CN102909449A - Induction brazing welding method for metal part - Google Patents
Induction brazing welding method for metal part Download PDFInfo
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Abstract
The invention discloses an induction brazing welding method for a metal part. The method utilizes induction brazing welding equipment and then is implemented according to the following steps of: a step 1 of selecting the induction brazing welding equipment and determining related parameters; a step 2 of carrying out weldment surface processing, i.e. roughening the welding surface of a weldment, processing the metal-plated surface of the weldment, carrying out matched selection between the weldment and a soldering flux, a brazing filler metal, a welding temperature and a brazing clearance and selecting each process parameter of induction brazing; a step 3 of assembling and fixing the weldment; and a step 4 of implementing welding. According to the induction brazing welding method disclosed by the invention, the induction welding and the induction brazing welding of structures of different materials, pipe fittings, sheets, tube plates and the like are implemented, the sealing performance of a weld joint is improved, the intensity of the weld joint is reduced, the electrical conductivity is obviously improved, and the weld joint has a reliable quality.
Description
Technical field
The invention belongs to the induction welding technical field, relate to a kind of method for welding induction brazing of metallic element.
Background technology
Induction brazing is the mutually result of comprehensive function such as current collection, magnetic, heat, phase transformation, mechanics, welding, metallography, existing theoretical each independently explain its mechanism since the principle of self, there are many weak points in eddy-current heating engineering design and the theory of computation, so far the neither one complete coupling theoretical can enough mathematics method come accurate quantification to be coupled qualitatively this adds thermal physical process.
At present popular theoretical research way is in the world, utilize various temperature measuring devices to measure temperatur-timel curve and high speed amplifying camera machine record induction brazing process for specific products, then utilize the limited method of difference (FDM), Finite Element (FEM), the methods such as volume-integration (VIM) and boundary element method (BEM), professional software at special-purpose computer carries out analogue simulation induction brazing process, temperature field and Study on Flow Field, set up one dimension to the different mathematics of three-dimensional various boundary, these analog results have the directive significance of directionality for the definite and academic theoretical developments of the actual sensed heating parameters of industrial enterprise.But high-frequency induction brazing just can not be determined the design parameters such as the required electric current (vortex flow) of heating, time, frequency fully, at present both at home and abroad do not have these welding conditions on teaching material and the expert data reference book, the actual high-frequency induction welding technique parameter study achievements such as so far there are no in the world electric current (vortex flow), time open with deliver.Technical specialist and scholar are normally according to production capacity both at home and abroad, the weldment size, limit of temperature rise and material, rule of thumb with the engineering simple computation, the a large amount of manpowers of cost before going into operation, material resources, repeatedly debug at the scene and test the high frequency electric in the heater coil in definite high-frequency induction brazing, the parameters such as time, parameter (vortex flow etc.) and the actual welding parameter of carrying out that actual emulation needs can not provide, for example actual production producer often provides the temperature field that the high frequency electric of several kiloamperes simulates, but be the temperature field of degree up to ten thousand or several ten thousand degree, make calculating, emulation and simulation, inconsistent with reality; Utilize high frequency electric simulation soldering, be applied such as materials such as steel and iron parts greater than 1 material at magnetic conductivity at present, but in the materials such as diamagnetic material such as copper, silver, gold, titanium, stainless steel, aluminum bronze, aluminium titanium spare, in high-frequency induction brazing, magnetic conductivity equals 1 material and can't induce energy high frequency electric identical or that be equal to and come, high frequency electric can not be simulated, and carries out accurate welding as eddy current.Utilize high frequency electric bad as the many quality of the simulation actual initiation of welding parameter, limited the promotion and application of technology, above-mentioned these deficiencies have obviously hindered high-frequency induction brazing technology and theoretical academic development and progress.
At present at copper, copper alloy, and the welding of copper or copper alloy and other kinds metalloid, Chinese invention patent " high-frequency induction brazing welding method and the welder of metallic element ", number of patent application 201110318708.8, publication number CN102357695A, open day on 02 22nd, 2012, this disclosure of the Invention corresponding welding technique and device, solve soldering and produced the leakiness weld seam, reduce weld strength and electric conductivity, absorb absorption moisture, cause the phenomenon of weld corrosion, these bad phenomenon comprise: mother metal autoclasis (penetrability fire check), corrosion, field trash (black burning oxide), fusion not enough (cracking), the edge fusion is not enough, middle part fusion not enough (middle part cold welding), weldbonding (cold welding), cast welding (fragility weldering), the problems such as pore (pin hole).But the soldering brazing flux is only for FB303 and part solder in the welding procedure of this disclosure of the Invention, and all the other brazing fluxes and solder do not relate to.
Existing induction brazing is collection skin and the contiguous principle of utilizing electric current, and brazed seam and solder rely on the faradic resistance heat in the high-frequency alternating magnetic field to realize, frequency is directly proportional with induced-current, is inversely proportional to the electric current length of penetration; The electric current length of penetration is directly proportional with the square root of the resistivity of conductor, is inversely proportional to the square root of frequency and magnetic conductivity; Along with the rising electric current length of penetration of temperature is just darker, therefore adopt but in brazing temperature range electric current length of penetration design parameter, do not have at present data introduction and open.
But the induction brazing technology field at carbon steel, stainless steel, silver and silver alloy, aluminium etc. does not disclose optimised welding procedure, and brazing product size and thickness still are restricted greatly, still exist these quality problems to be solved.Because being difficult to of welding procedure determines that its extensive use is restricted.
Realize good brazing quality, need the control weldment must not melt uniformity that solder fusing, trickling distribute and simultaneity, these couplings with coupling, welding procedure and the weldment of weldment and solder and induction coil are relevant; 1., the matching of coil and weldment is improper, the position of workpiece shape and heating part and size determine coil shape and size, the soldering frequency determines the infiltration thickness of soldering electric current, the soldering power decision is determined soldering current density and impedance magnitude, determine braze wire coil structures form and the type of cooling, the size of the working clearance of weldment and induction coil internal diameter with induction output current and power is inversely proportional to, the large leakage field in gap strengthens, induced-current and power reduce, the gap is too small, cause workpiece to the wearing and tearing of coil, mutually sparking, discharge, scaling loss, surface point-like crackles etc. are bad, the width of the internal-and external diameter of coil must guarantee indeformable under electromagnetic force and part and attached Action of Gravity Field and not damage, also be the very main parameter of coil.
