With Granular Flux Supply Patents (Class 219/73.2)
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Patent number: 10543549Abstract: An additive manufacturing system includes an additive manufacturing tool configured to receive a plurality of metallic anchoring materials and to supply a plurality of droplets to a part, and a controller configured to independently control the composition, formation, and application of each droplet to the plurality of droplets to the part. The plurality of droplets is configured to build up the part. Each droplet of the plurality of droplets includes at least one metallic anchoring material of the plurality of metallic anchoring materials.Type: GrantFiled: July 10, 2014Date of Patent: January 28, 2020Assignee: ILLINOIS TOOL WORKS INC.Inventors: Bruce Patrick Albrecht, Christopher Hsu
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Patent number: 10456854Abstract: Granular welding flux delivery devices and strip cladding systems with granular welding flux delivery devices are disclosed. A disclosed example granular welding flux delivery device includes a hopper having: an intake opening to receive granular welding flux; a chute; and an output opening to output the granular welding flux to an electroslag strip cladding process, a submerged arc welding process, or a submerged arc strip cladding process. The example granular welding flux delivery device further includes a chute divider positioned within the chute to reduce an intake rate of granular material through the intake opening by reducing a cross-section of the chute based on a dimension of the chute divider. The disclosed example granular welding flux delivery device includes an adjustable output cover attached to the chute proximate to the output opening to extend or retract a length of the chute by adjusting a location of the output opening along the chute.Type: GrantFiled: December 28, 2016Date of Patent: October 29, 2019Assignee: Illinois Tool Works Inc.Inventors: Fabrizio Bernardo Brambilla, Catalin Toma, Domenico Redaelli, Petrus Hermanus Keultjes
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Patent number: 9517521Abstract: A method for repairing a component is provided. The method comprises: tracing an electrode across a defect/damage on the component at a preselected distance from the component; feeding a first metal powder and a second metal powder into a discharging gap between the electrode and the component; controlling feed rates of the first and second metal powders separately; and electro-spark depositing the first and second metal powders to the component to form a hybrid metal coating. The first metal powder comprises a first metal or alloy with a Vickers hardness rating of about 70-200% of the Vickers hardness rating of the component. The second metal powder comprises a second metal or alloy having lubricating/anti-corrosion properties.Type: GrantFiled: July 3, 2013Date of Patent: December 13, 2016Assignee: GENERAL ELECTRIC COMPANYInventors: Mayank Tiwari, Laurent Cretegny, Yong Liu, Bala Srinivasan Parthasarathy, Ravi Agrawal, Yong Wu
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Patent number: 9085043Abstract: A submerged arc welding system includes a robot having a first arm connected to a second arm, and at least one wire supply. A welding torch is connected to a first end of the second arm of the robot. A wire motor is mounted to a second end of the second arm of the robot. The wire motor moves wire from the wire supply along a wire path to the welding torch. The system further includes a flux supply and a flux delivery system configured to move flux from the flux supply along a flux path to the welding torch.Type: GrantFiled: October 24, 2014Date of Patent: July 21, 2015Assignee: LINCOLN GLOBAL, INC.Inventor: David A. Mate
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Publication number: 20150102016Abstract: Methods for laser processing of reflective metals. A reflective metal (2) is heated by applying a laser beam (6) to a layer of flux (4) in contact with the reflective metal, in which the flux is a powdered flux composition. The laser beam (38) may be applied to a powdered flux composition (36) such that thermal energy absorbed from the laser beam is transferred to a reflective-metal filler material (32) situated on a support material (30), and the powdered flux composition and the reflective-metal filler material melt to form a melt pool (40) which solidifies to form a metal layer (42) covered by a slag layer (44).Type: ApplicationFiled: October 7, 2014Publication date: April 16, 2015Inventors: Gerald J. Bruck, Ahmed Kamel
