CN109759692B - Method for outdoor welding of aluminum bus in cold environment - Google Patents
Method for outdoor welding of aluminum bus in cold environment Download PDFInfo
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- CN109759692B CN109759692B CN201910053320.6A CN201910053320A CN109759692B CN 109759692 B CN109759692 B CN 109759692B CN 201910053320 A CN201910053320 A CN 201910053320A CN 109759692 B CN109759692 B CN 109759692B
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Abstract
The invention discloses a method for welding an aluminum bus outdoors in a cold environment, which comprises the steps of firstly predicting and preparing a certain mass of self-propagating flux according to the quantity of the aluminum bus to be welded, cleaning the section of the aluminum bus to be welded, closely attaching the aluminum bus to a base, placing a graphite crucible with a through hole at the bottom above the aluminum bus, blocking the through hole by a separation blade easy to melt, then sequentially adding the self-propagating flux and gunpowder, inserting a lead wire into the powder, placing a resistance wire heating device at the periphery of the graphite crucible for preheating and heat preservation, igniting the lead wire to enable the flux to perform self-propagating reaction to weld the aluminum bus, closing the resistance wire heating device after welding is finished, removing the resistance wire heating device and the graphite crucible after cooling to room temperature, removing welding slag and polishing to finish the welding of the aluminum bus. The invention has the advantages of simple operation, less working procedures, convenient carrying, low cost, good welding quality, safety and reliability, and can weld the high-quality aluminum bus in a cold outdoor environment.
Description
Technical Field
The invention belongs to the technical field of welding, and relates to a welding method of an aluminum bus. In particular to a method for welding an aluminum bus outdoors in a cold environment.
Background
Every winter solstice, the outdoor temperature in most regions in north of china will be greatly reduced. For example, the winter season of inner Mongolia is long and cold, and the cold season in most regions is as long as 5 months to half a year. Wherein, the temperature is coldest in 1 month, and the average temperature of the month is decreased from minus 10 ℃ to minus 32 ℃ from south to north. In northern aluminum factories such as Baotou Jitai rare earth aluminum industry, Tongxin aluminum industry and the like, the welding quality of an aluminum bus can be seriously influenced when outdoor welding is carried out in the severe environment. The aluminum bus is mainly applied to the power industry, and the power aluminum bus is used as a part of a power generation system and plays the roles of collecting, distributing and transmitting electric energy. The quality of which directly affects the energy consumption and the production efficiency. The high-quality power aluminum bus welding interface can greatly reduce the voltage drop of the system, thereby greatly saving the cost of energy consumption. Therefore, the welding quality of the power aluminum bus bar directly influences the effect and efficiency of power generation. However, too low outdoor temperature can greatly affect the welding quality of the aluminum bus bar. In a low-temperature environment, heat generated by combustion synthesis reaction of the welding rod is quickly dissipated to ambient air, so that the welding heat efficiency is low, the welding heat is less, the temperature of a molten pool is low, and phenomena of incomplete penetration, incomplete fusion, short welding line, poor welding bead formation and the like occur. Meanwhile, due to the low environmental temperature, the cooling speed of the molten pool is high, the existence time of the liquid molten pool is short, the crystallization and solidification are fast, so that the non-metal components and gas do not have enough time to float and overflow from the liquid alloy, the separation of slag liquid and gas liquid is incomplete, and the defects of slag inclusion, air holes and the like are formed. In addition, aluminum and aluminum alloys have a large coefficient of linear expansion, and therefore cracks are easily generated during welding. Based on these problems, many projects specify that outdoor welding is not allowed in a harsh environment, which may greatly delay construction. On the other hand, winter is a period of multiple failures of a power supply system, and outdoor welding repair is necessary to solve the power supply problem as soon as possible.
The self-propagating reaction is a high-temperature chemical reaction which can quickly and automatically extend to the whole reaction space once initiated. Applying this principle to welding can produce high temperature molten metal by spontaneous reaction of the ignited flux without relying on electricity. Compared with the traditional treatment method, the self-propagating welding has the advantages of less working procedures, simple process, high temperature rise and fall speed, less impurities, good metallurgical bonding quality and low cost. And can spontaneously and rapidly proceed once ignited without further supplying any energy to the device, and is very suitable for outdoor welding.
