Copper-Plated Welding Wire Surface for Stable Arc Feeding
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Solution Overview
Problem
Existing arc welding technologies face issues with arc stability and power supply tip wear during long-duration welding, particularly in carbon dioxide arc welding, due to surface lubricant separation, increased electrical contact resistance, and physical clogging, which affect feedability and construction efficiency.
Innovation Solution
An arc welding solid wire with a copper plating layer and controlled surface roughness, coated with a specific amount of lubricating oil and solid lubricant, maintains arc stability by stabilizing the power supply tip contact and reducing wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a surface lubricant is applied to the wire, then wire feedability is improved, but the lubricant separates during long-time continuous welding causing physical clogging and feeding hindrance
Solution Approach 1:
The wire surface is pre-treated with roughening before lubricant application to create a structure that prevents lubricant separation during long-time continuous welding. The roughened surface creates mechanical interlocking that holds the lubricant in place, addressing the stability issue before welding begins.
Solution Approach 2:
The wire surface is created with a porous or rough structure that can absorb and retain the lubricant, preventing it from separating during continuous welding. This porous structure acts as a reservoir that releases lubricant gradually, maintaining feedability without separation.
2Reliability
If copper plating is applied to the wire, then electrical contact resistance increases improving arc stability, but heat generation at the power supply tip increases causing tip damage
Solution Approach 1:
The copper content in the plating is precisely controlled within a specific range (0.03-0.08 mass%) to optimize the balance between electrical contact resistance for arc stability and heat generation at the power supply tip. This parameter optimization resolves the contradiction between arc stability and tip temperature.
3Productivity
If high current is used for high speed welding, then welding productivity increases, but the load on the power supply tip increases causing increased tip replacement frequency
Solution Approach 1:
The copper plating parameters (thickness and composition) are optimized to reduce electrical contact resistance, thereby reducing heat generation and extending power supply tip service life while maintaining high current welding capability for high productivity.
4Manufacturing precision
If the wire surface is made smooth, then manufacturing precision is improved, but wire feedability deteriorates due to lack of lubricant retention
Solution Approach 1:
The wire surface is given different local qualities: a controlled roughness at specific locations to retain lubricant, while maintaining overall manufacturing precision. This localized roughening allows both feedability and precision to coexist.
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 solution provides excellent arc stability and reduces power supply tip wear during long-duration welding, ensuring stable wire feeding and improved construction efficiency.
Implementation Method 1
an arc becomes stable due to an increase in an electrical contact resistance at a power supply tip
Implementation Method 2
by using a welding wire containing a surface lubricant containing appropriate amounts of molybdenum disulfide and phospholipid on a surface of the wire, feedability of the wire is stable
Implementation Method 3
droplets grow due to a push-up effect of an arc by an electromagnetic pinch force
Implementation Method 4
If the continuous welding is performed without a cleaning work on the separated surface lubricant, feeding may be physically hindered
Data Source
AI summary
An arc welding solid wire includes: a steel material; and a copper plating layer formed on a surface of the steel material, in which an amount of Cu in the steel material and the copper plating layer is 0.05 mass % to 0.30 mass % with respect to a total mass of the wire, a surface of the wire is coated with 0.05 g to 0.20 g of oil with respect to 1 kg of the wire, and on a surface of the copper plating layer, an arithmetic average roughness Rac in a circumferential direction is 0.25 μm to 1.00 μm, and an arithmetic average roughness Ral in a longitudinal direction is 0.07 μm to 0.50 μm.