APPARATUS AND METHOD FOR CLEANING OXIDE FILM

Abstract

An apparatus and method for cleaning an oxide film using a direct current reverse polarity are provided. The apparatus for cleaning an oxide film formed on a workpiece may include a power supply configured to apply direct current power and to include a positive electrode terminal and a negative electrode terminal, the workpiece configured to be electrically connected to the negative electrode terminal to act as a negative electrode to which a current is applied, and a torch having a positive electrode, which is spaced apart from the oxide film by a predetermined distance and is electrically connected to the positive electrode terminal, the torch being installed to be movable relative to the workpiece. The oxide film formed on the workpiece may be removed by applying a reverse polarity direct current between the workpiece, serving as the negative electrode, and the positive electrode to generate an arc.

Claims

1. An apparatus for cleaning an oxide film formed on a workpiece, comprising: a power supply configured to apply direct current power and to comprise a positive electrode terminal and a negative electrode terminal; the workpiece configured to be electrically connected to the negative electrode terminal to act as a negative electrode to which an electric current is applied; and a torch having a positive electrode, which is spaced apart from the oxide film by a predetermined distance and is electrically connected to the positive electrode terminal, the torch being installed to be movable relative to the workpiece, wherein the oxide film formed on the workpiece is removed by applying a reverse polarity direct current between the workpiece, serving as the negative electrode, and the positive electrode to generate an arc.

2. The apparatus according to claim 1, wherein the torch comprises: a torch body; and a nozzle installed on the torch body to inject shield gas in a form of a laminar flow.

3. The apparatus according to claim 2, wherein the torch further comprises a cooler to cool the positive electrode by water cooling.

4. The apparatus according to claim 1, wherein: the workpiece is a weld bead formed during gas tungsten arc welding; and the apparatus further comprises a drive device configured to transport the torch along the weld bead.

5. The apparatus according to claim 4, wherein the drive device has a torch travel speed of 20 to 30 cm/min.

6. The apparatus according to claim 1, wherein the positive electrode has an exposed length (Ls) that satisfies following conditional expression 1:
5<Ls<12 mm.[Conditional Expression 1]

7. The apparatus according to claim 2, wherein the positive electrode has an exposed length (Ls) that satisfies following conditional expression 1:
5<Ls<12 mm.[Conditional Expression 1]

8. The apparatus according to claim 3, wherein the positive electrode has an exposed length (Ls) that satisfies following conditional expression 1:
5<Ls<12 mm.[Conditional Expression 1]

9. The apparatus according to claim 4, wherein the positive electrode has an exposed length (Ls) that satisfies following conditional expression 1:
5<Ls<12 mm.[Conditional Expression 1]

10. The apparatus according to claim 1, wherein the positive electrode is a tungsten electrode.

11. A method of cleaning an oxide film using the apparatus according to claim 1, the method comprising: positioning the positive electrode on the oxide film, such that an exposure length (Ls) of the positive electrode and an arc gap (Ga) between the oxide film and the positive electrode satisfy following conditional expression 2; and
5<Ls<12 mm; and
1.5Ga2.5 mm,[Conditional Expression 2] applying, by the power supply, a reverse polarity direct current of a predetermined ampere to the positive electrode and the negative electrode in an inert gas atmosphere, wherein the oxide film formed on the workpiece is removed by applying the reverse polarity direct current.

12. The method according to claim 11, wherein the reverse polarity direct current is 30 A or more.

13. The method according to claim 11, wherein the torch comprises: a torch body; and a nozzle installed on the torch body to inject shield gas in a form of a laminar flow.

14. The method according to claim 13, wherein the torch further comprises a cooler to cool the positive electrode by water cooling.

15. The method according to claim 11, wherein: the workpiece is a weld bead formed during gas tungsten arc welding; and the apparatus further comprises a drive device configured to transport the torch along the weld bead.

