High-Strength Welding Wire Geometry for Low Wire Habit
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
High-strength solid welding wires, such as Ni-based superalloys, exhibit significant wire habit issues during welding, leading to reduced positional accuracy and increased wear on welding tips, particularly in applications requiring high precision like additive manufacturing.
Innovation Solution
A welding wire with a tensile strength of 800 MPa or more, a cast of 300 mm or more, and a helix of 20.0 mm or less, optionally coated with Cu or Cu alloys, is designed to minimize wire habit and improve feeding performance, reducing positional deviations and wear on welding tips.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high-strength solid welding wire is used, then tensile strength is improved, but wire habit occurs leading to reduced manufacturing precision
Solution Approach 1:
The patent applies parameter changes by controlling the helix diameter to be 20mm or less and the cast to be 300mm or more. These specific parameter ranges reduce wire habit while maintaining high tensile strength of 800MPa or more, thereby resolving the contradiction between strength and positional accuracy.
2Strength
If high-strength solid welding wire is used, then tensile strength is improved, but wear on welding tip increases
Solution Approach 1:
The patent controls the wire geometry parameters (helix diameter ≤20mm, cast ≥300mm) to minimize wire habit. This reduction in wire habit directly decreases the friction and contact pressure between the wire and welding tip, thereby reducing wear on the welding tip while maintaining high tensile strength.
3Manufacturing precision
If wire habit correction is performed, then positional accuracy is improved, but additional processing time is required
Solution Approach 1:
The patent implements preliminary action by controlling the wire geometry parameters during manufacturing (helix diameter ≤20mm, cast ≥300mm) to minimize wire habit before the wire is used for welding. This pre-control eliminates the need for time-consuming correction processes, thereby improving positional accuracy without adding processing time.
4Volume of moving object
If solid wire is wound in coil shape for storage, then storage efficiency is improved, but wire habit occurs
Solution Approach 1:
The patent specifies parameter ranges for coil winding (helix diameter ≤20mm, cast ≥300mm) that allow the wire to be wound efficiently for storage while minimizing wire habit. These parameters enable compact coiling without creating excessive bends or deformations that would affect positional accuracy during welding.
Data Source
AI summary
The present invention relates to a welding wire including a solid wire of metal that has a tensile strength of 800 MPa or more, in which the welding wire has a cast of 300 mm or more and a helix of 20.0 mm or less. The welding wire may include a coating layer including Cu or a Cu alloy on an outer periphery of the solid wire.