Arc Welding Pulse Control for Scaly Bead Formation
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Solution Overview
Problem
Existing arc welding methods, such as non-consumable electrode TIG welding, lack techniques for facilitating change and adjustment of welding conditions to form aesthetically pleasing scaly beads, while consumable electrode MIG or MAG welding does not address the need for high deposition efficiency and welding speed.
Innovation Solution
An arc welding control method that includes an initial condition setting step and a scaly bead formation step, with adjustable parameters like arc ON and OFF periods, welding speed, and interval between beads, allowing for continuous formation of scaly beads while maintaining quality and design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If non-consumable electrode TIG welding is used to form scaly beads, then aesthetic appearance is improved, but productivity deteriorates due to separate filler material supply requirement
Solution Approach 1:
The invention changes the welding parameters by using consumable electrode MIG/MAG welding with specific pulse current conditions (peak current Ip, base current Ib, pulse width tp, and cycle time T) to form scaly beads, replacing the traditional TIG welding process while maintaining aesthetic appearance and improving productivity
2Productivity
If consumable electrode MIG or MAG welding is used to improve productivity, then welding speed and deposition efficiency are improved, but the ability to form aesthetically pleasing scaly beads deteriorates
Solution Approach 1:
The invention applies periodic pulse current to the welding wire, alternating between peak current Ip and base current Ib with specific pulse width tp and cycle time T, which enables the formation of scaly beads while maintaining high welding speed and productivity of consumable electrode MIG/MAG welding
3Shape
If multiple welding parameters are adjusted to form scaly beads, then bead appearance is improved, but operation complexity increases
Solution Approach 1:
The invention establishes specific parameter ranges for pulse welding (peak current Ip, base current Ib, pulse width tp, cycle time T) that enable scaly bead formation with straightforward control, reducing the complexity of parameter adjustment while achieving desired bead appearance
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 enables the formation of scaly beads with a desired finish shape and quality by simplifying adjustments between welding parameters, ensuring consistent appearance and reducing defects like burn-through and pit occurrence.
Implementation Method 1
arc welding forming a plurality of scaly beads continuously arranged on a base material... during which a welding current flows to a welding wire... during which the welding current does not flow to the welding wire
Data Source
AI summary
An arc welding control method includes: an initial condition setting step of setting initial values of welding conditions for arc welding a base material; and a scaly bead formation step of forming a plurality of scaly beads in a predetermined welding section of the base material while moving a welding wire at a predetermined welding speed in the predetermined welding section of the base material. The welding conditions include an arc ON period and an arc OFF period, and at least one of a welding current, the predetermined welding speed, or an interval of the plurality of scaly beads. The arc welding control method further includes a welding condition change step of determining whether to change the initial value based on a predetermined finish condition for the plurality of scaly beads and changing at least one of a plurality of welding parameters to satisfy the predetermined finish condition.