CN115770929A - Process database component method for manufacturing typical characteristic structure by using arc additive - Google Patents

Process database component method for manufacturing typical characteristic structure by using arc additive Download PDF

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Publication number
CN115770929A
CN115770929A CN202211368923.3A CN202211368923A CN115770929A CN 115770929 A CN115770929 A CN 115770929A CN 202211368923 A CN202211368923 A CN 202211368923A CN 115770929 A CN115770929 A CN 115770929A
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establishing
arc additive
arc
characteristic structure
additive manufacturing
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Inventor
陈梦凡
侯正全
钟珂珂
陈一
刘思余
程鹏
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Shanghai Space Precision Machinery Research Institute
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Shanghai Space Precision Machinery Research Institute
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    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00Technologies related to metal processing
    • Y02P10/25Process efficiency

Abstract

The invention provides a process database component method of an arc additive manufacturing typical characteristic structure, which is characterized by comprising the following steps of: establishing typical characteristic structure types, shape curves and characteristic sizes thereof; inputting a target characteristic structure, a shape curve and a characteristic size; establishing the type, the grade and the diameter of the melting wire; establishing a corresponding mark and state of a substrate material; establishing the type of an electric arc additive heat source and a process mode thereof; establishing a protective gas type; establishing a characteristic structure model optimization scheme; suggesting an additive path of any feature structure model optimization scheme; establishing relevant parameters of an actuating mechanism and an external shaft; and establishing electric arc additive related process parameters. The invention realizes the rapid matching of the related process parameters of the electric arc additive, meets the requirements of the shape and the size of the preset characteristic structure, realizes the active control of the forming quality of the electric arc additive manufacturing, improves the surface quality, the forming precision and the forming efficiency of the electric arc additive manufacturing formed part, and ensures the mechanical property of the formed part.

