CN110977173A - Six-axis 3D printing robot arc welding preparation process - Google Patents
Six-axis 3D printing robot arc welding preparation process Download PDFInfo
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- CN110977173A CN110977173A CN201911350390.4A CN201911350390A CN110977173A CN 110977173 A CN110977173 A CN 110977173A CN 201911350390 A CN201911350390 A CN 201911350390A CN 110977173 A CN110977173 A CN 110977173A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/346—Working by laser beam, e.g. welding, cutting or boring in combination with welding or cutting covered by groups B23K5/00 - B23K25/00, e.g. in combination with resistance welding
- B23K26/348—Working by laser beam, e.g. welding, cutting or boring in combination with welding or cutting covered by groups B23K5/00 - B23K25/00, e.g. in combination with resistance welding in combination with arc heating, e.g. TIG [tungsten inert gas], MIG [metal inert gas] or plasma welding
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Abstract
The invention discloses an arc welding preparation process of a six-axis 3D printing robot. The laser beam and the electric arc move together along the abutted seam in a large-scale space; meanwhile, the laser beam performs oscillation scanning movement in a local micro-area around the arc action point, and the actual welding track is a curve formed by superposing two movements. The optimal range of the laser beam oscillation scanning displacement is-2-3 mm in the X-axis direction, the optimal range of the laser beam oscillation scanning displacement is-5-5 mm in the Y-axis direction, the optimal range of the laser beam oscillation scanning displacement is-2-2 mm in the Z-axis direction, and the oscillation frequency is 20-500 Hz. The invention forms the enhanced technical effect through the interaction of the laser beam oscillation scanning effect and the laser-electric arc synergistic effect, and improves the quality of the welding seam. Compared with the existing laser-electric arc hybrid welding and laser scanning welding, the invention has stronger weld seam blowhole inhibition capability and improves the weld seam strength by 10-50%.
Description
Technical Field
The invention discloses a hybrid welding technology, particularly relates to an arc welding preparation process of a six-axis 3D printing robot, and is particularly suitable for laser beam-arc hybrid welding of metal materials.
Background
The laser-arc hybrid welding utilizes the interaction between two heat sources of laser and arc, has better welding characteristics, has the advantages of large laser welding penetration, good joint quality, high efficiency, small deformation, good arc welding bridging property and strong adaptability to complex environments, and is one of the most attractive metal material connecting technologies at present. However, the significant difference in welding characteristics between arc and laser results in a laser-arc hybrid weld that still presents a number of technical challenges to overcome in terms of weld formation and joint structure uniformity. Specifically, the low energy density of the arc and its heat conduction characteristics cause the heat of the arc to accumulate mainly in the upper half of the weld, thereby causing the upper half of the composite weld to be wide, the grains to be coarse, the heat affected zone to be wide, and showing obvious arc weld characteristics; the lower half part of the welding seam is still formed by melting mainly by high-energy-density laser deep fusion welding, so that the lower half part of the welding seam is thin and narrow, the crystal grains are relatively fine, the heat affected zone is narrow, and the obvious laser deep fusion welding characteristic is shown. These non-uniformities in the form and microstructure increase the stress concentration of the laser-arc composite weld, which adversely affects its toughness, particularly fatigue strength.
For the existing laser-electric arc composite welding technology, when light alloys such as aluminum alloy, magnesium alloy, titanium alloy and the like are welded, weld joint air holes are easily formed due to instability of laser pinholes, and the problem greatly restricts the application and development of the technology in the industrial field, particularly the field of manufacturing light alloy structures. Generally, the inside of a keyhole formed by laser welding is in a dynamic vibration state, and the movement of a molten pool in the keyhole and the surrounding keyhole is very violent. For light alloys, low-melting-point and high-boiling-point elements such as magnesium, aluminum and zinc in the light alloys are easy to evaporate due to the high-temperature environment inside the laser small holes to increase the instability of the laser small holes, so that the laser small holes are closed to form bubbles and weld pores, and the mechanical properties of laser welds are greatly reduced. The existing laser-electric arc hybrid welding can improve the stability of a laser small hole to a certain extent through electric arc intervention and depending on laser-electric arc interaction, strengthen the flow of a molten pool and improve the escape capacity of bubbles, thereby reducing the air holes of a welding line. But do not
In the laser-arc hybrid welding, the characteristic of low energy density of the arc determines that the influence of the arc is difficult to penetrate into the lower part of a molten pool through the interaction of the laser and the arc, so that the flow of the lower part of the hybrid welding molten pool is still dominated by small laser holes, the laser welding characteristic is basically maintained, the forming tendency of air holes at the part is still large, and the characteristic is more remarkable when medium and thick plates are welded through the laser-arc hybrid welding. In summary, although the existing laser-arc hybrid welding technology has technical advantages obviously superior to the single laser and arc process, the problem of weld porosity of the light alloy is still greatly limited, thereby limiting the application space.
