Ceramic Profile Pieces for Weld Pool Backup
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Solution Overview
Problem
Existing ceramic melt pool backup pads for welding processes are limited in their ability to support both planar and spatially curved weld seams without forming gaps, which can lead to arc burn-through and molten metal drips, especially when the pads are not perfectly adjacent.
Innovation Solution
Ceramic profile pieces with spherical front and back sides of the same radius allow for seamless interlocking, preventing gaps even when not perfectly aligned, enabling support for complex weld seam courses without the need for precise positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If ceramic profile pieces are designed with flat front and back sides at right angles, then they can support straight weld seams, but they cannot support spatially curved weld seams without forming gaps
Solution Approach 1:
The front and back sides of the ceramic profile pieces are designed as spherical surfaces instead of flat surfaces. This curvature allows the pieces to conform to both straight and curved weld seams, eliminating gaps while maintaining structural integrity and reliable support across different geometries.
2Ease of operation
If ceramic profile pieces are placed with a small distance between them, then they are easier to position, but gaps are formed allowing arc burn-through and molten metal drips
Solution Approach 1:
The spherical front and back surfaces enable the profile pieces to interlock and overlap even when positioned with small distances between them. The curved geometry ensures that the convex surface of one piece fits into the concave surface of the adjacent piece, maintaining continuous coverage and preventing gaps that would allow arc burn-through.
3Reliability
If ceramic profile pieces are designed to interlock with overlapping edges, then gap-free support is achieved, but positioning precision becomes more critical
Solution Approach 1:
The spherical surfaces provide a self-aligning interlocking mechanism where the convex front side of one piece naturally fits into the concave back side of the adjacent piece. This geometric compatibility reduces sensitivity to positioning errors and ensures gap-free support even with moderate positioning variations.
Data Source
Figure 1~3
AI summary
The invention relates to a profiled piece (1) made of ceramic for the formation of securing supports for molten weld pools, in particular for arc welding, wherein a number of profiled pieces (1) can be laid next to each other with the front side (2) of one profiled piece next to the back side (3) of a preceding profiled piece (1) of the same design, and wherein each profiled piece (1) has an upper side (4) and a lower side (5) which are connected to each other by means of the side edges (6 and 7) and by the front sides (2) and the back sides (3), wherein the front side (2) and the back side (3) are spherical surfaces with the same radius, and wherein the spherical surface on the front side (2) of the profiled piece (1) is a convex curve and, on the back side (3), a concave curve. The centers of curvature (M1, M2) of both the front side (2) and the back side (3) are arranged above the center plane of the profiled piece (1).