U.S. patent application number 14/569307 was filed with the patent office on 2016-10-13 for welding method and apparatus therefor.
The applicant listed for this patent is HUYS INDUSTRIES LIMITED. Invention is credited to Wang HUIHU, Dominic Cheuk Hung LEUNG, Yang LIANZHUO, Luo PING, Liu QI, Nigel SCOTCHMER, Dong SHIJIE, Yang WEI, Wang YANQING, Chang YING, Xie ZHIXIONG, Zheng ZHONG.
Application Number | 20160297023 14/569307 |
Document ID | / |
Family ID | 53477191 |
Filed Date | 2016-10-13 |
United States Patent
Application |
20160297023 |
Kind Code |
A9 |
SCOTCHMER; Nigel ; et
al. |
October 13, 2016 |
WELDING METHOD AND APPARATUS THEREFOR
Abstract
A welding process involves a fixture for holding a workpiece and
a welder, or welding electrode. The fixture imposes ultrasonic
vibration on the workpiece. The welder vibrates during vibration,
and is operable at a first voltage for welding and a second voltage
for peening. The peening may occur while the weld metal is
crystallizing. The welding process may be a process of welding two
parts together, or of filling a groove or other feature, or of
applying or restoring a surface, or of applying a hard facing or
ceramic to a parent metal or object. The weld metal may be the
same, or substantially the same, as the parent metal, or it may be
different. The different material may be a ceramic material.
Inventors: |
SCOTCHMER; Nigel;
(Willowdale, CA) ; LEUNG; Dominic Cheuk Hung;
(Thornhill, CA) ; SHIJIE; Dong; (Wuhan, CN)
; PING; Luo; (Wuhan, CN) ; YING; Chang;
(Wuhan, CN) ; HUIHU; Wang; (Wuhan, CN) ;
ZHIXIONG; Xie; (Wuhan, CN) ; ZHONG; Zheng;
(Wuhan, CN) ; WEI; Yang; (Wuhan, CN) ;
LIANZHUO; Yang; (Wujan, CN) ; QI; Liu; (Wujan,
CN) ; YANQING; Wang; (Wuhan, CN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
HUYS INDUSTRIES LIMITED |
Weston |
|
CA |
|
|
Prior
Publication: |
|
Document Identifier |
Publication Date |
|
US 20150183042 A1 |
July 2, 2015 |
|
|
Family ID: |
53477191 |
Appl. No.: |
14/569307 |
Filed: |
December 12, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62010334 |
Jun 10, 2014 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
C23C 4/18 20130101; C23C
4/10 20130101; B23K 9/04 20130101; C23C 4/131 20160101; B23K
37/0426 20130101; B23K 9/30 20130101; B23K 37/00 20130101 |
International
Class: |
B23K 9/04 20060101
B23K009/04; C23C 4/18 20060101 C23C004/18; C23C 4/10 20060101
C23C004/10; B23K 9/30 20060101 B23K009/30; C23C 4/12 20060101
C23C004/12 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 16, 2013 |
CN |
201310681469.1 |
Dec 16, 2013 |
CN |
201310681859.9 |
Claims
1. A welding apparatus comprising: a fixture to which to secure at
least one workpiece; a welding head positioned to address a
workpiece held in the fixture; said fixture having a vibration
source by which to transmit vibration to the workpiece; and said
welding head being one at least of (a) operable during welding to
vary voltage between a first magnitude and a second magnitude; and
(b) operable during welding to vibrate independently of said
fixture.
2. The welding apparatus of claim 1 wherein said apparatus includes
at least one ultrasonic vibration head operable to transmit
ultrasonic vibration to the workpiece during welding.
3. The welding apparatus of claim 1 wherein said apparatus includes
a power source operable to drive said welding head in a welding
mode and in a peening mode.
4. The welding apparatus of claim 1 wherein at least one of said
fixture and said welding head includes a motion transmitting drive
apart from a vibration drive, said motion transmitting drive being
operable globally to cause relative motion between the fixture and
the welding head.
5. The welding apparatus of claim 5 wherein at least one of said
fixture and said welding head is programmable to move according to
a pre-set course.
6. The welding apparatus of claim 1 wherein, in use, the welding
head is biased against the workpiece.
7. The welding apparatus of claim 1 wherein the vibration source of
the fixture has an engagement member for contacting the workpiece,
and said engagement member is free from plastic deformation
elements.
8. The welding apparatus of claim 1 wherein said welding apparatus
is both (a) operable during welding to vary voltage between a first
magnitude and a second magnitude; and (b) operable during welding
to vibrate independently of said fixture.
9. A method of welding a workpiece, said method comprising:
mounting a vibration source to transmit a first vibration signal to
the workpiece; opposing the workpiece with a welder; operating the
welder according to at least one of: (a) operating at a first
voltage magnitude for a first time period; and operating at a
second voltage magnitude at a second time period; and (b) vibrating
the welder according to a second vibration signal; and operating
the vibration source while operating the welder.
10. The method of claim 9 wherein said method includes vibrating
the welder to peen deposited weld metal during transmission of the
first vibration signal.
11. The method of claim 9 wherein the second voltage magnitude is
zero.
12. The method of claim 9 wherein said method includes securing the
workpiece in a fixture.
13. The method of claim 12 wherein said method includes moving at
least one of the fixture and the welding head along a
pre-programmed path while transmitting said first vibration signal
to the workpiece.
14. The method of claim 9 wherein the workpiece has more than one
part, and said method includes welding at least two parts of the
workpiece together.
15. The method of claim 9 wherein the method includes operating the
welder to deposit a material on the workpiece that is different
from the parent material of the workpiece.
16. The method of claim 9 wherein said method is a method of
surface coating the workpiece.
17. The method of claim 9 wherein the first vibration signal is an
ultrasonic vibration signal said method includes both (a) operating
at a first voltage magnitude for a first time period; and operating
at a second voltage magnitude at a second time period; and (b)
vibrating the welder according to a second vibration signal; and
operating the vibration source while operating the welder.
18. The welding process of claim 9 wherein ultrasonic vibration is
applied directly to the workpiece during at least one of: (a)
application of a welding rod to the workpiece; (b) crystallization
of welded material; and (c) peening of welded material.
19. The welding process of claim 18 wherein ultrasonic vibration is
applied to the workpiece during at least two of: (a) application of
a welding rod to the workpiece; (b) crystallization of welded
material; and (c) peening of welded material.
20. The welding process of claim 19 wherein said welding process is
an ESD process and the welder uses a welding rod having a ceramic
material composition that includes at least one of (a) TiC; and (b)
TiB.sub.2.
Description
[0001] This application claims the benefit of the priority of U.S.
Provisional Patent Application Ser. No. 62/010,334, filed Jun. 10,
2014, the specification and drawings thereof being incorporated by
reference in their entirety herein.
[0002] This application claims the benefit under the Paris
Convention of the priority of Chinese Patent Application 2013 1068
1469.1 filed Dec. 13, 2013, the specification and drawings thereof
being incorporated herein by reference.
[0003] This application claims the benefit under the Paris
Convention of the priority of Chinese Patent Application 2013 1068
1599.1 filed Dec. 17, 2013, the specification and drawings thereof
being incorporated herein by reference.
FIELD OF THE INVENTION
[0004] This application relates to methods and associated tools for
welding.
BACKGROUND OF THE INVENTION
[0005] In a number of industries it may be helpful to be able to
coat a metal substrate, or to join together by welding, or to make
repairs by welding processes of existing objects. The weld metal
deposit may have certain desired qualities with a coating of a
similar or dissimilar material. In some cases it may be desirable
to coat a metal substrate with a ceramic surface coating. Sometimes
the coating is added for wear resistance, or to replace or
re-surface a worn member.
[0006] In the electro-spark deposition (ESD) process, a consumable
electrode material is brought into contact with a metallic base
surface to be treated to deposit a coating, which may be a ceramic
coating, on the metallic substrate. Electro-Spark Deposition (ESD).
One such application may pertain to welding electrodes for use in a
production line. Welding electrodes are generally made of copper.
The electrode may have a surface coating, such as a ceramic
coating, that may be intended to increase electrode life. However,
the substrate material need not be limited to welding electrodes or
to copper.
[0007] ESD is a low-stress surfacing-hardening process that causes
little distortion to the workpiece. ESD involves atomic-level
metallurgical bonding of a discharge electrode coating material to
the base metal by electro-spark discharge. ESD is a surface
treatment process that improves the physical and mechanic
properties of the surface of the base metal. As a form of micro-arc
welding technology, ESD introduces a large current pulse during a
capacitance discharge. A high temperature (5000.about.25000 K)
plasma arcing column melts or vaporizes a small part of the
electrode rod coating material. The molten or vaporized electrode
material is transferred to the surface of the base metal by this
pulsed arcing micro welding. These traits permit ESD to be used in
many surface treatment applications, including the surface coating
of resistance spot welding electrodes. Successful ESD examples of
resistance spot welding electrode coatings includes the surface
in-situ deposition of TiC, TiB2, and TiB2-TiC. Welding electrodes
with TiC, TiB2 or TiC-TiB2 coatings have been used in the spot
welding of automobiles. ESD treated welding electrodes have made
significant advances in industrial applications. coatings of
vanadium-carbide, tungsten-carbide, titanium-diboride,
zirconium-diboride, Titanium-carbide, Cr.sub.3C.sub.2, and so on,
might be applied to various tool steels or aluminum, or other
metals. However, there are some defects found in ESD coatings. For
example, the grain in the heat affected zone (HAZ) near the coating
layer may become coarse due to high thermal stresses arising during
the ESD process (as shown in the Figures). Consequently, welding
electrodes may not achieve the full potential life extension
because of the flaws in the heat affect zone of the substrate
matrix.
[0008] In the coating of welding caps using ESD technology, a TiC
rod is connected to the positive terminal of a capacitor, and then
brought toward the surface of a copper cap. The copper cap is
connected to the negative terminal of the capacitor. Arcing occurs
when they are brought close together. This raises the temperature
in the arcing column and a molten droplet is produced at the tip of
the TiC rod. The molten droplet will then be accelerated by the
plasma jet and will strike the surface of the substrate forming a
splash of TiC spot on the surface electrode material workpiece,
and, if successful, the coating material will weld to the
underlying substrate material. After many discharges, the surface
will be covered in a layer of TiC coating. During the coating
process, the molten droplets strike the substrate at a high
velocity in the arcing column. As seen in FIGS. 18a, 18b and 18c
herein, splashing may occur, resulting in cracks or delamination as
observed in the coating layer. These defects may tend to reduce the
product life of the caps to a great extent. Some researchers in
university or industry have been trying to understand the cause of
the coating defects and find ways to reduce them.
[0009] The surface area will be coated with a layer of the
electrode material when swept by the electrode. The electrode cap
may be mounted to a moving device. The condition of the contact may
be dependent on the relative motion of the rod of depositing
electrode coating material and the electrode cap to be coated.
[0010] Resistance spot welding is still the main technology used in
the automotive assembly, especially in body frame construction. The
life of welding electrodes has become an important issue in the
resistance welding of galvanized steel and aluminum sheets. This in
turn increases the consumption in automotive production and thus
raises the production cost. To solve this problem, researchers
conducted many studies. The most representative research result is
the application of a protective coating layer (metallic or cermet)
to the surface of welding electrodes through the electro-spark
deposition process. This helps the welding electrodes to resist or
delay alloy migration and plastic deformation during welding, thus
improving the usage life of resistance welding electrodes.
[0011] Electro-spark deposition (ESD) is a micro-arc pulse welding
technology which transfers electrode material to a metallic
substrate with the use of high frequency and short duration current
pulses. The main advantage of electro-spark deposition is the
ability to produce metallurgical bonding between the coating
material and the substrate base metal with low heat transfer. Due
to thermal shock when the spark discharges, ESD coatings may tend
to have flaws. FIG. 5 herein shows typical coating defeats
(delaminations, porosity, cracks and uneven coating) of a welding
electrode after the application of TiC coating using the ESD
process.
[0012] Different types of processing technology have been tried by
various domestic and foreign researchers to achieve grain
refinement using the friction stir welding processing. Ultrasonic
grain refinement processing, as a secondary process technology, has
been widely studied and reported in areas such casting, welding,
and surface material treatment. Kwanghyun Park was the first to
study the ultrasonic assisted friction stir spot welding equipment
and processes. Ultrasonic assisted friction stir welding process
can produce welded joints with better performance than friction
stir welding alone.
[0013] Friction stir processing technology is newly developed based
on the friction stir welding process for the surface coating
modification of composite material. Due to the unique thermal or
mechanical characteristics, or both, friction stir processing has
been used in the preparation and modification of surface coatings.
Zhou Xiaoping et al (Chinese invention patent CN201010570898.8, the
preparation and modification of Al2O3+TiB2+Al composite coating on
aluminum surface by friction stir welding) has demonstrated that
the density and micro-hardness of Al2O3+TiB2+Al composite coating
produced by thermal spraying process can be improved by friction
stir processing.
[0014] Similarly, Chinese invention patents (CN 201310050662.5) "A
semi-solid ultra fine grain/nano-crystalline plate processing
method based on ultrasound-assisted friction stir processing", (CN
201310049003.X) "An ultrasound-assisted semi-solid friction stir
processing method in a controlled low temperature environment", and
(CN 201310049927.X) "a realization of surface UFG/nano material
based on ultrasonic assisted semi-solid friction stir processing
method" have adopted ultrasound-assisted semi-solid friction stir
processing technology, implemented with the use of a stirring pin
for surface treatment. As a result, a friction stir process may not
be suitable for the modification of surface coatings, such as those
on resistance spot welding electrodes. In addition, the process is
difficult, and power consumption may be high.
