CN113941763A - Shaking/rotating arc consumable electrode welding method adopting coarse welding wire - Google Patents
Shaking/rotating arc consumable electrode welding method adopting coarse welding wire Download PDFInfo
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- CN113941763A CN113941763A CN202111382001.3A CN202111382001A CN113941763A CN 113941763 A CN113941763 A CN 113941763A CN 202111382001 A CN202111382001 A CN 202111382001A CN 113941763 A CN113941763 A CN 113941763A
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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
- B23K9/12—Automatic feeding or moving of electrodes or work for spot or seam welding or cutting
- B23K9/124—Circuits or methods for feeding welding wire
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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
- B23K9/18—Submerged-arc welding
- B23K9/186—Submerged-arc welding making use of a consumable electrodes
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Abstract
A rocking/rotating arc consumable electrode welding method using a coarse wire. According to the method, according to the material and groove form of a workpiece to be welded, a consumable electrode welding method is selected, a coarse welding wire is selected, then the motion trail and welding process parameters of an electric arc are set, an electric arc shaking/rotating driving mechanism is used for driving a bent or eccentric conducting rod mechanism, an electric arc with the lower end extending out of the tail end of the coarse welding wire in an inclined or eccentric mode is driven, reciprocating type circular arc shaking trail or unidirectional rotation trail motion is carried out, or reciprocating type circular arc shaking and unidirectional rotation alternate composite trail motion is carried out, and finally, under the protection of welding gas, slag, or welding gas and slag, shaking/rotating electric arc consumable electrode welding of the coarse welding wire with the outer diameter of 1.6-6.4 mm is adopted. The invention has low implementation cost, high deposition speed and stable welding process, can obviously improve the weld forming and joint structure performance of the rough welding wire, and is suitable for occasions of gas metal arc welding, submerged arc welding and the like in or on the surface of a workpiece notch.
Description
Technical Field
The invention relates to a method for realizing welding of a shaking/rotating arc consumable electrode by adopting a thick welding wire, belonging to the technical field of welding.
Background
The consumable electrode arc welding method is a welding method for melting a base metal and a filler metal by using an arc generated between the filler metal (a welding wire or a welding rod) and a workpiece to be welded as a heat source, and is commonly used in manufacturing industries of ships, pressure vessels, bridges, high-rise buildings, and the like. Among them, manual shielded metal arc welding has been gradually replaced by a gas metal arc welding method because of the need to frequently replace the welding rod, which is inefficient in welding and less in application.
The gas metal arc welding method of the consumable electrode usually adopts a solid welding wire or a flux-cored welding wire with the outer diameter less than or equal to 1.6mm as an electrode and a filling metal, and simultaneously utilizes active gas or inert gas (slag is also generated during the welding of the flux-cored welding wire) to protect an electric arc and a molten pool, so that the connection between metals to be welded can be quickly realized. In comparison with manual shielded metal arc welding, the method is carried out in such a manner that the welding wire is continuously fed into the welding region and melted by the arc, thereby achieving a higher welding efficiency. Submerged arc welding is a method for welding by igniting welding wires under a flux layer, can be performed by adopting a thick welding wire with large current, and has the advantages of no arc light, less smoke dust and the like.
The Chinese patent No. 201611233557.5 entitled "carbon dioxide gas shielded welding method for austenitic stainless steel pressure vessel" discloses a method for realizing austenitic stainless steel and CO welding by adopting a stainless steel flux-cored wire with an outer diameter of 1.2mm2The gas shielded welding reduces the stress and deformation of the joint and improves the corrosion resistance of the austenitic stainless steel joint by designing the welding sequence and the process parameters. But the method isThe diameter of the welding wire is small, the welding current is small, and the deposition amount in unit time is limited, so that the welding deposition speed is low, and the inherent welding efficiency is low.
The Chinese patent application No. 201810801292.7, entitled narrow-gap submerged arc welding method for circumferential weld of thick austenitic stainless steel plate, discloses a submerged arc welding method for circumferential weld of austenitic stainless steel with plate thickness greater than 50mm by adopting solid austenitic stainless steel welding wire with outer diameter of 1.6 mm. According to the method, the filling of deposited metal is reduced by reducing the angle of the groove, the production efficiency is improved, but the technical advantage of high-current high-deposition speed of submerged arc welding cannot be exerted, and the welding efficiency is equivalent to the gas shield welding efficiency.
The Chinese patent application No. 201710439703.8, entitled "double-wire submerged arc welding method of high-strength super-thick steel plate for high heat input welding", discloses a method for realizing multilayer and multi-pass submerged arc welding of high-strength steel plate with plate thickness greater than 50mm by adopting two solid welding wires with outer diameter of 4mm and common SJ101 welding flux. Although the method realizes the high heat input welding of the high-strength steel thick plate, the implementation of the asymmetric X-shaped groove with a special angle needs to strictly control the technological parameters such as the heat input, the distance between the double wires, the inclination angle, the current form and the like in the welding process, so the application has certain limitation.
