Pulse Arc Welding Current Control for Thin Aluminum Beads
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Solution Overview
Problem
Existing arc welding methods, particularly pulse welding, face challenges in controlling the shape of weld beads on thin aluminum materials due to high welding currents and difficulties in using inert gases as shield gases, leading to spatter generation and irregular bead formation.
Innovation Solution
An arc welding control method that alternates between a first peak current and a base current, with a second peak current superimposed at a higher frequency during the base period, to maintain a lower welding current and stabilize droplet transfer, ensuring a good appearance of the weld bead.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If pulse welding is used to control bead shape on thin aluminum materials, then welding efficiency is improved, but spatter is generated and bead appearance deteriorates due to high peak current
Solution Approach 1:
The welding process is segmented into multiple current levels: a base current level and multiple superimposed peak current levels. This segmentation allows the welding current to be divided into stages, where the base current maintains the arc and lower heat input, while superimposed peak currents provide additional heat only when needed for droplet detachment, thereby reducing overall spatter while maintaining welding efficiency
Solution Approach 2:
The welding process employs periodic superimposition of peak currents on the base current at specific frequencies. This periodic action creates cyclic variations in heat input that synchronize with the droplet formation and detachment process, enabling controlled droplet transfer at lower average current levels, thus reducing spatter while maintaining productivity
2Ease of operation
If high peak current is used for droplet detachment in pulse welding, then droplet transfer is achieved, but arc force increases making control difficult and generating more spatter
Solution Approach 1:
The welding current is made dynamic through superimposition of peak currents on the base current. This dynamic current variation allows the arc force to be modulated in real-time, providing sufficient force for droplet detachment only when needed, while maintaining lower arc force during base current periods, thus improving controllability and reducing spatter
Solution Approach 2:
The welding parameters are changed by superimposing peak currents at different frequencies and amplitudes on the base current. This parameter modulation allows precise control of arc force and heat input, enabling droplet detachment at lower overall current levels and improving the ease of operation while reducing harmful arc forces
3Ease of manufacture
If conventional pulse welding is used on thin aluminum plates, then welding can be performed, but heat input is too large causing poor bead shape control
Solution Approach 1:
Instead of applying full peak current continuously, the invention uses partial action by superimposing peak currents only during specific periods on the base current. This partial application of high current provides sufficient heat for droplet detachment and welding feasibility, while the base current maintains lower overall heat input, enabling precise bead shape control on thin aluminum plates
4Productivity
If CO2 gas is used as shield gas in pulse welding, then welding can be performed, but reaction force of arc is large making one-pulse one-drop control difficult
Solution Approach 1:
The welding parameters are modified by superimposing peak currents on the base current, which changes the thermal and dynamic characteristics of the arc. This parameter change reduces the reaction force of the arc by distributing heat input over time, making droplet transfer control easier even when using CO2 gas as shield gas, while maintaining welding capability
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 method enables stable pulse welding with low welding current and forms weld beads with a good appearance by controlling the heat input and arc force, preventing spatter and irregularities, especially on thin aluminum plates.
Implementation Method 1
welding is performed by causing a current to flow through a welding wire as an electrode while melting the welding wire using arc heat generated between the welding wire and a base material
Implementation Method 2
causing a current to flow through a welding wire as an electrode while melting the welding wire
Data Source
AI summary
A pulse welding period alternately includes a first peak period in which a first peak current whose peak value is a first current value is caused to flow through a welding wire and a base period in which a base current having a second current value is caused to flow through the welding wire. During the base period, a second peak current whose peak current value is a sum of a second current value and a third current value and is smaller than the first current value is superimposed on the base current at a second pulse frequency. A second peak period in which the second peak current is caused to flow once is shorter than the first peak period. During the first peak period, a droplet is transferred from the welding wire toward a base material.