CN107824937B - Automatic backing welding process method for narrow groove of thick-wall pipe and welding head - Google Patents

Automatic backing welding process method for narrow groove of thick-wall pipe and welding head Download PDF

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CN107824937B
CN107824937B CN201711114492.7A CN201711114492A CN107824937B CN 107824937 B CN107824937 B CN 107824937B CN 201711114492 A CN201711114492 A CN 201711114492A CN 107824937 B CN107824937 B CN 107824937B
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welding
pipe
thick
groove
narrow groove
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CN107824937A (en
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朱小明
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NANJING AUTO AUTOMATION Co.,Ltd.
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Nanjing Auto Electric Co Ltd
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00Arc welding or cutting
    • B23K9/02Seam welding; Backing means; Inserts
    • B23K9/028Seam welding; Backing means; Inserts for curved planar seams
    • B23K9/0282Seam welding; Backing means; Inserts for curved planar seams for welding tube sections
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00Arc welding or cutting
    • B23K9/16Arc welding or cutting making use of shielding gas
    • B23K9/167Arc welding or cutting making use of shielding gas and of a non-consumable electrode
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00Arc welding or cutting
    • B23K9/235Preliminary treatment
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00Arc welding or cutting
    • B23K9/24Features related to electrodes
    • B23K9/26Accessories for electrodes, e.g. ignition tips
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00Arc welding or cutting
    • B23K9/24Features related to electrodes
    • B23K9/28Supporting devices for electrodes

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  • Plasma & Fusion (AREA)
  • Mechanical Engineering (AREA)
  • Arc Welding In General (AREA)
  • Butt Welding And Welding Of Specific Article (AREA)

Abstract

The invention discloses an automatic backing welding process method and a machine head device for a narrow groove of a thick-wall pipe, wherein a research range of wall thickness is selected from a thick-wall pipe, the research range is 20-60 mm, the form and the size of the narrow groove are formulated according to groove specifications of a thick-wall pipe fitting based on different standards aiming at a double V groove and a U-shaped groove; meanwhile, according to the definition form of the narrow groove, a novel TIG welding head for the narrow groove of the thick-wall pipe of the automatic welding equipment is designed. The TIG welding head mainly comprises a clamping device special for a wire guide pipe and a lengthened flat ceramic nozzle, so that the smoothness of a guide wire is ensured, and the welding head has the applicability to narrow groove backing welding. The automatic backing welding device can adapt to the automatic backing welding of the thick-wall pipe with the thickness of 20-60 mm, meet the requirements of a welding process, reduce the metal filling amount of a welding seam during the welding of the thick-wall pipe, improve the welding efficiency, reduce the production cost of the pipeline and realize the double improvement of the welding quality and efficiency of the thick-wall pipe.

