Method of production of workpieces by welding equipment

Abstract

Starting on the surface of a foundation body (2) weld material is applied in runs to form layers by an equipment for profiling building-up welding and hence a workpiece (1) is manufactured, where the foundation body (2) may be a component of the workpiece (1). The course of runs to form layers as well as the approximate rate of application of weld material are calculated by a computer system (11), starting from a two- or three-dimensional data model of the workpiece (1) in the form of software, and given over to the system control (10) which positions the welding torch (7) by means of the robot (5) and the workpiece (1) located on a turntable (4) by a clamping mechanism (3) with respect to one another, and regulates the rate of application of weld material applied by the welding apparatus (8) in such a way that the liquid weld material adheres to the layer lying underneath without running down and irregularities in the runs to form layers are levelled out. Hence metal workpieces having manifold bodily shapes and theoretically of any size and having any thickness of wall, even consisting of different metallic materials, may be manufactured by profiling building-up welding without auxiliary cores or other devices supporting the liquid weld material.

What is claimed is: 
     
       1. A method of free-shape welding to form a rotationally asymmetric workpiece of any desired shape comprising the steps of providing a foundation body having a build-up surface for forming the workpiece thereon; determining a base-outline of the workpiece; positioning a weld head proximate the build-up surface of the foundation body; moving the foundation body relative to the weld head . .within.!. .Iadd.along .Iaddend.the workpiece base-outline; activating the weld head to deposit metal by . .metal electrode inert gas (MIG).!. .Iadd.electric arc .Iaddend.welding on the build-up surface and thereby form a . .first metal layer.!. .Iadd.contour bead .Iaddend.on the foundation body surface having the shape of the base-outline; .Iadd.thereafter moving the activated weld head within the confines of the contour bead and forming a first metal layer within the confines of the contour bead; .Iaddend.thereafter moving the weld head and the foundation body relative to each other generally transversely to the first metal layer; determining another outline of the workpiece; . .and.!. moving the foundation body relative to the .Iadd.activated .Iaddend.weld head within the other workpiece outline while weld-depositing metal on top of the first metal layer to form at least .Iadd.a second contour bead; and thereafter moving the activated welding head relative to the foundation body within the confines of the second contour bead to form at least .Iaddend.a second metal layer on top of the first metal layer to thereby finish form the workpiece. 
     
     
       2. A method according to claim 1, including the step of sensing surface discontinuities in a previously formed metal layer by monitoring at least one welding parameter selected from the group of welding parameters consisting of welding current and welding voltage. 
     
     
       3. A method of free-shape welding a Pelton wheel bucket on a hub, the method comprising the steps of determining a base-outline for the bucket on the hub; positioning a weld head proximate the hub; moving the hub relative to the weld head within the bucket base-outline; activating the weld head for weld-depositing metal on the hub and thereby forming a first metal layer thereon having the shape of the base-outline; thereafter moving the weld head and the hub relative to each other generally transversely to the first metal layer; determining another outline of the bucket; moving the hub relative to the weld head within the other bucket outline; weld-depositing metal on top of the first metal layer to form a second metal layer on top of the first metal layer; and repeating the steps of determining, moving the hub relative to the weld head, and weld-depositing metal on top of previously formed metal layers to thereby finish form the bucket, the step of moving for at least one of the metal layers including the step of tilting the hub relative to the weld head to angularly incline a top surface of a most recently formed metal layer relative to a horizontal plane, and the step of weld-depositing comprising the step of weld-depositing metal on top of said most recently formed metal layer so that the layer being deposited forms a top surface lying in a substantially horizontal plane. 
     