Patent document CN1559743A discloses a high power laser rotary scanning welding method. The robot drives the laser welding head to move and the laser beam to rotate, the weldment is driven by the other transmission shaft to do linear motion, and the two motions are combined to form laser scanning welding. In the laser swing welding research of the low-carbon steel material, the following results are found: the swinging and scanning action of the laser beam can reduce the temperature gradient of the molten pool, enhance the stirring effect on the flow of the molten pool, promote the non-spontaneous nucleation of the molten pool, change the preferred growth direction of columnar crystals, refine grains, reduce weld pores and finally improve the toughness of the joint. The laser beam scanning motion driven by a robot or other mechanical modes has the problems of high implementation difficulty, slow response time, low vibration frequency, poor stability, single laser beam scanning path and complex structure for implementing the process, so the research and application degree of the technology is very limited.
The laser galvanometer is the most effective laser oscillation scanning technology at present, and realizes the rapid positioning and position switching of laser beams by the deflection of optical lenses in a lens group, the positioning and switching time is almost zero, the oscillation frequency can reach 5000Hz, and the scanning path can be randomly planned by a computer program, so that the defects of the laser beam mechanical vibration technology can be overcome, and the technical advantages of laser scanning welding can be played. The laser galvanometer scanning welding can refine weld grains, reduce crack tendency and improve joint strength through oscillation scanning of laser beams, but because of the characteristics of narrow laser welding melting pool, high solidification speed and unstable laser pores, the process has relatively limited capacity of inhibiting pores, the weld pore tendency is still very large, and the welding requirements of light alloy structures such as aluminum alloy, magnesium alloy, titanium alloy and the like cannot be met.
Disclosure of Invention
The invention aims to provide a multi-station robot arc hybrid welding method, which can homogenize the macroscopic and microscopic structure of a welding seam, refine crystal grains and reduce the defects of the welding seam, thereby improving the toughness of the welding seam, and the welding capability is superior to that of the existing single process.
The invention provides a multi-station robot arc hybrid welding method, which comprises the following steps:
1, adjusting the spatial positions of the laser and the electric arc to enable the laser and the electric arc to be positioned in an effective composite range; wherein the adjusting range of the included angle between the laser beam and the arc welding gun is 20-50 degrees; the adjusting range of the laser-electric arc distance is 0.5mm-6 mm; the adjustment range of the defocusing amount of the laser beam is-4 mm-4 mm;
step 2, enabling the laser beam and the electric arc to act on the workpiece together to form a welding pool, starting to implement multi-station robot electric arc hybrid welding, forming a welding seam and finishing workpiece welding; wherein the laser power range is 500W-20000W; the arc current range is 30A-500A; the welding speed is in the range of 0.2m/min to 30 m/min.
The invention provides a multi-station robot arc hybrid welding system, which comprises a laser, a welding machine, a scanning galvanometer, a controller of the scanning galvanometer, a numerical control system, a movement mechanism and a hybrid welding processing head, wherein the laser is arranged on the welding machine;
the numerical control system is respectively in electrical signal connection with a laser, a welding machine, a scanning galvanometer, a controller of the scanning galvanometer and a movement mechanism, and the laser is in optical connection with the galvanometer focusing device through a transmission lens group or a transmission optical fiber; the movement mechanism is used for installing a composite welding head or a workpiece to realize the movement of the composite welding head or the workpiece; the galvanometer controller is connected with the galvanometer focusing device and is used for setting and controlling the scanning pattern, the amplitude and the oscillation frequency of the laser beam; the compound welding processing head is used for compounding a laser beam and an electric arc.
