CN110587165B - Composite welding method for aluminum and aluminum alloy section - Google Patents
Composite welding method for aluminum and aluminum alloy section Download PDFInfo
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- CN110587165B CN110587165B CN201910870554.XA CN201910870554A CN110587165B CN 110587165 B CN110587165 B CN 110587165B CN 201910870554 A CN201910870554 A CN 201910870554A CN 110587165 B CN110587165 B CN 110587165B
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Abstract
The invention relates to a composite welding process method of aluminum and aluminum alloy profiles, which adopts two welding methods of mutually complementary utilization of heat input, wherein the first method is friction stir welding which firstly carries out electric arc welding on fillet welds at two sides of a web plate and then welds a middle wing plate after a certain distance. The second method is to weld the middle friction stir welding to form a T-shaped joint and then perform the melting welding on two sides. The integrated hybrid welding of the invention can realize an automatic profile welding production line with high efficiency, high quality and relatively low cost.
Description
Technical Field
The invention belongs to the field of welding of non-ferrous metal aluminum and non-ferrous metal aluminum alloy, and particularly relates to a welding method for manufacturing a T-shaped or I-shaped section by welding aluminum and non-ferrous metal aluminum alloy.
Background
Aluminum is one of the most widely used metal materials at present, and has the remarkable characteristics of light weight, high strength ratio and atmospheric corrosion resistance. However, the welding process is troubled by the problems of much aluminum welding problems, large oxide film cleaning and welding deformation, fast heat conduction, difficulty in melting, low joint strength during welding of high-strength materials and the like. In the manufacture of large-thickness aluminum profiles, if T-shaped or I-shaped structures with high fatigue resistance are required to be welded, the connecting joints are required to be welded through and form smooth transition. Therefore, when a typical fusion welding method is used, it is necessary to perform a bevel welding of the web edges. The groove form can be opened into a single-side V shape or a single-side K shape according to the plate thickness or the stress characteristics, as shown in figure 1. To realize the process, a groove needs to be machined, then the assembly and the fixation are carried out, and then the groove is filled fully through multilayer or multi-pass welding, and an outer fillet welding seam with a proper welding leg size is formed, as shown in figure 2. The welding process consumes a lot of working hours, materials and electric energy and necessary auxiliary working hours, which inevitably causes high production cost for enterprises. In terms of welding deformation, it is also possible to cause angular deformation or bending deformation of the wing plate. In addition, in the process of melting and welding aluminum and aluminum alloy, the problems of serious softening of joint strength, difficult weld forming and the like are prominent. Therefore, the reduction of the welding workload in the melting welding process of aluminum and aluminum alloy directly affects the improvement of the welding quality of the weldment and the improvement of the welding operation efficiency.
For the welding of aluminium and its alloys there is also a very efficient high quality welding method, which was the friction stir welding invented by the british institute of welding in 1991. The method can be used for welding various aluminum alloys at present, can be used for butt joint, angle joint and other forms, and can also be used for welding dissimilar materials, such as welding between aluminum steel, aluminum copper and the like. However, if the t-joint is welded using friction stir welding alone, abrupt structural changes and partial lack of penetration may occur at the right angle of the joint.
Disclosure of Invention
The method aims to solve the problems of beveling when thick plate aluminum and alloy thereof are melted and welded to manufacture a section and stress concentration at weld toes caused by structure mutation reduction during friction stir welding. The invention provides a composite welding process, namely a composite welding process method for a T-shaped joint structural member by combining friction stir welding and electric arc melting welding.
The technical scheme of the invention comprises the following steps:
step 5, setting the transmission speed of the production line according to the welding speed, and synchronizing the welding speed of the friction stir welding machine with the welding speed of the double-arc welding system;
in the friction stir welding process, the length of a stirring pin of the stirring head exceeds the thickness of the wing plate, so that part of the stirring pin enters the middle of the web plate, and the friction stir connection between the web plate and the wing plate is realized; when the wing plates are spliced by two narrow plates with equal width, the butt joint between the wing plates is realized, and the T-shaped joint between the wing plates and the web plate is realized at the same time; in the arc welding process of the double-fillet weld, the electric arcs on the two sides of the web plate melt the connecting right angle between the web plate and the wing plate and form a certain penetration depth, and the melted filling metal is used as fillet weld metal to complete fillet weld welding; after the member is turned over, stirring, rubbing and welding the non-penetration part between the web plate and the wing plate which are subjected to double-arc welding in the upper half part of the I-shaped structure, and stirring, rubbing and welding the non-penetration part by using a stirring needle; and in the lower half part of the I-shaped structure, the double-arc welding system welds fillet welds on two sides of the web plate, the electric arc melts the connecting right angle between the web plate and the wing plate and forms a certain penetration depth, and the melted filling metal is used as fillet weld metal to complete fillet weld welding.
