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US 2011/0297658 A1Published application
Method and system to start and use combination filler wire feed and high intensity energy source for welding
AssigneeLincoln Global, Inc.
InventorsSteven R. Peters, Paul E. Denney, Terrance J. Wikberg, Michael D. Latessa
Life of this patent
Estimating the term…
Abstract
A method and system to weld or join workpieces employing a high intensity energy source to create a weld puddle and at least one resistive filler wire which is heated to at or near its melting temperature and deposited into the weld puddle.
Claims14
A method of welding, comprising:
- creating a weld puddle with at least one high intensity energy source;
- determining an upper threshold value;
- heating at least one filler wire with a filler wire heating signal from a power source to a temperature such that said filler wire melts in said weld puddle when said filler wire is in contact with said weld puddle;
- directing said filler wire to said weld puddle such that said filler wire maintains contact with said weld puddle during a welding operation;
- monitoring a feedback from said filler wire heating signal;
- shutting off said filler wire heating signal when said upper threshold value is reached by said filler wire heating signal such that no arc is generated between said filler wire and said weld puddle;
- and
- turning on said filler wire heating signal to continue heating said filler wire.
5 more elements
A method of welding, comprising:
- creating a weld puddle in a workpiece with at least one high intensity energy source;
- heating at least one filler wire with a filler wire heating signal from a power source to a temperature such that said filler wire melts in said weld puddle;
- directing said filler wire to said weld puddle such that said filler wire maintains contact with said weld puddle during a welding operation;
- and
- maintaining said filler wire heating signal at a level below an upper threshold level such that no arc is created between said weld puddle and said filler wire,
- wherein no shielding is employed during the welding operation.
3 more elements
A method of welding, comprising:
- creating a weld puddle in a workpiece having a coating on a surface thereof with at least one high intensity energy source, wherein said coating is not removed prior to the creation of said weld puddle;
- heating at least one filler wire with a filler wire heating signal from a power source to a temperature such that said filler wire melts in said weld puddle;
- directing said filler wire to said weld puddle such that said filler wire maintains contact with said weld puddle during a welding operation;
- and
- maintaining said filler wire heating signal at a level below an upper threshold level such that no arc is created between said weld puddle and said filler wire,
- wherein no shielding is employed during the welding operation.
3 more elements
A method of welding, comprising:
- creating a weld puddle in a workpiece having a coating on a surface thereof with at least one high intensity energy source, wherein said coating is not removed prior to the creation of said weld puddle;
- heating a filler wire with a filler wire heating signal from a power source to a temperature such that said filler wire melts in said weld puddle;
- directing said filler wire to said weld puddle such that said filler wire maintains contact with said weld puddle during a welding operation;
- and
- maintaining said filler wire heating signal at a level below an upper threshold level such that no arc is created between said weld puddle and said filler wire;
- and welding at a rate of at least 50 in/min,
- wherein a final weld created by said method of welding has a cross-section porosity ratio in the range of 0 to 20%, a length porosity ratio in the range of 0 to 20%, and a spatter factor in the range of 0 to 1, where said spatter factor is the ratio of spatter (mg) to consumed filler wire (Kg).
4 more elements
A method of welding, comprising:
- creating a weld puddle in a workpiece with at least one high intensity energy source;
- heating a filler wire with a filler wire heating signal from a power source to a temperature such that said filler wire melts in said weld puddle;
- directing said filler wire to said weld puddle such that said filler wire maintains contact with said weld puddle during a welding operation;
- and
- maintaining said filler wire heating signal at a level below an upper threshold level such that no arc is created between said weld puddle and said filler wire;
- and welding at a rate of at least 50 in/min,
- wherein a final weld created by said method of welding has a cross-section porosity ratio in the range of 0 to 20%, a length porosity ratio in the range of 0 to 20%, and a spatter factor in the range of 0 to 1, where said spatter factor is the ratio of spatter (mg) to consumed filler wire (Kg).
4 more elements
A method of welding, comprising:
- directing a first high intensity heat to a first workpiece to melt at least a portion of a surface of said first workpiece;
- directing a second high intensity heat to a second workpiece to melt at least a portion of a surface of said second workpiece, wherein said first and second workpieces create a joint to be welded;
- directing at least one filler wire to said joint such that said at least one filler wire maintains contact with at least one of said portions during a welding operation;
- heating said at least one filler wire with a filler wire heating signal from a power source to a temperature such that said at least one filler wire melts in said joint during welding;
- and;
- maintaining said filler wire heating signal at a level below an upper threshold level such that no arc is created between said filler wire and said joint,
- wherein said first workpiece has a different material composition than said second workpiece.
4 more elements
A method of welding, comprising:
- directing a first high intensity energy beam to a workpiece to generate a portion of a weld puddle, where said first high intensity energy beam has a first energy density and a first shape at said weld puddle;
- directing a second high intensity energy beam to said workpiece to generate another portion of said weld puddle, where said second high intensity energy beam has a second energy density and a second shape at said weld puddle, and where at least one of said second energy density and shape is different from said first energy density and shape;
- determining an upper threshold value;
- heating at least one filler wire with a filler wire heating signal from a power source to a temperature such that said filler wire melts in said weld puddle;
- directing said filler wire to said weld puddle such that said filler wire maintains contact with said weld puddle during a welding operation;
- monitoring a feedback from said filler wire heating signal;
- shutting off said filler wire heating signal when said upper threshold value is reached by said filler wire heating signal such that no arc is generated between said filler wire and said weld puddle;
- and
- turning on said filler wire heating signal to continue heating said filler wire.