[0015] Resistance welding electrodes serve several purposes or
functions: the conduction of welding current; application of
closing pressure on the mating parts to be welded, and heat
dissipation. The temperature of the welding electrode in contact
with the workpiece is quite high, and the welding electrode itself
generates heat when welding current flows due to its own internal
resistance. The temperature on the top surface of the welding
electrode may rise very quickly to a level that is only marginally
lower than the weld nugget temperature.
[0016] In the view of the inventors herein, ultrasonic vibration
may help to improve welding structure and performance in the
welding and casting industries. Ultrasonic cavitation and acoustic
streaming effects of ultrasonic vibration that may aid in refining
grains in the heat affects zones of castings and weld pools.
Chinese patent CN102019531A, which pertains to a portable
ultrasonic assisted electro-spark deposition integrated repair and
polish device and technology, suggests an ultrasonic approach.
However, the ultrasonic excitation is added to modulation of the
discharge electrode. This ultrasonic vibration applies only to the
coating transfer of the deposition material. It appears to have
little effect on the coating layer on the base metal of the
workpiece.
SUMMARY OF INVENTION
[0017] The following summary is provided to introduce the reader to
the more detailed discussion to follow. The summary is not intended
to limit or define the claims.
[0018] According to an aspect of the invention there is a vibrating
hand-held coating material electrode holder. In another aspect of
the invention there is a ventilated hand-held coating material
electrode holder. In a further aspect of the invention there is a
vibrating hand-held coating material electrode holder that is
internally ventilated.
[0019] In an aspect of the invention there is a welding apparatus.
It has a fixture to which to secure at least one workpiece; and a
welding head positioned to address a workpiece held in the fixture.
The fixture has a vibration source by which to transmit vibration
to the workpiece. The welding head is one at least of (a) operable
during welding to vary voltage between a first magnitude and a
second magnitude; and (b) operable during welding to vibrate
independently of the fixture.
[0020] In a feature of that aspect of the invention, the apparatus
includes at least one ultrasonic vibration head operable to
transmit ultrasonic vibration to the workpiece during welding. In
another feature, the apparatus includes a power source operable to
drive the welding head in a welding mode and in a peening mode. In
still another feature, at least one of the fixture and the welding
head includes a motion transmitting drive apart from a vibration
drive, the motion transmitting drive is operable globally to cause
relative motion between the fixture and the welding head. In a
further feature, at least one of the fixture and the welding head
is programmable to move according to a pre-set course. In another
feature, in use, the welding head is biased against the workpiece.
In still another feature, the vibration source of the fixture has
an engagement member for contacting the workpiece, and the
engagement member is free from plastic deformation elements. In a
further feature, the welding apparatus is both (a) operable during
welding to vary voltage between a first magnitude and a second
magnitude; and (b) operable during welding to vibrate independently
of the fixture.
[0021] In another aspect of the invention there is a method of
welding a workpiece. The method includes mounting a vibration
source to transmit a first vibration signal to the workpiece;
opposing the workpiece with a welder; and operating the welder
according to at least one of: (a) operating at a first voltage
magnitude for a first time period; and operating at a second
voltage magnitude at a second time period; and (b) vibrating the
welder according to a second vibration signal; and operating the
vibration source while operating the welder.
[0022] In a feature of that aspect of the invention, the method
includes vibrating the welder to peen deposited weld metal during
transmission of the first vibration signal. In another feature, the
second voltage magnitude is zero. In another feature, the method
includes securing the workpiece in a fixture. In a further feature,
the method includes moving at least one of the fixture and the
welding head along a pre-programmed path while transmitting the
first vibration signal to the workpiece. In another feature, the
workpiece has more than one part, and the method includes welding
at least two parts of the workpiece together.
[0023] In still another feature, the method includes operating the
welder to deposit a material on the workpiece that is different
from the parent material of the workpiece. In anther feature, the
method is a method of surface coating the workpiece. In still
another feature, the first vibration signal is an ultrasonic
vibration signal the method includes both (a) operating at a first
voltage magnitude for a first time period; and operating at a
second voltage magnitude at a second time period; and (b) vibrating
the welder according to a second vibration signal; and operating
the vibration source while operating the welder.
[0024] In yet another feature, ultrasonic vibration is applied
directly to the workpiece during at least one of: (a) application
of a welding rod to the workpiece; (b) crystallization of welded
material; and (c) peening of welded material. In another feature it
is applied during all of (a), (b), and (c). In another feature,
ultrasonic vibration is applied to the workpiece during at least
two of: (a), (b), and (c). In a further feature, the welding
process is an ESD process and the welder uses a welding rod having
a ceramic material composition that includes at least one of (a)
TiC; and (b) TiB.sub.2.
[0025] In an aspect of the invention there is a coating material
electrode holder It has a seat in which to mount an electrode; a
mechanical drive operable to cause the electrode holder to move;
and a power supply connection through which to supply electrical
power to the electrode. The electrode holder has at least two modes
of operation, the modes of operation including a first mode and a
second mode. In the first mode the vibrator imposes mechanical
motion upon the electrode seat and supplies an ESD spark initiation
voltage to the electrode seat. In the second mode the mechanical
drive imposes mechanical motion upon the electrode seat and
supplies a voltage to the electrode seat that is of lesser
magnitude than the ESD spark initiation voltage.
[0026] In a feature of that aspect of the invention the drive is a
vibrator. In another feature, the holder is an hand held electrode
holder. In a further feature the second mode the voltage has zero
magnitude. In another feature, the second mode the voltage is less
than one half of the ESD spark initiation voltage. In a further
feature, the drive oscillates, and is at least one of (a) amplitude
adjustable; and (b) frequency adjustable.
[0027] In another aspect, there is an electrode holder for a
coating material electrode. The holder has an electrically
insulated handle by which an operator may grasp the electrode
holder; an electrode seat mounted to the handle, the electrode seat
defining a seat for an electrode rod; a power source in
electrically conductive connection with the electrode seat, whereby
an electrode rod received in the electrode seat may receive
electrical current from the power source; and a vibration source
mounted to the handle; and a power supply controller. The power
supply controller is operable to supply power to the electrode seat
in at least a first mode and a second mode. In the first mode the
power supply is set to supply power at a first voltage, the first
voltage being an ESD initiation voltage. In the second mode the
power supply is set to supply power at a second voltage, the second
voltage having a magnitude less than the ESD initiation
voltage.
[0028] In a feature of that aspect of the invention, the vibration
source is frequency adjustable. In another feature, the vibration
source has an output frequency in the range of 100 Hz to 500 Hz. In
another feature, the second voltage is less than half the ESD
initiation voltage. In a further feature, the vibration source
includes an exciter and a resilient transmitter, the electrode seat
being mounted to the resilient transmitter. In still another
feature, the transmitter is adjustably tunable in vibration
frequency. In yet another feature, the electrode seat has an axial
direction associated with a long axis of electrode rods mounted
therein, and the vibration source, in operation, oscillates the
handle with a component of force in the axial direction. In still
another feature, the electrode seat has an axial direction; the
exciter oscillates in operation; and oscillation of the exciter
includes a component of force in the axial direction. In another
feature, the exciter includes a rotating eccentric. In still
another feature, the resilient transmitter includes a spring
mounted between the exciter and the electrode seat. In yet another
feature, the electrode seat is adjustably orientable relative to
the handle. In still yet another feature, the electrode holder
includes at least one electrical brush mounted between the power
source and the electrode seat, whereby the electrode seat remains
in electrically conducting relationship to the power source
notwithstanding re-orientation of the electrode seat.
[0029] In another aspect there is a method of surface coating
treatment of a coated welding electrode, the coating material
having a melting temperature. The method includes establishing a
coating deposition portion on at least a first region of the
welding electrode at an elevated temperature less than the melting
temperature of the coating material; and plastically deforming that
coating deposition portion at that elevated temperature.
[0030] In a feature of that aspect, the method includes beating the
coating deposition portion. In another feature, the method includes
melting a portion of a coating material electrode onto the welding
electrode to establish the coating deposition portion; and using
the coating material electrode subsequently to strike the coating
deposition portion at the elevated temperature thereby plastically
to deform it. In another feature, the method includes applying a
first voltage to establish the coating deposition portion, the
first voltage being a melting voltage; and applying a second
voltage, the second voltage being a non-melting voltage when
plastically deforming the coating deposition portion. In another
feature, the second voltage has a magnitude that is one of: (a)
less than the first voltage; and (b) substantially zero. In a still
further feature, the method includes establishing vibratory
relative motion between the coating material electrode and the
welding electrode workpiece.
[0031] In another aspect, there is a method of depositing a coating
on a welding electrode workpiece. The method includes establishing
a coating material electrode in an electrode holder proximate to a
workpiece; establishing a first voltage differential between the
coating material electrode and the electrode workpiece, the first
voltage differential being at least as great as an ESD initiation
voltage; striking an arc between the coating material electrode and
the welding electrode workpiece whereby to cause material of the
coating material electrode to be deposited on the electrode
workpiece; breaking contact between the coating material electrode
and the electrode workpiece; and striking the electrode workpiece
again while the coating material electrode is at a second voltage
differential, the second voltage differential being of lesser
magnitude than the ESD initiation voltage.
[0032] In a feature of that aspect, the welding electrode workpiece
is mounted to a drive, the drive being operable to move the welding
electrode workpiece in at least one degree of freedom of motion
while the coating material electrode is held in the electrode
holder; and while the electrode rod is biased against the
workpiece, vibrating the electrode holder, whereby coating material
from the coating material electrode is deposited on the workpiece.
In another feature, the second voltage differential has
substantially zero magnitude. In a further feature, the second
voltage differential is less than one half of the ESD initiation
voltage. In another feature, the method includes establishing
vibratory motion between the coating material electrode and the
electrode workpiece. In a still further feature, the method
includes establishing the vibratory motion in a frequency range
between 100 Hz and 500 Hz. In still another feature, the method
includes adjusting the voltage differential between contact periods
of the coating material electrode and the electrode workpiece. In
yet another feature, the method includes plastically deforming
deposited coating material from the coating material electrode as
that deposited material cools on the electrode workpiece. In a
further feature, the ESD initiation voltage is in the range of
25-50 V. In still another feature, the second voltage is in the
range of 5 to 30 V.
[0033] In a further feature of any of the methods herein, the
electrode rod is a ceramic composition. In a further feature that
ceramic composition is titanium carbide or titanium diboride. In
another feature the rod is a nickel rod.
[0034] In a further aspect of the invention there is the method of
using any of the apparatus having any combination of the aspects
and features described herein, that method including the steps of
mounting the electrode in the holder, or causing the holder to
vibrate, and of placing the electrode and the work piece in contact
while charged with opposite electrical polarities.
[0035] In an aspect of the invention there is a surface
modification apparatus and method for treating electro-spark
deposition coating layers. It may include a processing method for a
surface coating in which there is use of a flat or curved shaped
head applying pressurized, or force biased rotating friction to the
surface coating on a workpiece. Ultrasonic vibration is
simultaneously applied to the workpiece or the rotating head. In a
feature of that aspect of the invention the shape of the friction
spinning head or probe is flat or curved surface, without a
projection spinning pin or needle.
[0036] In this aspect, it may be that the coating material would
not be removed from the base material of the workpiece. It may be
that no base material of the substrate is disturbed in the process.
This may help to maintain the coating material composition during
the process. With the addition of ultrasonic vibration to the
surface coating during the process, coating defects (delaminations,
porosity, cracks and uneven coating) may be reduced or eliminated
and high binding strength to the base material may be achieved. In
addition, the physical and mechanical properties of the coating may
also be improved.
[0037] In a feature of that aspect of the invention, the
force-biased rotating friction head and the workpiece spin in
opposite directions. The surface coating may undergo a continuous
treatment process. The composition of the surface coating may
remain unchanged while coating defects are eliminated giving better
coating performance as a result.
[0038] In another aspect of the invention there is an apparatus for
the surface modification of surface coating on workpieces. It
includes a work table for the clamping of the workpieces. It has an
ultrasonic, force-biased rotating friction device and an ultrasonic
power source. The ultrasonic rotating friction device has a
force-biased rotating friction module and an ultrasonic transducer.
The ultrasonic transducer is electrically connected to the
ultrasonic power source. The shape of the rotating friction probe
may be either flat or curved. The friction probe may be free of any
projection pin on the flat or curved surface thereof. The surface
may be planar.
[0039] In various features of that aspect of the invention, the
apparatus may include one or more of the following: a rotating
electrode holder workstation having an equipment frame, an electric
motor, a transmission belt, pulley, supporting bearings, a
transmission shaft, a clamping chuck and a dual guiding rails; an
integrated ultrasonic transducer with rotating friction head
apparatus comprising: a pair of sliders, upper and lower panels,
screw shaft, positive and negative inputs of the ultrasonic power,
a sliding conductor, bearings, a belt pulley, a driving belt, an
electric motor, an ultrasonic transducer, a transducer horn, a
rotating friction head and the housing; an ultrasonic power source
having ultrasonic positive output terminal, an ultrasonic power
control knob, the ultrasonic negative output terminal, and a power
switch.
[0040] Integration of the workstation, pressurized rotating
friction module and the ultrasonic power source: The equipment
frame is fixed to the workstation, the electric motor drives the
transmission shaft through the coupling of the driving belt and
pulley; the clamping chuck for work pieces is mounted to the
transmission shaft; The integrated rotating friction assembly is
fitted to the workstation through the fitting of the sliders to
achieve free repeating movements, this allows rotating friction
application to the surface coating of workpiece on the workstation
assembly; the lower panel of the rotating friction assembly is
attached to the upper panel through the coupling of the screw
shaft, this allows the rotating friction assembly to move in a
vertical direction and thus to achieve the application of pressure
during the process by adjusting the screw shaft; the ultrasonic
input +ve and -ve terminals are connected to the corresponding
terminals of the ultrasonic power source; the sliding conductor is
connected to the ultrasonic transducer with the use of electrical
wires; the transducer horn is mounted to the ultrasonic transducer;
the rotating friction head is driven to rotate through the driving
of the electric motor, driving belt, belt pulley and the support
bearing; this setup achieves the application of the pressurized
rotating friction to workpiece on the workstation; the rotating
friction assembly is then enclosed in the housing.
