绝缘片约束TIG电弧的静电探针分析及其在超窄间隙中的加热特性
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摘要
超窄间隙TIG焊接方法兼具TIG焊和窄间隙焊接技术的优势,焊接效率高,接头力学性能优良。然而,由于超窄间隙宽度较小,坡口侧壁的存在使电弧电场分布发生变化,坡口底角处电流密度较低,容易产生底角熔合不良的缺陷,需要通过改变TIG电弧载流区形态及电流密度分布,来调控超窄间隙中电弧加热特性以使坡口底角获得可靠熔合。
本文提出了一种绝缘片约束TIG电弧的方法改变电弧载流区形态及电流密度分布,并将该方法用于调控超窄间隙中电弧加热特性；同时,通过静电探针分析绝缘片约束作用下载流区形态及电流密度分布的变化,对绝缘片对电弧的调控机制进行了研究。
设计并研制了一种低扰动静电探针试验装置对TIG电弧载流区形态进行研究。通过分析探针饱和离子电流和悬浮探针电位波形可以发现,饱和离子电流波形分布宽度能够看作电弧载流区宽度；悬浮探针电位波形宽度则与包括电弧外围负离子区在内的电弧宽度相当；电弧载流区内的正离子作用于探针,使悬浮探针电位幅值减小,并在电位波形上形成一个宽度与载流区相近的凹陷区；通过饱和离子电流的分布趋势可对载流区电流密度分布进行定性分析。
开发了超窄间隙TIG焊接专用焊枪和片状钨极,使用片状钨极可在更大的焊接电流下进行超窄间隙焊接。进一步通过低扰动静电探针研究片状钨极,焊接电流和弧长对TIG电弧载流区形态及电流密度分布的影响,结果表明,电弧弧根在片状钨极前端扩展,导致片状钨极氩弧载流区截面呈近似椭圆形,电流密度和电弧压力均为非轴对称分布；相同焊接参数下,与圆柱钨极氩弧相比,片状钨极氩弧载流区截面积更大,电流密度更低,从而造成片状钨极氩弧具有更小的电弧压力。随着焊接电流的增加,片状钨极氩弧载流区向外扩张,但弧柱内部电磁力产生的收缩效应限制了载流区的扩展,使载流区宽度增幅小于焊接电流的增幅,造成电流密度增大。弧长越小时,片状钨极氩弧载流区截面积越小,电流密度越大；采用较小的弧长,电弧在片状钨极前端扩展能力较弱,载流区电流密度接近于轴对称分布。
开发了用于调控电弧加热特性的绝缘片,通过绝缘片对电弧的约束作用使载流区形态及电流密度分布发生变化,从而达到改变电弧加热特性的目的。使用低扰动静电探针分析绝缘片约束TIG电弧载流区形态及电流密度的变化,研究绝缘片对电弧的约束机制。结果表明,绝缘片能够对片状钨极氩弧弧根起到有效的固壁约束作用,使载流区在绝缘片约束方向上发生收缩,并提高电流密度；同时,绝缘片对弧根产生的附加冷却效果,造成载流区电位梯度增大；随着绝缘片对弧根约束程度的增加,载流区电流密度将进一步增大,且在靠近电弧载流区截面中心的区域内,电流密度增幅较大,意味着绝缘片约束电弧的能量更加集中。
超窄间隙中采用绝缘片约束TIG电弧的方式调控电弧对母材的加热特性,并通过分析坡口截面熔化形貌及熔化面积的变化,研究约束程度、弧长、焊接电流以及焊接速度对电弧加热特性的影响。结果发现,紧贴坡口侧壁放置的绝缘片,能够对超窄间隙中TIG电弧弧根产生固壁约束作用,使电弧载流区发生收缩,电流密度提高,并将电弧加热区域限制在坡口底部,从而加强电弧对坡口底角的加热效果,并使底角处获得足够的电流密度以保证可靠熔合；焊接过程中,绝缘片对弧根的约束程度、弧长、焊接电流和焊接速度均会影响超窄间隙中电弧的加热特性,且以上焊接工艺参数必须相互匹配,才能使坡口底角熔合良好；同时,与已有的超窄间隙TIG焊接方法相比,绝缘片约束TIG电弧超窄间隙焊接方法能够获得更大的熔深。
The Ultra-narrow gap TIG welding combines advantages of TIG welding and narrow gap welding technique to get high efficiency and welded joint with excellent mechanic properties. However, the side of square groove in ultra-narrow gap would change the electric field distribution of TIG arc to cause the lack of fusion on the corner of square groove with low current density. The arc current-carrying region shape and current density can be changed to control the arc heating characteristic in ultra-narrow gap for solving this problem.
In this paper, the constricted TIG arc with insulating plate was applied to change arc current-carrying region shape and current density distribution for controlling the arc heating characteristic in ultra-narrow gap. Meanwhile, the electrostatic probe can be used to analyze the variation of arc current-carrying region shape and current density distribution for searching the controlling mechanism of constricted TIG arc with insulating plate.