Over the last two decades, both laser-arc hybrid welding and laser scanning welding have rapidly developed and significantly advanced in their respective fields, but suffer from the disadvantages described above. The invention discovers that the following components are prepared by a series of experimental researches, theoretical analysis and engineering practices: although both of the above-mentioned processes have the technical capabilities of inhibiting the metallurgical defects of the weld joint and improving the mechanical properties of the weld joint and the weldability of the material, the action modes and physical mechanisms of the two processes are obviously different. The present invention therefore proposes to integrate these two processes. Therefore, the technical advantages of the two processes can be continuously kept, and the defects of a single process are overcome through a new physical effect and an action mechanism generated by the interaction of the two processes, so that the enhanced processing effect and welding capacity are formed. This is the core of the present invention. The invention discloses a multi-station robot electric arc hybrid welding method, which has the innovation points and the technical advantages that:
(1) the method combines the laser-arc hybrid welding process and the laser scanning welding process, can complement the advantages while continuously retaining the technical advantages of the two processes, generates a new composite effect to form a processing effect of 1+1 > 2, has more excellent technical capabilities in the aspects of homogenizing macroscopic forming of welding seams, refining crystal grains and inhibiting welding defects, and is a novel method for improving the welding characteristics and the welding quality of metal materials. Compared with the existing laser-electric arc hybrid welding and laser scanning welding technologies, the invention can improve the tensile strength of the joint by 10-50% and the fatigue performance by 20-50% according to the difference of material systems.
(2) Based on a galvanometer scanning method, the invention provides a technical means for regulating and controlling stirring effect and liquid metal flow in a laser-electric arc composite welding pool. The specific method comprises the following steps: controlling the stirring intensity of the laser beam in the welding molten pool by adjusting the oscillation frequency, the amplitude and the laser power of the laser beam; the flow direction of the liquid metal in the molten pool is regulated and controlled by planning the scanning path of the laser beam.
(3) The method can promote the molten drop transition (consumable electrode gas shielded welding) through the electric arc interaction of the multi-station robot and improve the process stability. By utilizing the characteristics of rapid positioning, scanning path and controllable frequency of the oscillating laser beam, the invention can control the laser beam to be close to the molten drop when the arc current is in a peak stage, and the molten drop is assisted to be separated from the welding wire by the heat radiation effect of the photoinduced plasma on the molten drop; the laser beam is far away from the position of a molten drop point at the moment that the molten drop is separated from the welding wire, and the deviation or the blocking effect of the photo-induced plasma and the recoil pressure on the molten drop transition is avoided or relieved, so that the molten drop transition is promoted, the welding spatter is reduced, and the stability of the composite welding process is improved. Compared with the existing laser-electric arc hybrid welding, the invention can improve the process stability and reduce the welding spatter by 20-80%.
(4) The multi-station robot arc interaction can homogenize the weld forming and grain refining, and solve the problem of grain coarsening of the upper half part of the weld in the existing laser-arc hybrid welding. The oscillating scanning behavior of the oscillating scanning laser beam in the width direction of the welding seam widens the lower part of the welding seam, enhances the convection of a molten pool through the stirring effect, introduces the arc heat accumulated on the upper part of the molten pool in the existing composite welding process into the lower part, further widens the lower part of the welding seam, and improves the uniformity of the heat distribution of the whole welding molten pool, thereby promoting the macroscopic size of the welding seam and the uniformity of solidification crystallization. On the other hand, the oscillation stirring effect of the oscillation scanning laser beam on the molten pool can increase nucleation cores in the molten pool, promote non-spontaneous nucleation of the molten pool, change the preferred growth direction of columnar crystals and further refine weld grains. Therefore, the invention can solve the problem of coarsening of the crystal grains of the upper half part of the welding line in the existing laser-arc hybrid welding process, refine the crystal grains while homogenizing the welding line formation and improve the comprehensive mechanical property of the welding line.
