CN100584504C - Sub-jet transient self-adaption control method for aluminum and aluminum alloy consumable electrode gas-arc welding - Google Patents
Sub-jet transient self-adaption control method for aluminum and aluminum alloy consumable electrode gas-arc welding Download PDFInfo
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- CN100584504C CN100584504C CN200610013407A CN200610013407A CN100584504C CN 100584504 C CN100584504 C CN 100584504C CN 200610013407 A CN200610013407 A CN 200610013407A CN 200610013407 A CN200610013407 A CN 200610013407A CN 100584504 C CN100584504 C CN 100584504C
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Abstract
An adaptive subjet transition control method for the consumable electrode gas-protecting welding of Al or Al-alloy includes such steps as choosing that the slopes of lines ab and ed are greater than or equal to that of the arc' s static characteristic passing through dot a and d and the slope of line bc is obviously greater than that of isofusible curve, and making the arc to burn on line ae, or on line cd when the arc voltage is less than or equal to the voltage at dot a, or back on line ae when the arc voltage is greater than or equal to the voltage at some dot on line cd.
Description
Technical field
The present invention relates to materials processing technology, welding.Specifically, the present invention relates to the sub-jet transient self-adaption control method of aluminium and aluminum alloy melting utmost point gas shielded arc welding.
Background technology
The droplet transfer mode of aluminium MIG weldering has globular transfer, penetrate and drip a transition, short circuiting transfer and Asia and penetrate and drip a transition.Globular transfer is at electric current droplet transfer mode hour; When electric current surpass penetrate drip the transition critical current after, droplet transfer mode becomes to penetrate and drips a transition.At this moment, the molten drop diameter breaks away from welding wire transition vertically near gage of wire, and acceleration is greater than acceleration of gravity.
When the direct current welding was carried out in the MIG weldering (being gas metal-arc welding) of aluminium and aluminium alloy, the general employing penetrated a transient mode, is suitable for the welding requirements of cut deal or high current capacity.When needs reduce the welding current capacity, often adopt at present the method for pulse current welding, and do not adopt globular transfer and short circuiting transfer mode, because of such droplet transfer mode weldquality bad.
The pulse current MIG welding method of aluminium and aluminium alloy has many types, have as: power supply and vertically to add outer control thin plate Pulse MIG Welding for Aluminium Alloy of dragging external characteristics, dipulse MIG weldering, the AC pulse MIG weldering, the self-adapting closed loop control method of arc length, at the self balancing Synergic control of the arc length of wire feed rate fluctuation, or the like.But do not see specially the bibliographical information that electric arc and droplet transfer is controlled at the transition of inferior jet current district as yet.
The Asia is penetrated a transition and is called transition of inferior jet current traditionally, is a kind of droplet transfer mode that drips between transition and the short circuiting transfer between penetrating, and its arc length is shorter, generally changes between 2 ~ 8mm.Under the effect of arc heat, molten drop forms grows up, form necking down be about to penetrate the mode of dripping break away from welding wire when with the molten bath short circuit, thin neck is disrumpent feelings under the electromagnetic contractile force effect, arcing is finished transition again.The molten drop short circuit duration of transition of inferior jet current is extremely short, and electric current rises little, and necking down is fracture just, exists the zone very narrow, as shown in Figure 1.The electric current, the magnitude of voltage characteristics that produce transition of inferior jet current are: electric current generally will surpass penetrates a transition critical current, and voltage again can not be too high.
Utilize inferior jet arc welding aluminium and aluminium alloy just to exist some to be different from the characteristics of other welding methods.(1) advantage: (a) electric arc is dish, and the negative electrode range of atomization is big, and the wrinkling and surperficial black powder phenomenon of weld seam is lacked than spray transfer; (b) can adopt the welding of external characteristics of constant current power supply; (c) fusion penetration of jet electric arc is shaped as " finger-type ", and inferior jet electric arc is " bowl-type ", the defectives such as penetration deficiency of having avoided " finger-type " fusion penetration to cause.(2) shortcoming: inferior jet electric arc arc length scope is not wide, and (φ 1.6 aluminium welding wires 2 ~ 8mm), for certain wire feed rate, best welding current scope is rather narrow, and is wayward.
