Arc Welding of Overlapping Non-Ferrous Plates Without Backing Jigs
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Solution Overview
Problem
Existing arc spot welding methods require a backing tool, which is impractical when there is limited space on the back side of the workpiece, leading to limitations in workpiece shape and potential burn-through during welding of non-ferrous metal plates.
Innovation Solution
Form a machined hole that penetrates a non-ferrous metal plate on the arc-radiation side and extends to the plate farthest from the arc welder, allowing arc radiation to melt and weld without a backing jig, and inspect weld strength by measuring the diameter of the molten part on the back surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a backing tool is used to prevent burn-through during arc spot welding, then welding reliability is improved, but device complexity and space requirements increase
Solution Approach 1:
The invention extracts the backing tool from the welding system by forming a machined hole that eliminates the need for external backing support. The hole geometry itself provides the necessary control over melt depth and prevents burn-through without requiring additional backing devices.
Solution Approach 2:
The machined hole is prepared in advance before welding, with specific depth and diameter dimensions predetermined to control the welding process. This preliminary geometric configuration prevents burn-through and eliminates the need for backing tools during the actual welding operation.
2Manufacturing precision
If a backing tool is used to control melt depth, then manufacturing precision is improved, but ease of operation deteriorates due to space limitations
Solution Approach 1:
The machined hole dimensions (depth and diameter) are predetermined and prepared before welding to precisely control melt depth. This preliminary geometric configuration provides accurate melt depth control without requiring backing tools, making the process easier to operate in space-constrained environments.
Solution Approach 2:
The invention changes the geometric parameters of the workpiece by forming a machined hole with specific depth-to-diameter ratio. This parameter modification enables precise control over arc penetration and melt depth, replacing the need for backing tools while maintaining manufacturing precision.
3Ease of operation
If arc spot welding is performed without a backing tool, then ease of operation is improved, but manufacturing precision deteriorates due to burn-through
Solution Approach 1:
The machined hole is prepared in advance with precisely controlled depth and diameter dimensions. This preliminary geometric configuration ensures that when welding is performed without backing tools, the arc penetration is naturally limited to the hole depth, preventing burn-through while maintaining ease of operation.
Solution Approach 2:
By modifying the workpiece geometry to include a machined hole with specific dimensional parameters, the invention enables welding without backing tools while maintaining precise melt depth control. The hole dimensions are optimized to prevent burn-through through natural geometric constraints.
4Reliability
If the machined hole is made deeper to prevent burn-through, then reliability is improved, but loss of substance increases
Solution Approach 1:
The invention optimizes the machined hole parameters (depth and diameter) to achieve the minimum necessary material removal for preventing burn-through. By carefully selecting the depth-to-diameter ratio and absolute dimensions, reliable welding is achieved while minimizing material loss during hole formation.
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
Enables welding without a backing tool, reduces deformation and fume generation, and allows accurate estimation of weld strength by measuring the molten part diameter on the back surface.
Implementation Method 1
arc radiation is caused from an opening side of the machined hole, and the workpiece is melted and welded
Implementation Method 2
at least part of a workpiece made from a plurality of overlapping non-ferrous metal plates is melted and joined
Data Source
AI summary
An arc welding method melts and joins at least a part of a workpiece having a plurality of overlapping non-ferrous metal plates. The arc welding method includes forming a machined hole in a welded portion of the workpiece. The machined hole is a non-through-hole that penetrates a non-ferrous metal plate on an arc-radiation side, and reaches a non-ferrous metal plate on a side farthest from an arc welder to form a partial recess portion. The arc welding method further includes causing arc radiation from an opening side of the machined hole to melt and weld a back surface of the non-ferrous metal plate furthest from the workpiece without using a backing jig on an opposite side of the workpiece.