[0041] On the workstation, the clamping chuck for mounting the
workpiece is driven to rotate by the electric motor through the
transmission of the driving belt and pulley. With the fitting of
the 2 sliders on the lower panel and the 2 guiding rails on the
workstation, the integrated ultrasonic rotating friction assembly
can be used to process the workpiece repeatedly.
[0042] With the integrated ultrasonic rotating friction assembly
attached to the upper panel, the upper panel is attached to the
lower panel through the screw shaft. Not only does the screw shaft
move the upper panel in a vertical direction, it also allows
certain pressure to be applied to the workpiece. The ultrasonic
rotating friction assembly is driven by the motor through the
transmission of the pulley, belt and bearings. Through the
adjustment to the screw shaft, the pin-less friction head can be
moved to make friction contract with the workpiece. Furthermore,
with the application of pressure and the ultrasonic vibration
simultaneously, it is made possible to modify surface coatings on
workpiece using ultrasonic pressurized rotating friction
processing.
[0043] In an aspect of the invention there is a process of surface
treatment of an ESD coating. The process includes biasing a
friction head assembly against a workpiece to which an ESD coating
is applied; moving the workpiece relative to the friction head
while in contact therewith; and subjecting the coating to
ultrasonic vibration while the friction head is in contact
therewith.
[0044] In a feature of that aspect of the invention, the process
includes rotating the workpiece while the friction head is in
contact therewith. In another feature, the process includes
rotating said friction head assembly while it is in contact with
the workpiece. In a further, additional feature, the process
includes rotating the workpiece while the friction head is in
contact therewith. In another feature, the coating is a TiC
coating. In another feature, the process includes depositing the
ESD coating. In still other features, the process may include at
least one of: (a) an ultrasonic frequency of about 50 kHz; (b) a
biasing force of about 200 N; and (c) a rotational speed of the
rotating friction head of about 1400 rpm.
[0045] In another aspect of the invention, there is an apparatus
for the processing of surface coating modifications of an ESD
coating on a workpiece surface. The apparatus has a work station
for the mounting and rotation of the workpiece; a friction
assembly, operable, in use, to be biased against the workpiece; and
an ultrasonic transducer mounted to transmit ultrasonic vibration
to the workpiece while the workpiece is in contact with the
rotating friction assembly.
[0046] In a feature of that aspect of the invention, the apparatus
has an ultrasonic power source; and the ultrasonic transducer is
connected to the ultrasonic power source. In another feature, the
friction head has a shape that is one of (a) flat; and (b) curved.
In still another feature, the friction assembly is also mounted for
rotation. In still yet another additional feature, the apparatus is
such that at least one of (a) the ultrasonic transducer operates at
about 50 kHz; (b) in use, the biasing force is about 200 N; and (c)
the friction head is mounted for rotation at about 1400 rpm.
[0047] In another aspect of the invention there is a surface
coating process for use in applying an ESD coating to a workpiece.
The process includes applying a surface coating to a workpiece
using electro-spark deposition; and applying ultrasonic vibration
to the workpiece.
[0048] In a feature of that aspect of the invention, the ultrasonic
vibration is applied to the workpiece during the electro-spark
deposition of the coating. In another feature, the ultrasonic
vibration is applied to the workpiece during crystallization of the
coating. In still another feature, the ultrasonic vibration is
applied to the workpiece during the electro-spark deposition of the
coating and during crystallization of the coating. In a further
feature, the ESD coating is deposited on the workpiece by an
applicator. The applicator is a vibrating applicator. The
applicator vibrates during deposition of the coating independently
of the ultrasonic vibration. In still another feature, the
workpiece is held in a rotating tool holder, and the workpiece is
driven to rotate during the process. In a further additional
feature, at least one of (a) the ultrasonic vibration is applied to
the workpiece during the electro-spark deposition of the coating;
and (b) the ultrasonic vibration is applied to the workpiece during
crystallization of the coating. In a still further feature, the ESD
coating is deposited on the workpiece by an applicator. The
applicator is a vibrating applicator, and the applicator vibrates
during deposition of the coating in addition to the ultrasonic
vibration.
[0049] In another feature, the ESD coating is deposited on the
workpiece by an applicator. The applicator is a vibrating
applicator, and the applicator vibrates during deposition of the
coating in addition to the ultrasonic vibration. In an additional
feature, the process includes applying the ESD coating to a
resistance spot welding electrode as the workpiece. In still
another feature, the process includes depositing a coating that
includes at least one of (a) TiC and (b) TiB.sub.2, on the
workpiece. In yet another feature, the process includes applying
the coating to a metal matrix that includes copper. In a still
further feature, the process includes applying the ESD coating to a
resistance spot welding electrode as the workpiece, that spot
welding electrode having a metal matrix that includes copper; and
depositing a coating that includes at least one of (a) TiC and (b)
on the workpiece.
[0050] In another aspect of the invention there is an apparatus for
electro-spark deposition of a surface coating on a workpiece. The
apparatus has a tool holder to which the workpiece is mounted; a
coating applicator; and an ultrasonic vibration source mounted to
act on the tool holder, and thereby directly to apply ultrasonic
vibration to the workpiece.
[0051] In a feature of that aspect of the invention, the ultrasonic
vibration source is operably connected to apply ultrasonic
vibration to the tool holder at least one of (a) during the
electro-spark deposition of the coating; and (b) during
crystallization of the coating. In another feature, the coating
applicator is a vibrating coating applicator. In a further feature,
the tool holder is a rotating tool holder. In still another
feature, the tool holder is a rotating tool holder; and the
ultrasonic vibration source is operably connected to apply
ultrasonic vibration to the tool holder at least one of: (a) during
the electro-spark deposition of the coating; and (b) during
crystallization of the coating. In a further additional feature,
the coating applicator is a vibrating coating applicator. In a
still further feature, the workpiece is a resistance spot welding
electrode. In another feature, the apparatus has a vibrating
applicator, an ESD power supply, an ultrasonic transducer assembly,
a work station having a rotating drive and an ultrasonic generator;
the ultrasonic generator being connected to drive the ultrasonic
transducer; the ultrasonic transducer assembly and the rotating
drive work station being assembled as a single integrated unit; and
the workpiece being mountable in a tool holder seat vibrated by the
ultrasonic transducer.
[0052] In still another feature, the apparatus includes: an ESD
power supply having a positive power terminal and a negative power
terminal; a vibrating applicator having a resilient conductor
spring, a discharge electrode mounting, a discharge electrode, a
driven eccentric, a handle, an insulated support, a flexible drive
shaft, and a low-power applicator motor; an integrated transducer
assembly on which to mount a workpiece to be coated; a work-station
negative terminal, an integrated transducer negative terminal, an
integrated transducer positive terminal, an integrated transducer
body, a transducer horn, an ultrasonic transducer, a flat pulley,
bearing, and tool holder; a work-station drive assembly having a
work bench drive motor, a drive belt; an ultrasonic generator
having an ultrasonic power output negative terminal, and an
ultrasonic power output positive terminal. The ESD power positive
terminal is connected to the conductor spring. The ESD power
negative terminal is connected to the work-station negative
terminal. The discharge electrode is mounted to the conductor
spring. The applicator is connected to the low-power motor through
the flexible shaft. The eccentric wheel is driven in rotation by
the driving of the low-power motor through the flexible shaft to
drive vibrating deposition. The ultrasonic power output negative
terminal is connected to the integrated transducer negative
terminal. The ultrasonic power output positive terminal is
connected to the integrated transducer negative terminal. The
integrated ultrasonic transducer assembly is driven in rotation by
the drive motor through the flat pulley and drive belt. The
ultrasonic transducer is connected to the integrated transducer
negative terminal and the integrated transducer positive terminal,
respectively. The transducer horn and ultrasonic transducer are
combined to form a shaft of the rotary work station; the tool
holder being mounted to the rotary work station; whereby the
workpiece is mounted to the work-station for rotating
ultrasonic-assisted electro-spark deposition.
[0053] There are many combinations and permutations of aspects and
features. It will be understood that any of the features may be
combined, as appropriate, with any of the aspects enumerated
herein.
BRIEF DESCRIPTION OF THE ILLUSTRATIONS
[0054] The foregoing aspects and features of the invention may be
explained and understood with the aid of the accompanying
illustrations, in which:
[0055] FIG. 1 is a general arrangement perspective view of an
electrode handle apparatus according to an aspect of the invention
herein;
[0056] FIG. 2 is a first side view of the electrode handle
apparatus of FIG. 1;
[0057] FIG. 3 is a top view of the electrode handle of FIG. 1;
[0058] FIG. 4 is a side view of the electrode handle of FIG. 2 with
the near-side handle haft removed to expose interior features;
[0059] FIG. 5 is a longitudinal cross-sectional view of the
electrode handle of FIG. 2;
[0060] FIG. 6 is an end view of the electrode handle apparatus of
FIG. 1;
[0061] FIG. 7 is a side view of an alternate embodiment of
electrode handle to that of FIG. 1;
[0062] FIG. 8 shows the electrode handle of FIG. 7 with the near
side of the housing removed; and
[0063] FIG. 9 shows a cross-section of the electrode handle of FIG.
7 along its longitudinal central plane.
[0064] FIG. 10 shows a general arrangement perspective view of an
alternate electrode handle apparatus to that of FIG. 1;
[0065] FIG. 11 is a first side view of the electrode handle
apparatus of FIG. 10;
[0066] FIG. 12 is a bottom view of the electrode handle of FIG.
10;
[0067] FIG. 13 is an opposite side view to that of FIG. 11; and
[0068] FIG. 14 is a head end view of the apparatus of FIG. 10.
[0069] FIG. 15a shows a first side view of an alternate apparatus
to that of FIG. 1;
[0070] FIG. 15b show a second, opposite side view of the apparatus
of FIG. 15a with the foreground housing removed to reveal interior
detail;
[0071] FIG. 16 is a schematic of a power source for the handle of
FIG. 1, 10; or 15a;
[0072] FIG. 17a is a schematic representation of alternating
coating and peening stages as might be applied with the power
source of FIG. 16;
[0073] FIG. 17b is a time schedule for deposition and peening
switch-"On" and "Off" conditions for of the power source of FIG.
16;
[0074] FIG. 17c is a Time v. Voltage representation applied to and
through the electrode rod of the apparatus by the switching of FIG.
17a;
[0075] FIG. 17d is an alternate plot of Switching v. Time for an
alternate embodiment of operation of the power source of FIG.
16;
[0076] FIG. 18a is a much enlarged photograph of a "splash" of ESD
coating material;
[0077] FIG. 18b shows an enlarged view of as-coated ESD workpiece
surface; and
[0078] FIG. 18c is an enlarged cross-sectional view of an ESD
coating sample on a workpiece;
[0079] FIG. 18d is a photograph of defects in an ESD coating in a
surface view;
[0080] FIG. 18e is a photograph of defects in an ESD coating in
another surface view;
[0081] FIG. 18f is a photograph of typical defects in an ESD
coating in a cross sectional view;
[0082] FIG. 18g is a photographic view showing a comparison in
cross-section of ESD coating SEM views of effects of the ultrasonic
pressurized rotating friction processing, FIG. 18g being a before
the process view;
[0083] FIG. 18h is a photographic view showing a comparison in
cross-section of ESD coating SEM views of effects of the ultrasonic
pressurized rotating friction processing, FIG. 18h being an after
the process view.
[0084] FIG. 19 is a cross-sectional view of a welding arrangement
according to an aspect of the invention herein;
[0085] FIG. 20 is a side view of a welding arrangement of an aspect
of the invention;
[0086] FIG. 21 shows a conceptual relationship of elements
according to an embodiment of the invention;
[0087] FIG. 22 shows a schematic view of a workstation for the
clamping and rotation of a workpiece such as may be coated
according to the embodiment of FIG. 21;
[0088] FIG. 23 shows a general layout of structural and operational
elements of an integrated ultrasonic rotating friction assembly
according to the embodiment of FIG. 21;
[0089] FIG. 24 shows an ultrasonic power source for the embodiment
of FIG. 21;
[0090] FIG. 25 is a conceptual illustration of an embodiment of
apparatus according to an aspect of the invention herein;
[0091] FIG. 26 is a basic illustration of a workbench of the
apparatus of FIG. 25;
[0092] FIG. 27a shows a metallurgical comparison chart of coatings
of different technology, FIG. 27a being a coating that is not
ultrasonic-assisted;
[0093] FIG. 27b shows a metallurgical comparison chart of coatings
of different technology, FIG. 27b being a coating that is not
ultrasonic-assisted;
[0094] FIG. 28 is a micro-hardness comparison of different coating
technology; and
[0095] FIG. 29 is a metallurgical chart of a coating under patent
CN 102019531A.
DETAILED DESCRIPTION
[0096] The description that follows, and the embodiments described
therein, are provided by way of illustration of an example, or
examples, of particular embodiments of the principles of aspects
and features of the invention. These examples are provided for the
purposes of explanation, and not of limitation, of those principles
and of the invention. In the description, like parts are marked
throughout the specification and the drawings with the same
respective reference numerals. The drawings may be taken as being
to scale, or generally proportionate, unless indicated otherwise.
The photographic views may be taken as being to scale, or generally
proportionate, unless indicated otherwise.
[0097] The scope of the invention herein is defined by the claims.
Though the claims are supported by the description, they are not
limited to any particular example or embodiment, and any claim may
encompass processes or apparatus other than the specific examples
described below. Other than as indicated in the claims themselves,
the claims may not be limited to apparatus or processes having all
of the features of any one apparatus or process described below, or
to features common to multiple or all of the apparatus described
below.
