Welding Closed Section Rib Flat Root Surface
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Solution Overview
Problem
In the welding of steel plate decks, full-penetration welding is challenging due to the structure of closed-section ribs, leading to issues like slag inclusion and unstable penetration, as molten slag and blowholes often intrude deeper than desired, causing defects.
Innovation Solution
The method involves shaping the root portion of the closed-section rib to have a flat surface parallel to the deck plate, allowing the flat surface to contact the deck plate during welding, which limits the intrusion of molten slag and blowholes, ensuring stable penetration without increasing the penetration depth.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the amount of penetration is increased to prevent slag inclusion and blowholes, then the stability of penetration is improved, but excessive melting occurs that reaches the back surface of the closed section ribs
Solution Approach 1:
The root portion of the closed section rib is pre-shaped to have a flat surface before welding. This preliminary preparation creates a controlled geometry that limits slag and blowhole intrusion, allowing stable penetration to be achieved without increasing the penetration amount to the point of excessive melting.
Solution Approach 2:
The invention changes the geometric parameter of the root portion from an orthogonal or nearly orthogonal angle to a flat surface. This parameter change modifies the welding behavior, enabling the molten metal to fill the groove more effectively and prevent slag inclusion while maintaining controlled penetration depth.
2Ease of manufacture
If gas-shielded metal arc welding or submerged arc welding is used for closed section ribs, then welding can be performed without backing metal, but molten slag and blowholes intrude into the groove causing slag inclusion
Solution Approach 1:
The root portion is pre-shaped to have a flat surface that creates a groove structure. This preliminary geometric preparation ensures that during gas-shielded metal arc welding or submerged arc welding, the molten metal can effectively fill the groove and prevent slag and blowhole intrusion, achieving reliable welding without requiring backing metal.
Solution Approach 2:
The invention applies a specific geometric configuration (flat surface at root portion) only to the local area where welding occurs. This localized quality change at the root portion creates optimal conditions for slag prevention during welding, while the rest of the rib structure maintains its closed-section configuration that enables welding without backing metal.
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 prevents residual molten slag and blowholes, achieves stable penetration, and allows for controlled penetration dimensions, even under varying welding conditions, enhancing the structural integrity of the steel plate deck.
Implementation Method 1
gas-shielded metal arc welding, submerged arc welding
Implementation Method 2
molten slag generated during the welding
Implementation Method 3
molten slag generated during the welding intrudes into the groove
Implementation Method 4
shaping a root portion of the closed section rib to have a flat surface in parallel with a surface of the deck plate, and welding the deck plate and the closed section rib while making the flat surface of the closed section rib to contact the surface of the deck plate
Data Source
AI summary
A method of welding a deck plate and a closed section rib both constituting a steel plate deck, comprising: working a root portion of the closed section rib to have a flat surface in parallel with a surface of the deck plate; and welding the deck plate and the closed section rib while making the flat surface of the closed section rib to be in contact with the surface of the deck plate.