CN113210798B - Small-leg single-pass fillet welding method - Google Patents
Small-leg single-pass fillet welding method Download PDFInfo
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- CN113210798B CN113210798B CN202110396492.0A CN202110396492A CN113210798B CN 113210798 B CN113210798 B CN 113210798B CN 202110396492 A CN202110396492 A CN 202110396492A CN 113210798 B CN113210798 B CN 113210798B
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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
- B23K9/02—Seam welding; Backing means; Inserts
- B23K9/025—Seam welding; Backing means; Inserts for rectilinear seams
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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
- B23K33/00—Specially-profiled edge portions of workpieces for making soldering or welding connections; Filling the seams formed thereby
- B23K33/004—Filling of continuous seams
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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
- B23K9/173—Arc welding or cutting making use of shielding gas and of a consumable electrode
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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
- B23K9/235—Preliminary treatment
Abstract
The invention provides a small leg single-pass fillet welding method, which comprises the following steps: fixedly placing two pieces to be welded to form an included angle structure at the welding position of the two pieces to be welded; testing electricity before welding, and selecting welding parameters, wherein the current selection range is 240-260A, and the voltage selection range is 24-27V; adjusting the position of a welding gun to enable the arc starting and extinguishing positions of the welding gun to be always positioned at the root of the included angle structure, and welding from one end of the included angle structure to the other end of the included angle structure by adopting a single-point arc extinguishing welding mode to form fillet welds of a 2-a 4; in step S103, the arc striking position of the welding torch is advanced by 1 to 2mm with respect to the previous arc striking position, so that the molten pool formed by each arc burning overlaps the molten pool formed by the previous arc burning. The small-leg single-channel fillet welding method provided by the invention can improve the welding quality and efficiency, reduce the waste of welding flux and reduce the cost.
Description
Technical Field
The invention belongs to the technical field of manual gas shielded welding, and particularly relates to a small-leg single-pass fillet welding method.
Background
The size of a body part of a railway passenger car is large, most welding seams of a carriage are linear fillet welding seams formed by splicing 4-6 mm plates or annular fillet welding seams formed by splicing a pipe fitting and the plates, the requirement on the size of a welding corner is more than 3-5mm, for the small leg single-channel fillet welding seams, if welding parameters (current and voltage) are large during welding, the melting speed of a welding wire is high, clad metal easily drops, the welding seams cannot be formed, if the welding parameters are small, the penetration depth of the root of the welding seam is insufficient, and the welding strength cannot meet the requirement.
At present, the welding method adopted for such welding seams is that gas shielded welding with welding parameters of current 150-180A and voltage 20-21V is adopted, please refer to fig. 2 (reference numeral 33 is a fusion area of solder and a part to be welded 10), continuous welding is carried out by igniting electric arc at the end of a welding wire (the electric arc continuously burns to form a moving molten pool, and a continuous welding seam is formed after molten material is cooled), the welding process does not swing as much as possible or only swings transversely in a small amplitude, a convex welding seam is finally formed, most of invalid welding metal (namely, a convex part 32) is ground by an angle grinder or a straight grinder, only a required effective leg area 31 is reserved, and the mode not only wastes a large amount of solder, but also has large grinding workload after welding and affects efficiency; or the electric arc is ignited at the end part of the welding wire to have relatively large transverse swing amplitude, so that the molten metal of a welding pool is spread out, and a welding seam forming bulge can be avoided.
Disclosure of Invention
The embodiment of the invention provides a small-leg single-channel fillet welding method, aiming at improving the welding quality and efficiency of a small-leg single-channel fillet weld and reducing the waste of welding flux.
