CN106029280A

CN106029280A - Method and system to use combination filler wire feed and high intensity energy source for welding with controlled arcing frequency

Info

Publication number: CN106029280A
Application number: CN201580008867.4A
Authority: CN
Inventors: S·R·彼得斯; W·T·马修斯; J·B·亨利; K·约翰斯
Original assignee: Lincoln Global Inc
Current assignee: Lincoln Global Inc
Priority date: 2014-02-24
Filing date: 2015-02-23
Publication date: 2016-10-12
Also published as: JP2018114557A; DE212015000071U1; WO2015124997A1; JP3208810U

Abstract

Systems and methods consistent with embodiments of the present invention are directed to depositing a consumable (140) onto a workpiece (115) using a hot-wire welding technique which employs a combination of hot wire and arc welding. The waveform (500) creates arc events during the hot wire welding operation to add/control heat in the welding process. The hot-wire welding process can be used by itself, with a laser (120) or in con junction with other welding processes.

Description

Use combination filler wire to be sent into and high intensity energy source is in controlled arc discharge frequency Under carry out the method and system that welds

Quote and be incorporated to

This application claims that the provisional application 61/943,633 submitted on February 24th, 2014 and December in 2014 are submitted on the 5th The priority of U.S. Patent application 14/561,904, these applications combine here, and the application in full by quoting with it It is the part continuation application of U.S. Patent Application No. 13/212,025 submitted on August 17th, 2011 and requires its priority, This application combines with it here, this U.S. Patent Application No. 13/212,025 is to submit on January 13rd, 2009 in full by quoting The part continuation application of U.S. Patent Application No. 12/352,667, this application is combined in this by quoting in full with it.

Technical field

Specific embodiment relates to filler wire cladding (overlaying) and applies and weld and joint applications.More specifically Saying, specific embodiment relates to the use of hot filament deposit's technique and laser welding process or the system and method for arc welding process.The most more Saying, the present invention provides a kind of consumptive material depositing system and method according to the preamble of claim 1 and 12 respectively body.

Background of invention

Recently, make progress in heated filament welds.But, some in these techniques and system may not will be wished That hope or required heat input provides in welding or cladding operation.Accordingly, it may be desirable to provide welding by additional heat Or in cladding operation.

By this method compared with the embodiments of the invention illustrated referring to the drawings in the remainder of the application, often Rule, tradition and the further limitation of method proposed and shortcoming will become bright for those skilled in the art Aobvious.

Summary of the invention

Embodiments of the invention include that a kind of use heated filament technology is cladding, deposition (cladding), joint or Welder Skill makes the system and method that material deposits.Embodiments of the invention utilize hot filament deposit's method, wherein welding wire and workpiece it Between produce multiple arcing events to assist this technique.These arcing events can provide in this technique with assist control Heat input, and increase the performance of this technique, and do not endanger the integrity of this technique.

These and other features of the present invention for required protection and the details of embodiment shown thereof and other implement Example will be set forth in the description which follows, understood in claims and accompanying drawing comprehensively.

Brief Description Of Drawings

By the exemplary embodiment of the present invention is described in detail with reference to the accompanying drawings, above-mentioned and/or other aspects of the present invention Will become more apparent, in the accompanying drawings:

Fig. 1 is the graphic representation of an exemplary embodiment of heated filament and laser system；

Fig. 2 is the graphic representation of an exemplary embodiment of heated filament and arc welding system；

Fig. 3 is the further figure of an exemplary embodiment of heater supply and the system utilizing this heater supply wherein Solve and represent；

Fig. 4 is exemplary voltage and the graphic representation of current waveform of the heated filament technique according to the present invention；

Fig. 5 is the graphic representation of the exemplary heated filament current waveform Tong Bu with arc-welding current waveform；

Fig. 6 is the graphic representation of the example waveform when this technique starts of heated filament welding；

Fig. 7 is the graphic representation of another exemplary embodiment of the welding system of the present invention；

Fig. 8 A and the graphic representation that Fig. 8 B is the exemplary current waveforms that can use together with embodiments of the present invention；

Fig. 9 is the graphic representation of another exemplary weld waveform that can be utilized by embodiments of the invention；And

Figure 10 A and Figure 10 B is the exemplary weld seam cross section that can realize by the exemplary embodiment of the present invention.

Describe in detail

The exemplary embodiment of the present invention it is described below referring now to accompanying drawing.Described exemplary embodiment purport Understand the present invention in help, and be not intended as limiting by any way the scope of the present invention.Throughout, identical reference number Refer to identical element.

Fig. 1 show for perform soldering, deposition, built-up welding (building up), filling, Surface hardened layer cladding and joint/ The combination filler wire feeder of any one and the functional of exemplary embodiment of energy source system 100 in welding application are shown Meaning block diagram.System 100 includes making laser beam 110 focus on the lasertron heated on workpiece 115 thus to workpiece 115 System.This laser subsystem is high intensity energy source.This laser subsystem can be any kind of high energy laser sources, including but It is not limited to carbon dioxide, Nd:YAG, Yb-dish, YB-optical fiber, optical fiber conveying or direct diode laser system.If additionally, its The laser system of his type has sufficient energy, and they can be used.Other embodiments of this system can include being used as The electron beam of high intensity energy source, plasma arc-welding subsystem, Gas protection arc-welding subsystem, gas shielded metal-arc At least one in weldering subsystem, solder flux flux cored arc welding subsystem and submerged-arc welding subsystem.Following description is mentioned repeating Laser system, beam and power supply, however, it should be understood that this quoting is exemplary, because any high intensity can be used Energy source.Such as, high intensity energy source can provide at least 500W/cm².This laser subsystem includes being operatively connected each other A laser aid 120 and Laser Power Devices 130.Laser Power Devices 130 provide the power for operating laser aid 120.

System 100 also includes providing the workpiece near at least resistance filler wire 140 and laser beam 110 115 one contacted hot filler wire feeder subsystem.Of course it should be understood that by quoting workpiece in this article 115, fusion pool is considered as a part for workpiece 115, therefore to workpiece 115 contact quote and include and the connecing of molten bath Touch.This hot filler wire feeder subsystem includes 150, contact tube 160 of a filler wire feeder and a heat Silk power supply 170.In operation, the filler wire 140 of guided laser bundle 110 is by from being operatively connected to contact tube The current resistor heating of the heated filament source of welding current 170 between 160 and workpiece 115.According to one embodiment of present invention, hot wire welding Connecing power supply 170 is pulse direct current (DC) power supply, but exchange (AC) or other kinds of power supply are also possible.Welding wire 140 from Outside filler wire feeder 150 is sent into and is extended to this pipe 160 by contact tube 160 towards workpiece 115.Welding wire 140 Extension be resistively heated, so make extension close to or up molten before the welding pool touching on workpiece Point.Laser beam 110 some fusings in the base metal making workpiece 115 are to form welding pool and also to make welding wire 140 It is melted on workpiece 115.Power supply 170 provides the most of energy needed for resistance melting filler wire 140.According to certain of the present invention Other embodiments a little, feeder subsystem can may provide one or more welding wire simultaneously.Such as, the first welding wire may be used for Surface hardened layer and/or for workpiece provide corrosion resistance, and the second welding wire may be used for workpiece add structure.

System 100 farther includes to make laser beam 110 (energy source) and resistance filler wire 140 along workpiece 115 125 motion control subsystem moving (at least on relative meaning), so makes laser beam 110 and electricity in the same direction Resistance filler wire 140 keeps being relatively fixed each other.According to different embodiments, the phase between workpiece 115 with laser/welding wire combination Motion can be realized by actual travelling workpiece 115 or by moving laser device 120 and heated filament feeder subsystem.? In Fig. 1, this motion control subsystem includes the motion controller 180 being operatively connectable in a robot 190.Fortune Movement controller 180 controls the motion of robot 190.Robot 190 is operatively connected (such as, mechanically fixing) to work So that workpiece 115 moves on direction 125 on part 115, so make laser beam 110 and welding wire 140 effective along workpiece 115 Advance in ground.Can be integrated in single head according to the alternate embodiment of the present invention, laser aid 110 and contact tube 160.Should Head can move along workpiece 115 via the motion control subsystem being operatively connectable on this.

