CN112958888B - Full-section fusion welding method for aluminum bus - Google Patents
Full-section fusion welding method for aluminum bus Download PDFInfo
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- CN112958888B CN112958888B CN202110332665.2A CN202110332665A CN112958888B CN 112958888 B CN112958888 B CN 112958888B CN 202110332665 A CN202110332665 A CN 202110332665A CN 112958888 B CN112958888 B CN 112958888B
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- 238000003466 welding Methods 0.000 title claims abstract description 150
- 229910052782 aluminium Inorganic materials 0.000 title claims abstract description 74
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 title claims abstract description 73
- 238000000034 method Methods 0.000 title claims abstract description 37
- 230000004927 fusion Effects 0.000 title claims abstract description 21
- 238000004140 cleaning Methods 0.000 claims description 5
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 3
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 claims description 3
- 238000001816 cooling Methods 0.000 claims description 3
- 238000000227 grinding Methods 0.000 claims description 3
- 239000004570 mortar (masonry) Substances 0.000 claims description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 3
- 238000005520 cutting process Methods 0.000 claims description 2
- 230000000977 initiatory effect Effects 0.000 claims description 2
- 238000009966 trimming Methods 0.000 claims description 2
- 238000010791 quenching Methods 0.000 claims 1
- 230000000171 quenching effect Effects 0.000 claims 1
- 238000004227 thermal cracking Methods 0.000 claims 1
- 230000008901 benefit Effects 0.000 abstract description 8
- 239000000463 material Substances 0.000 abstract description 7
- 238000010276 construction Methods 0.000 abstract description 3
- 239000002893 slag Substances 0.000 abstract description 2
- 239000007788 liquid Substances 0.000 abstract 1
- 238000004519 manufacturing process Methods 0.000 abstract 1
- 238000001514 detection method Methods 0.000 description 6
- 238000012360 testing method Methods 0.000 description 5
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 4
- 239000011324 bead Substances 0.000 description 3
- 230000009286 beneficial effect Effects 0.000 description 3
- 238000005266 casting Methods 0.000 description 3
- 238000005516 engineering process Methods 0.000 description 3
- 229910052751 metal Inorganic materials 0.000 description 3
- 239000002184 metal Substances 0.000 description 3
- 229910052786 argon Inorganic materials 0.000 description 2
- 239000010949 copper Substances 0.000 description 2
- 238000011161 development Methods 0.000 description 2
- 239000002360 explosive Substances 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- 239000002994 raw material Substances 0.000 description 2
- 239000010936 titanium Substances 0.000 description 2
- VRAIHTAYLFXSJJ-UHFFFAOYSA-N alumane Chemical compound [AlH3].[AlH3] VRAIHTAYLFXSJJ-UHFFFAOYSA-N 0.000 description 1
- 239000010953 base metal Substances 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000010891 electric arc Methods 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 238000009863 impact test Methods 0.000 description 1
- 238000005498 polishing Methods 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 238000010301 surface-oxidation reaction Methods 0.000 description 1
- 238000009864 tensile test Methods 0.000 description 1
Images
Classifications
-
- 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
- B23K9/235—Preliminary treatment
-
- 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
- B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
- B23K37/003—Cooling means
-
- 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
-
- 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
Abstract
The invention discloses a full-section fusion welding method for an aluminum bus, and aims to solve the technical problem that the full-section fusion welding of the aluminum bus is difficult to realize in the prior art. Based on the material characteristics of the aluminum bus, the invention utilizes resistance heat generated by current passing through conductive liquid slag as a heat source by matching proper welding process parameters and developing a special regulator to continuously melt an aluminum welding wire and the aluminum bus for fusion welding. The method has the advantages of high welding efficiency and low welding cost, has the comprehensive advantages of excellent welding seam conductivity, large effective welding area, convenient operation, stable welding seam quality, no influence of a magnetic field and the like, is applied to the welding of the aluminum bus of an electrolytic aluminum enterprise, and can obviously improve the welding efficiency, reduce the construction cost, reduce the black voltage in production and operation and improve the economic benefit of the enterprise.
Description
Technical Field
The invention relates to the technical field of welding, in particular to an aluminum bus full-section fusion welding method.
Background
Currently, the traditional welding mode of the aluminum bus is 'staggered plate' welding; aluminum plates with the thickness of about 10mm are stacked and welded layer by layer in a staggered mode; because the effective welding area of the welding seam is limited, the quality of the welding seam is not easy to control, only 80 percent of weldment is qualified generally, and the time and the labor are wasted. In recent years, the application of the "explosive welding" welding technology to the welding of the aluminum bus bars appears, but the welding cost is too high, the quality of welding seams is unstable, and the "explosive welding" welding technology has not been widely applied to the welding of the aluminum bus bars.