In summary, in the conventional consumable electrode welding method, the diameter of the welding wire used in the consumable electrode gas shielded welding is usually thin, and the deposition speed is limited; the submerged arc welding method of a single thin welding wire has small welding current and fails to exert the advantage of high melting speed of submerged arc welding. In addition, after the diameter of the welding wire is increased, during gas metal arc welding, the size of a molten drop is increased, the drop is difficult to fall off, a large amount of welding spatter is easy to generate, and the forming quality of a welding seam is relatively poor; when submerged arc welding is carried out, large welding current can be adopted, but large welding spatter and welding through defects are easily generated. Therefore, the prior art fails to make good use of a thick wire to achieve efficient high quality welding.
Disclosure of Invention
The invention aims to provide a method for welding a consumable electrode by using a shaking/rotating arc of a thick welding wire, which aims at solving the problems of low deposition rate, poor weld forming quality of large-current submerged arc welding, large welding spatter and the like in the existing single-arc monofilament consumable electrode welding process technology during gas shielded welding and comprehensively utilizes the technical advantages of high welding deposition speed of the thick welding wire and improvement of weld forming by arc shaking/rotating energy.
The method has the technical advantages of low implementation cost, high welding efficiency, good weld forming quality, strong applicability and the like.
In order to achieve the purpose, the invention is realized by adopting the following technical scheme.
A method for welding a shaking/rotating arc consumable electrode by adopting a thick welding wire mainly comprises a wire feeder, a coupling head, an arc shaking/rotating driving mechanism, a conducting rod mechanism and a welding power supply, wherein the upper end of the arc shaking/rotating driving mechanism is fixedly connected with the coupling head for leading in welding current, the lower end of the arc shaking/rotating driving mechanism is fixedly connected with the conducting rod mechanism, a positive output cable of the welding power supply is fixedly connected with the coupling head, and a negative output cable of the welding power supply is fixedly connected with a workpiece to be welded; the technical scheme of the method specifically comprises the following steps:
selecting a consumable electrode welding method and an electric arc motion track according to the material and the welding groove form of a workpiece to be welded, and selecting a coarse welding wire and a shielding gas or a welding flux, wherein the consumable electrode welding method comprises a consumable electrode gas shielded welding or submerged-arc welding method, the electric arc motion track comprises a reciprocating type arc shaking track or a unidirectional rotation track or a combined track of reciprocating type arc shaking and unidirectional rotation alternation, the coarse welding wire is a single-strand coarse welding wire or a twist type coarse welding wire or a cable type coarse welding wire consisting of two or more than two fine welding wires with the same or different chemical components, the outer diameter of the selected coarse welding wire during consumable electrode gas shielded welding is 1.6-2.4 mm, and the outer diameter of the selected coarse welding wire during submerged-arc welding is 1.6-6.4 mm;
secondly, setting corresponding welding process parameters according to the consumable electrode welding method and the arc motion trail: when the rough welding wire is used for carrying out gas shielded arc welding of the swing arc consumable electrode, the average welding current is 100-1300A, the average arc voltage is 18-40V, the arc swing frequency is 0-5 Hz, the arc swing angle is 0-180 degrees, the minimum arc swing radius is 0.8-3.0 mm, and the residence time of the arc at the arc swing track limit point is 0-100 ms; when the thick welding wire is used for carrying out gas shielded arc welding of the rotating arc consumable electrode, the average welding current is 100-1300A, the average arc voltage is 18-40V, the arc rotating frequency is 0-100 Hz, and the arc rotating radius is 0.8-9.2 mm; when the coarse welding wire is adopted for carrying out rocking arc submerged-arc welding, the average welding current is 160-1500A, the average arc voltage is 20-50V, the arc rocking frequency is 0-5 Hz, the arc rocking angle is 0-180 degrees, the minimum arc rocking radius is 0.8-3.0 mm, and the residence time of the arc at the limit point of the arc rocking track is 0-100 ms; when the coarse welding wire is adopted for carrying out rotary arc submerged arc welding, the average welding current is 160-1500A, the average arc voltage is 20-50V, the arc rotating frequency is 0-100 Hz, and the arc rotating radius is 0.8-15.2 mm;
and thirdly, driving the bent or eccentric conducting rod mechanism through the electric arc shaking/rotating driving mechanism, so that the electric arc at the lower end of the conducting rod mechanism obliquely or eccentrically extends out of the end part of the thick welding wire moves around the central line of the welding torch according to a set electric arc motion track, and finally, under the protection of welding gas, slag, or the welding gas and the slag, the shaking/rotating electric arc consumable electrode welding of the thick welding wire with the outer diameter of 1.6-6.4 mm is realized.
Preferably, the welding groove in the first step is a V-shaped welding groove or a narrow gap welding groove; for the narrow gap welding groove, when single-channel shaking/rotating arc consumable electrode gas shielded welding of each layer is carried out, the gap of the groove root is 12-20 mm, meanwhile, when the arc carries out the combined type track motion, the maximum shaking radius and the maximum rotating radius of the arc are both 4-8 mm, and the frequency ratio of the unidirectional rotating track to the reciprocating type arc shaking track is 4-100; for the narrow gap welding groove, when single-pass rocking/rotating arc submerged arc welding of each layer is carried out, the gap of the groove root is 12-32 mm, meanwhile, when the arc carries out the combined motion, the maximum rocking radius and the maximum rotating radius of the arc are both 4-14 mm, and the frequency ratio of the unidirectional rotating track to the reciprocating arc rocking track is 4-100.