Typically, there are the several method that high intensity energy source/heated filament can be made to move relative to workpiece.If workpiece is Circle, such as, high intensity energy source/heated filament can be static, and workpiece can be at this high intensity energy source/heated filament backspin Turn.Alternately, robots arm or linear pulling machine can be parallel to round piece and move, when workpiece rotates, and high intensity energy Amount source/heated filament can continuously move or each circulation indexing is once so that the surface of (such as) cladding round piece.If Workpiece is flat or is not the most round, then workpiece can move as shown in Figure 1 under high intensity energy source/heated filament. But, robots arm or linear pulling machine or the balladeur train of beam is even installed may be used to high intensity energy source/heated filament head phase Workpiece is moved.

System 100 farther includes a sensing and current control subsystem 195, this sensing and current control subsystem behaviour Operatively it is connected on workpiece 115 and contact tube 160 (that is, be effectively connected on the outfan of heater supply 170) and energy Enough measure the electric potential difference (that is, voltage V) between workpiece 115 and heated filament 140 and by their electric current (I).Sensing and electric current control Subsystem 195 may be further able to calculate resistance value (R=V/I) and/or performance number (P from measured voltage and current =V*I).Generally, when heated filament 140 contacts with workpiece 115, the electric potential difference between heated filament 140 and workpiece 115 be zero volt or Closely zero volt.But, in other exemplary embodiments, the voltage drop between welding wire 140 and workpiece 115 is at 2 to 8 volts In the range of spy.As a result of which it is, as the most in greater detail, sensing and current control subsystem 195 can be at resistance Filler wire 140 senses when contacting with workpiece 115 and be operatively connectable on heater supply 170, thus is further able to Enough control in response to this sensing is flowed by the electric current of resistance filler wire 140.According to another embodiment of the invention, sense Survey with current control subsystem 195 part of the one that can be heater supply 170.

According to embodiments of the invention, motion controller 180 can be further operatively connected to Laser Power Devices 130 And/or sense and on current controller 195.In this way, motion controller 180 and Laser Power Devices 130 can communicate with one another, this Sample makes Laser Power Devices 130 know when workpiece 115 moves, and so makes motion controller 180 know that laser fills Put whether 120 be movable.Similarly, in this way, motion controller 180 and sensing and current controller 195 can be with those This communication, so makes sensing and current controller 195 know when workpiece 115 moves, and so makes motion control Device 180 processed knows whether hot filler wire feeder subsystem is movable.This type of communication may be used for coordination system 100 not With the activity between subsystem.

As described above, this high intensity energy source can be any number of energy source, including the source of welding current.This is high One exemplary embodiment in intensity energy source it is shown in fig. 2, the figure shows be similar to the system 100 shown in Fig. 1 be System 200.Many parts of this system 200 are similar to the parts in system 100, and therefore will not be discussed in greater detail these parts Operation and utilization.But, in system 200, this laser system is substituted by an arc welding system (such as GMAW system).Should GMAW system includes 213, wire feeder 215 of a power supply and a welding torch 212.Welding electrode 211 send via welding wire Enter device 215 and welding torch 212 is delivered to fusion pool.The operation of the GMAW welding system of the type described here is well-known , and need not be described in detail here.It should be noted that while GMAW system illustrates about the exemplary embodiment described And discussion, the exemplary embodiment of the present invention can also be used together with the following: GTAW, FCAW, MCAW and SAW system, Deposition system, soldering system and the combination etc. of these systems, transfer to consumptive material on workpiece including using electric arc to assist Those systems of fusion pool.Not shown in FIG. 2 is the protective gas system or son that can use according to known method Electric arc solder flux system.

Similar laser system described above, these electric arc generates system (it can serve as high intensity energy source) and is used for Produce fusion pool, use system as described in detail above and embodiment to add heated filament 140 to this fusion pool.But, utilize This electric arc generates system, as it is known, a kind of additional consumptive material 211 is also added into this molten bath.This additional consumptive material add to by The deposition properties increased that this heated filament technique described is provided.This performance is by discussion in further detail below.

Additionally, use high current level to come at the consumptive material advanced as it is generally known, electric arc generates system (such as GMAW) And generate electric arc between the fusion pool on workpiece.Similarly, GTAW system uses high current level to come between electrode and consumptive material Generating electric arc, consumptive material is added in this electric arc.As it is generally known, many different current waveforms can be used for GTAW or GMAW welding operation, such as constant current, pulse current etc..But, in the operating process of system 200, power supply 213 is generated Electric current may interfere with the electric current for heating welding wire 140 that power supply 170 is generated.Because welding wire 140 is given birth to adjacent to power supply 213 The electric arc (because each of which is directed to same fusion pool, be similar to molten bath discussed above) become, corresponding electric current can Can be interfering with each other.Specifically, each electric current generates a magnetic field, and those possibilities are interfering with each other and deleteriously affect it Operation.Such as, these magnetic fields that this heater current is generated may interfere with the stability of the electric arc that power supply 213 is generated. It is to say, in the case of suitably not controlling and synchronize between corresponding current, the magnetic field of these competitions may make this electric arc Unstable and therefore make this technique unstable.Therefore, exemplary embodiment utilizes the current synchronization between power supply 213 and 170 To guarantee stable operation, this will be further discussed following.

As it has been described above, may be interfering with each other by the magnetic field caused by corresponding current, and therefore embodiments of the invention make These corresponding current synchronize.Synchronization can realize via distinct methods.Such as, sensing and current controller 195 may be used for Control the operation of power supply 213 and 170 to make these current synchronization.Alternately, one in these power supplys is used for controlling In the case of another output, a kind of master slave relation can also be utilized.The control of these Opposed Current can be by multiple Method realizes, and these methods include state table or the use of algorithm controlling power supply, so makes the output electricity of these power supplys Flow and synchronized for stable operation.This will be discussed further below.Such as, one is similar to U.S. Patent Publication No. 2010/ System described by 0096373 and the system based on bifurcation of device and device can be utilized.Disclosed in 22 days April in 2010 U.S. Patent Publication No. 2010/0096373 is combined in this by quoting in full with it.

The structure of system 100 and 200, use, control, operate and being discussed more fully of function this application claims that it is preferential Listing in the U.S. Patent application (in the beginning of the application) of power, each in these U.S. Patent applications relates to due to them The system being described herein and discussing and the alternate embodiment discussed in it and be entirely incorporated in full with it by quoting This, these U.S. Patent applications do not repeat at this for the sake of clear for efficiency.

Fig. 3 depicts the graphic representation of another exemplary embodiment of the system 300 of the present invention.Similar system 200, be System 300 utilizes a heated filament combined and arc welding process.The function of system 300 and operation are similar to function and the behaviour of system 200 Make, and therefore functional by do not repeat to be similar to.As it can be seen, system 300 includes the guiding guiding traction heated filament 140 Arc Welding Power 301.Power supply 301 is shown as GMAW type power supply, but embodiment is not limited to this, as GTAW type power supply can also be sharp With.The source of welding current 301 can have any of structure.Additionally describe is that (it can be with Fig. 1 for a kind of heater supply 310 Identical with power supply illustrated in fig. 2) together with some of which parts.As explained above, it may be desirable to make from power supply 301 Synchronize with the current waveform output of each in 310.So, synchronizing signal 303 can be utilized to guarantee these power supplys Operation is to synchronize, and this will be further discussed below.

