CN113134665A - Flux-cored wire TIG arc welding and additive manufacturing molten drop transition control method and device - Google Patents
Flux-cored wire TIG arc welding and additive manufacturing molten drop transition control method and device Download PDFInfo
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- CN113134665A CN113134665A CN202010045233.9A CN202010045233A CN113134665A CN 113134665 A CN113134665 A CN 113134665A CN 202010045233 A CN202010045233 A CN 202010045233A CN 113134665 A CN113134665 A CN 113134665A
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- 230000007704 transition Effects 0.000 title claims abstract description 88
- 238000003466 welding Methods 0.000 title claims abstract description 64
- 239000000654 additive Substances 0.000 title claims abstract description 26
- 230000000996 additive effect Effects 0.000 title claims abstract description 26
- 238000000034 method Methods 0.000 title claims abstract description 25
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 22
- 238000005070 sampling Methods 0.000 claims abstract description 20
- 238000010891 electric arc Methods 0.000 claims abstract description 9
- 230000004907 flux Effects 0.000 claims description 7
- 238000012546 transfer Methods 0.000 claims description 2
- 239000000463 material Substances 0.000 claims 1
- 230000008569 process Effects 0.000 abstract description 15
- 238000005429 filling process Methods 0.000 abstract description 2
- 239000002893 slag Substances 0.000 description 5
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 4
- 229910052721 tungsten Inorganic materials 0.000 description 4
- 239000010937 tungsten Substances 0.000 description 4
- 230000008901 benefit Effects 0.000 description 3
- 238000010586 diagram Methods 0.000 description 3
- 239000007788 liquid Substances 0.000 description 3
- 239000007787 solid Substances 0.000 description 3
- 230000009471 action Effects 0.000 description 2
- 239000011324 bead Substances 0.000 description 2
- 238000002474 experimental method Methods 0.000 description 2
- 238000012360 testing method Methods 0.000 description 2
- 238000004458 analytical method Methods 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 230000004927 fusion Effects 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000011897 real-time detection Methods 0.000 description 1
- 238000009491 slugging Methods 0.000 description 1
- 230000003746 surface roughness Effects 0.000 description 1
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Classifications
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- 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
- B23K9/16—Arc welding or cutting making use of shielding gas
- B23K9/167—Arc welding or cutting making use of shielding gas and of a non-consumable electrode
-
- 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
- B23K9/1006—Power supply
- B23K9/1043—Power supply characterised by the electric circuit
-
- 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
- B23K9/12—Automatic feeding or moving of electrodes or work for spot or seam welding or cutting
- B23K9/133—Means for feeding electrodes, e.g. drums, rolls, motors
- B23K9/1336—Driving means
-
- 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
- B23K9/32—Accessories
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- Engineering & Computer Science (AREA)
- Physics & Mathematics (AREA)
- Plasma & Fusion (AREA)
- Mechanical Engineering (AREA)
- Arc Welding In General (AREA)
- Nonmetallic Welding Materials (AREA)
Abstract
The invention discloses a flux-cored wire TIG electric arc welding and additive manufacturing molten drop transition control method and a device, wherein a flux-cored wire TIG welding or additive manufacturing process is to feed a welding wire into a molten pool, the welding wire is melted in the molten pool to form contact transition, in order to ensure the contact transition, a wire is externally connected to a wire feeding nozzle and a workpiece and is connected with a power supply and an electronic device, a voltage signal sampling device is arranged in a circuit to collect voltage signals between the welding wire and the workpiece, voltage feedback control is carried out, the wire feeding speed is adjusted, different transition modes are realized, the circuit conduction conditions reflected by the collected voltage signals are different, the judgment result is used for adjusting the wire feeding speed, the signals are transmitted to a wire feeding motor driving circuit, and the wire feeding speed is adjusted to obtain a required molten drop transition mode. By using the technical scheme of the invention, the welding wire can be ensured to stably and stably complete the molten drop transition and wire filling processes in a contact transition (bridging transition) mode in the actual operation process.
Description
Technical Field
The invention belongs to the technical scheme in the field of welding and additive manufacturing processes, and mainly relates to a flux-cored wire TIG arc welding and additive manufacturing molten drop transition control method.