2., at present existing induction brazing technology is, utilize surface and kindred effect, the nearest local solder that is placed on induction coil at first melts, the weldment extension also is that temperature raises at first, but along with the continuous heating of soldering induced-current in permeate portion, rely on the high-temperature part of weldment outer ring heating, Xiang Zaiwu continues and enough faradic place (being the weldment center of hub of a spool) conduction temperature are carried out diathermanous, make the solder fusing realize soldering, this process has two characteristics and constraints, the weldment epitaxial temperature is high but must not be higher than the fusing point of weldment, and central temperature is low but must not be lower than the brazing temperature of solder and be higher than the fusing point of weldment; It is to flow to the high place of temperature that solder flows, that is to say that weldment liquefaction solder is from inner outside trickling, after the size of soldering area is subject to the middle place fusing of weldment, the temperature of weldment extension of continuous heating and at first heating must not be higher than fusion temperature, the continuation expansion of heated perimeter is restricted, so the soldering size of weldment is restricted.
3., the induction brazing programming rate is fast, skin effect is remarkable, causes the temperature difference inconsistent of weldment surfaces externally and internally, skin effect has the greatest impact both ways; In the induction brazing process, too high brazing temperature, improper programming rate or cooling rate, long or not enough temperature retention time, the saturating rate reduction of weldment cracking, the evaluation index ratio of brazing area that can cause brazing quality and pricker, face of weld fusing, weldment grain growth are caused in the capital, seam organization is by carefully becoming thick, weld seam broadens, the fragility of organizing of weldment and brazed seam increases Plasticity Decreasing, the structure property variation, and solder will run off or lose efficacy; These bad particularly to thick, the welding of unlike material performance more obvious, the optimised process of weldment and brazing seam structure is exactly within the shortest time, realizes good brazing quality, does not damage weldment and is not to make brazing seam structure's deterioration.The heating of soldering can't be accurately controlled and be switched at present manual operations, the process of insulation, cooling, the effectively accurate induction coil of controlling, mating of the technical process of solder, brazing flux, welding temperature, intensification and the cooling rate that selection and weldment mate, temperature retention time, heat tracing cooling and installation and soldering position etc. become the induction brazing technological parameter and must control project.
Research carbon steel, stainless steel, silver and silver alloy, the welding conditions such as the induction brazing induced-current (eddy current) of the tubing such as aluminium, sheet material, pipe plate, time, solder, brazing flux, temperature are extremely urgent.Reach and make it be widely used in the industrial circles such as high and low voltage electrical equipment, machine-building, automobile making, generating equipment, solar energy, electric power accessory, air-conditioning, compressor, cooler, light fixture, motor, shipbuilding, rail vehicle, Aero-Space, weaponry, nuclear industry, petrochemical industry, realize the good soldering effect of metal parts product.
Summary of the invention
The method for welding induction brazing that the purpose of this invention is to provide a kind of metallic element, solved in the prior art, dissimilar welding material for carbon steel, stainless steel, silver and silver alloy, aluminium and composition thereof, existence reduces easily the weld seam sealing, reduces weld strength and electric conductivity, causes weld seam to absorb the problem of adsorbing moisture, causing weld corrosion.
The technical solution adopted in the present invention is, a kind of method for welding induction brazing of metallic element, and the method is utilized the induction brazing welding equipment, implements according to following steps:
Step 1, select the induction brazing welding equipment, and definite relevant parameter
1.1) according to the requirement of weldment form factor in the table 1 and the part of welding, keeping the gap less than 0.2 times of weldment diameter between weldment and the induction coil, the internal-and external diameter width difference of coil is determined according to following formula:
The internal-and external diameter width difference of coil=9+50/ induction frequencies, its unit is millimeter, selects the induction coil internal diameter numerical value of suitable number of turns,
The corresponding relation of table 1, induction coil internal diameter and the heating target material selection number of turn
1.2) according to the difference of weldment weight, find the solution and obtain welding required theoretical power (horse-power), this computing formula is: theoretical power (horse-power) (KW)
=weldment weight (Kg) * temperature (℃) * specific heat capacity { J/ (kg) ℃ }/3600 (seconds)/(1-k),
That is:
Wherein, copper spare thermal loss coefficient k is got 0.30-0.35; Silver part thermal loss coefficient k is got 0.35-0.40; Steel and iron parts thermal loss coefficient k is got 0.28-0.32;
1.3) select the required induction coil size of welding, the number of turn according to the required theoretical power (horse-power) of welding, select corresponding plant capacity, the former limit of the sensor transformer extension set number of turn according to table 2;
The matching list of the size of table 2, induction coil and the number of turn and the former limit of the sensor transformer extension set number of turn
1.4) according to sensing apparatus and the induction coil former limit number of turn and the pitch of turn of above-mentioned selection, pitch of turn is got 1.5mm-3mm, according to equipment input power, equipment output welding current scope and power, and with reference to induction frequencies selection principle, tolerance frequency and frequency of optimum traffic when determining welding;
Table 3, equipment input power, output welding current and tolerance frequency matching list
Continued 3
Step 2, carry out the weldment surface treatment
2.1) roughening treatment of weldment solder side
The solder side roughening treatment content of soldered weldment comprises applying pit, compacting pit, the processing of reticulate pattern, protruding stupefied, salient point etc.; The butt-welding fitting surface degreases, the cleaning of deoxidation compound;
2.2) carry out the weldment coating metal surface and process
Specification requirement according to the induction brazing weldment plated metal material of table 4, definite needs carry out the coating surface method, the induction brazing of different materials weldment is preferentially selected coating surface, realized weldment coating layer thickness and material, weldment coating is selected silver, copper, nickel, molybdenum, niobium or aluminium silicon
The specification requirement of the induction brazing mother metal coating material of table 4, the inventive method
2.3) carry out the match selection of weldment and brazing flux, solder, welding temperature, joint gap
1., carry out the selection of brazing flux, solder
Solder and brazing flux are selected and are satisfied instructions for use and braze ability condition;