Heater supply 310 includes an inverter power part 311, and this inverter power part receives input power (its Can be AC or DC) and this input power is converted into the output for heating welding wire 140, so make this welding wire can To deposit in the molten bath on workpiece W.Inverter power part 311 can be configured for welding, cutting any The inverter type power supply known or heater supply.This power supply also comprises default heating voltage circuit 313, this default heating voltage electricity What road utilization was relevant to this technique enters data to arrange a default heating voltage for the output signal of power supply 310, so makes Obtain welding wire 140 and maintain a desired temperature, so make this welding wire suitably deposit on workpiece W.Such as, preset add Thermal voltage circuit 313 can utilize setting (such as wire size, wire types and feed rate of welding wire) to be provided with and stay in this This default heating voltage maintained in technical process.In operation, this output heating signal is maintained, and so makes this defeated Going out the average voltage of signal, to be maintained at this in the circulation of a predetermined persistent period section or predetermined number pre- If at heating voltage level.In certain embodiments, this default heating voltage level is in 2 to 9 volt range.Additionally, at this In the exemplary embodiment of invention, the feed rate of welding wire of welding wire 140 can affect this and most preferably preset heating voltage level, so makes During this feed rate of welding wire proper relatively low (at or below 200in/min), this default heating voltage level is at 2 to 4 volts of models In enclosing, but when this feed rate of welding wire higher (higher than 200in/min), this default heating voltage level is at 5 to 9 volts of models In enclosing.Additionally, in some exemplary embodiments, as electric current relatively low (at or below 150amp), this default heating voltage Level is in 2 to 4 volt range, but when this electric current higher (higher than 150amp), this default heating voltage level is 5 to 9 In volt range.Therefore, in operation, that the average voltage between welding wire 140 and workpiece W is maintained this is pre-for power supply 310 If for given operation at heating voltage level.In other exemplary embodiments, this default heating voltage circuit 313 is permissible One average voltage scope is set, in wherein this average voltage is maintained at this preset range.By the average electricity that will be detected Pressure maintains at this default heating voltage level maybe in the range of this default heating voltage, and power supply 310 provides heating as desired The heating signal of silk 140, but avoid producing electric arc.In an exemplary embodiment of the present invention, a predetermined time Measure average voltage in section, so make to determine rolling average in this technical process.This power utilization time average wave filter Circuit 315, this time average filter circuit senses output voltage by sense lead 317 and 319, and carries out above institute The voltage described is averaged calculating.As it is shown on figure 3, average voltage determined by inciting somebody to action subsequently compares with default heating voltage Relatively.

Certainly, in other exemplary embodiments, power supply 310 can use electric current predetermined threshold value and/or power to preset threshold Value controls the output signal of this power supply.The operation of this type of system will be similar to that control based on voltage described above.

Power supply 310 also comprises an arc-detection threshold circuit 321, and this arc-detection threshold circuit is compared and drawn by sensing The output voltage detected of line 319 and 317, and the output voltage this detected compares with arc-detection voltage level Relatively, in order to determine that arcing events or will occur between welding wire 140 and workpiece W.If this voltage detected Exceeding this arc-detection voltage level, circuit 321 exports a signal to inverter power part 311 (or control device), This signal causes power section 311 to close output to distinguish or suppress this electric arc or otherwise preventing it from producing. In some exemplary embodiments, this arc-detection voltage level is in 10 to 20 volt range.In other exemplary embodiments In, this arc-detection voltage level is in 12 to 19 volt range.In other exemplary embodiments, preset based on this and add thermoelectricity Voltage level and/or this feed rate of welding wire determine this arc-detection voltage level.Such as, in some exemplary embodiments, This arc-detection voltage level is in the range of 2 to 5 times of this default heating voltage level.In other exemplary embodiments, use Anode voltage level and cathode voltage level in any protective gas used may affect this default heating voltage level. In some exemplary application, this arc-detection voltage will be in 7 to 10 volt range, and it will be 14 in other embodiments To 19 volt range.In an exemplary embodiment of the present invention, this arc-detection voltage will be higher than in 5 to 8 volt range This default heating voltage level.

Power supply 310 also includes nominal shock pulse waveform circuit 323, and this nominal shock pulse waveform circuit generates will be by inverter power Part 311 uses, in order to desired heating waveform exports welding wire 140 and the waveform of workpiece W.As it can be seen, nominal arteries and veins Rush waveform circuit 323 and be connected to Arc Welding Power 301 via synchronizing signal 303, so make the output from each corresponding power Waveform is to synchronize as described herein.

As it can be seen, nominal shock pulse waveform circuit 323 makes its output signal synchronize with Arc Welding Power 301, and will be given birth to The heating waveform become exports multiplier, and this multiplier the most also receives error signal from comparator 327.This error signal Allow to be adjusted to the output command signal of inverter power part 311, in order to average desired by maintaining as described above Voltage.

It should be noted that these circuit described above and basic functionality are similar to utilization in welding and cutting power supply Circuit and basic functionality, and therefore the detailed configuration of these circuit need not be described in detail here.Additionally, it should also be noted that Some or all of function above can complete via the single controller in power supply 310.

Such as discussion final in the U.S. Patent application this application claims its priority, these patent applications are by quoting It is entirely incorporated in this and includes here, when using the heated filament side of jointing and cladding method, due to welding wire 140 as these disclose entirety Usual and molten bath maintains constant contact, it is desirable to prevent from producing electric arc between welding wire 140 and molten bath.But, send out In now some heated filaments application, it may be desirable to make discrete arcing events occur in heated filament technical process, in order to as wish That hopes adds heat to this technique and molten bath.This is in the joint coating at least one workpiece or cladding application (such as galvanized steel) It is especially true.This is being explained further below with reference to Fig. 4.

Fig. 4 depicts the exemplary voltage waveform for heated filament technique as described in this and current waveform.As it can be seen, Current waveform 500 includes multiple heating pulse 501 with a peak current level 503.This peak current level can be In the range of 200 to 700 amperes, and peak current level 503 is selected in order in this technical process the weldering desired by offer The heating of silk 140 and fusing.Similarly, voltage waveform 400 illustrates multiple potential pulses 401 with a crest voltage 403. But, it is also shown that be arc event, between welding wire 140 and this molten bath, wherein generate electric arc momently.In this arc event During, welding wire 140 loss contacts with molten bath, thus causes due to voltage spikes to reach electric arc level 405.At that time, heater supply Detect that arc event has occurred and that, and close electric current to extinguish or suppressing electric arc 507.Exemplary enforcement in the present invention In example, there is the time continued in 350 to 1000 microsecond range in this electric arc.In other exemplary embodiments, this electric arc exists Continue the time in 500 to 800 microsecond range.In the case of this type of relatively short persistent period of this electric arc, can be to molten Heat is added without causing the excessive turbulent flow caused by this electric arc in molten bath in pond.This power supply can use different controlling parties Method detects arcing events.In an exemplary embodiment of the present invention, this power supply arranges a threshold value, so makes when super When crossing this threshold value, this power supply determines that arc event has occurred and that.As previously explained, in some exemplary embodiments, this electricity Arc detection voltage level is in 10 to 20 volt range.In other exemplary embodiments, this arc-detection voltage level is 12 To 19 volt range.In other exemplary embodiments, based on this default heating voltage level and/or this feed rate of welding wire Determine this arc-detection voltage level.

After producing electric arc, no longer there is gap with between molten bath contact, and welding wire 140 and molten bath in welding wire 140.? After this power-off adds thermocurrent (507), this power supply provides the open-circuit voltage with peak level 409 with backward welding wire 140 (OCV) 407, so make this power supply can again detect contacting between welding wire 140 and molten bath, because welding wire 140 still exists It is sent into by wire feeder at molten bath.In an exemplary embodiment of the present invention, this OCV is in 10 to 25 volt range.At it In his exemplary embodiment, this OCV is in 17 to 22 volt range.It is potentially based on multiple ginseng for the OCV selected by this operation Number, includes but not limited to wire types and gage of wire.When welding wire 140 contacts with molten bath (at 410), this power supply (using any of contact sensing control method) is detected this contact and closes OCV and start to provide to welding wire 140 to add Thermocurrent.As shown in Figure 4, at the peak level 509 that this electric current may contact later, reach peak value, and maintain subsequently and draw Enter at electric current 511 level.

