Arc-Welded Metal Lamination Using Blocking Beads for Surface Quality
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing metal laminating and modeling methods using arc discharge face challenges in achieving high-speed manufacturing while maintaining surface quality, as high-temperature welding can cause molten metal to drop and adhere to the outer surface of the modeled article, leading to defects and longer formation times.
Innovation Solution
A method involving the sequential lamination of metal layers using blocking beads formed with a lower current arc welding on the outer periphery and inner beads formed with a higher current arc welding inside the blocking beads, preventing molten metal from dropping and ensuring efficient formation of the modeled article.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-temperature arc welding is used to laminate molten beads, then the manufacturing speed is improved, but molten metal drops and adheres to the outer surface causing quality deterioration
Solution Approach 1:
The welding process is segmented into two distinct phases: a first arc welding process that forms blocking beads at lower temperature, and a second arc welding process that fills the interior at higher temperature. This segmentation allows each phase to be optimized independently, preventing molten metal drops on the outer surface while maintaining high manufacturing speed in the filling phase.
Solution Approach 2:
The blocking beads are formed in advance along the outer peripheral shape before the main filling process. This preliminary action creates a protective barrier that prevents molten metal from the subsequent high-temperature filling process from dropping onto the outer surface, thus preserving surface quality while enabling high-speed manufacturing.
2Productivity
If high-temperature arc welding is used to increase manufacturing speed, then productivity is improved, but defects occur requiring removal and re-lamination which increases time
Solution Approach 1:
The welding process is divided into a first arc welding process for forming blocking beads and a second arc welding process for filling the interior space. This segmentation prevents defects by containing molten metal within the blocking beads during the high-speed second phase, eliminating the need for time-consuming removal and re-lamination operations.
Solution Approach 2:
The blocking beads, which initially might seem to slow down the process by requiring a two-phase approach, actually prevent harmful molten metal drops. This converts what could be a time-wasting defect prevention measure into a benefit that enables high-speed manufacturing without rework.
3Manufacturing precision
If low current arc welding is used to prevent molten metal drops, then surface quality is maintained, but the manufacturing speed decreases
Solution Approach 1:
The process segments the welding operations: the first arc welding process uses lower current to form blocking beads and prevent drops, while the second arc welding process uses higher current to rapidly fill the interior space. This segmentation maintains surface quality in the first phase while achieving high manufacturing speed in the second phase.
Solution Approach 2:
The lower current first arc welding process performs the preliminary action of forming blocking beads that protect the outer surface. This preliminary protective measure enables the subsequent high-current second arc welding process to operate at high speed without compromising surface quality, thus resolving the speed-quality trade-off.
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 enables the rapid and high-quality formation of metal articles by blocking molten metal with outer beads and efficiently filling the space with inner beads, preventing drops and enhancing surface quality.
Implementation Method 1
a technique of laminating and modeling metal has been developed and put into practical use. As such a metal laminating and modeling method, one in which a modeled article is formed by laminating metal layers using metal melted by an arc discharge has been developed.
Implementation Method 2
inner beads are formed by arc welding with a current higher than the current in the step of forming blocking beads
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
Provided is a metal laminating and modeling method including sequentially carrying out a step of laminating metal layer to form a modeled article, in which the step of laminating a metal layers includes a step of forming blocking beads that are continuous along the outer peripheral shape of the modeled article by arc welding on at least one end portion in the width direction of a target surface, on which the metal layers are to be formed, and a step of forming inner beads by arc welding with a current higher than the current in the step of forming blocking beads so as to fill a space on the inside of the blocking beads in the width direction of the target surface.