Cable-Type Welding Wire Lay Length for Low-Dilution Surfacing
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Solution Overview
Problem
Cable-type welding wires exhibit high penetration depth and dilution rates, making them unsuitable for applications requiring shallower penetration and thinner surfacing layers.
Innovation Solution
A cable-type welding wire design with a central wire and peripheral wires spirally wound, where the lay length of the peripheral wires is adjusted to achieve a smaller helix angle, reducing penetration depth and dilution rate, and allowing for control of welding parameters to achieve specific surfacing layer thicknesses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If cable-type welding wire is used with conventional lay length, then deposition efficiency and penetration depth are improved, but dilution rate increases and surfacing layer thickness becomes excessive
Solution Approach 1:
The patent applies parameter changes by adjusting the lay length of peripheral wires to control the helix angle. By reducing the lay length multiple to 3.2-16 (specifically 3.2-9 for thin surfacing), the helix angle is reduced to 26.99°-65.83°, which optimizes the arc distribution and reduces penetration depth while maintaining deposition efficiency. This parameter optimization resolves the contradiction between high deposition efficiency and excessive dilution rate.
2Length of moving object
If cable-type welding wire with large helix angle is used, then penetration depth increases, but surfacing quality control becomes difficult and dilution rate increases
Solution Approach 1:
The patent uses parameter changes to precisely control the helix angle within 26.99°-65.83° (and specifically ≤55.08° for thin surfacing applications). This controlled parameter range optimizes the balance between penetration depth and surfacing layer thickness, enabling precise control of surfacing quality while maintaining adequate penetration for welding integrity.
Solution Approach 2:
The patent introduces dynamic adjustability by providing different lay length multiple ranges for different surfacing layer thickness requirements. For thin surfacing (≤3mm), m≤9 and α≤55.08°; for medium thickness (3-6mm), 9<m≤14 and α≤65.83°; for thick surfacing (>6mm), m>14 and α≤76.74°. This dynamic parameter selection allows optimization for specific application requirements.
3Ease of operation
If conventional cable-type welding wire design is used, then coilability and wire feeding diameter are improved, but penetration depth becomes excessively large for thin surfacing applications
Solution Approach 1:
The patent maintains the cable-type structure for good coilability and wire feeding characteristics, but optimizes the lay length parameter to control the helix angle. By adjusting the lay length multiple to specific ranges, the penetration depth is reduced to suitable levels for thin surfacing while preserving the structural advantages of cable-type wires for coilability and feeding.
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 design allows for controlled penetration depth and dilution rate, enabling the use of cable-type welding wires in applications with strict requirements for surfacing quality and thickness, reducing production costs and improving economic benefits.
Implementation Method 1
n peripheral welding wires arranged so as to be spirally wound on the central welding wire... the peripheral welding wires have a lay length of T, which satisfies the equation of T=m×(dperipheral+dcentral)/2... a helix angle α, which satisfies the equation of α=arctan(m/2π)
Implementation Method 2
the cable-type welding wire has a vortex-type fluid flow pattern, causing the presence of vortex-type flow of the liquid metal in the molten pool during the welding process. The vortex motion of the liquid metal leads to depression in the middle of the molten pool, driving the high-temperature liquid metal to flow to the bottom of the molten pool
Implementation Method 3
during welding of the cable-type welding wire (such as CO2 metal inert gas welding), a small anode region thereof follows the feeding thereof and rotates around an anode region thereof, and quickly merges into a bundle-shaped rotating arc column area, the beam-shaped rotating welding arc is beneficial to the melting and the droplet transfer of the welding wire
Data Source
AI summary
A cable-type welding wire provided in the present application, includes a central welding wire and n peripheral welding wires arranged so as to be spirally wound on the central welding wire, with each of the peripheral welding wires having a diameter of dperipheral, and adjacent peripheral welding wires being arranged to be tangential to each other, wherein, the peripheral welding wires have a lay length of T, which satisfies the equation of T=m×(dperipheral+dcentral)/2, where m is a multiple of the lay length, dperipheral is a diameter of the peripheral welding wire, dcentral is a diameter of the central welding wire, and 3.2≤m<20. This application can obtain a smaller penetration depth when the welding parameters remain constant due to a small multiple of the lay length of the cable-type welding wire, and can further reduce welding arcing current.