16. The method according to claim 15, wherein the drive device has a torch travel speed of 20 to 30 cm/min.

17. The method according to claim 11, wherein the positive electrode has an exposed length (Ls) that satisfies following conditional expression 1:
5<Ls<12 mm.[Conditional Expression 1]

18. The method according to claim 12, wherein the positive electrode has an exposed length (Ls) that satisfies following conditional expression 1:
5<Ls<12 mm.[Conditional Expression 1]

19. The method according to claim 13, wherein the positive electrode has an exposed length (Ls) that satisfies following conditional expression 1:
5<Ls<12 mm.[Conditional Expression 1]

20. The method according to claim 11, wherein the positive electrode is a tungsten electrode.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0023] The above and other aspects will become more apparent from the following description of the exemplary embodiments with reference to the accompanying drawings, in which:

[0024] FIG. 1A is a transverse cross-sectional view illustrating a narrow gap groove in an ultra-thick-plate-shaped base metal;

[0025] FIG. 1B is a transverse cross-sectional view illustrating a base metal used in an exemplary embodiment;

[0026] FIG. 2 is a view schematically illustrating an apparatus for cleaning an oxide film according to an exemplary embodiment;

[0027] FIG. 3 is a perspective view illustrating a torch having a cooler in the apparatus for cleaning an oxide film according to an exemplary embodiment;

[0028] FIGS. 4A and 4B are photographs illustrating a result of cleaning according to the application of different current-specific arc gaps;

[0029] FIG. 5 is a photograph illustrating a result of cleaning according to the application of different currents;

[0030] FIGS. 6A and 6B are views illustrating a result of measurement of an electrode after cleaning;

[0031] FIG. 7 is a photograph illustrating a result of cleaning according to the application of different torch travel speeds relative to a workpiece;

[0032] FIGS. 8A to 8D are photographs illustrating a result of cleaning according to the application of different exposed lengths Ls of a positive electrode; and

[0033] FIG. 9 is a flowchart schematically illustrating a process of cleaning an oxide film according to another exemplary embodiment.

DETAILED DESCRIPTION

[0034] Various modifications and various embodiments will be described below in detail with reference to the accompanying drawings so that those skilled in the art can easily carry out the disclosure. It should be understood, however, that the various embodiments are not for limiting the scope of the disclosure to the specific embodiment, but they should be interpreted to include all modifications, equivalents, and alternatives of the embodiments included within the spirit and scope disclosed herein.

[0035] The terminology used herein is for the purpose of describing specific embodiments only and is not intended to limit the scope of the disclosure. The singular expressions a, an, and the are intended to include the plural expressions as well unless the context clearly indicates otherwise. In the disclosure, terms such as comprises, includes, or have/has should be construed as designating that there are such features, integers, steps, operations, components, parts, and/or combinations thereof, not to exclude the presence or possibility of adding of one or more of other features, integers, steps, operations, components, parts, and/or combinations thereof.

[0036] Hereinafter, exemplary embodiments will be described in detail with reference to the accompanying drawings. In order to clearly illustrate the disclosure in the drawings, parts irrelevant to the description may be omitted, and like reference numerals refer to like elements throughout the specification.

[0037] FIG. 1A is a transverse cross-sectional view illustrating a narrow gap groove in an ultra-thick-plate-shaped base metal. FIG. 1B is a transverse cross-sectional view illustrating a base metal used in an exemplary embodiment. Referring to FIGS. 1A and 1B, the base metal to be welded includes a first base metal 1 and a second base metal 3, which are arranged adjacent to each other, with a predetermined gap G therebetween. The first base metal 1 may be made of STS 304, and the second base metal 3 may be made of Inconel 690. In addition, a minimum gap G.sub.min between the first and second base metals 1 and 3 may be a narrow width of about 8 mm. A multi-layered workpiece 5 is formed by stacking a filler metal on the base metal to be welded through GTAW. Here, a backing bar 21 may be disposed beneath the gap G for GTAW.

[0038] While each layer of the workpiece 5 is welded and cooled, an oxide film is formed as a surface of each layer of a weld bead corresponding to the workpiece 5 is exposed to the atmosphere. The exemplary embodiment is for the purpose of removing the oxide film formed in the narrow gap.

[0039] FIG. 2 is a view schematically illustrating an apparatus for cleaning an oxide film according to an exemplary embodiment. FIG. 3 is a perspective view illustrating the torch of FIG. 2.

[0040] Referring to FIG. 2, the apparatus for cleaning an oxide film according to an exemplary embodiment that removes an oxide film 7 formed on a workpiece 5 may include a power supply 10, a backing bar 21, and a torch 30. Here, the workpiece 5 may be a multi-layered weld bead formed while gas tungsten arc welding (GTAW) is performed on a base metal. FIG. 2 illustrates that the oxide film 7 is formed on an uppermost surface of the workpiece 5, but it is understood that this is only an example and other exemplary embodiments are not limited thereto. For example, the oxide film may be formed on a surface of each layer of the weld bead. In this case, a process of removing a corresponding oxide film is performed before welding a next layer after each layer of the weld bead is formed.