In fact, in order to achieve a good outdoor welding, on the one hand, it is considered whether the welding method is suitable for outdoor execution, and on the other hand, the effect of the outdoor ambient temperature on the welding. The patent information that can be looked at present does not fully disclose a solution that meets both of the above aspects. For example, patent CN102126072A discloses a welding construction method for horizontally laying large-section aluminum bus bars, which uses MIG welding to make the filled welding material and welding wire cool and form simultaneously in the molten pool crystallizing tank, thus improving welding efficiency and reducing welding deformation and hot cracks. However, the equipment and operation of the method are complex, the required power of the power supply is large, and the method is not suitable for outdoor welding. Patent CN102151937A proposes a self-propagating high temperature synthesis method for in-situ synthesizing a metal matrix composite weld overlay, but it does not consider the effect of ambient temperature on welding. Patent CN103317226A uses a self-propagating technique to preheat the base material and the crucible. However, according to the traditional gas heating or flame heating method, the heating is not uniform, potential safety hazards exist, and the heating cannot be continuously carried out, so that the welding cooling speed is too high, and the welding quality is poor.
Disclosure of Invention
The invention aims to realize a welding method suitable for outdoor and overcome the influence of cold environment on welding quality.
In order to solve the technical problems, the technical scheme adopted by the invention is as follows:
a method for welding an aluminum bus outdoors in a cold environment is characterized by comprising the following steps:
firstly, preparing a certain mass of self-propagating flux according to the amount of the aluminum bus to be welded, cleaning the section of the aluminum bus to be welded, and placing the parts to be welded of the cleaned aluminum bus on a base in an attached manner;
secondly, fixedly placing the crucible with the through hole at the bottom above the aluminum bus to enable the through hole to be aligned to a gap of a to-be-welded section of the aluminum bus and fixing the crucible by using a clamp;
thirdly, attaching a separation blade which is easy to melt to a through hole in the crucible, then sequentially adding a proper amount of self-propagating flux and gunpowder, and inserting a lead wire for ignition into the self-propagating flux and the gunpowder;
fourthly, placing heating equipment at the periphery of the crucible, and heating the crucible to reach the required temperature by using the heating equipment;
igniting the lead wire to enable the welding flux to generate self-propagating reaction, wherein the melt generated after the reaction can melt the separation blade at the through hole of the crucible and flow into the gap of the aluminum bus along with the through hole for welding;
and step six, closing the heating equipment after welding is finished, removing the heating equipment and the crucible after the heating equipment and the crucible are cooled to room temperature, removing welding slag and polishing to finish welding of the outdoor aluminum bus.
Preferably, the self-propagating flux has the following components: 34 to 42 percent of aluminum powder; 32% -38% of tin oxide; 3 to 7 percent of aluminum-copper alloy; 2 to 3 percent of magnesium oxide; 12 to 17 percent of zinc sulfate; 3% -8% of silicon powder; 1% -3% of boron powder; 4.5 to 6 percent of calcium fluoride.
Preferably, the crucible is a graphite crucible with through holes, and the diameter of the crucible is 0.2-1 m.
Preferably, in step four, the desired temperature is from 30 to 60 degrees.
Preferably, the heating equipment is resistance wire heating equipment and comprises a heating cylinder body and a resistance wire, at least three support legs are arranged at the bottom of the heating cylinder body, the resistance wire is arranged on the inner wall of the heating cylinder body, and the inner diameter of the heating cylinder body is larger than the outer diameter of the crucible.
Preferably, the heating device is provided with a temperature control device, the temperature control device comprises a temperature sensor and a controller which are arranged in the heating cylinder, and the constant temperature in the heating cylinder is set through the temperature control device.
Preferably, the resistance wire material is 0Cr25Al5 iron chromium aluminum alloy.
Preferably, 4 groups of resistance wires are arranged on the inner wall of the resistance wire heating equipment respectively, and the heating power of each group of resistance wires is 1500-3000W.
Preferably, the graphene coating is sprayed on the inner wall of the heating cylinder of the resistance wire heating equipment.
Preferably, the powder fineness of the self-propagating flux is 150-375 meshes.
A self-propagating flux, the composition of which is as follows: 34 to 42 percent of aluminum powder; 32% -38% of tin oxide; 3 to 7 percent of aluminum-copper alloy; 2 to 3 percent of magnesium oxide; 12 to 17 percent of zinc sulfate; 3% -8% of silicon powder; 1% -3% of boron powder; 4.5 to 6 percent of calcium fluoride.
