Marine Riser 5G Filler Welding with Oscillation Laser-GMAW
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Solution Overview
Problem
The existing fully automatic welding systems for marine risers face a heavy workload in parameter exploration due to the need for angle partition control in GMAW processes, and the core welding technology is often kept secret, making manufacturer support critical.
Innovation Solution
The oscillation scanning laser-GMAW hybrid welding process is used to simplify the welding of a 5G position filler layer in marine risers, allowing the same process parameters to be used for each layer, reducing molten pool gravity, and increasing arc force through laser-arc interaction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If GMAW method with angle partition control is used for welding, then welding can be performed on different welding angles, but the workload in parameter exploration becomes heavy
Solution Approach 1:
The patent changes the welding parameters (current, voltage, speed) based on the welding angle using predetermined lookup tables. The control system automatically selects appropriate parameters from the tables based on the current welding angle, eliminating the need for manual parameter exploration and reducing control complexity while maintaining adaptability to different angles.
Solution Approach 2:
The system performs self-adjustment by automatically selecting welding parameters from predetermined tables based on the welding angle detected by sensors. This self-service mechanism eliminates the need for operator intervention in parameter selection, reducing workload while maintaining optimal welding conditions for different angles.
2Ease of manufacture
If conventional GMAW process is used for filler layer welding, then welding can be completed, but the process requires matching different welding process parameters through angle partitions
Solution Approach 1:
The patent implements predetermined parameter tables that store optimized welding parameters (current, voltage, speed) for different welding angles. The control system automatically retrieves and applies the appropriate parameters from these tables based on the current welding angle, simplifying the manufacturing process by eliminating manual parameter matching while maintaining optimization for each angle.
Solution Approach 2:
The welding parameters are predetermined and stored in lookup tables before the actual welding process. This preliminary preparation of parameter sets allows the control system to quickly retrieve and apply optimal parameters without real-time calculation or manual adjustment, simplifying the welding process execution.
3Power
If laser-GMAW hybrid welding is used, then energy density is increased and molten pool gravity is reduced, but the process requires precise control of laser power and welding speed
Solution Approach 1:
The patent implements predetermined parameter tables that store optimized combinations of laser power, welding current, voltage, and speed for different welding angles and positions. The control system automatically selects and applies these pre-optimized parameter combinations, maintaining high energy density benefits while reducing the complexity of real-time parameter coordination through automated lookup and control.
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 simplifies the welding process, ensures arc stability and molten pool metal filling, prevents lack-of-fusion defects, and optimizes penetration depth, providing a more efficient and reliable welding method for marine risers.
Implementation Method 1
gravity of a molten pool is reduced and an arc force is increased through interaction between laser and an arc
Implementation Method 2
a range of a welding molten pool is expanded through an oscillation scanning behavior of a laser beam
Data Source
AI summary
A simplified method for welding a 5G position filler layer of a marine riser and a product thereof are provided, and the disclosure belongs to the technical field of welding. The method specifically includes the following. performing filler welding on the marine riser using an oscillation scanning laser-GMAW hybrid welding process; performing welding on each layer using same process parameters, then reducing gravity of a molten pool and increasing an arc force through interaction between laser and an arc, meanwhile expanding a range of a welding molten pool through an oscillation scanning behavior of the laser beam. A lack-of-fusion defect is prevented from being generated. A 5G position filler layer welding process of the marine riser is effectively simplified in the disclosure. Further, laser beam scanning also expands the range of the welding molten pool and prevents generation of the lack-of-fusion defect on a side wall.