6 more elements
A method of welding, comprising:
- creating a weld puddle with at least one high intensity energy source;
- determining an upper threshold voltage level for a filler wire heating signal;
- heating at least one filler wire with said filler wire heating signal from a power source to a temperature such that said filler wire melts in said weld puddle;
- directing said filler wire to said weld puddle such that said filler wire maintains contact with said weld puddle during a welding operation;
- monitoring a voltage level of said filler wire heating signal;
- shutting off said filler wire heating signal when said monitored voltage level reaches said upper threshold voltage level such that no arc is generated between said filler wire and said weld puddle;
- and
- turning on said filler wire heating signal to continue heating said filler wire.
5 more elements
A method of welding, comprising:
- creating a weld puddle with at least one high intensity energy source;
- determining a heating power level and an upper threshold voltage level for a filler wire heating signal;
- heating at least one filler wire with said filler wire heating signal from a power source to a temperature such that said filler wire melts in said weld puddle;
- directing said filler wire to said weld puddle such that said filler wire maintains contact with said weld puddle during a welding operation;
- monitoring a voltage level of said filler wire heating signal;
- shutting off said filler wire heating signal when said monitored voltage level reaches said upper threshold voltage level such that no arc is generated between said filler wire and said weld puddle;
- and
- turning on said filler wire heating signal to continue heating said filler wire.
5 more elements
A method of welding, comprising:
- creating a weld puddle in an open root weld joint with at least one high intensity energy source;
- heating at least one filler wire with said a wire heating signal from a power source to a temperature such that said filler wire melts in said weld puddle when said filler wire is in contact with said weld puddle;
- directing said filler wire to said weld puddle such that said filler wire maintains contact with said weld puddle during a welding operation;
- monitoring a feedback from said filler wire heating signal;
- shutting off said filler wire heating signal when an upper threshold value is reached by said filler wire heating signal such that no arc is generated between said filler wire and said weld puddle;
- and
- turning on said filler wire heating signal to continue heating said filler wire,
- wherein said open root weld joint is created by at least two workpieces having a gap therebetween.
5 more elements
A method of welding, comprising:
- creating a weld puddle in an open root weld joint with at least one high intensity energy source;
- heating at least one filler wire with a filler wire heating signal from a power source to a temperature such that said filler wire melts in said weld puddle when said filler wire is in contact with said weld puddle;
- directing said filler wire to said weld puddle such that said filler wire maintains contact with said weld puddle during a welding operation;
- monitoring a feedback from said filler wire heating signal;
- shutting off said filler wire heating signal when said upper threshold value is reached by said filler wire heating signal such that no arc is generated between said filler wire and said weld puddle;
- and
- turning on said filler wire heating signal to continue heating said filler wire,
- wherein said open root weld joint is created by at least two workpieces having a gap therebetween, and
- wherein said workpieces have a thickness of at least 1 inch, and said gap has a maximum width in the range of 1.5 to 2 times the diameter of said filler wire.
6 more elements
A method of welding, comprising:
- creating a weld puddle with at least one high intensity energy source;
- heating at least one filler wire with a filler wire heating signal from a power source to a temperature such that said filler wire melts in said weld puddle;
- directing said filler wire to said weld puddle such that said filler wire maintains contact with said weld puddle during a welding operation;
- monitoring a feedback from said filler wire heating signal;
- shutting off said filler wire heating signal when an arc is detected between a distal end of said filler wire and said weld puddle such that said arc exists between said filler wire and said weld puddle for no more than 10 ms;
- and
- turning on said filler wire heating signal to continue heating said filler wire.
4 more elements
A method of welding, comprising:
- creating a weld puddle with at least one high intensity energy source;
- determining an upper threshold value and a background value;
- heating at least one filler wire with a filler wire heating signal from a power source to a temperature such that said filler wire melts in said weld puddle;
- directing said filler wire to said weld puddle such that said filler wire maintains contact with said weld puddle during a welding operation;
- monitoring a feedback from said filler wire heating signal;
- ramping down said filler wire heating signal to said background value when said upper threshold value is reached by said filler wire heating signal such that no arc is generated between said filler wire and said weld puddle;
- and
- turning on said filler wire heating signal to continue heating said filler wire.
5 more elements
A method of welding, comprising:
- creating a weld puddle with at least one high intensity energy source;
- heating at least one filler wire with a filler wire heating signal from a power source to a temperature such that said filler wire melts in said weld puddle;
- directing said filler wire to said weld puddle such that said filler wire maintains contact with said weld puddle during a welding operation;
- monitoring a feedback from said filler wire heating signal;
- shutting off said filler wire heating signal for a predetermined duration when said upper threshold value is reached by said filler wire heating signal such that no arc is generated between said filler wire and said weld puddle;
- and
- turning on said filler wire heating signal to continue heating said filler wire.
4 more elements
Dependencies are inferred from the claim text.