WO2025065088A1

WO2025065088A1 - Welding assembly

Info

Publication number: WO2025065088A1
Application number: PCT/CA2024/051256
Authority: WO
Inventors: Carlos Inzunza GONZALEZ
Original assignee: MAGNA INTERNATIONAL Inc; Magna International Inc
Current assignee: MAGNA INTERNATIONAL Inc; Magna International Inc
Priority date: 2023-09-27
Filing date: 2024-09-20
Publication date: 2025-04-03
Anticipated expiration: 2026-03-27

Abstract

A welding gun for welding a metal work piece includes a contact tip for being positioned along the work piece during welding. A gas diffuser supports the contact tip for emitting a gas about the contact tip from cooling the contact tip and preventing contaminants from impacting the weld during welding. The gas diffuser extends along an axis between a proximal end and a distal end and defines a gas channel along the axis. The contact tip is coupled with the gas diffuser at the distal end. The gas diffuser further defines at least one gas passage that extends away from the gas channel at an acute angle relative to the axis and terminating at a gas opening for directing the gas toward the contact tip.

Description

WELDING ASSEMBLY

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This PCT International Patent Application claims the benefit of and priority to U.S. Provisional Patent Application Serial No. 63/540,915, filed September 27, 2023, titled “Welding Assembly,” the entire disclosure of which is hereby incorporated by reference in its entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

[0002] The present disclosure relates to systems for welding. More particularly, the present disclosure relates to a system for preventing wear to a contact tip of a gas welding assembly.

2. Related Art

[0003] This section provides background information related to the present disclosure which is not necessarily prior art.

[0004] Welding is a process used to join metal work pieces together. Metal Inert Gas (MIG) welding (also referred to as “wire-feed” or “gas metal arc welding”) is a type of arc welding which uses a metal wire as filler for the weld. The metal wire is shielded from contaminants by an inert gas. FIG. 1 illustrates an arrangement of a conventional MIG welding assembly 10. The assembly includes a control housing 14. The control housing 14 includes a power source 16 for powering the welding assembly 10. The power source 16 has a first terminal 18 and a second terminal 20. One of the terminals 18, 20 is a positive terminal and the other of the terminals 18, 20 is a negative terminal. A welding gun 22 has a handle 24 for being gripped by an operator, and a welding tip region 26 for contacting the work piece 12 during welding to create the weld. A neck 27 connects the handle 24 and the welding tip region 26. A spool 28 of electrode wire 30 supplies the wire 30 to the welding gun 22 to serve as an electrode during welding. A wire feeder 32 is coupled to the control housing 14 and the electrode wire

30 for feeding the electrode wire 30 to the welding gun 22. A gas source 34 that contains a gas is connected to the welding gun 22 for being expelled from the tip region 26 of the welding gun 22 during welding for shielding molten metal from outside contaminants during welding. A gas line 36 extends from the gas source 34 to the control housing 14 and to the welding gun 22 for providing the gas to the welding gun 22. A first power cable 38 extends from one of the first and second terminals 18, 20 of the power source 16 and is electrically connected to the electrode wire 30 to provide a current to the electrode wire 30. A conductive clamp 42 is configured to be clamped to the work piece 12 during welding. A second power cable 40 extends from the other of the first and second terminals 18, 20 to the clamp 42 for completing a circuit between the electrode wire 30 and the work piece 12 during welding. The welding gun 22 also has a trigger 44 for permitting an operator to control the supply of the electrode wire 30 to the welding gun 22, to control a supply of power from the power source 16 to the welding gun 22, and/or to control a supply of gas to the welding gun 22 from the gas source 34.

[0005] FIGS. 2-3 disclose a known contact tip for a MIG welding gun 22 which includes a gas diffuser 48A for disseminating gas to the weld during welding to prevent wear. More particularly, the gas diffuser 48A extends along an axis A between a proximal end 50 and a distal end 52. The proximal end 50 of the gas diffuser 48A is coupled to the neck 27 of the welding gun 22. The gas diffuser 48 defines a gas channel 54 that extends axially through the gas diffuser 48 for receiving gas from the neck 27. The electrode wire 30 passes through the gas diffuser 48 between the proximal and distal ends 50, 52. A coupler 31 interconnects the neck 27 and the gas diffuser 48 A. The gas diffuser 48 further defines a coupling recess 58 at the distal end 52. A contact tip 60 is axially received and fixed in the coupling recess 48. The contact tip 60 protrudes out of the coupling recess 58 along the axis A. The electrode wire 30 passes through a passage 62 of the contact tip 60 and protrudes out of the contact tip 60 such that it may engage the work piece 12 during welding. The gas diffuser 48 A defines a plurality of gas passages 64A that extend away from the gas channel 54 at a ninety degree angle relative to the axis A for disseminating the gas to the contact tip 60 and weld. A nozzle 70 is disposed about the gas diffuser 48A and contact tip 60 and is coupled to an outside surface of the gas diffuser 48A. The nozzle 70 also helps to direct the gas flow toward the contact tip 60 and weld by trapping the gas within the confines of the nozzle70.

