Tracking System for Automatic Welding. Phase 2. Improvement of Contact- Tip Life for Through-the-Arc Welding System.

摘要

In Phase I of this project, an automatic seam tracking/adaptive control welding system, the M1000, was evaluated and weld-tested using the high heat, pulsed gas metal arc welding process. Phase I concluded with the finding that thru-the-arc seam tracking with computer control and adjustment of welding parameters was a viable technology. Potential savings in welding time would he possible if further development of hardware and computer software were achieved to more fully realize the potential of the system. Needed improvement in consistency of system response to changing conditions in the weld were recognized. It was determined that the most efficient utilization of available funds was support of development of weld head contact tips, which could function over longer periods of continuous welding without need for replacement due to wear. That objective became the primary focus of Phase II, the results of which are the subject of this report. The work reported involved the testing of the best identifiable candidate materials for improving contact-tip life. The material that provided the best results was the Series S, KWMA, Class 3 electrode material. It resulted in continuous running time of 99.8 minutes, significantly better than the 70 minutes minimum that was targeted. Another finding was that contact-tip life can he improved up to 77% by using an adaptive welding power supply which automatically compensates for varying contact-tip conditions.