Pulsed Waveform Control for Shielded Welding Wire Micro-Arcing
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Solution Overview
Problem
Current welding processes, particularly in MIG welding, face challenges in minimizing micro-arcing between the welding wire and other components, such as the welding torch contact tip, which can degrade the welding operation and result in poor weld quality, especially when using metal-cored or flux-cored wires.
Innovation Solution
A welding system and method that generate a controlled pulsed waveform with specific voltage and current ratios, including a background phase with at least 25% of peak current and 50% of peak voltage, to reduce micro-arcing by regulating successive peak and background phases, ensuring smooth transitions and maintaining higher background current and voltage levels compared to peak levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional welding processes are used with metal-cored or flux-cored wires, then welding operations can be performed, but micro-arcing occurs between the welding wire and contact tip causing torch degradation and poor weld quality
Solution Approach 1:
The patent applies periodic pulsed welding current with distinct peak and background phases. The current is pulsed at frequencies between 50-500 Hz, creating periodic cycles where high current peaks melt the wire and lower current backgrounds allow arc stabilization without micro-arcing. This periodic action eliminates continuous harmful micro-arcing while maintaining effective welding through controlled pulses.
Solution Approach 2:
The patent changes the electrical parameters by implementing a controlled pulsed waveform with specific characteristics: peak currents of 150-500 A, background currents of 25-75 A, peak voltages of 15-30 V, and background voltages of 10-20 V. By dynamically adjusting these parameters through the pulsed regime, the process eliminates micro-arcing while optimizing wire deposition and weld quality.
2Object-affected harmful factors
If higher background current and voltage levels are maintained, then micro-arcing is reduced, but energy consumption increases
Solution Approach 1:
The pulsed welding process uses periodic cycles with high current peaks for brief durations (providing melting energy) followed by lower current backgrounds (reducing energy consumption). This periodic action maintains sufficient background current to prevent micro-arcing while minimizing overall energy usage through the cyclic nature of the process.
Solution Approach 2:
The patent applies partial action by using elevated background current levels (25-75 A) only during the background phase portions of the cycle, rather than maintaining high current continuously. This partial application of high current is sufficient to prevent micro-arcing during critical periods while allowing energy reduction during other phases of the pulsed cycle.
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 effectively minimizes micro-arcing and enhances the quality of welds by optimizing the welding process for specific welding wire electrodes, improving the deposition and flowability of wire material, and reducing the risk of torch degradation.
Implementation Method 1
a power supply configured to convert electrical power from a source to a controlled pulsed waveform for performing a welding operation
Implementation Method 2
Electrical power is applied to the welding wire and a circuit is completed through the workpiece to sustain an arc that melts the wire and the workpiece to form the desired weld
Data Source
AI summary
A welding system and method provide for generating a controlled waveform for welding power output, the waveform comprising a plurality of successive peak phases designed to avoid or reduce micro-arcing when used with metal-cored or flux-cored electrode wires. Ratios of the background current and voltage levels are elevated as compared to conventional techniques, with the levels in most cases exceeding 50% of the peak currents and voltages. Transitions between background and peak levels of current and voltage are also smoothed, and the duration of the peak phase as compared to the duration of each pulse cycle is elongated to further reduce micro-arcing.