Description

Automatic backing welding process method for narrow groove of thick-wall pipe and welding head
Technical Field
The invention belongs to the technical field of automatic welding of pipelines, and particularly relates to an automatic backing welding process method and a machine head device for a narrow groove of a thick-wall pipe.
Background
In industries such as petroleum, thermal power plants, nuclear power plants, power generation equipment manufacturing and the like, a large number of thick-wall pipelines and related parts are welded, and the welding is carried out by adopting TIG (tungsten inert gas), SAW (surface acoustic wave), MIG (metal-inert gas)/MAG (metal active gas) and manual welding in a large number of specifications. However, the traditional welding mode has a large groove angle and a large amount of filled metal, so that qualitative waste of consumables is caused, and the production cost of the pipeline is high.
The argon arc welding (TIG) process is a high-quality welding technology with stable arc combustion and convenient operation and observation, is often used in automatic backing welding of pipelines, and has high efficiency and good quality. However, the size of the common welding gun is limited, the welding head is difficult to enter the bottom of the narrow groove of the thick-wall pipe, and the automatic backing welding of the narrow groove of the thick-wall pipe cannot be implemented.
Disclosure of Invention
The invention aims to overcome the defects of the prior art, provides an automatic backing welding process method and a machine head device for a narrow groove of a thick-wall pipe, solves the problems that the automatic backing welding of the narrow groove of the thick-wall pipe cannot be realized and the welding quality and efficiency are influenced because the automatic backing welding of the narrow groove of the thick-wall pipe is limited by the sizes of the groove and the machine head during the backing welding of an ordinary welding gun for automatically welding the pipeline in the industry, reduces the metal filling amount of a welding seam during the welding of the thick-wall pipe, improves the welding efficiency, reduces the production cost of the pipeline and realizes the double promotion of the welding quality and efficiency of the thick-wall pipe.
In order to solve the technical problems, the invention provides an automatic backing welding process method for a narrow groove of a thick-wall pipe, which comprises the following steps:
①, selecting a thick-wall pipeline with a wall thickness research range of 20-60 mm, and aiming at double V grooves and U-shaped grooves, formulating the form and size of narrow grooves according to groove specifications of thick-wall pipes based on different standards;
② designing a thick-wall pipe narrow groove automatic backing welding TIG welding head according to the planned narrow groove form and size;
③ cutting off the pipe to be welded by mechanical processing method, beveling the pipe according to the planned narrow bevel form and size, and removing rust, oil and dirt near the bevel of the pipe;
④ selecting welding materials matched with the base material, including dry, oil-free, and rust-free thick-wall welding wire;
⑤ adopts 1G process with unchanged position of the rotary welding head of the pipe, multi-layer and multi-pass welding of monofilament, and manual argon arc positioning welding is adopted when the pipe fittings are assembled.
Preferably, the narrow groove of the thick-walled pipe is dimensioned as follows: the groove angle of the double V-shaped groove is 37 +/-2.5 degrees, the groove surface angle is 10 +/-2.5 degrees, and the height of the large angle is 12 +/-2 mm; the groove angle of the U-shaped groove is 20 +/-2.5 degrees, and the radius of a fillet is 5 mm; the groove gap of the two types of grooves is 2-2.4mm, the thickness of the truncated edge is 1.6 +/-0.8 mm, and the misalignment amount is less than or equal to 1.5 mm.
The invention also provides an automatic bottoming welding head for the narrow groove of the thick-wall pipe, which comprises a welding gun, a wire guide pipe and a nozzle, and is characterized in that:
the special clamping device of seal wire pipe is connected with welder through special clamping device of seal wire pipe, special clamping device of seal wire pipe includes clamp splice, regulating block, support, link and seal wire pipe fixed block, the clamp splice: the upper end of the adjusting block is connected with a welding gun, and the adjusting block is connected with the clamping block and can move up and down relative to the clamping block; the clamping block and the adjusting block are connected and fixed through a hexagon bolt and a butterfly nut; two linking bridge at middle part the leg joint is at the end of regulating block, and the link rotates with the support to be connected, and seal wire pipe fixed block one end rotates with the link to be connected, and the other end is used for fixed seal wire copper pipe, seal wire copper pipe end-to-end connection seal wire mouth, seal wire mouth end-to-end connection nozzle. Compared with the prior art, the invention has the beneficial effects that:
the automatic backing welding process method and the machine head device for the narrow groove of the thick-wall pipe solve the problems that the automatic backing welding of the narrow groove of the thick-wall pipe cannot be realized and the welding quality and efficiency are influenced because the automatic welding of the narrow groove of the thick-wall pipe is limited by the sizes of the groove and the welding machine head during backing welding of an ordinary welding gun for automatic welding of pipelines in the industry, the automatic backing welding of the narrow groove of the thick-wall pipe is difficult to enter the bottom of the groove. Through the design of the special clamping device for the wire guide pipe, the welding head disclosed by the invention can realize the angle adjustment of the wire guide pipe in two dimensions (see a delta angle and a theta angle shown in the attached drawing 1), so that the nozzle can adapt to the automatic backing welding of a narrow groove of a thick-wall pipe with the thickness of 20-60 mm, the requirements of a welding process are met, the metal filling amount of a welding seam during the welding of the thick-wall pipe is reduced, the welding efficiency is improved, the production cost of a pipeline is reduced, and the double improvement of the welding quality and the welding efficiency of the thick-wall pipe is.
Drawings
FIG. 1 is a schematic view of a double V groove of the present invention;
FIG. 2 is a schematic view of a U-groove of the present invention;
FIG. 3 is a schematic view of the structure of the novel TIG welding machine of the present invention;
FIG. 4 is a flat ceramic nozzle layout.
Remarks to the attached drawings:
in fig. 1 and 2, α represents a groove angle of a double V groove or a U groove, β represents a groove surface angle of the double V groove, h represents a height of a large angle of the double V groove, t represents a pipe thickness, b represents a groove gap, d represents a blunt thickness, and r represents a U groove fillet radius.
In fig. 3, H is the adjustable height of the special clamping device for the guide wire and the welding gun, A is the width of the special clamping device for the guide wire, delta and theta are changeable angles of the special clamping device for the guide wire, L is the extension length of a tungsten electrode, and L is the extension length of a welding wire rod.
In FIG. 4, B is the flat end width of the flat ceramic nozzle, phi is the diameter of the round end of the flat ceramic nozzle, i.e., the flat end length, L1 is the total length of the flat ceramic nozzle, and C is the round end length of the flat ceramic nozzle.
Detailed Description
For a better understanding of the present invention, reference will now be made in detail to the embodiments of the present invention as illustrated in the accompanying drawings:
the thick-wall pipe narrow groove automatic backing TIG welding process method provided by the embodiment comprises the following steps:
①, starting from a thick-wall pipeline, selecting a wall thickness research range of 20-60 mm, and aiming at a double V groove and a U-shaped groove, drawing up the form and the size of a narrow groove according to the groove specification of a thick-wall pipe fitting based on different standards (such as ASME, national standard or European standard);
② designing a novel TIG welding head for automatically backing and welding the narrow groove of the thick-wall pipe according to the planned form and size of the narrow groove;
③ cutting off and beveling the pipe to be welded by machining, and removing rust, oil and dirt around the beveling;
④ selecting welding materials matched with the base material, including dry, oil-free, and rust-free thick-wall welding wire;
⑤ adopts a 1G process with unchanged position of a rotary welding head of the pipe, multi-layer and multi-pass welding of single wire, manual argon arc positioning welding is adopted during assembly of the pipe, the welding power supply is in direct current positive connection, the process parameters are welding current 195-220A, arc voltage 12-14V and welding speed 80-110 mm/min.
⑥, in the welding process, the butt joint of thick-wall pipes is realized by adjusting and controlling the position of a welding gun, welding parameters and the like;
⑦ and testing the welded seam appearance, X-ray detection, ultrasonic detection, tensile strength and impact toughness.
In actual operation, the welding method is as follows:
1. welding apparatus and materials
(1) The welding equipment adopts a cantilever welding machine, a welding power supply PIPEWAX 400 special for the Miller process pipeline is matched with an SB-10 wire feeder;
(2) the welding material base material is a carbon steel pipe A106Gr.B, which meets the ASTM A106/106M standard, and has the specification of phi 610 multiplied by 36mm, the yield strength of 247Mpa and the tensile strength of 410 Mpa; adopting a phi 1.2 carbon steel argon arc welding wire TM-56 which meets the standard AWSA5.18ER70S-6;
(3) the purity of the argon is more than or equal to 99.99 percent.
2. Preparation before welding
(1) And (3) groove machining, namely machining a double V-shaped groove or a U-shaped groove on the carbon steel pipe A106Gr.B by adopting a numerical control machine tool, wherein the double V-shaped groove is formed, as shown in figure 1, the groove angle α is 37 +/-2.5 degrees, the groove surface angle β is 10 +/-2.5 degrees, the large-angle height h of the double V-shaped groove is 12 +/-2 mm, as shown in figure 2, the U-shaped groove angle α is 20 +/-2.5 degrees, the fillet radius r is 5mm, the groove gap b of the two grooves is 2mm, the thickness d of the truncated edge is 1.6 +/-0.8 mm, and the misalignment c is less than or equal to 1.5 mm.
