removed and the filler wire to be properly welded without interference.
2Manufacturing precision
If the peak current is set to a temperature to melt and evaporate the plating layer, then the plating layer is removed, but the brazing filler metal evaporates and the base materials are not welded properly
Solution Approach 1:
The plating layer removal process is performed as a preliminary action before the filler wire welding process. By first removing the plating layer using higher current and then reducing the current for filler wire welding, the invention prevents the filler wire from being exposed to temperatures that would cause evaporation. The preliminary removal of the plating layer eliminates the barrier that would otherwise prevent proper welding.
Solution Approach 2:
The welding process employs periodic action by alternately applying different current values in a controlled sequence. The current is first increased to a higher value for plating layer removal, then reduced to a lower value for filler wire welding. This periodic variation in current enables both the plating layer to be removed and the filler wire to be properly welded without interference.
3Ease of manufacture
If the plating layer is not removed before welding, then the welding process is simpler, but the joint strength is weak due to plating layer interference at the joint interface
Solution Approach 1:
The welding process is segmented into two distinct phases: a plating layer removal process using higher current to eliminate the plating layer, and a filler wire welding process using lower current to melt and weld the filler wire. This segmentation allows each phase to be optimized independently, ensuring complete plating layer removal while maintaining proper filler wire welding.
Solution Approach 2:
The welding process employs periodic action by alternately applying different current values in a controlled sequence. The current is first increased to a higher value for plating layer removal, then reduced to a lower value for filler wire welding. This periodic variation in current enables both the plating layer to be removed and the filler wire to be properly welded without interference.
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 method enhances joint strength by preventing the plating layer from interfering with the weld and ensuring proper bonding of the filler metal, resulting in a stronger joint interface.
Implementation Method 1
performing an arc discharge at a first current value while moving a welding torch along a welding line in a state of stopping feed of the brazing filler metal
Implementation Method 2
removing a plating layer by performing an arc discharge
Implementation Method 3
welding the brazing filler metal to a position where the plating layer is removed, by performing the arc discharge at a second current value
Implementation Method 4
melts a filler wire (brazing filler metal) by high heat of the arc discharge
Implementation Method 5
the molten brazing filler metal enters a narrow gap of the joint portion
Implementation Method 6
the brazing filler metal (whose boiling point is lower than the melting point of the plating layer) evaporates
Data Source
AI summary
Provided is an arc welding method and arc welding apparatus for arc welding by a brazing filler metal two base materials subjected to a plating process. An arc welding method for arc welding two base materials, at least one of which has a plating layer thereon, by a brazing filler material, performs alternately a plating layer removal process of removing a plating layer by performing arc discharge at a first current value while moving a welding torch along a welding line in a state of stopping feed of the brazing filler metal, and a brazing filler metal welding process of welding the brazing filler metal to a position where the plating layer is removed, by performing arc discharge at a second current value smaller than the first current value while feeding the brazing filler metal in a state of stopping a movement of the welding torch.