Hot Wire Arc Steering via Magnetic Field Deflection
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Solution Overview
Problem
Welding systems, particularly those involving orbital and non-orbital processes, face challenges with lack of fusion and defects in deep groove geometries due to steeper sidewalls, leading to increased costs and time for repair.
Innovation Solution
A welder system that includes a welding torch with an electrode and a power source creating an arc, a wire feeder for delivering welding wire, and a controller to influence the arc direction using the polarity and location of the welding wire, allowing for precise control of the arc's direction and magnitude through a magnetic field generated by the welding wire's current.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If welding is performed on deep groove geometries with steeper sidewalls, then joint width is reduced and welding material is minimized, but lack of fusion and penetration defects occur
Solution Approach 1:
The system dynamically adjusts welding parameters including wire feed speed, wire extension length, and electrical parameters during the welding process to maintain optimal penetration and fusion on steep sidewalls, transforming a static welding process into an adaptive one that responds to real-time conditions
Solution Approach 2:
The invention changes multiple welding parameters simultaneously including wire extension length, wire feed speed, and electrical parameters to optimize the welding process for deep groove geometries, allowing penetration improvement without excessive material deposition
2Device complexity
If arc direction is not controlled in deep groove welding, then welding process is simpler, but lack of fusion defects occur on sidewalls
Solution Approach 1:
The welding wire acts as an intermediary element that, when extended beyond the arc, creates a magnetic field to deflect and redirect the arc toward the sidewalls, providing a simple mechanism to achieve precise arc control without complex positioning systems
Solution Approach 2:
The invention replaces mechanical arc positioning systems with a magnetic field-based arc deflection system using the welding wire's electrical current to generate a magnetic field that naturally redirects the arc, eliminating the need for complex mechanical adjustment mechanisms
3Manufacturing precision
If welding repairs are performed on lack of fusion defects, then fusion quality is improved, but time and cost increase
Solution Approach 1:
The system applies preliminary actions by extending the wire and deflecting the arc toward the sidewalls before welding begins, preventing lack of fusion defects from occurring in the first place, thereby eliminating the need for time-consuming repairs
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 solution effectively prevents lack of fusion and improves welding efficiency by allowing for better penetration and distribution of weld material in deep groove geometries, reducing repair needs and enhancing overall welding process efficiency.
Implementation Method 1
a magnetic field of the welding wire and the magnetic field is controlled by a current in the welding wire via the welding wire power source
Implementation Method 2
a power source that creates an arc between the electrode and the workpiece
Implementation Method 3
The hot wire welding process includes the resistance heating of the up to or near a melting point of such wire
Data Source
AI summary
The invention described herein generally pertains to a system and method related to influencing a direction of an arc within a welding operation. Within a hot wire welding operation, an arc is generated between an electrode and a workpiece and a welding wire is energized while being supplied to a puddle formed by the electrode in order to deposit the liquefied welding wire onto the workpiece. A welder system and/or method is provided that controls a direction of the arc based on at least one of a polarity of the welding wire (via a power supply that energizes the welding wire), a location of the welding wire in proximity to the arc, a synchronization and/or de-synchronization of a polarity of the welding wire with the electrode, an activation and/or a de-activation of energizing of the welding wire, or a combination thereof.