CN111822823B - Ultra-thick plate narrow gap welding process method - Google Patents
Ultra-thick plate narrow gap welding process method Download PDFInfo
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- CN111822823B CN111822823B CN202010626898.9A CN202010626898A CN111822823B CN 111822823 B CN111822823 B CN 111822823B CN 202010626898 A CN202010626898 A CN 202010626898A CN 111822823 B CN111822823 B CN 111822823B
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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
- B23K9/00—Arc welding or cutting
- B23K9/16—Arc welding or cutting making use of shielding gas
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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
- B23K9/00—Arc welding or cutting
- B23K9/24—Features related to electrodes
- B23K9/28—Supporting devices for electrodes
- B23K9/285—Cooled electrode holders
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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
- B23K9/00—Arc welding or cutting
- B23K9/32—Accessories
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Abstract
A narrow gap welding process for super-thick plate includes such steps as cutting the end face of 100-500mm thick plate to be welded into a straight 90 deg. cut surface, making two opposite bevel faces of thick plate to be welded to form an I-shaped groove, overlaying welding by CO2 gas shielded welding at the center of both sides of bevel face, grinding the weld meat, and forming a convex welding strip with a triangular cross section on the central line of bevel face. The butt joint groove gap of the thickness plates is 10-18mm, and a special welding gun for thick plate I-shaped groove narrow gap welding is adopted for welding. When welding, the thick plate is preheated to 150-.
Description
Technical Field
The invention relates to the technical field of welding, in particular to the technical field of narrow-gap welding of an ultra-thick plate.
Background
At present, with the rapid development of bridge, pressure vessel, shipbuilding and mine equipment manufacturing and the continuous large-scale construction equipment, the requirement on the thickness of the plate is increasingly thick. Higher requirements are put on the welding quality, the welding efficiency, the welding cost and the welding operability of the thick plate. The conventional CO2 gas shielded welding has the advantages of flexible operation, stable welding quality, high welding efficiency and the like, and is generally applied to various fields. In the CO2 gas shielded welding, a V-shaped groove and an X-shaped groove are usually adopted to meet the welding technical requirements of thick plates, the groove form can be used for welding plates with the thickness of less than 50mm, but when welding an ultra-thick plate, the waste of welding materials is increased, and the welding efficiency is extremely low.
Therefore, the welding process method can effectively reduce the problems of groove processing difficulty, high welding material consumption and the like, greatly improve the welding production efficiency and reduce the construction cost.
Disclosure of Invention
In order to solve the problems in the existing production construction, the invention provides a narrow gap welding process method for an ultra-thick plate, aiming at improving the welding quality and the welding efficiency of the thick plate and the ultra-thick plate and reducing the production cost.
The invention relates to a narrow gap welding process method of an ultra-thick plate, which is characterized by comprising the following steps:
(1) firstly, cutting a 90-degree straight section on the end face of a thick plate with the thickness of 100 plus 500mm to be relatively welded to enable two bevel faces of the thick plate to be relatively welded to form an I-shaped groove, performing surfacing welding on the central position of two sides of one bevel face by using CO2 gas shielded welding in advance, surfacing welding meat with the height of 4-8mm, preheating the thick plate with the thickness of 150 plus 250 degrees before surfacing welding, processing the welding meat, forming a convex welding strip with the cross section approximate to a triangle on the central line of the bevel face, and forming a double-U-shaped groove by enabling the two bevel faces of the thick plate to be relatively welded to be relatively opposite;
(2) two bevel faces of thick plates needing to be welded oppositely form a double-U-shaped groove, the groove where the thick plates are butted is assembled by adopting a tool, the gap of the groove is ensured to be between 10 and 18mm, and the gap of a convex welding strip is controlled to be between 0 and 4 mm.