Preferably, in the second step, when the surface of the workpiece to be welded is subjected to gas shielded surfacing welding by a shaking/rotating arc consumable electrode, the maximum shaking radius and the maximum rotating radius of the arc are both 22 mm; when the submerged arc surfacing welding of the shaking/rotating arc is carried out on the surface of a workpiece to be welded, the maximum shaking radius and the maximum rotating radius of the arc are both 31 mm; in the first step and the second step, when the selected rough welding wire is a twist type rough welding wire or a cable type rough welding wire, the set welding process parameters further comprise 200-1260A of arc striking current, and the arc striking current rising rate is 100-31500A/s.
Preferably, in the second step, when a coarse welding wire is adopted for carrying out shaking/rotating arc consumable electrode gas shielded welding, before welding, powdery or filamentous welding auxiliary filler is paved in the welding groove in the first step, or a cold welding wire or a hot welding wire which plays a role of auxiliary filler wire is synchronously fed in the welding process of the shaking/rotating arc consumable electrode, the outer diameter of the cold welding wire or the hot welding wire which is fed in the auxiliary filler is 1.6-2.4 mm, and meanwhile, when the welding wire which is fed in the auxiliary filler is a hot welding wire, the maximum current for heating the auxiliary filler welding wire is 650A; when the rough welding wire is adopted for shaking/rotating arc submerged arc welding, powdery or filiform welding auxiliary filler is paved in the welding groove in the step I before welding.
Preferably, when the selected thick welding wire is a twist thick welding wire or a cable thick welding wire, the arc does not move along any track in the step (iii), and the upper end of the conducting rod mechanism is directly connected with the coupling head for leading in the welding current.
Compared with the prior art, the invention has the main remarkable advantages and beneficial effects that:
(1) compared with the traditional single-arc gas metal arc welding technology using a single thin welding wire with the outer diameter of 1.2mm, the outer diameter of the used thick welding wire is 1.6-2.4 mm, the deposition rate at the same wire feeding speed is increased by more than 33%, meanwhile, the arc regularly shakes or rotates, so that droplet transition can be promoted, droplet size can be reduced, a molten pool can be stirred, welding spatter can be reduced, weld grains can be refined, the stability of the welding process can be enhanced, the formation of the weld can be improved, small balls at the end parts of the thick welding wire after welding can be reduced, the re-striking success rate of the thick welding wire can be improved, and efficient gas metal arc welding with the shaking/rotating thick welding wire can be finally realized.
(2) Compared with the traditional monofilament submerged arc welding method, the method utilizes the electric arc shaking/rotating control technology to adjust the thermal distribution of the electric arc, enhance the spreading performance of the molten pool, effectively inhibit the defective formation of the monofilament submerged arc welding seam such as excessive height, finger-shaped penetration, welding penetration defect and the like, fully stir the molten pool by electric arc shaking or rotating, obviously inhibit the growth of welding seam grains during high-current welding, improve the structure of the monofilament submerged arc welding joint and improve the mechanical property of the joint.
(3) Compared with the existing narrow-gap consumable electrode welding method of the thin welding wire, the thick welding wire with the outer diameter of 1.6-6.4 mm is used for large-current welding, and even if the arc shaking radius or the rotating radius is smaller, better groove side wall fusion depth can be obtained, so that the problem of poor side wall fusion of the narrow-gap welding groove can be effectively prevented, the requirement on assembling before welding the large-thick-plate narrow-gap welding groove is reduced, and meanwhile, the high-deposition-speed characteristic of the thick welding wire can further improve the large-thick-plate narrow-gap welding efficiency.
(4) Compared with the prior art of surfacing welding, the invention controls the electric arc to make rapid arc rocking or unidirectional rotation with larger radius, the action area of the electric arc in unit time is increased, the welding auxiliary filler synchronously fed is beneficial to further reducing the dilution rate of the base metal in the welding seam, and meanwhile, the high-melting speed advantage of the coarse welding wire is utilized, so that the surfacing welding efficiency of the single electric arc consumable electrode can be obviously improved under the condition of low cost.
(5) Compared with the traditional consumable electrode welding method, the method has the advantages that in the implementation process, the types and chemical components of the rough welding wires are various, meanwhile, cold-state or hot-state welding auxiliary fillers are synchronously fed in the laying before welding or welding process, a molten pool is fully stirred under the shaking or rotating action of the electric arc of the rough welding wires, the metal alloying action of a welding seam is enhanced, the component distribution uniformity is improved, and the structure performance of a welding joint is more uniform and stable.
Drawings
FIG. 1 is a schematic diagram of a method and apparatus for welding a V-groove by a rocking/rotating arc consumable electrode using a coarse wire according to the present invention.
Fig. 2 is a schematic view of a single strand thick wire.
Fig. 3 is a schematic view of a twist-type heavy wire made of 3 strands of thin wire.
Fig. 4 is a schematic view of a cable-type heavy wire consisting of 7 strands of thin wire.
Fig. 5 is a schematic diagram of the system of the present invention without any such orbital movement of the arc.
FIG. 6 is a schematic diagram of a welding trace of a thick wire arc during an I-type narrow gap welding groove.