Introducing electric current 509 is a relatively low current level (compared with peak value of pulse level), and is used for allowing Welding wire 140 accesses molten bath again and continues a predetermined distance, and allows impulsive synchronization (discussed further below).Should Introduce electric current and be maintained lasting duration T LI (this also will be explained further below).This introducing electric current is set by power supply Putting, and be current levels based on multiple selecting factors, these factors include any one in the following or own: welding wire Feed rate, wire types, gage of wire, heated filament pulse frequency and heated filament peak value of pulse 503 current level, and this draws Entering electric current can be about the 1/10 of this peak current level.Generally, introducing electric current 511 is low compared with peak value 503 level. In the exemplary embodiment, this pulse peak current and introducing current ratio are in the range of 10:1 to 5:1.In exemplary embodiment In, this introducing electric current is in the range of 25 to 100 amperes, and in other embodiments, this introducing electric current is at 40 to 80 amperes of models In enclosing.In other exemplary embodiments, this introducing can be arranged by using power level, as set with using current level Put contrary.In this type of embodiment, this introducing power level can be in the range of 100 to 1500 watts.Additional exemplary In embodiment, introducing electric current 509 and have a current level, this current level is less than the average current electricity of the heated filament part of waveform Flat, such as, as shown in Figure 4, less than the average current of the heating pulse 501 ' between arc event.In exemplary In, the peak point current and the average current that introduce electric current 509 are less than the average current of waveform 500 and the heat between arc event The average current of silk current impulse 501 '.

As explained above, this introducing electric current is maintained and continues duration T LI, thus allows welding wire 140 weight Newly penetrate the desired degree of depth in molten bath to.So, the feed rate of welding wire at least based on welding wire 140 determines TLI.Showing In example embodiment, introducing duration T LI is in the range of 5 to 20 milliseconds, and dwell time 507 is 1 to 7 millisecond of scope In.In the exemplary embodiment, the assembly time of dwell time 507 and TLI is in the range of 6 to 20 milliseconds.But, such as previous phase Fig. 2 and Fig. 3 is explained, in some exemplary embodiments, this heated filament technique and the arc-welding of operation in same molten bath Technique (such as GMAW) couples.In this type of embodiment, this introducing duration T LI is that welding wire based on welding wire 140 is sent into speed Degree and the persistent period of startup based on the current impulse from the arc welding process worked together with this heated filament technique.When making During by the heated filament technique coupled with arc welding process, it is desirable to make the current impulse from each corresponding technique synchronize.Therefore, In this type of embodiment, this heater supply after duration T LI, only (1) one predetermined introducing period of delay Full allow welding wire 140 suitably to penetrate this molten bath the most afterwards, and (2) allow and the opening of the next arc-welding pulse in this arc-welding waveform The first pulse 501 ' is just started when moving consistent.These conditions are met, it is ensured that welding wire 140 is by making duration T LI extend Through suitably penetrating this molten bath to start again at heated filament pulse 501, and this heater current waveform is and the arc-welding simultaneously used Technique suitably synchronizes.This is graphically represented in Figure 5, and wherein this welding procedure utilizes and the pulse using current waveform 600 The heater current waveform 500 that arc welding process (such as GMAW) synchronizes.As the reference of the application beginning and tie completely at this The priority application closed, and entitled use combination filler wire is sent into and high intensity energy source for the method welded and is System (METHOD AND SYSTEM TO USE COMBINATION FILLER WIRE FEED AND HIGH INTENSITY ENERGY SOURCE FOR WELDING) U.S. Patent application (this application is entirely incorporated in full with it also by quoting This, and meanwhile submit to) described in, it is desirable to the impulsive synchronization of these corresponding waveforms in some applications. Therefore, in an exemplary embodiment of the present invention, as it is shown in figure 5, this introducing duration T LI be penetrate duration T p and with The combination of step duration T s.Penetrate duration T p to be come at least based on the feed rate of welding wire of welding wire 140 by this heater supply Determine, in order to guarantee that welding wire 140 is suitably penetrated in molten bath, and to synchronize duration T s be in the phase penetrating duration T p Time between the startup of full and next arc-welding pulse 601 '.It is to say, typically, this introducing duration T LI (or is drawn Enter the period) the maximum persistent period will be the background parts 603 penetrating duration T p (or penetrating the period) and arc-welding waveform Persistent period.This guarantees that welding wire 140 is penetrating completely through in molten bath, and these two corresponding waveforms synchronize being.Therefore, at this In the operating process of the exemplary embodiment of invention, this heater supply penetrates duration T p by determining, and is introduced into electric current 511 are maintained at this introducing current level persistently this duration T p, and after this penetrates the expiring of period Tp, this heated filament electricity Source waits the pulse enabling signal from controller or this Arc Welding Power.Based on this startup or synchronizing signal, this heater supply exists The first pulse 501 ' is started so that consistent with the next pulse 601 ' in arc welding process after introducing electric current 511.

It should be noted that, Fig. 5 shows two corresponding waveforms 500/600 without phase shift, so make respective pulses 501 ' and 601 ' will start simultaneously.But, other exemplary embodiments can utilize the phase shift between current waveform 500 and 600, The pulse so making corresponding waveform is to synchronize, but phase shift each other.In this type of embodiment, this introducing duration T LI will There is this length, in order to guarantee that pulse 501 ' and 601 ' is worn at right times relative to each other, with appropriate phase shift and at this The saturating persistent period expires and starts afterwards.In some exemplary embodiments, this welding wire is allowed to penetrate this molten bath with a distance, This distance is almost identical with this gage of wire.

As discussed previously, arc event is for inputting additional heat in the process.For completing this purpose, this heat Silk power supply 170 is controlled, and so makes these arcing events occur with the frequency in the range of 1 to 20Hz.In other examples Property embodiment in, these arcing events with in the range of 1 to 10Hz frequency occur.Should by maintaining with an aturegularaintervals Arc discharge frequency, additional heat can add this technique to, without making this heated filament or arc-welding according to a kind of controlled way Unstable.In some exemplary embodiments, the frequency of these arcing events may be adjusted so that change is in this technique During heat input.It is to say, during the Part I of a technique, it may be desirable to use the electric arc of 3Hz to put Electricity frequency, and in another part of this technique, it may be desirable to there is the arc discharge frequency of 10Hz.This power supply 170 is permissible Control waveform 400/500 to realize the desired arcing events frequency of different piece for a technique, and because of This provides the bigger control that the total amount of heat to this technique inputs.

Multiple (n) current impulse that Fig. 4 is also shown between arcing events and potential pulse.As it can be seen, it is electric Stream pulse 501/501 ' has the peak current level 503 of a relative constancy.It is to say, the peak point current electricity of these pulses Flat is almost identical, but is likely to be due to the reality of welding operation and different, and has been not likely to be for each pulse Exactly the same.But, as it can be seen, these relevant voltage pulses have from the first potential pulse 401 ' (at arcing events Afterwards) to the most complete potential pulse 401 " crest voltage substantially increased by 403 of (after arcing events). Have been found that in some exemplary embodiments, it is desirable to allow pulse 401 ' to 401 " peak voltage level at electricity It is gradually increased between arc discharge event.Typically, this voltage increases at least partially due in welding wire 140 and in process Heat increase and occur, thus affect the all-in resistance of welding wire 140, and therefore cause this voltage between arcing events Multiple potential pulses on be generally raised to second from the first peak voltage level, higher, peak voltage level.Should note Meaning, although Fig. 4 depicts pulse 401 ' to 401 " the peak voltage level increased from pulse to pulse (it is applicable to Embodiment), some exemplary embodiments are not limited to this.It is to say, in some exemplary embodiments, although in these pulses Upper existence voltage substantially increases (as tilted shown in 413), and the crest voltage of the most each following pulse will be than its preceding pulse Higher.In certain embodiments, following pulse can have peak that is identical or that be even slightly less than its adjacent preceding pulse Threshold voltage.But, final pulse 401 " will have the crest voltage higher than the first pulse 401 '.Although additionally, shown reality Executing the generally linear increase (tilting 413) exemplifying crest voltage, other embodiments are not limited to linear voltage to be increased.Exemplary In embodiment, from the first potential pulse 401 ' to last potential pulse 401 " this peak electricity pressure reduction in 2 to 8 volt range. In other exemplary embodiments, this difference is in 3 to 6 volt range.Additionally, in an exemplary embodiment of the present invention, electric arc Potential pulse 401 '-401 between electric discharge event " number in the range of 8 to 22.In other exemplary embodiments, electricity The number of the potential pulse between arc discharge event is in the range of 12 to 18.