[0041] The power supply 10 for applying direct current (DC) power may include a positive electrode terminal 11 and a negative electrode terminal 15. The backing bar 21 which is electrically connected to the negative electrode terminal 15 is installed to apply an electric current to the workpiece 5. Here, a negative electrode is formed by an entirety of the first and second base metals 1 and 3, the workpiece 5, the oxide film 7, and the backing bar 21.

[0042] Referring to FIGS. 2 and 3, the torch 30 including a positive electrode 35 is installed to be movable relative to the workpiece 5. That is, if the workpiece 5 is formed in a longitudinal direction of the gap G between the first and second base metals 1 and 3, as illustrated in FIG. 1B, the torch 30 is installed to be movable in the longitudinal direction of the gap G. To this end, the apparatus according to the exemplary embodiment may include a drive device 41 that transports the torch 30 toward the weld bead, namely in the longitudinal direction of the gap G.

[0043] The torch 30 may further include a torch body 31 and a nozzle 33. The nozzle 33 may have an elongated shape in the longitudinal direction of the gap to be freely movable within the narrow gap groove.

[0044] The nozzle 33 is installed on the torch body 31 to inject shield gas in a form of a laminar flow. The nozzle 33 may be made of a material such as copper. The positive electrode 35 is fixed by a collet (not shown) provided in the torch body 31, and an exposed length Ls of the positive electrode 35 is adjustable by the collet.

[0045] The torch 30 may further include a cooler 37 to cool the positive electrode 35 by water cooling. The cooler 37 has a structure for cooling the positive electrode 35, thereby preventing the positive electrode 35 from melting by arc heat.

[0046] The positive electrode 35 which is spaced apart from the oxide film 7 by a predetermined distance Ga is electrically connected to the positive electrode terminal 11. The positive electrode 35 may be a tungsten electrode.

[0047] The apparatus according to the exemplary embodiment removes the oxide film 7 formed on the workpiece 5 by applying a reverse polarity direct current to the oxide film 7 through the negative electrode and the positive electrode 35. That is, in an inert gas atmosphere, the power supply 10 applies a reverse polarity direct current of a predetermined ampere to the positive electrode 35 and the negative electrode. The inert gas atmosphere may be formed by injecting argon (Ar) gas, in a predetermined amount, into a portion intended to remove the oxide film.

[0048] Here, the negative electrode may be a cold cathode with low temperature. The cold cathode is energized by the action of an electric field, thereby emitting electrons. In this case, the oxide film at a cold cathode spot 7a is removed while electrons are preferentially emitted from the oxide or the like with a low work function. The cold cathode spot 7a refers to a position on the oxide film, which faces an end of the positive electrode 35, with an arc gap Ga therebetween. The end of the positive electrode 35 may have a round shape. The cold cathode spot 7a moves unstably at a high speed during the removal of the oxide film. The high-speed movement of the cold cathode spot 7a is attributable to the property that the cold cathode spot 7a moves to a region with a low work function due to a difference between fine protrusions or oxide layers, a difference in density between various alloy elements, or the like. That is, once electrons are emitted, the oxide at a corresponding position has an increased work function while decaying, resulting in a difficulty in emitting electrons. Therefore, the cold cathode spot moves to another position with a low work function, so that the oxide film is removed from the cold cathode spot moved to that position.

[0049] The apparatus for cleaning an oxide film according to the exemplary embodiment is for the purpose of maximizing the removal efficiency of the oxide film. The following experiments show oxide film cleaning performance according to a travel speed of the torch 30 by the drive device 41, the exposed length Ls of the positive electrode 35, a size of the arc gap Ga, and an application of different currents, and an optimum range for oxide film cleaning is derived from these experiments.

Experimental Example

[0050] Cleaning Experiment for Change in Arc Gap (Experiment 1)

[0051] Table 1 illustrates cleaning conditions for confirming a cleaning effect according to the application of different arc gaps. Referring to Table 1, argon (Ar) gas with a purity of 100% is selected as inert gas (i.e., shield gas), and the gas is injected into a cleaning region in an amount of 10 liters per minute. In addition, the travel speed of a positive electrode is set to 10 cm/min, and a reverse polarity current of 20 A or 30 A is applied.

TABLE-US-00001 TABLE 1 Item Value Shield Gas Type Argon (Ar) 100% Shield Gas Injection 10 L/min Travel Speed 10 cm/min Current 20 A/30 A

[0052] FIGS. 4A and 4B are photographs illustrating a result of cleaning according to the application of different current-specific arc gaps under the conditions of Table 1.

