CN101491856B - Large forgings compression arc and induction composite heat-source repair-welding device and method - Google Patents

Large forgings compression arc and induction composite heat-source repair-welding device and method Download PDF

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CN101491856B
CN101491856B CN200910025645XA CN200910025645A CN101491856B CN 101491856 B CN101491856 B CN 101491856B CN 200910025645X A CN200910025645X A CN 200910025645XA CN 200910025645 A CN200910025645 A CN 200910025645A CN 101491856 B CN101491856 B CN 101491856B
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welding
repair
repair welding
inductor
arc
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CN101491856A (en
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葛艳明
王克鸿
黄�俊
周琦
顾民乐
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Jiangsu Jinyuan High-End Equipment Co Ltd
Nanjing University of Science and Technology
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Jiangsu Jinyuan Forging Co Ltd
Nanjing University of Science and Technology
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Abstract

The invention discloses a large forged piece compressed electric arc and induction composite heat source repair welding device and a method thereof. The repair welding device comprises a six-axis robot, a handling frame which can move up and down and backwards and forwards, a work table and a welding gun, wherein the six-axis robot is arranged on the handling frame; an inductor and the welding gun are arranged on the robot; a temperature sensor is arranged aside the inductor; and the welding gun can generate compressed electric arcs. The repair welding method comprises the following steps: firstly, preparing a protectant for repair welding and deposited metals according to material compositions of a large forged piece; secondly, presetting a program and related parameters; thirdly, placing the protectant on a repair welding area, and performing induction heating on the repair welding area; fourthly, acquiring the temperature of the repair welding area, judging whether the preset value is reached, and performing continuous heating if the preset value is not reached; fifthly, removing the inductor after the heating is over, and igniting the compressed electric arcs for starting welding; and sixthly, performing induction heating after the welding is over. The invention realizes preheating before repair welding, and the strength of a repair welding joint is more than that of the deposited metals.

