CN113210820B - Flash welding method - Google Patents
Flash welding method Download PDFInfo
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- CN113210820B CN113210820B CN202110450016.2A CN202110450016A CN113210820B CN 113210820 B CN113210820 B CN 113210820B CN 202110450016 A CN202110450016 A CN 202110450016A CN 113210820 B CN113210820 B CN 113210820B
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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
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/04—Flash butt welding
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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
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/36—Auxiliary equipment
Abstract
The invention discloses a flash welding method, which relates to the technical field of welding and comprises the steps of clamping and centering, flash heating, vibrating an end face, propping up and closing a seam, extruding and removing the abnormal shape, heating by plastic deformation, grinding and fine grain by sticking, upset forging welding and pressure maintaining cooling. The method is characterized in that five key steps of vibrating an end face, propping a tight joint, extruding and rejection, plastically deforming and heating and bonding and grinding crystals are added on the basis of the existing flash welding, molten metal, an overburning structure, oxide inclusions and the like in a joint surface area can be extruded out from the joint surface, molten crystals, impurities and other foreign matters in the joint surface area are crushed and discharged from the joint, the plasticity of the metal in the joint surface area reaches a thermoplastic state in a preset depth range, the grain structure in the joint surface area is refined, the mutual diffusion among atoms in the joint surface area is promoted, common grains are formed, the quality of a welded joint is improved, the stability and the consistency of the quality of the welded joint are ultra-strong, the mechanical performance of the quality of the welded joint is enhanced, and the method has a good application prospect.
Description
Technical Field
The invention relates to the technical field of welding, in particular to a flash welding method.
Background
Flash welding is a resistance welding method in which two welding members are oppositely placed and assembled to form a butt joint, the two welding members are connected with a power supply, end faces of the two welding members gradually approach to local contact, a liquid lintel is formed by heating and melting a contact point by resistance heat, the lintel is exploded to form flash and fire pits, when a predetermined temperature field is formed in a larger depth range at the end part, upsetting pressure is rapidly applied and the power supply is cut off, atoms on two separated surfaces are cooled and crystallized, and a sufficient amount of common crystal grains are generated, so that a pressure welding joint is obtained.
Flash welding has the characteristics of high thermal efficiency, good welding quality and wide range of weldable metals, thereby being widely used. However, the flash process is accompanied by a large amount of metal smoke and splashes, which are unfavorable to the working environment, the more the welding material is burnt, the more the smoke and splashes are generated, the more the material is consumed, the greater the energy loss is, and the more serious the environmental pollution is caused; in the welding process, high-temperature liquid metal exists on the end face of a welding material, and after welding is finished, defects related to melting crystallization exist in a joint, so that the toughness of the joint is reduced; in the later stage of flashing, an alloy element gathering area exists in liquid metal on the end face of the joint, and after upsetting is completed, the alloy element gathering area remains in a welded joint to form a gray spot defect, so that the performance of the joint is greatly reduced, and even the joint is broken; if the fire pit formed in the flash process is large, the molten metal, the overburning structure, the oxide inclusions and the like cannot be completely extruded in the later upsetting process to form slag inclusion defects; the grain structure of the welded joint area after flash heating is coarse, reducing the mechanical properties of the welded joint.
Disclosure of Invention
Therefore, the invention provides a flash welding method to solve the technical problems.
In order to achieve the above purpose, the invention provides the following technical scheme:
a flash welding method, comprising the steps of:
vibrating the end face; when a preset temperature field is built in the whole end part within a smaller depth range, applying vibration force in a direction parallel to the end faces to enable the end faces of the two welding parts to move relatively;
propping up and closing the seam; when the relative motion between the end surfaces of the two weldments reaches a preset amplitude and frequency, applying a jacking force in the direction vertical to the end surfaces to fold the two melted end surfaces, and extruding the molten metal, the overburning structure, the oxide inclusions and the like in the area of the joint surface from the joint surface;
extruding and removing the foreign matters; adjusting short circuit current, continuously heating the joint by using resistance heat, and under the action of vibration force and jacking force, mutually extruding and relatively shearing atoms of two contact end surfaces of the joint surface region, crushing molten crystals, impurities and other foreign matters in the joint surface region and discharging the foreign matters from a joint;
plastic deformation heating; adjusting short circuit current, continuously heating the joint by using resistance heat, adjusting the jacking force, and heating the joint area by using plastic deformation heat of plastic metal in the joint area to ensure that the plasticity of the metal in the joint area reaches a thermoplastic state within a preset depth range;
grinding the fine grains by sticking; adjusting current and jacking force, refining grain structure of the joint surface region by utilizing mutual adhesion and grinding among plastic metal atoms of the joint surface region, and promoting mutual diffusion among atoms of the joint surface region to form common grains.