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Patent number: 8957344Abstract: Various welding systems that provide communication over auxiliary or weld power lines are provided. The disclosed embodiments may include a multi-process welding power supply that is communicatively coupled to a pendant via an auxiliary conduit that facilitates the exchange of data and power between components of the welding system. In some embodiments, the pendant may also include auxiliary outlets that allow an operator to power auxiliary devices at the weld location. The disclosed embodiments further include a pendant with a wire spool and wire feeder drive circuitry that is configured to activate spooling during MIG welding. Embodiments are provided that also allow for bidirectional data communication over a power line in networked welding systems.Type: GrantFiled: July 26, 2010Date of Patent: February 17, 2015Assignee: Illinois Tool Works Inc.Inventors: James Francis Rappl, Brian Lee Ott, Andrew David Nelson, Jeremy Daniel Overesch, Anthony Van Bergen Salsich, Quinn William Schartner, Kenneth Austin Stanzel
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Publication number: 20150041440Abstract: A submerged arc welding system includes a robot having a first arm connected to a second arm, and at least one wire supply. A welding torch is connected to a first end of the second arm of the robot. A wire motor is mounted to a second end of the second arm of the robot. The wire motor moves wire from the wire supply along a wire path to the welding torch. The system further includes a flux supply and a flux delivery system configured to move flux from the flux supply along a flux path to the welding torch.Type: ApplicationFiled: October 24, 2014Publication date: February 12, 2015Inventor: David A. Mate
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Patent number: 8952292Abstract: A welding head is provided. The welding head includes a bracket and a plurality of blocks coupled to the bracket. Each of the plurality of blocks has a contact tip. The contact tips are adapted to receive an electrode. Further, at least one of the plurality of blocks is capable of variable positioning relative to the bracket.Type: GrantFiled: April 17, 2012Date of Patent: February 10, 2015Assignee: Caterpillar Inc.Inventors: Matthew J. Behmlander, Huijun Wang
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Publication number: 20150027993Abstract: Flux compositions adapted for use in laser welding, repair and additive manufacturing applications. Flux compositions contain 5 to 60 percent by weight of an optically transmissive constituent, 10 to 70 percent by weight of a viscosity/fluidity enhancer, 0 to 40 percent by weight of a shielding agent, 5 to 30 percent by weight of a scavenging agent, and 0 to 7 percent by weight of a vectoring agent, in which the percentages are relative to a total weight of the flux composition. Also disclosed are processes involving melting of a superalloy material in the presence of a disclosed flux composition to form a melt pool covered by a layer of molten slag, and allowing the melt pool and the molten slag to cool and solidify to form a superalloy layer covered by a layer of solid slag.Type: ApplicationFiled: July 28, 2014Publication date: January 29, 2015Inventors: Gerald J. Bruck, Ahmed Kamel
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Patent number: 8916792Abstract: A submerged arc welding system includes a robot having a first arm connected to a second arm, and at least one wire supply. A welding torch is connected to a first end of the second arm of the robot. A wire motor is mounted to a second end of the second arm of the robot. The wire motor moves wire from the wire supply along a wire path to the welding torch. The system further includes a flux supply and a flux delivery system configured to move flux from the flux supply along a flux path to the welding torch.Type: GrantFiled: September 4, 2013Date of Patent: December 23, 2014Assignee: Lincoln Global, Inc.Inventor: David A. Mate
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Publication number: 20140339201Abstract: A granular flux formulated to reduce copper cracking in a weld bead. The granular flux forms a slag during a welding process that inhibits or prevents migration of molten copper migration through the slag.Type: ApplicationFiled: July 18, 2014Publication date: November 20, 2014Applicant: Lincoln Global, Inc.Inventors: Matthew J. James, Teresa Ann Melfi
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Publication number: 20140220374Abstract: A process for growing a substrate (24) as a melt pool (28) solidifies beneath a molten slag layer (30) An energy beam (36) is used to melt a powder (32) or a hollow feed wire (42) with a powdered alloy core (44) under the slag layer The slag layer is at least partially transparent (37) to the energy beam, and it may be partially optically absorbent or translucent to the energy beam to absorb enough energy to remain molten As with a conventional ESW process, the slag layer insulates the molten material and shields it from reaction with air A composition of the powder may be changed across a solidification axis (A) of the resulting component (60) to provide a functionally graded directionally solidified product.Type: ApplicationFiled: December 31, 2013Publication date: August 7, 2014Inventors: Gerald J. Bruck, Ahmed Kamel
