WO2015124977A1 - Procédé et système de soudage au fil chaud et à l'arc hybride et système utilisant un positionnement décalé - Google Patents

Procédé et système de soudage au fil chaud et à l'arc hybride et système utilisant un positionnement décalé Download PDF

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Publication number
WO2015124977A1
WO2015124977A1 PCT/IB2015/000089 IB2015000089W WO2015124977A1 WO 2015124977 A1 WO2015124977 A1 WO 2015124977A1 IB 2015000089 W IB2015000089 W IB 2015000089W WO 2015124977 A1 WO2015124977 A1 WO 2015124977A1
Authority
WO
WIPO (PCT)
Prior art keywords
wire
arc
signal
current
consumable
Prior art date
Application number
PCT/IB2015/000089
Other languages
English (en)
Inventor
Steven R. Peters
William T. Matthews
Kent JOHNS
Original Assignee
Lincoln Global, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US14/504,807 external-priority patent/US20150014283A1/en
Application filed by Lincoln Global, Inc. filed Critical Lincoln Global, Inc.
Publication of WO2015124977A1 publication Critical patent/WO2015124977A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/02—Seam welding; Backing means; Inserts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/09—Arrangements or circuits for arc welding with pulsed current or voltage
    • B23K9/091—Arrangements or circuits for arc welding with pulsed current or voltage characterised by the circuits
    • B23K9/093—Arrangements or circuits for arc welding with pulsed current or voltage characterised by the circuits the frequency of the pulses produced being modulatable
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/095—Monitoring or automatic control of welding parameters
    • B23K9/0956—Monitoring or automatic control of welding parameters using sensing means, e.g. optical
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/10—Other electric circuits therefor; Protective circuits; Remote controls
    • B23K9/1093—Consumable electrode or filler wire preheat circuits

