CMT Welding Surface Structures on Metal Workpieces
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Solution Overview
Problem
Existing methods for producing three-dimensional structures on metallic surfaces are limited by the shape of weld points or anchor points, which are typically spherical or mushroom-like, restricting their application to specific connections between metallic and non-metallic materials, particularly excluding fiber composites and requiring increased effort for solid material connections.
Innovation Solution
The method employs a CMT (cold metal transfer) welding process, allowing precise control of heat input and droplet detachment, enabling the creation of structures with varied shapes, sizes, and directions by using different filler materials and diameters, and incorporating welding pauses for cooling, allowing for the production of complex geometries suitable for diverse applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If traditional welding processes are used to produce anchor points, then welding points can be formed on metallic surfaces, but the shape is limited to spherical or mushroom-like forms
Solution Approach 1:
The welding process transitions from static, fixed-shaped anchor points to dynamic, controllable structures. The CMT welding process enables real-time adjustment of welding parameters (current, voltage, wire feed speed) to create varying shapes and geometries on demand, making the anchor points adaptable to different connection requirements rather than being limited to predetermined spherical or mushroom shapes.
Solution Approach 2:
The invention changes the welding parameters (heat input, wire diameter, welding speed, arc voltage) to produce different anchor point geometries. By varying these parameters during the welding process, the system can create optimized shapes for specific applications, such as enhanced mechanical interlocking for fiber composites or flattened profiles for solid material connections, thereby resolving the shape limitation.
2Ease of manufacture
If spherical or mushroom-like anchor points are used, then connections with certain non-metallic materials are possible, but connections with fiber composite materials cannot be economically achieved
Solution Approach 1:
The welding process creates anchor points with locally optimized qualities tailored to the specific non-metallic material being connected. For fiber composite materials, the system produces anchor points with geometries that enhance mechanical interlocking and surface area for bonding, rather than using universal spherical shapes. This local optimization enables economical and effective connections specific to each material type.
Solution Approach 2:
The invention addresses connections between dissimilar materials (metal and fiber composites) by creating hybrid anchor point structures that combine metallic base with optimized surface geometries. These composite-like structures integrate the advantages of both materials, enabling economical connections between metallic workpieces and fiber composite materials that were previously difficult to achieve.
3Force
If traditional welding processes are used, then anchor points can be formed, but increased effort is required to press them into doughy or solid materials
Solution Approach 1:
The welding parameters are adjusted to create anchor points with optimized mechanical properties for insertion. By controlling heat input and cooling rates, the system produces anchor points with appropriate hardness and deformation characteristics that reduce insertion force requirements when pressing into doughy or solid materials, thereby easing the operation.
4Productivity
If continuous welding is performed without pauses, then production efficiency is maintained, but previously welded elements cannot cool down properly
Solution Approach 1:
The welding process incorporates periodic pauses between welding cycles to allow previously deposited elements to cool down. This rhythmic pattern of welding followed by cooling intervals ensures proper thermal management and material properties while maintaining overall production efficiency. The pause duration is optimized to balance cooling requirements with productivity demands.
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 the flexible production of surface structures adaptable to various applications, including connections with fiber composite materials, allowing for precise shaping and easy integration with metallic and non-metallic materials, enhancing the versatility and efficiency of the process.
Implementation Method 1
an arc (3) is ignited between the filler material (2) and the workpiece (4)... The arc (3) causes both the workpiece (4) and the filler material (2) to melt
Implementation Method 2
the previously welded individual element can cool down... the individual elements can cool down in an advantageous manner
Data Source
Figure 1~2
Figure 3~5
AI summary
The invention relates to a method for producing a structure (1) on a surface of a workpiece (4), said structure (1) contrasting with the surface, wherein a welding process (7) using a filler metal (2) melting off at least partially is employed, wherein during a weld cycle (8) of the welding process (7) an arc (3) is ignited between the filler metal (2) conducted in the welding torch (5) and the workpiece (4), and the heat input during the welding process (7) is set by regulating the weld parameters. According to the invention, the structure (1) is produced incrementally from a plurality of individual elements (6), wherein each individual element (6) is produced in a weld cycle (8) of the welding process (7) and after each weld cycle (8) a welding break (9) is added.