FIG. 7 is a schematic of an arc rotation trajectory of a heavy wire.
FIG. 8 is a schematic illustration of the present invention using a rocking/rotating arc consumable electrode welding process with a coarse wire for surfacing.
FIG. 9 is a photograph of a cross-section of a joint formed by single strand heavy wire rocking arc gas metal arc deposition.
FIG. 10 is a photograph of a cross-section of a joint formed by single strand heavy wire rotary arc submerged arc deposition welding.
FIG. 11 is a photograph of a cross-section of a joint formed by cable type heavy wire rocking arc narrow gap welding groove single layer single pass gas metal arc welding.
FIG. 12 is a photograph of the cross-section of the joint formed by the cable type thick wire shaking arc narrow gap welding groove single layer single submerged arc welding.
FIG. 13 is a photograph of a cross-section of a joint formed by single strand heavy wire rotary arc submerged arc welding.
FIG. 14 is a photograph showing a cross-sectional shape of a joint in a gas metal arc welding using a twisted thick wire.
In fig. 1 to 14: 1-coarse welding wire; 1-single strand thick wire; 1-2-twist type thick welding wire; 1-3-cable type thick welding wire; 2-wire feeder; 3-a coupling head; 4-arc rocking/rotating driving mechanism; 5-conducting rod mechanism; 6-electric arc; 7-torch centerline; 8-welding power supply; 9-a workpiece to be welded; 10-V-shaped welding groove; 11-reciprocating circular arc rocking track; 12-unidirectional rotation trajectory; 13-welding the groove with narrow gap; 13-1, 13-2-groove side wall; 14-the surface of a workpiece to be welded; d, the outer diameter of the thick welding wire; d, forming the outer diameter of the thin welding wire of the twisted or cable type thick welding wire; o is1-welding torch centre projection point; g- (G) -)The gap of the groove root; r is1-reciprocating circular arc rocking trajectory radius; r is2-radius of unidirectional rotation trajectory; A. b-limit point of arc rocking track.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is further described in detail with reference to the accompanying drawings and the detailed description, and all technical solutions obtained by using equivalent substitution or equivalent transformation are within the scope of the present invention.
The invention provides a welding method of a shaking/rotating arc consumable electrode by adopting a thick welding wire, which has the technical principle that: an arc shaking/rotating driving mechanism 4 on the welding torch is used for driving a conducting rod mechanism 5 to drive an arc 6 at the lower end of the welding torch to extend out of the tail end of the thick welding wire 1, and the shaking radius is r according to set welding process parameters1Or make a rotation radius r2The unidirectional rotation track 12 moves or the reciprocating arc rocking and unidirectional rotation alternate composite track motion is carried out, and finally under the protection of welding gas or slag or the welding gas and slag, the rocking/rotating arc consumable electrode welding of the thick welding wire 1 with the outer diameter D of 1.6-6.4 mm is realized. The method for welding the consumable electrode by adopting the shaking/rotating arc of the coarse welding wire can be used for the gas shielded welding or submerged arc welding of the consumable electrode when a V-shaped welding groove 10, a narrow gap welding groove 13 or other welding groove forms are formed on a workpiece 9 to be welded, and can also be used for the gas shielded welding or submerged arc welding of the consumable electrode on the surface 14 of the workpiece to be welded.
FIG. 1 is a schematic diagram of a method and apparatus for welding a V-groove by a rocking/rotating arc consumable electrode using a coarse wire according to the present invention, the apparatus comprising: wire feeder 2, coupling head 3, arc shaking/rotating driving mechanism 4, conducting rod mechanism 5, welding power supply 8. The upper end of the electric arc shaking/rotating driving mechanism 4 is connected with the coupling head 3 for leading in welding current, and the lower end of the electric arc shaking/rotating driving mechanism is fixedly connected with the conducting rod mechanism 5; and a positive output cable of the welding power supply 8 is fixedly connected with the coupling head 3, and a negative output cable of the welding power supply is fixedly connected with the workpiece 9 to be welded. The thick welding wire 1 sent by the wire feeder 2 passes through the coupling head 3 and the arc shaking/rotating driving mechanism 4, and then obliquely extends out from the lower end of the conducting rod mechanism 5 at a certain included angle with the central line 7 of the welding torch or eccentrically extends out from the lower end of the conducting rod mechanism parallel to the central line 7 of the welding torch. The electric arc shaking/rotating driving mechanism 4 can be a direct driving mechanism adopting a hollow shaft motor, or an indirect driving mechanism adopting a common motor to drive a gear pair (or a chain transmission pair or a belt transmission pair or a worm and gear transmission pair); the conductive rod mechanism 5 can be a bent conductive rod mechanism composed of a common conductive nozzle and a bent conductive rod, or an eccentric conductive rod mechanism composed of an eccentric conductive nozzle and a straight conductive rod, or an eccentric conductive rod mechanism composed of an eccentrically-mounted common conductive nozzle and a straight conductive rod. The thick welding wire 1 can be a single thick welding wire 1-1 (see fig. 2), or a twist thick welding wire 1-2 (see fig. 3) or a cable thick welding wire 1-3 (see fig. 4) consisting of two or more thin welding wires with the same or different chemical compositions. When the thick welding wire 1 is a twist thick welding wire 1-2 or a cable thick welding wire 1-3. If the arc 6 does not move along the arc motion track during the welding process, the upper end of the conducting rod mechanism 5 can be directly and fixedly connected with the coupling head 3 for leading in the welding current (see fig. 5).