In order to realize the purpose, the invention adopts the technical scheme that: the small-leg single-pass fillet welding method comprises the following steps:
s101, fixedly placing two pieces to be welded to form an included angle structure at the welding position of the two pieces to be welded;
step S102, testing power before welding, and selecting welding parameters, wherein the current selection range is 240-260A, and the voltage selection range is 24-27V;
step S103, adjusting the position of a welding gun to enable the arc starting and extinguishing positions of the welding gun to be always positioned at the root of the included angle structure, and welding from one end of the included angle structure to the other end of the included angle structure by adopting a single-point arc extinguishing welding mode to form fillet welds of a 2-a 4;
in step S103, the arc striking position of the welding gun is fed forward by 1 to 2mm relative to the previous arc striking position, so that the molten pool formed by each arc burning overlaps the molten pool formed by the previous arc burning.
In one possible implementation, the melt pool formed by each arc burn overlaps by two thirds the melt pool formed by the last arc burn.
In one possible implementation, the time of each arc striking of the welding gun is a node of the color of a molten pool formed by the last arc burning and converted from white to red.
In a possible implementation manner, step S103 further includes: and carrying out arc shaking in each arc combustion process so as to obtain the required size of the welding leg, wherein the amplitude of the arc shaking is less than or equal to 1mm.
In one possible implementation, the welding process employs MAG welding in a non-arcing mode.
In some embodiments, MAG welding uses a solid wire with a diameter of 0.9-1.2 mm, and the solid wire has a dry elongation of 12-15 mm.
In a possible implementation manner, after step S103, the method further includes:
and step S104, taking the fillet welds of a 2-a 4 formed in the step S103 as a priming layer, and continuously welding a filling layer and/or a cover layer on the priming layer by adopting a continuous welding mode to form fillet welds of a4 and above.
In a possible implementation manner, before step S101, the method further includes:
and S100, polishing the two pieces to be welded, and removing rust and oxide layer impurities.
In one possible implementation, the angled structure extends in a vertical or lateral or circumferential direction.
In one possible implementation, the angle structure is T-shaped or K-shaped or Y-shaped or V-shaped.
The small-leg single-pass fillet weld welding method provided by the invention has the beneficial effects that: compared with the prior art, the small-leg single-pass fillet welding method has the advantages that after the welding positions of two pieces to be welded are placed into corresponding included angle structures according to the requirements of welding seams, reasonable large welding parameters are selected within the range of current 240-260A and voltage 24-27V through test electricity, then the welding wire end of a welding gun is close to the root of the included angle structure to start single-point arc extinguishing welding, and the welding gun is fed to the front of welding after each arc extinguishing, so that a molten pool formed by arc combustion at each time is enabled to be overlapped with a molten pool formed by arc combustion at the last time, and continuous welding seams are formed; because the parameter that is far greater than conventional welding standard has been adopted, the welding wire is big at the instant melting volume of contained angle structure root, consequently, can improve root penetration, ensure welding strength, and because the welding wire is big in the instant melting volume, consequently, can reduce the arcing time, thereby improve welding efficiency, through adopting single-point arc extinguishing welded mode, can make the molten bath edge solidify through the arc extinguishing operation after the arcing forms the molten bath at every turn, thereby avoid the melt to descend, and through making the molten bath that the arcing formed at every turn overlap with last molten bath, thereby form the continuous no bellied welding seam, the invalid welding metal volume has been reduced, need not to carry out the repair of polishing after welding, not only can improve work efficiency, can also reduce the solder quantity, waste is reduced, thereby welding cost is reduced.
