DC electrode negative rotating arc welding method and system

• US 9,403,233 B2
• Filed: 11/20/2012
• Issued: 08/02/2016
• Est. Priority Date: 12/16/2011
• Status: Active Grant

• Current Assignee: Illinois Tool Works Inc.
• Original Assignee: Illinois Tool Works Inc.
• Inventors: Pagano, Kevin, Uecker, James Lee, Barhorst, Steven, Marschke, Bryan Dustin, Amata, Mario
• Primary Examiner(s): JENNISON, BRIAN W
• Application Number:
  US13/681,687
• Publication Number:
  US 20130153557A1
• Time in Patent Office: 1,351 Days
• Field of Search: 219/121.11, 219/130.1, 219/130.21, 219/130.31, 219/137.2, 219/137.WM
• US Class Current: 1/1
• CPC Class Codes: B23K 35/3611 Phosphates
• 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 9/0216 Seam profiling, e.g. weaving, multilayer
• CPC Class Codes: B23K 9/09 Arrangements or circuits for arc welding with pulsed current or voltage
• CPC Class Codes: B23K 9/12 Automatic feeding or moving of electrodes or work for spot or seam welding or cutting
• CPC Class Codes: B23K 9/173 and of a consumable electrode

Abstract

A welding operation is performed by moving or rotating an arc in a welding torch, and feeding a metal cored wire through the torch in a direct current, electrode negative welding process. The electrode may include one or more arc stabilizers. The welding process may be pulsed or non-pulsed. Moreover, the process may be used with a number of different base metals intended to be welded, such as thin plate, galvanized metals, painted metals, coated metals, and so forth.

Claims

1. A welding method comprising:

establishing an arc between a metal cored welding electrode and a workpiece in a direct current, electrode negative welding polarity, the metal cored welding electrode comprising a sheath and a core;

feeding the electrode from a welding torch while cyclically moving the electrode in a desired pattern by a motion control assembly within the welding torch to maintain an arc between at least the sheath and the workpiece; and

advancing the welding torch or the workpiece to establish a weld bead.

2. The method of claim 1, wherein the welding electrode comprises at least one arc stabilizer acting as a source of potassium and carbon.

3. The method of claim 2, wherein at least one arc stabilizer comprises at least one of potassium and compounds that contribute potassium during the welding process, potassium feldspar, potassium titanate, potassium manganite-titanate, potassium sulfate, potassium carbonate, potassium phosphate, potassium molybdate, potassium nitrate, potassium fluosilicate, complex oxide compounds containing potassium, graphitic and non-graphitic carbon sources.

4. The method of claim 3, wherein at least one hydrogen source comprises at least one of cellulose, sodium carboxy-methyl-cellulose, methyl cellulose and organic compounds and inorganic compounds that contain hydrogen.

5. The method of claim 1, wherein the welding electrode conforms to AWS standard A5.18 EXXC-6.

6. The method of claim 1, wherein the workpiece comprises a galvanized material.

7. The method of claim 1, wherein the workpiece comprises a coated or painted material.

8. The method of claim 1, wherein weld power provided to the metal cored welding electrode comprises a pulsed welding regime.

9. The method of claim 1, wherein the welding torch or the workpiece is advanced at a rate of at least 23 inches per minute.

10. The method of claim 1, wherein the electrode is moved at a rate of between approximately 50 Hz and approximately 120 Hz.

11. A welding system comprising:

a power supply configured to provide power to establish an arc between a metal cored welding electrode and a workpiece in a direct current, electrode negative welding polarity, the metal cored welding electrode comprising a sheath and a core;

a wire feeder coupled to the power supply and configured to feed the electrode from a welding torch; and

a welding torch that in operation receives the electrode from the wire feeder while cyclically moving the electrode in a desired pattern by a motion control assembly within the welding torch to maintain an arc between the sheath and the workpiece.

12. The system of claim 11, wherein the welding electrode comprises at least one arc stabilizer acting as a source of potassium and carbon.

13. The system of claim 12, wherein at least one arc stabilizer comprises at least one of potassium and compounds that contribute potassium during the welding process, potassium feldspar, potassium titanate, potassium manganite-titanate, potassium sulfate, potassium carbonate, potassium phosphate, potassium molybdate, potassium nitrate, potassium fluosilicate, complex oxide compounds containing potassium, graphitic and non-graphitic carbon sources.

14. The system of claim 13, wherein at least one hydrogen source comprises at least one of cellulose, sodium carboxy-methyl-cellulose, methyl cellulose and organic compounds and inorganic compounds that contain hydrogen.

15. The system of claim 11, wherein the welding electrode conforms to AWS standard A5.18 EXXC-6.

16. A welding method comprising:

providing welding power to establish an arc between a welding electrode and a workpiece in a direct current, electrode negative welding polarity, wherein the welding power comprises a pulsed welding regime;

feeding the electrode from a welding torch while cyclically moving the electrode in a desired pattern by a motion control assembly within the welding torch to maintain an arc between the electrode and the workpiece; and

advancing the welding torch or the workpiece to establish a weld bead.

17. The method of claim 16, wherein the electrode comprises a metal cored welding electrode comprising a sheath and a core.

18. The method of claim 17, wherein the arc is established between at least the sheath and the workpiece.

19. The method of claim 16, wherein the workpiece comprises a galvanized, coated, or painted material.