[0098] The terminology used in this specification is thought to be
consistent with the customary and ordinary meanings of those terms
as they would be understood by a person of ordinary skill in the
art in North America. Following from the decision of the Court of
Appeal for the Federal Circuit in Phillips v. AWH Corp., the
Applicant expressly excludes all interpretations that are
inconsistent with this specification, and, in particular, expressly
excludes any interpretation of the claims or the language used in
this specification such as may be made in the USPTO, or in any
other Patent Office, other than those interpretations for which
express support can be demonstrated in this specification or in
objective evidence of record in accordance with In re Lee, (for
example, earlier publications by persons not employed by the USPTO
or any other Patent Office), demonstrating how the terms are used
and understood by persons of ordinary skill in the art, or by way
of expert evidence of a person or persons of experience in the
art.
[0099] Reference is made herein to welding electrode tips and caps,
which are intended to provide a generic example of a work piece
that is movable with respect to at least one degree-of-freedom of
motion while being coated. Other objects could also be coated. In
respect of each tip or cap that is spinning on a mandrel, a
polar-cylindrical co-ordinate system may be defined, in which the
axial, or z-direction defines the axis about which the cap or
electrode tip is formed, or has a surface, on a body of revolution,
the term radial refers to a distance away from the z-axis, and
circumferential refers to an angular direction about the z-axis.
For generality, the workpiece may be other than a welding cap, and
may be mounted for one or two degrees-of-freedom of motion in
translation in, for example, an x-y plane in a Cartesian
co-ordinate system or frame of reference. That motion may be
reciprocating or cyclic motion, and may include both rotational and
translational components.
[0100] By way of general overview, an electrode handle apparatus,
or simply a handle, is shown in FIG. 1 as 20. Apparatus 20 has an
electrode holder, indicated generally as 22, in which an electrode
24 is mounted. Electrode 24 has a cylindrical shape, and is
relatively long and thin. Electrode 24 may be a semi-conducting
material, such as titanium carbide, titanium di-boride, or such
other material as may be. The outwardly extending tip of electrode
24 is seen positioned toward an object apparatus 26, which includes
a mandrel 28 upon which is mounted a workpiece to be coated, such
as may be a welding electrode cap 30. By the nature of the coating
process, electrode rod 24 is consumable and replaceable. The
mandrel, or support fitting, or jig, or fixture, upon which the
workpiece is mounted has at least one degree of freedom of motion.
In the example shown, the degree of freedom of motion is rotational
motion about the longitudinal axis of mandrel 28, such that cap 30
is spinning, as notionally indicated by arrow `A`. As noted above,
in general a workpiece may be mounted on a seat or jig and moved in
some manner be it rotational or translational in the x-y plane.
Mandrel 28 and apparatus 22 are both connected to an electrical
power source, such that they are of opposite polarity. When
electrode 24 is brought into contact with electrode cap 30,
electric current will flow between them. Inasmuch as current flow
is initiated by a spark as the two parts come into proximity, and
inasmuch as both parts are moving, contact may be intermittent, and
at each contact a portion of electrode 24 may melt or otherwise be
deposited upon cap 30. As cap 30 spins and electrode 24 makes and
breaks contact, the top of cap 30 becomes coated with the electrode
material. Cap 30 may be a copper cap, it may have a first coating
of nickel; and the TiC or TiB.sub.2, or other coating material, may
be laid down on top of the nickel. Handle apparatus 20 may be a
vibrating apparatus, such that the tendency to make and break
contact with the object workpiece is enhanced.
[0101] Considering again apparatus 20, there is housing, or
backshell, or haft, or body generally indicated as 32, that housing
including first and second portions 34, 36, which may be referred
to as backshell halves. First and second housing portions 34, 36
are held together by an array of fasteners such as may be in the
nature of threaded cap screws 48. Both backshell halves may have
porting in the nature of vents such as inlet vent array 38 and
outlet vent array 40, by which air or other gas coolant may be
admitted to, and enabled to depart from, the interior of housing
32. The backshell halves may be made of an electrically
non-conductive, or electrically insulating, material. The girth of
housing 32 may be suitable for being grasped in the hand of an
operator. Although not necessarily circular in section, as seen in
FIG. 6, the general proportions of housing 32 are that it may have
a through dimension of the order of 2 inches.
[0102] At the connected end, housing 32 has three input
connections, the first input being an electrode power connection,
which may be a DC power connection, indicated as 42, and which may,
ultimately, be connected to an ESD power source--the same power
source of which the opposite pole is connected to mandrel 28. The
power source may be indicated generically as a power supply 200,
discussed below. The second input is a motor power source 44 for
operation of an electric motor within housing 32, in the form of a
power cable which may be 120V AC 60 Hz. or 220 V AC 50 Hz, or a 12V
DC source, or such other source as may be, and could be a pneumatic
source. The power may in some embodiments also be provided by power
supply 200. The third input is a cooling line 46, such as may be an
air line. At the free end of housing 32 (i.e., the end distant from
the three connection inputs) is the tool holder assembly, indicated
generally as 50, and described in greater detail below.
[0103] Considering FIGS. 4 and 5, an internal machinery space 52 is
defined within the two halves or portions 34, 36 of housing 32. The
inputs pass into housing 32 at an opening 54. Opening 54 may be
located at the first end of housing 32. It may be that roughly half
of each opening is formed in each portion of the housing, the
perimeter of the opening being closed together when the halves are
assembled. There could, alternatively, be a separate opening for
each input as may be, and such an opening or penetration could be
formed entirely in one half the shell. The main power cable, namely
that of electrode power connection 42, is secured at a terminal lug
56 inside housing 32, adjacent to opening 54. The coolant conduit
may have the form of a hollow pipe 58 that is formed to run along
the inside proximal margin of housing 32, with an outlet 59
oriented toward tool holder assembly 50 adjacent the seat of
electrode 24. Coolant conduit 58 may be used to carry air as a
cooling fluid, or, alternatively, it may be used to conduct an
inert gas, such as argon, to electrode rod 24, and, whether used
for cooling or not, may be used for the alternate purpose of
providing an inert gas shielding to the coating process. That
portion of pipe 58 lying outside of opening 54 may be made of a
non-electrically conductive material such as a plastic tube. That
portion of pipe 58 lying within housing 32 may be made of a metal,
such as copper, aluminum, stainless steel, mild steel, or such
other metal as may be suitable, those metals tending to have higher
thermal conductivity than plastic pipe.
[0104] Also connected at terminal lug 56 is a predominantly
lengthwise-extending member defining a transmission 60. Assembly 50
is mounted to the far end of transmission 60. Transmission 60 may
have the form of a lever or spring or beam 62. The first end of the
spring or beam is secured at terminal lug 56, as indicated. The
main or medial portion of transmission 60 may lie next alongside
pipe 58 and may be contained between pipe 58 and a fulcrum 64
located intermediate the first and second ends of transmission 60.
In the embodiment illustrated, fulcrum 64 is located closer to tool
holder assembly 50 than to lug 56. The position of fulcrum 64 is
adjustable according to the various positions of an array of
mounting fittings, which may be threaded blind sockets, indicated
generally as 66. If the length of transmission 60 from the center
of lug 56 to the axial centerline of tool holder assembly 50 is
designated as "L", the position of fulcrum 64 may be in the range
of about 3/5-4/5 of L from lug 56 to assembly 50. That portion of
transmission 60 lying beyond fulcrum 64, i.e., between fulcrum 64
and tool holder assembly 50, is a cantilever. Tool holder assembly
50 acts as a concentrated mass at the end of the cantilever.
Transmission 60 so restrained has a configuration like a
spring-board or diving board.
[0105] Tool holder assembly 50 has a first portion 72, and a second
portion 74. The distal end of transmission 60 has an aperture
formed therethrough so male portion 76 of first portion 72 can mate
with the female portion 78 of second portion 74, with the end of
transmission member 60 sandwiched therebetween. It is arbitrary
which of portions 74 and 76 is male and which is female, the parts
are joined in a connection. As mated together, tool holder 50 is
rotatable about its long axis to permit electrode 24 to be turned.
First portion 72 may be a locking socket or chuck defining the seat
80 for electrode 24, and may have tightening or securing members,
such as a grub screw 82. Second portion 74 includes spring-biased
graphite brushes 84. A handle 86 is mounted to second portion 74,
the handle having an appropriate grip by which it may be turned,
such as by a person wearing gloves. Handle 86 may be made of an
electrically insulating material, such as a cast plastic. First
portion 72 and second portion 74 are both electrically conductive,
and may be made of copper or a copper alloy. Consequently an
electrically conductive path is completed from electrical power
connection 42 through transmission 60, through brushes 84, through
second portion 74 and first portion 72, and into electrode 24.
[0106] Also within housing 32 is a vibration assembly, or
oscillator, or shaker, or motion exciter such as may be identified
as 90. It may include a motor 92, which may be an electrical motor
connected to motor power source 44. Motor 92 may drive an output
shaft 94 that passes through near and far bearings 96, 98. An
eccentric 100 is mounted to shaft 94, such as at the distant end
thereof. Eccentric 100 may be a disc with either an unbalanced
weight or an unbalanced cavity indicated at 102, such that when
shaft 94 rotates, assembly 90 vibrates. The resultant vibration has
an amplitude having a component in the axial direction of electrode
rod 24. An air moving device, such as a fan blade, or impeller 104
is mounted to shaft 94, and, as shaft 94 turns impeller 104 draws
air in through inlet vent array 38, and urges it out through outlet
vent array 40. In an alternate embodiment, the direction of the
airflow may be in the opposite direction.
[0107] In use, an operator grasps housing 32, and uses electrode 24
much like a pencil to paint or coat the workpiece object. While
this is occurring, the rotation of eccentric 100 causes apparatus
20 to vibrate, which, in turn, causes electrode 24 rapidly and
repeatedly to make and break contact with the work piece. With each
oscillation there is a new spark and deposition of the material of
electrode rod 24 onto the workpiece.
[0108] Vibration assembly 90 provides a forcing function input to
transmission 60. Transmission 60 is not merely an electrical
conductor, but also a mechanical conductor or resilient transmitter
in terms of transmitting an input impulse, or wave-train of
impulses. The force and displacement transmissibility of
transmission 60 of the mechanical motion of the forcing function
input to electrode holder 50 is dependent upon the natural
frequency of the vibrational degree of freedom of interest. For
example, in assembly 50 the axial direction of electrode 24, that
direction being the same direction as the dominant vibration mode
of the spring board or beam of transmission 60 as it flexes
outboard of fulcrum 64. Although the axis of the cylindrical rod of
electrode 24 is shown as being perpendicular to the long axis of
apparatus 20, this need not necessarily be so. In another
embodiment, electrode 24 may have the form of a rod having an axis
parallel to, or concentric with, the main body of housing 32.
[0109] The handle apparatus drives the consumable electrode 24 to
vibrate in a first degree of freedom of motion in longitudinal or
predominantly longitudinal movement (i.e., having a component of
motion, possibly a predominant component of motion in the direction
of the longitudinal axis of the electrode rod) relative to the
metallic surface being coated or treated in the process. The
longitudinal force or displacement is generated by attaching an
eccentric circular metal load to a spinning motor. The positioning
of the eccentric weight determines the pounding or contact force
when the contacts are made. The frequency of vibration is
controlled with the speed of the motor to which the eccentric
weight is mounted, and the amplitude of vibration may be affected
by the placement of the fulcrum. The longitudinal movement of the
consumable electrode in a direction that includes a component of
motion, and usually a predominant component of motion, normal to
the surface to be treated, allows the periodic contacts to be made
with the metallic surface of the workpiece. This occurs while that
workpiece surface is being driven in a second degree of freedom of
motion. The combination of motions, and the vibration-driven urge
to make and break contact, may result in a relatively stable or
consistent sequence of electro-sparks (when the contacts open) and
depositions of coating material (when the open contacts approach)
that take place in the process. The vibrating motion is, or
includes, motion normal to the surface being coated, and occurs at
the same time as the surface is being moved in another degree of
freedom, e.g., as by rotating about an axis, or by translational
movement relative to the normal direction, such as to bring a
"fresh" portion of the work piece under the coating rod.
[0110] This process may be compared with a known process in which
only the workpiece is moving, e.g., by rotation, and the coating
electrode rod is held against the surface, or in which the
workpiece is stationary, and the electrode rod is spinning about
its axis. The coating material tends to be much harder than the
copper or other material being coated (which, if copper, may itself
have a nickel overlay). In the existing process, there may be a
grinding effect of the hard coating material, tending to remove the
soft material in the ESD process, including a fair portion of the
previously deposited coating material that one might wish to
retain. Such a process may not be as efficient as might be desired.
By contrast, the axial vibrating motion of rod 24 normal to the
surface may tend to facilitate relative translation of the
workpiece between electrosparks, possibly without the same grinding
effect, and perhaps with a greater output yield for a given
quantity of coating rod consumed.
[0111] The embodiment of electrode handle apparatus 120 of FIGS.
7-9 is substantially similar to the embodiment of electrode handle
apparatus 20 of FIGS. 1-6, and, to the extent applicable, common
parts are identified by common part numbers. Apparatus 120 differs
from apparatus 20 to the extent of employing a servo motor 122
carried on a motor mount 124 seated in housing 126. Servo motor 122
may be a brushless DC (BLDC) servo motor. Servo motor 122 is a
variable speed motor. A separate shaft 130 is carried in a first,
or mid-position bearing 132 and a second or distant position
bearing, or pilot bearing 134. An imbalance weight 136 and adapter
138 are mounted on the distal end of shaft 130 (i.e., the end
distant from motor 122), and correspond to eccentric 100. An
impeller 140 and impeller adapter 142 are mounted to shaft 130
between the front and mid bearings (i.e., bearings 134 and 132).
The proximal end of shaft 130 is connected to the output shaft 144
of motor 122 by a flexible coupling 146. Flexible coupling 146 may
tend to isolate motor 122 from radial loads on shaft 130.