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Patent number: 8704120Abstract: A welding device for powder welding is described, which comprises a welding head for transportation of at least one welding electrode to a welding area, and a powder transportation device for transportation of powder from a container to the welding area. The powder transportation device comprises at least a first pipe which at a first end has an opening which is arranged to be placed in the container in order to transport fluxing agent from the container. The powder transportation device comprises at least a first ejector which is connected to the second end of the first pipe and which is arranged to transport powder from the container via the first pipe using pressurized gas.Type: GrantFiled: June 11, 2009Date of Patent: April 22, 2014Assignee: ESAB ABInventors: Rolf Gösta Larsson, Björn Johansson
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Publication number: 20130299461Abstract: This disclosure relates generally to welding, and more specifically, to submerged arc welding (SAW). In an embodiment, a welding system includes a gas supply system configured to provide a gas flow. The system also includes a wire supply system configured to provide welding wire, and a flux supply system configured to provide flux near a welding arc during submerged arc welding (SAW). The system further includes a welding torch assembly configured to receive the gas flow and the welding wire and to deliver the gas flow and the welding wire near the welding arc during SAW.Type: ApplicationFiled: July 16, 2013Publication date: November 14, 2013Inventors: Kenneth Allen Fisher, Mario Anthony Amata, Steven Edward Barhorst, Joseph C. Bundy
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Publication number: 20130299462Abstract: This disclosure relates generally to welding, and more specifically, to submerged arc welding (SAW). In an embodiment, a welding system includes a gas supply system configured to provide a fluorine-containing gas flow. The system also includes a wire supply system configured to provide welding wire, and a flux supply system configured to provide flux near a welding arc during submerged arc welding (SAW). The system further includes a welding torch assembly configured to receive the fluorine-containing gas flow and the welding wire and to deliver the fluorine-containing gas flow and the welding wire near the welding arc during the SAW.Type: ApplicationFiled: July 16, 2013Publication date: November 14, 2013Inventors: Kenneth Allen Fisher, Mario Anthony Amata, Steven Edward Barhorst, Joseph C. Bundy
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Patent number: 8552329Abstract: A submerged arc welding system. In one embodiment, the submerged arc welding system includes a robot, a flux supply distal from the robot, and at least one wire supply distal from the robot. The system also includes a welding torch connected to the robot, a wire path connecting the wire supply to the welding torch, and a flux path connecting the flux supply to the welding torch. A flux delivery system is configured to move flux from the flux supply to the welding torch. At least one vent is disposed on the flux path adjacent the welding torch, to evacuate air from the flux path.Type: GrantFiled: July 16, 2009Date of Patent: October 8, 2013Assignee: Lincoln Global, IncInventor: David A. Mate
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Patent number: 8552330Abstract: A submerged arc welding system includes a robot having a first arm connected to a second arm, and at least one wire supply. A welding torch is connected to a first end of the second arm of the robot. A wire motor is mounted to a second end of the second arm of the robot. The wire motor moves wire from the wire supply along a wire path to the welding torch. The system further includes a flux supply and a flux delivery system configured to move flux from the flux supply along a flux path to the welding torch.Type: GrantFiled: April 11, 2012Date of Patent: October 8, 2013Assignee: Lincoln Global, Inc.Inventor: David A Mate
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Publication number: 20130256276Abstract: This disclosure relates generally to welding, and more specifically, to submerged arc welding (SAW). In an embodiment, a welding system includes a gas supply system configured to provide a gas flow. The system also includes a wire supply system configured to provide welding wire, and a flux supply system configured to provide flux near a welding arc during submerged arc welding (SAW). The system further includes a welding torch assembly configured to receive the gas flow and the welding wire and to deliver the gas flow and the welding wire near the welding arc during SAW.Type: ApplicationFiled: March 27, 2012Publication date: October 3, 2013Applicant: Illinois Tool Works Inc.Inventors: Kenneth Allen Fisher, Mario Amata, Steven Barhorst, Joseph Bundy