(3) When in welding, a welding gun special for thick plate I-shaped groove narrow gap welding is adopted for welding, the whole body of the welding gun except for the conduction connection of the middle connecting rod and the gun body is in an oblate or rectangular shape, the appearance of the protective sleeve is similar to that of the oblate or rectangular shape of the middle connecting rod, the protective sleeve is fixedly and hermetically connected with the middle connecting rod, the connecting position is above the CO2 air outlet of the middle connecting rod, a ventilation duct or a ventilation gap is arranged between the protective sleeve and the conductive nozzle, between the protective sleeve and the CO2 air outlet of the middle connecting rod and below the protective sleeve, and the narrowest gap between the protective sleeve and the terminal of the conductive nozzle is not more than 2 mm; a welding-resistant high-temperature insulating material layer is arranged outside the protective sleeve or the protective sleeve is made of a welding-resistant high-temperature insulating material;
(4) when welding, the thick plate is preheated by adopting heating modes such as electric heating, flame and the like to heat to 150-fold the materials to 250 ℃, two welding guns are adopted to symmetrically weld from two sides of the center of the double-U-shaped groove during welding, the first layer of backing welding and the welding of other layers of channels are carried out, the welding bead and two sides of the welding bead are immediately insulated after the welding is finished, and the temperature is kept between 200 ℃ and 300 ℃ for 2 hours.
(5) The temperature between the welding layers is always kept within the range of 150 ℃ and 250 ℃; performing first-layer backing welding, wherein when two welding guns are adopted for symmetrical welding, the distance between two electric arcs of the two welding guns is 10mm, so that mutual interference of the electric arcs is prevented, and welding defects can be avoided; other layers can be welded synchronously, so that the interlayer temperature can be fully ensured; when welding is performed, if the welding is stopped midway, mineral wool is immediately used for covering and heat preservation and slow cooling. And re-preheating is needed when re-welding is carried out, preheating is needed immediately if the interlayer temperature is lower than 150 ℃ during welding, and welding is stopped when the interlayer temperature is higher than 250 ℃ and is reduced to below 250 ℃.
The invention has the beneficial effects that:
the welding quality is improved: by using the process and the special welding gun for the narrow gap welding of the I-shaped groove of the thick plate, the filling amount of welding materials can be effectively reduced; the defects of welding slag inclusion, air holes and the like generated when multiple welding is adopted are reduced; preheating before welding is adopted, double symmetrical welding is carried out during welding to ensure interlayer temperature, postheating and other processes are carried out after welding, so that the generation of welding cracks is effectively prevented; the double symmetric welding can effectively prevent the generation of welding deformation.
The production efficiency is improved, and the construction cost is reduced:
because the groove of the thick plate adopts an I shape, the cutting is only carried out once, so that the number of times and time for grooving are reduced; because the welding meat with the thickness of 4-8mm is surfacing-welded in the middle of the I-shaped bevel face, the purchase width of the thick plate can be reduced; the double symmetrical welding is adopted during welding, so that procedures such as back buckle polishing and the like are not needed; because narrow gap welding is adopted during welding, the filling amount of welding materials is reduced, the welding efficiency is improved, and a large amount of labor hour and other production data are saved. The invention can obviously improve the production efficiency and reduce the construction cost; during welding, double symmetrical welding is adopted, and the flat nozzle can be conveyed to the root of the groove, so that a molten pool is better protected, and pores are prevented from being generated.
The protective sleeve is oblate or rectangular, a wide surface with larger width is formed, a circular arc surface or a narrow surface with smaller width is formed, and the distance between the outer surfaces of the two wide surfaces is the thickness. The lower end of the wide surface of the protective sleeve is provided with a semicircular, rectangular or elliptical opening. Because the wide face of protective sheath lower extreme adopts two openings, has reduced the welding and has splashed the phenomenon emergence that the bonding contact tip and protective sheath lower extreme, effectively avoided and significantly reduced lead to with the short circuit of groove wall and produce the copper infiltration.
Drawings
FIG. 1 is a schematic diagram of a standard CO2 gun body insulating sleeve and protective sleeve connection;
FIG. 2 is a schematic diagram of a standard CO2 gun body insulating sleeve, intermediate connecting rod and contact tip connection;
FIG. 3 is a schematic view of a standard CO2 gun body intermediate connecting rod and contact tip connection;
FIG. 4 is a schematic view of the connection of the components on the front (broad) side of the welding gun according to the present invention;
FIG. 5 is a schematic view showing the connection of the components on the side (narrow or arc) of the welding gun according to the present invention;
FIG. 6 is a schematic view of the operation of the special welding gun of the present invention;
FIG. 7 is a schematic cross-sectional view of a raised weld bead of approximately triangular cross-section formed by bead welding at the centerline of the bevel face of a thick plate according to the present invention;
FIG. 8 is a schematic view of a double U-shaped bevel according to the present invention;
FIG. 9 is a schematic view of a tooling plate specifically adapted to assemble a T-shape in accordance with the present invention;
FIG. 10 is an illustration of the plank assembly and tooling of the present invention;
FIG. 11 is a schematic view of the two-sided weld joint of the present invention;
FIG. 12 is a schematic view of the opening at the lower end of the front (broad) face of the shield of the weld gun of the present invention;
wherein: 1-insulating sleeve, 2 a-protective sleeve, 3 a-intermediate connecting rod, 4-conductive nozzle and 5-gun body.
