Arc-Welded Metal Layering With Blocking Beads for Surface Quality
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Solution Overview
Problem
The existing metal laminating and modeling methods face challenges in achieving high-speed manufacturing with favorable surface quality due to high-speed arc welding, which causes molten metal to drop and adhere to the modeled article, requiring additional steps to remove and re-laminate, thereby increasing production time.
Innovation Solution
A method involving the sequential formation of metal layers using blocking beads and inner beads, where blocking beads are formed with a lower current along the outer shape and inner beads with a higher current inside, preventing molten metal from dropping and allowing efficient layer formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-speed arc welding is used to laminate metal layers, then manufacturing speed is improved, but molten metal drops and adheres to the outer surface, deteriorating surface quality
Solution Approach 1:
The weld beads are segmented into two types: blocking beads formed at end portions with lower current to contain molten metal, and inner beads formed in the middle portion with higher current for efficient filling. This segmentation allows different regions to serve different functions, preventing surface contamination while maintaining high-speed manufacturing
Solution Approach 2:
Different welding currents are applied to different portions of the target surface: a first (lower) current is used at the end portions to form blocking beads that prevent molten metal drop, while a second (higher) current is used in the middle portion to form inner beads for efficient material filling. This local differentiation of welding parameters resolves the contradiction between speed and quality
2Productivity
If high-speed arc welding is used to laminate metal layers, then manufacturing speed is improved, but additional steps are required to remove and re-laminate dropped metal, increasing production time
Solution Approach 1:
Blocking beads are formed in advance at the end portions of the target surface before inner beads are deposited in the middle portion. This preliminary action creates containment structures that prevent molten metal from dropping during subsequent high-speed welding operations, eliminating the need for post-processing removal and re-lamination steps
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 creation of high-quality modeled articles by preventing molten metal from adhering to the outer surface and efficiently filling the inner spaces, thus reducing production time and improving surface quality.
Implementation Method 1
a step of forming blocking beads and a step of forming inner beads. In the step of forming blocking beads, blocking beads that are continuous along the outer peripheral shape of the modeled article are formed by arc welding
Implementation Method 2
The metal layer is formed by forming a plurality of weld beads using metal melted by an arc discharge
Data Source
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.