Description

Process database component method for manufacturing typical characteristic structure by arc additive manufacturing
Technical Field
The invention belongs to the technical field of electric arc additive manufacturing of aerospace structural parts, and relates to a process database construction method of an electric arc additive manufacturing typical characteristic structure.
Background
In the electric Arc Additive manufacturing technology (WAAM), an electric Arc is used as a heat source, and a layer-by-layer overlaying mode is adopted to compact a metal component at a position stacked by a line-surface-body path. Compared with the traditional casting/forging-material reducing manufacturing process, the manufacturing process has the advantages of short manufacturing period, high flexibility degree, high material utilization rate and high response speed to design, is particularly suitable for manufacturing products with small batch and various varieties, and has wide application prospect in the fields of aerospace, automobiles, ships and the like.
The invention of patent application No. 202011436187.1 discloses a GMWA electric arc additive manufacturing system and method for auxiliary wire filling of crossed metal parts, the method adopts a visual detection and feedback system, current and voltage are adjusted, and the wire feeding speed of a composite wire feeding device is adjusted to change the cladding amount at the position of a cross point, so that the cross point is kept flat in the forming process, and electric arc additive manufacturing of a crossed structure is realized. The method does not optimize the cross structure and path from the process angle, but corrects the cross point process parameters through a visual detection system, and has low applicability.
The invention with the patent application number of 201610408053.6 discloses an electric arc filler wire additive manufacturing method for an inclined thin-wall structural part. When a single-channel inclined thin-wall part is prepared, the first layer is formed by lapping two welding beads, and the second layer and the subsequent layers are formed into an inclined structure by adopting a welding gun to deflect along the direction vertical to the height direction; the problems of high equipment cost, complex system, low forming precision and the like in the preparation of the inclined structural part are solved, and the inclined structural part can be prepared without turning over a substrate by a positioner. The method is usually only suitable for preparing the inclined thin-walled part with a small angle, a thick-walled structural part or a large-inclined-angle structural part cannot be prepared, and the influence of temperature gradient on forming and the possibility of collapse failure are not considered.
The invention with the patent application number of 201811512386.9 discloses an electric arc additive manufacturing method for an aluminum alloy suspended structural part. After the area to be subjected to material increase of the aluminum alloy suspended structural member is preprocessed, the aluminum alloy suspended structural member is fixed on a working platform, the positions of an arc starting point and an arc ending point and a material increasing path are set to comprise a plurality of layers to be subjected to material increase, and the gravity and the surface tension of deposited metal are balanced by adopting an interlayer offset method, so that the suspended structure is formed. The method is characterized in that a thin-wall suspended structure is formed without adopting a positioner, and the positioner and a welding gun are required to be comprehensively used in an actual formed part to realize the formation of the thick-wall suspended structure.
In the electric arc additive manufacturing technology, the accuracy limit of electric arc deposition causes the formed part to have lower surface quality, and the high heat input amount and temperature gradient cause the formed part to have larger residual stress and deformation, poorer tissue form and the like, thereby influencing the forming and performance of the structural part. Based on the functional and weight-reduction design requirements, typical characteristic structures frequently contained in the electric arc additive forming part comprise a cross structure, a boss structure, an inclined structure and a suspension structure. If reasonable process parameters, material adding paths or feature structure optimization are not adopted in the process of the characteristic structure, various problems such as protrusion, necking, collapse, poor lap joint quality, incomplete fusion and the like are easy to occur, forming failure is even caused seriously, and forming efficiency and forming precision are greatly reduced.
Therefore, it is necessary to establish a process database of an arc additive typical feature structure, which is used for realizing fast matching of an arc additive manufacturing typical feature structure, a morphology curve, a feature size and a range with a molten wire material, a substrate material and a state, an arc additive heat source type and a process mode thereof, a shielding gas type and a flow rate, relevant parameters of an execution mechanism, a feature structure model optimization scheme, an additive path and relevant process parameters of arc additive.
Disclosure of Invention
The invention aims to provide a process database construction method of an arc additive typical characteristic structure, which can realize the rapid matching of the arc additive manufacturing typical characteristic structure, a shape curve, a characteristic size and a range with a molten wire material, a substrate material and a state, the type and the process mode of an arc additive heat source, the type and the flow rate of a protective gas, relevant parameters of an actuating mechanism, an optimization scheme of a characteristic structure model, an additive path and relevant process parameters of arc additive.
The invention provides a process database construction method of an arc additive manufacturing typical characteristic structure, which is characterized by comprising the following steps of:
step 1: establishing typical characteristic structure types, morphology curves and characteristic sizes thereof;
step 2: inputting a target characteristic structure, a morphology curve and a characteristic size;
and step 3: establishing the type, the grade and the diameter of the melting wire;
step 4; establishing a corresponding brand and a corresponding state of a substrate material;
and 5: establishing the type of an electric arc additive heat source and a process mode thereof;
step 6; establishing a protective gas type;
and 7: establishing a characteristic structure model optimization scheme;
and step 8: selecting a characteristic structure model optimization scheme and an additive path with the minimum residual stress;
and step 9: establishing relevant parameters of an actuating mechanism and an external shaft;
step 10: and establishing electric arc additive related process parameters.
Preferably: in the step 1, typical characteristic structure types include a cross structure, a boss structure, an inclined structure and a suspension structure.
