Support Bead Deposition for Inclined Surface Weld Build-Up
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Solution Overview
Problem
The challenge is to prevent dripping and humping of weld beads when forming a built-up object on an inclined base surface, as existing techniques are prone to these issues due to gravitational influence, and increasing torch speed to avoid dripping can lead to humping.
Innovation Solution
The method involves determining the portion with maximum gravitational influence and forming a low-heat-input supporting bead to stabilize the weld beads, which are then deposited on top of this supporting bead to prevent dripping and humping, using a welding robot and controller to manage the torch movement and heat input based on pre-defined process windows.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the travelling speed of the welding torch is heightened to avoid dripping, then productivity is improved, but humping occurs where the weld bead breaks
Solution Approach 1:
A supporting bead is formed in advance at the lower-end portion where gravitational influence is maximum, before the main weld bead is deposited. This supporting bead creates a stable foundation that prevents humping when welding at higher speeds, allowing improved productivity without sacrificing weld bead quality
2Manufacturing precision
If the travelling speed of the welding torch is reduced to prevent humping, then manufacturing precision is improved, but productivity deteriorates
Solution Approach 1:
By forming a supporting bead beforehand at the critical lower-end portion, the system enables maintenance of high welding speeds without humping. The supporting bead acts as a pre-prepared structure that stabilizes the weld bead formation, allowing both high productivity and manufacturing precision to be achieved simultaneously
3Adaptability or versatility
If welding is performed on an inclined base surface, then adaptability is improved, but dripping occurs due to gravitational influence
Solution Approach 1:
A supporting bead is formed in advance at the lower-end portion of the inclined surface where gravitational influence is maximum. This supporting bead counteracts the gravitational force that would otherwise cause dripping, enabling welding on inclined surfaces while maintaining weld bead quality and achieving both adaptability and manufacturing precision
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 approach allows for efficient formation of weld beads without dripping or humping, ensuring a high-quality built-up object by stabilizing the weld beads with supporting beads, even on inclined surfaces, while reducing production time.
Implementation Method 1
a 3D printer employing a metallic material melts the metal powder or metal wire using a heat source such as a laser or an arc
Implementation Method 2
a 3D printer employing a metallic material melts the metal powder or metal wire using a heat source such as a laser or an arc
Implementation Method 3
deposits the molten metal, thereby producing a built-up object
Implementation Method 4
there is a possibility that dripping might occur due to the influence of gravity
Data Source
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AI summary
Provided are a method for producing a molded article with which it is possible to mold a molded article by efficiently forming weld beads without producing defects such as sagging and humping, a production device, and a molded article. In this method for producing a molded article, a filler material is melted and solidified, a weld bead is formed on a base surface along the trajectory of a torch, and a molded article is formed by the weld bead. At such time, the molded article has a bead formation portion at which the influence of gravity is strongest, and a support bead that has higher viscosity during production of the weld bead than does the weld bead is formed on the bead formation portion. Another weld bead is then formed so as to overlap the support bead.