[0053] FIG. 4A illustrates a result of cleaning while increasing the length of the arc gap from 1 mm to 5 mm at a current of 20 A. FIG. 4B illustrates a result of cleaning while increasing the length of the arc gap from 1 mm to 5 mm at a current of 30 A. Referring to FIG. 4A, it can be seen that the arc is extinguished and the cleaning is thus not performed, while the length of the arc gap is increased to 4 mm. Referring to FIG. 4B, it can be seen that the arc is not extinguished throughout all sections, and the cleaning is thus performed, thereby exhibiting excellent workability. Therefore, it can be seen that a cleaning width increases at the high current.

[0054] In the experiment of cleaning according to the application of different arc gaps, the arc is extinguished as the arc gap is increased from 3 mm to 4 mm. Therefore, it is determined that if the arc gap is 3 mm or more, there is a risk that the arc is extinguished. That is, if the arc gap is 3 mm or more, it is difficult to produce a uniform result during welding. Thus, it is preferable that the arc gap be 2.5 mm or less.

[0055] In addition, in the case in which the arc gap is set to 1 mm, the cleaning is smoothly performed, but there is a risk of contact between the electrode and the base metal due to a short distance between the end of the electrode and the base metal. In view of this, the positive electrode is preferably positioned on the oxide film such that the arc gap Ga between the oxide film and the positive electrode is from 1.5 mm to 2.5 mm.

[0056] As described above, in the relationship between the cleaning widths according to the length of the arc gap and the current, it can be seen that the cleaning width decreases as the length of the arc gap increases, and the cleaning width increases as the current is high.

[0057] Cleaning Experiment for Change in Applied Current (Experiment 2)

[0058] Table 2 illustrates cleaning conditions for confirming a cleaning effect according to the application of different currents by a power supply. Referring to Table 2, argon (Ar) gas with a purity of 100% is selected as inert gas (i.e., shield gas), and the gas is injected into a cleaning region in an amount of 10 liters per minute. In addition, the travel speed of a torch is set to 25 cm/min, the exposed length of a positive electrode is set to 8 mm, and an arc length is set to 1.5 to 2.5 mm.

TABLE-US-00002 TABLE 2 Item Value Shield Gas Type Argon (Ar) 100% Shield Gas Injection 10 L/min Exposed Length of Positive 8 mm Electrode Arc Length 1.5 to 2.5 mm Travel Speed 25 cm/min

[0059] FIG. 5 is a photograph illustrating a result of cleaning according to the application of different currents under the conditions of Table 2. That is, FIG. 5 is a photograph illustrating a weld bead when the cleaning is performed while applying different currents of 30 A, 40 A, and 50 A.

[0060] Referring to FIG. 5, it can be seen that the cleaning is performed well at all the applied currents of 30 A, 40 A, and 50 A. A decay rate of the oxide film, which is irregularly formed, increases as the current increases from 30 A to 50 A. The oxide is typically decayed when electrons migrate from the oxide to the electrode. Accordingly, as the current is high, the amount of migration of electrons is increased, thereby causing an increase in the decay rate of the oxide film. Therefore, it is possible to perform the cleaning even at the high travel speed of the torch when the cleaning is performed at a high current.

[0061] Considering the results of Experiments 1 and 2, it is preferable that the reverse polarity direct current be set to 30 A or more. If the welding is performed at a current lower than 30 A, the travel speed of the torch should be decreased because of a low rate of cleaning, resulting in low productivity. On the other hand, if the cleaning is performed at a current of 50 A or more, as shown in FIGS. 6A and 6B, it can be seen that there is a concern that the cleaning is unstable due to an excessive amount of electrode consumption, which is uneconomical and is apt to easily increase the arc length.

[0062] Cleaning Experiment for Change in Travel Speed (Experiment 3)

[0063] Table 3 illustrates cleaning conditions for confirming a cleaning effect according to the application of different torch travel speeds. Referring to Table 3, argon (Ar) gas with a purity of 100% is selected as inert gas (i.e., shield gas), and the gas is injected into a cleaning region in an amount of 10 liters per minute. In addition, the exposed length of a positive electrode is set to 8 mm, an arc length, e.g., a size of an arc gap Ga is set to 1.5 to 2.5 mm, and a current of 40 A is applied.