[0006] There remains a need for further improvements to welding systems, in particular to reduce tip wear and provide more consistent welds.

SUMMARY OF THE INVENTION

[0007] According to an aspect of the disclosure a welding gun for welding a metal work piece includes a contact tip for being positioned along the work piece during welding. A gas diffuser supports the contact tip for emitting a gas about the contact tip from cooling the contact tip and preventing contaminants from impacting the weld during welding. The gas diffuser extends along an axis between a proximal end and a distal end and defines a gas channel along the axis. The contact tip is coupled with the gas diffuser at the distal end. The gas diffuser further defines at least one gas passage that extends away from the gas channel at an acute angle relative to the axis and terminating at a gas opening for directing the gas toward the contact tip.

[0008] According to another aspect of the disclosure, a method for welding a metal work piece includes providing a welding gun that includes a contact tip. A gas diffuser supports the contacting tip for emitting a gas about the contact tip from cooling the contact tip and preventing contaminants from impacting the weld during welding. The gas diffuser extends along an axis between a proximal end and a distal end and defines a gas channel along the axis. The contact tip is coupled with the gas diffuser at the distal end. The method also includes emitting a gas through at least one gas passage of the gas diffuser at an acute angle relative to the axis.

[0009] The orientation of the at least one gas passage improves a flow of gas via the “Coanda effect” to reduce a temperature at the contact tip, and also focalizes gas distribution to provide a higher quality weld. This leads to a longer life of the contact tip which results in avoided downtime replacing contact tips. This arrangement also efficiently uses the gas, which provides a reduction in gas consumption.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] These and other advantages of the present disclosure will be more readily understood by reference to the following description in combination with the accompanying drawings wherein:

[0011] FIG. 1 is a schematic diagram of an conventional welding system;

[0012] FIG. 2 is a side view of a known arrangement of a tip region of a welding gun of the welding system, illustrating a nozzle component in dashed lines;

[0013] FIG. 3 is a side, cross-sectional view of the known arrangement of the tip region and a nozzle component of the welding gun;

[0014] FIG. 4 is a perspective view of a welding gun with an embodiment of an improved tip region, and illustrating a nozzle component in dashed lines;

[0015] FIG. 5 is a side, cross-sectional view of the embodiment of the improved tip region, and a nozzle component of the welding gun;

[0016] FIG. 6 is a perspective view of the embodiment of the improved tip region, illustrating the nozzle component in dashed lines;

[0017] FIG. 7 is a front view of the embodiment of the improved tip region and the nozzle component of the welding gun; [0018] FIG. 8 is a side, cross-sectional view of the embodiment of the improved tip region of the welding gun; and

[0019] FIG. 9 is flow diagram of a method for welding a metal work piece.

DETAILED DESCRIPTION OF THE ENABLING EMBODIMENTS

[0020] Example embodiments will now be described more fully with reference to the accompanying drawings. In general, the subject embodiments are directed to a welding assembly. However, the example embodiments are only provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.

[0021] Referring to the figures, wherein like numerals indicate corresponding parts throughout the several views, a welding gun 122 for welding metal work pieces 120 is generally shown. The welding gun 122 includes an embodiment of an improved gas diffuser 148 for disseminating an inert gas (e.g., argon) during welding to shield the weld area from contamination. More particularly, the gas diffuser 180 extends along an axis A between a proximal end 150 and a distal end 152. The proximal end 150 of the gas diffuser 148 is coupled to the neck 127 of the welding gun 122. The gas diffuser 148 defines a gas channel 154 that extends axially through the gas diffuser 148 for receiving gas from the neck 127. The electrode wire 130 passes through the gas diffuser 148 between the proximal and distal ends 150, 152. A coupler 131 interconnects the neck 127 and the gas diffuser 148. Various types of connections may be used between the coupler 131 and the neck 127 and gas diffuser 148 including, but not limited to, a threaded connection.

[0022] The gas diffuser 148 further defines a coupling recess 158 at the distal end 152. A generally cylindrical contact tip 160 is axially received and fixed in the coupling recess 148. As shown, an arrangement of internal threads 159 on the gas diffuser 148 and an arrangement of external threads 161 on the contact tip 160 provide the connection, but other connections may be used. The contact tip 160 protrudes out of the coupling recess 158 along the axis A. The contact tip 160 defines a passage 162 that extends axially therethrough. The electrode wire 130 passes through the passage 162 of the contact tip 160 and protrudes out of the contact tip 160 such that it may engage the work piece 112 during welding.

[0023] The gas diffuser 148 defines a plurality of gas passages 164 that extend away from the gas channel 154 at an acute angle. According to the shown embodiment, the gas passages 164 extend at a thirty degree angle relative to the axis A for disseminating the gas around the contact tip 160 and weld. The plurality of gas passages 164 are equally circumferentially spaced from one another about the gas channel 154, but could be arranged in other manners.