Detailed Description
The invention relates to a narrow gap welding process method for an ultra-thick plate.
1. Firstly, processing a groove on a thick plate by adopting cutting modes such as flame, machinery and the like, cutting the thick plate into an I-shaped groove surface, checking whether the groove surface has a groove mark, repairing the groove surface when the groove mark of more than 1mm appears on the groove surface, and polishing the groove surface; carrying out surfacing welding on the central positions of the two sides of the bevel face by using CO2 gas shielded welding, preheating a thick plate at 250 ℃ by 150-8 mm before surfacing welding, carrying out surfacing welding on weld meat with the thickness of 4-8mm, grinding the weld meat and the like to form a convex welding strip with the cross section approximate to a triangle, and forming a bevel face of the double-U-shaped non-truncated edge groove (figure 7); and (4) polishing the bevel face after processing, carrying out PT detection on the bevel face, and assembling after determining no defect.
2. Two bevel faces of the thick plates which are oppositely welded are opposite to form a double-U-shaped groove (figure 8), the groove where the thick plates are butted is assembled by adopting a special tool, the tool adopts a T-shaped tool plate (figure 9), the gap of the groove is required to be ensured to be between 10 and 18mm in the assembly, and the gap of the convex welding strip is controlled to be between 0 and 4 mm; spot welding is carried out on the outer plane side of the tooling plate, a group of symmetrical T-shaped tooling plates are arranged at intervals of 500mm, and the front side and the back side of the thick plate to be butt-welded are fixed simultaneously (figure 10).
3. As shown in fig. 1 and 2, in a standard welding gun, the insulating sleeve 1 mainly plays two roles: the first is connecting and fixing the protective sleeve; and secondly, an insulating environment is provided for the protective sleeve. The gun body 5 is connected with the middle connecting rod through a thread pair, so that the gun body is in conductive connection with the middle connecting rod, and the upper end of the conductive nozzle is in conductive connection with the lower end of the middle connecting rod. Meanwhile, the gun body fixes the protective sleeve through the insulating sleeve 1. As shown in figures 4 and 5, the insulating sleeve 1 in the standard welding gun is removed in the invention, the protective sleeve 2a is directly connected and fixed on the intermediate connecting rod 3a, and the original insulating function is realized by the insulating property of the protective sleeve 2 a. The outer part of the protective sleeve 2a is coated, sprayed and coated with a welding-resistant high-temperature insulating material layer, or the protective sleeve 2a is made of a welding-resistant high-temperature insulating material, so that the insulating property between a welding gun and a welding part is realized. The whole appearance of protective sheath 2a is the same with middle connecting rod shape, and inboard thickness dimension is greater than middle connecting rod outside thickness 3mm, and the width is at 8~10mm, can realize welding operation in the I type groove in 12~15mm clearance. The inner side of the upper end of the protective sleeve is provided with a circle of bulges with the height of 1.5mm, the processing error size is the error size which forms static fit with the outside of the middle connecting rod, and the processing error size is sleeved outside the middle connecting rod and is positioned outside the middle connecting rod above the CO2 air outlet and forms fixed sealing connection with the middle connecting rod.
As shown in fig. 1, 2, 4 and 5, in the welding gun, the middle connecting rod 3 is directly connected with the gun body 5, the CO2 air outlet is positioned in the middle of the middle connecting rod, and the upper end of the contact tube is in conduction connection with the lower end of the middle connecting rod. As shown in fig. 4 and 5, the intermediate connecting rod 3 in the standard welding gun is replaced by a novel intermediate connecting rod 3a, the upper end of the novel intermediate connecting rod 3a is provided with an external thread, the external thread is connected with the internal thread of the gun body 5, the intermediate connecting rod 3a is integrally made into an oblate or rectangular shape below the external thread when all functions of the intermediate connecting rod 3 are completed, so that the thickness of the intermediate connecting rod is reduced, and the occupied space of the intermediate connecting rod in the width of an I-shaped groove is reduced.