Patent document CN1788885A discloses a method for welding aluminum materials by casting a high-temperature molten base metal in a weld bead, which requires preheating the weld bead position first, and has very strict requirements for the preheating temperature and the temperature of the high-temperature molten metal during casting, otherwise the weld bead is easily cracked.
Patent document CN102126072A discloses a welding method using semi-automatic consumable electrode MIG double-pulse argon arc welding, which needs to provide a welding pool crystallizing tank with a heater, and also needs to preheat the weld seam before welding, and the welding process needs to be strictly performed according to the operation program, and has higher requirements on welding equipment, and the operation of the whole welding process is more complicated. In the actual aluminum bus welding construction process, the application is very little.
At present, due to the fact that construction convenience and operation are relatively easy, most of electrolytic aluminum enterprises still adopt a traditional 'staggered plate' welding mode to weld aluminum buses, and due to the limitations of the electrolytic aluminum enterprises, the 'powder welding', 'fusion casting welding', 'MIG double-pulse argon arc welding' cannot be applied in a large range.
And the aluminum bus realizes full-section fusion welding and is very beneficial to improving the welding quality and reducing the black voltage loss in the power-on process. Therefore, the development of the aluminum bus full-section fusion welding method is still of great significance.
Disclosure of Invention
The invention aims to provide an aluminum bus full-section fusion welding method, which aims to solve the technical problem that the aluminum bus is difficult to realize full-section fusion welding in the prior art, and further improves the welding quality and efficiency of the aluminum bus and reduces the cost.
In order to solve the technical problems, the invention adopts the following technical scheme:
the method for designing the full-section fusion welding of the aluminum bus is based on brand-new aluminum-aluminum welding process parameters and development of a special regulator, realizes high-quality full-section fusion welding of aluminum and aluminum, and specifically comprises the following steps:
(1) cleaning a part to be welded: cleaning and removing water, oil stains, surface oxidation films and the like on the to-be-welded parts of the aluminum bus;
(2) adjusting the welding seam distance: reserving welding seams between aluminum bus workpieces to be welded;
(3) constructing a weld pool: installing a corresponding welding clamp at the position of a welding seam, filling refractory mortar in the gap to form a molten pool cavity at the position of the welding seam, and arranging a corresponding arc striking device and an arc extinguishing device for initiating and extinguishing electric arc;
(4) arranging a contact nozzle and an aluminum welding wire: arranging a corresponding number of contact nozzles according to the width of the aluminum bus;
(5) welding: starting a power supply of a welding machine to weld, adding a regulator into a molten pool in the welding process to resist hot cracks, wherein the total addition amount of the regulator is 0.5-5% of the amount of metal to be filled in a welding seam, namely the filling amount (kg) = the volume (cm) of the welding seam 3 ）×0.0027×（0.5%～5%）；
(6) Trimming: and removing the arc-closing device for cutting after welding and cooling, and polishing and flattening the welding part.
In the step (2), the welding seam is a vertical seam or a V-shaped groove welding seam; the distance between the lower openings of the welding seams is more than or equal to 10mm, and the distance between the upper openings of the welding seams is less than or equal to 150 mm.
In the step (4), one contact tip is distributed on average every 30-50 mm, and the diameter of the aluminum welding wire is 1.5-6.0 mm.
In the step (5), a direct current orthogonal method is adopted for welding, the welding current is 500-10000A, the welding voltage is 30-50 VDC, and the wire feeding speed of the aluminum welding wire is 2-15 m/s.
In the step (5), the regulator comprises 80-90% of titanium powder (with Ti content being more than or equal to 99% and granularity being 60-100 meshes) and 10-20% of copper powder (with Cu content being more than or equal to 99.8% and granularity being 60-100 meshes) in percentage by weight.
In the step (1), Al in the aluminum bus is more than or equal to 95 percent, and Fe is less than or equal to 0.3 percent; the width of the aluminum bus is 50-500 mm.
Compared with the prior art, the invention has the main beneficial technical effects that:
1. the method has the advantages of high welding efficiency and low welding cost of fusion welding, and also has the comprehensive advantages of excellent welding seam conductivity, large effective welding area, convenient operation, stable welding seam quality, no influence of magnetic field and the like; the welding method can be carried out around the aluminum electrolytic cell and can be carried out in the magnetic field environment within 3000 GS.
