Electrode assembly for arc welding
The disclosed technology relates generally to welding technologies and more particularly to electrode assemblies for arc welding, e.g., submerged arc welding. In one aspect, an electrode assembly for submerged arc welding (SAW) comprises a head portion and an extension portion that are arranged serially to feed a consumable electrode therethrough such that, during SAW, the head portion is disposed to be distal to an arcing tip of the consumable electrode and the extension portion is disposed to be proximal to the arcing tip of the consumable electrode. The head portion includes a contact tip configured to electrically contact the consumable electrode to deliver power thereto. The extension portion is formed of a single piece insulating article configured for the consumable electrode to finally pass through before the arcing tip is exposed.
1 . An electrode assembly for submerged arc welding (SAW), comprising:
a head portion and an extension portion that are arranged serially to feed a consumable electrode therethrough such that, during SAW, the head portion is disposed to be distal to an arcing tip of the consumable electrode and the extension portion is disposed to be proximal to the arcing tip of the consumable electrode;
an electrical contact portion; and
an electrical insulating tube,
wherein the head portion includes a main body portion and a contact nozzle disposed between the main body portion and the extension portion, wherein the contact nozzle includes a contact tip configured to electrically contact the consumable electrode to deliver power thereto, wherein the electrical contact portion is configured to receive the power from a power source and to deliver the power to the contact tip, wherein the extension portion is formed of a single piece insulating article configured for the consumable electrode to finally pass through after passing through the contact tip and before the arcing tip is exposed, and wherein the electrical insulating tube is configured to electrically insulate the consumable electrode from the main body portion, the electrical contact portion, and at least a portion of the contact nozzle.
2 . The electrode assembly of claim 1 , configured such that, during SAW with the consumable electrode inserted therethrough, a ratio between an electrical stick-out distance, measured between the contact tip disposed at an end of the head portion and the arcing tip of the consumable electrode, and a diameter of the consumable electrode exceeds 30.
3 . The electrode assembly of claim 2 , wherein the extension portion has a length of 80 mm or greater for the consumable electrode having a diameter of 3 mm or greater.
4 . The electrode assembly of claim 1 ,
wherein the contact tip is configured to electrically contact the consumable electrode to deliver power thereto.
5 . The electrode assembly of claim 4 , wherein the electrical contact portion is disposed between the main body portion and the contact nozzle, wherein the electrical contact portion is electrically connected to the contact nozzle.
6 . The electrode assembly of claim 5 , wherein the electrical insulating tube is configured to guide the consumable electrode.
7 . The electrode assembly of claim 4 wherein the contact nozzle has a length greater than 140 mm.
8 . The electrode assembly of claim 4 , wherein: the contact nozzle has opposing first and second ends,
the first end of the contact nozzle is coupled to the electrical contact portion,
the contact tip is at the second end, and
the electrical insulating tube extends through the first end to the second end.
9 . The electrode assembly of claim 8 , wherein the consumable electrode passes through the electrical insulating tube such that the electrical insulating tube is positioned between the consumable electrode and the main body portion, the electrical contact portion, and the portion of the contact nozzle.
10 . The electrode assembly of claim 9 , wherein:
the contact nozzle includes sidewalls that extend between the first end and the contact tip,
the portion of the contact nozzle tip includes the sidewalls and the first end, and
the contact tip directly contacts the consumable electrode.
11 . An electrode assembly for submerged arc welding (SAW), comprising:
a head portion including a main body portion and a contact nozzle disposed between the main body portion and the extension portion, wherein the contact nozzle includes a contact tip configured to electrically contact a consumable electrode to deliver power thereto;
an extension portion arranged serially with the head portion in a wire feed direction, wherein the head portion and the extension portion are configured to feed a consumable electrode therethrough;
an electrical contact portion; and
an electrical insulating tube, wherein:
the extension portion is configured to be disposed to be proximal to an arcing tip of the consumable electrode relative to the head portion,
the extension portion is formed of a single piece insulating article arranged to be serial to the contact tip,
the electrical contact portion is configured to receive the power from a power source and to deliver the power to the contact tip, and
the electrical insulating tube is configured to electrically insulate the consumable electrode from the main body portion, the electrical contact portion, and at least a portion of the contact nozzle.
12 . The electrode assembly of claim 11 , wherein the extension portion comprises a single piece of insulating material.
13 . The electrode assembly of claim 11 , wherein the extension portion has a length greater than 80 mm.
14 . The electrode assembly of claim 11 , wherein the extension portion has a shape, a length, and a width such that the extension portion is configured to not contact a sidewall of a triangular groove having a depth exceeding 4 inches and having an angle of an apex, that is less than 16 degrees while the tip of the consumable electrode contacts the apex.
15 . The electrode assembly of claim 11 ,
wherein the extension portion is formed of a ceramic material and is configured to surround the consumable electrode.
16 . The electrode assembly of claim 11 wherein the extension portion has a length greater than 120 mm.
17 . The electrode assembly of claim 11 wherein:
the extension portion comprises opposing first and second end portions,
the first end portion is configured to be positioned proximal to the head portion and has a first width,
the second end portion is configured to be positioned distal to the head portion and has a second width, and
the second width is less than the first width.
18 . The electrode assembly of claim 17 wherein the first width is 18 mm and the second width is 14 mm.
19 . The electrode assembly of claim 17 , wherein the extension portion comprises a tapered portion in which a width thereof decreases towards the arcing tip, wherein the tapered portion is configured such that tangents of an exterior surface of the extension portion form a triangle or a cone having an angle of apex that is less than 16 degrees.
20 . The electrode assembly of claim 19 , wherein the extension portion has a shape, length and a lateral dimension such that the extension portion is configured to not contact a sidewall of a triangular groove having a depth exceeding 4 inches and having an angle of an apex that is less than 16 degrees while the tip of the consumable electrode contacts the apex.
21 . The electrode assembly of claim 17 , wherein the first end portion comprises threading configured to releasably couple with threading on the head portion.