Integrated cold wire submerged arc welding device
Technical Field
The invention belongs to the technical field of welding equipment, and particularly relates to multi-wire submerged arc welding equipment.
Background
Submerged arc welding is one of the most widely used technological methods in welding production as the mechanized welding method that was the earliest to obtain the application. The welding penetration is large, the production efficiency is high, and the mechanization degree is high, so that the welding method is particularly suitable for welding long weld joints of medium plates. Submerged arc welding is a main welding production means in manufacturing of ship pressure vessels, chemical industry, bridges, engineering machinery, metallurgical machinery, marine structures, nuclear power equipment and the like.
The welding of medium plates with the thickness exceeding 90mm is more and more applied in actual production, and although the welding of the thick plates can be realized by the original single-wire submerged arc welding and the double-wire submerged arc welding, the multilayer multi-pass welding of the thick plates causes overlarge heat input quantity, so that the weld joint structure grains are coarse, and the mechanical property of the joint is reduced. With the development of technology, the requirements on production benefits are improved, and the submerged arc automatic welding has derived various forms, wherein compared with single-wire submerged arc welding, the multi-wire submerged arc welding and the strip submerged arc welding have the advantages of greatly improving the welding speed, improving the deposition efficiency, increasing the arc power and improving the welding quality. Compared with single-wire submerged arc welding, the welding method is characterized in that required energy is distributed to different welding wires during welding, so that one-step forming of a welding bead can be realized by using relatively smaller welding current and larger welding speed, in the actual welding process, the required shape and size of a welding seam can be obtained by adjusting the arrangement mode among the welding wires, the spacing between the welding wires, the inclination angle of the welding wires, the electric arc power and the like, and multiple wires complement each other, so that the welding production efficiency and the welding seam quality are obviously improved.
Integrated cold wire submerged arc welding (ICE) TM ) A cold wire is inserted between two parallel hot wires, and the redundant heat of the hot wires is utilized to melt the welding wire. During welding. The two hot wires are driven by a direct current motor to feed wires at the same speed, the cold wires are fed by an independent wire feeder, and the wire feeding speed of the cold wires can be independently controlled. The method can greatly improve the welding production efficiency, increase the welding speed, reduce the consumption of welding flux and realize high-efficiency high-quality low-cost welding. However, the core technology of the method is limited by foreign countries, the equipment cost is high, and in addition, the cold wire consumption part is caused when the thick plate is largeAnd the welding heat input is divided, so that a plurality of layers are still needed in the welding process, and the welding efficiency is reduced.
Disclosure of Invention
The invention aims to overcome the defects of the prior art, and provides novel submerged arc welding equipment, wherein a welding wire which is not connected with a main power supply is added behind two welding wires which are connected with the main power supply and is a cold wire, the two welding wires in front form an electric arc to preheat the welding wires in the rear, meanwhile, additional ultrasonic waves act on the cold wire, the cold wire vibrates at a high speed under the action of the ultrasonic waves, and enters a molten pool to stir the molten pool, so that grains are refined, the mechanical property of a welding seam is improved, and the ultrasonic auxiliary integrated cold wire function is realized. The welding gun can achieve minimum heat input under the same cladding efficiency, reduces the phase change deterioration of a welding seam structure caused by local overheating because of high heat input and high heating speed of submerged arc welding, is particularly important for submerged arc welding of high-current and quick welding, can obviously improve the mechanical property of a joint structure, reduce the deformation of the welding seam and improve the product quality.
In order to achieve the above purpose, the invention adopts the following technical scheme: an integrated cold wire submerged arc welding device comprises two arc starting welding wires and a cold wire, wherein the cold wire enters a molten pool formed by the arc starting welding wires under high-speed vibration.
As a preferred mode of the present invention, the cold wire is connected to an ultrasonic vibration device.
Further preferably, the ultrasonic vibration device comprises an ultrasonic generator, a transducer and a horn, and the horn is transversely connected with the cold wire.
Further preferably, the transducer is an eccentric motor.
As a preferred form of the invention, the two arc starting wires are arranged in the weld direction or in the perpendicular weld direction.
Further preferably, the cold wire is located behind the two arc starting wires.
Further preferably, the lower part of the wire feeding pipe of the cold wire is curved in an arc shape, and the tail end of the wire feeding pipe is close to the conductive nozzle of the arc starting welding wire.