Turning now to Fig. 6, depict another current waveform 600.But, this waveform 600 depicts heated filament welding procedure Beginning.As previously described, in hot wire welding termination process, consumptive material deposits in molten bath in the case of Arc-free, with Time to this consumptive material provide add thermocurrent, this adds thermocurrent and causes this consumptive material to melt in this molten bath.But, for this technique Speech, can need a fusion pool in this heated filament technique before starting.In some cases, this molten bath can by laser, come Produce from the electric arc of another technique or certain other thermal source.But, in an exemplary embodiment of the present invention, in this technique Heated filament consumptive material is used to produce this molten bath to set up this technique with short pulse welding routine during beginning.Formed this molten bath it After, this heated filament technique can be carried out subsequently.Such as, this heated filament can as described here relative to Fig. 4, described above enter OK.

As shown in Figure 6, waveform 600 has a beginning routine portion SR and heated filament part HWR.Can be similar to any Known arc-welding operation starts and starts routine portion SR.Such as, the known GMAW type that routine portion SR can start to be similar to is started Welding procedure, in order to start the electric arc between this consumptive material and this workpiece.After producing electric arc, there is multiple current impulse 601 A brief spikes welding procedure start, wherein these pulses have the background between peak current level 605 and pulse 601 Level 603.It is similarly to known GMAW type pulse welding technique.This pulse welding technique is molten for producing on the workpiece Pond, and it is maintained a lasting persistent period arranged to guarantee that this molten bath is produced fully.Once produce this molten bath, Waveform 600 starts technique SR from arc-welding and changes to heated filament part HWR.At the end of starting routine portion SR, electric current reduces or closes Close (610) so that the electric arc extinguished between this consumptive material and this molten bath.As previously in relation to described by Figure 4 and 5, this consumptive material is subsequently It is pushed into, so makes it carry out with this molten bath contacting and heated filament routine HWR is activated subsequently.As it can be seen, at waveform 600 In, this heated filament routine has multiple heating pulse 611, has peak level 611 and ambient level 613, and this ambient level is one A little embodiments it can be 0 ampere.Should be understood that the transformation that starts between routine portion SR and heated filament part HWR can as more than Explain relative to Fig. 4.

As explained above, this starts routine portion is relatively short.In an exemplary embodiment of the present invention, this starts The persistent period of course in the length range of 0.01 to 5 second, wherein this persistent period be initially that this electric arc is activated time Between, and the end of this persistent period is the time (such as, at 610) that this electric arc is off.In other exemplary embodiments In, this started routine in the range of 0.01 to 1 second.In other exemplary embodiments, this persistent period starting routine exists In the range of 0.1 to 0.5 second.In other exemplary embodiments, this power supply is by only from the background parts 603 turns starting routine SR Change to heated filament routine HWR.Such as, if this predetermined duration period terminates in the centre of electric arc pulse 601, this electricity Electric arc at this point is not only extinguished in source, and waits until that pulse 601 completes and this welding current arrived before changing Reach background parts 603.It should be noted that in some exemplary embodiments, this consumptive material welding wire during starting routine is sent into speed Degree can be slower than the feed rate of welding wire in the heated filament partial routine of this welding procedure.Additionally, this start routine can be This uses known arc welding process during starting routine, the shortest electric arc, STT, welding wire are retracted or other input arcs low in calories Welding.In this type of embodiment, input avoiding too much heat in starting process.

In other exemplary embodiments, continuing instead of using the time, this power supply uses the electric arc arteries and veins of predetermined number Punching 601 is used for starting routine SR, and extinguishes this electric arc after reaching the pulse of predetermined number.Such as, exemplary In embodiment, it is n pulse for this pulse number starting routine, so makes when reaching n pulse, this power source transition To heated filament routine HWR.In the exemplary embodiment, this pulse number n can be in the range of 1 to 1000 pulse.At other In exemplary embodiment, this pulse number n is in the range of 5 to 250 pulses, and in other embodiments, and this umber of pulse Mesh can be in the range of 5 to 100 pulses.In additional exemplary embodiment, this power supply can use the persistent period and The combination of pulse number determines the length starting routine SR.It is to say, in this type of embodiment, this power supply uses setting Persistent period and pulse number n, the transformation wherein arriving heated filament routine HWR does not occur until having reached persistent period and arteries and veins Which each in strokes per minute mesh, first reaches.

In the exemplary embodiment, this power-supply controller of electric predefines beginning routine portion SR based on user's input information In persistent period and/or pulse number, this user's input information may include that feed rate of welding wire, consumptive material size, consumptive material class Type, welding metal types etc..In other exemplary embodiments, other factors are determined for this when starting routine lasting Between and/or pulse number, these factors include whether this heated filament technique couples with laser, GMAW technique or SAW technique.At other In embodiment, the type of welding/joint applications may affect this parameter starting routine or desired pool size.Such as, This pool size is (the biggest for high speed thin plate technique (the least molten bath), weight manufacturing process (big molten bath) or deposition techniques Molten bath) can be different.In this type of embodiment, based on this user's input information, this power-supply controller of electric use look-up table, State table etc., in order to persistent period and/or pulse number are set for beginning routine SR to be used.Will select the persistent period and/ Or pulse number is to guarantee starting pool size, the degree of depth and/or the temperature reaching desired before this heated filament routine.At other In exemplary embodiment, system may be used for monitoring this molten bath and/or the heat of workpiece and/or monitoring the size/shape in this molten bath Shape.

As explained at this, from this start routine SR can be as relative to Fig. 4 and Fig. 5 to the transformation of this heated filament routine HWR Described execution.But, in other exemplary embodiments, this transformation may this start generated in routine process short Occur during line state.Such as, if this starts routine is just using the technique making consumptive material and molten bath/workpiece short circuit, should The controller of power supply can cause being converted to heated filament during short-circuit condition.Such as, just using such as when this starts routine SR When STT, short circuit welding or the beginning routine of short arc welding, this can realize.In this type of embodiment, this monitoring control devices should Start the persistent period of routine SR, and when desired persistent period and/or pulse number are complete, this power supply under It is converted to heated filament at one short circuit event.

In other exemplary embodiments, this starts routine and pulse welding can be used to operate, as shown in Figure 6.But, After predetermined persistent period/pulse number, the electric current of pulse 601 reduces to shorten arc length until short circuit event is sent out Raw.When short circuit occurs, the transformation to heated filament technique occurs.By using short circuit event, it is not necessary to artificially press down for transformation Electric arc processed.

In additional embodiment, during this persistent period starting routine SR can start routine SR by monitoring this Heat input determine.Such as, in this type of embodiment, this controller/power supply will use user described above to input number According to determine this start routine SR needed for desired by/predetermined heat input quantity.It is to say, the control of this power supply Device can arrange a predetermined heat input quantity, and when reaching this heat input threshold value, this power supply can be from this Electric arc routine is converted to this heated filament routine, as described in this.In the exemplary embodiment, this heat input threshold value can be In the range of 0.01 to 10Kj.In other exemplary embodiments, this heat input threshold value can be in the scope of 0.01 to 1Kj In.

Fig. 7 depicts to be had such as the additional embodiment of the system 700 relative to the heater supply 310 described in Fig. 3.Real at this Executing in example, power supply 310 is coupled on controller 710 (inside that this controller may be located at this power supply), and this controller is joined Receive on the sensor device 701 monitoring this technique.Sensor device 701 can be molten bath/workpiece parameter that monitoring is desired Any kind of sensor device.Such as, this sensor device can be a heat sensor, and this heat sensor is monitored this and melted Pond and/or the temperature of workpiece, and used to control this heated filament technique from the feedback of this sensor device by power supply 310 Start and/or this heated filament technique self.Such as, as explained relative to Fig. 4, arc discharge frequency can join with this heated filament technique Connect so that the heat controlled in this workpiece/molten bath.In this type of embodiment, the feedback from sensor 710 is made by this power supply With, in order to determine the suitable arc discharge frequency for heater current output from power supply 310.In other embodiments, Sensor 701 can be an optical pickocff, and generation and the size in the molten bath on this workpiece monitored by this optical pickocff, and Controller 710 uses the feedback of sensor since then to control output and/or the arc discharge frequency of this heated filament waveform.Other Sensor can also be used, or sensor combinations may be used for auxiliary control source 310.