2. The method replaces the welding process of the aluminum staggered plates adopted by the aluminum bus welding of the current electrolytic aluminum enterprise, and has the outstanding advantages that:
the method is beneficial to reducing the welding cost, adopts the full-section fusion welding technology to weld the aluminum bus, does not need to form a groove on a workpiece, can directly carry out vertical seam welding, has low requirement on the processing precision of the surface to be welded, does not need to grind the surface to be welded, saves the material cost and the processing cost of an aluminum connecting plate and the grinding cost of the aluminum bus, reduces the welding cost at a welding port, and has considerable economic benefit;
black voltage caused by welding seams of the aluminum bus is reduced, power consumption per ton of aluminum is reduced, and economic benefits of enterprises are improved; the effective welding area of the traditional manual welding seam is far smaller than the sectional area of the aluminum bus, and the resistance at the welding seam position is relatively large, so that when the aluminum bus is electrified to work, the welding seam position has high black voltage, and the power consumption per ton of aluminum is increased.
Drawings
FIG. 1 is a photograph of a cut of a welded joint portion of an aluminum bus bar welded by the method of the present invention.
Fig. 2 is a photograph of the appearance of the aluminum bus bar welded by the method of the present invention.
Detailed Description
The following examples are intended to illustrate the present invention in detail and should not be construed as limiting the scope of the present invention in any way.
The devices and apparatuses referred to in the following examples are conventional devices and apparatuses unless otherwise specified; the raw materials are all conventional commercial industrial raw materials if not specifically indicated; the preparation and detection methods are conventional methods unless otherwise specified.
Example 1: an aluminum bus full-section fusion welding method comprises the following steps:
(1) the adopted aluminum bus comprises the following components: more than or equal to 97 percent of Al and less than or equal to 0.3 percent of Fe; the width of the welded aluminum bus bar is: 250mm and a height of 220 mm.
(2) Cleaning a part to be welded: eliminating water, oil stain, surface oxide layer, etc.
(3) Adjusting the welding seam distance: and (3) reserving a 35mm welding seam between the aluminum bus workpieces to be welded, wherein the welding seam is a vertical seam.
(4) Constructing a weld pool: and installing a welding clamp, an arc striking device, an arc extinguishing device and gap filling refractory mortar at the position of the welding seam, so that the welding seam forms a cavity and the periphery of the welding seam is tightly sealed.
(5) Arranging a contact nozzle and an aluminum welding wire: the number of the contact nozzles is related to the width of the aluminum bus, one contact nozzle is distributed in every 50mm on average, and the diameter of the aluminum welding wire is 1.5 mm.
(6) Welding: starting an electric welding machine, welding by adopting a direct current orthogonal method, and welding a current range: 5000-10000A, welding voltage range: 30-42 VDC, and the wire feeding speed range of the aluminum welding wire is as follows: 2 to 8 m/s.
(7) Continuously filling a heat crack resisting regulator into a welding seam in the welding process, wherein the regulator comprises the following components: 80% of titanium powder (the Ti content is more than or equal to 99% and 60 meshes), 20% of copper powder (the Cu content is more than or equal to 99% and 60 meshes), 0.16kg of regulator, and the regulator is added according to 3% of the mass of the weld filler metal, namely: weld volume (cm) 3 ）×0.0027×（3%）=0.16kg。
(8) And (3) completing welding: and removing the arc-closing device after welding and cooling, and grinding and flattening the welding line.
(9) The welding seam after welding is respectively subjected to welding seam slicing detection (see fig. 1 and 2), ultrasonic detection and mechanical property detection (see tables 1 to 4), the result shows that the welding seam is well fused with the base material, the pressure drop at the welding seam is obviously lower than that of the traditional welding method, the welded joint is subjected to flaw detection, slicing and mechanical property detection, the defects of slag inclusion, pores, cracks and the like do not exist in the welding seam, the strength at the welding seam is equivalent to that of the base material, and the pressure drop at the welding seam is not greatly different from that of the base material with the same length.
TABLE 1 test results of tensile test of aluminum bus welding seam
TABLE 2 test results of aluminum bus bar weld shear test
TABLE 3 test results of bending test of aluminum bus bar welding sample
TABLE 4 impact test results of aluminum bus bar welding samples
While the invention has been described in detail with reference to the drawings and examples, it will be understood by those skilled in the art that various changes in the specific parameters of the embodiments described above may be made or equivalents of related methods, steps and materials may be substituted without departing from the spirit of the invention to form multiple embodiments, which are common variations of the invention and will not be described in detail herein.