Further, the flash welding method further comprises the following steps:
a flash heating step before the end face vibrating step; switching on a power supply, enabling the end faces of the two weldment to gradually approach to achieve local contact, and rapidly heating by using resistance thermal flash to melt the whole end faces of the two weldment;
further, the flash welding method further comprises the following steps:
a clamping and centering step before the flash heating step; the two welding parts are oppositely arranged and assembled to form a butt joint, the end faces of the two welding parts are lightly contacted, the end faces to be welded are aligned according to requirements, and one welding part slowly retreats a little and then stops.
Further, the flash welding method further comprises the following steps:
an upset forging welding step after the fine crystal bonding step; when the grain refinement degree and the eutectic quantity both reach the preset requirements, stopping the vibration force, adjusting the jacking force, promoting the thermoplastic metal in the joint surface area to generate extremely-fast plastic deformation and instantaneous flow, accelerating the mutual diffusion among atoms in the joint surface area, forming a sufficient amount of common grain structure with fine grain size, and immediately stopping heating the joint by resistance heat.
Further, the flash welding method further comprises the following steps:
a pressure maintaining cooling step after the upset welding step; maintaining the jacking force and controlling the cooling rate of the thermoplastic metal in the area of the joint surface.
Further, the step of propping up the tight seam specifically includes: when the relative movement between the end faces of the two weldments reaches a preset amplitude and frequency, a lower jacking force is quickly applied in the direction vertical to the end faces, so that the molten metal and the plastic metal in the two molten end face areas are quickly contacted and folded to form a joint area, flashing is stopped immediately, and the molten metal, the overburning structure, the oxide inclusion and the like in the joint area are extruded out from the joint area to form welding slag under the combined action of the jacking force and the vibration force.
Further, the extrusion rejection step specifically includes: applying larger short-circuit current, continuously heating the joint by using resistance heat, simultaneously, under the continuous combined action of the jacking force and the vibration force, thoroughly crushing the molten crystals, impurities and other foreign matters in the joint surface region by using the mutual extrusion and relative shearing processes between atoms of two contact end surfaces in the joint surface region, and discharging from the joint to form flash, thereby cleaning the foreign matters and the defects in the joint surface region and obtaining the plastic solid-phase structure of the pure original base material matrix in the joint region.
Further, the plastic deformation heating step specifically comprises: switching small short circuit current, continuing heating the joint by using resistance heat, properly adjusting the jacking force and the vibration force, heating the joint area by using a large amount of plastic deformation heat released by plastic metal in the joint area in the plastic deformation process, and enabling the plasticity of the metal in the whole joint area to reach a thermoplastic state within a preset depth range along with the temperature rise of the joint area.
Further, the step of bonding and grinding crystals specifically comprises the following steps: the current and the jacking force are properly adjusted, and the mutual adhesion and grinding process between the plastic metal atoms of the two contact end surfaces of the joint area is utilized, so that on one hand, the grain structure of the joint area is further refined to improve the toughness of the joint, and on the other hand, the mutual diffusion between the atoms of the joint area is promoted to form common grains.
The invention has the following advantages:
the method is characterized in that five key steps of vibrating an end face, propping up a tight joint, extruding and removing foreign matters, plastically deforming and heating and bonding and grinding crystals are added on the basis of the original flash welding method, molten metal, an overburning structure, oxide inclusions and the like in a joint surface region can be extruded out from the joint surface, molten crystals, impurities and other foreign matters in the joint surface region are crushed and discharged from the joint surface, the plasticity of the metal in the joint surface region reaches a thermoplastic state within a preset depth range, the grain structure of the joint surface region is refined, the mutual diffusion among atoms in the joint surface region is promoted, common grains are formed, the quality of a welding joint is improved, the stability and the consistency of the quality of the welding joint are ultra-strong, the mechanical performance of the quality of the welding joint is enhanced, and the method has a good application prospect.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below. It should be apparent that the drawings in the following description are merely exemplary, and that other embodiments can be derived from the drawings provided by those of ordinary skill in the art without inventive effort.
