Solid Lubricant Coating on Submerged Arc Welding Wire
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Solution Overview
Problem
Submerged arc welding (SAW) experiences significant contact tip abrasive wear due to friction and copper cladding stripping, leading to copper contamination and reduced weld integrity, necessitating the use of copper-clad welding wires despite the associated waste and contamination issues.
Innovation Solution
A SAW welding wire with a submerged arc welding wire substrate coated with a particulate solid lubricant, such as MoS2, WS2, ZnO, graphite, or PTFE, replaces copper cladding to reduce contact tip abrasive wear, eliminating copper waste and contamination while maintaining improved contact tip useful life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If copper-clad welding wire is used to reduce contact tip wear, then contact tip useful life is improved, but copper contamination and waste increase
Solution Approach 1:
The invention extracts and removes the copper cladding layer from the welding wire, replacing it with a solid lubricant coating. This eliminates the source of copper contamination while maintaining the wire's protective function against contact tip wear through the alternative lubricating mechanism.
Solution Approach 2:
The invention changes the material parameter of the wire coating from copper-based to solid lubricant-based (such as graphite, molybdenum disulfide, or PTFE). This parameter change maintains the lubricating function that extends contact tip life while eliminating the harmful copper contamination effect.
2Strength
If copper cladding is applied to welding wire to reduce friction, then contact tip abrasive wear is reduced, but manufacturing complexity and waste increase
Solution Approach 1:
The invention replaces the copper cladding layer with a thin coating of solid lubricant materials that are generally less expensive and can be applied more simply. The coating serves its protective function during the wire's usage life without requiring the complex copper cladding manufacturing process.
3Loss of substance
If solid lubricant coating is applied to welding wire, then copper waste is eliminated, but coating application complexity increases
Solution Approach 1:
The solid lubricant coating is designed to provide self-lubrication properties during welding operations. The coating materials (graphite, MoS2, PTFE) have inherent lubricating characteristics that reduce friction and wear without requiring additional active control or complex application systems beyond standard coating processes.
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 use of solid lubricants on SAW welding wires effectively reduces contact tip wear, extending the useful life of the contact tip and preventing copper contamination, thereby enhancing weld integrity and process efficiency.
Implementation Method 1
the welding wire comprises a welding wire substrate and a solid lubricant on the surfaces of the welding wire substrate
Implementation Method 2
due to friction and copper cladding stripping
Data Source
AI summary
The copper cladding normally applied to the surfaces of a submerged arc welding wire (50) for preventing weld gun contact tip abrasive wear is replaced with a solid lubricant. This eliminates copper contamination of the weld from the copper cladding while preserving the useful life of the contact tip.