Claims (5)
1. The full-section fusion welding method for the aluminum bus is characterized by comprising the following steps of:
(1) cleaning a part to be welded: cleaning and removing water, oil stains and oxide layers at the to-be-welded parts of the aluminum bus;
(2) adjusting the welding seam distance: reserving welding seams between aluminum bus workpieces to be welded;
(3) constructing a weld pool: installing corresponding welding clamps at the positions of welding seams, filling refractory mortar in the gaps to form a molten pool cavity at the welding seams, and arranging corresponding arc striking devices and arc extinguishing devices for initiating and extinguishing electric arcs;
(4) laying a contact tube and an aluminum welding wire: according to the width of the aluminum bus to be welded, a contact nozzle is distributed every 30-50 mm on average;
(5) welding: starting a welding machine to weld, adding a regulator into a molten pool in the welding process to resist thermal cracking, wherein the filling amount of the regulator = the volume of a welding seam multiplied by 0.0027 multiplied (0.5% -5%), the unit of the filling amount of the regulator is kg, and the unit of the volume of the welding seam is cm 3 (ii) a The regulator comprises, by weight, 80-90% of titanium powder and 10-20% of copper powder;
(6) trimming: and cutting off the arc quenching device after welding and cooling, and grinding and flattening the welding part.
2. An aluminum bus bar full-section fusion welding method as recited in claim 1, wherein in said step (2), said welding seam is a vertical seam; the distance between the lower openings of the welding seams is more than or equal to 10mm, and the distance between the upper openings of the welding seams is less than or equal to 150 mm.
3. The full-section fusion welding method of aluminum bus bars as claimed in claim 1, wherein in the step (4), the diameter of the aluminum welding wire is 1.5-6.0 mm.
4. The full-section fusion welding method of aluminum bus bars according to claim 1, wherein in the step (5), welding is performed by a direct current orthogonal method, the welding current is 500-10000A, the welding voltage is 30-50 VDC, and the wire feeding speed is 2-15 m/s.
5. The full-section fusion welding method of the aluminum bus bar as recited in claim 1, wherein in the step (1), Al in the aluminum bus bar is more than or equal to 95%, and Fe is less than or equal to 0.3%; the width of the aluminum bus is 50-500 mm.
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| CN2021100907502 | 2021-01-22 | ||
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Family Cites Families (12)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH04182078A (en) * | 1990-03-19 | 1992-06-29 | Mitsubishi Electric Corp | Electron beam welding method for aluminum conductor |
| CN101323039A (en) * | 2008-07-22 | 2008-12-17 | 渤海船舶重工有限责任公司 | Non-prewarming welding method for thick-wall red copper and low-carbon steel dissimilar metal material |
| CN102126072B (en) * | 2011-04-18 | 2012-09-05 | 中化二建集团有限公司 | Horizontally laid large-section aluminum bus welding construction method |
| CN102303178B (en) * | 2011-07-28 | 2013-06-19 | 四川电力建设三公司 | Semi-automatic gas shield welding construction technology for aluminum conductors |
| CN103626509B (en) * | 2013-12-06 | 2015-05-13 | 天津大学 | Method for controlling crack growth of aluminium- silicone fiber heat-sealing material |
| CN106735765B (en) * | 2016-11-30 | 2019-01-15 | 国网山东省电力公司电力科学研究院 | A kind of welding method improving aluminium alloy tube type bus welding point conductivity |
| CN206854914U (en) * | 2017-06-22 | 2018-01-09 | 郑州经纬科技实业有限公司 | Aluminium electrolytic cell cathode square steel welding jigs and fixtures |
| CN108526692B (en) * | 2018-04-10 | 2020-04-14 | 上海工程技术大学 | Laser filler welding process for magnesium/aluminum dissimilar metal |
| CN108637429A (en) * | 2018-04-14 | 2018-10-12 | 郑州经纬科技实业有限公司 | Electrolytic aluminium cathode steel bar total cross-section welding method under magnetic field environment |
| CN108723534B (en) * | 2018-04-14 | 2020-02-11 | 郑州经纬科技实业有限公司 | Electrolytic aluminum cathode steel-aluminum fusion brazing welding method |
| CN108687267A (en) * | 2018-05-16 | 2018-10-23 | 郑州经纬科技实业有限公司 | The method that aluminium busbar total cross-section welds under electromagnetic field |
| CN108890089A (en) * | 2018-08-06 | 2018-11-27 | 国网浙江省电力有限公司电力科学研究院 | A kind of electric power aluminum equipment wire clamp welding method |
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