     
       4. A method of free-shape welding to form a rotationally asymmetric workpiece of any desired shape comprising the steps of: providing a foundation body defining a welding surface for forming the workpiece thereon;   determining a two-dimensional base.Iadd.-.Iaddend.outline for the workpiece;   positioning a weld head proximate the welding surface, the weld head being adapted to form a bead of welded metal .Iadd.by deposit welding .Iaddend.on the weld surface;   .Iadd.initially forming a contour bead on the welding surface by moving the foundation body and the weld head relative to each other along the base-outline and simultaneously activating the weld head to deposit the contour bead; .Iaddend.   .Iadd.thereafter .Iaddend.moving the foundation body and the weld head relative to each other .Iadd.along a path contained .Iaddend.within the confines of . .said workpiece outline.!. .Iadd.the contour bead .Iaddend.and simultaneously activating the weld head to deposit said metal bead on the welding surface of the foundation body until a first metal layer with a shape of the base-outline has been formed on the welding surface; and   depositing at least one . .additional.!. .Iadd.second .Iaddend.layer of metal over the first metal layer by (i) determining . .an additional.!. .Iadd.a second .Iaddend.outline and a relative position for the additional metal layer from the desired shape of the workpiece;   (ii) activating the weld head to deposit . .by metal electrode inert gas (MIG) welding.!. a further weld bead on the first metal layer; and   (iii) moving the foundation body relative to the weld head so that the further weld bead is deposited on the first layer within and at the relative position of the . .additional.!. .Iadd.second .Iaddend.outline only;     whereby the finished workpiece will have the desired rotationally asymmetric, three-dimensional shape. . .5. A method according to claim 4 wherein the first mentioned moving step includes the steps of initially forming a contour bead on the welding surface by moving the foundation body and the weld head relative to each other along the base-outline, and thereafter moving the foundation body and the weld head relative to each other along a path contained within the contour bead until the first metal   
     
     
        layer is formed..!.6. A method according to claim . .5.!. .Iadd.4 .Iaddend.wherein step (iii) includes the step of initially moving the foundation body and the weld head relative to each other along the outline for the additional metal layer to deposit an additional contour bead on the first metal layer, and thereafter moving the foundation body relative to the weld head along a path contained within the additional contour bead 
     
     
        until the additional metal layer is formed. 7. A method according to claim 4 wherein the base-outline and the additional outline are identical in 
     
     
        shape. 8. A method according to claim 4 wherein the base-outline and the 
     
     
        additional outline differ in shape. 9. A method according to claim 4 wherein the welding surface is planar and the base-outline and the additional outline are offset from each other with respect to a line that is perpendicular to the welding surface of the foundation body, whereby a surface of the finished workpiece extending away from the welding surface 
     
     
        is nonperpendicular to the welding surface. 10. A method according to claim 4 wherein the outlines include at least one concavely curved section, at least one convexly curved section, and at least one section 
     
     
        which connects the concavely and convexly shaped outline sections. 11. A method according to claim 4 wherein the outlines include first and second outline sections which are angularly inclined with respect to each other, 
     
     
        converge and at their point of convergence define a workpiece corner. 12. A method according to claim 4 including the step of varying a height of at least a portion of at least one of the metal layers deposited by the 
     
     
        weld head. 13. A method according to claim 4 wherein at least one of the 
     
     
        metal layers has a substantially constant height. 14. A method according to claim 4 wherein at least one of the metal layers has a substantially constant height and at least one of the deposited metal layers has a 
     
     
        variable height. 15. A method according to claim 4 including the step of varying a height of the metal bead deposited by the weld head during the 
     
     
        formation of a metal layer. 16. A method according to claim 15 wherein the step of varying comprises the step of modulating a rate at which the weld 
     
     
        head forms the metal bead. 17. A method according to claim 15 wherein the step of varying comprises the step of changing the speed with which the 
     
     
        foundation body is moved relative to the weld head. 18. A method according to claim 17 including the step of adjusting the rate at which the weld bead is deposited when the weld head is at a surface discontinuity so that a surface of the metal layer being formed is substantially continuous. 
     