Drawings
FIG. 1 is a process diagram of a small leg single pass fillet weld welding method provided by an embodiment of the invention;
FIG. 2 is a schematic structural view of a small leg single pass fillet welded using a prior art method;
FIG. 3 is a schematic diagram of a weld structure obtained by a small-fillet single-pass fillet welding method according to an embodiment of the present invention;
fig. 4 is a schematic position diagram of an arc starting point adopted in the small-fillet single-pass fillet welding method according to the embodiment of the present invention;
FIG. 5 is a schematic diagram of the operation position of a welding gun used in the method for welding a single fillet corner weld with a small leg according to the embodiment of the present invention;
fig. 6 is a schematic structural diagram of a vertical (single V) weld seam applicable to the small-leg single-pass fillet weld welding method provided in the embodiment of the present invention;
FIG. 7 is a schematic structural diagram of a transverse (single V) weld seam applicable to the small-leg single-pass fillet weld welding method according to the embodiment of the present invention;
FIG. 8 is a schematic structural diagram of a Y-shaped weld seam applicable to the small leg single-pass fillet weld method according to the embodiment of the present invention;
fig. 9 is a schematic structural diagram of a K-shaped weld seam applicable to the small-fillet single-pass fillet weld method according to the embodiment of the present invention;
fig. 10 is a schematic structural diagram of a circumferential weld seam applicable to the small leg single-pass fillet weld method provided in the embodiment of the present invention.
In the figure: 10. a workpiece to be welded; 20. an included angle structure; 30. welding feet; 31. an effective fillet area; 32. a convex portion; 33. a fused region; 40. a welding gun; 41. a contact tip; 42. welding wires; 50. fillet welding; 51. a molten pool; 52. an arcing point; a. the thickness of the welding seam; z, weld height; l, dry elongation.
Detailed Description
In order to make the technical problems, technical solutions and advantageous effects of the present invention more clearly understood, the present invention is further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.
It should be noted that, referring to fig. 2, when the to-be-welded member 10 is a plate or a pipe, the size of the fillet formed by welding should not exceed the thickness of the to-be-welded member 10, and the small fillet 30 refers to a weld joint with a fillet size of a2mm to a4mm (international standard usually uses a value, i.e., the thickness of the weld joint indicates the size of the fillet, and domestic usually uses z value, i.e., the width/height of the weld joint indicates the size of the fillet), and the weld joint below a4mm specified in the international welding standard of ISO15085 may be directly welded in a single layer, while the weld joint above a4mm needs to be welded in a multi-layer manner; the single-point arc extinguishing welding is an operation mode of completing welding by starting and extinguishing arcs through a switch for uniformly opening and closing a welding gun, and the single-point arc extinguishing welding mode is different from a conventional pulse welding mode, the pulse welding has no arc extinguishing process and only changes welding current according to set frequency, so that molten pool metal cannot be cooled instantly, the fluidity of the molten pool metal is still good, the molten pool metal can flow down under the action of gravity (during vertical welding and overhead welding operation), and the weld seam is seriously fallen down after being formed.
Referring to fig. 1, 3 to 5, a method of single fillet welding with a small fillet according to the present invention will now be described. The small welding leg single-pass fillet welding method comprises the following steps:
step S101, fixedly placing two pieces to be welded 10 to enable the welding positions of the two pieces to be welded 10 to form an included angle structure 20;
step S102, testing power before welding, and selecting welding parameters, wherein the current selection range is 240-260A, and the voltage selection range is 24-27V;
step S103, adjusting the position of the welding gun 40 to enable the arc starting and extinguishing positions of the welding gun 40 to be always positioned at the root of the included angle structure 20, and welding from one end to the other end of the included angle structure 20 by adopting a single-point arc extinguishing welding mode to form fillet welds 50 of a 2-a 4;
in step S103, the arc starting point 52 of the welding gun 40 is fed forward by 1 to 2mm relative to the previous arc starting position, so that the molten pool 51 formed by each arc burning overlaps the molten pool 51 formed by the previous arc burning.
The principle of the small-leg single-pass fillet weld welding method provided by the invention is as follows:
the size of the molten pool 51 formed by each arc directly determines the size of the finally formed welding leg 30, under the same arc duration, the size of the molten pool 51 can be adjusted by adjusting welding parameters, the welding current determines the penetration depth, and the welding voltage determines the penetration width, so that the size of the molten pool does not need to be controlled by swinging an electric arc, and if the optimal selection is made, for a welding seam 50 with the minimum welding leg size of a2mm, the welding current 240A and the welding voltage 24V can be adopted; for a weld 50 with a leg size of a4mm, a welding current of 260A and a welding voltage of 27V may be used, although it is understood that after the welding current is selected, normal welding operations may be performed with a welding voltage in the range of 24-27V.