Preferably, in the step 3, the molten wire material includes metal, intermetallic compound and gradient functional material therebetween.
Preferably, in the step 4, the substrate material comprises a metal, an intermetallic compound and a gradient functional material therebetween; the substrate state includes: normalized, annealed, quenched, conditioned, solution treated, aged and other heat treated states.
Preferably, in the step 5, the electric arc additive heat source comprises automatic Submerged Arc Welding (SAW), non-consumable electrode gas shielded welding (GTAW), non-consumable electrode argon tungsten arc welding (TIG), consumable electrode inert/active gas shielded welding (MIG/MAG), cold Metal Transition (CMT), plasma Arc Welding (PAW) and other electric arc welding modes as a heat source; the process modes include dc/ac, pulse, polarity change pulse and other process modes.
Preferably, in step 6, the shielding gas includes argon, helium, carbon dioxide and a mixture gas.
Preferably, in step 7, the feature structure model optimization scheme conforms to the principle of minimum arc striking and extinguishing times, the principle of minimum path corner, and the principle of integrity of the filling path, including adding a transition fillet/a transition margin, reducing dead angle positions, short straight lines and irregular tracks, optimizing a cross path, optimizing a corner, increasing continuity between paths, and the like, so that the path is smoothly and stably changed. And after the characteristic structure optimization scheme is iterated, establishing a characteristic structure model optimization scheme library.
Preferably, in the step 8, after a feature structure model optimization scheme is selected, after simulation calculation, a corresponding matched material adding path is given according to the principle of minimum residual stress;
preferably, in step 9, the actuator-related parameters include an angle of the actuator, a material feeding path, swing parameters (a swing length, a swing width, and a swing curve), and distances between the actuator and the contact tip and the end face of the cladding layer. The external shaft related parameters comprise an external shaft angle and a rotating speed;
preferably, in the step 10, the arc additive related process parameters include a shielding gas flow rate, an arc starting current, an arc starting time, a transition time, an arc quenching current, a transition time, an arc quenching time, a deposition speed, a wire feeding speed and current-voltage curve, a deposition interlayer temperature range, a substrate initial temperature and an interlayer waiting time, and the like.
The invention provides a process database construction method of an electric arc additive manufacturing typical characteristic structure, which realizes the quick matching of the electric arc additive manufacturing typical characteristic structure and the characteristic dimension thereof with a molten wire material, a substrate material and a state, the electric arc additive material heat source type and a process mode thereof, the shielding gas type and the flow speed, the relevant parameters of an actuating mechanism, a characteristic structure model optimization scheme, an additive path and the relevant process parameters of electric arc additive material, meets the requirements of the shape and the dimension of a preset characteristic structure, realizes the active control of the electric arc additive manufacturing forming quality, improves the surface quality, the forming precision and the forming efficiency of an electric arc additive manufacturing formed part, and ensures the mechanical property of the formed part.
Drawings
FIG. 1 is a process database build roadmap for an arc additive signature of the present invention;
FIG. 2 is a schematic diagram of cross-class features and their feature sizes;
FIG. 3 is a schematic diagram of a cross-like feature path;
FIG. 4 is a schematic view of the actuator and the external shaft position.
Detailed Description
In order to make the aforementioned objects, features and advantages of the present invention comprehensible, embodiments accompanied with figures are described in further detail below.
The main elements of a process database of the arc additive manufacturing deposition layer comprise (1) typical characteristic structure types, morphology curves and characteristic sizes; (2) melting the wire material and the substrate material and state; (3) the type of an electric arc additive heat source and a process mode thereof; (4) shielding gas type; (5) optimizing a scheme of the characteristic structure model; (6) optimizing a residual stress minimum additive path of the solution; (7) actuator-related parameters; and (8) electric arc additive material related process parameter composition. The correspondence between the above-described main constituents is established.
The invention takes the fuse wire material grade and diameter, the electric arc additive material heat source and process mode, and the preset characteristic structure, the appearance curve and the characteristic dimension as input, and takes the characteristic structure model optimization scheme, the matched additive material path, the relevant parameters of the actuating mechanism and the relevant process parameters of the electric arc additive material as output, thereby realizing the active control of the electric arc additive material manufacturing forming quality while meeting the requirements of the preset characteristic structure shape and dimension, improving the surface quality, the forming precision and the forming efficiency of the electric arc additive material manufacturing formed piece, and ensuring the mechanical property of the formed piece.
Fig. 1 is a process database build roadmap for an arc additive signature of the present invention. As shown in fig. 1, the present invention provides a method for constructing a process database of an arc additive manufacturing typical feature structure, which is characterized by comprising the following steps:
step 1: establishing typical characteristic structure types, morphology curves and characteristic sizes thereof;
according to an embodiment of the present invention, in step 1, typical feature types include cross type structures, boss type structures, inclined type structures, and floating type structures.
And 2, step: inputting a target characteristic structure, a morphology curve and a characteristic size;
and step 3: establishing the type, the grade and the diameter of the melting wire;
according to one embodiment of the invention, in step 3, the molten wire material comprises a metal, an intermetallic compound and a gradient functional material therebetween.
Step 4; establishing a corresponding mark and state of a substrate material;
according to an embodiment of the present invention, in the step 4, the substrate material includes a metal, an intermetallic compound, and a gradient functional material therebetween. The substrate state includes: normalized, annealed, quenched, conditioned, solution treated, aged and other heat treated states.