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Patent number: 8502103Abstract: A submerged arc welding apparatus of the present invention includes: a flux receiver for receiving and holding flux in an area formed by itself and a workpiece inside thereof when abutting against the workpiece on the open side; a flux feeder for supplying flux to the flux receiver; a welding torch for supplying a welding wire toward the workpiece with the tip disposed in the area where the flux is held; and a moving mechanism for moving the flux receiver and the welding torch along the direction of a welding line of the workpiece with the flux receiver abutting against the workpiece. A submerged arc welding method of the present invention includes: performing welding by opposing the welding torch to the workpiece and by moving the welding torch along the direction of the welding line with flux held in an area formed between the workpiece and the welding torch.Type: GrantFiled: April 26, 2007Date of Patent: August 6, 2013Assignee: IHI CorporationInventor: Yutaka Mizo
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Publication number: 20130140279Abstract: A method of repairing service-induced surface cracks (92) in a superalloy component (90). A layer of powdered flux material (100) is applied over the cracks and is melted with a laser beam (98) to form a re-melted zone (104) of the superalloy material under a layer of slag (106). The slag cleanses the melt pool of contaminants that may have been trapped in the cracks, thereby eliminating the need for pre-melting fluoride ion cleaning. Optionally, alloy feed material may be applied with the powdered flux material to augment the volume of the melt or to modify the composition of the re-melted zone.Type: ApplicationFiled: January 31, 2013Publication date: June 6, 2013Inventors: Gerald J. Bruck, Ahmed Kamel
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Patent number: 8354608Abstract: A new method of process control for fusion welding maintains a controlled weld pool size or volume, for example in some applications a substantially constant weld pool size or volume. The invention comprises a method of linking machine and process variables to the weld pool size or volume in real time, thereby enabling constant weld pool volume control. The invention further comprises a method of using thermal inverse models to rapidly process real-time data and enable models-based control of welding processes so as to implement constant weld pool volume control.Type: GrantFiled: May 14, 2010Date of Patent: January 15, 2013Assignee: B6 Sigma, Inc.Inventors: Vivek R Dave, Mark J Cola
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Publication number: 20120181255Abstract: A method of shielding a weld. The method includes melting a substrate to form a weld pool using a high energy density welding technique of plasma arc welding, laser beam welding, or electron beam welding; and delivering a flux to the weld pool to produce a slag effective to shield against atmospheric contaminants.Type: ApplicationFiled: January 13, 2011Publication date: July 19, 2012Inventor: Gerald J. Bruck
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Publication number: 20120097643Abstract: A welding device for powder welding is described, which comprises a welding head for transportation of at least one welding electrode to a welding area, and a powder transportation device for transportation of powder from a container to the welding area. The powder transportation device comprises at least a first pipe which at a first end has an opening which is arranged to be placed in the container in order to transport fluxing agent from the container. The powder transportation device comprises at least a first ejector which is connected to the second end of the first pipe and which is arranged to transport powder from the container via the first pipe using pressurized gas.Type: ApplicationFiled: June 11, 2009Publication date: April 26, 2012Applicant: ESAB ABInventors: Rolf Gösta Larsson, Björn Johansson
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Patent number: 8124247Abstract: A high-strength steel pipe has a tensile strength of 800 MPa or more and includes a weld metal having high cold-cracking resistance and high low-temperature toughness, wherein the weld metal contains C: 0.04% to 0.09% by mass, Si: 0.32% to 0.50% by mass, Mn: 1.4% to 2.0% by mass, Cu: less than 0.5% by mass, Ni: more than 0.9% by mass but not more than 4.2% by mass, Mo: 0.4% to 1.5% by mass, Cr: less than 0.5% by mass, V: less than 0.2% by mass, and the remainder of Fe and incidental impurities, and CS values calculated from the weld metal components using the equation CS=5.1+1.4[Mo]?[Ni]?[Mn]?36.3[C] are equal to zero or more at both an internal surface and an external surface.Type: GrantFiled: March 19, 2008Date of Patent: February 28, 2012Assignees: JFE Steel Corporation, Kabushiki Kaisha Kobe Seiko ShoInventors: Naoya Hayakawa, Fumimaru Kawabata, Shuichi Sakaguchi, Mitsuhiro Okatsu, Makoto Ota, Shigeki Nishiyama, Kaoru Nagatani, Keito Ishizaki