Adopt the special welder who sets up semicircular or rectangle or oval-shaped opening (fig. 12) at protective sheath wide face lower extreme to weld during the welding, because welder's contact tube and protective sheath can send the root of groove to better protection the molten bath, avoid producing the appearance of gas pocket, reduced the welding and splashed the phenomenon emergence of gluing contact tube and protective sheath lower extreme, prevented to lead to with the short circuit of groove wall and production copper infiltration.
4. When welding, the thick plate is preheated by adopting electric heating, flame heating and the like to heat to 150-; other layers can be welded synchronously, so that the interlayer temperature can be fully ensured; when welding is performed, if the welding is stopped midway, mineral wool is immediately used for covering and heat preservation and slow cooling. And re-preheating is needed when re-welding is carried out, preheating is needed immediately if the interlayer temperature is lower than 150 ℃ during welding, and welding is stopped when the interlayer temperature is higher than 250 ℃ and is reduced to below 250 ℃. Immediately carrying out the postheating process of keeping the temperature at 200-300 ℃ for 2 hours after the welding is finished. The tooling plate is a T-shaped plate, the interval is 500mm, the welding gun operates in the space between the tooling plate and the surfacing welding, the welding operation of bottoming can be completed by connecting the front and rear welding beads through welding on the two sides of the tooling plate, and when the strength of the part to be welded is met, the continuous welding operation of the tooling plate can be removed.
The process area is different from the traditional narrow-gap welding process of the ultra-thick plate in that the process can reduce the difficulty of grooving, improve the material utilization rate of the ultra-thick plate, avoid air planing smoke dust and noise, reduce the polishing amount, reduce the consumption of welding materials, save the cost and obviously improve the efficiency.
Claims (7)
1. A narrow gap welding process method for ultra-thick plates is characterized in that:
(1) firstly, cutting a 90-degree straight section on the end face of a thick plate with the thickness of 100 plus 500mm to be relatively welded to enable two bevel faces of the thick plate to be relatively welded to form an I-shaped groove, performing surfacing welding by using CO2 gas shielded welding at the central positions of two sides of the bevel faces in advance, surfacing welding fillet with the height of 4-8mm, preheating the thick plate with the thickness of 150 plus 250 degrees before surfacing welding, and polishing the fillet, wherein a raised welding strip with the cross section approximate to a triangle is formed on the central line of the bevel face, so that the two bevel faces of the thick plate to be relatively welded are relatively opposite to form an approximate double-U-shaped groove;
(2) two bevel faces of thick plates needing to be welded oppositely form an approximate double-U-shaped groove, the groove where the thick plates are butted is assembled by adopting a tool, the gap of the groove is ensured to be between 10 and 18mm, and the gap between the raised surfacing welding is controlled to be between 0 and 4 mm;
(3) when in welding, a welding gun special for thick plate I-shaped groove narrow gap welding is adopted for welding, the whole body of a welding gun middle connecting rod (3a) except for the conduction connection with a gun body (5) is in an oblate or rectangular shape, the appearance of a protective sleeve (2a) is similar to that of the oblate or rectangular shape of the middle connecting rod, the protective sleeve is fixedly and hermetically connected with the middle connecting rod, the connecting position is above a CO2 air outlet of the middle connecting rod, a ventilation duct or a ventilation gap is arranged among the protective sleeve, a conductive nozzle (4), a CO2 air outlet of the middle connecting rod and the lower part, and the narrowest gap between the protective sleeve and the terminal gap of the conductive nozzle is not more than 2 mm; a welding-resistant high-temperature insulating material layer is arranged outside the protective sleeve or the protective sleeve is made of a welding-resistant high-temperature insulating material;
(4) when welding, the thick plate is preheated, the thick plate is heated to 150-fold sand-adding 250 ℃ by adopting an electric heating and flame heating mode, two welding guns are adopted to symmetrically weld from two sides of the center of the approximate double-U-shaped groove during welding, the first layer of backing welding and the welding of other layers of channels are carried out, the welding bead and two sides of the welding bead are immediately insulated after the welding is finished, and the insulation is carried out for 2 hours at the temperature of 200-300 ℃.