Before welding, a consumable electrode welding method and an electric arc movement track are selected according to the material and the welding groove form of a workpiece 9 to be welded, a thick welding wire 1 and protective gas or a welding flux are selected, and then corresponding welding process parameters are set according to the consumable electrode welding method and the electric arc movement track. The consumable electrode welding method comprises a consumable electrode gas shielded welding or submerged-arc welding method, the arc motion track comprises a reciprocating arc shaking track 11 or a unidirectional rotation track 12 or a composite track of reciprocating arc shaking and unidirectional rotation, and the thick welding wire 1 is a single-strand thick welding wire 1-1 or a twist type thick welding wire 1-2 or a cable type thick welding wire 1-3 consisting of two or more thin welding wires with the same or different chemical components. When the welding process parameters are set, corresponding welding process parameters are required to be set according to different welding methods and arc motion tracks. The specific method is as follows:
when the rough welding wire 1 is adopted for the gas metal arc welding of the shaking arc, the outer diameter D of the selected rough welding wire 1 is 1.6-2.4 mm, and the set average welding power is connectedThe flow is 100-1300A, the average arc voltage is 18-40V, and the applicable minimum groove root gap G is 12 mm; when the welding groove is in the form of a narrow-gap welding groove, the corresponding minimum arc rocking radius r is 3mm under the condition that the maximum reserved gap (namely the distance from the arc to the groove side walls 13-1 and 13-2 when the arc is respectively at the arc rocking track limit points A and B, see figure 6)10.8-3.0 mm (see figure 6), and the set arc shaking frequency is 0-5 Hz, the arc shaking angle is 0-180 degrees, and the staying time of the arc at the arc shaking track limit points A and B is 0-100 ms respectively.
When the thick welding wire 1 is adopted for carrying out the rotating arc consumable electrode gas shielded welding, the outer diameter D of the selected thick welding wire 1 is 1.6-2.4 mm, the set average welding current is 100-1300A, the average arc voltage is 18-40V, the applicable maximum groove root gap G is 20mm, and the corresponding arc rotating radius r20.8-9.2 mm (see figure 7), and the set arc rotation frequency is 0-100 Hz.
When the rough welding wire 1 is adopted for carrying out rocking arc submerged arc welding, the outer diameter D of the selected rough welding wire 1 is 1.6-6.4 mm, the set average welding current is 160-1500A, the average arc voltage is 20-50V, and the applicable minimum groove root gap G is 12 mm; when the welding groove is in a narrow gap welding groove form, under the condition that the maximum reserved gap is 3mm, the corresponding minimum arc shaking radius r1The arc oscillation frequency is 0.8-3.0 mm (see figure 6), the arc oscillation angle is 0-180 degrees, and the residence time of the arc at the arc track limit points A and B is 0-100 ms.
When the coarse welding wire 1 is adopted for carrying out rotary arc submerged arc welding, the outer diameter D of the selected coarse welding wire 1 is 1.6-6.4 mm, the set average welding current is 160-1500A, the average arc voltage is 20-50V, the applicable maximum groove gap G is 32mm, and the corresponding arc rotary radius r20.8-15.2 mm (see figure 7), and the set arc rotation frequency is 0-100 Hz.
In addition, when the selected thick welding wire 1 is the twist thick welding wire 1-2 or the cable thick welding wire 1-3, the set welding process parameters further comprise arc striking current and arc striking current rising rate, so that the welding wire can smoothly ignite the electric arc 6 after the subsequent welding starts, and the phenomena of explosion and breakage of the welding wire, splashing of large particles and wire blockage of a wire feeder are avoided. Correspondingly, the set arc striking current is 200-1260A, and the arc striking current rise rate is 100-31500A/s.
As shown in FIG. 6, when the present invention is used for performing the shaking/rotating arc consumable electrode gas metal arc welding of each layer of single channel of the narrow gap welding groove, the maximum shaking radius r of the electric arc is obtained when the minimum reserved gap is 2mm and the arc welding of the reciprocating arc shaking and the unidirectional rotation alternating compound track motion is simultaneously adopted1And maximum radius of rotation r2The same is 4 to 8mm, and the ratio of the frequency of the unidirectional rotation and the reciprocating circular arc oscillation in unit time is 4 to 100.
When the invention is adopted to carry out the shaking/rotating arc submerged arc welding of each layer of single channel of the narrow gap welding groove, the maximum shaking radius r of the electric arc is generated when the reciprocating arc shaking and the unidirectional rotation alternate compound track motion electric arc welding is adopted under the condition that the minimum reserved gap is 2mm1And maximum radius of rotation r2The same is 4 to 14mm, and the ratio of the frequency of the unidirectional rotation and the reciprocating circular arc oscillation in unit time is 4 to 100. In addition, under the condition of non-narrow gap welding notch, the electric arc can also perform reciprocating arc rocking and unidirectional rotation alternate composite track motion.
