Solid Wire Composition for Arc Welding Burn-through Resistance
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Solution Overview
Problem
The challenge in arc welding of high-strength steel sheets is the increased risk of burn-through and undercut due to reduced sheet thickness, which leads to instability in wire feed and higher welding costs, along with issues of spatter and crack formation, as existing solutions either increase costs or degrade weld quality.
Innovation Solution
A solid wire composition with specific ranges of C, Si, Mn, S, P, and other elements, along with controlled surface treatments like copper plating or MoS2 coating, to reduce viscosity and surface tension of the molten pool, enhance burn-through resistance, and improve wire feed stability while maintaining weld metal hardness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If sheet thickness is reduced to achieve lightweight, then fuel consumption improves, but burn-through resistance deteriorates
Solution Approach 1:
The patent changes the chemical composition parameters of the welding wire (C: 0.05-0.15%, Si: 0.50-1.50%, Mn: 1.00-2.00%, S: 0.010-0.050%) to optimize the properties of the molten pool, reducing viscosity and surface tension to prevent burn-through on thin sheets while maintaining weldability
Solution Approach 2:
The patent creates a composite chemical composition system in the welding wire that combines multiple elements (C, Si, Mn, S) working synergistically to achieve the desired molten pool properties, where each element contributes to reducing viscosity and surface tension while maintaining structural integrity
2Strength
If element content is increased to increase strength, then tensile strength improves, but viscosity of molten pool increases causing blendability degradation
Solution Approach 1:
The patent optimizes the chemical composition parameters by precisely controlling the content ranges of alloying elements (Si: 0.50-1.50%, Mn: 1.00-2.00%) to achieve the balance between strength and molten pool fluidity, where the deoxidizing elements reduce viscosity while maintaining strength
3Productivity
If welding speed is increased to improve efficiency, then productivity improves, but burn-through resistance deteriorates
Solution Approach 1:
The patent changes the chemical composition to reduce surface tension and viscosity of the molten pool, allowing the molten pool to remain stable and cohesive at higher welding speeds, preventing burn-through even when arc precedes the molten pool
4Reliability
If wire diameter is decreased to improve burn-through resistance, then burn-through resistance improves, but wire feed stability deteriorates
Solution Approach 1:
The patent changes the chemical composition parameters (increasing Si and Mn content) to reduce molten pool viscosity, which compensates for the reduced wire diameter by improving fluidity and stability of the molten pool, thereby maintaining wire feed stability while keeping wire diameter small for burn-through resistance
5Reliability
If Ar ratio in shielding gas is increased to improve burn-through resistance, then burn-through resistance improves, but shielding gas cost increases
Solution Approach 1:
The patent changes the chemical composition of the welding wire to reduce molten pool viscosity and surface tension, which allows for reduced Ar content in shielding gas while maintaining burn-through resistance, thereby lowering shielding gas 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 proposed solid wire composition effectively reduces burn-through and undercut risks, minimizes spatter generation, and ensures high weld metal hardness, thereby stabilizing the welding process and controlling costs.
Implementation Method 1
a viscosity and a surface tension of a molten pool are significantly reduced
Implementation Method 2
a viscosity and a surface tension of a molten pool are significantly reduced
Implementation Method 3
This increases electric resistance heat generation between a current supply point at an end of the welding power supply tip and an arc generation point, thereby heat input per deposition is decreased
Implementation Method 4
arc welding of a sheet
Implementation Method 5
a phenomenon that a steel sheet is locally melted due to arc heat
Data Source
AI summary
A solid wire contains in mass percent C 0.005 to 0.080%, Si 0.30 to 1.20%, Mn 1.15 to 1.65%, S 0.050 to 0.200%, P 0.017% or less, O 0.0070% or less, and N 0.0050% or less, wherein C+(P*5)≦0.135 mass percent is satisfied, and the remainder includes Fe and impurities, and the content of each of Ti, B, Cr, Ni, Nb, V, Zr, La and Ce as the impurities is controlled to be a certain content or less, and the amount of adhered oil on a surface of the relevant solid wire is controlled to be 1.2 g or less per wire of 10 kg. According to such a configuration, while increase in welding cost is controlled to the minimum, stability of wire feed, burn-through resistance, undercut resistance, and crack resistance becomes excellent, slag and spatter becomes hard to be generated, hardness of weld metal becomes equal to or higher than that of base metal, and brittle fracture becomes hard to occur.