Dual-Wire Contact Tip Layout for Wider Weld Beads
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Solution Overview
Problem
Existing welding methods face challenges in achieving an elongated weld puddle or widened weld bead without increasing electrode diameter, which leads to higher energy consumption and undesirable weld bead profiles.
Innovation Solution
A dual wire configuration contact tip that facilitates the formation of a bridge droplet between two electrodes before deposition, allowing for controlled weld puddle formation with reduced heat input and improved weld bead geometry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If electrode diameter is increased to widen weld bead or elongate weld puddle, then weld bead width and puddle length are improved, but energy consumption increases and heat input increases
Solution Approach 1:
The contact tip is divided into multiple separate bores (first bore, second bore, etc.) that deliver individual wire electrodes. This segmentation allows multiple smaller electrodes to work together to achieve the same or better weld bead width and puddle length as a single larger electrode, while consuming less energy and producing less heat input.
Solution Approach 2:
The invention transitions from a single-electrode configuration to a multi-electrode configuration by adding spatial arrangement of multiple bores and exit orifices. This dimensional change in electrode arrangement enables improved weld bead geometry and puddle characteristics without increasing the cross-sectional area of individual electrodes, thereby reducing energy consumption.
2Length of stationary object
If electrode diameter is increased to elongate weld puddle, then weld puddle length is improved, but heat input increases
Solution Approach 1:
Multiple separate bores deliver individual wire electrodes that work in parallel to elongate the weld puddle. This segmentation allows the puddle length to be increased through the combined effect of multiple smaller electrodes rather than one large electrode, thereby achieving the desired puddle geometry with reduced heat input.
3Productivity
If single electrode is used, then device complexity is low, but weld bead width and deposition rate are limited
Solution Approach 1:
The contact tip is segmented into multiple bores and exit orifices to accommodate multiple wire electrodes. This segmentation enables higher deposition rates by delivering multiple wires simultaneously, while the modular bore structure keeps the device complexity manageable through a systematic multi-channel design.
Solution Approach 2:
The contact tip structure is designed with multiple bores and exit orifices that can deliver multiple wire electrodes of different types and compositions. This multi-functional design allows the same contact tip to handle various welding applications and material combinations, increasing productivity without proportionally increasing complexity.
Data Source
Figure 1
Figure 2~3A
Figure 3B~3C
AI summary
A welding or additive manufacturing contact tip (200, 700) 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 (701, 702) at a distal end face of the body, and a second bore terminating at a second exit orifice (701, 702) at the distal end face of the body. The first and second exit orifices (701, 702) are separated from each other by a distance configured to facilitate formation of a bridge droplet between a first wire electrode (E1, E2) delivered through the first bore and a second wire electrode (E1, E2) delivered through the second bore during a deposition operation.