1. Characteristics of Traditional Heat Source Welding Processes

In oxy-acetylene deposition welding, three flame types are identified based on their flame characteristics: neutral flame, carburizing flame, and oxidizing flame. To effectively control the burn-off and decarburization of tungsten carbide particles, a carburizing flame with a temperature range of 2700-3500°C is typically used. While the carburizing flame increases the carbon content of the deposited welding layer, its relatively lower heat source temperature can affect the efficiency of the deposition process.

In contrast, tungsten inert gas (TIG) welding can reach temperatures over 4000°C. In this process, precise control of the heat input to the welding wire is critical. The standard operating procedure involves heating the base material to a mirror-like molten state using the arc, then adequately heating the welding wire before quickly feeding the wire into the arc zone.

2. Technical Challenges and Process Difficulties

During the welding process, the key challenge is to prevent excessive melting and burn-off of the welding wire in the arc. While various tungsten carbide rods or wires are available on the market, when used in the aforementioned welding methods, the inherent limitations in the melting mechanism of tungsten carbide materials often result in suboptimal cladding outcomes.

The industry urgently requires a new process that can prevent the burn-off of tungsten carbide particles and ensure their firm attachment to the deposition welding layer. However, it is important to note that tungsten carbide has a significantly higher density than typical molten steel, causing tungsten carbide particles to easily settle to the bottom of the molten pool during feeding. This results in a stratification effect between tungsten carbide and the cladding material, making it difficult to evenly distribute the tungsten carbide particles in the deposited welding layer. Consequently, the welding layer may fail to achieve the desired wear-resistant properties.

3. Innovative Design of Suspension Cladding Technology

Equipment Configuration and Pre-treatment

The steel workpiece is precisely fixed onto the mounting platform to ensure that the surface to be welded faces upward. Once the clamping is completed, the steel workpiece undergoes a proper preheating treatment to create optimal conditions for subsequent welding operations.

Tungsten Carbide Supply System Optimization

The lower section of the tungsten carbide delivery tube is positioned at an angle of 30°-45° to the vertical plane. Additionally, the end of the delivery tube is kept at an optimal distance of 20-35mm from the surface of the steel workpiece to be welded.

Welding System Integration

By accurately adjusting the welding device, the water-cooled welding torch is positioned directly above the cladding area of the steel workpiece. The torch should cover the removal area in both the forward and backward directions. The welding wire is fed steadily into the water-cooled welding torch by the wire feeder, and the cooling water circulation system of the welding torch is activated before welding begins to ensure optimal thermal management of the equipment.

4. Electromagnetic Control and Arc Stabilization Technology

On both sides of the water-cooled welding matrix, electromagnetic deflection devices are installed, including primary and secondary helical coils. When alternating current passes through these coils, a stable electromagnetic field is generated to effectively control the behavior of the arc.

Under the coordination of the control system, the wire feeder precisely delivers the welding wire to the welding area beneath the water-cooled welding matrix. A high current then flows through the welding torch’s gun body, welding wire, and arc starter, ultimately forming a stable, efficient arc on the arc plate. This ensures a reliable thermal source for high-quality cladding.

5. Greenstone-Tech’s Role in Advancing Laser Cladding Technology

Greenstone-Tech is committed to continuous optimization of the process parameters and system integration solutions for laser cladding equipment. By deeply analyzing the technical bottlenecks of traditional processes, Greenstone-Tech is focused on providing customers with more advanced and reliable surface engineering technology solutions.