     
            A new method according to claim 4 wherein the workpiece has a portion 
     
     
        which is cup-shaped. 20. A method according to claim 4, including the step of sensing surface discontinuities in a previously formed metal layer by monitoring at least one welding parameter selected from the group of 
     
     
        welding parameters consisting of welding current and welding voltage. 21. A method of free-shape welding to form a rotationally asymmetric workpiece of any desired shape by depositing successive metal layers on top of each other comprising the steps of: (a) computer modelling a three-dimensional shape for the workpiece including establishing a planar, two-dimensional base-outline for the workpiece and the shapes and relative positions for all additional metal layers to be deposited on top of each other to form the desired workpiece;   providing a foundation body including a welding surface;   providing a weld head for depositing a bead of metal by welding;   providing robot means operatively coupled with the foundation body and the weld head for three-dimensionally moving the body of the bead with respect to each other; . .and.!.   .Iadd.forming a contour bead on the welding surface which conforms in shape to the base-outline by activating the weld head and moving it relative to the welding surface; and .Iaddend.   activating the robot means to initially move the welding surface relative to the weld head within the base.Iadd.-.Iaddend.outline of the workpiece while energizing the weld head to deposit by . .metal electrode inert gas (MIG).!. .Iadd.electric arc deposit .Iaddend.welding a weld bead . .until a first metal layer is formed.!. on the welding surface .Iadd.within the confines of the contour bead until a first metal layer is formed .Iaddend.in the shape of the base.Iadd.-.Iaddend.outline, and thereafter to move the foundation body and the weld head relative to each other while continuing to energize the weld head to deposit weld beads on the first layer to form all additional metal layers with the predetermined outlines and at the relative positions;   whereby the workpiece of the desired shape is obtained following completion   
     
     
        of a last metal layer. 22. Apparatus for free-shape welding a rotationally asymmetric workpiece of any desired shape comprising: a workpiece holder including means for holding a foundation plate;   a metal . .electrode inert gas (MIG) weld.!. .Iadd.deposit welding .Iaddend.head positioned proximate the foundation plate for depositing a metal in liquid form on the foundation plate;   modelling means for generating a plurality of outlines for the workpiece so that all outlines together define the shape of the workpiece; and   robot means operatively coupled with the work table and the . .weld.!. .Iadd.welding .Iaddend.head for three-dimensionally moving the foundation plate and the . .weld.!. .Iadd.welding .Iaddend.head relative to each other, the robot means being further operatively coupled with the modelling means for .Iadd.initially .Iaddend.guiding relative movements between the foundation plate and the . .weld.!. .Iadd.welding .Iaddend.head .Iadd.along a path which coincides with the respective outlines to form respective contour beads and thereafter, .Iaddend.along paths wholly contained within said . .outlines.!. .Iadd.respective contour beads, .Iaddend.to deposit weld beads on the foundation body which are wholly contained within said outlines and which sequentially form a first metal layer on a welding surface of the foundation body and all additional metal layers, one on top of the other;   whereby, upon the completion of a last layer, a workpiece having the   
     