Compared with the traditional submerged arc welding gun, the integrated cold wire submerged arc welding device has the following beneficial effects:
(1) The welding arc is double-wire single-arc, two welding wires are led out through the same conductive nozzle, and when the welding wire distance is smaller, because the two welding wires simultaneously flow through the same-direction current during welding, the two welding wires are attracted to each other under the action of a magnetic field generated by the two welding wires and the current, so that a molten pool is formed. The weld formation can be controlled significantly by changing the direction of the wire arrangement at this time. The welding wires can be placed in the transverse direction of the welding seam or in the axial direction of the welding seam, and when the welding wires are arranged along the welding direction, a narrow and deep welding seam with large penetration depth is formed; when the welding wires are arranged in the vertical welding direction, the position of the root of the welding seam is changed, and a welding seam with large melting width and small melting depth is formed; the greater the distance between the welding wires, the more significant the shape and fusion width penetration of the weld. When the welding wires are arranged at different angles along the welding direction according to the requirement, welding seams with different penetration depths and widths are formed. The two welding wires can be adjusted to be made of different materials for welding, and alloying of weld metal can be effectively adjusted.
(2) The cold wire stirs the molten pool through the high-frequency vibration of the ultrasonic vibration device, so that crystal grains are refined, the mechanical property of the welding line is improved, and the transverse shearing force generated by the ultrasonic vibration to the tail end of the cold wire reduces the electromagnetic contraction force and the electric arc expands outwards; and the transverse shearing force acts on the molten drops, so that the transition frequency of the molten drops is accelerated, and the molten drop transition is promoted, thereby changing the shape of the welding seam and enabling the welding seam to be smooth.
Drawings
FIG. 1 is a schematic perspective view of an integrated cold wire submerged arc welding device under ultrasonic assistance provided by an embodiment of the invention;
FIG. 2 is a front view of an integrated cold wire submerged arc welding apparatus with ultrasonic assistance provided by an embodiment of the present invention;
FIG. 3 is a cross-sectional view taken along line A-A of FIG. 2;
FIG. 4 is a schematic view of the structure of an ultrasonic vibration device;
fig. 5 is a schematic view of an ultrasonic vibration device housing: a main housing, b auxiliary housing;
in the figure, 1. A double-wire conductive nozzle; 2. a compression nut; 3. a guidewire hose mount; 4. the lower section of the gun body; 5. the upper section of the gun body; 6. a hose holder base; 7. a wire feeding hose; 8. a motor; 9. an ultrasonic generator; 10. an eccentric wheel; 11. a fixed housing; 12. a horn; 13. a ceramic wire feeding pipe; 14. a clamping block; 15. and a fixed block.
Detailed Description
In order that the invention may be readily understood, a more particular description thereof will be rendered by reference to specific embodiments that are illustrated in the appended drawings. Preferred embodiments of the present invention are shown in the drawings. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete.
As introduced in the background art, in order to improve cladding efficiency and reduce heat input, the invention adds an ultrasonic vibration device for cold wire and optimizing weld formation on the basis of double-wire submerged arc welding. After the arc striking of the two hot wire welding wires, the two hot wire welding wires are mutually attracted under the action of a magnetic field generated by the two hot wire welding wires to form a molten pool, the cold wire is vibrated at high frequency under the action of ultrasound to stir the molten pool, crystal grains are refined, the mechanical property of a welding line is improved, and the transverse shearing force generated by the tail end of the ultrasonic vibration welding wire leads the electromagnetic shrinkage force to be reduced, and the electric arc is expanded outwards; and the transverse shearing force acts on the molten drops, so that the transition frequency of the molten drops is accelerated, and the molten drop transition is promoted, thereby changing the shape of the welding seam and enabling the welding seam to be smooth.
One of the embodiments provided by the invention is: an integrated cold wire submerged arc welding device has an external structure shown in figure 1 and mainly comprises a gun body, an ultrasonic vibration device and a cold wire device. The ultrasonic vibration device is connected with the gun body through a matching hole at one side of the fixed shell and is screwed and fixed through a screw on the side wall of the shell; the cold wire device is fixed on the side surface of the gun body through a clamping block 14.
Referring to fig. 1 and 3, the gun body of the welding device comprises two parts, namely a gun body upper section 5 and a gun body lower section 4, which are connected together by adopting threads. The lowest part of the lower section 4 of the gun body is provided with a double-wire conductive nozzle 1, the double-wire conductive nozzle is fixed on the lower section 4 of the gun body through a compression nut 2, and the compression nut 2 is screwed and fixed with external threads of the lower section 4 of the gun body.
