Cooling Nozzle Array for Arc Welding Heat Control
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Solution Overview
Problem
Existing arc welding processes, particularly in WAAM, face issues with overheating and uncontrolled changes in the workpiece's mechanical and thermal properties due to accumulated heat, leading to deformation and discoloration, especially when complex geometries or non-rotary structures are welded, as conventional cooling methods become ineffective.
Innovation Solution
A welding device with a circumferential array of cooling nozzles around the welding torch, featuring adjustable and rotatable/tiltable nozzles, allowing targeted cooling near the energy input, using multiple cooling media and adaptive control based on temperature and movement, to maintain consistent cooling as the torch direction changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling pauses are incorporated to allow workpiece cooling, then thermal distortion and material property changes are reduced, but production productivity decreases due to interrupted welding process
Solution Approach 1:
The patent implements continuous cooling during the welding process without interrupting the deposition cycle. Cooling nozzles are positioned to deliver coolant directly to the workpiece surface in the welding path, allowing simultaneous welding and cooling operations to proceed without pauses, thereby maintaining both temperature control and high productivity
Solution Approach 2:
A coolant fluid is introduced as an intermediary medium between the heat source (welding arc) and the workpiece surface. The coolant absorbs excess heat through direct contact with the workpiece, acting as a thermal mediator that prevents overheating while allowing the welding process to continue uninterrupted
2Temperature
If conventional cooling methods are used for simple geometries, then cooling effectiveness is achieved, but the method becomes ineffective for complex geometries or non-rotary structures
Solution Approach 1:
The cooling nozzle system is made dynamic and adjustable, allowing the nozzle positions, angles, and coolant flow rates to be varied in real-time based on the specific geometry being welded. This enables the system to adapt to complex shapes and orientations rather than requiring the workpiece to conform to a fixed cooling arrangement
Solution Approach 2:
Multiple cooling nozzles are positioned at different locations and angles to provide localized cooling tailored to specific areas of the workpiece. Each nozzle can be independently controlled to deliver coolant precisely where needed on complex geometries, rather than using a uniform cooling approach
3Adaptability or versatility
If multiple cooling nozzles are arranged circumferentially around the welding torch, then cooling adaptability to changing torch orientation is improved, but device complexity increases
Solution Approach 1:
The cooling system is divided into multiple independent nozzle segments arranged circumferentially around the welding torch. Each nozzle can be independently controlled and positioned, allowing the system to handle complex geometries while maintaining manageable modularity in the overall device structure
Solution Approach 2:
The circumferential nozzle array serves multiple functions simultaneously: it provides cooling coverage for various torch orientations, allows selective activation of individual nozzles based on geometry requirements, and can accommodate both simple and complex workpiece shapes with a single configurable system
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 device effectively maintains material properties and reduces thermal distortion, enabling faster production with predictable layer structures and minimized discoloration, even with complex geometries, by ensuring continuous cooling without pauses.
Implementation Method 1
the cooling nozzles are supplied with a coolant flow in order to cool the workpiece in the vicinity of the energy input
Implementation Method 2
When using arc welding technology for joining, weld overlay, and additive manufacturing, heat is introduced into the component or structure by melting or partially melting the base and filler material
Data Source
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AI summary
The invention relates to a welding device (1) for welding at least one workpiece, comprising: a welding torch (2), which is designed to create an electric arc (3) for welding the at least one workpiece; and a nozzle apparatus (20) arranged on the welding torch (2), which has a cooling nozzle array (21), which has at least one row (22) of cooling nozzles (23), it being possible to apply an adjustable volume flow of cooling medium (4) to each cooling nozzle (23) for cooling the workpiece.