Cooling Nozzle Array for Continuous WAAM Welding
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Solution Overview
Problem
In wire arc additive manufacturing (WAAM), the workpiece heats up during the welding process, leading to changes in electrical and thermal conditions, deformations, and uncontrolled changes in material properties due to the accumulation of heat from multiple layers, which is exacerbated by the need for cooling breaks when complex geometries are welded or the structure does not rotate.
Innovation Solution
A welding device equipped with a nozzle apparatus featuring a cooling nozzle array that can be supplied with a predefinable volume flow of a cooling medium, allowing for targeted cooling of the workpiece near the energy input, even as the welding torch changes direction or orientation, using multiple cooling nozzles arranged in a linear or curved configuration around the torch, with adjustable flow rates and media composition, and temperature-controlled operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling breaks are introduced to allow workpiece cooling, then thermal distortion and material property changes are reduced, but welding productivity and production speed decrease
Solution Approach 1:
The cooling system is segmented into multiple independent cooling nozzles arranged in rows, allowing selective cooling of different workpiece regions. Each nozzle can be independently controlled to eject cooling medium onto specific areas of the workpiece surface, enabling continuous cooling without interruption of the welding process.
Solution Approach 2:
The cooling nozzles are positioned to cool the workpiece surface before and during the welding process, preventing heat accumulation before it causes thermal distortion. The cooling medium is applied in advance to the areas that will be or are being welded, maintaining optimal temperature conditions continuously.
2Device complexity
If a single cooling nozzle is used, then the device complexity is low, but the cooling effectiveness changes when welding torch direction or orientation changes
Solution Approach 1:
The cooling system is divided into multiple cooling nozzles arranged in rows around the welding torch. This segmentation allows different nozzles to be activated depending on the welding torch position and orientation, ensuring that cooling effectiveness is maintained regardless of welding direction changes while keeping each individual nozzle simple in design.
Solution Approach 2:
The cooling nozzle array is configured to dynamically adapt to welding torch movements. By having multiple nozzles positioned at different locations and angles, the system can selectively activate appropriate nozzles based on the current welding position, maintaining optimal cooling effectiveness throughout the welding process without complex mechanical adjustments.
3Temperature
If cooling medium flow rate is increased to improve cooling effectiveness, then thermal distortion is reduced, but energy consumption and cooling medium usage increase
Solution Approach 1:
Different regions of the workpiece receive different cooling intensities based on their specific thermal conditions and welding parameters. The system applies higher cooling medium flow rates to areas experiencing greater heat input or higher temperatures, while reducing or eliminating cooling in areas that require less thermal management, thereby optimizing energy and cooling medium consumption.
Solution Approach 2:
The cooling medium flow rate is dynamically adjusted as a variable parameter based on real-time welding conditions, workpiece temperature feedback, and thermal modeling. This allows the system to maintain optimal cooling effectiveness while minimizing energy consumption by reducing cooling medium flow when high cooling intensity is not required.
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 solution effectively mitigates overheating and thermal distortion, allowing for continuous welding without cooling breaks, preserving material properties and increasing production speed by maintaining a predictable layer structure and reducing discolorations and thermal distortions.
Implementation Method 1
for cooling the workpiece (in particular during a welding process), the respective cooling nozzle can be supplied with a predefinable volume flow of a cooling medium and is designed to eject the cooling medium onto a surface of the workpiece to be cooled
Data Source
AI summary
The invention relates to a welding device for welding at least one workpiece, comprising: a welding torch, which is designed to create an electric arc for welding the at least one workpiece; and a nozzle apparatus, which is arranged on the welding torch and has a cooling nozzle array, which has at least one row of cooling nozzles, wherein for cooling the workpiece, the respective cooling nozzle can be supplied with an adjustable volume flow of a cooling medium.