The structures, ratios, sizes, and the like shown in the present specification are only used for matching with the contents disclosed in the specification, so that those skilled in the art can understand and read the present invention, and do not limit the conditions for implementing the present invention, so that the present invention has no technical significance, and any structural modifications, changes in the ratio relationship, or adjustments of the sizes, without affecting the functions and purposes of the present invention, should still fall within the scope covered by the contents disclosed in the present invention.
FIG. 1 is a flow chart of a flash welding method according to an embodiment of the present invention;
FIG. 2 is a schematic view of the current variation in a flash welding process according to an embodiment of the present invention;
FIG. 3 is a schematic view of the variation of vibration displacement in a flash welding process according to an embodiment of the present invention;
fig. 4 is a schematic view illustrating variation of upset displacement in the flash welding method according to the embodiment of the present invention.
Fig. 5 is a schematic view illustrating variation of the upsetting force in the flash welding method according to the embodiment of the present invention.
FIG. 6 is a schematic view of a welding system used in the flash welding method according to an embodiment of the present invention.
In the figure: 1-fixed end clamp, 2-movable end clamp, 3-steel rail, 4-flash power supply, 5-vibration cylinder, 6-vibration clamp and 7-upsetting cylinder.
Detailed Description
The present invention is described in terms of particular embodiments, other advantages and features of the invention will become apparent to those skilled in the art from the following disclosure, and it is to be understood that the described embodiments are merely exemplary of the invention and that it is not intended to limit the invention to the particular embodiments disclosed. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
In the present specification, the terms "upper", "lower", "left", "right", "middle", and the like are used for clarity of description, and are not intended to limit the scope of the present invention, and changes or modifications in the relative relationship may be made without substantial changes in the technical content.
As shown in fig. 1 and 6, a flash welding method includes the steps of:
and S1, clamping and centering. The two welding parts are oppositely arranged and assembled to form a butt joint, the end faces of the two welding parts are lightly contacted, the end faces to be welded are aligned according to requirements, and one welding part slowly retreats a little and then stops. Specifically, a fixed end clamp 1 and a movable end clamp 2 respectively clamp two steel rails 3 and are oppositely placed to assemble a butt joint, so that the welding end surfaces of the two steel rails 3 are in slight contact, and a centering mechanism is adjusted to align the end surfaces to be welded according to requirements; subsequently, the moving end jig 2 is slowly retreated by a little (1 mm) and then stopped.
And step S2, heating by flashing. The power supply is switched on, the end faces of the two weldment are gradually close to achieve local contact, and the whole end faces of the two weldment are melted by rapid heating of resistance thermal flash. Specifically, a flash power supply 4 is switched on, and the movable end clamp 2 moves forward slowly to enable the two end surfaces to be welded to be in slight contact to form a plurality of contact points; when current passes through the contact point, the contact point is melted into a liquid metal lintel; because the current density in the liquid metal lintel is extremely high, the liquid metal in the lintel is evaporated and the lintel is exploded, liquid metal particles are continuously ejected from the gap of the end face to form spark rush current-flash, and a fire pit is left at the end face after explosion; along with the slow propulsion of the moving end clamp 2, the liquid lintel is continuously generated and exploded, and the quantity of the liquid lintel is gradually increased until a layer of liquid metal layer is formed on the whole end surface of the steel rail 3, so that the whole end surface is melted.
And S3, vibrating the end face. When a predetermined temperature field is established over a small depth range across the end portions, a vibratory force is applied in a direction parallel to the end faces to cause relative movement between the end faces of the two weldments. Specifically, when a predetermined temperature field is established at the end of the steel rail 3 in a small depth range, the vibration cylinder 5 applies a vibration force to the steel rail 3 in a direction parallel to the end face by the vibration jig 6 which clamps the steel rail and is close to the end face to be welded of the steel rail.
And S4, propping up the joint tightly. When the relative motion between the end faces of the two weldments reaches a preset amplitude and frequency, a jacking force is applied in the direction vertical to the end faces to enable the two melted end faces to be folded, and molten metal, overburning structures, oxide inclusions and the like in the joint area are extruded out of the joint area. Specifically, when the relative motion between the end faces of the two rails 3 reaches a predetermined amplitude and frequency, the upsetting cylinder 7 pushes the moving end fixture 2 to rapidly apply a low upsetting force to the rails 3 in a direction perpendicular to the end faces of the rails 3, so that the molten metal and the plastic metal in the molten end face regions of the two rails 3 are rapidly contacted and folded to form a joint region, flashing is immediately stopped, and the molten metal, the overburning structure, the oxide inclusions and the like in the joint region are extruded from the joint region to form welding slag under the combined action of the upsetting force and the vibration force.