TABLE-US-00003 TABLE 3 Item Value Shield Gas Type Argon (Ar) 100% Shield Gas Injection 10 L/min Exposed Length of Positive 8 mm Electrode Arc Length 1.5 to 2.5 mm Current 40 A

[0064] FIG. 7 is a photograph illustrating a weld bead when the cleaning is performed while applying different torch travel speeds of 20 cm/min, 30 cm/min, and 40 cm/min, relative to a workpiece under the conditions of Table 3. Referring to FIG. 7, it can be seen that the cleaning is insufficiently performed at travel speeds of 30 cm/min and 40 cm/min. On the other hand, it can be seen that the effect of cleaning the oxide film is excellent at a travel speed of 20 cm/min. In view of this, the travel speed of the torch 30 by the drive device 41 may be set to be from 20 to 30 cm/min.

[0065] Cleaning Experiment for Change in Exposed Length Ls of Positive Electrode (Experiment 4)

[0066] Table 4 illustrates cleaning conditions for confirming a cleaning effect according to the application of different exposed lengths Ls of a positive electrode. Referring to Table 4, argon (Ar) gas with a purity of 100% is selected as inert gas (i.e., shield gas), and the gas is injected into a cleaning region in an amount of 10 liters per minute. In addition, the travel speed of a torch is set to 25 cm/min, an arc length, e.g., a size of an arc gap Ga is set to 1.5 to 2.5 mm, and a reverse polarity current of 40 A is applied.

TABLE-US-00004 TABLE 4 Item Value Shield Gas Type Argon (Ar) 100% Shield Gas Injection 10 L/min Arc Length 1.5 to 2.5 mm Travel Speed 25 cm/min Current 40 A

[0067] FIGS. 8A to 8D are photographs illustrating a weld bead when the cleaning is performed while applying different exposed lengths Ls of 5, 8, 12, and 16 mm of a positive electrode under the conditions of Table 4. Referring to FIGS. 8A to 8D, it can be seen that the cleaning region is narrow at an exposed length of 5 mm, and the cleaning is unstable due to an occurrence of arc blow at exposed lengths of 12 mm and 16 mm. On the other hand, at an exposed length of 8 mm of FIG. 8B, the cleaning effect is excellent and the arc is stably generated without the arc blow.

[0068] In view of this, the exposed length Ls of the positive electrode may be 5 to 12 mm. Preferably, the exposed length Ls of the positive electrode may be set to 8 mm.

[0069] FIG. 9 is a flowchart schematically illustrating a method of cleaning an oxide film according to another exemplary embodiment.

[0070] Referring to FIGS. 2 and 9, the positive electrode 35 is positioned on the oxide film 7 (operation S10), such that the exposure length Ls of the positive electrode 35 and the arc gap Ga satisfy the following Equation 1:

1.5Ga2.5 mm; and

5<Ls<12 mm,[Equation 1]

[0071] where the condition ranges for the exposure length Ls of the positive electrode and the arc gap Ga are set based on the above Experiments 1 and 4.

[0072] Next, in the inert gas atmosphere, the power supply 10 applies a reverse polarity direct current of a predetermined ampere to the positive electrode 35 and the negative electrode (operation S20). Thus, it is possible to remove the oxide film formed on the workpiece 5.

[0073] Referring to Experiment 2, the reverse polarity direct current may be set to 30 A or more. The inert gas atmosphere may be formed by injecting argon (Ar) gas, in an amount of 10 L/min, into a portion intended to remove the oxide film during the removal of the oxide film.

[0074] The apparatus and method for cleaning an oxide film according to the exemplary embodiments can rapidly remove the oxide film formed in the working process, for example, the oxide film formed on the weld bead, using a reverse polarity direct current. That is, it is possible to effectively remove the oxide film while the cleaning is maintained at a speed of 20 to 30 cm/min. Therefore, according to the exemplary embodiment, it is possible to replace the related art method of removing the oxide film by mechanically shaving the bead surface by grinding.

[0075] In addition, because the cleaning is performed between the welding passes if the exemplary embodiment is applied to the GTAW, it is possible to continuously perform the welding process and the oxide film removal process.

[0076] While one or more exemplary embodiments have been described with reference to the accompanying drawings, it is to be understood by those skilled in the art that various modifications in form and details may be made therein without departing from the sprit and scope as defined by the appended claims. Therefore, the description of the exemplary embodiments should be construed in a descriptive sense and not to limit the scope of the claims, and many alternatives, modifications, and variations will be apparent to those skilled in the art.