As shown in FIG. 8, when the method of the present invention is used for gas metal arc welding with shaking/rotating arc on the surface 14 of the workpiece 9 to be welded, there is no restriction of the V-shaped welding groove 10 or the narrow gap welding groove 13, and when the maximum dry extension of the welding wire is 25mm, the maximum shaking radius r of the arc is1Or maximum radius of rotation r2The same is 22 mm. Similarly, when the method of the invention is used for rocking/rotating arc submerged arc surfacing on the surface 14 of the workpiece 9 to be welded, the maximum arc rocking radius r of the arc is equal to the maximum dry wire elongation of 60mm1Or maximum radius of rotation r2Is 31 mm.
After the welding process parameters are set, an arc starting switch of the welding power supply 8 is closed, and the rough welding wire 1 is controlled to ignite the electric arc 6 in the V-shaped welding groove 10 of the workpiece 9 to be welded or in the narrow gap welding groove 13 or on the surface 14 of the workpiece to be welded. And then, driving a conducting rod mechanism 5 by an electric arc shaking/rotating driving mechanism 4 on the welding torch, so that an electric arc 6 at the end part of a single-strand thick welding wire 1-1 or a twist-type thick welding wire 1-2 or a cable-type thick welding wire 1-3 which obliquely or eccentrically extends out of the lower end of the conducting rod mechanism 5 moves around a central line 7 of the welding torch in a reciprocating type circular arc shaking track 11 or a unidirectional rotating track 12 or in a reciprocating type circular arc shaking and unidirectional rotating alternate composite track, and finally, under the protection of welding gas, slag, or welding gas and slag, the shaking/rotating electric arc consumable electrode welding of the thick welding wire 1 with the outer diameter D of 1.6-6.4 mm is realized.
When the selected thick welding wire 1 is a solid welding wire and shaking/rotating arc consumable electrode gas shielded welding is carried out, the welding shielding gas which has the protective effect on the electric arc 6 and molten pool liquid metal is mainly used, and a small amount of slag is also contained; when the selected thick welding wire 1 is a solid welding wire and is subjected to shaking/rotating arc submerged arc welding, the welding slag which has the protective effect on the electric arc 6 and molten pool liquid metal is mainly used, and in addition, a small amount of welding gas generated by a submerged arc welding agent is also contained; when the selected rough welding wire 1 is a self-shielded flux-cored wire or a common flux-cored wire and shaking/rotating arc consumable electrode gas shielded welding is carried out, slag and welding protective gas which play a role in protecting an arc 6 and molten pool liquid metal are mainly used, and the welding protective gas comes from the self-shielded flux-cored wire or is fed from the outside.
In addition, when the gas metal arc welding is carried out by adopting the method, before welding, powdery or filamentous welding auxiliary filler can be laid in the V-shaped welding groove 10 or the narrow gap welding groove 13, or a cold welding wire or a hot welding wire which has the outer diameter of 1.6-2.4 mm, is the same as or different from the main wire in material and plays a role of auxiliary filler wire is synchronously fed into a welding area in the welding process, so that the deposition speed of the shaking/rotating arc gas metal arc welding is further increased; at this time, if the auxiliary welding wire is a hot welding wire, the maximum current for heating the auxiliary welding wire is 650A. Similarly, when the method of the invention is used for submerged arc welding, powdery or filiform welding auxiliary filler can be laid in the V-shaped welding groove 10 or the narrow gap welding groove 13 before welding, thereby further improving the deposition speed of the shaking/rotating arc submerged arc welding of the invention.
The following provides 4 embodiments of the present invention, which are applied to a welding method using a welding wire with a rotating arc and a shaking arc, respectively, to illustrate the method for setting parameters of the present invention under different welding conditions. In the embodiment, the workpieces 9 to be welded are all made of low alloy steel Q370, the welding wire used for gas metal arc welding has the brand number ER50-6, and the protective gas Ar 80% + CO2The gas flow is 40L/min, the material grade of a welding wire used for submerged arc welding is H08Mn2E, and the grade of a welding flux is CHF 101Q.
Example 1
Fig. 9 and 10 show photographs of cross-sectional shapes of joints obtained by performing gas metal arc gas shielded arc deposition and rotating arc submerged arc deposition, respectively, using a single strand of thick wire 1-1, wherein the single strand of thick wire 1-1 has an outer diameter D of 2.4 mm. Wherein the average welding current used in FIG. 9 is 550A, the average arc voltage is 38V, the welding speed is 300mm/min, the arc oscillation frequency is 2.5Hz, the arc oscillation angle is 120 degrees, and the arc oscillation radius r17.5mm, and the staying time of the electric arc at the arc track limit point is 40 ms; FIG. 10 shows an average welding current of 500A, an average arc voltage of 36V, a welding speed of 350mm/min, an arc rotation frequency of 50Hz, and an arc rotation radius r2Is 3.5 mm. As can be seen from fig. 9 and 10, in the rocking arc consumable electrode gas shielded surfacing and the rotating arc submerged arc surfacing using the rough welding wire, the thermal distribution area of the arc is widened due to the rocking or rotation of the arc, so that the spreading performance of the weld pool is improved, and finally, a surfacing joint with good formation and no obvious finger-shaped penetration is obtained.
