CN117884802A - High temperature wire lubricant for preheated wire system and related method - Google Patents

High temperature wire lubricant for preheated wire system and related method Download PDF

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Publication number
CN117884802A
CN117884802A CN202311321590.3A CN202311321590A CN117884802A CN 117884802 A CN117884802 A CN 117884802A CN 202311321590 A CN202311321590 A CN 202311321590A CN 117884802 A CN117884802 A CN 117884802A
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China
Prior art keywords
lubricant
wire electrode
degrees celsius
high temperature
welding
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Pending
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CN202311321590.3A
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Chinese (zh)
Inventor
乔恩·埃里克·斯尼德
约瑟夫·克拉克·邦迪
杰克·布拉德利·茨魏尔
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Hobert Brothers LLC
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Hobert Brothers LLC
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Priority claimed from US18/377,543 external-priority patent/US20240123555A1/en
Application filed by Hobert Brothers LLC filed Critical Hobert Brothers LLC
Publication of CN117884802A publication Critical patent/CN117884802A/en
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Abstract

The present disclosure relates generally to high temperature lubricants used in preheated welding wire systems. The lubricant may comprise one or more high melting point materials at a concentration of from 0.5 to 30wt% by weight of the lubricant. The high melting point material may include graphite, molybdenum disulfide, tungsten disulfide, or boron nitride. The lubricant is configured to remain on the lubricant-coated wire electrode without melting when the pre-heater heats the wire electrode to a high temperature (e.g., between 500 degrees celsius and 900 degrees celsius). The lubricant may be a powder or a liquid. When the lubricant is a liquid, the liquid may further comprise a solvent, such as 2-propanol or water.

