Narrow-Gap Laser-TIG Hybrid Welding for Thick-Section Deformation Control
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Solution Overview
Problem
Traditional TIG welding methods suffer from low welding speed, high heat input, and resulting deformation, making them inefficient for high-quality welding of thick materials, especially in applications like aerospace and nuclear power.
Innovation Solution
A narrow gap laser-TIG arc hybrid welding apparatus and method that combines a tungsten inert gas (TIG) arc with a laser beam to create a hybrid heat source, allowing for precise control of weld width and improved deposition efficiency through the use of a swing welding gun assembly and hot wire feeding system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional TIG welding method is used, then welding quality is good, but welding speed is low and welding efficiency is low
Solution Approach 1:
The patent combines laser welding and TIG welding into a hybrid welding system. The laser provides high energy density for deep penetration and fast welding speed, while the TIG arc ensures stable welding process and high quality welds. This merging of two different welding methods allows the system to achieve both high welding speed and high welding quality simultaneously, resolving the contradiction between productivity and reliability.
2Reliability
If traditional TIG welding method is used, then welding quality is good, but heat input is large causing welding deformation
Solution Approach 1:
By combining laser and TIG arc, the system achieves concentrated heat input from the laser for deep penetration with minimal heat affected zone, while the TIG arc provides supplemental heat for stable welding. This results in reduced overall heat input compared to traditional TIG welding, thereby reducing welding deformation while maintaining weld quality.
Solution Approach 2:
The hybrid welding system changes the thermal parameters by introducing laser energy with much higher energy density than arc welding. This parameter change allows for lower total heat input to achieve the same welding depth and quality, thereby reducing thermal distortion and deformation.
3Productivity
If laser welding is used, then welding speed is fast and energy density is high, but requirements for groove assembly are high and容易产生 pores and cracks
Solution Approach 1:
The TIG arc acts as an intermediary that stabilizes the welding process. The laser provides the high energy density for fast welding, but the TIG arc supplements the heat input and improves fluidity of the molten pool, which helps prevent pores and cracks. This intermediary role of the TIG arc allows the system to achieve high welding speed without the severe constraints of pure laser welding.
4Strength
If laser-TIG arc hybrid welding is used for large thick materials, then weld penetration increases, but metal filling amount increases leading to reduced welding efficiency
Solution Approach 1:
The system changes the energy distribution parameters by using laser as the primary heat source for deep penetration and TIG arc as supplemental heat. This parameter change allows for efficient melting and reduced metal filling requirements compared to traditional arc welding, thereby maintaining high welding efficiency even for thick materials with deep penetration requirements.
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
The hybrid welding method significantly enhances welding efficiency by up to three times, reduces material consumption, minimizes deformation, and achieves high-quality welds with precise control over weld width, addressing the limitations of traditional TIG welding.
Implementation Method 1
laser welding technology has developed rapidly. Different from traditional welding heat sources, laser welding has the advantages of high energy density
Implementation Method 2
Tungsten inert gas welding (TIG), as one of the traditional arc welding technologies, has many advantages, such as good arc stability
Implementation Method 3
the deposition efficiency of welding wire is low, especially for the welding of medium-thick structural parts
Data Source
AI summary
Disclosed are a narrow gap laser-TIG arc hybrid welding apparatus and method. The welding apparatus includes a welding gun body, a swing welding gun assembly, a welding wire feeding and heating assembly, and a gas conveying assembly; the swing welding gun assembly includes a welding gun rotating shaft, a stepper motor, a large gear, a pinion, an upper insulating sleeve, a lower insulating sleeve, a tungsten electrode clamp, and a tungsten electrode; the stepper motor is mounted on a motor connection seat; the pinion is mounted on the output shaft of the stepper motor; the large gear is mounted on the welding gun rotating shaft; the pinion is engaged with the large gear; the welding gun rotating shaft is mounted and positioned on the welding gun body; the tungsten electrode is mounted at the tail end of the welding gun rotating shaft by means of the tungsten electrode clamp.