Three guide wire hose fixing pieces 3 are arranged in the gun body and are respectively fixed in a groove of the lower section 4 of the gun body, a groove below the upper section 5 of the gun body and a hose fixing base 6 connected with the upper section 5 of the gun body. The hose holder base 6 is screwed with the upper section 5 of the gun body. The three guide wire hose fixing pieces 3 are the same in size, and two threaded holes penetrating through the three guide wire hose fixing pieces are in threaded fit with the two guide wire hose 7. Two welding wires parallel to each other are respectively arranged in the two wire feeding hoses 7 and are connected with a direct current power supply for arcing. By rotating the hose holder base 6, the three wire-guide hose holders 3 can be driven to rotate, thereby changing the positional relationship between the two wire-feeding hoses and the welding direction, and arranging the two arc-striking wires along the welding direction or perpendicular to the welding direction.
The ultrasonic vibration device mainly comprises a shell 11, an ultrasonic generator 9, a motor 8 and an amplitude transformer 12. As shown in fig. 5 (a), (b), the housing 11 includes a main casing and an auxiliary casing. The matching hole on one side of the main shell is assembled with the upper section 5 of the gun body, and then is fixed by three screws with equal distance from top to bottom. Grooves with different apertures are arranged in the other side and are respectively matched with the ultrasonic generator 9, the motor 8 and the amplitude transformer 12, and then the auxiliary shell is buckled with the main shell to completely fix the structure.
The ultrasonic generator 9 is connected with direct current and converts commercial power into high-frequency alternating current signals matched with the ultrasonic transducer. The transducer uses a motor 8 with an eccentric to convert electrical energy into mechanical energy having one or more vibration frequencies. The eccentric 10 is used to amplify the vibrations generated by the motor 8 and transmit them to the horn 12. The horn 12 is used to amplify the mass displacement or velocity of the mechanical vibrations and concentrate the ultrasonic energy to a smaller area, which is transferred to the cold wire apparatus by a fixed block 15 connected transversely to the lower end of the horn 12.
The wire cooling device mainly comprises a ceramic wire feeding pipe 13 and a corresponding wire feeding mechanism. The outer part of the ceramic wire feeding pipe 13 is subjected to surface treatment for increasing roughness, so that the ceramic wire feeding pipe is convenient to clamp and fix. The ceramic wire feeding pipe 13 is internally provided with a cold wire which is not connected with a power supply. As shown in fig. 1, the lower section of the ceramic wire feeding tube 13 is bent, the tail end of the ceramic wire feeding tube is close to the double-wire conductive nozzle 1, and the upper end of the ceramic wire feeding tube is fixed on the upper section 5 of the gun body through a matching hole by a clamping block 14; the lower end is inserted into a fixing block 15 transversely connected with the tail end of the amplitude transformer 12, and is tightly supported and fixed by a jackscrew.
The magnetic field-assisted integrated hot wire submerged arc welding device of the embodiment comprises two arc-starting welding wires and a cold wire, wherein the two arc-starting welding wires share the same power supply, the cold wire is not connected with the power supply, and is positioned behind the two arc-starting welding wires. During welding, three welding wires can be arranged front and back in a mode parallel to a welding bead to realize welding, and a wire feeding hose of two arcing welding wires can be integrally rotated by 90 degrees, so that the two welding wires are arranged along a direction perpendicular to the welding bead, and a cold wire is positioned in a position behind the middle of the two welding wires to perform welding. When all welding wires are in parallel welding paths, a welding line with large penetration depth and narrow and deep is formed; when the arc starting welding wires are transversely arranged along the direction perpendicular to the welding direction, the position of the root of the welding seam is changed, and a welding seam with large melting width and small melting depth is formed; the greater the distance between the arc starting wires, the more significant the shape and penetration of the weld. The two arc starting welding wires can be adjusted to be made of different materials for welding, and alloying of weld metal can be effectively adjusted.
After the two arc starting welding wires are started, the two arc starting welding wires are mutually attracted under the action of a magnetic field generated by the two arc starting welding wires to form a molten pool, the cold wires enter the molten pool and stir the molten pool under the action of ultrasonic energy which is generated by an ultrasonic generator and a transducer and is intensively amplified by an amplitude transformer, grains can be refined, the mechanical property of a welding line is improved, and the transverse shearing force generated by the tail end of the welding wires by ultrasonic vibration reduces electromagnetic contraction force and expands the electric arc; and the transverse shearing force acts on the molten drops, so that the transition frequency of the molten drops is accelerated, and the molten drop transition is promoted, thereby changing the shape of the welding seam and enabling the welding seam to be smooth.
In the welding process, the integrated cold wire submerged arc welding device of the embodiment not only can reduce welding heat input, reduce plate deformation, increase cladding efficiency and reduce burning loss of alloy elements, but also enables cold wires to vibrate and stir a molten pool at high frequency under the auxiliary effect of ultrasound, refines grains, reduces internal stress of a welding line, promotes molten drop transition, and integrally optimizes welding line forming. The welding efficiency, the welding quality and the aesthetic degree are obviously improved.