Solder and brazing flux are selected physics and chemistry and the technical process matching properties condition that satisfies weldment and solder;
2., carry out the selection of brazing flux, solder brazing temperature
Select brazing flux welding fusion temperature at 10 ℃ of solder melting temperatures ~ below 30 ℃, the solder liquidus temperature is lower than at least 40 ℃ of mother metal solidus ~ 50 ℃, and lowest activity temperature thermal stable temperature scope is not less than 100 ℃;
The selection of solder requires liquid and solid-state temperature difference requirement little, and brazing flux melts rear 5s ~ 10s solder fully and begins fusing, and the solder temperature is chosen in and is higher than 20 ℃ ~ 50 ℃ intervals of brazing flux;
3., select brazing flux, solder, brazing temperature and joint gap
Require high, firmness requirement height according to electric conductivity, select silver-base solder and weldment coupling; Perhaps,, firmness not high according to electric conductivity requires high, selects solder and weldment coupling; Be equipped with simultaneously the principle of brazing flux;
According to table 5 data, weldment for different materials, select brazing flux, solder, welding temperature and the joint gap of coupling: according to different situations, at the solder that is welded to connect face placement coupling, the weldment surface applies paste or aqueous brazing flux, and solder and brazing flux position provide solder and an amount of configuration of brazing flux and suitable joint gap:
Table 5, the inventive method are selected temperature range and the joint gap of brazing flux, solder
2.4) each technological parameter of selection induction brazing
1., the selection of initial parameter
Weldment is after solder, brazing flux, welding temperature, the frequency of coupling are determined, induction brazing is divided into welding current penetrates the heating welding, weldment heating thickness is △ L, provide the welding temperature △ L value corresponding with frequency in the table 6, after welding current penetrated heating welding continuous heating, the part in no current zone was the diathermanous heating welding portion of weldment, weldment heating full-size D2, the diathermanous heating welding of its weldment segment thickness is the difference that D2 subtracts △ L
According to table 6, according to above-mentioned welding temperature, welding frequency, weldment material thickness parameter, select corresponding current flow heats thickness and the power frequency of penetrating;
Wherein the relation of non-ferrous metal welding frequency and current flow heats infiltration thickness is: welding frequency increases 23-25 doubly, and electric current infiltration thickness reduces 1mm;
The relation of ferrous metal welding frequency and current flow heats infiltration thickness is: welding frequency increases 16-19 doubly, and electric current infiltration thickness reduces 1mm; Along with the rising of heating-up temperature, the increase of heating thickness is synchronous minimizing along with the increase of frequency,
Penetrate current flow heats thickness and power frequency when table 6, the inventive method induction brazing
2., according to initial parameter, the welding condition that calculates successively
According to aforesaid selection parameter, obtain needed welding current, weld interval and temperature retention time according to the correlation formula in table 7, table 8, the table 9;
In table 7, table 8 and table 9, G wherein represents weight, and unit is gram; T represents the time, and unit is second; △ L represents the depth of current penetration, and unit is millimeter; D2 represents weldment faying face full-size scope, and unit is millimeter; D2-△ L represents diathermanous district, and unit is millimeter,
Induction brazing technical process and time distribution principle:
In the electric current penetration range in the heating frequency, temperature retention time is 0.3～0.6 times of heat time heating time,
Outside the electric current penetration range in the heating frequency, temperature retention time is 0.7～2 times of heat time heating time,
Welding current formula in table 7, the inventive method
Formula weld interval in table 8, the inventive method
Temperature retention time formula in table 9, the inventive method
Step 3, weldment assembling are with fixing
3.1) assembling induction welding equipment induction coil and magnetic head depression bar
Induction coil and magnetic head depression bar are set respectively, the diameter of magnetic rings termination according to:
Determine;
3.2) the assembling weldment
The weldment of prepackage is placed in the anchor clamps, set solder and brazing flux, weldment places induction coil (or near coil), reserve corresponding fit-up gap, the fit-up gap of induction coil and weldment arranges respectively, get 3mm-6mm for the ferrous metal fit-up gap, get 1.5-3mm for the non-ferrous metal fit-up gap; Each induction coil is adjusted to and weldment welding position equal-height position (or near weldment place), the magnetic rings depression bar is pushed down respectively the weldment that has applied brazing flux and solder downwards, make fit-up gap and expansion clearance guarantee 0.05mm-0.12mm and contact firm;
Step 4, enforcement welding
By welding controller corresponding frequency of utilization, welding current, weld interval, insulation electric current and temperature retention time are set, start welding equipment, begin to weld, the induction coil butt-welding fitting heats, the rear outage of insulation passes to cooling water and carries out cool to room temperature.
The invention has the beneficial effects as follows:
1) be applicable to the metallic elements such as carbon steel and low alloy steel, mild steel (quenched and tempered steel), tool steel and carbide alloy, carbide alloy, copper and copper alloy, copper and brass, silver and alloy, dissimilar metal iron copper spare, copper silver part, copper facing, silver plate, titanium steel, titanium and stainless steel, ferrotianium, aluminum bronze spare, imitative golden part, the full-size scope exists
With interior metal parts, use 200KZ to carry out induction brazing with lower frequency, possess efficient, environmental protection, reliable, low, energy-conservation, good, the second best in quality characteristics of versatility of cost;
2) provided welding equipment and the technology key parameter of welding required the best, eliminated the bad of seam organization, overcome the problem that common induction brazing solder technology can produce the leakiness weld seam, such as the mother metal autoclasis, corrosion, field trash (black burning oxide), fusion not enough (cracking), the edge fusion is not enough, middle part fusion not enough (middle part cold welding), weldbonding (cold welding), cast welding (fragility weldering), the phenomenon of pore (pin hole), provide simultaneously and determined fast to select optimum welding process parameter, realize tubing, sheet material, the good induction brazing of pipe plate, improve the sealing of weldment, weld strength and electric conductivity, prevented weld corrosion, the weld is accepted rate brings up to 100%;
3) fast, the diathermanous glossiness of the method heating is good, the surface without burn, oxide layer is few, energy-conservation, the welding smoothness is even, the welding good evenness, adhesive force is good, heat treatment deformation is little; Can heat complex-shaped weldment; Operating environment is good, easy to operate, easy control of temperature, and good product quality is protected for coating material and surface, weldment surface, makes it have vast potential for future development.