During welding, single-point arc extinguishing operation is realized by uniformly raking a welding gun switch, the arc burning time after each arc striking is matched with the required size of a molten pool 51 (namely a welding leg size a value or a z value), the larger the required molten pool 51 is, the longer the corresponding arc burning time is, and the specific judgment mode is that visual inspection is carried out through goggles in the welding process; in addition, the time interval between the previous arc extinction and the next arc extinction is determined by the solidification state of the molten pool 51, specifically, the molten material at the edge of the molten pool 51 formed in the previous time is solidified, and the intermediate molten material is not solidified, so that the next arc extinction is performed, and the next arc extinction is performed, so that the solder can be prevented from flowing down to form a protrusion, and the molten material in the middle of the molten pool can be prevented from forming a shrinkage cavity to affect the welding quality.
Compared with the prior art, the method for welding the small-leg single-pass fillet weld provided by the embodiment has the advantages that after the welding positions of two workpieces to be welded 10 are placed into the corresponding included angle structures 20 according to the requirements of the weld, reasonable large welding parameters are selected within the range of current 240-260A and voltage 24-27V through test electricity, then the end of a welding wire 42 of a welding gun 40 is close to the root of the included angle structure 20 to start single-point arc extinguishing welding, and the welding gun 40 is fed to the front of welding after each arc extinguishing, so that a molten pool 51 formed by each arc combustion is ensured to be overlapped with a molten pool 51 formed by the last arc combustion, a continuous weld 50 is formed, and the appearance quality and the welding strength are ensured; because the parameters far larger than the conventional welding specifications are adopted, the instantaneous melting amount of the welding wire 42 at the root of the included angle structure 20 is large, the penetration depth of the root can be improved (see a melting area 33 shown in fig. 3), the welding strength is ensured, and because the instantaneous melting amount of the welding wire 42 is large, the arcing time can be reduced, so the welding efficiency is improved.
In one possible implementation, referring to fig. 4, the melt pool 51 formed by each arc burn overlaps two thirds of the melt pool 51 formed by the last arc burn. That is, each arc starting point 52 should be located at two thirds of the area pressed over the last molten pool 51, if the distance is too large, the problem of poor consistency of the depth of the molten pool 51 formed by each arc burning is caused, so that large welding stress is generated, if the distance is too small, the solder between the adjacent molten pools 51 is accumulated, so that the problem of protruding welding seams is caused, the appearance is influenced, and the solder is wasted.
In one possible implementation, each arc strike by the torch 40 is at a node where the color of the molten pool 51 formed by the last arc burn changes from white to red. In the actual welding process, when the molten pool 51 is formed by the previous ignition arc and after arc extinction, the edge of the molten pool 51 is instantly cooled and solidified, in the process, the color of the molten pool 51 is changed from white to red, at the moment, the molten material at the center of the molten pool 51 is still in a molten state, when the molten pool 51 is changed from red to dark red (approaching to gray black), a shrinkage cavity is formed at the center of the molten pool 51, in order to avoid that the formation of the shrinkage cavity affects the welding quality, next arc striking should be immediately carried out at a node where the color of the molten pool 51 is changed from white to red until the whole welding line is finished, arc shrinkage is carried out, and thus, by visually observing the change node of the color of the molten pool as the time of each arc striking, an operator can conveniently and visually judge and grasp the arc striking time, thereby reducing the operation difficulty and improving the welding quality.