Transition of inferior jet current electric arc arc length is shorter, to around expand to dish.Its different characteristics are also arranged on pre-arcing characterisitics, Fig. 2 is that the pre-arcing characterisitics curve of φ 1.6 aluminium welding wires is [data from the research paper Electrode melting in arcwelding of E.Halmoy, Physical aspects of arc welding, 81 ~ 93, IIW Group212,1993.9], fusion curve such as can be described as again.Each bar curve is represented a wire feed rate, the numeral wire tip on the characteristic curve and the distance on mother metal surface (being the visual length of electric arc).As can be seen from the figure, the wire melting characteristic curve almost is a vertical line penetrating a transitional region, and the wire melting coefficient is not subjected to the influence of arc length substantially.But it is crooked left to enter behind the transition of inferior jet current district characteristic curve, and fusing coefficient increases with arc length and reduces, and reduces and increases with arc length.And this variation is more obvious under big electric current.Arc length is if further reduce (about 2mm is following), and characteristic curve is crooked to the right again, and the frequent short circuit of welding wire and workpiece enters the short circuiting transfer district.The fusing of aluminium alloy welding wire also presents similar characteristics.Though the indicatrix of Fig. 2 is φ 1.6 aluminium welding wires, other scopes also all have similar indicatrix at the aluminium and the aluminium alloy welding wire of φ 0.8 ~ 2.4 diameter.
In sum, at present, there are some bigger technical problems in the welding of aluminium and aluminium alloy, as producing defectives such as pore, crackle, slag inclusion, and problem such as appearance of weld, crystal grain be thick.
The interval of transition of inferior jet current is very narrow, and arc length is short, and is wayward.If the control arc length is short, then arc length has fluctuation slightly, just is easy to enter the short circuiting transfer district; If the control arc length is big, then is easy to enter penetrate and drips transition region.Moreover, the control of arc length is mainly undertaken by detecting arc voltage, and the arc voltage variation that arc length variation in transition of inferior jet current district causes to be less, constant interval is very narrow, and electric current is more little, and the interval that this arc voltage changes is narrow more.
Summary of the invention
For overcoming the deficiencies in the prior art; the objective of the invention is to: the sub-jet transient self-adaption control method that a kind of aluminium and aluminum alloy melting utmost point gas shielded arc welding are provided; control welding arc length; solve some bigger technical problems of the welding existence of aluminium and aluminium alloy; as produce defectives such as pore, crackle, slag inclusion, and problem such as appearance of weld, crystal grain be thick.
The technical solution used in the present invention is: the sub-jet transient self-adaption control method of aluminium and aluminum alloy melting utmost point gas shielded arc welding comprises the following steps:
Determine a, b, c, d and e 5 points: select the slope of the slope of ab line more than or equal to the static characteristic of arc of ordering by a, the slope of ed line should be more than or equal to the slope of the static characteristic of arc of ordering by d, 14～19 volts of a point voltages, 20～30 volts of d point voltages, the c point voltage is less than 5 volts of d point voltages, ae line and cd line are two power supply constant current characteristics, and the slope of bc line should be obviously greater than the slope that waits fusion curve;
Electric arc is burnt on the ae line, arc voltage reduces gradually, when arc voltage is less than or equal to a point voltage, making arc current skip to the b point increases along the bc line, constant to cd line arc current, makes electric arc smooth combustion on the cd line, voltage increases gradually, when arc voltage more than or equal to the cd line on during certain any magnitude of voltage, arc current skips to the burning of ae line, enters next circulation.
Described ae line constant current value is a background current, less than 50 amperes.
Described ae line constant current value is a background current, is chosen as 30 amperes.
Described cd line constant current value is a pulse current, greater than 180 amperes.
Described cd line constant current value is a pulse current, is chosen as 235 amperes.
Between a, d point during redirect, the frequency of pulse current increases described arc current automatically continually.
The electric arc arc length fluctuation range that the difference decision of described a point and d point voltage value allows, when the arc length fluctuation range that allows hour, arc current redirect between a, d point continually, the frequency that makes pulse current increases automatically with the redirect of arc current.
The constant current of described cd line is a pulse current, along with the variation of described arc voltage, adjusts the time that increase (or reducing) works in pulse current automatically.