(2) Customizing a machine head: the novel TIG welding head of design preparation mainly has two parts of special clamping device of seal wire pipe and the flat ceramic nozzle of extension: the special clamping device for the wire guide pipe is made of stainless steel materials, and mainly comprises the following components in parts by weight: the device comprises a clamping block 1, an adjusting block 2, a support 3, a connecting frame 4 and a guide wire pipe fixing block 5. The clamping block 1 is connected with a welding gun 8, the adjusting block 2 is provided with a groove, and the groove is connected with the clamping block 1 through a hexagon bolt and a butterfly nut and can move up and down relative to the clamping block 1. The bracket 3 is connected to the tail end of the adjusting block 2 by a cross-slot pan head screw and an I-shaped hexagon nut. The bracket 3 is designed to have a U-shaped bifurcation (or a V-shaped bifurcation), the connecting frame 4 is designed to have a V-shaped bifurcation (or a U-shaped bifurcation), the two are connected through the bifurcation by using a cross recessed pan head screw and an I-shaped hexagon nut, and the connecting frame 4 can rotate relative to the bracket 3. One end of the wire guide pipe fixing block 5 is rotatably connected with the connecting frame 4 through a screw and a nut, and the other end of the wire guide pipe fixing block is used for clamping and fixing the wire guide copper pipe 6. The tail end of the guide wire copper pipe 6 is connected with a guide wire nozzle 7 through threads, and the tail end of the guide wire nozzle 7 is connected with a nozzle 9 through threads.
The wire guide tube clamping device can realize the conversion of two dimensional angles (delta angle and theta angle in figure 1, and the up-down and front-back adjustment of the nozzle) so as to increase the adaptability of the automatic priming of the narrow groove to the wall thickness of the thick-wall tube.
The nozzle 9 adopts ceramic material, the rear end is cylindricly, the front end is the platykurtic, the flat end length of nozzle 9 adopts the extension design, nozzle length is 20 ~ 60mm in order to adapt to the wall thickness scope of pipe, can go deep into narrow groove bottom, when adjustment tungsten utmost point extension length is 15mm, the welding head can stretch into narrow groove bottom, space is surplus about the tungsten utmost point, can realize 3.0 ~ 4.0 mm's swing through the oscillator welder during bottoming welding, guarantee that bottoming is respond well, do not have the incomplete penetration of welding.
(3) Cleaning: polishing dirt such as rust, oil stain and the like in the range of 20-30 mm of the edge of the groove of the pipe fitting by using an angle grinder;
(4) butt joint assembly: the pipe fitting assembly is subjected to positioning welding by manual argon arc welding, 7-8 positioning welding points are uniformly distributed on the circumference, and the positioning welding requires through welding. The edge staggering amount is small as much as possible during assembly, and the assembly gap is controlled to be 2-2.4 mm. After the assembly, the positioning welding points need to be polished to be in smooth transition, so that the molten pool can be smoothly transited at the positioning welding positions during welding.
(4) Before welding, the assembled pipe fittings are assembled on a cantilever welding machine. In order to ensure the penetration of the back, the position of a welding gun is adjusted, the TIG automatic backing welding position selects downward welding, the welding gun is arranged at the position of 12 o' clock and a half clock of the pipe fitting, the angle of the welding gun is between 20 degrees and 30 degrees and is perpendicular to the tangent plane of the pipe fitting, the position can use larger welding current to improve the welding efficiency, meanwhile, the welding seam is well formed, and during actual operation, the proper height of the welding gun needs to be selected according to the groove condition and the welding specification.
(5) Checking whether the gas path of the water path is smooth, and adjusting the flow of the protective gas (Ar being more than or equal to 99.9%) to 10-15L/min (firstly ventilating and then stagnating).
3. Welding process
(1) Welding positions: 1G, rotating the pipe and keeping the welding gun still;
(2) welding gun position: in order to ensure the penetration of the back, the position of a welding gun is adjusted, the TIG bottoming welding position selects downward welding, the welding gun is arranged at the position of 12 o' clock and a half clock of the pipe fitting, and the angle of the welding gun is between 20 and 30 degrees and is vertical to the section of the pipe fitting;
(3) and (3) adjusting and controlling the welding position, the welding parameters, the interlayer temperature and the like, and performing a bottoming process test by adopting a process method of automatic bottoming and hot welding, wherein the welding process parameters are shown in the table 1.
Table 1: automatic backing weld parameters
Figure BDA0001465901380000051
4. And (3) postweld detection: through weld joint appearance detection, X-ray detection, ultrasonic detection, tensile strength and impact toughness tests, the detection and test results show that the weld joint is good in forming, the surface of the weld joint has no obvious macro-welding defects such as unfused, incomplete penetration, undercut and the like, the strength of the weld joint can reach 90% of that of a base metal, and the interior of the weld joint has no micro-welding defects such as pores, slag inclusion, cracks and the like.
The above embodiments are only for illustrating the technical idea of the present invention, and the protection scope of the present invention is not limited thereby, and any modifications made on the basis of the technical scheme according to the technical idea of the present invention fall within the protection scope of the present invention.