In some embodiments, in order to obtain a larger fillet size and meet a relatively larger fillet requirement, such as an a4 fillet, the step S103 further includes: and carrying out arc shaking in each arc combustion process so as to obtain the required size of the welding leg, wherein the amplitude of the arc shaking is less than or equal to 1mm. Because the adopted welding parameters (current and voltage) are high, the over-long arcing time can cause the over-large penetration and even the penetration of the to-be-welded piece, when the size of the welding leg is large, the expansion of a molten pool is realized by adopting an electric arc shaking mode, so that the size requirement of the welding leg is met, of course, the amplitude of the electric arc shaking is within 1mm, and the requirement of the maximum a4 welding leg can be realized (the welding legs of a 2-a 3 can be formed without shaking, and the shaking within 1mm is carried out on the basis of a3, so that the a4 welding leg is inevitably formed), the welding leg exceeding a4 is required to adopt a multilayer welding mode in the international welding standard, and in addition, in the electric arc shaking process, the welding wire is always positioned at the root of an included angle structure, and the electric arc is pressed to the lowest position as much as possible, so that the penetration of the root is ensured, and the welding strength is improved.
Specifically, referring to fig. 5, the Welding process uses MAG (Metal Active Gas Arc Welding) Welding in a non-Arc mode, and the MAG Welding uses a solid wire 42 with a diameter of 0.9-1.2 mm, and the dry elongation L (the distance from the end of the wire 42 to the end of the contact tip 41 of the Welding gun 40) of the solid wire 42 is 12-15 mm. MAG welding is a mixed gas shielded welding in which a small amount of oxidizing gas such as oxygen, carbon dioxide or a mixture thereof is added into argon gas, arc ending refers to a process of extinguishing an arc after welding is stopped, and common arc ending methods include a repeated arc breaking ending method, a circle ending method, a reflow ending method and a transfer ending method, that is, the arc is extinguished through actions such as repetition, convolution or stay after welding is completed, so that arc craters are prevented from being generated at the end point of a welding seam, in the welding process of the embodiment, a solid welding wire 42 of 1.2mm is preferably adopted, the dry elongation L is 12-15 mm (according to an included angle structure 20, the end of the welding wire 42 is preferably close to the root of the included angle structure 20), arc extinguishing is not required to be performed at each arc extinguishing time, that is to perform arc extinguishing only by loosening a welding gun switch (a welding gun is usually powered on in a manner of pressing a button or pushing a fuse, and to perform loosening and closing), on the one hand, arc extinguishing time can be improved, on the other hand, the stability of the position of the welding gun head is improved, and the welding quality and the stability is improved.
For the welding seam with the fillet size requirement a4 and above, please refer to fig. 1, after step S103, the method further includes: and step S104, taking the fillet welds of a 2-a 4 formed in the step S103 as a priming layer, and continuously welding a filling layer and/or a cover layer on the priming layer by adopting a continuous welding mode to form fillet welds of a4 and above. Because the welding seam of the welding leg size more than a4, require to adopt the multilayer welding mode in the international welding standard, the small welding leg welding seam that forms through step S101 to step S103 here is as the priming layer, then adopt conventional continuous welding mode welding filling layer and capping layer on the priming layer, the welding seam more than a4 that finally forms can ensure that the penetration of welding seam root satisfies the requirement to improve welding strength, in addition because the shaping of priming layer is of high quality, do not have the arch, consequently need not polish and clear away invalid metal solder meat to the priming layer, consequently can reduce the solder waste, improve welding efficiency.
In addition, in the embodiment provided by the present invention, referring to fig. 1, before step S101, the method further includes: and S100, polishing the two pieces to be welded, and removing rust and oxide layer impurities. The areas 20mm away from the two sides of the position (welding seam) to be welded are polished in a focused mode during polishing, the welding area is guaranteed to be free of rust and oxide skin, accordingly, impurities can be prevented from entering a molten pool to influence the final welding seam forming strength or cause a welding cavity, and therefore welding quality is improved.
