Method and apparatus for joining components with multiple filler materials

A multiple-filler-material guide nozzle assembly having a non-circular cross-sectional shape adapted to fit in a very-reduced-width weld groove, comprising:

• a first nozzle for guiding a first filler material to a first desired location inside the weld groove, said first nozzle having a first outlet for said first filler material at a distal end thereof;
• a second nozzle for guiding a second filler material to a second desired location inside the weld groove, said second nozzle having a second outlet for said second filler material at a distal end thereof;
• and
• means for maintaining a fixed positional relationship between said first and second outlets of said first and second nozzles such that said first and second filler materials exit said first and second outlets respectively at a predetermined angle with respect to each other, wherein said means for maintaining a fixed positional relationship between said first and second outlets of said first and second nozzles comprise a non-consumable electrode blade.

A system for welding in a very-reduced-width weld groove, comprising:

• a welding torch;
• a welding electrode extending from said welding torch and adapted to fit in the weld groove;
• and
• a multiple-filler-material guide nozzle assembly having a non-circular cross-sectional shape adapted to fit in the weld groove, comprising:
• a first nozzle for guiding a first filler material to a first desired location inside the weld groove, said first nozzle having a first outlet for said first filler material at a distal end thereof;
• a second nozzle for guiding a second filler material to a second desired location inside the weld groove, said second nozzle having a second outlet for said second filler material at a distal end thereof;
• and
• support means for maintaining a fixed positional relationship between a portion of said first nozzle which penetrates into the weld groove and a portion of said second nozzle which penetrates into the weld groove such that said portions of said first and second nozzles penetrating into the weld groove generally lie in a plane, wherein said nozzle assembly is configured and dimensioned to fit in the weld groove only when said plane is generally perpendicular to a width direction of the weld groove.

A filler material guide nozzle assembly adapted to fit in a weld groove, comprising:

• a first curved nozzle for guiding a distal end of a first unwound filler wire to a first desired location inside the weld groove, said first curved nozzle having an outlet for said first unwound filler wire at a distal end thereof;
• a second curved nozzle for guiding a distal end of a second unwound filler wire to a second desired location inside the weld groove, said/second curved nozzle having an outlet for said second unwound filler wire at a distal end thereof;
• and
• support means for maintaining a fixed positional relationship between a portion of said first curved nozzle which penetrates into the weld groove and a portion of said second curved nozzle which penetrates into the weld groove.

A method for welding in a very-reduced-width weld groove having a bottom, comprising the steps of:

• inserting a welding electrode in the weld groove, said welding electrode having a tip separated from the bottom of the weld groove by a gap;
• generating an electric arc across the gap;
• feeding a first filler material to a first locus in the weld groove, said first filler material at said first locus being melted by heat from said arc;
• feeding a second filler material to a second locus in the weld groove, said second filler material at said second locus being melted by heat from said arc, said first and second loci being situated such that said molten first and second filler materials form a weld puddle;
• and
• allowing said weld puddle of molten first and second filler materials to fuse;
• wherein said first and second filler materials are different in composition.

A system for welding in a very-reduced-width weld groove, comprising:

• a welding torch;
• a welding electrode extending from said welding torch and adapted to fit in the weld groove, said welding electrode comprising a tip;
• a first curved filler material guide nozzle adapted to fit in the weld groove, said first curved guide nozzle having an outlet for a first filler material at a distal end thereof;
• a second curved filler material guide nozzle adapted to fit in the weld groove, said second curved guide nozzle having an outlet for a second filler material at a distal end thereof;
• and
• support means for maintaining a fixed positional relationship between a portion of said first curved filler material guide nozzle which penetrates into the weld groove and a portion of said second curved filler material nozzle which penetrates into the weld groove such that said portions of said first and second curved filler material guide nozzles generally lie in a plane, wherein said nozzle assembly is configured and dimensioned to fit in the weld groove only when said plane is generally perpendicular to a width direction of the weld groove.

A system for welding in a very-reduced-width weld groove, comprising:

• a welding torch;
• a welding electrode extending from said welding torch and adapted to fit in the weld groove, said electrode having a tip;
• a first nozzle extending into the weld groove for guiding a first filler material toward a point of convergence, said first nozzle having a first outlet for said first filler material at a distal end thereof;
• and
• a second nozzle extending into the weld groove for guiding a second filler material toward said point of convergence, said second nozzle having a second outlet for said second filler material at a distal end thereof,
• wherein said first and second filler materials are concurrently melted by an arc from said electrode tip during feeding toward said point of convergence.