Nickel-Core Stick Electrode for Lower-Cost AWS-Grade Weld Beads
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current nickel-containing stick electrodes for forming weld beads that satisfy AWS A 5.15-90 for ENiFe-CI and ENiFe-CI-A classes are expensive and difficult to produce due to the high cost and difficulty in obtaining nickel sheets of desired alloy composition, limiting their use in both continuous arc welding processes and stick welding operations.
Innovation Solution
Development of consumable electrodes with a high nickel core composition and an iron sheath that can be used in both continuous arc welding and stick welding operations, featuring a core with at least 35 wt.% nickel and a sheath that encircles the core, with the sheath comprising primarily iron and minimal nickel content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If nickel sheets of desired alloy composition are used to form a sheath for a stick electrode, then the weld bead composition can satisfy AWS A 5.15-90 for ENiFe-CI and ENiFe-CI-A classes, but the manufacturing cost and difficulty increase significantly
Solution Approach 1:
The patent applies local quality by concentrating the high nickel content (at least 35 wt.%) specifically in the core of the electrode, while the sheath is made of iron with minimal nickel content. This localized distribution of nickel ensures the weld bead achieves the required composition (at least 35 wt.% nickel) while avoiding the need for expensive nickel sheets throughout the entire electrode structure, thereby reducing manufacturing cost and difficulty.
2Adaptability or versatility
If a solid wire of nickel alloy is used, then continuous arc welding processes can be performed, but the electrode cannot be used for stick welding operations
Solution Approach 1:
The patent creates a universal electrode design with a iron sheath surrounding a nickel-rich core that can function in both stick welding operations and continuous arc welding processes. The sheath provides the structural integrity and flux coating attachment needed for stick welding, while the nickel-rich core ensures adequate nickel content (at least 35 wt.%) is deposited in the weld bead for both welding methods, thus achieving multi-functionality.
3Manufacturing precision
If the nickel content in the core is increased to at least 35 wt.%, then the weld bead can satisfy AWS A 5.15-90 requirements, but the cost of producing the electrode increases
Solution Approach 1:
The patent concentrates the high nickel content (at least 35 wt.%) specifically in the core of the electrode, while the sheath is made of iron with minimal nickel content. This localized distribution ensures the weld bead achieves the required composition without requiring high nickel content throughout the entire electrode, thereby reducing the total quantity of nickel needed and lowering material costs.
Solution Approach 2:
The patent uses a composite structure combining iron sheath with a nickel-rich core, creating a cost-effective electrode that meets AWS A 5.15-90 requirements. The composite design allows the expensive nickel material to be used only where necessary (in the core at least 35 wt.%), while the cheaper iron sheath provides structural support, optimizing both performance and cost.
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 solution provides a cost-effective electrode that can form weld beads with at least 35 wt.% nickel, suitable for both continuous arc welding and stick welding, addressing the production challenges and cost issues of existing electrodes.
Implementation Method 1
coalescence is produced by heating with an electric arc between a bare-metal electrode and the metal being worked
Implementation Method 2
The welding operation is started by striking an arc beneath the flux to produce heat to melt the surrounding flux
Implementation Method 3
The molten filler metal displaces the flux pool and forms the weld
Data Source
AI summary
A metal-cored electrode for welding to form a weld bead on a ferrous material, which weld bead includes at least 35 wt. % nickel. The metal-cored electrode includes a metal sheath surrounding a core. The core includes greater than 35 wt. % nickel.