[0112] Further, apparatus 120 has a movable fulcrum 150 that is
externally accessible, and adjustable by means of access slot 152
and set screw 154. As previously, the ability to move fulcrum 150
longitudinally toward tool holder assembly 160 may tend to permit
the cantilevered portion of transmission 60 to be choked down, both
by shortening the length of the cantilever, and by constraining its
lateral motion. Fulcrum 150 may, in that sense be said to choke
down, or damp down, the amplitude of vibration of tool holder
assembly 160 in direction namely the axial direction of rod 24.
[0113] An alternate electrode handle apparatus 220 is shown in
FIGS. 10-14. Apparatus 220 may be taken as being the same, or
substantially the same as apparatus 20, to the extent that similar
parts may be indicated with the same item numbers, and the
foregoing description may be taken to apply to the features of
apparatus 220.
[0114] Apparatus 220 differs from apparatus 20 in a number of
features. As preliminary points, although apparatus 220 does not
show a third input, namely cooling line 46, it may be understood
that apparatus 220 may include such a line in other embodiments.
Electrical power connection line 44 feeds electrical power from a
power source to motor 92. Apparatus 220 includes a flexible couple
or connection or clutch or damper, indicated as connection 230.
Connection 230 may include a spring or resilient member such as may
tend to provide a dynamic filter between motor 92 and the eccentric
weight 100. Connection 230 is mounted to the output shaft of motor
92. Driven shaft 232 is connected to, and extends from connection
230 to an impeller 104, and, in turn, to eccentric weight 100. As
motor 92 turns, impeller 104 draws ventilating air through inlet
apertures or vents or ports 38, across motor 92, and forces it out
exhaust ports 40. Driven shaft 232 is carried in front and rear
bearings 234 (axially near motor 92) and 236 (axially more distant
from motor 92), with weight 100 being mounted axially outboard of
bearing 236. The axial spacing of bearings 234 and 236 may provide
a long moment arm, and may tend to aid in resolving the eccentric
imbalance into the housing, or housing body, 240 through bearings
234 and 236 rather than through the bearings of motor 92. Motor 92
may have an on-off switch or speed control as shown on the dorsal
portion of apparatus 220 at 238.
[0115] Housing body 240 may be open at the head or front end,
(i.e., the end nearest electrode 24) as at 242. Housing body 240
may have left and right hand parts of halves 244, 246, that fit
together, as above, and that may have indexing pins and blind
sockets for that purpose. One or the other of halves 244, 246 may
include an access port or keyway 248 through which a tool, such as
a screw driver, socket, wrench, or Allen key, may be introduced to
tighten or loosen the securing fastener, such as a grub screw, of
eccentric weight 100. To the extent that end 242 is open, eccentric
weight 100 may then be removed or replaced, as may be desired or
suitable for the speed of operation such as may be set or adjusted
with speed control 238.
[0116] Further, apparatus 220 may include an externally adjustable
fulcrum, or seat, or snubber, or damper 250 that, when secured,
bears against the motion transmitting member to which electrode 24
is mounted, such as spring 62. In essence, damper 250 functions as
a guitar fret, changing the natural frequency of the cantilever of
spring 62, and also as an amplitude limiting device, to the extent
that damper 250 confines spring 62. Damper 250 may include a rubber
(or other polymer or elastomer) body, and may have a wedge shape.
The fastener 252 of damper 250, and its range of adjustable
locations, is seen in FIG. 13.
[0117] Further still, apparatus 220 includes a different electrode
holding fitting or seat, 260. While handle 258 may still be rotated
about its longitudinal axis by virtue of its rotatable mounting 262
to spring 62, a split collar 264 has left and right jaws 266, 268
that seize upon the end of electrode 24, and are secured by a
chuck, or lock, or lateral fastener 270. The jaws of apparatus 220
may tend to hold a smaller portion of rod 24 than the fitting of
apparatus 20, thus tending to reduce the wastage of the expensive
sintered coating composition rods.
[0118] A further alternate embodiment is shown in FIGS. 15a and 15b
in which there is a vibrating handle apparatus 280. Apparatus 280
is substantially the same as apparatus 220, and may be taken as
being the same except as noted. Apparatus 280 differs from
apparatus 220 to the extent that housing 282 of apparatus 280 has
in both left and right hand half-shells a forwardly extending
bulge, or protrusion, or head, indicated generally as 284, that
defines an internal chamber or accommodation 286. Accommodation 286
provides a seat for a motor 288. Motor 288 may be a brushless DC
servo-motor. The axis of rotation of the output shaft of motor 288
is aligned with the axis of rotation of electrode rod 24. The
output shaft of motor 288 is connected to the chuck (i.e., mounting
262, and jaws 266, 268) that hold rod 24 by a loose-splined fitting
or coupling 290. Coupling 290 tolerates relative axial displacement
of rod 24 as spring 62 vibrates. Motor 288, when in operation, may
turn at a relatively slow speed. The speed of the output shaft of
motor 288 driving the chuck may have a chuck speed in the range of
40-120 rpm, and may in one embodiment have a speed of about 60 rpm.
Motor 288 need not be activated, and may be programmed for a single
output speed, a choice of output speeds, or a continuously variable
output speed such as may be controlled by the operator's
inputs.
[0119] In the examples of apparatus 20 and apparatus 220, there may
be an implicit assumption that the workpiece is moving, such that
it has (at least) a single degree-of-freedom of motion, e.g.,
rotational spinning about an axis as indicated by arrow `A` in FIG.
1. In addition there is at least a second degree-of-freedom of
relative motion between electrode rod 24 and workpiece 30 by virtue
of the vibration of rod 24 driven by the mechanical forcing
function oscillator, (i.e., driven eccentric weight 136 input to
spring 62, for example).
[0120] It may be that the workpiece to be coated or treated is not
a welding cap spun about the axis of the body of revolution. The
workpiece may not be a body of revolution. It may be that the
workpiece is stationary, or, alternatively, that the workpiece is
constrained to other degrees of freedom of motion, such as motion
in an x-y plane, which may be linear motion along an axis in that
x-y plane. That motion may be periodic and may be reciprocating. In
the example of apparatus 280, quite aside from the manner in which
the user manipulates the handle, the handle apparatus has both
first and second degrees of freedom of driven motion in terms a
driven function in reciprocating axial translation due to
vibration, and a second degree-of-freedom of driven motion in
rotation about the axis of rod 24. In this embodiment, whether the
workpiece is stationary or not, the (at least)
two-degrees-of-freedom of relative motion is provided by apparatus
280 in any event. Further, whatever orientation may be used by the
operator, it is thought that rotation of rod 24, even relatively
slow rotation, about its axis, may tend to promote more even
consumption of rod 24 as a function of circumferential angular
orientation of rod 24. That is, as rod 24 rotates it may tend
continually to present "fresh" rod material to contact the work
piece, and may tend to be consumed evenly.
[0121] ESD Surface Modifications
[0122] As noted above, crack formation and delamination are known
phenomena in electrode coating processes (See FIGS. 18b and 18c).
There are different approaches to treating the ESD coating to
reduce or to attempt to eliminate defects such as may be found in
the coating. However, ESD coatings treated by post-processing may
require expensive tooling and procedures. In an alternate approach
described herein, an in-process ESD coating treatment action may
occur during the coating process, substantially simultaneously. In
this process the ESD power source 200 has an output that alternates
between an ESD phase, or step, or duty-cycle portion, or period;
and a peening power during the surface coating process as suggested
by the alternating coating and peening stages 202, 204 in FIG.
17a.
[0123] It has been observed by the inventors that peening the
surface coating 206 using the same vibrating applicator may cause
plastic deformation of the coating, and, in so doing, may tend to
close up the gaps or cracks 208 and reduce the number of
delaminations 210 in the coating. That is, when the electrical
power provided is reduced, as by reducing the voltage to a second
voltage, V.sub.2, below the voltage at which arcing can initiate,
defined as the ESD initiation voltage, or first voltage, V.sub.1,
the melting of the approaching rod may tend not to occur. Instead,
in the period of time in which contact is broken between the
electrode rod and the workpiece no electrical current flows. Thus
both rod 24 and the previously deposited material cool rapidly.
However, while the temperature may still be high, it may not be
high enough for the coating material to remain molten. Although
below the melting point of the deposition material, and no longer
molten, the coating may still be at a temperature at which the
coating is soft and plastic, i.e., not fully hardened. At this
elevated temperature striking the coating may tend to cause plastic
deformation of the coating, which may tend to force closed cracks
in the surface, such as cracks 208. It may be more effective to
modify the surface, defects in the coating when the temperature of
the coating is high, but not high enough to be molten.
[0124] As suggested in FIGS. 16, and 17a-17d, the ESD power source
has a controller indicated generally as 212 that is capable of
operation at two (or more) different levels of output power or
voltage, or in (at least) two different modes of operation. There
may be a first mode of operation, which may be termed an ESD
coating mode corresponding to stage 202, in which the voltage
differential V between the electrode rod and the electrode
workpiece to be coated may be established at a first level, or
first magnitude, which may be a voltage sufficient to cause arcing
between the rod and the workpiece when they are brought into
proximity with each other, and are then in contact. This is a
deposition mode in which the coating materials melts and "splashes"
onto the workpiece (See FIG. 18a). The deposition mode starts at a
time x.sub.1 at the ESD initiation voltage, although that voltage
may drop rapidly as deposition occurs. The physical motion of the
moving rod, e.g., due to an imposed mechanical vibration forcing
function such as oscillation of handle apparatus 20, may then break
the contact, ceasing the current flow, and ceasing deposition at
time x.sub.2 the time interval of deposition then being
x.sub.1-x.sub.2=t.sub.1.
[0125] Power supply 200 may then sense the cessation of current
flow, and, given that sharp and sudden interruption in current, may
drop the magnitude of the output voltage to electrode rod 24. This
may be done by switching off the switch T1 that is connected to a
first or main capacitor (or capacitor bank), C1, that is typically
charged (and re-charged, as may be) to the ESD initiation voltage
by ESD Power Control 214 typically by switching the controlling
switch or transmitter T.sub.1 to the "off condition", and by
switching to another branch of the circuit having a capacitor (or
capacitor bank) C2 whose initial charge is at a second, lesser
selected voltage V.sub.2 typically by switching the controlling
switch on transmitter T.sub.2 to the "on condition" Voltage
V.sub.2. charged and recharged across capacitor bank C2 by a
Peening Power Control 216. Contact remains open over time period
t.sub.2. When the rod again approaches the workpiece and makes
contact as at time x.sub.3, the peening voltage is applied and
current flows until contact breaks.
[0126] During the discharge phase, the power supply to the first
capacitor bank is interrupted, i.e., shut off, so that the power
supply does not supply power to C1 during discharge. Only once T1
has been opened (i.e, turned off), after the discharge phase of C1,
is power reconnected to charge C1. Similarly, switch T1 does close
(i.e., turn on or activated) until C1 has been charged to the
programmed voltage threshold, (in this example, the ESD spark
initiation voltage). Thus only once the capacitor bank has been
fully charged is the apparatus enabled to discharge by turning "On"
switch T1, at which time further charging current from the power
supply is also inhibited. Thus the logic for switch T1 to be turned
on requires that two conditions be met: first, that C1 has been
charged to V1; and, second, that the time period counted out by the
clock between the most recent previous step has expired. When
switch T1 is activated to the "On" condition, the next time that
the tip of rod 24 approaches the workpiece, discharge will
ensue.
[0127] Similarly, the second capacitor or capacitor bank, C2,
cannot be discharged unless it has been fully charged to its
programmed or preset threshold voltage, V2. Switch T2 is only
activated to the "On" condition when C2 is fully charged, and the
pre-set timing gap between the most recent current flow has
expired.
[0128] It follows that T1 and T2 are not "On" at the same time,
although they may both be "Off" during the timing intervals between
a T1 or T2 current flow cessation and the next succeeding T2 or T1
current flow commencement. While, in general, the time duration of
each successive T2 or T1 "On" condition may be individually varied,
they may typically be the same. Similarly, while the duration of
the gap period (where neither T1 nor T2 is "On", but rather, both
are "Off") may be individually varied it is convenient that they be
uniform. Further, while the "On" and "Off" periods may differ, they
may typically be of about the same duration, that duration being
typically of the order of 1 mS-5 mS, and, in one embodiment, about
2 or 3 mS. The gap period may be very short, particularly where
more than two capacitor banks are employed.
[0129] In one embodiment the second or lesser electrode voltage may
be cut to zero. In another embodiment the magnitude of the second
output voltage V.sub.2 may be different from, such as being cut
below, the ESD initiation voltage V.sub.1, to a non-zero level at
which current may flow on contact, and so a heating or warming
effect may take place, but not so much heating as to cause melting.
The warming may prolong the time during which the coating remains
suitably soft for plastic deformation. In this second mode the
voltage differential between the power supply output to the rod and
the workpiece connection to the power supply may be commenced at,
and continue at, a level that is less than, and may be
substantially less than, of the ESD initiation voltage at
commencement of discharge. In some embodiments it may be less than
1/2 of the ESD initiation voltage. For example, in some embodiments
the first voltage may be in the range of 25 to 50 V DC and may in
one embodiment be approximately 30 V. The second voltage may then
be chosen to be a value of less than 30V, such as 0-30 V, and in
one embodiment may be about 20V (or roughly, up to about 1/4 of the
first ESD initiation voltage, and in one embodiment about 2/3 of
that initial voltage). In the first discharge circuit, there stored
charge on the capacitor C1 is connected directly to the terminal,
i.e., there is no intermediate current-limiting resistive element.
Once arcing occurs, the discharge may have the form of a very rapid
spike in which voltage drops rapidly. In the process, ESD Power
Control supply 214 This lesser voltage may also decay somewhat over
the contact time of the rod with the workpiece with the use of a
resistor R1 mounted in series with the thyristor, or switch, T2.