And 5: establishing the type of an electric arc additive heat source and a process mode thereof;
according to an embodiment of the invention, in the step 5, the arc additive heat source includes non-gas metal arc welding (TIG), gas metal inert/active gas metal arc welding (MIG/MAG), cold Metal Transition (CMT), plasma Arc Welding (PAW) and other arc welding methods as the heat source; the process modes include dc/ac, pulsed, polarity-changed pulsed, and other process modes.
Step 6; establishing a protective gas type;
according to an embodiment of the present invention, in the step 6, the shielding gas includes argon, helium, carbon dioxide and a mixture gas.
And 7: establishing a characteristic structure model optimization scheme;
according to an embodiment of the present invention, in the step 7, the feature structure model optimization scheme conforms to a principle of minimum arc striking and extinguishing times, a principle of minimum path corners, and a principle of integrity of a filling path, including adding a transition fillet/a transition margin, reducing a dead angle position, a short straight line and an irregular track, optimizing a cross path, optimizing a corner, increasing continuity between paths, and the like, so that the path is smoothly and stably changed. And after the characteristic structure optimization scheme is iterated, establishing a characteristic structure model optimization scheme library.
And 8: selecting a characteristic structure model optimization scheme and a matched material adding path;
according to an embodiment of the present invention, in step 8, an additive path based on the minimum residual stress corresponding to any one of the feature-structure simulation optimization schemes is established. After a characteristic structure model optimization scheme is selected, a corresponding matched material adding path is given according to the principle of minimum residual stress after simulation calculation.
And step 9: establishing relevant parameters of an actuating mechanism and an external shaft;
according to an embodiment of the present invention, in step 9, the actuator-related parameters include an angle of the actuator, a material feeding path, swing parameters (a swing length, a swing width, and a swing curve), a distance between the actuator and the contact tip and the end face of the cladding layer, and the outer shaft-related parameters include a table angle and a rotation speed.
Step 10: and establishing related process parameters of the electric arc additive.
According to an embodiment of the invention, in the step 10, the arc additive related process parameters include a shielding gas flow rate, an arc starting current, an arc starting time, a transition time, an arc quenching current, a transition time, an arc quenching time, a deposition speed, a wire feeding speed and a current-voltage curve, a deposition interlayer temperature range, a substrate initial temperature and an interlayer waiting time, and the like.
An embodiment of the present invention will be described with reference to fig. 2 to 4. The following examples will assist those skilled in the art in further understanding the invention, but are not intended to limit the invention in any way. It should be noted that variations and modifications can be made by persons skilled in the art without departing from the spirit of the invention. All falling within the scope of the invention.
FIG. 2 is a schematic diagram of cross-class features and their feature sizes. Taking the cross-shaped cross structure shown in fig. 2 as an example, taking a black dotted line as a target cross-shaped cross structure model, inputting characteristic dimensions L1/H1, L2/H2, L3/H3, L4/H4, a1/a2/a, fuse material grade and diameter, an arc additive heat source and a process mode, and obtaining a model optimization scheme as shown in fig. 3. Fig. 3 is a schematic diagram of a cross-like feature structure path, a thin black solid line is a cross-shaped cross structure after model optimization, and a thick black solid line is a melting channel. P1P2P3P4 is an arc starting point and an arc extinguishing point, A1A2A3A4 is a melting channel corner point, and R1R2 is a corner arc radius respectively. Then, the actuator-external shaft related parameters are obtained, which are shown in fig. 4. FIG. 4 is a schematic view of the position of the actuator and the external shaft, the angle between the actuator (welding gun) and the workpiece is α, and the distance between the actuator (welding gun) and the workpiece is h. When viewed from the top of the outer shaft, the self-rotation angle of the outer shaft is β, and the self-rotation angular velocity w is w. The inclination angle is gamma when viewed from the front view of the outer shaft. Finally, arc additive related parameters are obtained, wherein the parameters comprise protective gas flow rate, arc starting current, arc starting time, transition time, arc extinction current, transition time, arc extinction time, deposition speed, wire feeding speed, current-voltage curve, deposition interlayer temperature range, substrate initial temperature, interlayer waiting time and the like.
According to the invention, the process database of the arc additive typical characteristic structure is established, the grade and the diameter of a fuse wire material, an arc additive heat source and process mode, a preset characteristic structure, a morphology curve and a characteristic dimension are used as input, and arc additive related process parameters corresponding to the morphology curve and the characteristic dimension of a deposition layer are used as output, so that the arc additive typical characteristic structure and the characteristic dimension thereof are rapidly matched with a molten wire material, a substrate material and state, the type of the arc additive heat source and the process mode thereof, the type and the flow rate of protective gas, the related parameters of an execution mechanism and an external shaft, the optimization scheme of a characteristic structure model and additive path and the related process parameters of arc additive. The invention realizes the active control of the forming quality of the electric arc additive manufacturing while meeting the requirements of the shape and the size of the preset typical characteristic structure. The surface quality, the forming precision and the forming efficiency of the electric arc additive manufacturing formed part are improved, and the mechanical property of the formed part is ensured.
And through the same process trial and error and process simulation iterative optimization of the typical characteristic structure optimization scheme and the additive path, a process database of the arc additive typical characteristic structure can be established, and the parameters can be quickly matched.
It will be apparent to those skilled in the art that various changes and modifications may be made in the invention without departing from the spirit and scope of the invention. Thus, if such modifications and variations of the present invention fall within the scope of the claims of the present invention and their equivalents, the present invention is also intended to include such modifications and variations.