The low disturbance electrostatic probe is developed for studying the TIG arc current-carrying region shape and current density distribution. This low disturbance electrostatic probe is applied to measure the floating potential and ion saturation current in various sections along the axial direction of TIG arc. The ion saturation current width is equal to current-carrying region width of TIG arc; the width of floating potential can be representative of the arc width; the ions act on probe to cause reduction of floating potential amplitude, and there is a depression on the potential waveform in the same width as arc current-carrying region; the qualitative analysis of current density distribution can be obtained by ion saturation current distribution.
The torch and sheet tungsten electrode is developed for ultra-narrow gap TIG welding. With the application of the sheet tungsten electrode, the welding current of ultra-narrow gap TIG welding can be enhanced. In different welding current and arc length, the shape and current density distribution of arc current-carrying region of sheet tungsten electrode would be also analyzed by the low disturbance electrostatic probe. The arc root expands on sheet tungsten electrode to make the arc current-carrying region section approximate oval, and the distribution of current density and pressure are not ax symmetric; in contrast with the arc current-carrying region area of cylinder tungsten electrode, the arc current-carrying region area of sheet tungsten electrode is larger to get lower current density and pressure; the electromagnetic force of arc limits the enlargement of arc current-carrying region with enhancement of welding current, so the increment of arc current-carrying region area is smaller than that of welding current to make the current density rising; when the arc length reduced, the arc current-carrying region area of sheet tungsten electrode decreased to take higher current density, and the current density distribution close to ax symmetric distribution in short length arc.
The insulating plate is developed for changing arc current-carrying region shape and current density to control the arc heating characteristic. The insulating plate can be placed on the both side of sheet tungsten electrode to constrict arc. And then the low disturbance electrostatic probe is applied to analyze variation of constricted arc current-carrying region shape and current density distribution for searching controlling mechanism of constricted arc with insulating plate. The results show the constricting action of insulating plate on arc root causes the arc current-carrying region pinch in the direction of constriction to make the arc current density increased; meanwhile, the insulating plate produce cooling effect on arc to enhance the potential gradient of current-carrying region; when the constricting action was intensified, the current density would rise further, and in the area near the center of current-carrying region section, the increment of current density is larger to make the heat of constricted arc concentrated.
The constricted TIG arc with insulating plate is used for ultra-narrow gap welding. With different welding parameters, the heating characteristic of constricted TIG arc with insulating plate in ultra-narrow gap can be analyzed by variation of melted regions morphology and area of groove section. The results show the constricting action of insulating plate on arc root can restrict the arc in the bottom of square groove to intensify the heating effect on corner; the rising of constricted arc current density is beneficial to get good fusion on corner; when the welding parameters, including constricting level, arc length, welding current and welding speed, match with each other, the corner of square groove can get good fusion; in comparison with other ultra-narrow gap TIG welding, the constricted TIG arc with insulating plate would take larger penetration in ultra-narrow gap.
本文提出了一种绝缘片约束TIG电弧的方法改变电弧载流区形态及电流密度分布,并将该方法用于调控超窄间隙中电弧加热特性；同时,通过静电探针分析绝缘片约束作用下载流区形态及电流密度分布的变化,对绝缘片对电弧的调控机制进行了研究。
设计并研制了一种低扰动静电探针试验装置对TIG电弧载流区形态进行研究。通过分析探针饱和离子电流和悬浮探针电位波形可以发现,饱和离子电流波形分布宽度能够看作电弧载流区宽度；悬浮探针电位波形宽度则与包括电弧外围负离子区在内的电弧宽度相当；电弧载流区内的正离子作用于探针,使悬浮探针电位幅值减小,并在电位波形上形成一个宽度与载流区相近的凹陷区；通过饱和离子电流的分布趋势可对载流区电流密度分布进行定性分析。
开发了超窄间隙TIG焊接专用焊枪和片状钨极,使用片状钨极可在更大的焊接电流下进行超窄间隙焊接。进一步通过低扰动静电探针研究片状钨极,焊接电流和弧长对TIG电弧载流区形态及电流密度分布的影响,结果表明,电弧弧根在片状钨极前端扩展,导致片状钨极氩弧载流区截面呈近似椭圆形,电流密度和电弧压力均为非轴对称分布；相同焊接参数下,与圆柱钨极氩弧相比,片状钨极氩弧载流区截面积更大,电流密度更低,从而造成片状钨极氩弧具有更小的电弧压力。随着焊接电流的增加,片状钨极氩弧载流区向外扩张,但弧柱内部电磁力产生的收缩效应限制了载流区的扩展,使载流区宽度增幅小于焊接电流的增幅,造成电流密度增大。弧长越小时,片状钨极氩弧载流区截面积越小,电流密度越大；采用较小的弧长,电弧在片状钨极前端扩展能力较弱,载流区电流密度接近于轴对称分布。
开发了用于调控电弧加热特性的绝缘片,通过绝缘片对电弧的约束作用使载流区形态及电流密度分布发生变化,从而达到改变电弧加热特性的目的。使用低扰动静电探针分析绝缘片约束TIG电弧载流区形态及电流密度的变化,研究绝缘片对电弧的约束机制。结果表明,绝缘片能够对片状钨极氩弧弧根起到有效的固壁约束作用,使载流区在绝缘片约束方向上发生收缩,并提高电流密度；同时,绝缘片对弧根产生的附加冷却效果,造成载流区电位梯度增大；随着绝缘片对弧根约束程度的增加,载流区电流密度将进一步增大,且在靠近电弧载流区截面中心的区域内,电流密度增幅较大,意味着绝缘片约束电弧的能量更加集中。
超窄间隙中采用绝缘片约束TIG电弧的方式调控电弧对母材的加热特性,并通过分析坡口截面熔化形貌及熔化面积的变化,研究约束程度、弧长、焊接电流以及焊接速度对电弧加热特性的影响。结果发现,紧贴坡口侧壁放置的绝缘片,能够对超窄间隙中TIG电弧弧根产生固壁约束作用,使电弧载流区发生收缩,电流密度提高,并将电弧加热区域限制在坡口底部,从而加强电弧对坡口底角的加热效果,并使底角处获得足够的电流密度以保证可靠熔合；焊接过程中,绝缘片对弧根的约束程度、弧长、焊接电流和焊接速度均会影响超窄间隙中电弧的加热特性,且以上焊接工艺参数必须相互匹配,才能使坡口底角熔合良好；同时,与已有的超窄间隙TIG焊接方法相比,绝缘片约束TIG电弧超窄间隙焊接方法能够获得更大的熔深。