Thus there is a first mode at a first voltage or first power, and a
second mode at a second, lesser, voltage or lesser power. In one
embodiment the operator may set the selected first and second
voltage levels V.sub.1 and V.sub.2.
[0130] Contact may again be broken when further motion of the
welding rod occurs, as due to the mechanical vibration forcing
function of the handle. Again, the power supply may sense the
abrupt cessation of current flow, and may use that step change
signal again as a signal, or datum, or indexing feature, or
trigger, or triggering event to alter the voltage supplied. For
example, in response to that triggering event, C2 power supply may
switch off the second capacitor or capacitor bank C2 by switching
off switch T2, (such that C2 may revert to a charging or recharging
mode powered by Peening Power Control 216); and may revert to the
first capacitor C1, such that a new deposition period or step or
stage, or duty cycle, may commence.
[0131] Alternatively, power supply 200 may switch to a third
capacitor, or capacitor bank which may be at either the same
initial voltage as C1 (in the event that C1 is still recharging and
a fresh, fully charged ESD initiation voltage charge is required);
or the same voltage as the initial voltage of C2 (in the event that
a fresh lesser voltage charge is desired); or a third voltage, that
is different from either of them. For example, the initial voltage
of C2 (or a cut-off condition of no voltage to the electrode
holder, whether there is a sec/ond bank of capacitors or not), may
be zero. Alternatively that second voltage, or power level, may be
quite low because the newly deposited coating material remain very
hot, and needs little or no additional heat when the rod approaches
to contact it for a second time. It may be that by the third period
of contact, the deposited material may be somewhat cooler than it
was during the second contact period, and so it may be that more
heating than previously is desirable to slow cooling such that the
surface coating may remain plastic, or more easily made plastic.
Thus the third voltage may be higher than the second voltage, and
yet still well below the level of voltage and power such as might
cause the coating again to become molten. The schedule of first,
second, and third voltages may be pre-programmed into the power
source controller, or the voltages may be selected by the user.
[0132] After being contacted for a third time, contact may be
broken again due to the motion forcing function of the electrode
holder. Once again, the sensors of the power supply, monitoring
current, for example, may indicate a step change in current (i.e.,
a drop to zero) when contact is broken, and voltage may be switched
"off" or "on", accordingly in respect of the next branch of the
circuit. There may be several low voltage or zero voltage impacts
of the rod with the work piece. However many "cold" impacts there
may be, be it one or more than one, after a period of time the
process may start back at the beginning with C1 and a higher
voltage, namely the ESD spark initiation voltage, such as to cause
additional new coating material from the electrode rod to be
deposited on the work piece.
[0133] In the process described above, the power supply may tend
continuously to be sensing and evaluating current flow as a means
to trigger switching or altering of voltage levels supplied to
electrode rod 24. In an alternative to the process described above,
the speed of rotation of the workpiece may be known, and the
frequency of vibration of the motion forcing function of the
vibrating handle may also be known, such that the period of time
between successive contacts, and breaks of contact, between the
electrode rod and the workpiece is known, at least in an
approximate sense. With the frequency of vibration being known, the
power supply may be programmed to run at the first voltage for a
given period of time, that period of time being at least as great
as one wavelength of the forcing frequency. That is, if the forcing
frequency is 100 Hz, then the time of C1 voltage "on" would be at
least 10 ms. That period may then be followed by a period of time
at least as long as one wavelength of the forcing frequency in
which the C2 voltage is applied. In the event that there is a third
voltage, the power supply may follow the second period of time by a
third period of time of at least one wavelength at the third
capacitor bank voltage, and so on, for as many time periods and
voltage variations as may be.
[0134] In the embodiments described, the nature of the deposition
step is different from the nature of the non-deposition step. In
the deposition step, the action is, substantially, a discharge of
accumulated charge against a very low, or approximately zero,
resistance. The essence of the step is a capacitive discharge. It
may be characterized as a spike that commences at V1, and in which
the current is very large, but of short duration at a rapidly
falling voltage level. By contrast, the presence of resister R1 in
the second circuit, namely the circuit of switch T2, may tend to be
current limiting. R1 may have a resistive value in the range of 1/2
or 3 Ohms. The current flow in that second stage or phase or
portion does not then approximate a sudden surge or spike of an
unrestricted capacitive discharge, but rather a portion, perhaps an
initial portion, of a controlled capacitive decay curve with an RC
time constant, that constant being a function of the product of
R1.times.C2. That decay curve commences at V2. Where the time
period of contact is very short, the end voltage may be relatively
close to V2. While there may be an initial very short period of a
spark during the T2 "On" phase or stage, given the voltage drop
across R1 the phenomenon is one of high current flow heating the
coating during contact, as opposed to an arcing phenomenon.
[0135] In the process, the welding electrode cap to be coated may
be spinning or turning at some rotational speed. That speed of
rotation of the workpiece may be of the order of as low as about
200 rpm, and may be as high as 1200-1800 rpm. In one embodiment it
may be about 300 rpm to about 600 rpm. It may be driven by a motor
running at 1725 rpm through a reduction drive. The BLDC motor of
the oscillator drive in the vibrating handle may run at speeds in
the range 15,000-20,000 rpm, and in one embodiment may be about
18,000 rpm, or 300 Hz. The mean contact time of the rod with the
electrode cap such as t.sub.1, t.sub.3, t.sub.5, etc., may be in
the range of 1-10 mS, and in one embodiment may be about 3 mS. In
general t.sub.1=t.sub.2=t.sub.3=t.sub.4=t.sub.5=t.sub.6, although
this need not be so. That is, the mean contact time need not be
equal to the mean dis-engagement time. The contact time while
melting and depositing material may vary from the contact time
while peening the coating.
[0136] The hammering or repeated mechanical impact process that
occurs while the voltage is reduced (or cut to zero), may be termed
"peening" of the coating, and may be associated with a lower,
peening power level. Normal ESD electro-spark depositions are
formed during the coating cycles (or periods). The peening actions
used to modify the surface coating layer are introduced during the
peening periods or reduced power. As described above, the output of
the ESD power source is switched to a different power level, which
could be zero voltage, during the Peening cycles (periods). The
already-deposited surface is modified by the peening actions. That
is, while the coating material is still warm, immediately after
deposition, the vibrating action of the electrode rod, driven by
the vibrating handle, contacts the deposited surface, tending to
make it an impact surface. As the name may suggest, the surface is
thought to undergo a "peening" or hammering during the repeated
impacts. Plastic deformation of the cooling, formerly molten and
temporarily deformable surface may tend to reduce, or close up,
cracks and may discourage delamination that may have occurred
during, or to have arisen from the ESD coating actions. While
peening may occur with no electrical current to the electrode rod,
the use of some continuing current as a peening power level may
tend to maintain the temperature of the spot under the peening
actions and thereby slow the cooling process, such as may tend to
allow a longer time period in which the coating may be locally
plastically deformed. The peening power electrical voltage and
current levels may be adjusted depending on the coating subjects
and applications.
[0137] The power source, or power supply described above may be
used to implement the in-process coating and peening actions during
the coating process. That is, the dual action ESD power source is
able to deliver the voltage or power for the regular ESD actions,
and also to deliver power (electrical power could be zero) for the
peening actions.
[0138] The Dual Action ESD power source or power supply 200
includes the following modules: [0139] ESD Power Control 214: for
the voltage control of the ESD capacitor, C1. [0140] Peening Power
Control 216: for the voltage control of the Peening capacitor, C2.
[0141] Dual Action Control Unit 218: for the voltage control of the
ESD and Peening capacitors; also the switching control of the ESD
and Peening power outputs. [0142] User Panel 215: for the
programming of the ESD and Peening capacitor voltages; and the
control pattern of the ESD and Peening actions.
[0143] The ESD and peeing output pattern is programmable by setting
some parameters via user panel 215. This may permit flexibility for
the control of output patterns in different application
environments.
[0144] The length and frequency of the coating and peening periods
are adjustable, and may depend on the target coating subjects and
materials. There power level may also be adjusted according to
variations in the nature of the coating and peening action and
these parameters are dependent on the target subjects and
materials.
[0145] Surface coating modification methods may employ ultrasonic
pressurized rotating friction process. This method may be used to
encourage improvement of the density of the coating layer material
and the bonding of the coating material to the base metal of the
substrate. This process may be applied in respect of the coating of
welding electrodes. Coating electrodes, or other surfaces.
[0146] Material of FIGS. 18d-18h, 21, 22, 23 and 24
[0147] FIGS. 21, 22, 23 and 24 show details of an apparatus for the
modification of surface coatings on resistance welding electrodes.
That is, in the example the workpiece may be a welding electrode
cap. The cap may have a coating. The coating may be a TiC coating.
The workstation for the clamping and rotation of the workpiece may
include a work bench A; an equipment frame 302; an electric motor
303; a transmission belt 304; a pulley 305; a supporting bearing
306; a transmission shaft 307; a clamping chuck 308 for holding the
workpiece, and guiding rails 309 and 310. Components of an
integrated ultrasonic rotating friction head assembly may include
sliders 311; a lower panel 312; a screw shaft 313; an upper panel
314; an ultrasonic positive power terminal or input 315; an
ultrasonic negative power terminal or input 316; a bushing or brush
or sliding conductor 317; bearings 318; a belt pulley 319; a
transmission or drive belt 320; an electric motor 321; an
ultrasonic transducer 322; a transducer horn 323; a rotating
friction head 324; a housing 325 and a slider 326. Components of
the ultrasonic power source may include an ultrasonic power source
positive terminal or output 327; an ultrasonic power control knob
328; an ultrasonic power source positive output 329, and an
ultrasonic power source power switch 330.
[0148] The following is a description of an apparatus and method
for post deposition treatment of a coated resistance welding
electrode, as shown in FIGS. 21, 22, 23 and 24.
[0149] A work table A is employed for the clamping of the
workpieces. Table A may have an equipment base or frame 203, an
electric motor 303, a mechanical transmission or drive belt 304, a
pulley 305, a supporting bearing 306, a transmission shaft 307, a
clamping chuck, or tool-holder, in which to hold the workpiece 308,
a first track or guide rail 309 and a second track or guide rail
310.
[0150] The integrated ultrasonic rotating friction head assembly B
(which may in essence be apparatus 20, 120, etc.) may have a slider
311, a lower panel 312, a screw shaft 313, an upper panel 314, an
ultrasonic transducer positive input terminal 315, an ultrasonic
transducer negative input terminal 316, a brush or shoe, or sliding
conductor 317, bearings 318, a belt pulley 319, a mechanical
transmission or drive belt 320, an electric motor 321, a transducer
322, a transducer horn 323, a rotating friction head 324, a housing
325 and a slider 326.
[0151] An ultrasonic power supply C may include an ultrasonic
output positive terminal 327, an ultrasonic output power knob 328,
an ultrasonic output negative terminal 329, and an ultrasonic power
switch 330.
[0152] The apparatus may include the integration of the combined
apparatus of assemblies A, B and C. Electric motor 303 of the
workstation A is fixed to, or mounted to, the main machine frame
302. Drive power from the output shaft of electric motor 303 is
coupled to drive transmission shaft 307 in rotation through the
transmission belt 304, pulley 305 and supporting bearings 306.
[0153] The workpiece having a surface coating to be treated or
modified is mounted to, or in, clamping chuck 308. Clamping chuck
308 is connected to the transmission shaft 307, such that operation
of motor 303 may cause corresponding driven rotation of chuck 308.
Guide rails 309 and 310 of module A are fitted to, or mated to, or
engaged with, sliders 311 and 326 respectively of the integrated
ultrasonic rotating friction head assembly B.
[0154] Pressurized rotating friction motion from rotating friction
head assembly B can be repeatedly applied to the surface coating on
the workpiece 301 as required for the processing procedure. In this
description the term "pressurized" may tend to mean pressing or
forcing, or biasing, the coating apparatus against workpiece 301
under some biasing force, where at least a component of the force
is normal to the surface of workpiece 301 at the location of
contact of the coating interface, such that the coating apparatus
is biased against the workpiece such that relative motion (e.g.,
including a component of motion tangential to the normal vector
defining the line of contact of the surfaces) between them will
give rise to friction between the coating apparatus and the
workpiece surface, e.g., in the tangential plane to which the
normal vector of the surface is perpendicular.
[0155] Upper panel 314, which is mounted with the rotating friction
head assembly, is connected to lower panel 312 through the coupling
of screw rail 313. Rotating friction module B can be driven up and
down with the use of the screw shaft of screw rail 313. Application
of certain pressure, or force, of, or against, the coating surface
of workpiece A can also be achieved with simultaneous rotational
motion, be it of workpiece A or of the coating apparatus. The
positive 315 and negative 316 terminals of the ultrasonic
transducer are connected to the output positive 327 and negative
329 terminals, respectively, of ultrasonic power supply C. Sliding
conductor 317 is connected to transducer 322 with the use of a pair
of electrical wires. Transducer 322 is connected to the
transmission horn 323 for the transmission of ultrasonic energy to
rotating friction head 324.
[0156] The shape of the top of the friction head could be flat or
curved according to the requirement of the workpiece. Ultrasonic
pressurized rotating friction, i.e., friction at the contact
interface of the rotating surface under a biasing force normal to
that surface, can be applied onto the coating surface of workpiece
301 with the use of the integrated friction head assembly. The
rotation is driven through electric motor 321, driving belt 320,
belt pulley 319 and bearings 318.
[0157] In this application example, on workstation A, the
transmission shaft that is mounted with a clamping chuck is driven
in rotation by the electric motor through the coupling of
transmission belt, pulley and bearings. The integrated ultrasonic
rotating friction head assembly can be moved vertically through the
fitting of the two sliders on the lower panel with the two guiding
rails on workstation A. The rotating friction process can be
applied to the workpiece repeatedly.