And S5, extruding and rejecting. Adjusting short circuit current, continuously heating the joint by using resistance heat, and under the action of vibration force and jacking force, mutually extruding and relatively shearing atoms of two contact end faces in the joint surface region, so as to crush foreign matters such as molten crystals, impurities and the like in the joint surface region and discharge the foreign matters from the joint. Specifically, a large short-circuit current is applied, the resistance heat is used for continuously heating the joint, meanwhile, under the continuous combined action of the jacking force and the vibration force, the mutual extrusion and relative shearing processes between atoms of two contact end faces in the joint face area are used for thoroughly crushing the molten crystals, impurities and other foreign matters in the joint face area, the foreign matters and the defects in the joint face area are discharged from the joint to form flash, and therefore the foreign matters and the defects in the joint face area are cleaned up, and the plastic solid-phase structure of the pure original base material matrix is obtained in the joint area.
And S6, plastic deformation heating. And adjusting short-circuit current, continuously heating the joint by using resistance heat, adjusting the jacking force, and heating the joint area by using plastic deformation heat of plastic metal in the joint area so that the plasticity of the metal in the joint area reaches a thermoplastic state within a preset depth range. Specifically, a small short-circuit current is switched, resistance heat is used for continuously heating the joint, the jacking force and the vibration force are properly adjusted, a large amount of plastic deformation heat is released by plastic metal in the joint area in the plastic deformation process to heat the joint area, and the plasticity of the metal in the whole joint area reaches a thermoplastic state within a preset depth range along with the temperature rise of the joint area.
And S7, grinding fine grains by sticking. Adjusting current and jacking force, refining grain structure of the joint surface region by utilizing mutual adhesion and grinding among plastic metal atoms of the joint surface region, and promoting mutual diffusion among atoms of the joint surface region to form common grains. Specifically, the current and the jacking force are properly adjusted, and the mutual grinding process between plastic metal atoms of two contact end surfaces of the joint area is utilized, so that on one hand, the grain structure of the joint area is further refined to improve the toughness of the joint, and on the other hand, the mutual diffusion between the atoms of the joint area is promoted to form common grains.
And S8, upset forging and welding. When the grain refinement degree and the eutectic quantity both meet the preset requirements, stopping the vibration force, adjusting the jacking force, promoting the thermoplastic metal in the joint surface area to generate extremely-fast plastic deformation and instantaneous flow, accelerating the mutual diffusion among atoms in the joint surface area, forming a sufficient amount of common grain structure with fine grain size, and immediately stopping heating the joint by resistance heat.
And S9, maintaining the pressure and cooling. The jacking force is kept, the cooling speed of the thermoplastic metal in the joint surface area is controlled, the phase change process of the thermoplastic metal in the joint area can be rapidly completed, and a solid-state welding joint with excellent comprehensive performance can be obtained.
In fig. 2-5, T represents a time node, and a time period between Tn and Tn +1 corresponds to each step described above, wherein a change in current is shown in fig. 2, a vibration displacement of the end portion under a vibration force is shown in fig. 3, an upsetting displacement under an upsetting force is shown in fig. 4, and a change in the upsetting force is shown in fig. 5; wherein, the larger or smaller tightening force and the larger or smaller current are relative terms, as shown in fig. 2 and fig. 5.
The invention provides a novel flash welding method, which is improved on the basis of the original flash welding method, and is provided with five key steps of vibrating an end face, propping up a tight joint, extruding rejection, plastic deformation heating and bonding and grinding crystals, molten metal, overburning structures, oxide inclusions and the like in a joint surface region can be extruded out from the joint surface, and molten crystals, impurities and other foreign matters in the joint surface region are crushed and discharged from the joint, so that the plasticity of the metal in the joint region reaches a thermoplastic state within a preset depth range, the grain structure of the joint surface region is refined, the interatomic mutual diffusion of the atoms in the joint surface region is promoted, common grains are formed, the quality of a welding joint is improved, the stability and the superstrong property of the quality of the welding joint are ensured, and the mechanical property of the quality of the welding joint is enhanced.
