【Hot Wire TIG Overlay Welding System】

TechnicalSolution

Part I: Workpiece Specifications

Workpiece Specifications:

Workpiece shape: channel (through hole), end face (trapezoidal groove), outer circle (through hole), intersecting line, etc.

Workpiece inner diameter range: post-welding Ø35~1500mm;

Workpiece internal control depth: ≤1000mm;

Workpiece base material: 4130, 30CrMo, 410, F51, F55, LF2 and other base materials;

Overlay welding materials:ERNiCrMo-3,ER316L,ER2594,ER2520,Stellite alloy etc. φ1.2 welding wire.

Technical requirements:

Welding process requirements:

Welding materials for the inner wall of the workpiece; Welding materials for the end face of the workpiece;

Overlay welding thickness:Single layer≤3mm;

Dilution rate less than 10%;

During welding, the hot wire TIG welding process with filler wire is adopted;

When welding end faces, the workpiece rotates while the welding torch remains stationary during welding, and the welding process is automatically completed;

When welding the inner hole, the workpiece rotates while the welding torch remains stationary during the welding process, and the welding is completed automatically.

Pre-welding requirements for the workpiece:

The surface of the workpiece to be overlaid must be smooth, clean, free of rust spots and oil stains, and the machining must meet the overlay welding requirements.

This welding system adopts a positioner combined with an operator structure, where the workpiece is directly mounted on the positioner's disk surface. The welding torch bracket and the torch movement system are both installed on the cross-shaped operator frame. During welding, the workpiece rotates while the welding torch moves linearly in synchronization, which can be either stepwise or continuous linear motion. By adjusting the angle of the welding torch, overlay welding on the inner contact surface of the workpiece can be achieved.

Part Two Brief Introduction to Surfacing Equipment Tooling

Equipment Description and Configuration Instructions:

This welding system adopts arotary platform combined with an operator structure, where the workpiece is directly placed on the surface of the rotary platform. The welding gun bracket and welding gun motion system are both installed on thecross operator frame;during the welding process,the workpiece rotates while the welding gun simultaneously performs linear motion, which can be either stepwise or continuous linear motion.By adjusting the welding gun angle, surfacing welding on the inner contact surface of the workpiece can be achieved.

MainEquipmentConfiguration:

Customized CNC-linked High-Precision Manipulator Model ACB2020S:

Structural Features:

Machine Base:

The base is a steel structure component with sufficient rigidity and strength to meet the requirements of the entire machine; the column consists of the column body, linear guide rails, lifting screw, and drive mechanism, among others; it is installed on the rotating component, with a gear rack transmission part mounted between the two guide rails. The front side is equipped with a slide plate, and the top surface is fitted with a servo-driven lifting mechanism, which drives the screw through a gearbox to achieve the lifting process;

Beam:

Precision guide rails are employed, with servo drive and high-rigidity design, featuring relatively low extension deflection. The beam travel speed is highly accurate, and the end is equipped with a wire feeder and welding torch, among other components;

Oscillation:

Utilizing precision guide rails combined with precision lead screws and servo motors, achieving long lifespan and stable reliability.

Technical Parameters:

ART5T Welding Rotary Table:

Structural Features:

Directly fixed to the ground;

Exquisitely designed with high rotational accuracy, low inertia,excellent braking performance and smooth operation;

Utilizes precision slewing bearings combined with dual reducers and servo motors to achieve true zero-backlash leveling;

Anti-recoil mechanism;

Pre-installed grounding wirerotationtightening interface;

Configure4 leveling pins to adjust the workpiece horizontally;

Technical parameters:

To meet customer needs for both large and small workpieces, our company standardly equips three welding torches: a conventional standard 50mm diameter surfacing torch, a standard 25mm diameter surfacing torch, and a WP-27 external circular torch. Different torch sizes are selected based on the diameter of the workpiece being welded.

Hot wire feed bracket system:

Supports the welding wire, guiding it at a preset angle with adjustable wire positioning.

High-speeddigital wire feeder:

Four-wheel drive, compatible with TIG torch operation, used for wire feeding during automatic welding;

Wire feed speed: 400～8000mm/min, adjustable speed;

Compatible wire spool diameter: 300mm;

Wire feed diameter: 1.2/1.6mm.