In theory, different materials, pipe fitting, plate, the isostructural induction welding of tube sheet and soldering, by the inventive method, all there are the optimum welding process parameter and the device parameter that adapt with it, for the high-frequency induction brazing of realizing this desirable optimised welding procedure provide foundation and may, be worthy of popularization.
The specific embodiment
The method for welding induction brazing of metallic element of the present invention, utilize following welder to implement:
Comprise a plurality of induction coils, the copper pipe that these a plurality of induction coils are a water flowing (or excellent part or plate) along continuous straight runs turns to a plurality of annulus that vertical direction is not less than 1 circle, each annulus divide axial multiturn or radially multiturn arrange, each induction coil diameter and weldment heating part match, and current direction is consistent between the copper pipe at each induction coil induction position and adjacent turn parallel or equidistant with the heating surface of corresponding weldment; A corresponding magnetic rings depression bar, the axis centre of each magnetic rings depression bar and the central vertical of corresponding induction coil of arranging above each induction coil.A plurality of weldments of prepackage are placed in separately the anchor clamps, each induction coil is adjusted to and weldment welding position equal-height position (or near weldment place), set solder and brazing flux, the magnetic rings depression bar is pushed down respectively each weldment downwards, contact firm after, weight and weldment diameter foundation dimension and correlation formula hereinafter according to weldment, draw the parameters of implementing induction brazing welding equipment and technique, welding controller is used for arranging control high-frequency welding electric current and weld interval, and the process of control preheating (or crying heating) insulation electric current and preheating (or crying heating) temperature retention time realization heating and insulation, stopped heating adopts air cooling, air-cooled, and the form of water-cooled or its combination makes work-piece cools arrive the process that normal temperature is realized cooling, utilizing radially multiturn coil heating to be implemented in the operation finishes simultaneously to a plurality of small size, little heating surface area, the weldment of short weld seam, the multiple welding moulding of multiple operation multiple spot, or utilize axial multiturn coil heating to realize the large scale specification, large heating surface area, the high-speed welding of the welding of long weld seam.
The method for welding induction brazing of metallic element of the present invention carries out according to following steps
Step 1, select the high-frequency induction brazing welding equipment, and definite relevant parameter
1.1) according to the requirement of weldment form factor in the table 1 and the part of welding, keeping the gap less than 0.2 times of weldment diameter between weldment and the induction coil, the internal-and external diameter width difference of coil is determined according to following formula:
The internal-and external diameter width difference of coil=9+50/ induction frequencies, its unit is millimeter (mm), selects the induction coil internal diameter numerical value of suitable number of turns,
The corresponding relation of table 1, induction coil internal diameter and the heating target material selection number of turn
1.2) according to the difference of weldment weight, find the solution and obtain welding required theoretical power (horse-power), the computing formula of required theoretical power (horse-power) is:
Theoretical power (horse-power) (KW)
=weldment weight (Kg) * temperature (℃) * specific heat capacity { J/ (kg) ℃ }/3600 (seconds)/(1-k),
That is:
Wherein, copper spare thermal loss coefficient k is got 0.30-0.35; Silver part thermal loss coefficient k is got 0.35-0.40; Steel and iron parts thermal loss coefficient k is got 0.28-0.32;
1.3) select the required induction coil size of welding, the number of turn according to the required theoretical power (horse-power) of welding, select corresponding plant capacity, the former limit of the sensor transformer extension set number of turn according to table 2;
The matching list of the size of table 2, induction coil and the number of turn and the former limit of the sensor transformer extension set number of turn
1.4) according to sensing apparatus and the induction coil former limit number of turn and the pitch of turn of above-mentioned selection, pitch of turn is got 1.5mm-3mm, according to equipment input power, equipment output welding current scope and power, and with reference to induction frequencies selection principle " weldment that volume is little, zone of heating is shallow or tubing, sheet material are selected high frequency and hyperfrequency; Volume is large, the weldment of the zone of heating depth or tubing, sheet material are selected powerful high frequency and superaudio and intermediate frequency ", tolerance frequency and frequency of optimum traffic when determining welding.
Table 3, equipment input power, output welding current and tolerance frequency matching list
Continued 3
For arranging of part induction of high frequency machine industry power supply enterprise: the electric current of the actual output of power supply is very little, but for the consideration in user's uses, usually multiply by multiple in the power supply demonstration, and such as multiply by 20 times, sensuously electric current is very large.Therefore, not multiply by 20 times in the show value of the output current of above table 3 * 20 times, the specific embodiment, still, both substantially are consistent in the actual output current of the required power supply of welding.
Step 2, carry out the weldment surface treatment
2.1) roughening treatment of weldment solder side
The solder side roughening treatment content of soldered weldment comprises applying pit, compacting pit, the processing of reticulate pattern, protruding stupefied, salient point etc.; The butt-welding fitting surface degreases, the cleaning of deoxidation compound.
2.2) carry out the weldment coating metal surface and process
Specification requirement according to the induction brazing weldment plated metal material of table 4, definite needs carry out the coating surface method, the induction brazing of different materials weldment is preferentially selected coating surface, realized weldment coating layer thickness and material, and weldment coating is selected silver, copper, nickel, molybdenum, niobium or aluminium silicon.