Description

The large forgings compression arc and induction composite heat-source repair-welding method
Technical field
The invention belongs to extraordinary welding method, particularly a kind of large forgings compression arc and induction composite heat-source repair-welding method at large forgings surface deposited metal deposited metal.
Background technology
The arc surfacing technology is to adopt heat fused wire, metal tape, metal powders etc. such as melt pole electrical arc, submerged arc, TIG electric arc, plasma arc, and molten metal is deposited over matrix surface, solidifies the back and forms overlay cladding.Conventional overlaying method such as consumable electrode and submerged arc overlay welding, welding wire automatic feed, electric arc result between welding wire and the parent metal, the means of fusion arc welding silk forms molten drop, and is deposited at matrix surface through freedom, short circuit or flux-wall guided transfer, forms overlay cladding, efficient is higher, and the matrix fusing is many; TIG built-up welding and plasma surfacing electric arc result between tungsten electrode and the workpiece, and welding wire is sent into below, the bright clear zone of electric arc and obtained heating and melt to splash into matrix surface, solidifies the back and forms overlay cladding.
Large forgings is generally tens of heavily approximately to hundreds of kilograms, the repair welding area is generally less, the overall thermal input is little, the Fast Heating of built-up welding and quick cooling easily make the forging welding point produce cold crack, the large forgings volume is big, thermal capacity is big, and rapid heat dissipation adopts conventional overlaying process, forging easily produces the incomplete fusion defective, thereby avoids occurring crackle and the incomplete fusion defective is one of main difficult point of large forgings repair welding.There is not the prefabricated research report that presets the deposited welding process method of repair welding material of automatic condensed electric arc+induction composite heat power supply for large forgings at present.
Summary of the invention
The object of the present invention is to provide the prefabricated deposited soldering method that presets the repair welding material of a kind of large forgings automatic condensed electric arc loading induction composite heat-source.
The technical solution that realizes the object of the invention is: a kind of large forgings compression arc and induction composite heat-source repair-welding device, comprise six-joint robot, can about, the crosshead that seesaws, workbench, welding gun; On the described crosshead six-joint robot is set, inductor and welding gun are set in this robot, inductor is other to be provided with temperature sensor, and welding gun can produce compression arc.
The repair method of large forgings compression arc and induction composite heat-source repair-welding device may further comprise the steps:
Step 1, according to the material composition of large forgings, preparation repair welding protective agent; Size and form according to the repair welding zone prepare the repair welding deposited metal;
Step 2, robot controller program and compression arc parameter are preset; Default control program comprises: the track of eddy-current heating program, inductor operation, track, posture of welding torch, the welding schedule of electric arc operation;
Step 3, protective agent is placed on the repair welding zone;
Step 4, eddy-current heating is carried out in the repair welding zone; By six-joint robot control inductor, make it carry out eddy-current heating to the repair welding zone according to the default eddy-current heating program and the track of operation;
Step 5, collection repair welding district temperature, and judge whether the temperature in repair welding zone reaches preset value, if reach then execution in step 6, otherwise continue heating;
Step 6, remove inductor, the repair welding deposited metal is preset at the repair welding zone, and welding gun is moved to the position of repair welding deposited metal, according to the default compression arc parameter of step 2 and the welding condition compression arc that ignites, track and the posture of welding torch according to the default electric arc operation of step 2 begins welding then;
Step 7, utilize current sensor, voltage sensor to gather electric current, the magnitude of voltage of welding process, carry out welding parameter observing and controlling by the welding schedule that is stored in the controller, the electric current that successively decreases is received arc, finishes the welding gun motor program, and removes welding gun;
Step 8, eddy-current heating is carried out in the repair welding zone, the induction heat source power of successively decreasing is removed inductor;
Step 9, the forging after the repair welding is carried out the extrusion molding modification, finish repair welding.
The present invention compared with prior art, 1), adopted composite heat power supply its remarkable advantage:, the preheating before the repair welding has been realized in the temperature field of having improved forging before the heap repair welding; 2), can be according to the form size and the forging composition in need repair welding zone, adopt the prefabricated deposited metal of method of powder precompressed, guarantee shape size and composition, composition and performance adjustment are very easy to; 3), adopt compression arc, can change the energy density of compression arc according to repair welding material material, form size, obtain the joint of high-quality; 4), adopt composite heat power supply, can carry out after-baking at postwelding, adjust cooling velocity, obtain the tissue that requires; 5), the repair welding strength of joint is greater than the intensity of deposited metal self.
Description of drawings
Fig. 1 is the structural representation of large forgings compression arc and induction composite heat-source repair-welding device of the present invention.
Fig. 2 is the flow chart of large forgings compression arc and induction composite heat-source repair-welding method of the present invention.
Fig. 3 is the compression arc nozzle arrangements schematic diagram of large forgings compression arc and induction composite heat-source repair-welding device of the present invention.
The specific embodiment
Below in conjunction with accompanying drawing the present invention is described in further detail.
In conjunction with Fig. 1, a kind of large forgings compression arc and induction composite heat-source repair-welding device of the present invention comprises six-joint robot 1, welding gun 2, can about, the crosshead 5 that seesaws, welding system 6, robot controller 7, workbench 8, temperature sensor 9; On the described crosshead 5 six-joint robot 1 is set, inductor 2-2 and welding gun 2 are set in this robot, inductor 2-2 is other to be provided with temperature sensor 9, and tungsten electrode 2-3 and nozzle 2-4 are set in the welding gun 2, and tungsten electrode 2-3 and nozzle 2-4 can produce compression arc 2-1.