The Ultra-narrow gap TIG welding combines advantages of TIG welding and narrow gap welding technique to get high efficiency and welded joint with excellent mechanic properties. However, the side of square groove in ultra-narrow gap would change the electric field distribution of TIG arc to cause the lack of fusion on the corner of square groove with low current density. The arc current-carrying region shape and current density can be changed to control the arc heating characteristic in ultra-narrow gap for solving this problem.
In this paper, the constricted TIG arc with insulating plate was applied to change arc current-carrying region shape and current density distribution for controlling the arc heating characteristic in ultra-narrow gap. Meanwhile, the electrostatic probe can be used to analyze the variation of arc current-carrying region shape and current density distribution for searching the controlling mechanism of constricted TIG arc with insulating plate.
The low disturbance electrostatic probe is developed for studying the TIG arc current-carrying region shape and current density distribution. This low disturbance electrostatic probe is applied to measure the floating potential and ion saturation current in various sections along the axial direction of TIG arc. The ion saturation current width is equal to current-carrying region width of TIG arc; the width of floating potential can be representative of the arc width; the ions act on probe to cause reduction of floating potential amplitude, and there is a depression on the potential waveform in the same width as arc current-carrying region; the qualitative analysis of current density distribution can be obtained by ion saturation current distribution.
The torch and sheet tungsten electrode is developed for ultra-narrow gap TIG welding. With the application of the sheet tungsten electrode, the welding current of ultra-narrow gap TIG welding can be enhanced. In different welding current and arc length, the shape and current density distribution of arc current-carrying region of sheet tungsten electrode would be also analyzed by the low disturbance electrostatic probe. The arc root expands on sheet tungsten electrode to make the arc current-carrying region section approximate oval, and the distribution of current density and pressure are not ax symmetric; in contrast with the arc current-carrying region area of cylinder tungsten electrode, the arc current-carrying region area of sheet tungsten electrode is larger to get lower current density and pressure; the electromagnetic force of arc limits the enlargement of arc current-carrying region with enhancement of welding current, so the increment of arc current-carrying region area is smaller than that of welding current to make the current density rising; when the arc length reduced, the arc current-carrying region area of sheet tungsten electrode decreased to take higher current density, and the current density distribution close to ax symmetric distribution in short length arc.
The insulating plate is developed for changing arc current-carrying region shape and current density to control the arc heating characteristic. The insulating plate can be placed on the both side of sheet tungsten electrode to constrict arc. And then the low disturbance electrostatic probe is applied to analyze variation of constricted arc current-carrying region shape and current density distribution for searching controlling mechanism of constricted arc with insulating plate. The results show the constricting action of insulating plate on arc root causes the arc current-carrying region pinch in the direction of constriction to make the arc current density increased; meanwhile, the insulating plate produce cooling effect on arc to enhance the potential gradient of current-carrying region; when the constricting action was intensified, the current density would rise further, and in the area near the center of current-carrying region section, the increment of current density is larger to make the heat of constricted arc concentrated.
The constricted TIG arc with insulating plate is used for ultra-narrow gap welding. With different welding parameters, the heating characteristic of constricted TIG arc with insulating plate in ultra-narrow gap can be analyzed by variation of melted regions morphology and area of groove section. The results show the constricting action of insulating plate on arc root can restrict the arc in the bottom of square groove to intensify the heating effect on corner; the rising of constricted arc current density is beneficial to get good fusion on corner; when the welding parameters, including constricting level, arc length, welding current and welding speed, match with each other, the corner of square groove can get good fusion; in comparison with other ultra-narrow gap TIG welding, the constricted TIG arc with insulating plate would take larger penetration in ultra-narrow gap.
引文
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