In some embodiments, referring to fig. 6-10, the angled structures 20 extend in a vertical or lateral or circumferential direction. For a vertical welding seam (see fig. 6), namely, vertical welding, in the step S103, the welding gun is moved from bottom to top, so that the penetration of the root of the welding seam can be ensured, and the welding seam is prevented from being protruded; for the transverse welding seam (see fig. 7 to 9), both a top welding mode and a bottom welding mode are involved, the welding gun adopts a translation mode during welding, the problem of welding seam protrusion can be avoided on the basis of ensuring the size of a small welding leg during top welding, and the welding seam protrusion caused by falling of molten materials can be avoided through the welding mode of the step S103 during top welding; in contrast to circumferential welds (see fig. 10), which are usually a single circumferential weld along the circumferential wall of the pipe, both overhead and overhead welding methods are also involved, and the difference between the circumferential weld and the horizontal weld is that the movement of the welding gun needs to ensure that the axis of the welding gun is always perpendicular to the tangential direction of the welding leg, thereby ensuring the penetration consistency at the root of the weld.
Referring to fig. 5 to 10, the angle structure may be T-shaped (shown in fig. 5), K-shaped (shown in fig. 9), Y-shaped (shown in fig. 8), or V-shaped (shown in fig. 6 or 7). That is to say, the method provided by the embodiment can be used for welding the directly and vertically overlapped plate type to-be-welded parts 10, the one-way beveled-butted plate type or pipe type to-be-welded parts 10 (see fig. 10) and the two-way beveled-butted plate type to-be-welded parts 10, so that the method has a wide application range, can meet the welding requirements of various types of small fillet welds at various positions in the railway vehicle, and improves the assembly quality and efficiency of the railway vehicle.
The above description is intended to be illustrative of the preferred embodiment of the present invention and should not be taken as limiting the invention, but rather, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention.
Claims (7)
1. The small-leg single-pass fillet weld welding method is characterized by comprising the following steps of:
s101, fixedly placing two pieces to be welded to form an included angle structure at the welding position of the two pieces to be welded;
step S102, testing power before welding, and selecting welding parameters, wherein the current selection range is 240-260A, and the voltage selection range is 24-27V;
s103, adjusting the position of a welding gun to enable the arc starting and extinguishing positions of the welding gun to be always positioned at the root of the included angle structure, and welding from one end of the included angle structure to the other end of the included angle structure by adopting a single-point arc extinguishing welding mode to form fillet welds of a 2-a 4;
in step S103, the arc striking position of the welding gun is fed forward by 1 to 2mm relative to the arc striking position of the last time, so that the molten pool formed by each arc combustion overlaps with the molten pool formed by the last arc combustion;
the time of each arc striking of the welding gun is a node of the color of a molten pool formed by the last arc combustion, which is changed from white to red;
the step S103 further includes: and carrying out arc shaking in each arc combustion process so as to obtain the required size of the welding leg, wherein the amplitude of the arc shaking is less than or equal to 1mm.
2. The small leg single pass fillet welding method according to claim 1, wherein the weld pool formed by each arc burning overlaps the weld pool formed by the previous arc burning by two thirds.
3. The small leg single pass fillet welding method as recited in claim 1, wherein solid wire with a diameter of 0.9-1.2 mm is adopted in MAG welding, and a dry elongation of the solid wire is 12-15 mm.
4. The small fillet single-pass fillet welding method according to claim 1, further comprising after said step S103:
and step S104, taking the fillet welds of a 2-a 4 formed in the step S103 as a priming layer, and continuously welding a filling layer and/or a cover layer on the priming layer by adopting a continuous welding mode to form fillet welds of a4 and above.
5. The small fillet single fillet weld method according to claim 1, further comprising, before the step S101:
and S100, polishing the two pieces to be welded, and removing rust and oxide layer impurities.
6. The method of welding small leg single pass fillets according to any one of claims 1 to 5, wherein said angled structure extends vertically or laterally or circumferentially.
7. The method of welding small leg single pass fillets of claim 6, wherein said angled structure is T-shaped, K-shaped, Y-shaped, or V-shaped.
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