Ignition Flux for Arc Stud Welding Without Tip Insertion
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Solution Overview
Problem
The conventional arc stud welding method requires inserting an ignition tip into the fastener, which is complex and costly, reducing welding efficiency and increasing production costs, especially when using large diameter fasteners.
Innovation Solution
An ignition flux comprising 30-55 wt % SiO2, 30-55 wt % NiO, 10-35 wt % AlF3, and 5-25 wt % NiF2, or 30-55 wt % TiO2, 30-55 wt % NiO, 10-35 wt % AlF3, and 5-25 wt % NiF2 is coated onto the metal workpiece, allowing for the creation and smooth formation of an electric arc without the need for an ignition tip, enhancing the welding process and joint strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an ignition tip is inserted into the welding portion of the fastener, then the electric arc can be created and the welding can be performed, but the process becomes complicated and costly
Solution Approach 1:
The invention extracts the ignition function from the fastener (ignition tip insertion) and transfers it to the welding zone (flux coating). The flux layer becomes the independent ignition medium that eliminates the need for modifying the fastener structure, thereby simplifying the overall welding process while maintaining reliable arc initiation.
Solution Approach 2:
The flux layer acts as an intermediary substance between the fastener and the welding zone. It facilitates arc ignition by providing a low-breakdown-voltage medium that bridges the gap during the lifting stage, enabling reliable arc formation without requiring structural modifications to the fastener itself.
2Reliability
If an ignition tip is inserted into the welding portion of the fastener, then the welding can be performed, but the production cost increases
Solution Approach 1:
The flux layer serves as a disposable, low-cost consumable material that is applied to the welding zone. It performs its ignition function during the welding process and is consumed, eliminating the need for expensive, reusable ignition tips and their associated insertion/removal operations, thereby reducing production costs.
Solution Approach 2:
The flux is pre-applied to the welding zone before the welding operation begins. This preliminary action prepares the ignition medium in advance, eliminating the need for costly and time-consuming ignition tip insertion procedures during the actual welding process, thus reducing production costs and improving efficiency.
3Reliability
If an ignition tip is inserted into the welding portion of the fastener, then the welding can be performed, but the welding efficiency decreases
Solution Approach 1:
The flux is pre-applied to the welding zone before welding, preparing the ignition medium in advance. This eliminates the time-consuming ignition tip insertion and removal steps during each welding operation, thereby improving welding efficiency and productivity while maintaining reliable arc formation.
Solution Approach 2:
The invention removes the ignition tip insertion step from the welding process by transferring the ignition function to the flux-coated welding zone. This extraction of the complex insertion operation simplifies the workflow and improves welding efficiency while maintaining arc formation reliability through the flux medium.
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 method simplifies the welding process, improves the strength and penetration of the welded joint, and reduces production costs by eliminating the need for an ignition tip, while maintaining high welding efficiency.
Implementation Method 1
a voltage is applied to the fastener to form a current flowing from the fastener to the metal workpiece, such that the electric current flows through the fastener to the metal workpiece. A push-pull mechanism will then lifts off the fastener from the metal workpiece to draw an electric arc
Implementation Method 2
heating temperature of the electric arc can be increased. Hence, the welding process can be simplified and strength of the welded joint can be enhanced
Implementation Method 3
the welding portion of the fastener and the welding zone of the metal workpiece are melted by the heat of said electric arc
Data Source
AI summary
The invention provides an ignition flux for arc stud welding, including 30-55 wt % SiO2, 30-55 wt % NiO, 10-35 wt % AlF3, and 5-25 wt % NiF2, or including 30-55 wt % TiO2, 30-55 wt % NiO, 10-35 wt % AlF3, and 5-25 wt % NiF2. As such, the electric arc can be easily created and smoothly formed. The invention further provides an arc stud welding method utilizing such ignition flux. As such, the fastener and the metal workpiece can be tightly connected together without the need of inserting an ignition tip into the welding portion of a fastener.