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Publication number: 20120012559Abstract: A heat input control method for a welding system includes the step of receiving data encoding a desired heat input range having heat input values included between an upper limit and a lower limit. The method also includes the step of receiving data encoding a desired change to a level of a first weld variable of a set of weld variables. Further, the method includes determining a change to a level of a second weld variable of the set of weld variables. The determined change to the level of the second weld variable is suitable to maintain a heat input of a welding operation within the desired heat input range.Type: ApplicationFiled: July 13, 2011Publication date: January 19, 2012Applicant: Illinois Tool Works Inc.Inventors: Kenneth Allen Fisher, James F. Ulrich, Ryan Jerome Lindeman
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Publication number: 20110290763Abstract: A welding device (1) for powder welding and a method for powder welding is described. The welding device comprises at least a first container (4) for fluxing agent in powder form, which first container (4) comprises an outlet (6) with an outlet direction (7) arranged for outflow of powder. The welding device (1) comprises a first member for inlet of heated gas into the first container. According to the method powder is arranged in the first container. Gas is heated and is allowed to pass into the first container (4) for heating of the powder. The powder is then fed out on a welding area (3).Type: ApplicationFiled: April 30, 2008Publication date: December 1, 2011Applicant: ESAB ABInventors: Rolf Gösta Larsson, Sievert Karl Gunnar Karlsson
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Publication number: 20110108527Abstract: A method for root pass welding steel plate and pipe is provided that uses pulse arc welding having a current pulse waveform exhibiting a low constant background current and fixed frequency. The welding process may be performed without a backer or backing material.Type: ApplicationFiled: November 11, 2009Publication date: May 12, 2011Applicant: LINCOLN GLOBAL, INC.Inventors: Steven R. Peters, Frank M. Dragolich, JR., David Barton
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Publication number: 20110089144Abstract: A welding device for powder welding is described, which comprises a welding head for transportation of at least one welding electrode to a welding area, and a powder transportation device for transportation of powder from a container to the welding area. The powder transportation device comprises at least a first pipe which at a first end has an opening which is arranged to be placed in the container in order to transport fluxing agent from the container. The powder transportation device comprises at least a first ejector which is connected to the second end of the first pipe and which is arranged to transport powder from the container via the first pipe using pressurized gas.Type: ApplicationFiled: June 11, 2009Publication date: April 21, 2011Applicant: ESAB ABInventors: Rolf Gosta Larsson, Bjorn Johansson
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Publication number: 20110073569Abstract: Various welding systems that provide communication over auxiliary or weld power lines are provided. The disclosed embodiments may include a multi-process welding power supply that is communicatively coupled to a pendant via an auxiliary conduit that facilitates the exchange of data and power between components of the welding system. In some embodiments, the pendant may also include auxiliary outlets that allow an operator to power auxiliary devices at the weld location. The disclosed embodiments further include a pendant with a wire spool and wire feeder drive circuitry that is configured to activate spooling during MIG welding. Embodiments are provided that also allow for bidirectional data communication over a power line in networked welding systems.Type: ApplicationFiled: July 26, 2010Publication date: March 31, 2011Applicant: Illinois Tool Works Inc.Inventors: James Francis Rappl, Brian Lee Ott, Andrew David Nelson, Jeremy Daniel Overesch, Anthony Van Bergen Salsich, Quinn William Schartner, Kenneth Austin Stanzel
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Publication number: 20110011835Abstract: A submerged arc welding system. In one embodiment, the submerged arc welding system includes a robot, a flux supply distal from the robot, and at least one wire supply distal from the robot. The system also includes a welding torch connected to the robot, a wire path connecting the wire supply to the welding torch, and a flux path connecting the flux supply to the welding torch. A flux delivery system is configured to move flux from the flux supply to the welding torch. At least one vent is disposed on the flux path adjacent the welding torch, to evacuate air from the flux path.Type: ApplicationFiled: July 16, 2009Publication date: January 20, 2011Applicant: Lincoln Global, Inc.Inventor: David A. MATE
