Dual-Wire Contact Tip Layout for Wider Weld Puddles
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Solution Overview
Problem
Existing welding methods that increase electrode diameter to elongate or widen the weld puddle result in excessive heat input, which is undesirable.
Innovation Solution
A dual wire configuration using two electrodes with a circular cross-section passing through a single contact tip orifice, oriented in tandem or side-by-side, to achieve the desired weld puddle width or length without increasing heat input.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a larger electrode diameter is used to increase weld puddle width or length, then the weld bead width and puddle length are improved, but the heat input and energy consumption increase
Solution Approach 1:
The patent divides a single large electrode into multiple smaller electrodes (dual wire configuration) that pass through a single contact tip. This segmentation allows the weld puddle area to be increased by using multiple wires while maintaining smaller individual wire diameters, thereby reducing the heat input required compared to using a single large diameter electrode.
2Length of stationary object
If a larger electrode diameter is used to elongate the weld puddle, then the weld puddle length is improved, but the energy consumption increases
Solution Approach 1:
The dual wire configuration segments the welding function into multiple smaller electrodes. By feeding two or more smaller diameter wires through a single contact tip, the system achieves extended weld puddle length without requiring a single large diameter electrode, thus maintaining lower energy consumption.
3Productivity
If a larger electrode diameter is used to increase wire deposition rate, then the deposition rate is improved, but the heat input increases
Solution Approach 1:
The patent applies segmentation by using multiple smaller electrodes instead of a single large electrode. This configuration increases the wire deposition rate by utilizing multiple wires simultaneously while keeping the individual wire diameters small, thereby achieving high productivity with reduced heat input compared to conventional single large electrode welding.
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
The dual wire configuration allows for an increased weld puddle size with reduced heat input, enabling more stable welding arcs at higher wire feed speeds and efficient filler material deposition.
Implementation Method 1
a welding power supply provides a welding waveform to a contact tip having an exit orifice
Data Source
AI summary
A system and method of welding is provided where at least two welding electrodes are provided to and passed through a single orifice on a single contact tip and a welding waveform is provided to the electrodes through the contact tip to weld simultaneously with both electrodes.