The specification requirement of the induction brazing mother metal coating material of table 4, the inventive method
2.3) carry out the match selection of weldment and brazing flux, solder, welding temperature, joint gap
1., carry out the selection of brazing flux, solder
1), solder and brazing flux select and satisfy instructions for use and braze ability condition: selecting of solder must be from coupling, solder temperature and the heating means of instructions for use (such as mechanical property, operating temperature, corrosion resistance, electric conductivity etc.), solder and weldment, and the aspect such as economy considers.Solder with respect to mother metal and brazing flux with respect to the solder requirement, interval in brazing temperature, wettability is good, viscosity is little, flowability is strong, good penetrability, metallic element without evaporate,, ratio of brazing area good without scaling loss, non-oxidation, high-temp plastic and the saturating rate height of pricker, Joint intensity be high.
2), solder and brazing flux are selected physics and chemistry and the technical process matching properties condition that satisfies weldment and solder: chemical composition or the adjacent elements periodic table selection components such as solder selection and weldment, the electrode potential of element is good near mutual solubility, prevents the generation of electrochemical corrosion.Brazing flux and volatile matter are little to brazed seam corrosivity.The solder surface should be bright and clean, do not have affect the greasy dirt of brazing property, pit, leakage, segregation knurl, organize partially clear, field trash, peeling, pin hole layering and defects i.e.cracks, wherein the total amount of impurity element must not surpass 0.15%; Brazing flux should melt and begin and work before the solder fusing, increases solder to the wettability of mother metal, improves the cross flow effect of the spreading wetting of liquid solder, fully fills in the mutual dissolving and diffusion of play movement and mother metal diffusion.Dissolve simultaneously and abolish mother metal and the oxide-film on joint gap and solder surface and the impurity of brazing flux, cross flow is to the weld seam outside, the outer coated with flux of weldment again cross flow away from weld seam after, the impurity that cooling water is poured on the weldment oxide-film and brazing flux washes away, the soldering of weldment is finished.
2., carry out the selection of brazing flux, solder brazing temperature
The temperature alternative condition of induction brazing: select brazing temperature to be complementary with heat treating regime, to obtain best mechanical property.
Select brazing flux welding fusion temperature at 10 ℃ of solder melting temperatures ~ below 30 ℃, the solder liquidus temperature is lower than at least 40 ℃ of mother metal solidus ~ 50 ℃, the heat endurance requirement that brazing flux is good, lowest activity temperature thermal stable temperature scope is not less than 100 ℃, keeps its composition of brazing flux and effect to stablize constant in the heating process;
The selection of solder requires liquid and solid-state temperature difference requirement little, and brazing flux melts rear 5s ~ 10s solder fully and begins fusing, and the solder temperature is chosen in and is higher than 20 ℃ ~ 50 ℃ intervals of brazing flux, guarantees that solder begins fusing at the flux activity high water time; The selection joint fit clearance that fusion range is little is little to be good, and the solder that fusion range is large selects the large and inhomogeneous joint applicability in play movement better;
Brazing flux is comprised of stripper and activating agent, and each group gasification (evaporation) temperature is lower than the melting temperature of solder, and the oxide that brazing flux is removed and the impurity ability is strong and density is little floats over brazing metal surfaces, and secluding air prevents the oxidation generation of solder and oxygen.
3., select brazing flux, solder, brazing temperature and joint gap
Require high, firmness requirement height according to electric conductivity, select silver-base solder and weldment coupling; Perhaps,, firmness not high according to electric conductivity requires high, selects solder and weldment coupling; Be equipped with simultaneously the principle of paste (or aqueous) brazing flux; According to the weldment of table 5 data pin to different materials, select brazing flux, solder, welding temperature and the joint gap of coupling: according to different situations, that the solder shape is selected is bar-shaped, tabular, paper tinsel shape, washer-shaped, powder, paste or tubulose, at the solder that is welded to connect face placement coupling, the weldment surface applies paste or aqueous brazing flux, and solder and brazing flux position provide solder and an amount of configuration of brazing flux and suitable joint gap:
Table 5, the inventive method are selected temperature range and the joint gap of brazing flux, solder
2.4) each technological parameter of selection induction brazing
1., the selection of initial parameter
Weldment is after solder, brazing flux, welding temperature, the frequency of coupling are determined, the present invention is divided into welding current with induction brazing and penetrates the heating welding, weldment heating thickness is △ L(mm), provide the welding temperature △ L value corresponding with frequency in the table 6, after welding current penetrated heating welding continuous heating, the part in no current zone was the diathermanous heating welding portion of weldment, weldment heating full-size D2, the diathermanous heating welding of its weldment segment thickness is the difference that D2 subtracts △ L
According to table 6, according to above-mentioned welding temperature, welding frequency, weldment material thickness parameter, select corresponding current flow heats thickness and the power frequency of penetrating,
Penetrate current flow heats thickness and power frequency when table 6, the inventive method induction brazing
2., according to initial parameter, the welding condition that calculates successively
According to aforesaid selection parameter, obtain needed welding current, weld interval and temperature retention time according to the correlation formula in table 7, table 8, the table 9;
In table 7, table 8 and table 9, G wherein represents weight, and unit is gram (g); T represents the time, and unit is second (s); △ L represents the depth of current penetration, and unit is millimeter (mm); D2 represents weldment faying face full-size scope, and unit is millimeter (mm); D2-△ L represents diathermanous district, unit is millimeter (mm), what programming rate represented is the heating process temperature rate of climb, and what cooling rate represented is the cooling rate of insulating process heating-up temperature, and (water-cooled+air cooling) cooling rate is the cooling rate of temperature cooling after the weldment outage;
The programming rate of several metals and cooling rate are respectively in table 8 and the table 9:
58 ℃ of the programming rates of copper/S-21 ℃/S, 13.5 ℃/S of cooling rate, water-cooled+air cooling get 188 ℃/S-120 ℃/S;
104.4 ℃ of the programming rates of steel/S-30 ℃/S, 37.5 ℃/S of cooling rate, water-cooled+air cooling is got 479 ℃/S;
88 ℃ of the programming rates of silver/S-40 ℃/S, 13.5 ℃/S of cooling rate, water-cooled+air cooling is got 363 ℃/S;
135.5 ℃ of the programming rates of aluminium/S-60 ℃/S, 20 ℃/S of cooling rate, water-cooled+air cooling is got 465 ℃/S;
Induction brazing technical process and time distribution principle:
In the electric current penetration range in the heating frequency: temperature retention time is 0.3～0.9 times of heat time heating time.