Background
The TIG electric arc is used for welding and additive manufacturing and has the advantages of stable electric arc, high forming quality, easy control of electric arc parameters, easy realization of automation and the like; at present, solid welding wires are mostly adopted in wire-filling TIG welding, wire-filling TIG welding or additive manufacturing of TIG electric arcs matched with flux-cored wires is rare, the flux-cored wires have the advantage of flexible regulation and control of components and tissues, the matching of the solid welding wires and the flux-cored wires has considerable advantages, and the solid welding wires are only required to be carried out in a stable and reliable droplet transfer mode.
The wire electrode spacing (the distance of the wire from the tungsten electrode axis on the workpiece surface) of flux cored wire fed TIG arc welding or additive manufacturing has a significant impact on the quality of the forming. When the distance between the filament poles is larger under a certain fixed wire feeding angle, the molten drop transition process is as shown in figure 1, and the molten drop transition process is characterized in that free molten drops are not formed and a liquid bridge exists between a welding wire and a molten pool, and the transition form is typical bridging transition, namely, the welding wire with a flux core is contacted with the molten pool to form the liquid bridge and flows into the molten pool after being melted; and as the distance between the filament poles is reduced, the transition form of the filament poles is obviously changed, one side of the welding wire, which is closer to the electric arc, is melted first, a slag column is formed below the molten drop due to the flux-cored slugging, the molten drop positioned in a high-temperature region is moved to one side, which is far away from the electric arc, of the tail end of the welding wire around the slag column after being formed, and then the molten drop is melted together with the slag column and then is contacted with a molten pool to generate the molten drop transition, as shown in fig. 2, the transition form is called slag column transition according to the characteristics of the transition process. The two transition modes are contact transition molten drop transition modes, which are stable molten drop transition modes mainly adopted by the invention, and the realization of the stable molten drop transition mode is ensured by properly controlling the wire feeding angle and the filament electrode distance and adopting proper measures.
When the distance between the filament electrodes is continuously reduced, the welding wire is melted at a position very close to the tungsten electrode, a welding wire droplet can not be contacted with a molten pool, the droplet gradually grows up under the continuous action of arc heat to form a liquid small ball to be hung at the tail end of the welding wire, and the droplet drops under the action of gravity along with the continuous growth of the droplet and drops into the molten pool in a free transition mode, as shown in figure 3; the molten drop transition mode has certain splashing, particularly causes tungsten electrode pollution, has poor stability and can be used only under the condition of special requirements. In the actual operation process, a certain wire feeding angle and a certain wire electrode distance are kept, so that contact transition can be maintained to a certain extent, but due to the fact that real-time detection of a transition mode is not available, contact transition or free transition is easily caused to pollute a tungsten electrode due to the fact that the contact transition is caused by the influence of various factors, or wire cutting is formed, so that a welding wire cannot be completely melted.
Disclosure of Invention
The invention aims to overcome the defects of the prior art, provides a control method for flux-cored wire TIG arc welding and additive manufacturing molten drop transition, and ensures that the welding wire stably and stably completes molten drop transition and wire filling processes in a contact transition (bridging transition) mode.
The technical purpose of the invention is realized by the following technical scheme.
Flux cored wire TIG electric arc welding and additive manufacturing molten drop transition control method, external circuit and access power and electron device on the wire feeding mouth and the work piece of waiting to weld set up voltage signal sampling device in the circuit, voltage signal sampling device links to each other with the control unit, and the control unit links to each other with a motor that send, wherein:
the voltage signal sampling device is used for collecting a voltage signal between the welding wire and a workpiece to be welded and transmitting the voltage signal to the control unit;
the control unit is used for receiving the voltage signal collected by the voltage signal sampling device, comparing the voltage signal with a preset value and outputting a control signal to the wire feeding motor according to a comparison result;
and the wire feeding motor is used for receiving the control signal output by the control unit and adjusting the wire feeding speed according to the control signal so as to realize the molten drop transition control.
And the control unit is a PLC or a singlechip or an analog circuit.
And an external circuit is arranged between the wire feeding nozzle and the workpiece to be welded, and the external circuit consists of a 5-24V external power supply and two resistors.