[0024] An outside surface of the gas diffuser 148 defines a plurality of diffuser channels

166 that extend axially, each in alignment with one of the gas passages 164. Furthermore, an outside surface of the contact tip 160 defines a plurality of tip channels 168 that extend axially, each in alignment with one of the diffuser channels 166. The channels 166, 168 have a convex shape. The arrangement of the acute-angled gas passages 164 and the convex-shaped channels 166, 168 promote a flow of the gas via the Caonda effect. More particularly, according to the Coanda effect, a fluid jet is biased towrd folloing a contour of a curved surface rather than following a straight line. In this case the Coanda effect causes the fluid to flows along the channels 166, 168 and more precisely over the contact tip 160, which reduces a temperature at the contact tip 160 and also focalizes gas distribution to provide a higher quality weld. This leads to a longer life of the contact tip 160 which results in avoided downtime. Furthermore, this arrangement more efficiently uses the gas providing a reduction in gas consumption.

[0025] As best shown in FIG. 4, a nozzle 170 is disposed about the gas diffuser 148 and contact tip 160 and is coupled to an outside surface of the gas diffuser 148. More particularly, the nozzle 170 has an inner surface 171 which presents inside threads 173 which are threadedly connectable to outside threads 175 on the gas diffuser 148. The nozzle 170 may be connected to the neck 127 and/or gas diffuser 148 in various manners. The nozzle 170 also further helps to direct the gas flow toward the contact tip 160 and weld by trapping the gas within the confines of the nozzle 170.

[0026] As shown in FIG. 9, a method 200 for welding a metal work piece includes 202 providing a welding gun 122 as described above. The method also includes 204 emitting a gas through at least one gas passage 164 of the gas diffuser 148 at an acute angle relative to the axis A. The method further includes 206 directing the gas over the convex arc-shaped surfaces of the diffuser and tip channels 166, 168.

[0027] Obviously, many modifications and variations of the present disclosure are possible in light of the above teachings and may be practiced otherwise than as specifically described.

Claims

CLAIMS What is claimed is:

1. A welding gun for welding a metal work piece, comprising: a contact tip for being positioned along the work piece during welding; a gas diffuser supporting the contact tip for emitting a gas about the contact tip from cooling the contact tip and preventing contaminants from impacting the weld during welding; the gas diffuser extending along an axis between a proximal end and a distal end and defining a gas channel along the axis, the contact tip coupled with the gas diffuser at the distal end; and the gas diffuser further defining at least one gas passage extending away from the gas channel at an acute angle relative to the axis and terminating at a gas opening for directing the gas toward the contact tip.

2. The welding gun as set forth in claim 1, wherein the angle is approximately thirty degrees.

3. The welding gun as set forth in claim 1, wherein an outside surface of the gas diffuser defines at least one diffuser channel extending axially and in alignment with the at least one gas passage.

4. The welding gun as set forth in claim 3, wherein an outside surface of the contact tip defines at least one tip channel extending axially and in alignment with the at least one diffuser channel.

5. The welding gun as set forth in claim 4, wherein each of the diffuser channels and tip channels has a convex shape.

6. The welding gun as set forth in claim 1, wherein the at least one gas passage of the gas diffuser includes a plurality of gas passages being circumferentially spaced from one another.

7. The welding gun as set forth in claim 6, wherein the plurality of gas passages are equally circumferentially spaced from one another.

8. The welding gun as set forth in claim 6, wherein the outside surface of the gas diffuser defines a plurality of axially extending diffuser channels, each in alignment with one of the gas passages.

9. The welding gun as set forth in claim 8, wherein the outside surface of the contact tip defines a plurality of axially extending tip channels, each in alignment with one of the diffuser channels.

10. The welding gun as set forth in claim 1, wherein a nozzle is disposed about the gas diffuser and contact tip for retaining the contact tip and gas diffuser in place.

11. The welding gun as set forth in claim 1 , wherein the contact tip defines a passage extending axially through the contact tip, and wherein an electrode wire extends through the passage and protrudes out of the contact tip for engaging the work piece during welding.

12. The welding gun as set forth in claim 1, further including a gas source fluidly connected to the gas channel of the gas diffuser for transmitting gas to the gas diffuser.

13. A method for welding a metal work piece, comprising: providing a welding gun including a contact tip, a gas diffuser supporting the contacting tip for emitting a gas about the contact tip from cooling the contact tip and preventing contaminants from impacting the weld during welding, the gas diffuser extending along an axis between a proximal end and a distal end and defining a gas channel along the axis, the contact tip coupled with the gas diffuser at the distal end; and emitting a gas through at least one gas passage of the gas diffuser at an acute angle relative to the axis.

14. The method as set forth in claim 13, wherein the angle is approximately thirty degrees.

15. The method as set forth in claim 1, further including emitting the gas along at least one diffuser channel of the gas diffuser extending axially in alignment with the at least one gas passage.