Short-Circuit Arc Welding Current Profile for Spatter Reduction
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Solution Overview
Problem
Existing arc welding technologies face challenges in effectively reducing spatter occurrence due to a large initial welding current during the decrease in short-circuit state, which hinders efficient spatter reduction.
Innovation Solution
An arc welding control method that involves a first increase and decrease in welding current with specific slopes, followed by a second increase and decrease, reducing the welding current amount at the start of the second decrease, thereby minimizing spatter occurrence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a single decrease in welding current is executed after a increase in the short-circuit state, then the arc force and spatter occurrence are reduced, but the spatter reduction effectiveness is insufficient when the welding current amount at the start of decrease is large
Solution Approach 1:
The single current decrease is segmented into two sequential decreases: a first decrease executed immediately after current increase, and a second decrease executed after a subsequent current increase. This segmentation allows the second decrease to start from a lower current baseline, achieving more effective spatter reduction at short-circuit opening while maintaining proper molten metal droplet formation during the first decrease.
Solution Approach 2:
The first decrease in welding current is executed as a preliminary action to reduce the current amount before the second increase. This preliminary reduction ensures that when the second decrease occurs at short-circuit opening, the starting current amount is already reduced, thereby enhancing spatter reduction effectiveness.
2Shape
If the welding current is increased with a predetermined slope in the short-circuit state, then the molten metal droplet formation is controlled, but the spatter occurrence cannot be sufficiently reduced due to large current amount at decrease start
Solution Approach 1:
The welding current is applied in periodic cycles consisting of: increase phase, first decrease phase, second increase phase, and second decrease phase. This periodic action pattern allows controlled formation of molten metal droplets during increase phases while ensuring spatter reduction during decrease phases, particularly the second decrease that occurs from a reduced current baseline.
3Ease of operation
If a single current control pattern is used in short-circuit arc welding, then the control simplicity is maintained, but the spatter reduction effectiveness is limited
Solution Approach 1:
The welding current control transitions from a static single-decrease pattern to a dynamic multi-phase pattern that adapts to different stages of the short-circuit cycle. The control dynamically adjusts current magnitude and rate of change through four distinct phases, optimizing both droplet formation and spatter reduction at different moments in the welding cycle.
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
The method effectively reduces spatter occurrence by controlling the welding current through multiple slope changes, ensuring a smaller current at the short-circuit opening, thus enhancing spatter reduction.
Implementation Method 1
short-circuit arc welding of feeding a welding wire toward a base metal and alternating a short-circuit state and an arc state
Implementation Method 2
executing, in the short-circuit state, a first increase in the welding current with a first slope
Data Source
Figure 1
Figure 2
Figure 3~3(d)
AI summary
Disclosed is an arc welding control method of controlling a welding current (Ia) in short-circuit arc welding of feeding a welding wire (3) toward a base metal (5) 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 (Ia) with a first slope (S1), a first decrease in the welding current (Ia) to a first bottom value (B 1) after executing the first increase, a second increase in the welding current (Ia) with a second slope (S2) after executing the first decrease, and a second decrease in the welding current (Ia) to a second bottom value (B2) that is smaller than the first bottom value (B1) after executing the second increase to shift a state to the arc state.