(5) The multi-station robot electric arc hybrid welding method is superior to the existing laser-electric arc hybrid welding and laser scanning welding technologies in the inhibition capability of weld defects, particularly air holes and cracks. The periodic regular scanning movement of the oscillating laser beam can enable the lower half part of the welding seam to be remelted, so that the solidification time of a molten pool in the area is prolonged, and bubbles can escape. On the other hand, the flow of the molten pool driven by the oscillating scanning laser beam can strengthen and regulate the flow of the molten pool, so that the bubble escape is facilitated, and the formation of crystal cracks is inhibited. Compared with the existing laser-electric arc hybrid welding and laser scanning welding technologies, the method has stronger weld seam blowhole inhibition capability and can eliminate the weld seam blowholes.
(6) The multi-station robot electric arc hybrid welding method is suitable for high-quality manufacturing of almost all metal material welding structures including steel, aluminum alloy, titanium alloy and titanium alloy, can greatly improve production efficiency and reduce manufacturing cost, and is an advanced manufacturing technology which is green, environment-friendly, efficient and clean.
Detailed Description
The invention provides a multi-station robot arc hybrid welding method suitable for metal materials based on experimental findings, theoretical research and engineering practice. The invention can generate new composite effect while keeping the technical advantages of laser-arc composite welding and laser scanning welding, thereby having enhanced processing effect and welding capability.
The electric arc hybrid welding method of the multi-station robot specifically comprises the following steps:
and 1, adjusting the spatial positions of the laser and the electric arc to enable the laser and the electric arc to be positioned in an effective recombination range. Wherein the adjusting range of the included angle 21 between the laser beam and the arc welding gun is 20-50 degrees, and the optimal range is 30-40 degrees; the adjusting range of the laser-arc distance 22 is 0.5-6mm, and the preferable range is 1-4 mm; the adjustment range of the defocusing amount of the laser beam is-4-4 mm, and the preferable range is-2-2 mm.
And step 2, the laser beam 3 and the electric arc 8 act on the workpiece 11 together according to the set parameters to form a welding pool, and the multi-station robot electric arc hybrid welding is started to form a welding seam and finish the material welding. At the moment, the laser beam and the electric arc move linearly or curvilinearly along the abutted seam in a large-scale space along with the composite welding machining head; meanwhile, the laser beam performs oscillatory scanning motion in a local micro range around the arc action point, the laser-arc interaction (including plasma synergistic effect and heat flow coupling effect in a welding molten pool) is enhanced through the oscillatory scanning action of the laser beam, the molten drop transition is promoted, the arc stability is improved, the molten pool convection is enhanced, the weld forming is homogenized, the crystal grains are refined, the metallurgical defects such as weld pores are inhibited, and the toughness of the weld is improved.
In this step, the laser power range is 500-; the arc current is in the range of 30-500A, and the preferred range is 150-320A; the range of the welding speed (the moving speed of the composite welding head driving the laser beam and the electric arc in a large-range space) is 0.2-30m/min, and the optimized range is 2-6 m/min. According to the coordinate system, the displacement range of the laser beam oscillation scanning is as follows: the X axis direction is-4-8 mm, the optimization range is-2-3 mm, the Y axis direction is-10-10 mm, and the optimization range is-5-5 mm; the Z axis direction is minus 5 to 5mm, and the optimized range is minus 2 to 2 mm. The oscillation frequency of the laser beam is 5-2000Hz, and the optimized range is 20-500 Hz.
Through the optimized displacement parameter of the laser beam oscillating and scanning around the arc action point in the local micro range, the laser beam can be controlled to be close to the molten drop when the arc current is in the peak stage, and the molten drop is assisted to be separated from the welding wire through the heat radiation effect of the photoinduced plasma on the molten drop; the laser beam is far away from the position of a molten drop point at the moment that the molten drop is separated from the welding wire, so that the stability of electric arc molten drop transition is improved. On the other hand, the stirring intensity of the laser beam in the welding molten pool can be regulated and controlled by regulating the oscillation frequency of the laser beam and the displacement amplitude, the flowing direction of liquid metal in the welding molten pool is regulated and controlled, the flowing of the liquid metal in the composite welding molten pool, particularly the liquid metal in the lower half part, is enhanced, the forming of the welding seam is homogenized and grains are refined, the problem of coarsening of the grains in the upper half part of the welding seam of the existing laser-electric arc composite welding process is solved, the pore defect of the welding seam is inhibited, and the.