The invention has the following beneficial effects:
the flux used in the invention has stable reaction and low cost. The components such as silicon, aluminum, calcium fluoride and the like added into the welding flux can reduce slag inclusion and improve the welding quality. The invention uses the heat release of the self-propagating high-temperature synthesis reaction as a welding heat source, uses the metal product generated by the reaction as a filler, and realizes the welding of the metal structure under the conditions of no electricity and no gas. The reaction speed is fast, easy operation, and the staff only need ignite the lead wire and can realize automatic weld, and need not to carry large-scale equipment. In addition, the zinc sulfate added into the flux has the characteristic of generating a large amount of heat during decomposition, and can further promote the self-propagating reaction. The resistance wire heating equipment is adopted, and on one hand, the resistance wires are uniformly distributed on the inner wall of the equipment, so that the base material and the crucible can be uniformly heated in the welding process. The even heating not only can effectively improve welding quality, but also can prevent the potential safety hazard that local high temperature produced. On the other hand, the equipment does not need manual operation for automatic heating, and has the advantage of continuous heating in the process of strong welding reaction. This advantage has solved the problem of welding cooling rate overquick and operating personnel personal safety simultaneously. In addition, the resistance wire heating equipment not only selects the resistance wire with low cost and low power consumption on the premise of achieving an ideal heating and heat preservation effect, but also sprays the graphene coating on the inner wall of the equipment. The graphene has strong heat conductivity and large specific surface area, and can be fully filled in the base material to increase the heat dissipation surface, so that the heat conductivity of the coating is very outstanding. Some heating devices have used this coating in the early days and worked well. In conclusion, the invention has the advantages of simple operation, less working procedures, convenient carrying, low cost, good welding quality, safety and reliability, and the welding effect is not influenced by the ambient temperature, thus being capable of fully realizing outdoor welding under cold conditions.
Drawings
FIG. 1 is a schematic view of a resistance wire heating apparatus used in the welding process of the present invention.
FIG. 2 is a schematic view of the crucible installation used in the welding process of the present invention.
1-steel shell, 2-resistance wire, 3-temperature control device, 4-steel inner wall, 5-lead, 6-gunpowder, 7-graphite crucible, 8-self-propagating flux, 9-baffle plate and 10-support leg.
Detailed Description
The invention is illustrated in the following with reference to the accompanying drawings.
As shown in fig. 1, the heating device for sampling an outdoor welding aluminum bus in a cold environment is a resistance wire heating device and comprises a heating cylinder body and a resistance wire 2, wherein the bottom of the heating cylinder body is provided with at least three support legs 10, the resistance wire 2 is arranged on the inner wall of the heating cylinder body, the inner diameter of the heating cylinder body is larger than the outer diameter of a crucible, and the heating cylinder body is made of steel and comprises a steel shell 1 and a steel inner wall 4. The heating equipment is further provided with a temperature control device 3, the temperature control device 3 comprises a temperature sensor and a controller which are arranged in the heating cylinder, the constant temperature in the heating cylinder is set through the temperature control device 3, the constant temperature in the crucible is maintained within 30-60 ℃ in the initial heating stage, in the embodiment, the resistance wire 2 is made of 0Cr25Al5 iron-chromium-aluminum alloy, 4 groups of resistance wires 2 are respectively arranged on the inner wall of the resistance wire heating equipment, the heating power of each group of resistance wires 2 is 1500-3000W, and the graphene coating is sprayed on the inner wall of the heating cylinder so as to improve the heat conductivity between the heating cylinder and the graphite crucible 7.
As shown in fig. 2, the crucible is a through-hole graphite crucible 7, the diameter of the crucible is generally 0.2-1 m, a through hole is arranged in the middle of the bottom of the crucible, the self-propagating flux 8 in the through hole can flow down from the through hole to be welded with an aluminum bus bar after being melted, a separation blade 9 which is easy to melt is placed at the top of the through hole before the graphite crucible 7 is filled with the self-propagating flux 8, and the self-propagating flux 8 is prevented from being leaked out before being melted, and in the embodiment, any one of a thin copper sheet, an aluminum sheet and a paper sheet can be adopted as.
In the embodiment of the invention, the self-propagating flux 8 comprises the following components: 34 to 42 percent of aluminum powder; 32% -38% of tin oxide; 3 to 7 percent of aluminum-copper alloy; 2 to 3 percent of magnesium oxide; 12 to 17 percent of zinc sulfate; 3% -8% of silicon powder; 1% -3% of boron powder; 4.5 to 6 percent of calcium fluoride. In the embodiment, the self-propagating flux 8 is a powdery flux, and the fineness of the powder of each component is 150-375 meshes.
A method for welding an aluminum bus outdoors in a cold environment comprises the following steps:
firstly, predicting and preparing a certain mass of self-propagating flux 8 according to the amount of the aluminum bus to be welded, cleaning the section of the aluminum bus to be welded, and then placing a base with proper height below the aluminum bus to be welded and enabling the parts to be welded of the aluminum bus to be tightly attached together.
