High-Strength Welding Wire Geometry for Stable Precision Feeding
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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 a Cu or Cu alloy layer, 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 wire is used to achieve high tensile strength, then welding strength is improved, but wire habit occurs more frequently leading to reduced positional accuracy
Solution Approach 1:
The patent applies parameter changes by controlling the wire diameter within a specific range (0.8mm to 1.6mm) and managing the coil winding parameters (cast and helix) to optimize the balance between strength and wire habit. This parameter optimization reduces positional deviation during wire feeding while maintaining high tensile strength of 800MPa or more
2Strength
If high-strength solid wire is used to achieve high tensile strength, then welding strength is improved, but wear on welding tip increases due to friction and fusion
Solution Approach 1:
The patent applies this principle by using a consumable solid wire that is fed through the welding tip. The wire acts as a disposable element that protects the expensive welding tip from excessive wear. By optimizing wire diameter and surface properties, the patent reduces friction and fusion wear on the welding tip while maintaining high strength welding performance
3Stability of the object's composition
If wire diameter is increased to reduce wire habit, then wire stiffness is improved, but feeding control precision is reduced
Solution Approach 1:
The patent applies parameter changes by optimizing the wire diameter to a specific range (0.8mm to 1.6mm) that balances wire stiffness and feeding control precision. This parameter optimization ensures the wire is stiff enough to resist habit formation while remaining thin enough for precise feeding control in automated welding systems
4Ease of operation
If wire is wound in tight coil for storage and handling, then handling convenience is improved, but wire habit occurs more frequently
Solution Approach 1:
The patent applies preliminary action by pre-controlling the coil winding parameters (cast of 300mm or more and helix of 20.0mm or less) during wire manufacturing. This preliminary control of the coil structure minimizes wire habit formation while maintaining compact coil shape for convenient storage and handling throughout the wire's service life
Data Source
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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.