Insulated MIG Contact Tip Assembly for Stable Arc Feeding
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Solution Overview
Problem
In metal inert gas welding (MIG-welding), there are issues with clogging of the guidance channel due to spark erosion and inadequate electrical contact, leading to instability in the electric arc and potential blockages, which affect the throughput and yield of direct metal deposition processes, especially when working with materials like titanium alloys.
Innovation Solution
The implementation of a contact tip assembly with an electrically insulating lining within the guide channel and a separate electric contact unit that connects with the metal wire after it has passed through the guide, ensuring a stable electrical connection and preventing clogging by isolating the guide from the metal wire.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the guide channel is used to guide the metal wire in MIG-welding, then the wire positioning is achieved, but spark erosion causes clogging of the guidance channel
Solution Approach 1:
The guide channel is segmented into an electrically insulating section and a conductive section. The insulating section prevents spark erosion and clogging, while the conductive section maintains electrical contact with the wire. This segmentation resolves the contradiction by separating the functions of mechanical guidance and electrical conduction.
Solution Approach 2:
An electrically insulating material is introduced as an intermediary between the metal wire and the guide channel wall. This intermediary prevents direct electrical contact that causes spark erosion, while still allowing mechanical guidance of the wire through the channel.
2Reliability
If the guide channel provides electrical contact with the metal wire, then electrical connection is established, but inadequate contact leads to arc instability
Solution Approach 1:
The electrical contact function is segmented from the mechanical guidance function. A separate electric contact element provides dedicated electrical contact with the wire, while the guide channel provides mechanical guidance. This ensures stable electrical connection without compromising arc stability.
Solution Approach 2:
An electric contact element serves as an intermediary to provide reliable electrical connection between the power source and the wire. This dedicated contact element ensures adequate electrical contact for stable arc formation, separate from the guide channel's mechanical guidance function.
3Device complexity
If a single integrated guide channel is used for both mechanical guidance and electrical contact, then device complexity is reduced, but clogging and arc instability occur
Solution Approach 1:
The integrated guide channel is segmented into separate functional sections: an electrically insulating section for mechanical guidance without electrical contact, and a conductive section or separate contact element for electrical connection. This segmentation improves reliability by preventing clogging and arc instability while maintaining reasonable device complexity.
Solution Approach 2:
An electrically insulating material is introduced as an intermediary within the guide channel structure. This intermediary prevents direct electrical contact between the wire and channel wall, eliminating spark erosion and clogging, while the overall structure remains relatively simple.
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 significantly reduces clogging and enhances the stability of the electric arc, improving the throughput and yield of direct metal deposition processes by maintaining a stable and efficient electrical connection, thus promoting smooth and well-defined deposition boundaries.
Implementation Method 1
a center bore (130) extending and running along the longitudinal center axis of the guide (120) from its first end (140) to its second end (150)... An electrically insulating lining (160) that is inside of the center bore (130) and that extends at least from the first end (140) to the second end (150) of the guide (120)
Implementation Method 2
an electric contact unit (200) containing a contact tip (215) in electric contact with an electric energy source
Implementation Method 3
The metal wire is made to melt at the end and the molten metal is deposited by positioning the end over the deposition point. The required heat for melting the metal wire is supplied by an electric arc
Implementation Method 4
It is known to use a plasma arc to provide the heat for welding metallic materials. This method may be employed at atmospheric or higher pressures
Data Source
AI summary
A contact tip assembly having an electric contact unit containing a contact tip with an electric energy source, where the electric contact unit is positioned at a distance away from the outlet opening of a guide.