A hybrid welding system and method with overall electrical insulation and thermal conductivity and cooling

Abstract

A hybrid welding system that comprises a plasma welding unit (Plasma unit) and a MIG welding unit with a non-consumable electrode (cathode) and a consumable electrode, where the electrodes are positioned relative each other so that their respective axes form an angle α so that arcs initiated from the electrodes intersect a workpiece plane to define an impingement point distance D. A gas shielding nozzle forms a confined space around the tips of the electrodes, accommodates and covers them and keeps the angle α between them inside the confined space and impingement point distance D. The Plasma unit comprises thermal cooling means with a channel surrounding the cathode down to the nozzle and tip of the cathode and also the tip of the MIG electrode around the gas shielding nozzle. A heat absorbing fluid circulates inside the cooling channel, especially at the electrodes tips that concentrate the highest amount of heat at highest temperature. Electrically insulating porous ceramic cover and filler surround the cathode. Oval shaped magnetic horns control the distance D and prevent the electrical arcs of the two electrodes from deflecting from and brought closer to each other. This prevents disturbances in the melting pool and controls the deposition rate.

Dependencies are inferred from the claim text.