Constricted TIG Welding Nozzle for Stable Spot Welding Arcs
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Solution Overview
Problem
Conventional TIG welding methods for spot welding of low electrical resistance metals like copper and aluminum face challenges such as incomplete joining due to gaps, unstable heat input, and require skilled operators to maintain arc length and prevent short circuits, leading to low workability and productivity.
Innovation Solution
A TIG welding torch with a constricted nozzle and electrode nozzle configuration that maintains constant arc length, prevents short circuits, and enhances shielding gas flow to improve welding quality and productivity, allowing beginners to perform effective spot welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional TIG welding torch is used for spot welding, then welding can be performed on metal plates, but arc length cannot be kept constant and short circuits occur requiring skilled operators
Solution Approach 1:
The patent introduces an intermediary component (electrode holder with insulating structure) between the electrode and the operator's hand. This insulating holder prevents accidental short circuits and maintains stable arc length, allowing beginners to operate the welding torch safely and effectively without requiring extensive skill
2Reliability
If pressing jig is used to maintain close contact between metal plates, then complete joining is achieved, but workability deteriorates
Solution Approach 1:
The welding torch design allows the operator to maintain proper contact pressure through natural hand pressure and wrist control, eliminating the need for external pressing jigs. The self-adjusting nature of the torch positioning and the operator's natural dexterity provide sufficient pressure control for reliable spot welding
3Reliability
If laser beam emission unit or plasma welding torch is used for spot welding, then welding of low electrical resistance metals is achieved, but position must be kept constant requiring jig
Solution Approach 1:
The patent replaces complex mechanical positioning systems with a simplified TIG welding approach. The flexible tungsten electrode and natural operator control replace rigid mechanical positioning jigs, allowing the torch to adapt to position variations while maintaining stable arc and reliable welding results
4Productivity
If tungsten electrode rod tip is exposed, then welding can be performed, but oxidation occurs and electrode is consumed requiring polishing
Solution Approach 1:
The patent employs an inert shielding gas atmosphere that envelops the tungsten electrode tip during welding operations. This inert environment prevents oxidation of the electrode tip, eliminating the need for frequent polishing and maintaining consistent welding performance, thereby improving both productivity and reliability
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
The TIG welding torch with a constricted nozzle ensures consistent arc length, deep penetration, and prevents oxidation of the tungsten electrode, allowing for high-quality spot welding even by novice operators, while minimizing exposure to harmful radiation and improving workability and productivity.
Implementation Method 1
when two metal plates W are tack-welded by spot welding using TIG welding torch 33
Implementation Method 2
applying a current, thereby welding portions are melted and joined by Joule heat
Implementation Method 3
eliminate the oxidation phenomenon of the tungsten electrode rod
Implementation Method 4
defining a gas passage through which the shielding gas flows between the tungsten electrode rod and the constricted nozzle for discharging the shielding gas
Data Source
AI summary
The present invention enables even a beginner to acquire the technique easily and perform suitable spot welding, and achieves improved workability, improved welding quality, improved productivity, and the like. The present invention includes a torch body 2 for passing a shielding gas, a tungsten electrode rod 5 inserted into the torch body 2 and connected to a cathode, a constricted nozzle 6 for supporting a distal end portion of the tungsten electrode rod 5 concentrically, defining a gas passage 6e between the tungsten electrode rod 5 and the constricted nozzle 6 for flowing a shielding gas G, and discharging the shielding gas G from the constricted nozzle 6 at a higher speed than the shielding gas G discharged from the distal end of the torch body 2, and a cylindrical electrode nozzle 7 having conductivity arranged concentrically with the tungsten electrode rod 5 on the outer circumference of the constricted nozzle 6, connected to the anode via a ground cable 18, and configured to have a tapered shape at a distal end portion, wherein the tapered distal end portion is located further outside than the distal end portion of the tungsten electrode rod 5, gas vent ports 7c and 7d of the shielding gas G are provided on the electrode nozzle 7.