Description

High temperature wire lubricant for preheated wire system and related method
Cross Reference to Related Applications
The present application claims the benefit of priority from U.S. provisional patent application No. 63/416320 filed on 10/14 2022, which is incorporated herein by reference in its entirety.
Technical Field
The present disclosure relates generally to high temperature lubricants used in preheated welding wire systems.
Background
Welding is a process that is becoming more and more common in all industries. Welding is by its very nature the way two pieces of metal are joined. A wide variety of welding systems and welding control schemes have been implemented for various purposes. In continuous welding operations, metal Inert Gas (MIG) welding and Submerged Arc Welding (SAW) techniques allow for a continuous bead to be formed by feeding a welding wire shielded by inert gas or granular flux from a welding torch. The wire feed system may be used in other welding systems, such as Tungsten Inert Gas (TIG) welding. Power is applied to the wire and the electrical circuit is completed through the workpiece to maintain a welding arc that melts the wire electrode and the workpiece to form the desired weld.
Existing wire lubricants include low melting point lubricants such as petroleum distillates, oils, soaps, waxes or detergents. One example is sodium stearate. When used in preheated welding wire systems, these low melting point lubricants tend to melt in the preheating zone, which may subsequently clog the welding gun and cause the welding wire to stop feeding or not feed properly. This may lead to downtime when correcting the problem, which may offset some of the advantages of using a preheated welding wire system.
There is a need for an improved high temperature lubricant for use in preheated welding wire systems.
Disclosure of Invention
The present disclosure relates generally to high temperature lubricants used in preheated welding wire systems and related systems and methods.
According to one aspect of the present disclosure, a lubricant for coating a wire electrode to be used in a preheated wire system comprises one or more high melting point materials in a concentration of from 0.5wt% to 30wt% by weight of the lubricant. The one or more high melting point materials include graphite, molybdenum disulfide, tungsten disulfide, or boron nitride. The lubricant is configured to remain on the lubricant-coated wire electrode without melting when the pre-heater heats the wire electrode to between 500 degrees celsius and 900 degrees celsius. The lubricant may be a powder or a liquid. When the lubricant is a liquid, the liquid may comprise a solvent, such as 2-propanol (2-propanol) or water. The lubricant may contain up to 5wt% by weight of binders, dispersants, surfactants or petroleum distillates. In such lubricants, the binder may be a cellulosic resin or a thermoplastic resin.
In accordance with another aspect of the present disclosure, a preheated welding wire system includes a welding wire electrode and a preheater configured to heat the welding wire electrode to between 500 degrees celsius and 900 degrees celsius. The wire electrode is coated in a high temperature lubricant to form a coating on the outer surface of the wire electrode. The coating is configured to remain on the wire electrode without melting when the pre-heater heats the wire electrode to between 500 degrees celsius and 900 degrees celsius.
According to another aspect of the present disclosure, a method for manufacturing a lubricated wire electrode includes the steps of: (a) forming a wire electrode; and (b) applying a high temperature lubricant to the wire electrode to form a coating on the outer surface of the wire electrode. The wire electrode may then be preheated to between 500 degrees celsius and 900 degrees celsius and then used during welding. The coating is configured to remain on the wire electrode without melting when the wire electrode is preheated to between 500 degrees celsius and 900 degrees celsius.
It is to be understood that both the foregoing general description and the following detailed description present various embodiments, and are intended to provide an overview or framework for understanding the nature and character of the claimed subject matter. The accompanying drawings are included to provide a further understanding of the embodiments and are incorporated in and constitute a part of this specification. The drawings illustrate various embodiments described herein and, together with the description, serve to explain the principles and operation of the claimed subject matter.
Drawings
The following is a description of examples depicted in the accompanying drawings. The figures are not necessarily to scale and certain features and certain views of the figures may be shown exaggerated in scale or in schematic for clarity and conciseness.
Fig. 1 shows a block diagram of preheating and welding current paths in a conventional welding system using resistive preheating.
FIG. 2 illustrates a flow chart of a method of forming and using a wire electrode coated with a high temperature lubricant.
The foregoing summary, as well as the following detailed description of the invention, will be better understood when read in conjunction with the appended drawings. It should be understood that the claims are not limited to the arrangements and instrumentality shown in the drawings. Furthermore, the appearance shown in the drawings is one of many decorative appearances that may be employed to achieve the claimed function of the device.
Detailed Description
In the following detailed description, specific details may be set forth in order to provide a thorough understanding of embodiments of the present disclosure. It will be apparent, however, to one skilled in the art that the disclosed examples may be practiced without some or all of these specific details. Well-known features or processes may not be described in detail for the sake of brevity. In addition, similar or identical reference numbers may be used to identify the same or similar elements.
One or more specific embodiments of the present disclosure will be described below. In an effort to provide a concise description of these embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.