Claims (9)

1. An automatic backing welding process method for a narrow groove of a thick-wall pipe is characterized by comprising the following steps:
①, selecting a thick-wall pipeline with a wall thickness research range of 20-60 mm, and aiming at double V-shaped grooves or U-shaped grooves, formulating the form and size of narrow grooves according to groove specifications of thick-wall pipes based on different standards;
wherein the groove angle of the double V-shaped groove is 37 +/-2.5 degrees, the groove surface angle is 10 +/-2.5 degrees, and the height of the large angle is 12 +/-2 mm; the groove angle of the U-shaped groove is 20 +/-2.5 degrees, and the radius of a fillet is 5 mm; the groove gap of the two types of grooves is 2-2.4mm, the thickness of the truncated edge is 1.6 +/-0.8 mm, and the misalignment amount is less than or equal to 1.5 mm;
② designing a thick-wall pipe narrow groove automatic backing welding TIG welding head according to the planned narrow groove form and size;
the TIG welding head for automatic backing welding comprises a welding gun, a wire guide pipe and a nozzle, wherein the wire guide pipe is connected with the welding gun through a special clamping device for the wire guide pipe, the special clamping device for the wire guide pipe comprises a clamping block (1), an adjusting block (2), a support (3), a connecting frame (4) and a wire guide pipe fixing block (5), the clamping block (1) is connected with the welding gun (8), and the adjusting block (2) is connected with the clamping block (1) and can move up and down relative to the clamping block (1); the support (3) is connected to the tail end of the adjusting block (2), the connecting frame (4) is rotatably connected with the support (3), one end of the guide wire pipe fixing block (5) is rotatably connected with the connecting frame (4), the other end of the guide wire pipe fixing block is used for fixing the guide wire copper pipe (6), the tail end of the guide wire copper pipe (6) is connected with the guide wire nozzle (7), and the tail end of the guide wire nozzle (7) is connected with the nozzle (9);
③ cutting off the pipe to be welded by mechanical processing method, beveling the pipe according to the planned narrow bevel form and size, and removing rust, oil and dirt near the bevel of the pipe;
④ selecting welding materials matched with the base material, including dry, oil-free, and rust-free thick-wall welding wire;
⑤ adopts 1G process with unchanged position of the rotary welding head of the pipe, multi-layer and multi-pass welding of monofilament, and manual argon arc positioning welding is adopted when the pipe fittings are assembled.
2. The automatic backing welding process method for the narrow groove of the thick-wall pipe according to claim 1, which is characterized in that: the pipe fitting assembly is subjected to tack welding by manual argon arc welding, 7-8 tack welding points are uniformly distributed on the circumference, and the tack welding requires through welding; the misalignment amount is small as much as possible during assembly, and the assembly gap is controlled to be 2-2.4 mm; after the assembly, the positioning welding points are polished to be in smooth transition, so that the molten pool can be smoothly transited at the positioning welding positions during welding.
3. The automatic backing welding process method for the narrow groove of the thick-wall pipe according to claim 1, which is characterized in that: the welding power supply is in direct current positive connection, single-wire multilayer multi-pass welding is adopted at the welding position of 1G, and the welding process parameters are welding current 195-220A, arc voltage 12-14V and welding speed 80-110 mm/min.
4. The automatic backing welding process method for the thick-wall pipe and the narrow groove according to claim 1, further comprising a post-welding detection step, wherein the weld appearance detection step, the X-ray detection step, the ultrasonic detection step, the tensile strength test step and the impact toughness test step ensure good weld forming, no obvious macroscopic welding defects exist on the surface of the weld, the weld strength reaches 90% of the base metal strength, and no microscopic welding defects exist inside the weld.
5. The utility model provides an automatic welding head of bottoming of narrow groove of thick-walled pipe, includes welder, wire guide pipe and nozzle, its characterized in that:
the wire guide pipe is connected with a welding gun through a special clamping device for the wire guide pipe, the special clamping device for the wire guide pipe comprises a clamping block (1), an adjusting block (2), a support (3), a connecting frame (4) and a wire guide pipe fixing block (5), the clamping block (1) is connected with a welding gun (8), and the adjusting block (2) is connected with the clamping block (1) and can move up and down relative to the clamping block (1); support (3) are connected at the end of regulating block (2), and link (4) are rotated with support (3) and are connected, and seal wire pipe fixed block (5) one end is rotated with link (4) and is connected, and the other end is used for fixed seal wire copper pipe (6), seal wire copper pipe (6) end-to-end connection seal wire mouth (7), seal wire mouth (7) end-to-end connection nozzle (9).
6. The automatic backing welding machine head for the narrow groove of the thick-wall pipe according to claim 5, characterized in that: the adjusting block (2) is provided with a groove and is connected with the clamping block (1) through a hexagon bolt and a butterfly nut.
7. The automatic backing welding machine head for the narrow groove of the thick-wall pipe according to claim 5, characterized in that: the bracket (3) and the connecting frame (4) are provided with U-shaped or V-shaped branches and are connected through screws and nuts.
8. The automatic backing welding machine head for the narrow groove of the thick-wall pipe according to claim 5, characterized in that: nozzle (9) adopts ceramic material, and the rear end is cylindricly, and the front end is the platykurtic, and the platykurtic end extension design of nozzle, length satisfy: when the extension length of the tungsten electrode is adjusted to be 15mm, the welding head can extend into the bottom of the narrow groove, and the left space and the right space of the tungsten electrode are surplus.
9. The automatic backing welding machine head for the narrow groove of the thick-wall pipe according to claim 5, characterized in that: the guide wire copper pipe (6), the guide wire nozzle (7) and the nozzle (9) are connected through threads.
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