The present invention provides for the welding of copper using activated TIG welding (8). In particular, the copper coils (6) of electrical generators (2) are welded using the present invention.
Description
BRIEF DESCRIPTION OF THE FIGURES
The invention is explained in more detail by way of example with reference to the following drawings:
FIG. 1 illustrates where in a generator's rotor winding joints are typically made.
FIG. 2 illustrates a close-up view of rotor windings.
FIG. 3 illustrates a welder welding two copper ends.
Claims
1. A method of welding unbeveled copper comprising:
placing an activated flux on the desired site of a copper weld; andwelding the copper using TIG without a filler material;wherein the activated flux comprises 20-50% by weight of at least one of SiO2, TiO2, Cr2O3 and a halide.
2. The method of claim 1, wherein the welding of copper is on copper coils in an electrical generator.
3. The method of claim 2, wherein targets on said copper coils are at least one of end turns, consolidation joints and series connections between top and bottom strands.
4. The method of claim 1, wherein the copper is at least one of pure copper and a high copper alloy.
5. A copper weld produced by:
applying an activated flux on the weld site; andwelding the copper with a TIG welding process;wherein the depth of the weld is at least 5 mm;whereby the copper is not preheated prior to welding.
6. The copper weld of claim 5, wherein the length of the weld is 3.2-4.0 cm.
7. The copper weld of claim 5, wherein said activated flux comprises 20-50% by weight of at least one of SiO2, TiO2, Cr2O3 and a halide
8. The copper weld of claim 5, wherein said copper is not beveled.
9. The copper weld of claim 5, wherein filler material is not used in the welding.
10. A method of welding copper coils comprising:
applying an activated flux to abutted ends of copper coils, wherein said abutted copper coils are between 0.0-2.0 mm apart; andwelding said copper coils at approximately 220 amps, and 9-11 volts, and a speed of approximately 7.5-9.0 cm/min, wherein the welding is preformed without preheating said copper coils and without a filler material;wherein said copper coils are unbeveled;wherein no filler material is used in the welding;wherein said copper coils are at least 95% copper.
11. The method of claim 10, wherein said copper coils are about 99% copper.
12. The method of claim 10, wherein the length of the weld is approximately 3.2-4.0 cm (1.25-1.6 inches).
13. The method of claim 10, wherein said activated flux comprises 40-50% by weight of at least one of SiO2, TiO2, Cr2O3.
14. The method of claim 10, wherein said copper coils are being assembled within a generator.
Patent Application
20070181550
