Dual-Electrode Arc Welding Using Excess Arc Energy
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Solution Overview
Problem
Existing electric arc welding methods face challenges in increasing production rate and efficiency, particularly with the use of cold wires, which can cause process instability and weld defects due to uneven melting and limited energy input.
Innovation Solution
The method employs a welding arrangement with a first electrode generating a primary arc and a second semi-hot wire that consumes excess energy from the first electrode to maintain a secondary arc, allowing for increased deposition rates with minimal energy input, and optionally a third electrode to further enhance energy efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If cold wire is used to increase deposition rate, then productivity increases, but process stability deteriorates and weld defects occur
Solution Approach 1:
The patent changes the thermal state parameter of the wire from cold (ambient temperature) to hot (preheated to melting point or above). This parameter change enables the wire to melt more uniformly and controllably, improving process stability while maintaining high deposition rates. The hot wire is heated before entering the arc region, transforming its thermal state to achieve better melting characteristics.
Solution Approach 2:
The wire is preheated to the melting point or above before entering the welding arc region. This preliminary heating action ensures that the wire is already in a suitable thermal state for controlled melting, preventing the instability and defects associated with cold wire melting. The preheating occurs in a heating zone before the arc acts on the wire.
2Productivity
If cold wire is used to increase deposition rate, then productivity increases, but weld quality deteriorates due to uneven melting
Solution Approach 1:
The thermal state parameter of the wire is changed from cold to hot through preheating. This parameter change ensures uniform melting of the wire in the arc region, improving weld quality by eliminating uneven melting characteristics. The preheated wire melts more consistently, producing better weld metal homogeneity and reducing defects.
3Productivity
If multiple electrodes are used to increase production rate, then productivity increases, but device complexity increases
Solution Approach 1:
The patent combines multiple welding functions into a single integrated welding head assembly. Multiple electrodes (cold wire, hot wire, semi-hot wire) are housed together with their respective contact devices and power sources in one unit. This merging approach enables simultaneous multi-electrode welding to increase production rate while managing device complexity through integrated design.
4Use of energy by moving object
If excess energy from first electrode is used to maintain second arc, then energy efficiency improves, but heat input control becomes more complex
Solution Approach 1:
The second electrode (semi-hot wire) utilizes excess energy from the first electrode's arc to maintain its own arc and melt the wire. This self-service approach allows the semi-hot wire to benefit from the energy field of the first arc without requiring a separate full-power source, improving overall energy efficiency. The semi-hot wire is heated to near-melting point and uses residual arc energy to complete the melting process.
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 higher production rates with improved weld quality and stability by optimizing energy use and preventing weld defects, while maintaining acceptable heat input levels.
Implementation Method 1
a first electrode (2) adapted to act on a work piece (27) for generating a weld pool (28) via a first electric arc present between the first electrode (2) and the work piece (27)
Implementation Method 2
The thus generated heat will assist in melting the electrode material
Implementation Method 3
a second electrode (7) adapted to act on said work piece (27) for generating said weld pool (28) via a second electric arc present between the second electrode (7) and the work piece (27) within a second arc region (33)
Implementation Method 4
the thus generated magnetic fields will assist in metal transfer from the electrodes to the weld pool
Data Source
AI summary
The present application relates to an arc welding arrangement and an electric arc welding method to be used with the arc welding arrangement. The arc welding arrangement comprising a first power source, a first electrode connected to say first power source, and a second electrode, said first electrode being adapted to generate a weld pool via a first electric arc present within a first arc region. The second electrode is operated at welding parameters adapted to ensure that excess energy from at least said first electrode is required to maintain said second arc ignited. The method comprises the step of feeding said second electrode so that it is allowed to consume excess energy from said first electrode to maintain said second arc ignited.