Water, gas, and cable connection assembly:

This assembly is used to connect various system equipment, including: welding cables, control cables, air hoses, water pipes, and variousinterface aviation plugs, etc..

Part Three YC-400TX4HG5Main Control SystemWelding Power Sourceand Hot Wire Power Source:

YC-400TX4HG5TIG Welding Power Source:

Technical Features:

Digital display of current and voltage with accurate and convenient preset parameters;

Three functions: DC TIG welding, DC pulse TIG welding, and DC manual welding, offering wide applicability;

Equipped with two pulse functions: low frequency (0.5～30Hz) and medium frequency (10～500Hz);Low-frequency pulse is suitable for welding medium-thickness plates, thick plates, and tubular materials inall positions; Medium-frequency pulse provides high arc stiffness and excellent concentration, making it more suitable for welding various heat-sensitive materials,heat-resistant materials, and thin plates;

Pulse current, base current, pulse frequency, and pulse width can be steplessly adjusted, suitable for welding under various specifications;

Built-in anti-electric shock device enhances operational safety;

Three-layer four-chamber dustproof structure with IP23 enclosure protection rating, suitable for harsh environments;

Technical parameters:

YC-400TX4HGK Hot Wire Power Supply:

Main Features:

Hot Wire TIG Inverter DC Welding Power Source;

Operationis extremely convenient, featuring fully digital control and perfect welding results;

Technical Parameters:

Part IV ESY-HTIGSpecializedControl System for Surfacing

Specialized Control System Software for Surfacing:

Designed for programming surfacing processes for different workpieces, the welding control program is pre-written via PLC, and operations are performed using touch screens and handheld remote control boxes to manage various welding parameters, including: welding current control, automatic motion control, automatic wire feeding control, automatic oscillation control, automatic arc length control, and shielding gas timing control, among others. The system performs automatic internal wall surfacing of workpieces according to pre-set welding programs;

ESY-HTIG Surfacing Control System offers the following workpiece welding functions:

Inner/outer circumference welding of spherical body:

Channel welding

Ring groove welding

Intersecting line welding

Flat surface welding

Meniscus welding

Welding process parameter settings with the following functions:

Welding current control:

Precise control of current rise and fall process

All current control parameters are configurable.

Current fine-tuning can be achieved during the welding process.

Welding rotation/travel motion control:

Rotation/Travel Method: Constant speed, reversible rotation can be freely set.

Fine-tuning of rotation/travel speed can be achieved during the welding process.

Capable of welding circular channels, end faces, trapezoidal grooves, etc.

Wire Feed Control:

Wire Feed Method: Constant speed

Automatic or manual wire feeding control can be selected.

Can preciselycontrol the delay timeor position of wire feeding.

During welding,wire feed speedcan be fine-tuned.

Arc length control technology

Accurately control the timing of arc length delay initiation.

During welding,arc voltage orarc length can be fine-tuned.

Welding torch joglongitudinal, transversecontrol;

Weaving control

Dwell time at left/right edges can be individually set, facilitating welding between dissimilar materials or workpieces with varying plate thicknesses;

Precisely controls the timing or position for initiating weave lag;

Allows micro-adjustment of the weaving center during welding;

Accurately achieves weaving center arc termination;

Shielding gas control

Controlled shielding gas;

Separately achieve functions such as pre-flow and post-flow of shielding gas.

Programming operation:

Intuitive programming method: Parameters such as "pipe diameter" and "welding speed" are displayed in actual measurement units;

Supports up to4-hole through-hole welding;

Controller panel programming allows setting all welding parameters, with independent adjustment for each channel'spre-flow protection andpost-flow time, as well as parameters for different zones, including peak/base time, peak/base current, arc voltage, workpiece rotation speed and angle, motion mode (capable of simultaneously controlling multiple axes—when one axis moves, another can choose synchronized stepping or constant-speed motion),wire feed speed,wire feed lagtime,wire retractiontime, current step modes for different zones, oscillation speed, and oscillation width.

Operation via pendant control allows fine-tuning of welding parameters during the process, such as current,wire feed speedincrease/decrease, enabling/disablingwire feed, etc..