In the step 6, the heat input of the two welding methods is mutually supplemented and utilized; the first is to perform electric arc welding of fillet welds at two sides of a web plate, and to weld friction stir welding of a middle wing plate after a certain distance is formed; the second method is to weld the middle friction stir welding to form a T-shaped joint and then perform the melting welding on two sides.
In the step 6, the stirring head comprises a stirring head clamping part, a shaft shoulder and a stirring needle, the stirring head clamping part, the shaft shoulder and the stirring needle are sequentially connected, the stirring needle is in a step shape formed by a large stirring needle and a small stirring needle, the length of the large stirring needle corresponds to the thickness of the wing plate, and the diameter of the large stirring needle is 0.5-0.9 times of the thickness of the wing plate; the length of the small stirring pin is 0.2-0.3 times of the diameter of the large stirring pin; the diameter of the small stirring pin is 0.6-0.8 times of that of the large stirring pin; the diameter of the end face of the shaft shoulder is 2.5-3 times of that of the large stirring needle.
The diameter of the large stirring pin is selected according to the thickness of the web plate, the lower limit of the thick plate is taken, and the upper limit of the thin plate is taken.
The invention has the following advantages and effects:
the friction stir welding and the electric arc welding system are integrated on a T-shaped joint welding production line. The root part which is difficult to be welded completely by fusion welding is subjected to friction stir welding by friction stir welding, and the right-angle part of the T-shaped joint connecting part is subjected to arc fusion welding by utilizing a fusion welding process method, so that smooth transition of the weld toe part is realized to reduce corresponding stress concentration. In addition, by utilizing the integrated hybrid welding, the heat input of the two welding methods can be mutually supplemented and utilized, and the welding efficiency is improved. Two different effects can be produced depending on the positional arrangement of the two welding methods. The first is friction stir welding in which fillet welds on both sides of a web are arc-welded and a middle wing plate is welded at a predetermined distance. In this case, the fillet welds on both sides can meet the design requirements and can also serve as the support restraint points on both sides of the friction stir weld. If the welding points of the two welding methods are close to each other, the waste heat of the arc welding workpiece can preheat the friction stir welding, and accordingly the welding speed is increased or the rotating speed of the friction stir welding is reduced. Because aluminum has good thermal conductivity, after the two welding methods are carried out for a certain distance, the temperature fields of the two methods are superposed to establish a new temperature field, and the two methods are in a state of mutual influence when in dynamic balance. The second method is to weld the middle friction stir welding to form a T-shaped joint and then perform the melting welding on two sides. In this case, the existence of the residual heat of the friction stir welding workpiece is equivalent to the preheating of the fusion welding, so that the heat input of the fusion welding can be reduced. Also, if the welding positions of the two methods are close, the heat during arc welding adversely affects the friction stir welding, thereby increasing the friction stir welding speed. Thus, in either combination, positive effects are produced on both welding methods. Thus, integrated hybrid welding can enable an automated profile welding line with high efficiency, high quality, and relatively low cost.
Drawings
FIG. 1 is a schematic diagram of a T-joint with a bevel.
FIG. 2a is a schematic view of a single-sided V fillet weld.
FIG. 2b is a schematic view of a single-sided V-belt blunt bevel weld.
FIG. 2c is a schematic view of a two-sided V-groove fillet weld.
FIG. 2d is a schematic view of a double-sided V-belt blunt bevel weld.
FIG. 2e is a schematic view of a blunt J-fillet weld.
FIG. 2f is a schematic view of a double-sided J fillet weld with a blunt edge.
FIG. 3 is a schematic diagram of the welding system of the present invention.