[0158] In this embodiment, the ultrasonic rotating friction head
assembly is attached to upper panel 314 which is connected to lower
panel 312 through screw shaft 313. The screw shaft serves two
purposes, namely, first, to move the ultrasonic rotating friction
head assembly vertically (up and down); and, second, to apply
pressure, or a biasing force, to workpiece A.
[0159] The ultrasonic rotating friction head assembly is driven in
rotation by the electric motor through the coupling of the belt and
bearings, such that the workpiece rotates. It is also driven to
make contact and apply pressure, that is a biasing force, to the
workpiece through the control of the screw shaft. With the
application of ultrasonic vibration, the apparatus is able to
perform ultrasonic pressurized rotating friction processing to the
surface coating of the resistance welding electrodes. That is,
while the apparatus is under the biasing force against workpiece A,
and while there is rotating friction, ultrasonic vibration is also
being applied and transmitted across the same contact
interface.
[0160] The following gives the procedure of the ultrasonic
pressurized, or force-biased, rotating friction process: [0161] 1)
The welding electrode is mounted to the clamping chuck properly.
[0162] 2) Turn on the power to the workstation, ultrasonic power
source and the rotating friction head assembly. [0163] 3) Adjust
for proper pressure, i.e., biasing force, workpiece rotational
speed, rotating friction head speed, and ultrasonic power
level.
[0164] The rotating friction head, with external pressure (i.e.,
biasing force) and ultrasonic vibration is then used to treat or
modify the surface coating of the welding electrode, or to such
other coated surface as may be. The rotating friction head is
moved, or translated, or reciprocated, along guide rails 309, 310
to cover the complete surface of the coating on the welding
electrode. The power is turned off when the process is
finished.
[0165] In this example application, the ultrasonic power may be
about, or is 100 W; ultrasonic frequency may be about, or is 50
kHz; pressure (i.e., biasing force) on the surface coating from the
rotating friction head may be about, or is, 200 N; rotational speed
of the rotating friction head may be about, or is 1400 rpm. For a
welding electrode cap the process time may be about, or is, 3
minutes.
[0166] FIGS. 18g and 18h show the change in the electro-spark
deposition surface coating of a sample after modification according
to the ultrasonic pressurized rotating friction process using this
setup of apparatus as described above.
[0167] In the example described, the microscopic views show an
improvement in respect of the coating defects. That is, the
delaminations, cracks, discontinuities and voids are significantly
reduced, or eliminated, with the application of the process
described. It is also noted that the grain of copper alloy near the
coating boundary zone has also been refined, i.e., made finer,
after the process.
[0168] To summarise, the above example discloses a method and
apparatus for the processing of a surface coating. It includes an
ultrasonic pressurized, or force-biased, rotating friction head
assembly that is used to apply the surface coating of the
workpieces. The shape of the friction head could either be flat or
curved depending on the surface of the coating on the workpiece. In
this process, rotating action (i.e., rotation of the workpiece, or,
more generally, relative motion between the workpiece and the
coating apparatus to which the normal vector of contact is
perpendicular) in conjunction with ultrasonic vibration while the
applicator is force-biased against the workpiece, is used to apply
the surface coating on the workpiece, and to improve the properties
of the surface coating. In the particular application, the
apparatus used for the ultrasonic pressurized rotating friction
coating processing may have a work station in which to mount and in
which to rotate a TiC coated welding electrode as the workpiece.
There is an integrated rotating friction head assembly completed
with an ultrasonic transducer; and an ultrasonic power source. The
process includes the integration of a force-biased rotating
friction device with an ultrasonic transducer. The integrated
device, with the concurrent application of rotating friction and
ultrasonic vibration, may tend to reduce the defects that might
otherwise occur on the TiC coatings on welding electrodes produced
using the electro-spark deposition process.
[0169] The process described, with the application of ultrasonic
rotating friction under a normal force, may tend to improve the
binding strength of the ESD coating layers and also may tend to
reduce or eliminate coating defects. It may improve the physical
and mechanical properties of the coating while preserving the
material contents intact. The apparatus and process of the example
described may have advantages of reduced cost and increased ease of
use. In addition to treating electrospark deposition coating
defects, this invention may also have other applications, such as
being employed to repair other surface coatings covering a wide
range of applications. This description is intended to apply to
such other coating applications as may be amenable to the
application of the ultrasonic pressurized (or force-biased)
rotating friction process.
[0170] Thus, in the forgoing, a welding electrode is mounted in a
tool holder that is part of a handle apparatus. The handle
apparatus has an electrode power connection. The handle apparatus
has a housing defining a haft that can be grasped in the hand of an
operator. A vibrator is mounted inside the haft. The vibrator
includes a force transmitter in the form of a cantilevered beam.
The cantilevered beam is electrically conductive and carries power
to the tool holder. The tool holder has a handle that penults the
welding rod to be rotated about its axis as it wears during
deposition of welding rod material on the object work piece. The
handle has a power supply that may vary voltage level to permit
deposition cycles and peening cycles.
[0171] Description Pertaining to FIGS. 25 to 29
[0172] In the various Figures the annotations identify the
following features: [0173] A Electro-spark deposition ESD power
source; [0174] Vibrating ESD coating applicator; [0175] C
Integrated transducer assembly I and workbench drive assembly II;
[0176] D Ultrasonic Generator; [0177] 401 ESD power source positive
terminal; [0178] 402 ESD power source negative terminal; [0179] 403
Resilient conductor spring; [0180] 404 Discharge electrode
mounting; [0181] 405 Discharge electrode; [0182] 406 Eccentric
wheel; [0183] 407 Handle; [0184] 408 Bakelite insulator; [0185] 409
Flexible shaft; [0186] 410 Low power applicator motor; [0187] 411
Workpiece; [0188] 412 Work bench negative terminal; [0189] 413
Integrated transducer negative terminal; [0190] 414 Integrated
transducer positive terminal; [0191] 419 Integrated transducer
body; [0192] 420 Transducer horn; [0193] 15, 421 Ultrasonic
transducer; [0194] 422 Flat pulley; [0195] 423 Ball bearing; [0196]
424 Jaw chuck; [0197] 425 Drill chuck; [0198] II Drive assembly;
[0199] 415 Work bench drive motor; [0200] 416 V-belt; [0201] 417
Ultrasonic power output negative terminal; [0202] 418 Ultrasonic
power output positive terminal
[0203] The aspects of the invention to which FIGS. 18g, 18h, 25,
26, 27a, 27b, 28 and 29 pertain may tend to provide a rotary
electro-spark deposition surface coating process and apparatus,
such as may be intended to improve electrode coating quality,
tending to aid in increasing electrode life. This invention is
particularly suitable to the application of electro-spark
deposition coating of resistance spot welding electrodes.
[0204] In an embodiment herein, a rotary electro-spark deposition
surface coating process includes: mounting a workpiece on to a
rotating base or fitting table. The surface of the workpiece is
coated using an electro-spark deposition (ESD) process. Ultrasonic
vibration is applied to the deposition layer during its
crystallization phase. The crystallization phase of the deposition
coating is completed while ultrasonic vibration continues to be
applied to the workpiece. The process is a rotary electro-spark
deposition surface coating process. In this process the workpiece
as described may be a resistance spot welding electrode.
[0205] In one embodiment, the rotary electro-spark deposition
surface coating apparatus may include: a vibrating ESD coating
applicator, an electro-spark deposition power source; an integrated
transducer assembly; a drive or transmission at, or of, a table, or
bench or work-station for driving, e.g., rotating, the workpiece
relative to the coating applicator; and an ultrasonic vibration
generator. The sonic vibration transducer may be mounted to
co-operate with the work bench drive. The workpiece is mounted to
the integrated transducer and motive drive assembly. In the
process, the rotary electro-spark deposition surface coating
apparatus may coat or treat workpieces that may be resistance spot
welding electrodes.
[0206] The rotary electro-spark deposition surface coating
apparatus may further include an electro-spark deposition power
source A. Power source A may include an ESD power source positive
terminal, 401, and an ESD power source negative terminal, 402.
[0207] Vibrating applicator B (in essence, apparatus 20, 120, etc.)
may include a spring conductor 3, a discharge electrode mounting
screw 404, a consumable welding rod of coating material, such as
may be indicated as a discharge electrode 405, an eccentric wheel
406, a handle, or rod holder, or arm 407, a bakelite insulator 408,
a flexible shaft 409 and a low power applicator motor 410.
[0208] In use integrated transducer assembly I may show, or have,
the following features, namely a workpiece to be coated 411, work
bench or workstation negative terminal 412, an integrated
transducer negative terminal 413, an integrated transducer positive
terminal 414, an integrated transducer body 419, a transducer horn
420, an ultrasonic transducer 421, a flat pulley 422, a ball
bearing 423, a jaw chuck 424 and drill chuck 425.
[0209] Workbench drive assembly II may include, or have, a work
bench or workstation drive motor 415, and V-belt 416.
[0210] Ultrasonic generator D may have or include an ultrasonic
power output negative terminal 417, and ultrasonic power output
positive terminal 418.
[0211] ESD power positive terminal 401 may be connected to a
resilient member identified as a conductor spring 403. ESD power
negative terminal 402 is connected to workbench negative terminal
412. Discharge electrode 405 is mounted to the spring bar, namely
conductor spring 403 by tightening a discharge electrode mounting
screw 404. Applicator handle 407 is connected to the low power
motor 410 through a connection of, or with, flexible shaft 409.
Eccentric wheel 406 is driven in rotation by the driving of the low
power motor 410 through the connection of flexible shaft 409 and
handle 407 for, or during, the vibrating coating deposition
process.
[0212] Ultrasonic power output negative terminal 417 is connected
to integrated transducer negative terminal 413. Ultrasonic power
output positive terminal 418 is connected to integrated transducer
negative terminal 414. Integrated ultrasonic transducer assembly I
is driven in rotation by drive motor 415 by the use of flat pulley
422 and V-belt 416. Ultrasonic vibration transducer 421 is
connected to the integrated transducer negative terminal 413 and
integrated transducer positive terminal 414, respectively.
Transducer horn 420 and ultrasonic transducer 421 combine to act on
the shaft of the rotary work platform. A tool holder, or seat, or
mandrel, or center, or jig, in the form of a drill chuck 425, is
mounted to the rotary work platform by means of being clamped in
the jaws of a rotatable driven chuck 424. Workpiece 411 is mounted
to drill chuck 425 during the rotary ultrasonic-assisted ESD
process.
[0213] The vibrating applicator described above may act as the
positive terminal of the ESD process. It is connected to positive
terminal, 401, of the ESD power supply. The discharge electrode 405
(i.e., the welding rod composed of the coating material to be
deposited on the workpiece) is mounted to conductor spring 403 by
tightening discharge electrode mounting screw 404. Negative
terminal 402 of the ESD power source, or power supply, A, is
connected the negative terminal 412 of the work bench or work
station. Vibrating ESD deposition is carried out during
simultaneous operation of the low power motor 410, flexible shaft
409, handle 408 and eccentric wheel 406.
[0214] The ultrasonic generator output positive terminal 418, and
ultrasonic output negative terminal 417 are connected to the
respective positive and negative terminals 414 and 413 of the work
bench respectively.
[0215] Transducer horn 420 is connected to the ultrasonic
transducer 421 by a shaft. Transducer horn 420 then drives the jaw
chuck 424 and the tool holder, namely drill chuck 425 of the work
bench rotation through the couplings of the rotating shaft. The
ultrasonic transducer is contained inside a transducer casing or
housing. The transducer casing is built of insulating materials.
Jaw chuck 424 is mounted to the driven output rotating shaft using
a dedicated screw. Drill chuck 425 is then mounted to, or connected
to, jaw chuck 424. The workpiece, in this embodiment resistance
spot welding electrode 411, which is secured to or in drill chuck
425, is driven in rotation and the coating material is applied
according to the ultrasonic assisted electro-spark deposition
process. The rotating shaft drive driven by motor 415 and the
vibrating drive provided by ultrasonic transducer 421 are thus,
combined in an integrated unit.
[0216] This description describes, inter alia, an apparatus such as
may be used to apply ESD coatings to work piece surfaces to modify
the properties of those surfaces. The work piece may be moving,
e.g., rotating during the process. That apparatus may be used
according to an ESD coating application procedure that may include
the steps of:
1. Choosing a type of discharge electrode prepared with the proper
composition of materials for the desired ESD coating to be applied;
and mounting the discharge electrode to the vibrating applicator. A
resistance spot welding electrode may be selected as the workpiece
in this application example. 2. Turning on power to the apparatus,
including power to the electro-spark deposition power source, power
to the ultrasonic generator, power to the workbench motor drive and
to the vibrating applicator. The process may include adjusting the
associated operational parameters including the vibrating
applicator frequency, motor drive speed and ultrasonic generator
power. In the ultrasonic assisted electro-spark deposition process,
contact between the discharge electrode and the workpiece should be
made lightly, with a component of relative horizontal (e.g.,
tangential) modulation movement to cause a layer of coating to be
deposited on the workpiece surface. The time duration of the
process may depend on the thickness to be deposited and the type of
coating material. The basic principle is that the coating be
applied made evenly on the surface of the workpiece, and should
cover the surface completely. No base metal of the workpiece
contact surface should be left open or uncovered. Also, the time
duration of the electro-spark deposition process should not be too
long, to avoid softening and annealing of the copper alloy material
of the workpiece. 3. Turning off the power to the workbench when
the electro-spark deposition process is completed; and removing the
coated electrode (workpiece) from the fixture assembly. This
coating process may then be repeated with another uncoated
workpiece, as may be. 4. Turning off power to all other devices if
there is another coating process to implement.
