中厚板低频脉冲TIG打底焊的电弧形态及熔池行为
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摘要
针对中厚钢板传统背衬板手工打底焊接工艺存在的效率低、工序复杂、过程稳定性差等问题,采用低频率、大占空比的脉冲TIG方法来实现无衬板5 mm大钝边16MnR钢的单面焊双面成形.利用高速摄像详细观察了焊接电弧穿过熔孔的被压缩过程,统计分析了一定焊接速度下电弧尾焰偏转角度和长度与焊缝熔透的相关性.实验结果表明:在一定焊接规范下,电弧熔化钝边形成孔状熔池,穿过熔孔的电弧尾焰偏转角度和长度均与焊接速度呈负相关,且与焊缝熔透程度约呈现正相关,通过观测电弧尾焰尺寸,可对打底焊时焊缝的熔透程度做出预判;电弧周期性变化的热力耦合作用增强了熔池液态金属的搅拌及对流作用,在表面张力、重力、电弧力以及气体吹力的共同作用下,熔孔侧壁上的液态金属向熔池边缘及底部流动,增强了熔池中的热传导,能有效增加焊缝熔深.
The pulse TIG welding with low frequency and large duty cycle was used to realize single-side welding without subtrate and double-side forming of 16 MnR steel plates with 5 mm large blunt edge, in view of the low efficiency, complex process and poor stability in traditional manual welding with subtract for medium and thick plates backing welding. The compression process of welding arc passing through the molten hole was captured by a high-speed camera. And the correlation between deflection angle and length of arc tail flame and weld penetration at a certain welding speed was analyzed. The results show that a hole-shaped weld pool is formed under a certain para-meters, and the deflection angle and length of the arc tail flame passing through the hole is negatively correlated with the welding speed, and positively correlated with the weld penetration. By observing the size of the arc tail flame, the weld penetration can be estimated, and the stirring and convection of liquid in weld pool is enhanced under the thermo-mechanical coupling effect of periodic arc.Under the combined action of surface tension, gravity, arc force and gas blowing force, the liquid metal on the side wall of the welding hole flows to the edge and bottom,which enhances the heat conduction in the weld pool and effectively increases the weld penetration.
The pulse TIG welding with low frequency and large duty cycle was used to realize single-side welding without subtrate and double-side forming of 16 MnR steel plates with 5 mm large blunt edge, in view of the low efficiency, complex process and poor stability in traditional manual welding with subtract for medium and thick plates backing welding. The compression process of welding arc passing through the molten hole was captured by a high-speed camera. And the correlation between deflection angle and length of arc tail flame and weld penetration at a certain welding speed was analyzed. The results show that a hole-shaped weld pool is formed under a certain para-meters, and the deflection angle and length of the arc tail flame passing through the hole is negatively correlated with the welding speed, and positively correlated with the weld penetration. By observing the size of the arc tail flame, the weld penetration can be estimated, and the stirring and convection of liquid in weld pool is enhanced under the thermo-mechanical coupling effect of periodic arc.Under the combined action of surface tension, gravity, arc force and gas blowing force, the liquid metal on the side wall of the welding hole flows to the edge and bottom,which enhances the heat conduction in the weld pool and effectively increases the weld penetration.
引文
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[2] 唐郑磊,许少普,陆岳璋,等.国内中厚板热处理需求分析与发展展望 [J].中国冶金,2016,25(3):1- 5.TANG Zheng-lei,XU Shao-pu,LU Yue-zhang,et al.Heat treatment requirements analysis and development pro-spects for domestic plate [J].China Metallurgy,2016,25(3):1- 5.
[3] 刘殿宝,张广军,吴林.大厚板双面双TIG电弧打底焊熔池成形特性 [J].焊接学报,2012,33(3):37- 40.LIU Dian-bao,ZHANG Guang-jun,WU Lin.Forming mo-lten pool forming characteristics of double-sided double TIG arc backing welding for thick plate [J].Transactions of the China Welding Institution,2012,33(3):37- 40.
[4] WU C S,WANG L,REN W J,et al.Plasma arc welding:process,sensing,control and modeling [J].Journal of Manufacturing Processes,2014,16(1):74- 85.
