Refractory Anchor Welding Using Straight-Neck GMAW Gun
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Solution Overview
Problem
Current methods for attaching refractory materials to surfaces, such as vessels, are cumbersome, require excessive materials and labor, and often involve potential failure points like threaded studs and torque tubes, while lacking a streamlined approach for creating strong and consistent joints.
Innovation Solution
A method using a portable metal inert gas welding gun with a straight neck to embed an anchor in refractory material, allowing for one-handed installation by inserting the nozzle and neck through a channel, confirming contact with a continuity sensor, and performing a test using a special tool to ensure the integrity of the weld.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If threaded studs and torque tubes are used to attach refractory materials, then the refractory material can be securely anchored, but the installation process becomes cumbersome and requires excessive materials and labor
Solution Approach 1:
The patent removes threaded studs and torque tubes from the anchoring system, retaining only the essential weldable anchor embedded in the refractory material. This extraction of unnecessary components simplifies the installation process while maintaining secure anchoring through direct welding of the anchor to the vessel surface
Solution Approach 2:
The patent combines the anchoring function and the attachment function into a single integrated anchor component. The anchor serves both as the securing element welded to the vessel and as the direct attachment point for the refractory material, eliminating the need for separate studs and torque tubes
2Reliability
If threaded studs and torque tubes are used to attach refractory materials, then the refractory material can be securely anchored, but potential failure points are introduced into the system
Solution Approach 1:
The patent eliminates threaded studs and torque tubes from the system, removing the threaded interfaces and mechanical fastening components that serve as potential failure points. By using direct welding, the system reduces the number of potential failure locations while maintaining or improving anchoring reliability
3Strength
If traditional welding methods are used to attach refractory materials, then strong joints can be achieved, but the installation process requires two hands and is less efficient
Solution Approach 1:
The patent segments the installation process into distinct functional components: the anchor is pre-embedded in the refractory material during manufacturing, and the installation phase only requires welding the exposed anchor portion to the vessel surface. This segmentation allows for simplified, one-handed operation while maintaining strong joint integrity through proper welding techniques
Solution Approach 2:
The anchor is pre-positioned and embedded in the refractory material during manufacturing before installation. This preliminary action ensures proper alignment and positioning, allowing the installer to focus solely on the welding operation with one hand, thereby improving installation efficiency without compromising joint strength
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 simplifies the installation process, reduces material costs, enhances reliability, and achieves stronger and more consistent joints without the need for threaded studs or torque tubes, enabling efficient and reliable anchoring of refractory materials in industrial applications.
Implementation Method 1
The weld may be made using GMAW spray transfer, GMAW globular transfer or GMAW pulsed transfer
Implementation Method 2
a timed current is applied through the small protrusion tip at the end of the stud. The stud weld current melts the protrusion at the end of the stud tip and a high energy arc is generated between the stud and the grounded vessel
Implementation Method 3
a 2-, 3- or 4-component shielding gas mixture is typically used, along with sufficient current and voltage to produce a stream of weld metal or a stream of weld droplets that cascade across an open arc from the electrode to the weld site
Data Source
AI summary
A method and apparatus for installing a refractory material to a surface by inserting a nozzle and a neck of a welding gun through a channel in a refractory material, positioning the refractory material on the surface using the welding gun, firmly pushing the welding gun into the channel of the refractory material until the nozzle of the welding gun, an anchor embedded in the refractory material and the surface are in contact, welding the anchor of the refractory material to the surface with the welding gun, and removing the nozzle and the neck of the welding gun from the channel in the refractory material.