Moreover, when the molten drop transition is non-contact transition, the collected voltage signal is large and is in a range of 3-24V; when the molten drop transition is contact transition, the collected voltage signal is small and is in a range of 0-3V; and converting, analyzing and judging the acquired voltage signals by using the control unit, using the judgment result for adjusting the wire feeding speed, transmitting a control signal to the wire feeding motor, and adjusting the wire feeding speed to obtain a required molten drop transition mode.
Compared with the prior art, the technical scheme of the invention can ensure that the welding wire stably and stably finishes the processes of molten drop transition and wire filling in a contact transition (bridging transition) mode in the actual operation process.
Drawings
FIG. 1 is a schematic diagram of the bridging transition process of the present invention.
FIG. 2 is a schematic view of the slag column transition process in the present invention.
FIG. 3 is a schematic diagram of a non-contact transition process in the present invention.
Fig. 4 is a schematic structural diagram of an integrated wire-filling TIG welding gun used in the embodiment of the invention.
FIG. 5 is a schematic view of the voltage-wire feed speed control of the present invention.
FIG. 6 is a photograph of the weld profile at different wire feed speeds in accordance with the present invention.
Fig. 7 is a photograph of a multi-lane additive manufactured board sample resulting from a contact transition in accordance with the present invention.
Fig. 8 is a photograph of a multi-run additive manufactured board sample for a non-contact transition in accordance with the present invention.
FIG. 9 is a photograph of experimental voltage waveforms and welds in accordance with the present invention.
Detailed Description
The technical scheme of the invention is further explained by combining specific examples.
As shown in fig. 4, the structure of the welding gun for integrated wire-filling TIG welding is schematically illustrated, when welding or additive manufacturing is performed, the welding wire is fed into the molten pool by the flux-cored wire TIG welding or additive manufacturing process, and the welding wire is melted in the molten pool to form contact transition. In order to ensure that the contact transition is realized in the whole process, a flux-cored wire TIG electric arc welding and additive manufacturing molten drop transition control device is required to be additionally arranged, external leads are connected to a wire feeding nozzle and a workpiece and are connected with electronic devices (such as a power supply, a resistor and the like), a voltage signal sampling device is arranged in a circuit to collect voltage signals between the welding wire and the workpiece, and voltage feedback control is carried out to adjust the wire feeding speed. A voltage signal sampling device is arranged between the wire feeding nozzle and a workpiece to be welded; the voltage signal sampling device is connected with the control unit, and the control unit is connected with a wire feeding motor, such as a wire feeding motor driving circuit.
As shown in fig. 5 (flux-cored wire TIG arc welding and additive manufacturing molten drop transition control device), a voltage signal sampling device is used for collecting a voltage signal between a welding wire and a workpiece to be welded and transmitting the voltage signal to a control unit, and the control unit is a PLC, a single chip microcomputer or an analog circuit; the control unit is used for receiving the voltage signal collected by the voltage signal sampling device, comparing the voltage signal with a preset value and outputting a control signal to the wire feeding motor according to a comparison result; and the wire feeding motor is used for receiving the control signal output by the control unit and adjusting the wire feeding speed according to the control signal. Meanwhile, an external circuit, namely a 5-24V external power supply and two resistors, is arranged between the wire feeding nozzle and a workpiece (namely a weldment) to be welded.
Different transition modes are adopted, the collected voltage signals reflect different circuit conduction conditions, and when the molten drop transition is non-contact transition, the collected voltage signals are larger and are in a range of 3-24V; when the molten drop transition is contact transition, the collected voltage signal is small and is in a range of 0-3V; the acquired voltage signals are converted, analyzed and judged by a single chip microcomputer or a PLC or an analog judgment circuit, the judgment result is used for adjusting the wire feeding speed, the signals are transmitted to a wire feeding motor driving circuit, and the wire feeding speed is adjusted to obtain the required molten drop transition mode.