The gage of wire that adopts is between Φ 0.8 and Φ 2.4.
The present invention possesses following effect: because the selection of a of the present invention, b, c, d and 5 of e and line, weldingvoltage, electric current are defined in the transition of inferior jet current district, thereby the present invention will weld arc length and be strict controlled in the interval of transition of inferior jet current, some big technical problems of the welding existence of aluminium and aluminium alloy have been solved, as produce defectives such as pore, crackle, slag inclusion, and problem such as appearance of weld, crystal grain be thick.
Description of drawings
Fig. 1 aluminium MIG weldering mode of metal transfer distributes
Fig. 2 aluminium MIG welds pre-arcing characterisitics
The control of the inferior jet electric arc of Fig. 3
Fig. 4 Al pulse MIC welding Self Adaptive Control experimental waveform 1
Fig. 5 Al pulse MIC welding Self Adaptive Control experimental waveform 2
The high-speed camera 3 of Fig. 6 pulse MIC welding adaptive control process (1000 width of cloth/seconds, φ 1.6)
The specific embodiment
Further specify the present invention below in conjunction with drawings and Examples.
The interval of transition of inferior jet current is very narrow, and arc length is short, and is wayward.If the control arc length is short, then arc length has fluctuation slightly, just is easy to enter the short circuiting transfer district; If the control arc length is big, then is easy to enter penetrate and drips transition region.Moreover, the control of arc length is mainly undertaken by detecting arc voltage, and the arc voltage variation that arc length variation in transition of inferior jet current district causes to be less, constant interval is very narrow, and electric current is more little, and the interval that this arc voltage changes is narrow more.
For overcoming above-mentioned shortcoming, adopt pulse current adaptive control scheme as shown in Figure 3.The fusion curve such as grade of aluminium MIG weldering in the dotted line representative graph 2 among the figure, the zone between corresponding ab line and the ed line is in the transition of inferior jet current district; The mn line is represented aluminium MIG weldering static characteristic of arc, is in the ascent stage of U-shaped curve; Ae line and cd line are represented two power supply constant current characteristics, and the ae line current is very little, and such electric current is difficult to form the droplet transfer, and the cd line current is bigger, is positioned at the spray transfer district, are enough to produce penetrate drip transition; The bc line slope should be greater than the slope of fusion curves such as transition of inferior jet current district.
Control procedure shown in Figure 3 is as follows: suppose that at first electric arc burns on the ae line, voltage reduces gradually, and when arc voltage was less than or equal to a point voltage, electric current skips to the b point to be increased along the bc line, to the smooth combustion of cd line arc current; Electric arc smooth combustion on the cd line, voltage increases gradually, when arc voltage more than or equal to the cd line on during certain any magnitude of voltage, electric current skips to the burning of ae line, enters next circulation.To select be crucial in the position of 2 of a, d among the figure, and a point voltage value is a lower voltage limit, and d point voltage value is a upper voltage limit.When arc voltage was lower than a point voltage, molten drop was easy to and the molten bath short circuit, enters the short circuiting transfer district: when arc voltage is higher than the d point voltage, be easy to enter the spray transfer district.
The slope of selection ab line should be more than or equal to the slope of the static characteristic of arc of ordering by a, and the slope of ed line should can guarantee that like this electric current, the voltage change of electric arc is in the transition of inferior jet current district more than or equal to the slope of the static characteristic of arc of ordering by d.Arc current is more little, and the transition of inferior jet current district is narrow more, thus a point voltage control and control point choose very importantly, the little short circuiting transfer that then easily produces of this magnitude of voltage greatly then easily produces globular transfer, influences welding effect; According to experimental result, this magnitude of voltage is greatly in the scope of 14～19v.When arc current is big, transition of inferior jet current district broad, so d point voltage range of choice broad, it is worth in 20～30v scope, even this point selection still can make the most of the time of pulse current welding process be in the transition of inferior jet current district in the spray transfer district in a little higher than transition of inferior jet current district.
Above-mentioned control procedure is a kind of adaptive control process, and it determines the size of arc current according to arc voltage value, automatically with the electric current of electric arc, Control of Voltage in the transition of inferior jet current district.
