CN110920080A - 一种热塑性聚合物矩形平板的对接焊方法 - Google Patents
一种热塑性聚合物矩形平板的对接焊方法 Download PDFInfo
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Abstract
本发明提供一种热塑性聚合物矩形平板的对接焊方法,步骤如下:对待焊接相连的平板在焊接区域处开出双面坡口,并焊前处理;在平板朝外的两端施加压力使得平板在焊接区域处的截面紧密接触,向焊接区域吹入热风,将其熔化,再挤入熔融的焊条,使平板在这一面的坡口处连成一体;翻转平板,在已焊接的区域背面进行焊接的底部二次处理,热风吹化焊接处,开槽至露出正面底部焊肉,再挤入熔融的焊条;磨平两面焊接处突出的焊肉,并在两面焊肉上各覆盖焊接上一块热塑性聚合物矩形平板,用于增强焊接区域的强度。利用该焊接方法焊接成的结构,焊接区域强度远大于焊前材料本体强度,不易变形,抗冲击性更强,极大降低焊接带来的风险,从而提高整体的安全性。
Description
技术领域
本发明涉及热塑性聚合物的焊接工艺,特别是涉及一种热塑性聚合物矩形平板的对接焊方法。
背景技术
随着高分子材料科学技术的飞跃进步,聚合物型材开发利用的深化,生产设备、工艺的不断改进,聚合物型材淋漓尽致地展示其卓越性能。一场“以塑代钢”的革命正在进行。其中,热塑性聚合物凭借其优异的机械、物理化学性能及良好的可塑性被广泛用于各类管道及平板的制作。随着热塑性聚合物矩形平板在汽车、船舶工业上的应用,平板间的焊接工艺也越发凸显其重要性。传统工艺由简单热气焊接而成的结构,存在焊接部位强度弱于本体强度、各种原因导致的焊接缺陷等缺点,使焊接部位成为整体结构的弱点和短板,无法满足高工况下抵抗外载荷的要求。
发明内容
基于此,有必要提供一种热塑性聚合物矩形平板的对接焊方法,解决传统热气焊接而成的塑料结构无法满足抵抗破坏、抵抗变形的情况。
本发明的技术方案:
一种热塑性聚合物矩形平板的对接焊方法,步骤如下(图1):
步骤一、在待焊接相连的两块平板的焊接区域处开出一定角度的双面坡口,并对其进行焊前处理;
步骤二、在平板朝外的两端施加一定压力使得两块平板在焊接区域处的截面紧密接触,向焊接区域吹入热风,将其熔化,再挤入熔融的焊条,使两块平板在这一面的坡口处连成一体;
步骤三、翻转已完成单面焊接的矩形平板,在另一侧坡口,开槽至露出对面的底部焊肉,并对其进行焊前处理,再重复步骤二;
步骤四、磨平两面焊接处突出的焊肉,并在两面焊肉上各覆盖焊接上一块辅助平板,用于增强焊接区域的强度。
所述的平板为热塑性聚合物矩形平板。
步骤一涉及的焊前开出的双面坡口,其焊缝角度取决于待焊接平板的厚度,见图2。
焊接所采用的焊条,为待焊接平板为相同材质,在焊接前应在60~80℃条件下至少烘干12小时,保持其干燥,焊条的熔融指数(测试标准及条件:GB/T3682,190℃/5kg)在0.2~1.7g/10min范围内。
步骤二涉及的施加在平板两端的压力,其值应在0.1~0.3MPa范围内,焊接完成后应继续保持压力直至焊接区域充分冷却,其冷却保压时间根据待焊接平板的厚度确定,见下表。
壁厚(mm) | 冷却保压时长(min) |
<4.5 | 6 |
4.5~7 | 6~10 |
7~12 | 10~6 |
12~19 | 16~24 |
19~26 | 24~32 |
26~37 | 32~45 |
37~50 | 45~60 |
50~70 | 60~80 |
步骤一和步骤三涉及的焊前处理,指利用不与待焊接材料起化学反应的有机溶剂棉纸将焊接区域表面进行擦拭,去除表面的油污及加工残渣等杂质。
步骤四涉及的辅助平板,与待焊接平板为相同材质,且满足如下要求:
a)辅助平板板厚:不小于待焊接平板板厚的1/4,且不大于待焊接平板板厚的1/2;
b)辅助平板长度:等于焊缝长度;
c)辅助平板宽度:不小于焊缝长度的1/3,且不大于焊缝长度1/2;
在步骤二和步骤四涉及的焊接过程中,必须保持焊接环境温度在5℃以上,确保焊接时焊条熔融体不会过快冷却凝固。
在步骤二和步骤四涉及的焊接过程中,热风及熔融焊条的温度取决于具体材料,常见热塑性聚合物的焊接温度要求见下表。
本发明的有益效果:所述的热塑性聚合物矩形平板的对接焊方法,不同于传统的直接热气对接焊方法,能极大地增加焊接部位的强度和稳定性,解决了传统热气焊接而成的结构,其焊接部位强度低于平板本体强度,且存在较大缺陷风险的情况。利用该焊接方式焊接而成的结构,将拥有更好的结构稳定性和强度,不易变形,抗冲击性更强,从而提高了整体的安全性。
附图说明
图1是本发明的焊接工艺过程图;
图2是本发明的热塑性聚合物矩形平板焊缝角度与平板厚度的关系曲线。
具体实施方式
下面结合附图和技术方案,进一步说明本发明的具体实施方式。
实施例
一种25mm厚度的聚丙烯(PP)矩形平板的对接焊方法,步骤如下:
步骤一、将2块平板端部相对,在焊接区域处开出双面坡口,坡口的焊缝角度根据图2,取55°,然后,利用95%酒精棉纸擦拭焊接区域,去除表面的油污和加工残渣等杂质;
步骤二、在平板两段施加0.2MPa压力使得两块平板在焊接区域处的截面紧密接触,再向焊接区域吹入热风,将其熔化,热风的温度为270℃,再挤入焊条熔融体,焊条熔融体的温度为230℃,使两块平板在这一面的坡口处连成一体,焊接完成后,需保持施加的压力30分钟,再进行下一个步骤;在此步骤中,须保持焊接环境温度在5℃以上,以确保焊接时焊条熔融体不会过快冷却凝固,同时选用的焊条也应为聚丙烯材质,组分与待焊接平板一致,且在焊接前应在70℃条件下至少烘干12小时,保持其干燥,焊条的熔融指数(测试标准及条件:GB/T3682,190℃/5kg)在0.2~1.7g/10min范围内;
步骤三、翻转平板,用270℃热风吹化焊接区域,开槽至露出底部焊肉,然后,利用95%酒精棉纸擦拭焊接区域,去除表面的油污和加工残渣等杂质,重复步骤二;
步骤四、磨平两面焊接处突出的焊肉,并在两面焊肉上各覆盖焊接上一块辅助平板,平板几何尺寸(单位:mm)为W(长)×0.4W(宽)×8(厚),用于增强焊接区域的强度,提高抗破坏性。在此步骤中,W为焊缝长度,即待焊接平板的宽度;选用的辅助平板也应为聚丙烯材质,组分与待焊接平板一致;焊接辅助平板时,热风与焊条熔融体的温度与步骤二一致。
Claims (9)
1.一种热塑性聚合物矩形平板的对接焊方法,其特征在于,步骤如下:
步骤一(1)、在两块矩形平板(5)的焊接区域处开出双面坡口(6),并对其进行焊前处理(7);
步骤二(2)、在矩形平板两端施加压力(8)使其在焊接区域处的截面紧密接触,向坡口吹入热风(9),将其表面熔化,再挤入焊条(10)熔融体,使两块矩形平板在这一面的坡口处连成一体;
步骤三(3)、翻转已完成单面焊接的矩形平板,在另一侧坡口,开槽至露出对面的底部焊肉,并对其进行焊前处理(7),再重复步骤二(2);
步骤四(4)、磨平两面焊接处突出的焊肉,并在两面焊肉上各覆盖并焊接上一块辅助平板(11),用于增强焊接区域的强度。
2.如权利要求1所述的热塑性聚合物矩形平板的对接焊方法,其特征在于,所述的矩形平板(5)、焊条(10)、辅助平板(11)均为相同材质,即热塑性聚合物。
3.如权利要求1所述的热塑性聚合物矩形平板的对接焊方法,其特征在于,所述的坡口(6)的焊缝角度取决于待焊接矩形平板的厚度。
4.如权利要求1所述的热塑性聚合物矩形平板的对接焊方法,其特征在于,所述的焊前处理(7)是指利用不与待焊接材料起化学反应的有机溶剂棉纸将焊接区域表面进行擦拭。
5.如权利要求1所述的热塑性聚合物矩形平板的对接焊方法,其特征在于,所述的在矩形平板两端施加的压力(8)为0.10~0.30MPa,在每一步焊接完成后需要继续保持压力等待焊肉冷却,冷却保压时间取决于板厚。
6.如权利要求1所述的热塑性聚合物矩形平板的对接焊方法,其特征在于,所述的热风(9),其温度取决于具体材料;出风量为285-315L/min;风压为8-12kPa,风压不允许负偏差。
7.如权利要求1所述的热塑性聚合物矩形平板的对接焊方法,其特征在于,所述的焊条(10),在焊接前应在60~80℃条件下至少烘干12小时,焊条的熔融指数在0.2~1.7g/10min范围内。
8.如权利要求1所述的热塑性聚合物矩形平板的对接焊方法,其特征在于,所述的辅助平板(11),其板厚不小于待焊接平板板厚的1/4,且不大于待焊接平板板厚的1/2;长度应等于焊缝长度;宽度应不小于焊缝长度的1/3,且不大于焊缝长度1/2。
9.如权利要求1所述的热塑性聚合物矩形平板的对接焊方法,其特征在于,所述的步骤二(2)和步骤四(4),涉及焊接过程,必须保持焊接环境温度在5℃以上。
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Cited By (2)
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CN113246478A (zh) * | 2021-04-25 | 2021-08-13 | 白蕊 | 一种波浪接缝式pe板材热熔接方法 |
CN113665130A (zh) * | 2021-08-23 | 2021-11-19 | 大连蓝旗船舶科技有限公司 | 一种大型塑料部件的焊接工艺 |
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CN113246478A (zh) * | 2021-04-25 | 2021-08-13 | 白蕊 | 一种波浪接缝式pe板材热熔接方法 |
CN113665130A (zh) * | 2021-08-23 | 2021-11-19 | 大连蓝旗船舶科技有限公司 | 一种大型塑料部件的焊接工艺 |
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