FIG. 4 is a schematic view of a stirring head structure according to the present invention.
In fig. 1: 101 is a web, 102 is a web, and 103 is a fillet.
In fig. 3, 1 is a stir head, 2 is an upper wing, 3 is a web, 4 is MIG arc welding, 6 is a friction stir weld, and 7 is an arc welding fillet.
In FIG. 4, φ 1, the stirring head holding diameter; phi 2, the diameter of the shaft shoulder of the stirring head; phi 3, the diameter of a large stirring pin of the stirring head; phi 4, the diameter of a small stirring pin of the stirring head; l1, stir head clamping length; l2, stir head shoulder length; l3, large pin length; l4, small pin length.
Detailed Description
Examples
step 5, setting the transmission speed of the production line according to the welding speed, and synchronizing the welding speed of the friction stir welding machine with the welding speed of the double-arc welding system;
in the friction stir welding process, the length of a stirring pin of the stirring head exceeds the thickness of the wing plate, so that part of the stirring pin enters the middle of the web plate, and the friction stir connection between the web plate and the wing plate is realized; when the wing plates are spliced by two narrow plates with equal width, the butt joint between the wing plates is realized, and the T-shaped joint between the wing plates and the web plate is realized at the same time; in the arc welding process of the double-fillet weld, the electric arcs on the two sides of the web plate melt the connecting right angle between the web plate and the wing plate and form a certain penetration depth, and the melted filling metal is used as fillet weld metal to complete fillet weld welding; after the member is turned over, stirring, rubbing and welding the non-penetration part between the web plate and the wing plate which are subjected to double-arc welding in the upper half part of the I-shaped structure, and stirring, rubbing and welding the non-penetration part by using a stirring needle; and in the lower half part of the I-shaped structure, the double-arc welding system welds fillet welds on two sides of the web plate, the electric arc melts the connecting right angle between the web plate and the wing plate and forms a certain penetration depth, and the melted filling metal is used as fillet weld metal to complete fillet weld welding.
Examples of implementation: by using the invention, the subject group realizes the welding of the T-shaped aluminum metal structure with the thickness of 5mm in a laboratory by using friction stir welding and double-pulse MIG. The profile dimensions were 5mm 100mm 300mm 110 mm. The stirring pin diameter is 4mm, length is 6mm, and the dipulse MIG welding parameters are: current 120A, wire diameter 1.2 mm. The voltage is 20V. The welding speed is 120 mm/min.
The integrated composite welding production line can be composed of the following four parts:
1. the section bar group is to the installation fixed part.
The main function of the part is to complete the assembly, installation and fixation of the web plate, the upper wing plate and the lower wing plate after blanking. The welding process is mainly completed by a tool clamp with corresponding size and 2 or 4 movable arc welding operators. Arc welding with proper weld seam length can be carried out at certain intervals according to design. The length and the interval of the point fixing welding seam are determined according to the thicknesses of the wing plates and the web plates.
2. And moving the fusion pressing welding platform.
The welding platform is provided with a lower wing plate supporting mechanism, an upper wing plate pressing mechanism, a profile moving driving mechanism, a stirring friction welding system mechanism, two MIG arc welding operators, a track conveying mechanism of finished parts, a parameter adjusting and program control system of the whole system and the like. The system composition diagram is shown in fig. 3. When the joint of the upper wing plate and the web plate is welded by friction stir welding, two fillet welds at the joint of the lower wing plate and the web plate are respectively melted and welded by two melting and welding operators. And after welding, turning over the workpiece, welding again, and performing friction stir welding on the side with the fillet weld. While the other side is fusion welded with a fillet weld.
3. Arc welding system parts.
At present, the fusion welding of aluminum and aluminum alloy is mainly alternating current TIG welding and direct current MIG, wherein the MIG welding efficiency is high, and the robot welding is relatively easy to realize. Therefore, the method proposes to use mainly MIG welding. The MIG welding of aluminum and aluminum alloy is mainly direct current pulse MIG welding and double pulse MIG welding. Both welding process methods have good welding seam quality and forming, relatively speaking, the heat input of double pulses is easier to adjust, and the welding seam forming is more beautiful. Therefore, double pulse MIG welding under robot operation should be used. Although four welding seams are adopted, when two times of separate welding are adopted, the arc welding can be carried out at a straight angle position, the welding seam forming is facilitated, and therefore two double-pulse MIGs under the operation of two robots are adopted. After the welding procedure is programmed, the welding can be symmetrically welded with the friction stir welding at the same time.
