Dual-Wire Contact Tip Assembly for Wide Beads and Lower Heat Input
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Solution Overview
Problem
Existing welding methods face challenges in increasing the width or length of the weld bead without simultaneously increasing the heat input, which can lead to undesirable weld profiles and mechanical applications, especially when using larger electrodes.
Innovation Solution
A dual wire configuration using a contact tip assembly with adjustable spacing between two wire electrodes, forming a bridge droplet before deposition, allows for controlled weld bead formation with reduced heat input and improved mechanical performance.
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 is elongated and widened, but more energy is needed and heat input increases
Solution Approach 1:
The invention divides a single large electrode into multiple smaller electrodes (typically two or more wires). This segmentation allows the system to achieve the same or greater weld bead area while using smaller individual electrodes that require less energy each, thereby reducing total energy consumption compared to using one large electrode.
Solution Approach 2:
The invention combines multiple smaller electrodes to work together in a single welding operation. By merging the deposition from multiple wires into a unified weld puddle, the system achieves the desired weld bead dimensions without the excessive heat input associated with a single large electrode.
2Area of stationary object
If a larger electrode diameter is used to increase weld bead width, then the weld bead width increases, but the weld bead profile may not be ideal for certain mechanical applications
Solution Approach 1:
By using multiple smaller electrodes instead of one large electrode, the system can achieve the desired weld bead width through the combined deposition of several wires. This segmentation allows for better control over the weld bead profile, as each smaller electrode contributes to a specific portion of the final bead geometry, enabling more precise control over the cross-sectional shape.
3Productivity
If a larger electrode diameter is used to increase wire deposition rate, then the deposition rate increases, but more energy is consumed
Solution Approach 1:
The invention combines multiple smaller electrodes to achieve a high wire deposition rate equivalent to or exceeding that of a single large electrode. By merging the material deposition from multiple wires into a single weld puddle, the system maintains high productivity while consuming less total energy, as each smaller electrode requires less energy to operate.
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 the creation of wider and longer weld beads with improved mechanical bond strength and reduced heat input, enhancing deposition rates and stability in welding operations.
Implementation Method 1
A current waveform is provided to both of the first wire electrode and the second wire electrode through the contact tip assembly. A bridge droplet is formed between the first wire electrode and the second wire electrode using the current waveform.
Data Source
AI summary
A system and method of welding or additive manufacturing is provided where at least two welding electrodes are provided to and passed through a two separate orifices on a single contact tip and a welding waveform is provided to the electrodes through the contact tip to weld simultaneously with both electrodes, where a bridge droplet is formed between the electrodes and then transferred to the puddle.