During welding, if the molten drops are in contact transition, short circuits are formed among the welding wire, the workpiece and the voltage sampling signal device; if the non-contact transition is carried out, a circuit break is formed, the voltage waveforms of the two conditions are obviously changed, the PLC or the single chip microcomputer or the analog circuit carries out analysis and judgment according to the voltage acquisition signal at the moment, the voltage signal is kept in a proper range between 0 and 3 volts, if the voltage signal is in the range, the molten drop transition mode is judged to be in a reliable contact transition process, the wire feeding speed is not required to be adjusted, and the welding system is ensured to operate stably; if the voltage signal is not in the range, the error result out of the range is fed back to a wire feeding motor driving circuit as an adjusting signal of the wire feeding speed, and the wire feeding machine changes the wire feeding speed to ensure that the welding wire is melted in the molten pool to form contact transition.
According to the experimental result, starting from a lower wire feeding speed (the lower wire feeding speed refers to the speed when the molten drop transition is just converted into contact transition from free transition), the range of the increase of the wire feeding speed can be increased by 30-40% on the basis of the wire feeding speed, and the stable contact transition can still be ensured; if the wire feeding speed is increased to a certain degree and the contact transition cannot be realized, the welding parameters are not matched properly, and the parameters need to be readjusted. The welding seams listed in the figure 6 are welded under the condition of TIG arc current 135A, the wire feeding speeds are respectively 160cm/min, 150cm/min, 140cm/min, 130cm/min and 120cm/min from top to bottom, other conditions are kept unchanged, the weld bead fusion width is increased, the rest height is reduced, the forming is more uniform when the wire feeding speed is high, but the welding seams are in contact transition, which shows that the wider range exists when the wire feeding speed is increased, the operability is realized, and the weld bead quality can be improved. Fig. 7 shows a plurality of additive manufactured board samples obtained by contact transition, and although the molten droplets are hung on the wall due to the occasional unstable wire feeding during the experiment, the whole is smooth. FIG. 8 is a sample of a non-contact transitional multi-pass additive manufactured board with high surface roughness and poor forming quality.
The flux-cored wire pulse TIG welding experiment is carried out in a laboratory, an oscilloscope is used as voltage signal sampling equipment, no welding wire is filled after arc striking, theoretically, the arc striking is equivalent to non-contact transition of the welding wire, a circuit is in an open circuit state, and the voltage is higher; after the welding wires are filled, the power supply is short-circuited, the voltage is reduced, and the waveform is close to a straight line; the wire filling is stopped again, the voltage is changed back to the state of the unfilled wire at the beginning, the test process goes through wire filling twice and is not filled with the wire for three times, and the test voltage waveform and the welding seam are shown in fig. 9. The change of the voltage waveform in the whole welding process completely corresponds to the wire filling condition, and the feasibility of the invention is verified.
According to the invention, the process parameters are adjusted, so that the effective control of flux-cored wire TIG arc welding and additive manufacturing molten drop transition can be realized. The invention has been described in an illustrative manner, and it is to be understood that any simple variations, modifications or other equivalent changes which can be made by one skilled in the art without departing from the spirit of the invention fall within the scope of the invention.
Claims (7)
1. Flux cored wire TIG electric arc welding and additive manufacturing molten drop transition control method, its characterized in that, external circuit and access power and electron device on the wire feeding mouth and the work piece of waiting to weld, set up voltage signal sampling device in the circuit, voltage signal sampling device links to each other with the control unit, the control unit links to each other with a motor that send a silk, wherein:
the voltage signal sampling device is used for collecting a voltage signal between the welding wire and a workpiece to be welded and transmitting the voltage signal to the control unit;
the control unit is used for receiving the voltage signal collected by the voltage signal sampling device, comparing the voltage signal with a preset value and outputting a control signal to the wire feeding motor according to a comparison result;
and the wire feeding motor is used for receiving the control signal output by the control unit and adjusting the wire feeding speed according to the control signal so as to realize the molten drop transition control.
2. A flux-cored TIG arc welding and additive manufacturing molten drop transition control method according to claim 1, characterized in that an external circuit is arranged between a wire feeding nozzle and a workpiece to be welded, and the external circuit is composed of a 5-24V external power supply and two resistors.
3. The flux cored TIG arc welding and additive manufacturing droplet transfer control method of claim 1 or 2, wherein the control unit is a PLC, a single chip, or an analog circuit.