Outside the electric current penetration range in the heating frequency: temperature retention time is 0.7～2 times of heat time heating time.
The used time of process of outage cooling: be 0.1～0.2 times of heat time heating time cool time
The heating of weldment, insulation, cooling brazing process adopt switching time relay or time controller, in conjunction with the detection of infrared radiation thermometer or thermocouple, temperature and time is automaticallyed switch, can take respectively thick, heating, insulation, the cooling of large faying face especially, by the heating for multiple times programming rate carry out heating for multiple times, repeatedly programming rate and cooling rate in conjunction with repeatedly be incubated, repeatedly slowly the mode of air cooling cooling and water-cooled is finished brazing process.
Wherein weld interval T determine it mainly is according to interval in the selected selected welding temperature of solder, brazing flux with the weldment coupling, the programming rate of different metal, temperature retention time, cooling rate, and welding process be divided into the diathermanous heating that electric current penetrates heating and material and determine.
Welding current formula in table 7, the inventive method
Formula weld interval in table 8, the inventive method
Temperature retention time formula in table 9, the inventive method
Step 3, weldment assembling are with fixing
3.1) assembling induction welding equipment induction coil and magnetic head depression bar
Induction coil and magnetic head depression bar are set respectively, the diameter of magnetic rings termination according to:
Determine;
3.2) the assembling weldment
The weldment of prepackage is placed in the anchor clamps, sets solder and brazing flux, weldment places induction coil, reserve corresponding fit-up gap, the fit-up gap of induction coil and weldment arranges respectively, gets 3mm-6mm for the ferrous metal fit-up gap, gets 1.5mm-3mm for the non-ferrous metal fit-up gap; Each induction coil is adjusted to and weldment welding position equal-height position (or near weldment place), the magnetic rings depression bar is pushed down respectively the weldment that applied brazing flux and solder downwards, made the fit-up gap guarantee 0.05mm-0.1mm, and contact firm.
Step 4, enforcement welding
On induction coil, bonding power, induction brazing power supply unit, by welding controller corresponding frequency of utilization, welding current, weld interval, insulation electric current and temperature retention time are set, starting device, begin to weld, the induction coil butt-welding fitting heats, the rear outage of insulation passes to cooling water and carries out cool to room temperature, finishes different materials, pipe fitting, plate, the isostructural induction welding of tube sheet and induction brazing welding.
In addition, the inventive method can also comprise the subsequent processing steps 5 of weldment as required:
The subsequent treatment of step 5, weldment: after above-mentioned institute finishes in steps; also need butt-welding fitting to carry out the follow-up cleaning of soldering; the conservation treatment of brazed seam or whole weldment postwelding namely cleans brazing flux residue, plates other inert metal protective layer, oxidation or Passivation Treatment, sprays paint.
Embodiment
Below be brass tube and copper plate, hard red copper contact plate on the A.C. contactor and silver cadmium oxide electrical contact form the contact bridge product, adopt induction brazing method of the present invention, welding base metal (copper pipe end face, the silver cadmium oxide electrical contact surface) silver of the plating 0.2mm-0.3mm of solder side place, the weight theory of computation and actual welding power demand according to weldment, select welding equipment power, select corresponding induction coil and induction frequencies according to weldment diameter and plant capacity, select welding current depth of penetration △ L according to induction frequencies and welding temperature, depth of penetration heating is that weldment maximum magnitude D2 deducts the only poor of depth of current penetration △ L, table 10 provides the welding material of typical metal weldment, specification, and the performance indications requirement after the welding, weld required radio-frequency induction coil, equipment and frequency, all welding weldments of table 11 are all according to the method for calculated example 1 and calculated example 2, according to table 8 and table 9 HFI welding technological parameter Mathematical Modeling formula, calculate table 11 welding current, time and temperature, power, the parameters such as the solder flux that the surface applies and solder, carry out induction brazing according to the HFI welding processing step, after the welding by metallographic structure, ultrasound detection, shearing force and suppress sealing detection, table 12 is the testing result contrast of the bad and existing new technology welding quality of the original technology of typical high-frequency induction brazing soldering, the copper pipe plate contacts the original solder technology weld seam of bridge welding internal flaw and obtains eradicating with A.C. contactor, the weld is accepted rate brings up to 100%, and the indices that meets Product jointing performance requirement in the table 10 requires and specification.
The welding material of weldment, performance requirement, welding equipment among table 10, the inventive method embodiment
Calculated example 1(is to the brass tube among the embodiment and brass sheet induction brazing welding condition, and the designing and calculating that formula and rule are concrete according to the present invention is given an example, and result of calculation sees Table 11, and the welding result contrast sees Table 12).
Brass tube ￠ 10mm * 1mm length 21mm, with brass sheet 50mm * 50mm * 5mm, adopt silver-base solder TS-34CT(silver pricker silk ￠ 1.8mm), paste brazing flux QJ103, utilize SP-40 equipment 47KHZ frequency, induction coil is by turning to internal diameter ￠ 50mm with ￠ 5mm red copper, the vertical number of turn 3 circles, and the heat induced coil of spacing 2.5mm carries out high-frequency induction brazing.
Welding material weight G=brass tube G+ brass sheet G
=5cm×5cm×0.5cm×8.9g/cm
3+(1cm÷2)
2×3.14×0.1cm×8.9g/cm
3
=118.24g。
Utilize table 6 the induction brazing different materials penetrate current flow heats thickness and power frequency, the 47KHZ welding frequency is near the 45KHZ of corresponding copper alloy, high frequency electric depth of penetration △ L is 2.06.