4. Friction stir welding system
As shown in figure 4, the stirring head comprises a stirring head clamping part, a shaft shoulder and a stirring pin, wherein the stirring head clamping part, the shaft shoulder and the stirring pin are sequentially connected, the stirring pin is in a step shape formed by a large stirring pin and a small stirring pin, the length L3 of the large stirring pin corresponds to the thickness of a wing plate, and the diameter of the large stirring pin is 0.5-0.9 times of the thickness of the wing plate. The thickness of the web plate can be selected according to the lower limit of the thick plate and the upper limit of the thin plate. The length L4 of the small stirring pin is 0.2-0.3 times of the diameter phi 3 of the large stirring pin. The diameter phi 4 of the small stirring pin is 0.6-0.8 times of the diameter phi 3 of the large stirring pin; the diameter of the shaft shoulder is 2.5-3 times of that of the large stirring needle.
According to the general structural design, for the I-shaped symmetrical section component, the lap joint mode of friction stir welding is adopted at the connecting center of the upper wing plate and the web plate for welding. This requires accurate control of the weld position during friction stir welding to maintain the weld at the web center. In the welding process, in order to prevent the extrusion cracking phenomenon generated after the stirring pin is inserted into the web plate at two sides of the upper edge of the web plate, the stirring pin adopts a step shape, and the diameter and the length of the stirring pin inserted into the web plate are smaller.
The system can also be formed by combining two sets of welding systems into a production line for work, wherein a workpiece turnover mechanism is arranged between the two sets of systems, and after the first set of welding is finished, the turnover system turns over the semi-finished weldment for second welding. Because the weldment has residual heat, which is equivalent to preheating for the second weld, the heat input for the second weld can be small.
The system integrates two welding methods in the welding process of the T-shaped joint of the aluminum and the aluminum alloy, and has the following remarkable characteristics and advantages in two aspects:
1. the electric arc heat assists the friction stir welding process, the friction stir welding power is reduced, and the welding efficiency is improved.
The good thermal conductivity of thick aluminum and its alloy makes the welding process require friction stir welding to generate enough heat to plasticize the metal in the welding area for welding, which makes it necessary to increase the rotation speed and pressure of the stirring head or decrease the welding speed, so that the metal is in an overheated state in the friction contact area of the shaft shoulder of the stirring head due to excessive heat generation, and a huge temperature gradient is generated in the thickness direction of the metal. On the contrary, if the surface metal temperature is in a proper state, the temperature of the bottom area of the thick plate is correspondingly in a low state, which is not beneficial to the stirring process and reduces the efficiency of friction stir welding. Particularly in the case of lap joints, an air gap exists between the two plates to reduce heat transfer. Meanwhile, the heat of the web plate mainly comes from the friction heat between the front end part of the stirring pin and the web plate, and the heat generation amount is relatively small due to the small contact area. Thus, the plasticization of the web is more difficult. And arc welding heat of the symmetrical edges is transferred to a web area for friction stir welding through heat conduction to form a preheating state for the friction stir welding. The improvement of the friction stir welding efficiency of the thick plate is mainly to increase the temperature of the plate appropriately, and there are many documents and techniques in this respect, such as preheating by TIG or PAW, laser, and the like. The technology utilizes the waste heat of the workpiece when the symmetric-edge arc welding fillet weld is integrated in the system to preheat the friction stir welding.
2. The waste heat of the friction stir welding has the preheating effect on the melting welding process, reduces the arc welding parameters and is favorable for improving the performance and the efficiency of the welding seam.
For the arc welding T-shaped joint, heat conduction is in three directions according to the characteristics of a welding structure, the wing plate conducts heat in two dimensions, and the web plate conducts heat in one dimension. Therefore, when arc welding is carried out, the heat of the arc needs to be increased, and the most heat of the arc is also required to be directed to the side of the wing plate for two-dimensional heat transfer, so that a proper temperature field can be formed and a welding seam can be formed. Because the temperature of the web plate is raised by the waste heat of the arc symmetric welding and the friction stir welding, the heat dissipation of the web plate can be slowed down, and therefore, the heat input for the T-shaped joint welding can be greatly reduced.