Make repair welding deposited metal 4 and protective agent 4-1 according to large forgings 3 materials and size design before the repair welding; adjust the parameter of compression arc 2-1; design compression arc movement locus and posture of welding torch program design composite sensing Moving Heat Sources program, and related data is stored in the robot controller 7.Earlier protective agent 4-1 is placed on the repair welding zone during repair welding, inductor 2-2 by six-joint robot 1 control carries out eddy-current heating according to default track to the repair welding zone, and temperature sensor 9 work are when detected temperatures reaches required value, inductor 2-2 is removed in 6 robot 1 motions; Preset repair welding deposited metal 4 simultaneously, produce compression arc 2-1 between tungsten electrode 2-3 and the nozzle 2-4, welding gun 2 drives compression arc 2-1 with 6 robots 1 and crosshead 5 motions, and welding gun 2 is moved to the position of repair welding deposited metal 4, begins welding; After welding gun motion finished, blow-out was also removed welding gun by 6 robots 1, then inductor 2-2 is moved into the repair welding zone, heated mobilely, and the heating power that progressively successively decreases is removed inductor 2.
In conjunction with Fig. 2, large forgings compression arc and induction composite heat-source repair-welding method of the present invention may further comprise the steps:
Step 1, according to the material composition of large forgings, preparation repair welding protective agent; Size and form according to the repair welding zone prepare the repair welding deposited metal;
Step 2, robot controller program and compression arc parameter are preset; Default content comprises: the track of eddy-current heating program, inductor operation, track, posture of welding torch, the welding schedule of electric arc operation; The compression arc parameter can be made as nozzle bore 2mm, the first compression angle α 1Be 100 °, the second compression angle α 2Be 90 °, radius R is 25mm, and the first nozzle orifice throat length h value is 2mm, the second nozzle orifice throat length h 1Value is 1.5mm, the 3rd nozzle orifice throat length h 2Value is 1.5mm.
Step 3, protective agent is placed on the repair welding zone;
Step 4, eddy-current heating is carried out in the repair welding zone; By six-joint robot control inductor, make it carry out eddy-current heating to the repair welding zone according to the default eddy-current heating program and the track of operation;
Step 5, collection repair welding district temperature, and judge whether the temperature in repair welding zone reaches preset value, if reach then execution in step 6, otherwise continue heating;
Step 6, remove inductor, the repair welding deposited metal is preset at the repair welding zone, and welding gun is moved to the position of repair welding deposited metal, according to the default compression arc parameter of step 2 and the welding condition compression arc that ignites, track and the posture of welding torch according to the default electric arc operation of step 2 begins welding then; In welding process, welding gun drives compression arc and moves to apart from 0.3-0.8mm place, large forgings edge, stops 0.2-2 second.
Step 7, utilize current sensor, voltage sensor to gather electric current, the magnitude of voltage of welding process, carry out welding parameter observing and controlling by the welding schedule that is stored in the controller, the electric current that successively decreases is received arc, finishes the welding gun motor program, and removes welding gun;
Step 8, eddy-current heating is carried out in the repair welding zone, the induction heat source power of successively decreasing is removed inductor;
Step 9, the forging after the repair welding is carried out the extrusion molding modification, finish repair welding.
Protective agent granularity in the above-mentioned steps 1 is the 60-180 order.Protective agent can protect the large forgings of eddy-current heating process not oxidized; the molten bath that can protect simultaneously the fusing of repair welding deposited metal to produce is not oxidized; deposited metal adopts the method preparation of powder precompressed; its alloying component and large forgings are roughly the same; carbon content is than the low 10-40% of large forgings, and carbon equivalent is hanged down 20-50%.The compression arc parameter can be according to the size of repair welding material material, form size, thickness and forging etc., changes plasma duct diameter and length, adjusts the energy density of compression arc, obtains the forging repair welding joint of high-quality.
Below in conjunction with embodiment, the present invention will be further described.
With the dark 3mm forging of 1500mm diameter 40Cr disc end face repair welding Φ 60mm is example.Shape size and 40Cr material according to the dark 3mm of repair welding zone Φ 60mm; adopt iron powder, Cr powder to form middle carbon and contain Cr repair welding deposited metal; carbon content is controlled at 0.25-0.3%; and be pressed into the unsintered powder metallurgy piece of the high 3.3mm of Φ 59.8mm; select the protective agent (J05-2) that to remove Cr, Fe, Si, Mn element for use, order several 120.
Protective agent (J05-2) 20g put into treat the repair welding zone, set circular inductor Φ 40mm, make circus movement; track diameter of phi 54mm has set welding gun 2 repair welding campaigns for along the profound track that moves, and is divided into 12 rectilinear motions; amplitude of fluctuation is 2mm, and data are stored in the system controller 7.
Design compression arc 2-1 parameter, in conjunction with Fig. 3, arc parameters of the present invention can be nozzle bore 2mm, the first compression angle α 1Be 100 °, the second compression angle α 2Angle is 90 °, and radius R is 25mm, and the first nozzle orifice throat length h value is 2mm, the second nozzle orifice throat length h 1Value is 1.5mm, the 3rd nozzle orifice throat length h 2Value is 1.5mm.
The inductor 2-2 that adopts 1 control of 6 robots of patent device makes the circus movement of track diameter of phi 54mm according to Φ 59.8mm size and rounded form, when Temperature Detector 9 detects forging 3 repair welding regional temperatures and reaches 180-200 ℃, stops eddy-current heating; Compression arc 2-1 between welding gun 2 tungsten electrode 2-3 and the nozzle 2-4 ignites, welding gun 2 drives compression arc 2-1 with 6 robots 1 and crosshead 5 motions, welding gun 2 is moved to the home position of repair welding deposited metal 4, begin welding, electric arc is with crosshead 5 and six-joint robot 1 motion, its track and attitude are according to the size of repair welding zone and repair welding deposited metal 4, form and position are determined in advance, promptly according to 12 rectilinear motions, amplitude of fluctuation is 2mm, when moving to the repair welding round edge, welding gun keeps welding gun and Edge Distance 0.5mm, stop 0.3s, welding current 220-230A, arc voltage 23-23.5V welds fast 15cm/min, welding finishes, remove welding gun 2, start eddy-current heating, inductor 2-2 remakes the circular motion of Φ 54mm under the drive of six-joint robot 1, its peak power is 2/3 of a pre-thermal power, behind the eddy-current heating 30 seconds, progressively reduce the composite sensing heating power, close the composite sensing heating power supply after 30 seconds.