The invention relates to a multi-station robot electric arc hybrid welding system, which comprises the following main devices: the device comprises a laser 13, a welding machine 18, a galvanometer controller 14, a numerical control system 15, a motion mechanism, a light guide system 17 or a transmission optical fiber 24 and a composite welding machining head 19.
Claims (7)
1. A multi-station robot arc hybrid welding method comprises the following steps:
1, adjusting the spatial positions of the laser and the electric arc to enable the laser and the electric arc to be positioned in an effective composite range; wherein the adjusting range of the included angle between the laser beam and the arc welding gun is 20-50 degrees; the adjusting range of the laser-electric arc distance is 0.5mm-6 mm; the adjustment range of the defocusing amount of the laser beam is-4 mm-4 mm; step 2, enabling the laser beam and the electric arc to act on the workpiece together to form a welding pool, starting to implement multi-station robot electric arc hybrid welding, forming a welding seam and finishing workpiece welding; wherein the laser power range is 500W-20000W; the arc current range is 30A-500A; the welding speed is in the range of 0.2m/min to 30 m/min.
2. The multi-station robot electric arc hybrid welding method according to claim 1, wherein an adjustment range of an included angle between the laser beam and the electric arc welding gun is 30 ° to 40 °.
3. The adjusting range of the laser-electric arc distance is 0.5mm-6mm, and the preferable range is 1 mm-4 mm; the adjustment range of the defocusing amount of the laser beam is-4 mm, and the preferable range is-2 mm.
4. The multi-station robot arc hybrid welding method according to claim 1, wherein in the step 2, the laser power ranges from 3000W to 10000W; the arc current range is 150A-320A; the welding speed is in the range of 2m/min to 6 m/min.
5. A multi-station robot arc hybrid welding method according to claim 1, 2 or 3, wherein a direction of a weld is taken as an X-axis direction, a transverse direction of the weld in a workpiece surface is taken as a Y-axis direction, a direction perpendicular to the workpiece surface is taken as a Z-axis direction, and a displacement range of laser beam oscillation scanning is: the X axis direction is-4 mm to 8 mm; y axis direction is minus 10mm to 10 mm; the Z axis direction is minus 5mm to 5mm, and the oscillation frequency of the laser beam is 2Hz to 2000 Hz.
6. A multi-station robot arc hybrid welding method according to claim 1, 2 or 3, wherein a direction of a weld is taken as an X-axis direction, a transverse direction of the weld in a workpiece surface is taken as a Y-axis direction, a direction perpendicular to the workpiece surface is taken as a Z-axis direction, and a displacement range of laser beam oscillation scanning is: the X axis direction is-2 mm-3 mm; the Y-axis direction is-5 mm; the Z-axis direction is-2 mm, and the oscillation frequency of the laser beam is 20 Hz-500 Hz.
7. A multi-station robot arc hybrid welding system comprises a laser, a welding machine, a galvanometer controller, a numerical control system, a movement mechanism and a hybrid welding head; the numerical control system is respectively in electrical signal connection with a laser, a welding machine, a galvanometer controller and a movement mechanism, and the laser is in optical connection with the galvanometer focusing device through a transmission lens group or a transmission optical fiber; the movement mechanism is used for installing a composite welding head or a workpiece to realize the movement of the composite welding head or the workpiece; the galvanometer controller is connected with the galvanometer focusing device and is used for setting and controlling the scanning pattern, the amplitude and the oscillation frequency of the laser beam; the compound welding processing head is used for compounding a laser beam and an electric arc.
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Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN103056533A (en) * | 2012-12-20 | 2013-04-24 | 华中科技大学 | Oscillatory scanning laser beam-electric arc hybrid welding method and system |
| CN203197472U (en) * | 2012-12-20 | 2013-09-18 | 华中科技大学 | Oscillatory scanning laser beam-electric arc hybrid welding system |
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Patent Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN103056533A (en) * | 2012-12-20 | 2013-04-24 | 华中科技大学 | Oscillatory scanning laser beam-electric arc hybrid welding method and system |
| CN203197472U (en) * | 2012-12-20 | 2013-09-18 | 华中科技大学 | Oscillatory scanning laser beam-electric arc hybrid welding system |
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Application publication date: 20200410 |