When introducing elements of various embodiments of the present disclosure, the articles "a/an," "the," and "said" are intended to mean that there are one or more of the elements. The terms "comprising," "including," and "having" are intended to be inclusive and mean that there may be additional elements other than the listed elements.
As used herein, preheating refers to heating the wire electrode prior to welding arc or deposition on the wire electrode's travel path.
The preheated welding wire system may include a welding wire electrode and a preheater configured to heat the welding wire electrode to between 500 degrees celsius and 900 degrees celsius. The system may be configured for use in a high deposition rate welding process. The wire electrode is coated in a high temperature lubricant to form a coating on the outer surface of the wire electrode. The coating is configured to remain on the wire electrode without melting when the pre-heater heats the wire electrode to between 500 degrees celsius and 900 degrees celsius.
Fig. 1 is a block diagram showing preheating and welding current paths in a conventional welding system 200 using resistive preheating. The conventional welding system 200 includes a welding torch 201 having a first contact tip 202 and a second contact tip 204. The system 200 further includes a wire electrode 114 fed from a wire spool 206, a pre-heating power supply 208, and a welding power supply 210. The system 200 is shown in operation as generating a welding arc 212 between the wire electrode 114 and the workpiece 106.
In operation, the wire electrode 114 passes from the wire spool 206 through the second contact tip 204 and the first contact tip 202, between which a pre-heating power supply 208 generates a pre-heating current to heat the wire electrode 114. Specifically, in the configuration shown in fig. 1, the preheat current enters the wire electrode 114 via the second contact tip 204 and exits via the first contact tip 202. At the first contact tip 202, welding current may also enter the wire electrode 114. The welding current is generated or otherwise provided by the welding power supply 210. The welding current exits the wire electrode 114 and returns via the workpiece 106. When the wire electrode 114 is in contact with the target metal workpiece 106, the electrical circuit is completed and welding current flows through the wire electrode 114, past the metal workpiece(s) 106 and back to the welding power supply 210. The welding current melts the wire electrode 114 and the parent metal of the workpiece(s) 106 in contact with the wire electrode 114, thereby engaging the workpiece as the melt solidifies. By preheating the wire electrode 114, a welding arc 212 with reduced arc energy may be generated. In general, the preheat current is proportional to the distance between contact tips 202, 204 and wire electrode 114.
The welding current is generated or otherwise provided by the welding power supply 210, while the preheating current is generated or otherwise provided by the preheating power supply 208. The pre-heating power supply 208 and the welding power supply 210 may ultimately share a common power source (e.g., a common generator or line current connection), but the current from the common power source is converted, inverted, and/or regulated to produce two separate currents, the pre-heating current and the welding current. For example, a single power supply and associated inverter circuitry may be utilized to facilitate the preheating operation, in which case three leads may extend from the single power supply.
During operation, the system 200 establishes the welding circuit 214 to conduct a welding current, which is shown by the welding current path 216. A welding current path 216 flows from the welding power supply 210 to the first contact tip 202 and returns to the welding power supply 210 via the welding arc 212, the workpiece 106, and the work lead 218. To enable connection between the welding power supply 210 and the first contact tip 202 and the workpiece 106, the welding power supply 210 includes terminals 220, 222 (e.g., positive and negative terminals).
During operation, the pre-heating power supply establishes a pre-heating circuit to conduct a pre-heating current through the section 226 of the wire electrode 114, the pre-heating current represented by the pre-heating path 224. To enable connection between the pre-heating power supply 208 and the contact tips 202, 204, the pre-heating power supply 208 includes terminals 228, 230. The preheat current path 224 flows from the welding power supply 210 to the second contact tip 204, the section 226 of the wire electrode 114, the first contact tip 202, and back to the preheat power supply 208 via a cable 232 connecting the terminal 220 of the welding power supply 210 to the terminal 230 of the preheat power supply 208.
Because the preheat current path 224 overlaps the weld current path 216 on the connection between the first contact tip 202 and the power supplies 208, 210, the cable 232 may enable a more cost-effective single connection (e.g., a single cable) between the first contact tip 202 and the power supplies 208, 210 rather than providing separate connections for weld current to the first contact tip 202 and preheat current to the first contact tip 202.
The wire 114 may be heated to a pre-heating temperature. This preheating temperature may be, for example, in the range of 500 to 900, or 650 to 850, or 600 to 800, or 650 to 750 degrees celsius.
Further details regarding preheated welding systems can be found in U.S. patent publication nos. 2017/0165778A1 and 2018/0354055A1, and each of the patent publications is incorporated herein by reference.
Fig. 2 illustrates a method 100 for forming and using a wire electrode. The method includes forming 120 a wire electrode and then applying 140 a high temperature lubricant to the wire electrode to form a coating on an outer surface of the wire electrode. At this point, the manufacture of the wire electrode may end. To use the wire in a preheated welding system, 160 preheats the wire electrode to between 500 degrees celsius and 900 degrees celsius before 180 welding using the wire electrode. The coating is configured to remain on the wire electrode without melting during the preheating step 160.