Copper alloy welding time formula in the option table 8:
Utilize the welding current formula of table 11 copper alloy:
Calculated example 2(is to the U-shaped contact bridge among the embodiment and silver contact induction brazing welding condition, and the designing and calculating that formula and rule are concrete according to the present invention is given an example, and result of calculation sees Table 11, and the welding result contrast sees Table 12).
The ac contactor contact high frequency brazing
According to the method for calculated example 1 to the contact bridge of following A.C. contactor (U-shaped contact bridge 1, U-shaped contact bridge 2, U-shaped contact bridge 3) and the high frequency brazing technological parameter of contact:
U-shaped contact bridge is by silver contact contact plate lead welding and shaping:
Silver contact size: 18mm * 13mm * 1.7mm;
T3, Y4 contact plate size: 18mm * 55mm * 18mm * 5;
Solder Bag30CuZn sheet: 0.2mm * 13mm * 18mm * R15;
Brazing flux is paste FB303P, and all faces all apply brazing flux FB303P before the welding;
Utilize SP-50 equipment 80KHZ, the magnetic rings diameter is
Pressure is 0.2Mpa; The series inductance coil is
Silver contact and contact plate assembly welding weight are 0.098kg; Theoretical power demand is 8.1746-9.555KW; Actual power demand is 12.56-14.7KW, and welding current is 47-50A; Be 18-23s weld interval; The insulation electric current is 38-41A; Temperature retention time is 50-60s.
The high-frequency induction brazing technological parameter of weldment among table 11, the inventive method embodiment
The induction brazing soldering result of weldment contrast among table 12, the inventive method embodiment
Use the inventive method and carry out pilot production, all conform to quality requirements through production, use, check to 8.53 ten thousand products of 10.63 ten thousand products of 13.78 ten thousand products of 2.5 ten thousand products of Tube-sheet Welding, contact bridge 1, contact bridge 2, contact bridge 3, the weld is accepted rate keeps 100%, and welding efficiency improves respectively 130%, 310%, 220%, 380%.Data result shows that the inventive method can reduce equipment investment, stops the destruction that original technology heating makes product surface or coating, and it is bad to have eliminated the leakiness weld seam, improves sealing, weld strength and the electric conductivity of weldment, has prevented weld corrosion; According to above-mentioned respective formula and welding range of choice, obtain fast optimum welding process parameter simultaneously, significantly reduce cost, increase the performance of enterprises.
Claims (4)
1. the method for welding induction brazing of a metallic element is characterized in that, the method is utilized the high-frequency induction brazing welding equipment, implements according to following steps:
Step 1, select the high-frequency induction brazing welding equipment, and definite relevant parameter
1.1) according to the requirement of weldment form factor in the table 1 and the part of welding, with the gap that keeps between weldment and the induction coil less than 0.2 times of weldment diameter, the internal-and external diameter width difference of induction coil is determined according to following formula:
The internal-and external diameter width difference of induction coil=9+50/ induction frequencies, the unit of width difference is millimeter, selects the induction coil internal diameter numerical value of suitable number of turns,
The corresponding relation of table 1, induction coil internal diameter and the heating target material selection number of turn
1.2) according to the difference of weldment weight, find the solution according to the following equation and obtain welding required theoretical power (horse-power): theoretical power (horse-power)=weldment weight (Kg) * temperature (℃) * specific heat capacity { J/ (kg) ℃ }/3600 (seconds)/(1-k),
Wherein, the unit of theoretical power (horse-power) is KW, and copper spare thermal loss coefficient k is got 0.30-0.35; Silver part thermal loss coefficient k is got 0.35-0.40; Steel and iron parts thermal loss coefficient k is got 0.28-0.32;
1.3) select the required induction coil size of welding, the number of turn according to the required theoretical power (horse-power) of welding, select corresponding plant capacity, the former limit of the sensor transformer extension set number of turn according to table 2;
The matching list of the size of table 2, induction coil and the number of turn and the former limit of the sensor transformer extension set number of turn
1.4) according to sensing apparatus, the induction coil former limit number of turn and the pitch of turn of above-mentioned selection, pitch of turn is got 1.5mm-3mm, according to equipment input power, equipment output welding current scope and power, and with reference to induction frequencies selection principle, tolerance frequency and frequency of optimum traffic when determining welding;
Table 3, equipment input power, output welding current and tolerance frequency matching list
Continued 3
Step 2, carry out the surface treatment of weldment
2.1) roughening treatment of weldment solder side
The solder side roughening treatment content of soldered weldment comprises applying pit, compacting pit, the processing of reticulate pattern, protruding stupefied, salient point; The butt-welding fitting surface degreases, the cleaning of deoxidation compound;
2.2) carry out the weldment coating metal surface and process
Specification requirement according to the induction brazing weldment plated metal material of table 4, definite needs carry out the coating surface method, the induction brazing of different materials weldment is preferentially selected coating surface, realized weldment coating layer thickness and material, weldment coating is selected silver, copper, nickel, molybdenum, niobium or aluminium silicon
The specification requirement of the induction brazing mother metal coating material of table 4, the inventive method
2.3) carry out the match selection of weldment and brazing flux, solder, welding temperature, joint gap
1., carry out the selection of brazing flux, solder
Solder and brazing flux are selected and are satisfied instructions for use and braze ability condition;
Solder and brazing flux are selected physics and chemistry and the technical process matching properties condition that satisfies weldment and solder;
2., carry out the selection of brazing flux, solder brazing temperature
Select brazing flux welding fusion temperature at 10 ℃ of solder melting temperatures ~ below 30 ℃, the solder liquidus temperature is lower than at least 40 ℃ of mother metal solidus ~ 50 ℃, and lowest activity temperature thermal stable temperature scope is not less than 100 ℃;
The selection of solder requires liquid and solid-state temperature difference requirement little, and brazing flux melts rear 5s ~ 10s solder fully and begins fusing, and the solder temperature is chosen in and is higher than 20 ℃ ~ 50 ℃ intervals of brazing flux;
3., select brazing flux, solder, brazing temperature and joint gap