And step two, placing the graphite crucible 7 with the through hole at the bottom above the aluminum bus to enable the through hole to be aligned to the gap of the section to be welded of the aluminum bus and clamping and fixing the gap by using crucible tongs or other fixtures.
And step three, attaching a baffle plate 9 which is easy to melt to a through hole in the graphite crucible 7, then sequentially adding a proper amount of self-propagating flux 8 and a small amount of gunpowder 6, and inserting a lead 5 for ignition into the powder.
And fourthly, placing the resistance wire heating equipment at the periphery of the graphite crucible 7, so that the graphite crucible 7 is positioned in the center of the resistance wire heating equipment. Switching on a power supply, setting the heating temperature and the heating time by using the temperature control device 3, generally 1-2 h, and then preheating and preserving heat, wherein the preserving temperature is generally 30-60 ℃.
And fifthly, igniting the lead 5 to enable the welding flux to generate self-propagating reaction, and melting the baffle plate 9 at the through hole of the graphite crucible 7 by the melt generated after the reaction and flowing into the aluminum bus gap along with the through hole for welding.
And step six, turning off a power supply of the resistance wire heating equipment after welding is finished. And after cooling to room temperature, removing the resistance wire heating equipment and the graphite crucible 7, removing welding slag and polishing to complete the welding of the outdoor aluminum bus.
The following are specific examples:
example 1
And carrying out outdoor welding in an environment with the outdoor temperature of 5 ℃. Cleaning the section of the aluminum bus to be welded, and then placing a base with proper height below the aluminum bus to be welded and enabling the parts to be welded of the aluminum bus to be tightly attached together. A graphite crucible 7 having a through hole of 0.2 to 1m in diameter as shown in FIG. 2 was prepared and placed over the aluminum busbar. The baffle plate 9 is attached to a through hole in the graphite crucible 7, and then a self-propagating flux 8 with the mass fraction of 37% of aluminum powder, 32% of tin oxide, 6% of aluminum-copper alloy, 2% of magnesium oxide, 14% of zinc sulfate, 1% of boron powder, 3% of silicon powder and 5% of calcium fluoride is added. After no powder leakage phenomenon is detected, the powder is stirred uniformly, a layer of gunpowder 6 is paved on the surface of the welding flux, and a lead 5 for ignition is inserted into the powder. The resistance wire heating device shown in fig. 1 is arranged at the periphery of the graphite crucible 7, so that the graphite crucible 7 is positioned at the center of the resistance wire heating device. The power is switched on, the heating temperature and the heating time are set by using the temperature control device 3, and then preheating and heat preservation are carried out. After the interior of the heating device reaches the required temperature after 1-2 hours, the lead 5 is ignited to enable the welding flux to perform self-propagating reaction. And after welding, turning off the power supply, cooling to room temperature, removing the resistance wire heating equipment and the graphite crucible 7, removing welding slag, and polishing to complete welding of the outdoor aluminum bus.
Example 2
And carrying out outdoor welding in an environment with outdoor temperature of-20 ℃. Cleaning the section of the aluminum bus to be welded, and then placing a base with proper height below the aluminum bus to be welded and enabling the parts to be welded of the aluminum bus to be tightly attached together. A graphite crucible 7 having a through hole of 0.2 to 1m in diameter as shown in FIG. 2 was prepared and placed over the aluminum busbar. The baffle plate 9 is attached to a through hole in the graphite crucible 7, and then a self-propagating flux 8 with the mass fraction of 35% of aluminum powder, 33% of tin oxide, 5% of aluminum-copper alloy, 3% of magnesium oxide, 13% of zinc sulfate, 2% of boron powder, 4% of silicon powder and 5% of calcium fluoride is added. After no powder leakage phenomenon is detected, the powder is stirred uniformly, a layer of gunpowder 6 is paved on the surface of the welding flux, and a lead 5 for ignition is inserted into the powder. The resistance wire heating device shown in fig. 1 is arranged at the periphery of the graphite crucible 7, so that the graphite crucible 7 is positioned at the center of the resistance wire heating device. The power is switched on, the heating temperature and the heating time are set by using the temperature control device 3, and then preheating and heat preservation are carried out. After the interior of the heating device reaches the required temperature after 1-2 hours, the lead 5 is ignited to enable the welding flux to perform self-propagating reaction. And after welding, turning off the power supply, cooling to room temperature, removing the resistance wire heating equipment and the graphite crucible 7, removing welding slag, and polishing to complete welding of the outdoor aluminum bus.
The above description provides specific embodiments of the present invention, but in practice the above-described flow is not necessarily followed completely. The operation and technical personnel can carry out partial modification according to own knowledge and actual construction conditions on the premise of not violating the policy of the invention.
