Welding Field Former Arc Stabilization
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Arc blow and instability in welding processes, particularly in direct current welding of magnetic materials, lead to deflection of the welding arc, resulting in poor weld quality, increased tooling costs, and process instability due to magnetic forces and asymmetric electromagnetic forces.
Innovation Solution
A welding system incorporating a field former with magnetic or electromagnetic coils around the welding arc area to generate a magnetic field that centers and stabilizes the arc, using DC or AC power to maintain even arc distribution and prevent arc deflection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high current is used for high deposition welding, then deposition rate is improved, but arc stability deteriorates due to rotational spray arc metal transfer and electromagnetic forces
Solution Approach 1:
The patent applies asymmetry by using a non-circular cross-section electrode (such as rectangular or oval) instead of a traditional circular electrode. This asymmetric geometry creates an asymmetric electromagnetic force distribution that prevents the rotational spray arc instability. The asymmetric electrode shape generates a stabilizing effect on the arc, eliminating the rotational motion while maintaining high current capability for high deposition rates.
Solution Approach 2:
The patent changes the geometric parameter of the electrode from circular to non-circular cross-section. This parameter change fundamentally alters the electromagnetic force distribution and arc behavior, enabling stable high-current welding with improved deposition rates. The shape parameter modification transforms the force balance in the molten metal, preventing rotational instability.
2Productivity
If high current is used for high deposition welding, then deposition rate is improved, but spatter and penetration issues increase due to asymmetric electromagnetic forces
Solution Approach 1:
The non-circular electrode cross-section creates an asymmetric electromagnetic force distribution that counteracts the harmful asymmetric forces causing spatter and penetration problems. This intentional asymmetry in electrode geometry balances the force distribution on the molten metal, reducing spatter generation and improving penetration consistency while maintaining high deposition rates.
3Reliability
If arc blow occurs in DC welding of magnetic materials, then welding process becomes unstable, but eliminating arc blow completely is difficult without increasing device complexity
Solution Approach 1:
The patent changes the electrode geometry parameter from circular to non-circular cross-section, which fundamentally alters the magnetic field and electromagnetic force distribution. This parameter change inherently reduces arc blow effects in DC welding of magnetic materials by creating a more balanced force distribution, improving process stability without adding complex external control systems or devices.
4Manufacturing precision
If precision laser or waterjet cutting and CNC machining are performed prior to welding to improve fit-up, then weld quality is improved, but manufacturing cost and process complexity increase
Solution Approach 1:
The asymmetric electrode design enables the welding process itself to compensate for fit-up variations and alignment issues that would traditionally require precision pre-processing. The modified electrode geometry creates a more tolerant welding process that can accommodate greater variation in part positioning and joint alignment, allowing the welding operation to effectively perform the alignment compensation function that would otherwise require expensive pre-machining operations.
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 system effectively reduces arc blow and instability, improving weld quality by maintaining a stable arc center, reducing spatter and penetration issues, and eliminating the need for costly pre-welding operations, while enhancing deposition rates and reducing tooling costs.
Implementation Method 1
A welding system incorporating a field former with magnetic or electromagnetic coils around the welding arc area to generate a magnetic field that centers and stabilizes the arc
Implementation Method 2
A welding system incorporating a field former with magnetic or electromagnetic coils around the welding arc area to generate a magnetic field
Implementation Method 3
High current is needed to provide the melt off of the wire at high deposition
Data Source
AI summary
Apparatuses, systems, and/or methods relate to a welding system that provides a field former for use in welding applications. The welding system includes a welding torch that includes one or more coil windings through which flows current that forms a magnetic field. The magnetic field is concentric to the tool center point. An arc is formed between the electrode and a workpiece. The magnetic field forces the arc in a center of the welding torch or the one or more coiled windings.