Fig. 8 A and Fig. 8 B depicts the example waveform added can being used together with the exemplary embodiment of the present invention. As described above, current waveform 800 and 800 ' is similar to the waveform that Fig. 4 is discussed.Definitely, waveform 800 and 800 ' is Combination heated filament waveform and arc discharge waveform.But, in waveform 800 and 800 ', exist more than one between these heated filament parts Individual arc-welding pulse.The heat that this type of embodiment may be used for controlling the most further in workpiece inputs and/or excellent Change welding parameter.Additionally, this type of embodiment above can use at coating workpieces (such as galvanized workpiece), and desired by realization Performance and there is no the porous typically arrived together with arc-welding coating material.

Fig. 8 A depicts the current waveform 800 with arc-welding part 801 and heated filament part.Arc-welding part 801 can be to appoint What known pulse welding technique, such as GMAW type pulse welding technique.Arc-welding part 801 includes by background current separate many Individual pulse 802.Because GMAW type pulse welding waveform is known, they need not be discussed at length here.A time period, Or after having produced desired number of pulse 801, this arc-welding part point 804 at terminate, at this point electric current reduce or Close, so make electric arc be off and waveform 800 is converted to the heated filament stage 820.It should be noted that this arc-welding stage and this heat Transformation part between the silk stage can use introducing electric current etc. to describe relative to the waveform in Fig. 4.In shown enforcement In example, after arc-welding electric current terminates (804), when consumptive material advances towards molten bath, this electric current was set during the time 805 Become low-down or close (this is because this welding wire as previously explained due to arc-welding operation and molten bath contact).Stopping During time 805, OCV can be applied to this consumptive material so that detection and the contacting of this molten bath.As previously explained, detection is worked as During to contact, add thermocurrent and be applied in (at point 807) to introducing level 809 (it can be introduced into current level) and being tieed up Continue an introducing time (as previously described).After this introducing, this electric current increases to and adds thermal current level 810, should Add thermal current level to be maintained and heat this consumptive material, in order to guarantee that this consumptive material melts without producing electric arc in molten bath.As The the same of (such as, Fig. 4 with Fig. 5 embodiment) had previously been discussed, and this power supply uses arc extinguishing controlling party during heated filament part 820 Case, in order to guarantee not produce electric arc between this consumptive material and this workpiece, but this consumptive material suitably deposits in molten bath.

Being different from the heated filament pulse shown in Fig. 4, in fig. 8 a, it is constant that this heater current is shown at level 810 Electric current.In this type of embodiment, add thermal current level 810 and be maintained at a desired fusing level.But, at other In exemplary embodiment, the heated filament part 820 of the waveform in Fig. 8 A (and Fig. 8 B and Fig. 9) can use pulse heated filament waveform (class It is similar to the pulse heated filament waveform shown in Fig. 4) substitute.It is to say, in this type of embodiment, arc-welding part 810 can be used for The constant current of heated filament part 820 or pulse heated filament waveform couple.After a time period, heated filament part 820 stop and Transform back into arc-welding part 810 to perform this arc-welding operation.As shown in Figure 8 A, this heater current drops to an electricity reduced Flat, the level of this reduction can be 0 ampere, continue a time period 811, and this arc-welding electric current is activated level subsequently 813 and arc-welding pulse subsequently 802 start again at.Of course, it is possible to start any of arc-welding operation, such as pulse welding, The welding of STT type, short arc welding etc..Embodiments of the invention are not limited in this respect.Additionally, in the heated filament part 820 of this waveform The arc-welding operation started afterwards need not identical with the arc-welding operation used before this heated filament part.For example, it is possible at waveform Heated filament part before use pulse welding arc-welding waveform, and STT type waveform can be used after heated filament part 820.From Heated filament welding portion 820 can perform via known arc-welding startup program to the transformation of arc-welding part 810.In some examples Property embodiment in, this wire feeder can make this consumptive material slow down or extract this consumptive material out, in order to electric arc start before in this consumption Gap is produced between material and this molten bath.In other exemplary embodiments, changing routine can be by this power initiation, in order to pinch off The end of this consumptive material and subsequent start-up electric arc.Embodiments of the invention are not limited in this respect.As previously explained, showing In example embodiment, STT, short arc or welding wire retraction technique may be used for arcing phase, and arrive the transformation of heated filament only in short circuit State procedure occurs.

Had heated filament technique and the arc welding process of identical consumptive material by utilization, embodiments of the invention allow enhancing right The control of the heat input in welding procedure, and the welding performance of some welding operation can be improved.Such as, the showing of the present invention Example embodiment can use the system being similar to the system shown in Fig. 7, within the system monitoring workpiece temperature, and based on inspection The temperature measured, controller 710 controls waveform 800 so that the shifting process desired by Shi Yonging.It is to say, controller 710 can To control the ratio that arc-welding is welded with heated filament, in order to the heat input controlled in welding.Such as, if it is determined that need additional heat Amount, this control can increase, in welding waveform, the ratio that arc-welding is welded with heated filament.If it addition, heat input is too high, controlled Device 710 can control power supply 310, in order to reduces the arc-welding amount of waveform 800 and increases heated filament welding capacity.

In the exemplary embodiment, this heated filament technique is optimised with the ratio of arc welding process, in order to the heat desired by acquisition Amount input and sedimentation rate.Such as, in the exemplary embodiment, heated filament technique and the ratio of arc welding process are 50/50 to 0/100 In the range of, wherein this ratio uses process lasting time.50/50 ratio means that the weld interval of 50% is in heated filament mould Formula, and the time of other 50% is in arc-welding pattern.It should be noted that, it should select to guarantee that suitable molten bath is formed and guarantees this The ratio of the consumptive material suitably fusing in realizing heated filament phase process.It should also be noted that in the exemplary embodiment, can be one In individual preset time section or adjust this ratio based on heat input feedback so that the heat desired by Huo get ing inputs.It should be noted that Arrive, arc-welding or heated filament when that current waveform being in turn model, may be characterized as, therefore in this type of embodiment, should The persistent period of arc welding process be confirmed as electric arc exist persistent period, as with heated filament process lasting time (when there is no electric arc In the presence of) compare.In the case of without departing from the spirit or scope of the present invention, other exemplary embodiments can use in this work Other ratio between heated filament part and the arc-welding part of skill.Such as, in other exemplary embodiments, it is possible to use arteries and veins The ratio of punching counting, wherein this ratio represents the ratio of heated filament pulse and the number of arc-welding pulse.In other exemplary embodiments In, the ratio of the step-by-step counting of each corresponding part (heated filament is to arc-welding) is maintained, and the frequency of these respective pulses is adjusted. In this type of embodiment, because this respective pulses frequency shift, the total duration of each corresponding technique is adjusted.Such as, exist In Fig. 8 A, the frequency of arc-welding pulse 802 can be adjusted (such as, increase), and the persistent period in heated filament stage 820 can be tieed up Hold, so make the sum frequency in heated filament stage 820 or occur more frequently-arc-welding part 801 general on the persistent period It is shorter.Other control methods can also be used.