     
        desired rotationally asymmetric, three-dimensional shape is formed. 23. Apparatus according to claim 22 including sensor means for sensing surface discontinuities in a most recent formed metal layer by monitoring at least one welding parameter selected from the group of welding parameters consisting of welding current and welding voltage, and means, operatively coupled with the sensor means, for adjusting the rate with which the . .weld.!. .Iadd.welding .Iaddend.head deposits metal when the . .weld.!. .Iadd.welding .Iaddend.head is over a sensed surface discontinuity to correspondingly adjust a height of the metal layer being formed at the surface discontinuity so that the metal layer being formed has a continuous surface. .Iadd.24. A method according to claim 1 wherein the step of activating the weld head to deposit metal by electric arc welding comprises depositing the metal by gas shielded electric arc welding. .Iaddend..Iadd.25. A method according to claim 24 wherein the gas shielded electric arc welding comprises metal electrode inert gas (MIG) welding. .Iaddend..Iadd.26. A method according to claim 4 wherein the step of activating include the step of flowing a gas over the metal bead as it is being deposited. .Iaddend..Iadd.27. A method according to claim 26 wherein deposit welding comprises metal electrode inert gas (MIG) welding. .Iaddend..Iadd.28. A method according to claim 21 wherein electric arc deposit welding comprises gas shielded electric arc welding. .Iaddend..Iadd.29. A method according to claim 28 wherein the gas shielded electric arc welding comprises inert gas shielded electric arc welding. .Iaddend..Iadd.30. Apparatus according to claim 22 wherein the welding head includes means for flowing a gas over metal being deposited by the head. .Iaddend..Iadd.31. A method of free-shape welding to form a rotationally asymmetric workpiece of any desired shape comprising the steps of providing a foundation body having a build-up surface for forming the workpiece thereon; determining a base-outline of the workpiece; positioning a weld head proximate the build-up surface of the foundation body; moving the weld head relative to the foundation body along the base-outline and activating the weld head while it moves to weld-deposit metal with a metal wire on the build-up surface and thereby form a contour bead which is parallel to the base-outline; thereafter moving the foundation body relative to the weld head within the contour bead and activating the weld head to weld deposit metal with the metal wire on the build-up surface and thereby form a first metal layer on the foundation body surface having the shape of the base-outline; thereafter moving the weld head and the foundation body relative to each other generally transversely to the first metal layer; determining another outline of the workpiece; and moving the foundation body relative to the weld head within the other workpiece outline while weld-depositing metal on top of the first metal layer to form at least a second metal layer on top of the first metal layer and thereby finish form the workpiece. .Iaddend..Iadd.32. A method according to claim 31 wherein the step of activating includes the step of forming an electric arc between the metal wire and the build-up surface. .Iaddend..Iadd.33. A method according to claim 32 wherein the step of activating includes the step of flowing a gas over the metal being weld deposited. .Iaddend..Iadd.34. A method of free-shape welding to form a rotationally asymmetric workpiece of any desired shape comprising the steps of providing a foundation body having a build-up surface for forming the workpiece thereon; determining a base-outline of the workpiece; positioning a weld head proximate the build-up surface of the foundation body; moving the weld head relative to the foundation body along the base-outline and activating the weld head while it moves to weld-deposit metal with a metal wire on the build-up surface and thereby form a contour bead which is parallel to the base-outline; thereafter moving the foundation body relative to the weld head within the contour bead and activating the weld head to deposit metal by deposit welding on the build-up surface and thereby form a first metal layer on the foundation body surface having the shape of the base-outline; thereafter moving the weld head and the foundation body relative to each other generally transversely to the first metal layer; determining another outline of the workpiece; and moving the foundation body relative to the weld head within the other workpiece outline while deposit welding metal on top of the first metal layer to form at least a second metal layer on top of the first metal layer and thereby finish form the workpiece. .Iaddend..Iadd.35. A method according to claim 4 wherein deposit welding comprises electric arc welding. .Iaddend..Iadd.36. A method according to claim 35 wherein electric arc welding comprises electric arc welding with a metal wire. .Iaddend..Iadd.37. A method according to claim 36 including the step of supplying metal for the metal bead being weld deposited with the metal wire. .Iaddend..Iadd.38. A method according to any of claims 1, 4, 21, 22, 31 and 34 wherein the first metal layer is formed with a bead of welded metal deposited within the contour bead, and wherein the bead of welded metal has a height greater than a height of the contour bead. .Iaddend..Iadd.39. A method according to claims 1, 4, 21, 22, 31 and 34 wherein the step of forming the second metal layer comprises sensing surface irregularities in the first layer; and adjusting weld-depositing metal on the first layer so that the metal being weld-deposited compensates for the sensed surface irregularities by correspondingly adjusting the weld-depositing of metal on the first layer. .Iaddend..Iadd.40. A method according to any one of claims 1, 4, 21, 22, 31 and 34 wherein the step of relatively moving the weld head to form the first metal layer comprises relatively moving the weld head so that the weld head follows a meandering line within the confines of the contour bead. .Iaddend.