[5] BENYOUNIS K Y,OLABI A G,HASHMI M S J.Effect of laser welding parameters on the heat input and weld-bead profile [J].Journal of Materials Processing Technology,2005,164(10):978- 985.
[6] SHARMA A,CHAUDHARY A K,ARORA N,et al.Estimation of heatsource model parameters for twin-wire submerged arc welding [J].International Journal of Advanced Manufacturing Technology,2009,45(11/12):1096- 1103.
[7] 刘殿宝,李福泉,谭财旺,等.EH36钢厚板双面双弧打底焊焊缝组织及性能研究 [J].焊接学报,2011,32(1):81- 84.LIU Dian-bao,LI Fu-quan,TAN Cai-wang,et al.Study on microstructure and properties of double-sided double-arc backing weld for EH36 steel thick plate [J].Transactions of the China Welding Institution,2011,32(1):81- 84.
[8] 周彦彬,史吉鹏,刘黎明.MAG-TIG双电弧共熔池热源打底焊接自由成形研究 [J].机械工程学报,2018,54(10):78- 84.ZHOU Yan-bin,SHI Ji-peng,LIU Li-ming.Study on the back formation of root welding by MAG-TIG twin-arc welding in thick plate [J].Journal of Mechanical Engineering,2018,54(10):78- 84.
[9] 王涛,郑振太,董天顺,等.脉冲TIG焊接工艺参数对Inconel601H镍基合金焊缝晶粒大小的影响 [J].焊接学报,2015,36(4):109- 112.WANG Tao,ZHENG Zhen-tai,DONG Tian-shun,et al.Effect of pulse TIG welding process parameters on grain size of Inconel601H nickel-base alloy weld [J].Transactions of the China Welding Institution,2015,36(4):109- 112.
[10] 常云龙,梅强,张伟,等.低频磁场对轧辊埋弧堆焊组织及性能的影响 [J].中国表面工程,2011,24(6):98- 103.CHANG Yun-long,MEI Qiang,ZHANG Wei,et al.Effect of low-frequency magnetic field on the mechanical prorerty of submerged-are deposited metal on roll [J].China Surface Engineering,2011,24(6):98- 103.
[11] 赵明,武传松,赵朋成.GTAW熔池形状数值模拟精度的改进 [J].焊接学报,2006,27(3):17- 20.ZHAO Ming,WU Chuan-song,ZHAO Peng-cheng.Impro-vement of numerical simulation accuracy of GTAW molten pool shape [J].Transactions of the China Welding Institution,2006,27(3):17- 20.
[12] 邱灵,范成磊,林三宝,等.高频脉冲变极性焊接电源及电弧压力分析 [J].焊接学报,2007,28(11):81- 84.QIU Ling,FAN Cheng-lei,LIN San-bao,et al.Analysis of high frequency pulse variable polarity welding power supply and arc pressure [J].Transactions of the China Welding Institution,2007,28(11):81- 84.
[13] REDDY G M,MOHANDAS T.Explorative studies on grain refinement of ferritic stainless steel welds [J].Journal of Materials Science Letters,2001,20(8):721- 723.
[14] 杨明轩,从保强,齐铂金,等.脉冲电流参数对奥氏体不锈钢电弧行为的影响 [J].焊接学报,2012,33(10):67- 70.YANG Ming-xuan,CONG Bao-qiang,QI Bo-jin,et al.Effect of pulse current parameters on arc behavior of austenitic stainless steel [J].Transactions of the China Welding Institution,2012,33(10):67- 70.
[15] 李冬杰,陆善平,李殿中,等.TIG焊接过程中熔池对流形式的示踪分析 [J].焊接学报,2011,32(8):45- 48.LI Dong-jie,LU Shan-ping,LI Dian-zhong,et al.Tracer analysis of convection form of molten pool in TIG welding process [J].Transactions of the China Welding Institution,2011,32(8):45- 48.
[16] 周方明,钱乙余,张景,等.钽薄壁管GTA焊接接头晶粒细化机理 [J].焊接学报,2006,27(6):41- 44.ZHOU Fang-ming,QIAN Yi-yu,ZHANG Jing,et al.Grain-refinement mechanism of GTA welded joint of tantalum thin-walled pipe [J].Transactions of the China Welding Institution,2006,27(6):41- 44.
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