MICRO-POROUS TUBULAR WELDING WIRE

• US 20190329362A1
• Filed: 04/25/2019
• Published: 10/31/2019
• Est. Priority Date: 04/27/2018
• Status: Active Grant

• Current Assignee: Hobart Brothers LLC (Illinois Tool Works Inc.)
• Original Assignee: Hobart Brothers LLC (Illinois Tool Works Inc.)
• Inventors: Barhorst, Steven E., Bundy, Joseph C.
• Granted Patent: US 11,590,612 B2
• Time in Patent Office: Days
• CPC Class Codes: B23K 2035/408 with welded longitudinal seam
• CPC Class Codes: B23K 35/0266 flux-cored
• CPC Class Codes: B23K 35/286 Al as the principal constituent
• CPC Class Codes: B23K 35/3053 Fe as the principal constituent
• CPC Class Codes: B23K 35/365 Selection of non-metallic compositions of coating materials either alone or conjoint with selection of soldering or welding materials
• CPC Class Codes: B23K 35/368 Selection of non-metallic compositions of core materials either alone or conjoint with selection of soldering or welding materials
• CPC Class Codes: B23K 35/406 Filled tubular wire or rods B23K35/402 takes precedence

Abstract

A microporous tubular welding electrode having a length and a circumference may comprise a granular flux fill core extending substantially along the length of the electrode and a sheath extending substantially along the length of the electrode and substantially surrounding and substantially encasing the granular flux fill core. The sheath may comprise a plurality of pores distributed around the circumference and along the length of the microporous tubular welding electrode. The microporous tubular welding electrode may be formed by first creating a plurality of pores in a strip of material (such as a steel or aluminum alloy) using a process such as laser drilling or chemical etching. Second, the strip may be formed into a tubular welding wire electrode containing a core of a granular powder flux material.

Claims

1. A tubular welding electrode having a length and a circumference comprising:

a granular flux fill core extending substantially along the length of the electrode; and

a sheath having a sheath width and extending substantially along the length of the electrode and substantially surrounding and substantially encasing the granular flux fill core;

wherein the sheath comprises a plurality of pores that extend at least partially through the sheath width and are distributed around the circumference and along the length of the tubular welding electrode.

2. The tubular welding electrode of claim 1, wherein the pores have an average pore size of between 1-30 microns.

3. The tubular welding electrode of claim 1, wherein the sheath is a steel material.

4. The tubular welding electrode of claim 1, wherein the sheath is an aluminum material.

5. The tubular welding electrode of claim 1, wherein at least some of the plurality of pores extend only partially through the sheath width and contain a lubricant.

6. A method for producing a tubular welding electrode comprising the steps of:

a. providing a strip of a metallic material having a length and a width;

b. creating a plurality of pores extending at least partially through the width of the strip;

c. forming the strip into a “

U”

shape along the length;

d. filling the “

U”

shape of the strip with a granular powder flux; and

e. mechanically closing the “

U”

shape to form a tubular welding electrode containing a core of the granular powder flux.

7. The method of claim 6, wherein the pores have an average pore size of between 1-30 microns.

8. The method of claim 6, further comprising a step f) of drawing the tubular welding electrode to a desired diameter.

9. The method of claim 6, further comprising a step g) of baking the tubular welding electrode to allow moisture and hydrocarbons from the granular powder flux to diffuse out of the tubular welding electrode.

10. The method of claim 6, wherein at least some of the plurality of pores extend only partially through the width of the strip and further comprising a step h) of filling at least some of the plurality of pores that extend only partially through the width of the strip with a liquid such as a lubricant.

11. The method of claim 6, wherein the creating a plurality of pores of step b) involves laser drilling the strip to create the plurality of pores.

12. The method of claim 6, wherein the creating a plurality of pores of step b) involves chemically etching the strip to create the plurality of pores.

13. The method of claim 6, wherein the mechanical closing of step e) involves forming a butt or overlap seam.

14. A method for producing a tubular welding electrode comprising the steps of:

a. providing a strip of a metallic material having a length and a width;

b. creating a plurality of pores extending at least partially through the width of the strip;

c. forming the strip into a substantially circular shape along the length;

d. welding the strip to form a tube sealed along the length; and

e. filling the tube with a granular powder flux to form a tubular welding electrode.

15. The method of claim 14, wherein the pores have an average pore size of between 1-30 microns.

16. The method of claim 14, further comprising a step f) of drawing the tubular welding electrode to a desired diameter.

17. The method of claim 14, further comprising a step g) of baking the tubular welding electrode to allow moisture and hydrocarbons from the granular powder flux to diffuse out of the tubular welding electrode.

18. The method of claim 14, wherein at least some of the plurality of pores extend only partially through the width of the strip and further comprising a step h) of filling at least some of the plurality of pores that extend only partially through the width of the strip with a liquid such as a lubricant.

19. The method of claim 14, wherein the creating a plurality of pores of step b) involves laser drilling the strip to create the plurality of pores.

20. The method of claim 14, wherein the creating a plurality of pores of step b) involves chemically etching the strip to create the plurality of pores.