Example 2
Fig. 11 and 12 show the cross-section forming photos of the joint obtained after shaking arc narrow gap welding groove single-layer single-pass gas metal arc welding and shaking arc narrow gap welding groove single-layer single-pass submerged arc welding are respectively carried out by adopting cable type thick welding wires 1-3, wherein the cable type thick welding wires 1-3 with the outer diameter D of 2.4mm are formed by winding 7 thin welding wires with the outer diameter D of 0.8 mm. Wherein, the gap G of the I-shaped narrow gap welding groove 13 of the workpiece 9 to be welded in FIG. 11 is 12mm, an average welding current of 450A, an average arc voltage of 35V, a welding speed of 250mm/min, an arc oscillation frequency of 3Hz, an arc oscillation angle of 50 DEG, and an arc oscillation radius r16.5mm, the staying time of the electric arc at the arc track limit point is 20ms, the arc striking current is 650A, and the arc striking current rise rate is 6500A/s; in FIG. 12, the gap G of the I-shaped narrow gap welding notch 13 of the workpiece 9 to be welded is 16mm, the average welding current used is 600A, the average arc voltage is 40V, the welding speed is 420mm/min, the arc rotation frequency is 25Hz, and the arc rotation radius r24mm, the arc striking current is 1000A, and the arc striking current rise rate is 1000A/s. As can be seen from FIGS. 11 and 12, the single-layer single-channel gas metal arc welding head and the single-layer single-channel buried arc welding head for electric arc narrow gap welding of the groove obtained by using the cable type rough welding wires 1-3 have better side wall penetration and attractive integral formation.
Example 3
FIG. 13 is a photograph showing the cross-sectional shape of a joint obtained by the submerged arc welding using a single-strand welding wire 1-1, in which the single-strand welding wire 1-1 has an outer diameter D of 4mm, a V-shaped welding groove 10 of 30 degrees is formed in a workpiece 9 to be welded, and a root gap is 16 mm. The average welding current is 800A, the average arc voltage is 42V, the welding speed is 350mm/min, the arc rotation frequency is 75Hz, and the arc rotation radius r2Is 4.2 mm. As can be seen in FIG. 13, a well formed rotary arc submerged arc welding joint was obtained with the single strand wire 1-1.
Example 4
Fig. 14 is a photograph showing the cross-section of the joint obtained after gas metal arc welding using a twist thick welding wire 1-2, in which the twist thick welding wire 1-2 having an outer diameter D of 6.4mm is formed by winding 3 thin welding wires having an outer diameter D of 2.97mm, and a workpiece 9 to be welded is provided with a 9 ° V-shaped welding groove 10, and a root gap G is 13 mm. The average welding current used is 950A, the average arc voltage is 43V, the welding speed is 320mm/min, the arc striking current is 800A, and the arc striking current rise rate is 16000A/s. During the welding process, the arc does not move along any arc motion track. As can be seen from fig. 14, the gas metal arc welded joint obtained with the twisted welding wire 1-2 was well formed.
The present invention may be embodied in other specific forms, and it will be apparent to those skilled in the art that various modifications and improvements can be made without departing from the spirit and scope of the invention.
Claims (7)
1. The utility model provides an adopt shake of thick welding wire/rotatory arc consumable electrode welding method, its shake that uses/rotatory arc consumable electrode welding set mainly includes send a silk machine (2), coupling head (3), arc shake/rotatory actuating mechanism (4), conducting rod mechanism (5), welding power supply (8), wherein the upper end of arc shake/rotatory actuating mechanism (4) is linked firmly with leading-in welding current's coupling head (3), the lower extreme of arc shake/rotatory actuating mechanism (4) is linked firmly with conducting rod mechanism (5), the anodal output cable of welding power supply (8) is linked firmly with coupling head (3), the negative pole output cable of welding power supply (8) is linked firmly with work piece (9) of waiting to weld, characterized by: the method for welding the shaking/rotating arc consumable electrode by adopting the thick welding wire comprises the following steps of:
firstly, according to the material and welding groove form of the workpiece (9) to be welded, a consumable electrode welding method and an electric arc motion track are selected, a thick welding wire (1) and a protective gas or a welding flux are selected, the consumable electrode welding method comprises a consumable electrode gas shielded welding or submerged arc welding method, the arc motion track comprises a reciprocating arc shaking track (11) or a unidirectional rotation track (12) or a composite track of alternating reciprocating arc shaking and unidirectional rotation, the thick welding wire (1) is a single-strand thick welding wire (1-1), or a twist type thick welding wire (1-2) or a cable type thick welding wire (1-3) which is composed of two or more thin welding wires with the same or different chemical compositions, the outer diameter (D) of the selected rough welding wire (1) during gas metal arc welding is 1.6-2.4 mm, and the outer diameter (D) of the selected rough welding wire (1) during submerged arc welding is 1.6-6.4 mm;