Further specify the present invention below in conjunction with key issue.
(1) in fact the difference of a point and d point voltage value has determined the arc length fluctuation range that allows, because aluminium MIG weldering electric arc is operated in the ascent stage of static characteristic of arc, as long as a, d point voltage difference are in the certain limit, the arc length fluctuation range that allows is also little, means that this control system has suitable arc length Stable Adaptive Control ability.When the arc length fluctuation range that allows hour, arc current redirect between a, d point continually, the frequency of pulse current increases automatically.
(2) when wire feed rate increased (or reducing), welding wire melting rate also should correspondingly increase (or reducing).This control system is except utilizing the intrinsic self-regulation effect of transition of inferior jet current, also can be according to the variation of arc voltage, automatically adjust the time that increase (or reducing) works in pulse current, that is adjust increase (or reducing) pulse current frequency, thereby increase (or reducing) welding wire melting rate.Like this, this control system has also just had the ability of automatic adaptation wire feed rate fluctuation and variation.
(3) a point is when the redirect of d point, and electric current changes along the bcd line, is to wish the control welding arc from transition of inferior jet current district process, and owing to being the positive feedback relation between electric current on the bc line and the voltage, actual electric current pace of change is very fast.The d point jumps directly to the constant current characteristic of ae line when the redirect of a point, avoid in the spray transfer district or the elapsed time in globular transfer district long.
(4) a point position determines
Demarcate by electric current and voltage coordinate.Electric current should be penetrated the critical current that drips transition less than generation, and the electric current of selection is not produced the droplet transfer as far as possible, and this is worth generally below 50A; Two line reverse extendings on the border, transition of inferior jet current district on Fig. 2 are seen Fig. 3, meet at a, e 2 points with the electric current line of selecting, thereby determine it.When actual selection, a point voltage can be a little more than transition of inferior jet current district lower boundary, and it is worth generally in 14～19v scope.
(5) d point position determines
Demarcate by electric current and voltage coordinate.Electric current should obviously be penetrated the critical current that drips transition greater than generation, and the electric current of selection can be produced the droplet transfer, and this is worth generally more than 180A; Fig. 3 is seen in two line forwards prolongations on the border, transition of inferior jet current district on Fig. 2, and top curve meets at the d point with the electric current line of selecting, thereby determines it.When actual selection, the d point voltage can be a little more than coboundary, transition of inferior jet current district, and it is worth generally in 20～30v scope.
(6) the c point voltage should be starkly lower than the d point voltage, but the two electric current is identical, and the c point is in the transition of inferior jet current district certainly, and the present invention generally gets the c point voltage and is lower than about d point voltage 5v.The fusion curve process is arranged near the c point among Fig. 3 etc., and the slope of bc line should can be determined the b point so obviously greater than the slope that waits fusion curve.
The present invention can obtain following beneficial effect:
Utilizing inverter arc welding power source to experimentize, verify the sub-jet transient self-adaption control scheme of above-mentioned aluminium and aluminum alloy melting utmost point gas shielded arc welding, is that example is illustrated with the welding wire of diameter 1.6mm.Main process control parameters is ae line background current, cd line pulse current, a point voltage and four physical quantitys of d point voltage.According to above-mentioned condition, table 1 has been listed the parameter (wherein Ar protects throughput 15L/min, stem elongation 16～20mm, welding wire AlMg2/ φ 1.6) of a plurality of experimental waveforms, I
AeRepresent the ae line current, I
CdRepresent the cd line current, U
aRepresent a point voltage, U
dRepresent the d point voltage.
Table 1 aluminium pulse MIC welding Self Adaptive Control welding experimental technique parameter list
Tab.1?Welding?parameters?of?Al?pulse?MIG?welding?under?self-adapting?control
Adopt the also desirable result same of welding wire of AlMg2/ Φ 0.8 and Φ 2.4 with last epiphase.
Generation transition of inferior jet current electric current, magnitude of voltage characteristics are: electric current generally will surpass penetrates a transition critical current, and voltage again can not be too high.Aluminium MIG weldering produces the critical current of penetrating a transition and can reach more than the 180A, and welding current then is difficult for producing the droplet transfer when 50A is following.Therefore, this experimental selection pulse current is 235A, and far away surpassing penetrated the critical current that drips transition, and background current is chosen as 30A.
