Dual-Wire Contact Tip Assembly for Wide Beads With Lower Heat
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Solution Overview
Problem
Existing welding techniques face challenges in increasing the width of the weld bead or length of the weld puddle without simultaneously increasing heat input and weld bead profile, which can lead to porosity and mechanical application issues.
Innovation Solution
A dual wire configuration using a single contact tip assembly with two exit orifices, where a welding power supply provides a welding waveform to two electrodes passing through separate channels, forming a bridge droplet before transfer to the weld puddle, allowing for controlled heat input and improved weld geometry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a larger electrode diameter is used to increase weld bead width and puddle length, then the weld bead width and puddle length increase, 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 contributes to the weld bead width, and their combined effect achieves the desired wide weld bead and elongated puddle without requiring a single large electrode that would consume excessive energy and generate excessive heat input.
2Productivity
If a larger electrode diameter is used to increase weld bead width, then the deposition rate increases, but the weld bead profile becomes non-ideal for mechanical applications
Solution Approach 1:
By using multiple smaller electrodes instead of a single large electrode, the patent achieves high deposition rates through the combined material contribution of all electrodes while maintaining a more controlled and ideal weld bead profile. The segmented approach allows better distribution of heat and material flow, resulting in superior weld geometry suitable for mechanical applications.
3Duration of action of moving object
If a larger electrode diameter is used to elongate the weld puddle, then the molten period increases and porosity reduces, but the energy consumption increases
Solution Approach 1:
The patent uses multiple smaller electrodes to collectively elongate the weld puddle and extend the molten period, which allows harmful gases to escape before solidification. This segmented approach achieves the desired extended molten period and reduced porosity without the excessive energy consumption that would result from using a single large electrode.
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 a wider weld bead with improved mechanical performance and reduced heat input, achieving higher deposition rates and stability in welding operations, including additive manufacturing.
Implementation Method 1
a welding power supply provides a welding waveform to a contact tip assembly having two exit orifices. A wire feeding mechanism provides at least two welding electrodes to two different channels in the contact tip assembly
Implementation Method 2
The welding waveform is provided to each of the electrodes by the contact tip assembly for a welding operation
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.