The wire electrode may comprise one or more high melting point materials. The one or more high melting point materials may be present at a concentration of from 0.5wt% to 30wt%, 1.0wt% to 25wt%, 2.0wt% to 20wt%, 3.0wt% to 15wt%, or 5.0wt% to 10wt% lubricant. The one or more refractory materials may include graphite, molybdenum disulfide, tungsten disulfide, or boron nitride. In particular, graphite has the advantage of having a high melting point and being electrically conductive, which is an advantage in arc welding using a welding wire. Graphite and molybdenum disulfide have high lubricity for mating parts to tight tolerances that make each a high performance component in lubricants for welding wire applications, especially when evaluated for long periods of time in high demand industrial applications. The lubricant may contain more than one high temperature, high melting point material to optimize design. Other high melting point materials that may be used as lubricants are materials having a melting point of 600 degrees celsius or more, or 900 degrees celsius or more, particularly when the welding wire is to be preheated to between 600 degrees celsius and 900 degrees celsius.
The high melting point material may allow for ultra-thin film coatings, especially when applied with a liquid medium. The coating may not always be a continuous coating, but may be present in the form of stripes and patches on the surface of the wire electrode. This is often acceptable and not detrimental to its end use. The high melting point material dissolved in the liquid medium has the advantages that: the precise and controlled amount of coating on the surface of the wire electrode is achieved using a variety of well-designed application systems. This may help achieve a low or ultra low amount of lubricant coating on the welding wire, which may help avoid lubricant build up in the welding gun.
High melting point materials dissolved in 2-propanol or other media having a low flash point have a fast cure time, which may be advantageous in the manufacturing process of the welding wire. A low flash point medium may also be advantageous in manufacturing cored welding wire with a longitudinal seam because if the medium enters the core, it will evaporate.
High melting point materials (sometimes also referred to as dry lubricants) have additional advantages over other lubricants such as stearates and oils typically used in welding wire. This additional advantage is that the high melting point material is free of hydrocarbons. Hydrocarbons may increase the diffusible hydrogen content of the steel weld metal, which is undesirable.
The lubricant may be a powder or a liquid. When the lubricant is a powder, it may contain a single component or a powder mixture. While binders, dispersants, and other additives in the high temperature lubricant mixture may be used to obtain a good uniform and adherent coating on the welding wire, such additives may not be needed to obtain a welding wire with the proper properties of the high temperature lubricant coating for the preheating system. For example, the powder coating (without liquid and without additives) on the welding wire may have sufficient properties.
When the lubricant is a liquid, the liquid may comprise a solvent, such as 2-propanol or water. The lubricant may contain up to 25wt% of binders, dispersants, surfactants or petroleum distillates. For example, the lubricant may comprise up to 5wt% of a binder, up to 5wt% of a dispersant, up to 5wt% of a surfactant, and up to 5wt% of a petroleum distillate. In the liquid lubricant, the binder may be a cellulose resin or a thermoplastic resin. These additional additives (such as binders and dispersants) can help to obtain a good, uniform and adherent coating on the wire electrode. The lubricant may be applied in liquid form using solvents other than 2-propanol or water. In this case, a process such as baking may be used during the manufacturing process of the wire electrode to remove solvent from the wire while allowing the high temperature lubricant to remain. In this method, the solvent is harmless when used to apply the high temperature lubricant to the wire electrode used with the preheating system.
Binders, dispersants, and other additives are typically low melting temperature materials (such as thermoplastic resins) and may be disadvantageous in preheated welding systems if their amounts are not kept to a minimum on the wire surface. For example, the binder, dispersant, surfactant, and petroleum distillate may be materials having melting points below 500 degrees celsius. Minimization of low melting temperature additives on the wire surface may be achieved by reducing the concentration of the low melting temperature additives in the mixture, reducing the amount of the mixture applied to the wire, or by baking the wire during the manufacturing process (after the high temperature lubricant dissolved in 2-propanol or other solvent with additives has been applied to the wire) between about 400 degrees celsius and 600 degrees celsius. It may not be necessary to add additives to the lubricant.
According to a further aspect of the invention, a very low melting point lubricant or material may be used that will evaporate or liquefy harmlessly in the preheated section of the welding gun so that it does not clog the welding gun.
According to further aspects of the invention, mating parts of the welding gun may be lubricated so that the welding wire does not require a lubricant. In this case, the lubricant would be applied to the liner, insulator tubing, contact tips, and other components of the welding gun.
The electrode may be metal cored, solid or flux cored. The metal core or flux core electrode may be with or without seams. The electrode may have an external metal coating, such as a copper coating, or may be devoid of an external metal coating.
The various aspects and embodiments disclosed herein are not intended to be limiting. Other embodiments may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented herein. It will be readily understood that the aspects of the present disclosure, as generally described herein, and illustrated in the figures, could be arranged, substituted, combined, separated, and designed in a wide variety of different configurations, all of which are contemplated herein.