Claims (8)
1. A method for welding an aluminum bus outdoors in a cold environment is characterized by comprising the following steps:
firstly, preparing a certain mass of self-propagating flux according to the amount of the aluminum bus to be welded, cleaning the section of the aluminum bus to be welded, and placing the parts to be welded of the cleaned aluminum bus on a base in an attached manner;
secondly, fixedly placing the crucible with the through hole at the bottom above the aluminum bus to enable the through hole to be aligned to a gap of a to-be-welded section of the aluminum bus and fixing the crucible by using a clamp;
thirdly, attaching a separation blade which is easy to melt to a through hole in the crucible, then sequentially adding a proper amount of self-propagating flux and gunpowder, and inserting a lead wire for ignition into the self-propagating flux and the gunpowder;
fourthly, placing heating equipment at the periphery of the crucible, and heating the crucible to reach the required temperature by using the heating equipment;
igniting the lead wire to enable the welding flux to generate self-propagating reaction, wherein the melt generated after the reaction can melt the separation blade at the through hole of the crucible and flow into the gap of the aluminum bus along with the through hole for welding;
step six, after welding, closing the heating equipment, after cooling to room temperature, removing the heating equipment and the crucible, removing welding slag and polishing to complete welding of the outdoor aluminum bus;
the heating device is a resistance wire heating device and comprises a heating cylinder body and a resistance wire, at least three support legs are arranged at the bottom of the heating cylinder body, the resistance wire is arranged on the inner wall of the heating cylinder body, and the inner diameter of the heating cylinder body is larger than the outer diameter of the crucible.
2. The method of claim 1, wherein: the self-propagating flux comprises the following components: 34% -42% of aluminum powder; 32% -38% of tin oxide; 3% -7% of aluminum-copper alloy; 2% -3% of magnesium oxide; 12% -17% of zinc sulfate; 3% -8% of silicon powder; 1% -3% of boron powder; 4.5-6% of calcium fluoride.
3. The method of claim 1, wherein: the crucible is a through-hole graphite crucible, and the diameter of the crucible is 0.2-1 m.
4. The method of claim 1, wherein: in step four, the required temperature is 30-60 ℃.
5. The method of claim 1, wherein: the heating equipment is provided with a temperature control device, the temperature control device comprises a temperature sensor and a controller which are arranged in the heating cylinder body, and the constant temperature in the heating cylinder body is set through the temperature control device.
6. The method of claim 1, wherein: the resistance wire is made of 0Cr25Al5 iron-chromium-aluminum alloy.
7. The method of claim 1, wherein: the inner wall of the resistance wire heating equipment is provided with 4 groups of resistance wires respectively, and the heating power of each group of resistance wires is 1500-3000W.
8. The method of claim 1, wherein: and a graphene coating is sprayed on the inner wall of a heating cylinder of the used resistance wire heating equipment.
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| CN202655792U (en) * | 2012-05-25 | 2013-01-09 | 施密特钢轨技术（昆山）有限公司 | Heat preservation cover for aluminum hot welding at low temperature |
| CN207564653U (en) * | 2017-12-18 | 2018-07-03 | 郑州远东耐火材料有限公司 | A kind of zirconia-corundum refractory brick riser head heat-preserving structure |
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| CN101697662B (en) * | 2009-10-29 | 2011-04-27 | 深圳市唯特偶新材料股份有限公司 | High heat-resistance organic solder ability preservative |
| CN102990222A (en) * | 2012-11-16 | 2013-03-27 | 中国铝业股份有限公司 | Electrolytic tank aluminum bus and soft tape electric heat-release welding method |
| CN105171266B (en) * | 2015-08-28 | 2017-06-09 | 武汉大学 | A kind of self- propagating aluminum solder and its welding method |
| CN106903455A (en) * | 2016-12-26 | 2017-06-30 | 长沙理工大学 | A kind of high temperature resistant organic solderability preservative and apply usage |
| CN107971655B (en) * | 2018-01-23 | 2019-12-27 | 永星化工(上海)有限公司 | High-heat-resistance organic solder flux and application thereof |
| CN208320696U (en) * | 2018-04-24 | 2019-01-04 | 嘉瑞科技（惠州）有限公司 | A kind of metal-base composites Preparation equipment |
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| CN202655792U (en) * | 2012-05-25 | 2013-01-09 | 施密特钢轨技术（昆山）有限公司 | Heat preservation cover for aluminum hot welding at low temperature |
| CN207564653U (en) * | 2017-12-18 | 2018-07-03 | 郑州远东耐火材料有限公司 | A kind of zirconia-corundum refractory brick riser head heat-preserving structure |
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