Although the invention has been described in detail above with reference to a general description and specific examples, it will be apparent to one skilled in the art that modifications or improvements may be made thereto based on the invention. Accordingly, such modifications and improvements are intended to be within the scope of the invention as claimed.
Claims (4)
1. A flash welding method, comprising the steps of:
flash heating;
vibrating the end face; when a preset temperature field is built in the whole end part within a smaller depth range, applying vibration force in a direction parallel to the end faces to enable the end faces of the two welding parts to move relatively;
propping and closing the seam; when the relative motion between the end surfaces of the two weldments reaches a preset amplitude and frequency, applying a jacking force in the direction vertical to the end surfaces to enable the two melted end surfaces to be folded, and extruding the molten metal, the overburning structure and the oxide inclusions in the joint surface area from the joint surface; specifically, when the relative motion between the end surfaces of two weldments reaches a preset amplitude and frequency, a lower jacking force is quickly applied in the direction vertical to the end surfaces, so that molten and plastic metals in the two molten end surface areas are quickly contacted and folded to form a joint area, flashing is immediately stopped, and the molten metal, the overburning structure and the oxide inclusions in the joint area are extruded out from the joint area to form welding slag under the combined action of the jacking force and the vibration force;
extruding and removing the foreign matters; adjusting short circuit current, continuously heating the joint by using resistance heat, and under the action of vibration force and jacking force, mutually extruding and relatively shearing atoms of two contact end surfaces of the joint surface region, crushing molten crystals and foreign impurities in the joint surface region and discharging the crushed impurities from a joint; specifically, a large short-circuit current is applied, the resistance heat is utilized to continuously heat the joint, meanwhile, under the combined action of the jacking force and the vibration force, the mutual extrusion and relative shearing process between atoms of two contact end surfaces of the joint surface region is utilized, the molten crystals and foreign matters of impurities in the joint surface region are thoroughly crushed, and are discharged from the joint to form a flash, so that the foreign matters and the defects in the joint surface region are cleaned, and the plastic solid-phase structure of the pure original base metal matrix is obtained in the joint region;
plastic deformation heating; adjusting short circuit current, continuously heating the joint by using resistance heat, adjusting jacking force, and heating the joint area by using plastic deformation heat of plastic metal in the joint area to enable the plasticity of the metal in the joint area to reach a thermoplastic state within a preset depth range; specifically, a small short-circuit current is switched, resistance heat is used for continuously heating the joint, the jacking force and the vibration force are properly adjusted, a large amount of plastic deformation heat is released by plastic metal in the joint area in the plastic deformation process to heat the joint area, and the plasticity of the metal in the whole joint area reaches a thermoplastic state within a preset depth range along with the temperature rise of the joint area;
grinding the fine grains by sticking; adjusting current and jacking force, refining the grain structure of the joint surface region by utilizing mutual adhesion and grinding among plastic metal atoms of the joint surface region, and promoting mutual diffusion among atoms of the joint surface region to form common grains; specifically, the current and the jacking force are properly adjusted, and the mutual adhesion and grinding process between plastic metal atoms of two contact end surfaces of a joint area is utilized, so that on one hand, the grain structure of the joint area is further refined to improve the toughness of a joint, and on the other hand, the mutual diffusion between the atoms of the joint area is promoted to form common grains;
upsetting and welding; when the grain refinement degree and the eutectic quantity both meet the preset requirements, stopping the vibration force, adjusting the jacking force, promoting the thermoplastic metal in the joint surface area to generate extremely-fast plastic deformation and instantaneous flow, accelerating the mutual diffusion among atoms in the joint surface area, forming a sufficient amount of common grain structure with fine grain size, and immediately stopping heating the joint by resistance heat;
and (5) maintaining the pressure and cooling.
2. The flash welding method of claim 1, wherein the flash heating step comprises: the power supply is switched on, the end faces of the two weldment are gradually close to achieve local contact, and the whole end faces of the two weldment are melted by rapid heating of resistance thermal flash.
3. The flash welding method according to claim 2, characterized in that it further comprises the steps of:
a clamping and centering step before the flash heating step; the two weldments are oppositely arranged and assembled to form a butt joint, the end faces of the two weldments are lightly contacted, the end faces to be welded are aligned according to requirements, and one of the weldments slowly retreats for 1mm and then stops.
4. The flash welding method according to claim 1, wherein the dwell cooling comprises: maintaining the jacking force and controlling the cooling rate of the thermoplastic metal in the area of the joint surface.
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