Short-Circuit Arc Welding Current Profile for Spatter Reduction
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Solution Overview
Problem
Existing arc welding control methods, such as those described in Japanese Patent No. 4760053, may not effectively reduce the occurrence of spatter due to a large initial welding current, which hinders the reduction of arc force and spatter occurrence at the time of short-circuit opening.
Innovation Solution
The proposed arc welding control method involves a series of current control actions in short-circuit arc welding: a first increase in welding current with a first slope, followed by a first decrease, then a second increase with a second slope, and finally a second decrease, resulting in a reduced welding current at the time of short-circuit opening, thereby minimizing spatter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a single decrease in welding current is executed after a single increase, then the welding current is reduced at the time of opening the short-circuit, but the occurrence of spatter is not effectively reduced due to the large initial welding current
Solution Approach 1:
The welding current control is segmented into multiple distinct phases: a first increase phase with a first slope, a first decrease phase, a second increase phase with a second slope, and a second decrease phase. This segmentation allows the welding current to be carefully managed through multiple stages, ensuring that the current amount at the time of short-circuit opening is sufficiently reduced to minimize spatter occurrence.
Solution Approach 2:
The first decrease in welding current is executed as a preliminary action before the second increase and final opening of the short-circuit. This preliminary reduction in welding current ensures that when the short-circuit eventually opens, the welding current has already been reduced to a level that effectively minimizes spatter, addressing the harmful effect before the critical moment of opening.
2Object-affected harmful factors
If the welding current is reduced too much, then spatter occurrence is minimized, but the welding penetration and bead formation may be insufficient
Solution Approach 1:
The welding current is applied in periodic cycles consisting of increase phases followed by decrease phases. Each cycle includes a first increase, first decrease, second increase, and second decrease. This periodic action allows the welding current to be temporarily reduced to minimize spatter during short-circuit opening, while ensuring adequate current is maintained during the increase phases to provide sufficient heat for proper weld penetration and bead formation.
Solution Approach 2:
The welding current control system dynamically adjusts the current through multiple phases with different slopes and timing. The system transitions between increasing and decreasing current states, optimizing the current level at each stage of the welding cycle. This dynamic control ensures that the current is high enough during welding phases for proper penetration while being reduced at critical moments to minimize spatter.
Data Source
AI summary
Disclosed is an arc welding control method of controlling a welding current in short-circuit arc welding of feeding a welding wire toward a base metal and alternating a short-circuit state and an arc state. The arc welding control method includes: executing, in the short-circuit state, a first increase in the welding current with a first slope, a first decrease in the welding current to a first bottom value after executing the first increase, a second increase in the welding current with a second slope after executing the first decrease, and a second decrease in the welding current to a second bottom value that is smaller than the first bottom value after executing the second increase to shift a state to the arc state.