Fig. 4 (a) and (b) are time basic temporal patterns of No.1 in the table 1～2.With the increase of wire feed rate, the shared time scale of pulse current increases, and average welding current also increases, but average weldingvoltage is then constant substantially.This explanation adaptive control system can be regulated the variation that burn-off rate adapts to wire feed rate automatically, and arc voltage then is controlled within the voltage upper and lower limit of setting.The labile states such as short circuit that Fig. 4 (b) occurs have shown a kind of critical limit state, particularly short circuit duration is very short, almost do not have the rising of short circuit current, a kind of critical condition of transition of inferior jet current just, its control procedure have embodied aforementioned transition of inferior jet current control thought.
Fig. 5 (a) and (b) are time basic temporal patterns of No.3 in the table 1～4.With upper voltage limit U
dIncrease, the time width of pulse current increases, average weldingvoltage also increases, but average welding current is then constant substantially.This explanation arc length fluctuation does not cause the variation of welding current, has the characteristics of intrinsic self-regulation effect.Anatomize Tu Shiji temporal pattern Fig. 5 (a) as can be seen: all have the trend of short circuit in many moment, illustrate to be in the transition of inferior jet current district; The labile states such as short circuit that Fig. 5 (b) occurs have shown a kind of critical limit state, particularly short circuit duration is very short, almost do not have the rising of short circuit current, a kind of critical condition of transition of inferior jet current just, its control procedure have embodied aforesaid transition of inferior jet current control thought equally.
Sum up above-mentioned several control result, utilize the inferior jet electric arc Self Adaptive Control of pulse MIC welding, can be effectively electric current, the voltage parameter of electric arc be controlled at the transition of inferior jet current district, suitably select the upper and lower limit of voltage, can make transition of inferior jet current that bigger adjustable range is arranged, adapt to the fluctuation of conditions such as wire feed rate, arc length automatically.
The high-speed camera of MIG weldering sub-jet transient self-adaption control procedure:
According to the control thought of the inferior jet electric arc Self Adaptive Control of aforementioned MIG weldering, carry out the high-speed camera under this process control.
Fig. 6 is corresponding to one group of high-speed camera picture between 20～39ms among Fig. 8-5 (b).Produced extremely of short duration short circuit between the 2nd width of cloth (21ms)～the 3rd width of cloth (22ms) and the 6th width of cloth (25ms)～the 7th width of cloth (26ms), between the 9th width of cloth (28ms)～the 11st width of cloth (30ms), the pulse current of the 14th width of cloth (33ms)～the 15th width of cloth (34ms) and the 17th width of cloth (36ms)～the 19th width of cloth (38ms) all produced the droplet transfer fast, and other less electric currents and fluctuation thereof all do not produce the droplet transfer.Fig. 6 presents the feature of transition of inferior jet current.
Can find out obviously that by actual welding appearance of weld is better, the negative electrode range of atomization is bigger; Can find defectives such as face of weld pore-free after testing.The present invention has carried out experimental study to the sub-jet transient self-adaption control thought that is proposed on the basis of a large amount of experiments.
(1) verifies the feasibility of the control thought of being set forth, realized the control of aluminium and aluminum alloy MIG weldering sub-jet transient self-adaption.
(2) suitably select the upper and lower limit of control arc voltage for realizing that the control of aluminium and aluminum alloy MIG weldering sub-jet transient self-adaption is extremely important.
(3) function admirable of aluminium of being set up and aluminum alloy MIG weldering sub-jet transient self-adaption control system can adapt to the fluctuation of factors such as wire feed rate, electric arc arc length effectively automatically.
Claims (9)
1. the sub-jet transient self-adaption control method of aluminium and aluminum alloy melting utmost point gas shielded arc welding is characterized in that, comprises the following steps:
In electric current and voltage coordinate, determine a, b, c, d and e 5 points: select the slope of the slope of ab line more than or equal to the static characteristic of arc of ordering by a, the slope of ed line should be more than or equal to the slope of the static characteristic of arc of ordering by d, 14～19 volts of a point voltages, 20～30 volts of d point voltages, the c point voltage is less than 5 volts of d point voltages, ae line and cd line are two power supply constant current characteristics, the ae line current should be penetrated the critical current that drips transition less than generation, and the electric current of selection is not produced the droplet transfer, the cd line current should be penetrated the critical current that drips transition greater than generation, and the electric current of selection can be produced the droplet transfer; The slope of bc line should be obviously greater than near the slope that waits fusion curve the c point.
