Arc-Welding Head With Insulated Cold-Wire Feed for Higher Deposition
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Solution Overview
Problem
Existing submerged arc welding methods face limitations in achieving high productivity and deposition rates while maintaining weld quality, particularly in handling cold electrodes and managing heat impact on workpieces.
Innovation Solution
An electric arc-welding welding head with an electrically insulated duct for at least one electrode, allowing independent manipulation and separate wire feeders for hot and cold wire electrodes, enabling improved deposition rates and reduced heat generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple electrodes are used to increase deposition rate, then productivity is improved, but device complexity increases due to handling multiple cold electrodes
Solution Approach 1:
An electrically insulating duct is introduced as an intermediary component to guide the cold wire electrode through the welding head. This duct electrically insulates the cold wire from other electrodes and the welding head structure, enabling safe passage and independent manipulation of the cold wire electrode without increasing overall system complexity
Solution Approach 2:
The welding head is segmented into distinct functional zones: hot wire electrodes for arc generation and cold wire electrodes for additional metal deposition. The cold wire electrode system is further segmented with separate feeding mechanisms and individual electrical insulation, allowing independent control and manipulation of each electrode type
2Productivity
If cold wire electrodes are added to improve deposition rate, then productivity is improved, but heat management becomes more difficult due to additional heat sources
Solution Approach 1:
Different electrodes are assigned different functional qualities: hot wire electrodes are designed to generate arcs and high heat for penetration, while cold wire electrodes are designed to melt without arcs for additional deposition with reduced heat input. The electrically insulating duct allows the cold wire to be positioned and fed independently to optimize its local thermal contribution
3Ease of operation
If electrically insulating duct is added for cold wire electrode, then ease of operation is improved, but device complexity increases
Solution Approach 1:
The electrically insulating duct serves multiple functions simultaneously: it provides electrical insulation for the cold wire electrode, guides the wire through the welding head, protects the wire from contact with other electrodes, and maintains proper positioning. This multi-functionality justifies the added component by delivering several operational benefits from a single element
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 solution enhances deposition rates by up to 50% and improves productivity without increasing welding speed, while maintaining high weld quality and allowing for easier adjustment of welding parameters.
Implementation Method 1
one or more sequentially arranged welding electrodes melt in arcs
Implementation Method 2
melted by resistance heating as well as by the heat generated by the middle electrode 36
Implementation Method 3
The flux melts in part during the process, thus creating a protecting layer of slag on the weld pool
Implementation Method 4
These additional electrodes 32, 38, also known as 'cold wires' or 'cold wire electrodes' are in continuous short-circuit contact with the weld pool 12. The two electrodes 32, 38 consumed in the molten weld pool 12 without the formation of arcs are melted by resistance heating
Data Source
AI summary
The invention relates to an electric arc-welding welding head comprising a contact device and one or more wire feeder units, the contact device encompassing an electrode assembly, the electrode assembly comprising at least two fusible continuously-fed wire electrodes arranged in a contact device. An electrically insulated duct is provided for electric insulation of at least one of the electrodes so that the electrode is electrically insulated from other electrodes in the electrode assembly. The invention also relates to an electric arc-welding contact device and an electric arc-welding welding head assembly.