4. The flux-cored TIG arc welding and additive manufacturing molten drop transition control method according to claim 2, wherein when the molten drop transition is non-contact transition, the collected voltage signal is large and ranges from 3 volts to 24 volts; when the molten drop transition is contact transition, the collected voltage signal is small and is in a range of 0-3V; and converting, analyzing and judging the acquired voltage signals by using the control unit, using the judgment result for adjusting the wire feeding speed, transmitting a control signal to the wire feeding motor, and adjusting the wire feeding speed to obtain a required molten drop transition mode.
5. Flux cored wire TIG arc welding and vibration material disk molten drop transition controlling means, its characterized in that, send the wire mouth with wait to weld workpiece go up external circuit and insert power and electron device, set up voltage signal sampling device in the circuit, voltage signal sampling device links to each other with the control unit, the control unit with send a motor to link to each other, wherein:
the voltage signal sampling device is used for collecting a voltage signal between the welding wire and a workpiece to be welded and transmitting the voltage signal to the control unit;
the control unit is used for receiving the voltage signal collected by the voltage signal sampling device, comparing the voltage signal with a preset value and outputting a control signal to the wire feeding motor according to a comparison result;
and the wire feeding motor is used for receiving the control signal output by the control unit and adjusting the wire feeding speed according to the control signal so as to realize the molten drop transition control.
6. A flux-cored TIG arc welding and additive manufacturing molten drop transition control device according to claim 5, wherein an external circuit is arranged between a wire feeding nozzle and a workpiece to be welded, and the external circuit comprises a 5-24V external power supply and two resistors.
7. The flux cored TIG arc welding and additive manufacturing molten drop transition control device according to claim 5 or 6, wherein the control unit is a PLC or a single chip microcomputer or an analog circuit.
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CN202010045233.9A CN113134665A (en) | 2020-01-16 | 2020-01-16 | Flux-cored wire TIG arc welding and additive manufacturing molten drop transition control method and device |
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CN202010045233.9A CN113134665A (en) | 2020-01-16 | 2020-01-16 | Flux-cored wire TIG arc welding and additive manufacturing molten drop transition control method and device |
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Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN114083086A (en) * | 2021-12-15 | 2022-02-25 | 北京理工大学 | Control method and device for stabilizing electric arc additive manufacturing process |
CN114178546A (en) * | 2021-11-25 | 2022-03-15 | 清华大学 | Method and device for monitoring transition state of deposited molten drops of dual-channel electron beam fuse |
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CN108145280A (en) * | 2017-12-29 | 2018-06-12 | 南京理工大学 | A kind of Regulation Control formula electric arc robot increases material formation system |
CN109079325A (en) * | 2018-10-23 | 2018-12-25 | 吉林大学 | Wire filling laser welding transient mode real time monitoring apparatus and method |
CN109277669A (en) * | 2018-09-28 | 2019-01-29 | 上海通用重工集团有限公司 | The pulse GMAW machine of arc stability |
CN109500474A (en) * | 2018-12-11 | 2019-03-22 | 西安航天发动机有限公司 | It is a kind of to guarantee that wire feed stablizes the method and apparatus for entering molten bath |
-
2020
- 2020-01-16 CN CN202010045233.9A patent/CN113134665A/en active Pending
Patent Citations (6)
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JPH0839252A (en) * | 1994-07-27 | 1996-02-13 | Hitachi Ltd | Control method of welding wire position and device therefor |
CN203992755U (en) * | 2014-01-27 | 2014-12-10 | 深圳市佳士科技股份有限公司 | The welding machine with the accurate short circuiting transfer control circuit of arc welding based on AVR single-chip microcomputer |
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CN109079325A (en) * | 2018-10-23 | 2018-12-25 | 吉林大学 | Wire filling laser welding transient mode real time monitoring apparatus and method |
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Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN114178546A (en) * | 2021-11-25 | 2022-03-15 | 清华大学 | Method and device for monitoring transition state of deposited molten drops of dual-channel electron beam fuse |
CN114083086A (en) * | 2021-12-15 | 2022-02-25 | 北京理工大学 | Control method and device for stabilizing electric arc additive manufacturing process |
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