2. The ultra-thick plate narrow gap welding process method according to claim 1, characterized in that: the temperature between the welding layers is always kept within the range of 150 ℃ and 250 ℃; performing first-layer backing welding, wherein when two welding guns are adopted for symmetrical welding, the distance between two electric arcs of the two welding guns is 10mm, so that mutual interference of the electric arcs is prevented, and welding defects can be avoided; other layers can be welded synchronously, so that the interlayer temperature can be fully ensured; when welding is carried out, if the welding is stopped midway, mineral wool is immediately used for covering for heat preservation and slow cooling, preheating is needed again when welding is carried out again, if the interlayer temperature is lower than 150 ℃ when welding is carried out, preheating is needed immediately, and if the interlayer temperature is higher than 250 ℃, the welding is stopped, and the welding is carried out after the interlayer temperature is reduced to below 250 ℃.
3. The ultra-thick plate narrow gap welding process method according to claim 1 or 2, characterized in that: during assembly, the tooling adopts a T-shaped tooling plate to assemble, spot welding is carried out on the outer plane side of the tooling plate, a group of symmetrical T-shaped tooling plates are arranged every 500mm, and the front side and the back side of a thick plate are fixed simultaneously.
4. The ultra-thick plate narrow gap welding process method according to claim 1, characterized in that: the protective sleeve is oblate or rectangular, the surface with larger width is a wide surface, the surface with circular arc or smaller width is a narrow surface, the distance between the outer surfaces of the two wide surfaces is the thickness, and the lower end of the wide surface of the protective sleeve is provided with a semicircular, rectangular or elliptical opening.
5. The ultra-thick plate narrow gap welding process method according to claim 1, characterized in that: checking whether the I-shaped bevel face has groove marks, performing weld repair when the groove marks exceed 1mm, and polishing the bevel face; during welding assembly, oil, water and dirt in the welding groove and the range of 20mm on two sides of the groove are polished completely.
6. The ultra-thick plate narrow gap welding process method according to claim 1, characterized in that: when the first layer of welding bead of the symmetrical welding is welded, the distance of 10mm between the two electric arcs is ensured, the mutual interference between the electric arcs is prevented, and the welding defect can be avoided; other layer welding seams can be synchronously welded, so that the interlayer temperature can be fully ensured.
7. The ultra-thick plate narrow gap welding process method according to claim 1, characterized in that: carbon dioxide gas shielded welding or consumable electrode gas shielded welding can be adopted, a solid core or flux-cored wire is adopted, the diameter of the wire is 0.8-1.2mm, and pure carbon dioxide or mixed gas is adopted as shielding gas for welding.
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Citations (5)
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CN101293303A (en) * | 2008-06-13 | 2008-10-29 | 中国船舶重工集团公司第七二五研究所 | TIG automatic welding technique for titanium alloy thick plate narrow interstice |
JP2010284691A (en) * | 2009-06-12 | 2010-12-24 | Aichi Sangyo Kk | Narrow gap welding method of thick steel plate and thick steel tube |
CN103317218A (en) * | 2012-11-01 | 2013-09-25 | 上海振华重工(集团)股份有限公司 | Double-sided dual-narrow-gap non-back-gouging welding method for large thick plates |
CN104209625A (en) * | 2014-09-16 | 2014-12-17 | 武汉一冶钢结构有限责任公司 | Q460 steel thick plate welding process |
CN105057856A (en) * | 2015-06-12 | 2015-11-18 | 招商局重工(江苏)有限公司 | Extra-thick sheet submerged-arc welding technique |
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2020
- 2020-07-02 CN CN202010626898.9A patent/CN111822823B/en active Active
Patent Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN101293303A (en) * | 2008-06-13 | 2008-10-29 | 中国船舶重工集团公司第七二五研究所 | TIG automatic welding technique for titanium alloy thick plate narrow interstice |
JP2010284691A (en) * | 2009-06-12 | 2010-12-24 | Aichi Sangyo Kk | Narrow gap welding method of thick steel plate and thick steel tube |
CN103317218A (en) * | 2012-11-01 | 2013-09-25 | 上海振华重工(集团)股份有限公司 | Double-sided dual-narrow-gap non-back-gouging welding method for large thick plates |
CN104209625A (en) * | 2014-09-16 | 2014-12-17 | 武汉一冶钢结构有限责任公司 | Q460 steel thick plate welding process |
CN105057856A (en) * | 2015-06-12 | 2015-11-18 | 招商局重工(江苏)有限公司 | Extra-thick sheet submerged-arc welding technique |
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