In other exemplary embodiments, sensor 710, controller 710 is not used to use the power integral of waveform 800 With determine welding in total amount of heat input, and based on determined by heat input, controller 710 controls the electricity of waveform 800 Arc and heated filament ratio.In the exemplary embodiment, controller 710 uses user's input information to determine for desired by operation Heat input, and maintain this desired heat to input.Such as, in certain embodiments, controller 710 determine for The desired rolling average heat of fixed operation and/or power input, and control this power supply to provide this rolling average.Heat The rolling average of amount and/or power input can be that user inputs or user setup but it also may by this controller based on user Input data determine.Such as, user can input any one in the following or combine: workpiece material, consumable information, welding wire (deposition, high gait of march engage, and resedimentation engages for feed rate, thickness of workpiece, weld size, position while welding, application type Deng), gap size and any growth parameter or requirement.Based on this information, controller 710 determines it can is rolling average threshold value Heat and/or power input threshold value, and control this power supply so as output realize desired by setting quantity of heat given up and/or The waveform 800 of power.Certainly, controller 710 can also monitor actual heat (via sensor 701 etc.) and/or calculating is carried The actual power of confession and heat, and adjust waveform 800 as required so that the heat desired by Wei Chiing and/or power export. Controller 710 can use many different control methods.Such as, in some exemplary embodiments, controller 710 can be One persistent period set or the rolling average inputted apart from the heat desired by interior use and/or power, and adjust ripple Shape 800 is so that the rolling average desired by Wei Chiing.In this type of embodiment, joule/second or joule/inch ratio may be used for this Controlling, wherein this predetermined rolling average is arranged based on user's input information.

Such as, in some exemplary embodiments, arc procedure joule can be used with the offset ratio of heated filament technique joule In system control.Such as, this system controller is it is ensured that desired or predetermined heat input ratio is permissible It is determined, and this technique is controlled within a preset time or realizes desired ratio in a rolling average. In the exemplary embodiment, arc procedure joule determined by and heated filament technique joule ratio are in the range of 2.5:1 to 10:1. In other exemplary embodiments, this ratio is in the range of 3:1 to 7:1.

Fig. 8 B depicts another exemplary embodiment of waveform 800 ', and this waveform is similar to the waveform 800 in Fig. 8 A.So And, in this embodiment, the heated filament part 820 ' of waveform 800 ' has negative polarity, and therefore total waveform 800 ' is AC type ripple Shape.It should be noted that, during some welding operations, the constant use of same current polarity can make workpiece and/or workpiece clamp Tool magnetization.This is probably undesirable due to multiple reasons.But, being replaced by the electric current that makes as shown in Figure 8, magnetic increases can To be mitigated and to minimize.Generally, the waveform 800 ' mode in the way of being similar to above with respect to Fig. 8 A discussion generates and controls System, but heated filament part has negative polarity as shown in the figure.Different from arc-welding, because not having electric arc, the use of negative polarity is by right The total amount of heat input of welding operation has little to no effect.It is true that in some exemplary embodiments, this power supply can use figure The combination of two shown in 8A and Fig. 8 B waveform.It is to say, the heated filament part of current waveform can be in positive polarity and negative polarity Between alternately, and identical polarity be need not for whole welding procedure.AC electric current has erasure effect, and AC to fixture Frequency is relevant to this effect.Therefore, in some exemplary embodiments, this polarity is altered to optimize this erasure effect.? In some embodiments, continuous print pulse replaces in polarity.Additionally, this welding procedure can use has the first polarity (such as, Multiple continuous heated filament part just), is single (or multiple) the heated filament part with the second polarity (such as, negative) afterwards.This control Device/power supply processed can adjust the polarity of these heated filament parts as required so that the performance desired by Shi Xianing, prevent simultaneously workpiece/ Magnetic force in fixture increases.Additionally, be possible not only to change the polarity of these heated filament parts, it is also possible to change waveform 800/800 ' Arc-welding part 810 (polarity).It is to say, embodiments of the invention can also use AC arc-welding work for arc-welding part 810 Skill.Additionally, other embodiments can use negative polarity arc-welding, use positive polarity heated filament welding simultaneously-contrary with shown in Fig. 8 B.

In other exemplary embodiments, controller 710 can be coupled on Magnetic Sensor, this Magnetic Sensor detection work Part and/or the growth in the magnetic field in holding the fixture of this workpiece.Based on carrying out the feedback of Magnetic Sensor since then, controller 710 is permissible Control this power supply to adjust the polarity of heated filament part 820/820 ', in order to alleviate or control the growth of any undesirable magnetic force.

Fig. 9 depicts another exemplary embodiment of waveform 900, and this waveform is similar to the waveform 800 shown in Fig. 8 A.So And, in this embodiment, this power supply is converted to arc-welding part 810 from the heated filament part 820 of this waveform rapidly.As it can be seen, In this embodiment, this heater current is reduced to transition level 901, this transition level less than heater current (810) peak value or The peak value of arc-welding pulse 802, but higher than background current 803.When this electric current reaches transition level 901, this power supply is grasped from arc extinguishing Operation mode is switched to traditional electric arc and generates operator scheme, and produces electric arc immediately.This type of embodiment can use height weldering It is used during silk feed rate, in order to prevent consumptive material from bottoming out in molten bath, simultaneously from heated filament process changeover to arc welding process.Showing In example embodiment, this transition level is in the range of 100 to 250 amperes.In other exemplary embodiments, this transformation can make The blast in producing arc process or the probability of splashing event is minimized with a slope current.Other embodiments also may be used To make welding wire retract or slow down in transition process.In other exemplary embodiments, it is possible to use STT control method, at this In method, early warning circuit is just producing the electric current before electric arc for reducing.Additionally, other embodiments can use independence Peak point current in this process current comes the gap just setting up between molten bath and consumptive material after generation electric arc.Additionally, other Exemplary embodiment can utilize the background current of extension when from this arc welding process to the transformation of this heated filament welding procedure.Extension Background will promote short circuit event, and when this short circuit occurs, the transformation of heated filament can be started to.

Certainly, it shall be noted that other transition waveforms and control method may be used for the heated filament from waveform 800/800 '/900 Part 820 changes to arc-welding part 810.

In an exemplary embodiment of the present invention, the feed rate of welding wire of this consumptive material can also obtain in this technical process Adjust to optimize this technique.Such as, in the exemplary embodiment, the feed rate of welding wire in arc-welding phase process can compare Feed rate of welding wire in heated filament technical process is slow.Such as, if using short arc welding process in the arc-welding stage, this welding wire send Enter speed to slow down in the transition process from heated filament to arc-welding, and accelerate when transforming back into this heated filament technique subsequently.

Because embodiments of the invention provide the computer heating control strengthened, they may be used for optimizing welding operation.Such as, originally Inventive embodiment may be used for the solder joint of such as butt-welded side seam and T seam without backing, especially in relative thin On workpiece.This generally describes in Figure 10 A and Figure 10 B.Figure 10 A depicts a butt-welded side seam, the wherein back of the body of this weld seam Side BS does not uses backing plate to support this weld seam.Because embodiments of the invention have enhanced computer heating control, this welding may be Complete in the case of there is no the welding pool of liner and the dorsal part BS that do not blows this weld seam.In the exemplary embodiment, should Arc welding process may be used for adding penetrating desired by heat and offer to welding, and the heated filament part of this welding procedure can subsequently For interpolation material without superheated (or even cooling) this technique, so make molten bath by not by the back of the body of seam Side.This is significantly enhanced the productivity ratio of welding operation.Additionally, in the additional embodiment of the present invention, sensor 701 (such as, heat Sensor) may be oriented such that the dorsal part BS of monitoring solder joint, and be used for controlling electricity from the feedback of sensor 701 The output in source 310, in order to the heat input desired by realization and deposition.It is to say, the feedback from sensor 701 can be used In the ratio of control heated filament technique with arc welding process, it is the output from this power supply.Such as, if at the back of the body of this welded seam Detecting on the BS of side that undesirable temperature increases, this power supply will be switched to heated filament to cool down this technique, and prevent this molten bath Penetrate the dorsal part of this welded seam.Similarly, embodiments of the invention may be used for welding the T of the seam shown in similar Figure 10 B Seam and do not use backing.Certainly, embodiments of the invention are not limited solely to these seam types but it also may connect in many differences Use in seam type.