secondly, setting corresponding welding process parameters according to the consumable electrode welding method and the arc motion trail: when the rough welding wire (1) is adopted to carry out the swing arc consumable electrode gas shielded welding, the average welding current is 100-1300A, the average arc voltage is 18-40V, the arc swing frequency is 0-5 Hz, and the arc swing angle is0 to 180 DEG, minimum arc rocking radius (r)1) 0.8-3.0 mm, and the staying time of the electric arc at the limit point of the arc rocking track is 0-100 ms; when the thick welding wire (1) is used for rotating arc consumable electrode gas shielded welding, the average welding current is 100-1300A, the average arc voltage is 18-40V, the arc rotating frequency is 0-100 Hz, and the arc rotating radius (r)2) 0.8-9.2 mm; when the rough welding wire (1) is adopted for carrying out the rocking arc submerged arc welding, the average welding current is 160-1500A, the average arc voltage is 20-50V, the arc rocking frequency is 0-5 Hz, the arc rocking angle is 0-180 degrees, and the minimum arc rocking radius (r)1) 0.8-3.0 mm, and the staying time of the electric arc at the limit point of the arc rocking track is 0-100 ms; when the coarse welding wire (1) is adopted for carrying out the rotating arc submerged arc welding, the average welding current is 160-1500A, the average arc voltage is 20-50V, the arc rotating frequency is 0-100 Hz, and the arc rotating radius (r)2) 0.8-15.2 mm;
and thirdly, driving the bent or eccentric conducting rod mechanism (5) through the electric arc shaking/rotating driving mechanism (4), enabling the electric arc (6) at the lower end of the conducting rod mechanism (5) to obliquely or eccentrically extend out of the end part of the thick welding wire (1) to move around a central line (7) of a welding torch according to a set electric arc motion track, and finally realizing shaking/rotating electric arc consumable electrode welding by adopting the thick welding wire (1) with the outer diameter (D) of 1.6-6.4 mm under the protection of welding gas or slag or welding gas and slag.
2. A method of welding with a welding wire using a rocking/rotating arc consumable electrode as set forth in claim 1, wherein: the welding groove form in the step I is a V-shaped welding groove (10) and a narrow gap welding groove (13); for the narrow gap welding groove (13), when the shaking/rotating arc consumable electrode gas shielded welding of each layer of single channel is carried out, the groove root gap (G) is 12-20 mm, and simultaneously when the electric arc carries out the combined type track motion, the maximum shaking radius (r) of the electric arc1) And maximum radius of rotation (r)2) 4-8 mm, and the ratio of the frequency of the unidirectional rotation to the frequency of the reciprocating circular arc shaking is 4-100; for the narrow gap welding groove (13), when the shaking/rotating arc submerged arc welding of each layer of single channel is carried out, the groove root gap (G) is 12-32 mm, the same as the groove root gapWhen the arc is subjected to said compound movement, the maximum rocking radius (r) of the arc1) And maximum radius of rotation (r)2) The same is 4 to 14mm, and the ratio of the frequency of the unidirectional rotation to the frequency of the reciprocating circular arc oscillation is 4 to 100.
3. A method of welding with a welding wire using a rocking/rotating arc consumable electrode as set forth in claim 1, wherein: in the second step, when the surface (14) of the workpiece to be welded is subjected to rocking/rotating arc consumable electrode gas protection surfacing, the maximum rocking radius (r) of the arc1) And maximum radius of rotation (r)2) The same is 22 mm; maximum rocking radius (r) of arc during rocking/rotating arc submerged arc weld deposition of a surface (14) of a workpiece to be welded1) And maximum radius of rotation (r)2) The same is 31 mm.
4. A method of welding with a welding wire using a rocking/rotating arc consumable electrode as set forth in claim 1, wherein: in the first step and the second step, when the selected rough welding wire (1) is a twist type rough welding wire (1-2) or a cable type rough welding wire (1-3), the set welding process parameters further comprise 200-1260A of arc striking current, and the arc striking current rising rate is 100-31500A/s.
5. A method of welding with a welding wire using a rocking/rotating arc consumable electrode as set forth in claim 1, wherein: secondly, when the gas shielded welding of the shaking/rotating arc consumable electrode is carried out by adopting the rough welding wire (1), before the welding, powdery or filamentous welding auxiliary filler is paved in the welding groove in the step I, or a cold welding wire or a hot welding wire which plays the role of auxiliary filler is synchronously fed in the welding process of the shaking/rotating arc consumable electrode in the step III; when the rough welding wire (1) is adopted for carrying out shaking/rotating arc submerged arc welding, powdery or filamentous welding auxiliary filler is paved in the welding groove in the step I before welding.
6. A method of welding with a welding wire using a rocking/rotating arc consumable electrode as set forth in claim 1, wherein: when the thick welding wire (1) is adopted for carrying out shaking/rotating arc consumable electrode gas shielded welding, the outer diameter of the cold welding wire or the hot welding wire which is filled in an auxiliary mode is 1.6-2.4 mm, and meanwhile when the welding wire which is filled in the auxiliary mode is the hot welding wire, the maximum current for heating the welding wire which is filled in the auxiliary mode is 650A.
7. A method of welding with a welding wire using a rocking/rotating arc consumable electrode as set forth in claim 1, wherein: when the selected thick welding wire (1) is a twist thick welding wire (1-2) or a cable thick welding wire (1-3), the electric arc (6) does not move along any track in the step III, and the upper end of the conducting rod mechanism (5) is directly connected with the coupling head (3) for leading in welding current.
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