Require high, firmness requirement height according to electric conductivity, select silver-base solder and weldment coupling; Perhaps,, firmness not high according to electric conductivity requires high, selects solder and weldment coupling; Be equipped with simultaneously the principle of brazing flux;
According to table 5, for the weldment of different materials, select brazing flux, solder, welding temperature and the joint gap of coupling; According to different situations, place the solder that mates at the face that is welded to connect, the weldment surface applies brazing flux, and solder and brazing flux position provide solder and an amount of configuration of brazing flux and suitable joint gap:
Table 5, the inventive method are selected temperature range and the joint gap of brazing flux, solder
2.4) each technological parameter of selection induction brazing
1., the selection of initial parameter
After the solder that weldment mates, brazing flux, welding temperature, frequency are determined, induction brazing is divided into welding current penetrates the heating welding, weldment heating thickness is △ L, provide the welding temperature △ L value corresponding with frequency in the table 6, after welding current penetrated heating welding continuous heating, the part in no current zone was the diathermanous heating welding portion of weldment, weldment heating full-size D2, the diathermanous heating welding of its weldment segment thickness is the difference that D2 subtracts △ L
According to table 6, according to above-mentioned welding temperature, welding frequency, weldment material thickness parameter, select corresponding current flow heats thickness and the power frequency of penetrating;
Wherein, the relation of non-ferrous metal welding frequency and current flow heats infiltration thickness is: welding frequency increases 23-25 doubly, and electric current infiltration thickness reduces 1mm;
The relation of ferrous metal welding frequency and current flow heats infiltration thickness is: welding frequency increases 16-19 doubly, and electric current infiltration thickness reduces 1mm;
Along with the rising of heating-up temperature, the increase of heating thickness is synchronous minimizing along with the increase of frequency,
Penetrate current flow heats thickness and power frequency when table 6, the inventive method induction brazing
2., according to initial parameter, the welding condition that calculates successively
According to aforesaid selection parameter, obtain needed welding current, weld interval and temperature retention time according to the correlation formula in table 7, table 8, the table 9;
In table 7, table 8 and table 9, G wherein represents weight, and unit is gram; T represents the time, and unit is second; △ L represents the depth of current penetration, and unit is millimeter; D2 represents weldment faying face full-size scope, and unit is millimeter; D2-△ L represents diathermanous district, and unit is millimeter,
Induction brazing technical process and time distribution principle:
In the electric current penetration range in the heating frequency, temperature retention time is 0.3～0.6 times of heat time heating time,
Outside the electric current penetration range in the heating frequency, temperature retention time is 0.7～2 times of heat time heating time,
Welding current formula in table 7, the inventive method
Formula weld interval in table 8, the inventive method
Temperature retention time formula in table 9, the inventive method
Step 3, weldment assembling are with fixing
3.1) assembling induction welding equipment induction coil and magnetic head depression bar
Induction coil and magnetic head depression bar are set respectively, and the diameter of magnetic rings termination is determined according to following formula:
3.2) the assembling weldment
The weldment of prepackage is placed in the anchor clamps, sets solder and brazing flux, weldment places induction coil, reserve corresponding fit-up gap, the fit-up gap of induction coil and weldment arranges respectively, gets 3mm-6mm for the ferrous metal fit-up gap, gets 1.5-3mm for the non-ferrous metal fit-up gap; Each induction coil adjusted to and weldment welding position equal-height position or near the weldment place, the magnetic rings depression bar pushed down respectively the weldment that has applied brazing flux and solder downwards, make fit-up gap and expansion clearance guarantee 0.05mm-0.12mm and contact firm;
Step 4, enforcement welding
By welding controller corresponding frequency of utilization, welding current, weld interval, insulation electric current and temperature retention time are set, start welding equipment, begin to weld, the induction coil butt-welding fitting heats, the rear outage of insulation passes to cooling water and carries out cool to room temperature.
2. the method for welding induction brazing of metallic element according to claim 1, it is characterized in that: in the described step 2, in table 8 and the table 9, what programming rate represented is the heating process temperature rate of climb, what cooling rate represented is the cooling rate of insulating process heating-up temperature, the cooling rate of water-cooled+air cooling is the cooling rate of temperature cooling after the weldment outage
The programming rate of several metals and cooling rate are respectively in table 8 and the table 9:
58 ℃ of the programming rates of copper/S-21 ℃/S, 13.5 ℃/S of cooling rate, water-cooled+air cooling get 188 ℃/S-120 ℃/S;
104.4 ℃ of the programming rates of steel/S-30 ℃/S, 37.5 ℃/S of cooling rate, water-cooled+air cooling is got 479 ℃/S;
88 ℃ of the programming rates of silver/S-40 ℃/S, 13.5 ℃/S of cooling rate, water-cooled+air cooling is got 363 ℃/S;
135.5 ℃ of the programming rates of aluminium/S-60 ℃/S, 20 ℃/S of cooling rate, water-cooled+air cooling is got 465 ℃/S.
3. the method for welding induction brazing of metallic element according to claim 1, it is characterized in that: the structure of described induction brazing welding equipment is, comprise a plurality of induction coils, the copper pipe along continuous straight runs that these a plurality of induction coils are a water flowing turns to a plurality of annulus of vertical direction at least 1 circle, each annulus divide axial multiturn or radially multiturn arrange, each induction coil diameter and weldment heating part match, and current direction is consistent between the copper pipe at each induction coil induction position and adjacent turn parallel or equidistant with the heating surface of corresponding weldment; A corresponding magnetic rings depression bar, the axis centre of each magnetic rings depression bar and the central vertical of corresponding induction coil of arranging above each induction coil.
4. the method for welding induction brazing of metallic element according to claim 1; it is characterized in that: also comprise step 5 after the described step 4; it is the subsequent treatment of weldment; after above-mentioned step 4 is finished; also need butt-welding fitting to carry out the follow-up cleaning of soldering; the conservation treatment of brazed seam or whole weldment postwelding namely cleans brazing flux residue, plates other inert metal protective layer, oxidation or Passivation Treatment, sprays paint.
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