Claims (20)

1. A lubricant for coating a wire electrode to be used in a preheated welding wire system, the lubricant comprising:
one or more refractory materials at a concentration of from 0.5wt% to 30wt% by weight of the lubricant, wherein the one or more refractory materials comprise graphite, molybdenum disulfide, tungsten disulfide, or boron nitride; and is also provided with
Wherein the lubricant is configured to remain on the wire electrode that has been coated with the lubricant without melting when the pre-heater heats the wire electrode to between 500 degrees celsius and 900 degrees celsius.
2. The lubricant of claim 1, wherein the lubricant is a powder.
3. The lubricant of claim 1, wherein the lubricant is a liquid.
4. A lubricant according to claim 3, wherein the lubricant comprises 2-propanol or water as solvent.
5. The lubricant of claim 4, wherein the lubricant further comprises up to 25wt% by weight of one or more binders, dispersants, surfactants, or petroleum distillates.
6. The lubricant according to claim 5, wherein the binder is a cellulose resin or a thermoplastic resin.
7. A preheated welding wire system, comprising:
a wire electrode; and
a pre-heater configured to heat the wire electrode to between 500 degrees celsius and 900 degrees celsius;
wherein the wire electrode is coated in a high temperature lubricant to form a coating on the outer surface of the wire electrode, and
wherein the coating is configured to remain on the wire electrode without melting when the pre-heater heats the wire electrode to between 500 degrees celsius and 900 degrees celsius.
8. The preheated welding wire system of claim 7, wherein the high temperature lubricant comprises one or more high melting point materials, and wherein the one or more high melting point materials comprise graphite, molybdenum disulfide, tungsten disulfide, or boron nitride.
9. The preheated welding wire system of claim 7, wherein the high-temperature lubricant is applied to the wire electrode in powder form.
10. The preheated welding wire system of claim 7, wherein the high-temperature lubricant is applied to the wire electrode in liquid form.
11. The preheated welding wire system of claim 10, wherein the high temperature lubricant comprises 2-propanol or water as a solvent.
12. The preheated welding wire system of claim 10, wherein a concentration of the one or more high-melting point materials in the high-temperature lubricant is in a range from 0.5wt.% to 30 wt.%.
13. The preheated welding wire system of claim 10, wherein the high temperature lubricant further comprises up to 25wt% of at least one binder, dispersant, surfactant, or petroleum distillate.
14. A method for manufacturing a lubricated wire electrode, the method comprising the steps of:
forming a welding wire electrode; and
applying a high temperature lubricant to the wire electrode to form a coating on an outer surface of the wire electrode;
wherein the coating is configured to remain on the wire electrode without melting when the wire electrode is preheated to between 500 degrees celsius and 900 degrees celsius.
15. The method of claim 14, wherein the high temperature lubricant comprises one or more high melting point materials, and wherein the one or more high melting point materials comprise graphite, molybdenum disulfide, tungsten disulfide, or boron nitride.
16. The method of claim 14 wherein the high temperature lubricant is applied to the wire electrode in powder form.
17. The method of claim 14, further comprising the step of: the high temperature lubricant is suspended or dissolved in a liquid prior to application to the wire electrode.
18. The method of claim 17, wherein the lubricant comprises 2-propanol or water as a solvent.
19. The method of claim 17, wherein the concentration of the one or more high melting point materials in the lubricant is in a range from 0.5wt.% to 30 wt.%.
20. The method of claim 17, wherein the lubricant further comprises up to 25wt% of at least one binder, dispersant, surfactant, or petroleum distillate.
CN202311321590.3A 2022-10-14 2023-10-12 High temperature wire lubricant for preheated wire system and related method Pending CN117884802A (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US63/416,320 2022-10-14
US18/377,543 US20240123555A1 (en) 2022-10-14 2023-10-06 High temperature welding wire lubricant for preheated welding wire system and related methods
US18/377,543 2023-10-06

Publications (1)

Publication Number Publication Date
CN117884802A true CN117884802A (en) 2024-04-16

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CN202311321590.3A Pending CN117884802A (en) 2022-10-14 2023-10-12 High temperature wire lubricant for preheated wire system and related method

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