Dual-Wire Contact Tip Layout for Wide Weld Beads With Lower Heat
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Solution Overview
Problem
Existing welding techniques face challenges in increasing the width or length of the weld bead without simultaneously increasing the heat input and weld bead profile, which can lead to porosity and mechanical application issues.
Innovation Solution
A dual wire configuration using a contact tip with separate bores and exit orifices to facilitate the formation of a bridge droplet between two wire electrodes, allowing for controlled deposition and reduced heat input while maintaining a wider weld bead.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a larger electrode diameter is used to increase weld bead width and length, then the weld puddle becomes elongated and widened, but the heat input and energy consumption increase
Solution Approach 1:
The patent divides a single large electrode into multiple smaller electrodes (typically two or more wires). Each smaller electrode deposits metal independently, and their combined effect creates a wide weld bead without requiring a single large electrode that would generate excessive heat. The segmentation allows the weld pool to be widened through multiple deposition points rather than one large heat source.
Solution Approach 2:
The patent combines the deposition effects of multiple smaller electrodes to achieve the same weld bead width that would otherwise require a single large electrode. By merging the metal deposition from multiple wires into a single weld pool, the system achieves wide bead coverage with lower individual electrode diameters, thereby reducing overall heat input while maintaining the desired weld geometry.
2Area of stationary object
If a larger electrode diameter is used to increase weld bead width, then the weld puddle is elongated and widened, but the weld bead profile becomes不理想 for certain mechanical applications
Solution Approach 1:
By using multiple smaller electrodes instead of one large electrode, the patent enables better control over the weld bead profile. Each smaller electrode creates a more controlled, narrower deposition pattern, and the combination of multiple such patterns allows for a flatter, more uniform weld bead cross-section. This segmented approach prevents the excessive penetration and irregular profile that can result from using a single large electrode.
3Productivity
If two smaller electrodes are used simultaneously to avoid increasing heat input, then the wire deposition rate can be increased, but the system complexity increases
Solution Approach 1:
The patent combines multiple wire feeding systems and electrode holders into a single integrated torch assembly. The multiple electrodes are positioned and fed through a unified contact tip and shielding gas delivery system, merging what would otherwise be separate welding operations into one coordinated process. This integration reduces the operational complexity despite the increased number of components.
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 improved mechanical weld performance with lower heat input and increased deposition rates, achieving wider weld beads and improved symmetry without the drawbacks of using larger electrodes.
Implementation Method 1
The first and second exit orifices are separated from each other by a distance configured to facilitate formation of a bridge droplet between a first wire electrode delivered through the first bore and a second wire electrode delivered through the second bore during a deposition operation. The bridge droplet couples the first wire electrode to the second wire electrode prior to contacting a molten puddle created by the deposition operation.
Data Source
AI summary
A welding or additive manufacturing contact tip includes an electrically-conductive body extending from a proximal end of the body to a distal end of the body. The body forms a first bore terminating at a first exit orifice at a distal end face of the body, and a second bore terminating at a second exit orifice at the distal end face of the body. The first and second exit orifices are separated from each other by a distance configured to facilitate formation of a bridge droplet between a first wire electrode delivered through the first bore and a second wire electrode delivered through the second bore during a deposition operation.