Electric arc is burnt on the ae line, arc voltage reduces gradually, when arc voltage is less than or equal to a point voltage, making arc current skip to the b point increases along the bc line, constant to cd line arc current, electric arc smooth combustion on the cd line, voltage increases gradually, when arc voltage more than or equal to the cd line on during certain any magnitude of voltage, arc current skips to the burning of ae line, enters next circulation.
2. the sub-jet transient self-adaption control method of a kind of aluminium according to claim 1 and aluminum alloy melting utmost point gas shielded arc welding is characterized in that, ae line constant current value is a background current, less than 50 amperes.
3. the sub-jet transient self-adaption control method of a kind of aluminium according to claim 1 and aluminum alloy melting utmost point gas shielded arc welding is characterized in that, ae line constant current value is a background current, is chosen as 30 amperes.
4. the sub-jet transient self-adaption control method of a kind of aluminium according to claim 1 and aluminum alloy melting utmost point gas shielded arc welding is characterized in that, described cd line constant current value is a pulse current, greater than 180 amperes.
5. the sub-jet transient self-adaption control method of a kind of aluminium according to claim 1 and aluminum alloy melting utmost point gas shielded arc welding is characterized in that, described cd line constant current value is a pulse current, is chosen as 235 amperes.
6. the sub-jet transient self-adaption control method of a kind of aluminium according to claim 1 and aluminum alloy melting utmost point gas shielded arc welding is characterized in that, between a, d point during redirect, the frequency of pulse current increases described arc current automatically continually.
7. the sub-jet transient self-adaption control method of a kind of aluminium according to claim 1 and aluminum alloy melting utmost point gas shielded arc welding; it is characterized in that; the electric arc arc length fluctuation range that the difference decision of described a point and d point voltage value allows; when the arc length fluctuation range that allows hour; arc current is continually between a, d point during redirect, and the frequency that makes pulse current increases automatically with the redirect of arc current.
8. the sub-jet transient self-adaption control method of a kind of aluminium according to claim 1 and aluminum alloy melting utmost point gas shielded arc welding; it is characterized in that; described cd line constant current value is a pulse current, along with the variation of described arc voltage, adjusts the time that increases or reduce to work in pulse current automatically.
9. the sub-jet transient self-adaption control method of a kind of aluminium according to claim 1 and aluminum alloy melting utmost point gas shielded arc welding is characterized in that, the gage of wire of employing is between Φ 0.8 and Φ 2.4.
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| CN102363237A (en) * | 2011-09-22 | 2012-02-29 | 中国航天科工集团第二研究院二一〇所 | Method for welding thick aluminum alloy plate |
| CN103230703A (en) * | 2013-04-07 | 2013-08-07 | 上海闰铭精密技术有限公司 | High-corrosion resistance aluminum alloy filter and process thereof |
| CN110899922A (en) * | 2018-09-14 | 2020-03-24 | 中国商用飞机有限责任公司 | Welding method of 6061 aluminum alloy |
| CN110802303A (en) * | 2019-10-30 | 2020-02-18 | 深圳市佳士科技股份有限公司 | CO2Welding control method and device, terminal equipment and computer readable storage medium |
| CN111044434B (en) * | 2019-12-31 | 2022-02-15 | 太原科技大学 | Simulation device and method for gas metal arc welding molten drop transition process |
| CN113770488B (en) * | 2021-10-13 | 2022-09-27 | 上海交通大学 | Arc length control method for short circuit transition of pulse gas metal arc welding |
| CN115007977A (en) * | 2022-05-16 | 2022-09-06 | 昆明理工大学 | MIG welding method of aluminum alloy plate |
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| 熔化极气体保护焊熔滴过渡过程控制的精确化趋势. 杨立军，李桓，李俊岳，胡胜钢.焊管，第22卷第6期. 1999 |
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