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Publication number: 20100288734Abstract: A new method of process control for fusion welding maintains a controlled weld pool size or volume, for example in some applications a substantially constant weld pool size or volume. The invention comprises a method of linking machine and process variables to the weld pool size or volume in real time, thereby enabling constant weld pool volume control. The invention further comprises a method of using thermal inverse models to rapidly process real-time data and enable models-based control of welding processes so as to implement constant weld pool volume control.Type: ApplicationFiled: May 14, 2010Publication date: November 18, 2010Inventors: Vivek R. Dave, Mark J. Cola
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Publication number: 20100119861Abstract: A high-strength steel pipe having a tensile strength of 800 MPa or more that includes a weld metal having high cold-cracking resistance and high low-temperature toughness is provided. The high-strength steel pipe is a high-strength welded steel pipe in which the welded steel pipe is manufactured by double one layer submerged arc welding performed on an internal surface and an external surface of a base metal, both the base metal of the welded steel pipe and a weld metal have a tensile strength of 800 MPa or more, the weld metal contains C: 0.04% to 0.09% by mass, Si: 0.32% to 0.50% by mass, Mn: 1.4% to 2.0% by mass, Cu: less than 0.5% by mass, Ni: more than 0.9% by mass but not more than 4.2% by mass, Mo: 0.4% to 1.5% by mass, Cr: less than 0.5% by mass, V: less than 0.2% by mass, and the remainder of Fe and incidental impurities, and CS values calculated from the weld metal components using the equation CS=5.1+1.4[Mo]?[Ni]?0.6[Mn]?36.Type: ApplicationFiled: March 19, 2008Publication date: May 13, 2010Applicants: JFE STEEL CORPORATION, KABUSHIKI KAISHA KOBE SEIKO SHOInventors: Naoya Hayakawa, Fumimaru Kawabata, Shuichi Sakaguchi, Mitsuhiro Okatsu, Makoto Ota, Shigeki Nishiyama, Kaoru Nagatani, Keito Ishizaki
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Publication number: 20090188895Abstract: A submerged arc welding apparatus 10 according to the present invention comprises: a flux receiver (12) for receiving and holding flux in an area formed by itself and a workpiece (1) inside thereof when abutting against the workpiece (1) on the open side; a flux feeder (24) for supplying flux to the flux receiver (12); a welding torch (32) for supplying a welding wire (34) toward the workpiece (1) with the tip disposed in the area where the flux is held; and a moving mechanism (36) for moving the flux receiver (12) and the welding torch (32) along the direction of a welding line (2) of the workpiece (1) with the flux receiver (12) abutting against the workpiece (1). In the submerged arc welding method of the present invention, comprises: performing welding by opposing the welding torch (32) to the workpiece (1) and by moving the welding torch along the direction of the welding line (2) with flux (11) held in an area formed between the workpiece (1) and the welding torch (32).Type: ApplicationFiled: April 26, 2007Publication date: July 30, 2009Applicant: IHI CORPORATIONInventor: Yutaka Mizo
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Patent number: 6649858Abstract: A welding gun includes a welding handle and at least one interchangeable assembly. A plurality of interchangeable assemblies are securable to the welding handle to enable the welding gun to be configured for operation in a plurality of welding applications. A first interchangeable assembly enables the welding gun to receive gas and wire. A second interchangeable assembly enables the welding gun to receive flux and wire. The welding gun is coupled to a power source. The welding gun may be coupled to a flux reservoir or a source of gas. The welding gun may be coupled to the system by a cable operable to convey wire, gas, and flux to the welding handle.Type: GrantFiled: July 17, 2001Date of Patent: November 18, 2003Assignee: Illinois Tool Works Inc.Inventor: Robert W. Wakeman
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Patent number: 6399912Abstract: A welding apparatus for submerged arc welding is disclosed. The welding apparatus includes a welding power supply and a wire feeder in electrical communication with the power supply. A torch is in electrical communication with the power supply and is adapted to deliver an electrode wire from the wire feeder to an arc. A flux system having a flow path for delivering flux to the arc includes a pinch valve disposed to open and close the flow path.Type: GrantFiled: April 25, 2000Date of Patent: June 4, 2002Assignee: Illinois Tool Works Inc.Inventors: Robert D. Steenis, David J. Lease
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Patent number: 6331688Abstract: The present invention concerns the use of a pre-alloyed atomised powder in combination with at least one melting electrode wire in the SAW method. The electrode wire is an unalloyed or low-alloy metal wire and the metal powder is a metal powder containing a higher percentage of alloying elements than the electrode wire.Type: GrantFiled: March 23, 1999Date of Patent: December 18, 2001Assignee: Höganás ABInventors: Hans Hallén, Karl-Erik Johansson