Dual-Wire Feed Groove for Wider Weld Beads With 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 and weld bead profile, which can be undesirable for certain mechanical applications.
Innovation Solution
A dual wire configuration using two smaller electrodes driven by a system with circumferential grooves and a contact tip assembly that facilitates the formation of a bridge droplet between the electrodes before deposition, allowing for controlled current delivery and reduced heat input.
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 the welding function into two separate electrodes instead of using one large electrode. Each electrode operates independently with its own drive roll groove, allowing the weld bead width to be increased by using two smaller electrodes side-by-side rather than one large electrode, thereby reducing the heat input requirement while achieving the desired weld bead dimensions
Solution Approach 2:
The invention transitions from a single-electrode configuration to a dual-electrode configuration, adding a dimensional aspect to the welding process. The two electrodes are positioned adjacent to each other in the circumferential groove, creating a wider effective welding area without increasing the diameter of individual electrodes, thus achieving wider weld beads with reduced heat input per 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 two separate smaller electrodes instead of one large electrode, the invention allows for better control of the weld bead profile. Each electrode contributes to a portion of the weld bead, enabling a more controlled and ideal profile shape that suits specific mechanical applications while achieving the desired overall width
Solution Approach 2:
The dual electrode configuration allows different regions of the weld bead to have different characteristics. Each electrode can be optimized for specific local requirements, creating a weld bead with varying properties across its width that can be tailored for specific mechanical performance requirements
3Use of energy by moving object
If two smaller electrodes are used simultaneously to avoid increased heat input, then energy consumption is reduced, but the system complexity increases with dual drive rolls and grooves
Solution Approach 1:
The drive roll is designed with a universal circumferential groove structure that can accommodate and drive two electrodes simultaneously. This multi-functional groove design integrates the driving mechanism for both electrodes into a single component, reducing the overall system complexity compared to having separate driving mechanisms for each electrode while still achieving reduced heat input
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 a wider weld bead with improved mechanical performance and reduced heat input, achieving stable deposition rates and weld quality while avoiding the limitations of using larger electrodes.
Implementation Method 1
The power supply provides a current waveform to the contact tip assembly... The contact tip assembly is configured to deliver the current waveform to both of the first wire electrode and the second wire electrode... the distance S is configured to facilitate formation of a bridge droplet between the first wire electrode and the second wire electrode by the current waveform
Implementation Method 2
welding or additive manufacturing wire drive system... welding torch includes a contact tip assembly... The first wire electrode contacts the second wire electrode within the circumferential groove
Data Source
Figure 1A
Figure 1B
Figure 2
AI summary
A welding or additive manufacturing wire drive system includes a first drive roll and a second drive roll. One or both of the drive rolls has a circumferential groove for simultaneously driving both of a first wire electrode and a second wire electrode located between the drive rolls in the circumferential groove. A sensor device generates a signal or data corresponding to a consumed or remaining amount of one or both of the wire electrodes. The first wire electrode contacts the second wire electrode within the circumferential groove. The first wire electrode further contacts a first sidewall portion of the circumferential groove. The second wire electrode further contacts a second sidewall portion of the circumferential groove. Both of the wire electrodes are offset from a base portion of the circumferential groove, said base portion extending between the first sidewall portion and the second sidewall portion of the circumferential groove.