Claims (10)

1. A method for constructing a process database of an arc additive manufacturing typical feature structure is characterized by comprising the following steps of:
step 1: establishing typical characteristic structure types, shape curves and characteristic sizes thereof;
step 2: inputting a target characteristic structure, a morphology curve and a characteristic size;
and step 3: establishing the type, the grade and the diameter of the melting wire;
step 4; establishing a corresponding mark and state of a substrate material;
and 5: establishing the type of an electric arc additive heat source and a process mode thereof;
step 6; establishing a shielding gas type;
and 7: establishing a characteristic structure model optimization scheme;
and step 8: suggesting an additive path of any feature structure model optimization scheme;
and step 9: establishing relevant parameters of an actuating mechanism and an external shaft;
step 10: and establishing electric arc additive related process parameters.
2. The method for building a process database of arc additive manufacturing signature structures according to claim 1, wherein: in the step 1, typical characteristic structure types include a cross structure, a boss structure, an inclined structure and a suspension structure.
3. The method for building a process database of arc additive manufacturing features of claim 1, wherein in step 3, the molten wire comprises a metal, an intermetallic compound, and a gradient functional material therebetween.
4. The method for building a process database of arc additive manufacturing typical features according to claim 1, wherein in the step 4, the substrate material comprises metal, intermetallic compound and gradient functional material between them; the substrate state includes: normalized, annealed, quenched, conditioned, solution treated, aged and other heat treated states.
5. The method for constructing a process database of arc additive manufacturing typical features according to claim 1, wherein in the step 5, the arc additive heat source comprises automatic Submerged Arc Welding (SAW), non-consumable gas shielded welding (GTAW), non-consumable argon tungsten arc welding (TIG), consumable inert/active gas shielded welding (MIG/MAG), cold Metal Transition (CMT), plasma Arc Welding (PAW) and other arc welding modes as a heat source; the process modes include dc/ac, pulse, polarity change pulse and other process modes.
6. The method for building a process database of arc additive manufacturing signature structures as claimed in claim 1 wherein in step 6, shielding gas species include argon, helium, carbon dioxide, and mixtures thereof.
7. The method for building a process database of arc additive manufacturing signature structures according to claim 1, wherein: in the step 7, the characteristic structure model optimization scheme conforms to the principle of minimum arc starting and extinguishing times, the principle of minimum path corner and the principle of integrity of the filling path, including adding transition fillets/transition margins, reducing dead angle positions, short straight lines and irregular tracks, optimizing cross paths, optimizing corners and increasing continuity between paths, so that the paths are smooth and stably changed; and after the characteristic structure optimization scheme is iterated, establishing a characteristic structure model optimization scheme library.
8. The method for building a process database of arc additive manufacturing signature structures according to claim 1, wherein: in the step 8, after a characteristic structure model optimization scheme is selected, a corresponding matched additive path is provided according to the principle of minimum residual stress after simulation calculation.
9. The method for building a process database of arc additive manufacturing signature structures according to claim 1, wherein: in the step 9, the relevant parameters of the actuator include an angle of the actuator, a material adding path, swing parameters, and a distance between the contact tip and an end face of the cladding layer, the swing parameters include a swing length, a swing width, and a swing curve, and the relevant parameters of the external shaft include an angle of the external shaft and a rotating speed.
10. The method for building a process database of arc additive manufacturing signature structures according to claim 1, wherein: in the step 10, the arc additive related process parameters include protective gas flow rate, arc starting current, arc starting time, transition time, arc quenching current, transition time, arc quenching time, deposition speed, wire feeding speed, current-voltage curve, deposition interlayer temperature range, substrate initial temperature and interlayer waiting time.
CN202211368923.3A 2022-11-03 2022-11-03 Process database component method for manufacturing typical characteristic structure by using arc additive Pending CN115770929A (en)

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN117359640A (en) * 2023-11-22 2024-01-09 南京衍构科技有限公司 Additive manufacturing path planning method for crossed workpiece

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN117359640A (en) * 2023-11-22 2024-01-09 南京衍构科技有限公司 Additive manufacturing path planning method for crossed workpiece

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