Dual-Wire Contact Tip Assembly for Wide Weld Beads With Lower Heat
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Solution Overview
Problem
Existing welding methods using larger electrodes to increase weld bead width or length result in excessive heat input and undesirable weld profiles, as they often elongate and widen the weld puddle simultaneously, leading to inefficiencies and mechanical application issues.
Innovation Solution
A welding system with a dual wire configuration using a single contact tip assembly, where two electrodes of different diameters are fed through separate channels and exit orifices, creating a bridge droplet that is transferred to the weld puddle, allowing 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 or length, then the weld puddle becomes elongated and widened, but the heat input and energy consumption increase excessively
Solution Approach 1:
The single electrode is segmented into two separate electrodes of different diameters that are fed through separate channels in the contact tip assembly. This allows independent control of each electrode's contribution to the weld bead, enabling width increase without proportional heat input increase.
Solution Approach 2:
The contact tip assembly provides different local qualities through its two channels - one channel accommodates a larger diameter electrode for width contribution, while the other accommodates a smaller diameter electrode for controlled heat input, allowing optimized local characteristics in different regions of the weld.
2Area of stationary object
If a larger electrode diameter is used to increase weld bead width, then the weld puddle is elongated and widened, but the weld bead profile becomes non-ideal for mechanical applications
Solution Approach 1:
By segmenting the welding function into two separate electrodes with different diameters, the system can independently optimize each electrode's contribution to achieve the desired weld bead profile while maintaining adequate width, avoiding the distorted profiles caused by single large electrodes.
Solution Approach 2:
The system changes the parameter of electrode diameter from a single value to two different values, allowing precise control over weld bead geometry and profile characteristics to meet mechanical application requirements.
3Duration of action of moving object
If a larger electrode diameter is used to increase weld bead length, then the weld and filler metals remain molten longer reducing porosity, but the energy consumption increases
Solution Approach 1:
The welding function is segmented into two electrodes where the larger diameter electrode extends the weld puddle duration to reduce porosity, while the smaller diameter electrode contributes to the weld bead formation with lower energy consumption, achieving both goals simultaneously.
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 wider weld penetration with lower heat input, achieving improved mechanical weld performance and deposition rates while maintaining control over weld bead geometry and stability, even at high deposition speeds.
Implementation Method 1
welding power supply provides a welding waveform to a contact tip assembly
Implementation Method 2
welding waveform is provided to each of the electrodes by the contact tip assembly for a welding operation
Implementation Method 3
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
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.