Claims (2)

1. large forgings compression arc and induction composite heat-source repair-welding method, wherein adopt the large forgings compression arc and induction composite heat-source repair-welding device of this method to comprise six-joint robot [1], can about, the crosshead [5] that seesaws, workbench [8] and welding gun [2], six-joint robot [1] is set on the described crosshead [5], inductor [2-2] and welding gun [2] are set in this robot, the other temperature sensor [9] that is provided with of inductor [2-2], welding gun [2] can produce compression arc [2-1], it is characterized in that, said method comprising the steps of:
Step 1, according to the material composition of large forgings, preparation repair welding protective agent; Size and form according to the repair welding zone prepare the repair welding deposited metal;
Step 2, robot controller program and compression arc parameter are preset, default content comprises: the track of eddy-current heating program, inductor operation, track, posture of welding torch, welding schedule, the compression arc parameter of electric arc operation;
Step 3, protective agent is placed on the repair welding zone;
Step 4, eddy-current heating is carried out in the repair welding zone; By six-joint robot control inductor, make it carry out eddy-current heating to the repair welding zone according to the default eddy-current heating program and the track of operation;
Step 5, collection repair welding district temperature, and judge whether the temperature in repair welding zone reaches preset value, if reach then execution in step 6, otherwise continue heating;
Step 6, remove inductor, the repair welding deposited metal is preset at the repair welding zone, and welding gun is moved to the position of repair welding deposited metal, according to the default compression arc parameter of step 2 and the welding condition compression arc that ignites, track and the posture of welding torch according to the default electric arc operation of step 2 begins welding then;
Step 7, utilize current sensor, voltage sensor to gather electric current, the magnitude of voltage of welding process, carry out welding parameter observing and controlling by the welding schedule that is stored in the controller, the electric current that successively decreases is received arc, finishes the welding gun motor program, and removes welding gun;
Step 8, eddy-current heating is carried out in the repair welding zone, the induction heat source power of successively decreasing is removed inductor;
Step 9, the forging after the repair welding is carried out the extrusion molding modification, finish repair welding.
2. repair method according to claim 1 is characterized in that, protectant granularity is the 60-180 order in the step 1.
CN200910025645XA 2009-03-05 2009-03-05 Large forgings compression arc and induction composite heat-source repair-welding device and method Active CN101491856B (en)

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Address after: 213300 No. 8, Zhongguancun Avenue, Liyang, Jiangsu

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Patentee before: Nanjing University of Science and Technology