Definitions

  • FIG. 3 illustrates a flow chart of an embodiment of a post start-up method used by the system of FIG. 1 ;
  • the feeder subsystem may be capable of simultaneously providing one or more wires, in accordance with certain other embodiments of the present invention.
  • a first wire may be used for hard-facing and/or providing corrosion resistance to the workpiece
  • a second wire may be used to add structure to the workpiece.
  • the sensing and current control subsystem 195 is capable of sensing when the resistive filler wire 140 is in contact with the workpiece 115 and is operatively connected to the hot wire power supply 170 to be further capable of controlling the flow of current through the resistive filler wire 140 in response to the sensing, as is described in more detail later herein.
  • the sensing and current controller 195 may be an integral part of the hot wire power supply 170 and/or the arc welding power supply 130.
  • FIG. 3 illustrates a flow chart of an embodiment of a post start-up method 300 used by the system 100 of FIG. 1 A.
  • step 310 move the arc welding operation and at least one resistive filler wire 140 along a workpiece 115 such that the distal end of the at least one resistive filler wire 140 melts in the created puddle and is deposited onto the workpiece 1 5 as the at least one resistive filler wire 140 is fed toward the workpiece 115.
  • FIG. 5 illustrates a second exemplary embodiment of a pair of voltage and current waveforms 510 and 520, respectively, associated with the post start-up method of FIG. 3.
  • the voltage waveform 510 is measured by the sensing and current controller 195 between the contact tube 160 and the workpiece 115.
  • the current waveform 520 is measured by the sensing and current controller 195 through the wire 140 and workpiece 15.
  • Such advantages include, but are not limited to, reduced total heat input resulting in low distortion of the work- piece, very high welding travel speeds, very low spatter rates, welding plated or coated materials at high speeds with little or no spatter and welding complex materials at high speeds.
  • very high welding speeds as compared to arc welding, can be obtained using coated workpieces, which typically require significant prep work and are much slower welding processes using arc welding methods.
  • the following discussion will focus on welding galvanized workpieces. Galvanization of metal is used in increase the corrosion resistance of the metal and is desirable in many industrial applications. However, conventional welding of galvanized workpieces can be problematic.
  • the current pulses 721 are separated by a background level 723 of a lesser current level.
  • the hot wire current 720 may not have a background current level between pulses, where the current is dropped to zero in between pulses.
  • the background 723 for the hot wire current can be low (compared to typical background current levels for welding waveforms) and can be in the range of 5 to 15% of the peak current level for the hot-wire pulses 721.
  • the waveform 720 is used to heat the wire 140 to at or near its melting temperature and uses the pulses 721 and background to heat the wire 140 through resistance heating. As shown in Figure 7A the pulses 711 and 721 from the respective current waveforms are synchronized such that they are in phase with each other.
  • Figure 7B depicts waveforms from another exemplary embodiment of the present invention.
  • the heating current waveform 720 is controlled/synchronized such that the pulses 721 are in-phase with the pulses 711 and the pulses have the same pulse width. That is, the pulses 711/721 have the same duration their respective peak current levels.
  • the pulses can have a different pulse width.
  • the peak current duration for the hot-wire pulses 721 are within +/-10% of the peak current duration of the welding pulses 711. In other exemplary embodiments, the difference is +/- 5%.
  • embodiments of the waveforms shown in Figure 7B use the same frequency as well.
  • the heating current is shown as a pulsed current, for some exemplary embodiments the heating current can be constant power as described previously.
  • the hot-wire current can also be a pulsed heating power, constant voltage, a sloped output and/or a joules/time based output.
  • the filler wire 140 - which is resistance heated as described previously - is directed to the weld puddle to provide the needed filler material for the weld bead.
  • the filler wire 140 makes contact and is plunged into the weld puddle during the welding process. This is because this process does not use a welding arc to transfer the filler wire 140 but rather simply melts the filler wire into the weld puddle.
  • embodiments of the present invention can have high material deposition rates at high speeds compared to known arc welding systems.
  • Spatter Factor (spatter weight (mg)/consumed filler wire weight (Kg))
  • the power supply 170 monitors the voltage and as the voltage reaches or approaches a voltage value at some point above 0 volts the power supply 170 stops flowing current to the wire 140 to ensure that no arc is created.
  • the voltage threshold level will typically vary, at least in part, due to the type of welding electrode 40 being used.
  • the instantaneous arc detection voltage level can be in the range of 12 to 19 volts.
  • the power supply 170 contains circuits which monitor the rate of change of the heating voltage (dv/dt), current (di/dt), and or power (dp/dt). Such circuits are often called premonition circuits and their general construction is known. In such embodiments, the rate of change of the voltage, current and/or power is monitored such that if the rate of change exceeds a certain threshold the heating current to the wire 140 is turned off.
  • the power supply 170 rather than shutting off the heating current when the threshold level is detected, the power supply 170 reduces the heating current to a non-arc generation level.
  • a level can be a background current level where no arc will be generated if the wire is separated from the weld puddle.
  • an exemplary embodiment of the present invention can have a non-arc generation current level in the range of 5 to 25 amps, where once an arc generation is detected or predicted, or an upper threshold (discussed above) is reached, the power supply 170 drops the heating current from its operating level to the non-arc generation level for either a predetermined amount of time (for example, 1 to 10 ms) or until the detected voltage, current, power, and/or resistance drops below the upper threshold.
  • This non-arc generation threshold can be a voltage level, current level, resistance level, and/or a power level.
  • Figures 1 A-C depict exemplary current and voltage waveforms utilized in embodiments of the present invention for the hot wire 140. Each of these waveforms will be discussed in turn.
  • Figure 11 A shows the voltage and current waveforms for an embodiment where the filler wire 140 touches the weld puddle after the power supply output is turned back on - after an arc detection event. As shown, the output voltage of the power supply was at some operational level below a determined threshold (9 volts) and then increases to this threshold during welding.
  • the operational level can be a determined level based on various input parameters (discussed previously) and can be a set operational voltage, current and/or power level.
  • Figure 11B is similar to that described above, except that the filler wire 140 is contacting the weld puddle when the output of the power supply is increased. In such a situation either the wire never left the weld puddle or the wire was contacted with the weld puddle prior to point C.
  • Figure 11 B shows points C and D together because the wire is in contact with the puddle when the output is turned back on. Thus both the current and voltage increase to the desired operational setting at point E.
  • the sensing and control unit 195 can be coupled to a feed force detection unit (not shown) which is coupled to the wire feeding mechanism (see 150 in Figure 1 ).
  • the feed force detection units are known and detect the feed force being applied to the wire 140 as it is being fed to the workpiece 115.
  • a detection unit can monitor the torque being applied by a wire feeding motor in the wire feeder 150. If the wire 140 passes through the molten weld puddle without fully melting it will contact a solid portion of the workpiece and such contact will cause the feed force to increase as the motor is trying to maintain a set feed rate. This increase in force/torque can be detected and relayed to the control 195 which utilizes this information to adjust the voltage, current and/or power to the wire 140 to ensure proper melting of the wire 140 in the puddle.
  • the wire is not constantly fed into the weld puddle, but can be done so intermittently based on a desired weld profile.
  • the versatility of various embodiments of the present invention allows either an operator or the control unit 195 to start and stop feeding the wire 140 into the puddle as desired.