Additionally, the improvement welding that embodiments of the invention are additionally provided on coating workpieces (the most zinc-plated).Commonly known Be that the welding of traditional zinc-plating material needs remove coating before welding and/or very slowly weld, in order to prevent weldering Seam becomes excessive porous.But, embodiments of the invention may be used for engaging coating/zinc-plated workpiece and not having this A little shortcomings.It is to say, utilized arc-welding and the combination of heated filament welding of identical consumptive material by use, the speed that can improve is produced Raw solder joint, minimizes the porous in this seam simultaneously.This arc welding process may be used for penetrating this workpiece and making this coating Vaporization, and this heated filament technique can make total amount of heat input keep relatively low and prevent any coating (such as, zinc) in this welding Heat affected area vaporizes.In an exemplary embodiment of the present invention, when welding coating workpieces, the arc-welding persistent period holds with heated filament The ratio of continuous time is in the range of 70/30 to 40/60.In other embodiments, this ratio 60/40 to 45/55 scope In.Therefore, embodiments of the invention may be used for when welding coating material, it is achieved is better than the improvement of known welding method Energy.

The system and method consistent with embodiments of the invention is directed to use with a kind of hot wire welding connection technology and is deposited by consumptive material 140 On workpiece 115, this hot wire welding connection technology uses heated filament and the combination of arc-welding.Waveform 500 is in the welding operating process of this heated filament Produce arc event, in order in welding procedure, add/control heat.This heated filament welding procedure can be used alone, with sharp Light 120 or be used in combination with other welding procedures.

Although the present invention of being described with reference to certain embodiments, but those of ordinary skill in the art it will be appreciated that Various change can be made without departing from the scope of the invention and replace equivalent.Furthermore, it is possible to carry out it is many Amendment so that particular situation or material adapt to the present invention teach content without deviating from its scope.Therefore, the present invention is not intended to It is confined to disclosed specific embodiment, but the present invention will include all embodiments fallen within the scope of the present application.

Reference number

100 systems

110 laser beams

115 workpiece

120 laser aids

125 directions

130 Laser Power Devices

140 filler wires

150 filler wire feeders

160 contact tubes

170 heater supplies

180 motion controllers

195 current controllers

200 systems

211 welding electrodes

212 welding torches

213 power supplys

215 wire feeders

300 systems

301 sources of welding current

303 synchronizing signals

310 heater supplies

311 inverter power parts

313 preset heating voltage circuit

315 time average filter circuits

317 sense leads

319 sense leads

321 arc-detection threshold circuits

323 nominal shock pulse waveform loops

400 voltage waveforms

401 potential pulses

403 crest voltages

405 electric arc level

407 open-circuit voltages (OCV)

409 peak levels

500 current waveforms

501 heating pulse

503 peak current level

507 electric arcs

509 introduce electric current

511 introduce electric current

600 current waveforms

601 arc-welding pulses

603 background option

611 heating pulse

700 systems

701 sensor devices

710 controllers

800 current waveforms

800 ' current waveforms 801

801 arc-welding forms

802 pulses

804 points

805 times

809 level

810 add thermal current level

811 time periods

813 level

820 heated filament stages

900 waveforms

901 transition level

Claims

1. a consumptive material depositing system (100), including:

One power supply (170), this power supply is to be deposited to a consumptive material in the fusion pool at least one workpiece (115) (140) current waveform (500) is provided, it is characterised in that described current waveform (500) including:

One arc deposited part, this arc deposited part produces electric arc between described consumptive material (140) and described molten bath；And

One heated filament part, adds thermocurrent in this heated filament partial routine and is provided to described consumptive material (140), and in described consumption Electric arc is not produced between material (140) and described molten bath；

Wherein said power supply (170) includes a controller, this controller determine from described current waveform (500) to described at least Desired heat in one workpiece (115) inputs, and described power supply (170) makes described current waveform (500) described Between arc deposited part and described heated filament part alternately, in order to control from described current waveform (500) to described workpiece (115) In the input of described heat, thus maintain described desired heat to input.

2. depositing system as claimed in claim 1, wherein said arc deposited part is GMAW type technique.

3. depositing system as claimed in claim 1 or 2, farther includes a sensor, and this sensor detects to described work Heat in part (115) inputs, and described controller uses the feedback from described sensor to control described power supply (170), and make described current waveform (500) between described arc deposited part and described heated filament part alternately.

4. the depositing system as described in one of claims 1 to 3, wherein said controller controls described current waveform so that institute State the described heated filament part of current waveform and the ratio of described arc deposited part in the range of 50/50 to 0/100.

5. the depositing system as described in one of Claims 1-4, wherein said controller controls the described heat of described current waveform Silk part and the ratio of described arc deposited part, in order to maintain described desired heat to input.

6. the depositing system as described in one of claim 1 to 5, wherein said controller controls described heated filament part and described electricity At least one in the frequency of at least one in arc deposition fraction and current impulse number, in order to maintain described desired heat Input.

7. the depositing system as described in one of claim 1 to 6, the input of wherein said desired heat is for described current wave The rolling average heat input of shape.

8. the depositing system as described in one of claim 1 to 7, wherein said desired heat inputs based in the following At least one or combination determine: the material type of described workpiece；The type of described consumptive material；Weld size, welding position, application Type, gap size to be filled, for the feed rate of welding wire of described consumptive material and the thickness of described workpiece.

9. the depositing system as described in one of claim 1 to 8, the input of wherein said desired heat is for described current wave The rolling average power input of shape.

10. the depositing system as described in one of claim 1 to 9, wherein said controller controls described current waveform so that institute State the ratio of the joule of arc deposited technique and the joule of described heated filament technique in the range of 2.5:1 to 10:1.

11. depositing systems as claimed in claim 10, wherein said controller controls described current waveform so that described electric arc The ratio of the joule of the joule of depositing operation and described heated filament technique is in the range of 3:1 to 7:1.

12. 1 kinds of consumptive material deposition process (100), including:

Generate deposition current and deliver this deposition current to consumptive material (140)；

Described consumptive material (140) is made to advance towards a workpiece (115), in order to use described deposition current by described consumptive material (140) It is deposited on described workpiece (115)；

It is characterized in that described generation current waveform (500) including:

Generating an arc deposited part, this arc deposited part produces electric arc between described consumptive material (140) and described molten bath, Wherein said arc deposited part is preferably GMAW type technique；And

Generate a heated filament part, this heated filament partial routine adds thermocurrent and is provided to described consumptive material (140), and in institute State and do not produce electric arc between consumptive material (140) and described molten bath；And

Determine the desired heat input from described current waveform (500) to described at least one workpiece (115), and make institute State current waveform (500) to replace between described arc deposited part and described heated filament part, in order to control from described current wave Shape (500) arrives the described heat input in described workpiece (115), thus maintains described desired heat to input.

13. deposition process as claimed in claim 12, farther include sensing heat input in described workpiece, and make With the feedback from described sensor control between described arc deposited part and described heated filament part described in alternately；With/ Or farther include to control described current waveform so that the described heated filament part of described current waveform and described arc deposited part Ratio in the range of 50/50 to 0/100；With or farther include to control the described heated filament part of described current waveform and institute State the ratio of arc deposited part, in order to maintain described desired heat to input.

14. deposition process as described in claim 12 or 13, farther include to control described heated filament part and described electric arc sink At least one in the frequency of at least one in long-pending part and current impulse number, in order to maintain described desired heat defeated Enter；And/or the input of wherein said desired heat is to input for the rolling average heat of described current waveform；And/or wherein The input of described desired heat is the rolling average power input for described current waveform.

15. deposition process as described in one of claim 12 to 14, wherein said desired heat inputs based on the following In at least one or combination determine: the material type of described workpiece；The type of described consumptive material；Weld size, welding position, Application type, gap size to be filled, for the feed rate of welding wire of described consumptive material and the thickness of described workpiece；And/or Wherein said controller controls described current waveform so that the joule of described arc deposited technique and the joule of described heated filament technique Ratio in the range of 2.5:1 to 10:1；The most preferably: described controller controls described current waveform so that described electricity The ratio of the joule of the joule of arc depositing operation and described heated filament technique is in the range of 3:1 to 7:1.