Clad Welding Torch Control for Fusion Completeness
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Solution Overview
Problem
The existing clad welding methods face complications in covering a wide surface area of base materials with weld metal while preventing incomplete fusion and dilution, requiring additional steps such as removing one end of the preceding weld bead, which increases operational complexity.
Innovation Solution
The proposed clad welding method involves increasing welding heat input by temporarily stopping the weaving of the welding torch and/or increasing the welding current at the overlap points of preceding and succeeding weld beads, creating a deep penetration portion to prevent incomplete fusion and suppress dilution, allowing for wider coverage without additional removal steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the welding torch is woven continuously without stopping at overlap points, then the welding process is simple and fast, but incomplete fusion occurs at the ends of weld beads
Solution Approach 1:
The welding torch weaving is controlled to stop periodically at the overlap points of weld beads, creating a periodic action pattern. This temporary stopping allows increased heat input at critical locations to ensure complete fusion, while maintaining continuous weaving in other areas to preserve overall process efficiency.
2Manufacturing precision
If the weaving of the welding torch is stopped temporarily at overlap points to increase heat input, then incomplete fusion is prevented, but the welding operation becomes more complex
Solution Approach 1:
The welding process applies different quality standards to different locations: at overlap points, the torch stops temporarily to provide increased heat input and ensure complete fusion, while in non-overlap areas, continuous weaving is maintained for efficiency. This local differentiation of process quality resolves the contradiction between precision and operational simplicity.
3Productivity
If conventional clad welding is used with continuous torch weaving, then the welding process is simple, but incomplete fusion occurs at weld bead ends requiring additional removal work
Solution Approach 1:
The welding process performs a preliminary action by temporarily stopping the torch at overlap points before completing the weld bead. This preliminary pause ensures adequate heat input and complete fusion at critical locations, preventing the need for subsequent removal work and maintaining both productivity and precision.
4Speed
If the welding torch is moved quickly without stopping, then welding speed is high, but dilution of weld metal increases
Solution Approach 1:
The welding torch employs periodic stopping at overlap points, creating a rhythm of fast movement interspersed with brief pauses. During these pauses, heat input increases to prevent dilution, while the overall welding speed remains high due to the minimal duration of stops. This periodic action reconciles the contradiction between speed and composition stability.
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 method effectively prevents incomplete fusion and suppresses weld metal dilution, enabling the coverage of a wide surface area with weld metal using a simpler technique, ensuring deep penetration and maintaining corrosion resistance.
Implementation Method 1
a plasma arc 103 is generated between a plasma torch 101 and a base material 102, whereby a molten pool 104 of a predetermined size is formed in the base material 102
Data Source
Figure 1(a)~1(b)
Figure 2(a)~2(b)
Figure 3
AI summary
A clad welding method, which canprevent the occurrence of incomplete fusion, and can cover the surface of a base material over a wide range with a weld metal, while suppressing the dilution of the weld metal, by use of a relatively simple technique, is provided. For this purpose, a welding heat input is increased at a location where one end (10a) of a preceding weld bead (10) and the other end (20b) of a succeeding weld bead (20) overlap, as compared with a welding heat input at a location where the preceding weld bead (10) and the succeeding weld bead (20) do not overlap, to produce a deep penetration portion (12a) involving locally deep penetration (12) .