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Mechanical Engineering (AREA)
  • Arc Welding In General (AREA)

Abstract

L'invention concerne un procédé et un système (100, 1200) permettant de souder ou d'assembler des pièces revêtues (115, W1, W2) à l'aide d'une opération de soudage à l'arc et d'au moins une opération de soudage au fil chaud (140) au moyen d'un fil chauffé par résistance. Chacune des opérations de soudage à l'arc et au fil chaud est dirigée vers le même bain (P). Cependant, l'opération de soudage à l'arc est décalée hors du joint à partir de l'opération de soudage au fil chaud, le fil chaud étant dirigé dans le joint.
PCT/IB2015/000089 2014-02-21 2015-01-29 Procédé et système de soudage au fil chaud et à l'arc hybride et système utilisant un positionnement décalé WO2015124977A1 (fr)

Applications Claiming Priority (6)

Application Number Priority Date Filing Date Title
US201461942887P 2014-02-21 2014-02-21
US61/942,887 2014-02-21
US201461943633P 2014-02-24 2014-02-24
US61/943,633 2014-02-24
US14/504,807 2014-10-02
US14/504,807 US20150014283A1 (en) 2009-01-13 2014-10-02 Hybrid Hot-Wire And Arc Welding Method And System Using Offset Positioning

Publications (1)

Publication Number Publication Date
WO2015124977A1 true WO2015124977A1 (fr) 2015-08-27

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Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN108145332A (zh) * 2017-12-12 2018-06-12 南京理工大学 机器人电弧增减材成形装置及方法
CN109773310A (zh) * 2019-03-12 2019-05-21 江苏顺发电热材料有限公司 激光诱导变极性方波钨极氩弧焊接小孔径薄壁管的方法
CN111344098A (zh) * 2017-06-09 2020-06-26 伊利诺斯工具制品有限公司 控制焊接电极预热的系统和方法
CN114101856A (zh) * 2021-12-10 2022-03-01 浙江巴顿焊接技术研究院 一种载流热填丝的焊接方法
US11980977B2 (en) 2017-06-09 2024-05-14 Illinois Tool Works Inc. Systems, methods, and apparatus to control weld current in a preheating system

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4866247A (en) 1986-12-11 1989-09-12 The Lincoln Electric Company Apparatus and method of short circuiting arc welding
US5148001A (en) 1986-12-11 1992-09-15 The Lincoln Electric Company System and method of short circuiting arc welding
US6051810A (en) 1998-01-09 2000-04-18 Lincoln Global, Inc. Short circuit welder
US7109439B2 (en) 2004-02-23 2006-09-19 Lincoln Global, Inc. Short circuit arc welder and method of controlling same
US20100096373A1 (en) 2005-09-15 2010-04-22 Lincoln Global, Inc. System and method for controlling a hybrid welding process
US20130043219A1 (en) * 2009-01-13 2013-02-21 Lincoln Global, Inc. Method and system to start and use combination filler wire feed and high intensity energy source for welding
WO2014009800A2 (fr) * 2012-07-12 2014-01-16 Lincoln Global, Inc. Procédé et système pour démarrer et utiliser une alimentation en fil de charge et une source d'intensité élevée en combinaison pour soudage

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4866247A (en) 1986-12-11 1989-09-12 The Lincoln Electric Company Apparatus and method of short circuiting arc welding
US5148001A (en) 1986-12-11 1992-09-15 The Lincoln Electric Company System and method of short circuiting arc welding
US6051810A (en) 1998-01-09 2000-04-18 Lincoln Global, Inc. Short circuit welder
US7109439B2 (en) 2004-02-23 2006-09-19 Lincoln Global, Inc. Short circuit arc welder and method of controlling same
US20100096373A1 (en) 2005-09-15 2010-04-22 Lincoln Global, Inc. System and method for controlling a hybrid welding process
US20130043219A1 (en) * 2009-01-13 2013-02-21 Lincoln Global, Inc. Method and system to start and use combination filler wire feed and high intensity energy source for welding
WO2014009800A2 (fr) * 2012-07-12 2014-01-16 Lincoln Global, Inc. Procédé et système pour démarrer et utiliser une alimentation en fil de charge et une source d'intensité élevée en combinaison pour soudage

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN111344098A (zh) * 2017-06-09 2020-06-26 伊利诺斯工具制品有限公司 控制焊接电极预热的系统和方法
US11344964B2 (en) 2017-06-09 2022-05-31 Illinois Tool Works Inc. Systems, methods, and apparatus to control welding electrode preheating
CN111344098B (zh) * 2017-06-09 2022-07-08 伊利诺斯工具制品有限公司 控制焊接电极预热的系统和方法
US11980977B2 (en) 2017-06-09 2024-05-14 Illinois Tool Works Inc. Systems, methods, and apparatus to control weld current in a preheating system
CN108145332A (zh) * 2017-12-12 2018-06-12 南京理工大学 机器人电弧增减材成形装置及方法
CN109773310A (zh) * 2019-03-12 2019-05-21 江苏顺发电热材料有限公司 激光诱导变极性方波钨极氩弧焊接小孔径薄壁管的方法
CN114101856A (zh) * 2021-12-10 2022-03-01 浙江巴顿焊接技术研究院 一种载流热填丝的焊接方法

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