[0217] The apparatus shown and described herein concerns use of
ultrasonic-assisted ESD coating technology. It differs from
traditional vibrating ESD coating processes. Comparison may be made
with patent CN102019531A:
1. In the apparatus and method described herein, ultrasonic
vibration is applied to the workpiece being coated in the
electro-spark deposition process. Grain crystallization of the
coating material takes place under the application of ultrasonic
vibration. By contrast, patent CN102019531A specifies the
application of ultrasonic vibration to the discharge electrode. The
surface coating on the workpiece produced directly under the
application of ultrasonic vibration is different from the ones
produced by using the other approach. Having direct ultrasonic
vibration applied to the workpiece is thought to be a new, useful,
and unobvious feature of the apparatus and method shown and
described herein. Having ultrasonic vibration applied to the
workpiece during the grain crystallization of the coating material
in the electro-spark deposition process is also understood to be a
new, useful, and unobvious feature shown and described herein.
These features are thought to tend to improve grain refinement of
the coating material and adhesion between the coating and the metal
matrix of the base substrate. 2. In the apparatus shown and
described herein, ultrasonic vibration is applied to the workpiece
being coated in the ESD process. Ultrasonic vibration in this case
may improve or reduce the influence of the heat-affected zone
(HAZ). Meanwhile the application of ultrasonic vibration to the
discharge electrode as claimed in CN 10201931A appears to have no
influence on the HAZ between the ESD layer and the substrate metal
matrix.
[0218] The apparatus and method described herein may have relative
simplicity of operation, may be relatively low in cost, may have
high applicability, and may emit relatively little noise. In the
embodiment or application example described herein, the ultrasonic
power may be 70 W, ultrasonic frequency may be 50 kHz, the
rotational speed of the workbench may be 700 rpm, the material of
the discharge electrode may be TiC, the electro-spark deposition
voltage may be 7V, and deposition time duration may be 2
minutes.
[0219] For comparison, samples were produced with the same
parameters except that one set was treated with the application of
ultrasonic vibration as described herein, while the other sample
was treated without ultrasonic vibration. From this comparison
test, it was found that the electro-spark deposition coating
applied under ultrasonic vibration exhibited improvements over the
ones in which the coating was applied without ultrasonic vibration:
Higher coating hardness; reduction in coating defects; and better
adhesion of the coating to the metal matrix substrate. Performing
welding life tests, the working life of TiC electro-spark
deposition coated under ultrasonic vibration welding electrodes was
found to be 800 welds while the ones coated without ultrasonic
vibration was 500 welds.
[0220] FIGS. 27a and 27b illustrate the microstructure of the
coatings produced under the two different conditions. FIG. 27b
shows that coating defects are reduced when the coating is
deposited at the same time as ultrasonic vibration is applied to
the workpiece. The size of the HAZ zone and its grain size is
significantly less than that of the sample coated without the
application of ultrasonic vibration as shown in FIG. 27a.
[0221] FIG. 28 charts micro-hardness of coating layers applied with
and without ultrasonic vibration. It is observed that the
micro-hardness of the coating applied with the use of ultrasonic
vibration (small round dot line) is very even across, such that a
HAZ region transition is not obvious. Meanwhile it is noted that
there is a section of the micro-hardness line of the coating
applied without the use of ultrasonic vibration (small square dot
line) has a significant drop in hardness indicating the existence
of the HAZ. It can be concluded that grain growth in the HAZ at the
coating is significantly affected by the application of ultrasonic
vibration. The dendrites which exist in the HAZ area are reduced,
or broken off, when the coating is produced with the application of
ultrasonic vibration on the workpiece. This may tend to avoid the
formation of large grains and thus a significant HAZ.
[0222] FIG. 29 shows the microstructure of the coating applied
according to Patent CN 102019531, in which ultrasonic vibration is
applied to the discharge electrode. In this case, ultrasonic power
is 70 W, ultrasonic frequency is 50 kHz, rotational speed of the
work station is 700 rpm, the material of the discharge electrode is
TiC, the electro-spark deposition voltage is 7V, deposition time is
2 minutes. By comparing FIGS. 29 and 27a, the coating defects and
the grain sizes of the HAZ when coating with ultrasonic vibration
applied to the discharge electrode appears to yield no significant
difference from the coating deposited without application of
ultrasonic vibration. A welding electrode life test was performed.
It found that the welding life of the electrode coated with the
application of ultrasonic vibration to the discharge electrode to
be 500 welds. This is the same as the working life of the welding
electrode coated without ultrasonic vibration.
[0223] With the ultrasonic-assisted electro-spark deposition
technology, this apparatus and method described herein may yield
improved grain refinement of the coatings, and may tend to avoid or
reduce the occurrence of a HAZ that might cause increased service
problems. The apparatus and method may tend effectively to
overcome, or ameliorate, the defects and difficult problems of
coatings produced using conventional electro-spark deposition
technology. In addition, the cost of the apparatus may be modest,
and the apparatus may be relatively simple to operate. The
apparatus and method described herein may have a wide spectrum of
application. Other than the resistance welding electrodes, the
apparatus and method may be applied to the ESD coating of other
workpieces, such as rotating workpieces.
[0224] A surface modification process and apparatus for the
electro-spark deposition (ESD) on a workpiece may include mounting
a workpiece on a rotationally driven mounting. The contact surface
of the workpiece is ESD coated. Ultrasonic vibration is applied to
the deposition layer during its crystallization phase. The
workpiece may be a resistance spot welding electrode. The apparatus
may have a vibrating applicator, ESD power supply, integrated
ultrasonic transducer assembly, a work station having a rotational
drive and an ultrasonic generator. The ultrasonic generator is
connected to the ultrasonic transducer. The ultrasonic transducer
assembly and the rotating driving work bench unit are integrated in
a single assembly. The workpiece seats on the ultrasonic transducer
assembly. The deposition of a surface coating occurs during
simultaneous application of electro-spark deposition and ultrasonic
vibration.
[0225] As explained above, in this third portion of the description
there is a method and apparatus for the processing of surface
coating is disclosed concerning the design of an ultrasonic
pressurized rotating friction head assembly used to apply a surface
coating to a workpiece. The shape of the friction head may be flat
or curved as appropriate for the workpiece. The surface coating is
rotated under repeated contact and ultrasonic vibration. The
apparatus includes: a work station for the mounting and rotation of
a TiC coated welding electrode workpiece; a rotating friction head
assembly with an ultrasonic transducer and power source. Concurrent
application of pressurized rotating friction and ultrasonic
vibration, may tend to reduce the defects in the TiC coatings on
welding electrodes produced using the electro-spark deposition
process. While maintaining the basic coating material component
contents, mechanical and physical properties unaltered, defects
such as delaminations, cracks, discontinuities and voids may be
reduced. Control and operation of the may be adapted to other
applications.
[0226] In FIG. 19 there is a welding arrangement. In that
arrangement there is a workpiece 440, which may be a single
workpiece, or may be two workpieces 442, 444 that are to be joined
together. In some instances a backing bar 446 may be provided to
prevent weld-through of work pieces 442, 446 at the penetration at,
for example, a bevel weld 448. The depth of the bevel, and the
depth of the abutting edges of items 442 and 444 below the bevel
may depend on the expected depth of penetration of the weld.
[0227] Although the workpiece is shown in two parts in the context
of welding the two parts together, workpiece 440 could be a single
workpiece, and the bevel may be a slot, or groove or channel, or
gouge. That is, in some embodiments, the process may be filling a
gouge or damage of whatever cause where the gouge needs to be
filled. In other embodiments, the accommodation in the surface may
be a slot or groove that forms the root or base of a dissimilar
material insert, such as may be desired to add a ceramic insert for
a wear surface or cutting element, such as in a drill bit or in
forestry equipment, or in mounting teeth or wear surfaces on mining
or construction equipment, such as the teeth of loaders, buckets,
and so on.
[0228] However it may be, a welding tool, or welding head, or
welder, or welding electrode, is shown generally as 450. It may
include an electrode holder 452 and may have mounted therein an
electrode 454. The electrode may be a consumable electrode rod 456.
Holder 452 may be a vibrating holder, and may be a vibrating holder
as described hereinabove, such as items 20 and 120, or as may be.
Holder 452 may be hand-held, or may be mounted to a welding head or
frame or jig, or welding table, such as suggested by the
arrangement of FIG. 20, for example. However it may be, holder 452
may be a vibrating holder, and may be provided with a power supply
as described above such as may be operable at a first voltage, such
as an initiation or striking voltage, and at a second, lesser
voltage. That lesser voltage may be zero. Whatever the lesser
voltage may be, during the cycles of vibration of holder 452 (and
therefore of rod 456) in which the lesser voltage is applied, the
electrode may agitate the deposited material 458, and where that
material has begun to solidify, to strike that material in the
hitting, deforming, or peening manner discussed above.
[0229] Whatever the case may be, the workpiece is secured
appropriately to the jig or table, or holder, or mounting, or
fixture (however it may be termed) for the welding process, whether
by clamping or other means. The workpiece may be secured to a
movable bed. The movable bed may have a single degree of freedom of
motion (as in being spun or rotated in a single angular degree of
freedom; or as in linear translation in a translational degree of
freedom); or it may have more than one degree of freedom of motion,
whether those degrees of freedom include, for example, x and y
translation, or also include an angular degree of freedom, alpha or
theta. The motion may be reciprocating motion. The motion may also
follow a particular path, such as a programmed path, such as may
follow a line or contour or pattern (e.g., to follow a weld fillet,
or the shape of a gouge or other damage, or a desired wear plate or
insert, boundary, shape or pattern, as may be.
[0230] Alternatively, or additionally, or equivalently, the
workpiece may be held on a stationary bed or fixture while holder
452 may be movable, or both the bed and holder 452 may have degrees
of freedom of motion such that they can move relative to each
other.
[0231] Whether or not a backing bar is used, once an initial pass
has been laid down, the weld may be self-backing. That is, an
initial weld may be made in the normal manner, with or without
vibration of holder 452. Subsequent passes may follow, with holder
452 set to vibrate. Several passes may be applied to build up a
weldment.
[0232] Also in the arrangement of FIG. 19, a vibration transmission
is indicated as 460. There may be a single vibration head 462, or
more than one head, 464, 466, 468. At least one of the heads is
actively operable to transmit vibration to the workpiece. One or
more of the other heads may act as stationary reaction members, or
abutments, or all of them may be "live". They may transmit on
individual frequencies. The frequencies need not be the same. They
may be the same frequencies, or ranges of frequencies as described
above. Some of the heads may be on one side of the material, some
may be on the other side of the weldment in the y-direction, or,
alternatively, or additionally, may be on opposite faces of the
workpiece, as shown. Pairs of heads may be opposed, such as 462,
466, or 464, 468.
[0233] It may be that one or more of the heads has an engagement
member, or pad, or sole plate, or foot 470. It may be that foot 470
is free of gouging or plastic deformation elements. That is,
whereas indenters or other probes for vibrating workpieces are
known, the act of indenting may introduce local plastic deformation
defects or non-homogeneities, or singularities in the workpiece
where such defects may not be desired, e.g., as where they may tend
subsequently to act as fatigue initiation sites. Foot 470 may
therefore not include, that is, may be free of, plastic deformation
members, such as indentation members. Foot 470 may be substantially
flat or smooth. In some embodiments, foot 470 may be a roller,
whether cylindrical or spherical. In either case foot 470 provides
a workpiece engagement, or workpiece interface, member, that acts
as a vibration transmitter or transmission member or transition
interface, through which an exciting vibration may be introduced
into the adjacent workpiece. Foot 470 may be clamped or otherwise
held against the workpiece. Foot 470 may be urged against the
workpiece with biasing members, such as springs, which are
themselves backed by a jog, or fitting, or frame.
[0234] The vibration so introduced into the workpiece may be
ultrasonic vibration, such as described above. The vibration need
not be sinusoidal, and need not be period. It may, however, be
convenient for the vibration to have a given frequency (which may
be adjustable) and amplitude. The vibration imposed upon the
workpiece may be independent of the vibration applied to holder
454, and may be applied whether holder 454 is then vibrating or
not. Vibration may be applied to the workpiece when holder 454 is
not transmitting welding current to the workpiece, or when the
welding current is at the reduced voltage. The vibration imposed on
the workpiece may be imposed either during the welding material
deposition, or during agitation or peening at reduced (or zero)
voltage.
[0235] As suggested in FIG. 20, the welding head (which may be
multiple welding heads) may be mounted on a frame 470. And the
workpiece may be mounted on a moving table or bed 472, suggested by
an array of rollers 474. The table or bed may, for example, move in
translation under electrode 474, such as horizontally in the
x-direction (across the page as shown) or transversely in the
y-direction (into or out of the page as shown). These degrees of
freedom of motion may be independent of any vibratory or
oscillatory drive. That is, ultrasonic vibration may take place at
a very small scale of displacement. The table or bed may move
globally. The table or bed or welding head may be programmed to
follow a path which one or the other, or both, of the welding head
and the workpiece vibration exciter is in operation.
[0236] The various materials, processes, drives, voltages and
frequencies of the embodiments described above in the context of
FIGS. 1 to 17 and 21 to 29 are applicable to the apparatus and
method pertaining to FIGS. 19 and 20. The welding tool of the
apparatus and method of FIGS. 21-29 may be the apparatus of FIGS.
1-17, suitably adjusted and employed to conform to that
description.
[0237] As many variations and modifications are possible, the
application of this invention covers is intended not only to
encompass the above mentioned example, but also to encompass such
other concepts or alternations falling within the principles,
aspects, and features of the invention shown and described
herein.
[0238] What has been described above has been intended illustrative
and non-limiting and it will be understood by persons skilled in
the art that other combinations of the features described above,
and modifications, may be made without departing from the scope of
the disclosure as defined in the claims appended hereto. Various
embodiments of the invention have been described in detail. Since
changes in and or additions to the above-described apparatus and
process may be made without departing from those aspects, the
invention is not to be limited to those details but only by the
appended claims
* * * * *