Build-Up Welding With Oscillating Wire Feed for Bead Integrity
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Solution Overview
Problem
Existing build-up welding methods face limitations in speed due to breakage of the welding bead and undesirable mixing of build-up material with the workpiece, resulting in poor material properties and reproducibility.
Innovation Solution
Guiding a non-melting electrode normal to the workpiece and moving the fed wire back and forth along its infeed direction to achieve a homogeneous arc, controlled penetration depth, and regulated temperature conditions, allowing for high build-up speeds while maintaining material properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the guidance speed of the welding torch is increased, then the productivity is improved, but the welding bead breaks and the manufacturing precision deteriorates
Solution Approach 1:
The patent applies dynamics by making the wire feed speed variable rather than constant. The wire feed speed is dynamically adjusted based on the guidance speed of the welding torch, allowing the system to maintain optimal welding conditions at different speeds. This dynamic adaptation prevents welding bead breakage even at high guidance speeds, resolving the contradiction between productivity and manufacturing precision.
2Productivity
If the infeed speed of the wire is increased, then the productivity is improved, but the penetration depth increases and the build-up material mixes with the workpiece, deteriorating the purity of the build-up material
Solution Approach 1:
The patent applies parameter changes by adjusting the wire feed speed as a controllable parameter. Rather than using a fixed high infeed speed, the system optimizes the wire feed speed parameter based on the specific welding conditions, electrode diameter, and guidance speed. This parameter optimization allows high productivity while controlling penetration depth to prevent unwanted mixing, thus maintaining build-up material purity.
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 approach enables faster, more reproducible build-up welding with improved material connection and retention of build-up material properties, outperforming previous methods in both PC and PA welding positions.
Implementation Method 1
at least one melting wire serving as a build-up material is fed at an infeed speed into the arc between at least one non-melting electrode of the welding torch and the workpiece
Implementation Method 2
a capillary action on the melt can be achieved, advantageously making it possible to avoid a formation of droplets from the melt
Data Source
AI summary
A build-up welding method is disclosed in which a welding torch is guided along a metallic workpiece and at least one melting wire serving as a build-up material is fed at an infeed speed into the arc between at least one non-melting electrode of the welding torch and the workpiece. In order to achieve a build-up welding method with higher build-up speeds in comparison to the prior art, it is proposed for the non-melting electrode positioned normal to the workpiece to be guided along the workpiece and for the fed wire to also be moved back and forth along its infeed direction.