During the second set of system welding, the workpiece is at a higher overall temperature through the dual heating of the friction stir welding system and the arc welding system, so that preheating exists in both the friction stir welding and the arc welding of the second pass. This can greatly reduce the parameters required for welding or increase the welding speed. And the reduction of the arc heat input of the welding seam is beneficial to the refinement of welding seam crystal grains and the improvement of welding seam performance.
Claims (3)
1. A composite welding method of aluminum and aluminum alloy profiles is characterized by comprising the following steps:
step 1, preparing aluminum and alloy wing plates and web plates thereof which meet the size requirement of the section;
step 2, utilizing a tool fixture group to assemble the wing plate and the web plate and performing point-fixing welding and shape correction on the section bar according to the size requirement;
step 3, putting the fixedly welded section into a welding production line, and opening a web clamping mechanism and a wing plate clamping mechanism to clamp the production line operation system;
step 4, adjusting the friction stir welding machine to the wing plate welding position of the upper T-shaped joint, and adjusting the double-arc welding system manipulator to the fillet weld position of the lower T-shaped joint;
step 5, setting the transmission speed of the production line according to the welding speed, and synchronizing the welding speed of the friction stir welding machine with the welding speed of the double-arc welding system;
step 6, starting the friction stir welding machine, starting the double-arc welding system and starting the assembly line conveying mechanism to form a welding process after the position to be welded reaches the plasticizing temperature;
in the friction stir welding process, the length of a stirring pin of the stirring head exceeds the thickness of the wing plate, so that part of the stirring pin enters the middle of the web plate, and the friction stir connection between the web plate and the wing plate is realized; when the wing plates are spliced by two narrow plates with equal width, the butt joint between the wing plates is realized, and the T-shaped joint between the wing plates and the web plate is realized at the same time; in the arc welding process of the double-fillet weld, the electric arcs on the two sides of the web plate melt the connecting right angle between the web plate and the wing plate and form a certain penetration depth, and the melted filling metal is used as fillet weld metal to complete fillet weld welding; after the member is turned over, stirring, rubbing and welding the non-penetration part between the web plate and the wing plate which are subjected to double-arc welding in the upper half part of the I-shaped structure, and stirring, rubbing and welding the non-penetration part by using a stirring needle; and in the lower half part of the I-shaped structure, the double-arc welding system welds fillet welds on two sides of the web plate, the electric arc melts the connecting right angle between the web plate and the wing plate and forms a certain penetration depth, and the melted filling metal is used as fillet weld metal to complete fillet weld welding.
2. The composite welding method of aluminum and aluminum alloy profiles as claimed in claim 1, wherein in step 6, the heat input of the two welding methods is utilized in a complementary manner; the first is to perform electric arc welding of fillet welds at two sides of a web plate, and to weld friction stir welding of a middle wing plate after a certain distance is formed; the second method is to weld the middle friction stir welding to form a T-shaped joint and then perform the melting welding on two sides.
3. The composite welding method of aluminum and aluminum alloy sections according to claim 1, wherein in step 6, the stirring head comprises a stirring head clamping portion, a shaft shoulder and a stirring pin, the stirring head clamping portion, the shaft shoulder and the stirring pin are sequentially connected, the stirring pin is in a step shape formed by a large stirring pin and a small stirring pin, the length of the large stirring pin corresponds to the thickness of the wing plate, and the diameter of the large stirring pin is 0.5-0.9 times of the thickness of the wing plate; the length of the small stirring pin is 0.2-0.3 times of the diameter of the large stirring pin; the diameter of the small stirring pin is 0.6-0.8 times of that of the large stirring pin; the diameter of the end face of the shaft shoulder is 2.5-3 times of that of the large stirring needle.
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Effective date of registration: 20210422 Address after: Hebei Xiang Dong Gou Cun 113123 Fushun City Shuncheng District in Liaoning Province Patentee after: Fushun chuangde mechanical equipment Co.,Ltd. Address before: Wanghua District West Dandong Road 113001 Liaoning city of Fushun province No. 1 Patentee before: Liaoning Shihua University |