CN114101856A - Welding method of current-carrying hot-fill wire - Google Patents
Welding method of current-carrying hot-fill wire Download PDFInfo
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- 238000003466 welding Methods 0.000 title claims abstract description 251
- 238000000034 method Methods 0.000 title claims abstract description 59
- 238000010438 heat treatment Methods 0.000 claims abstract description 66
- 238000002844 melting Methods 0.000 claims abstract description 11
- 230000008018 melting Effects 0.000 claims abstract description 11
- 239000010959 steel Substances 0.000 claims description 19
- 229910000831 Steel Inorganic materials 0.000 claims description 15
- 229910000838 Al alloy Inorganic materials 0.000 claims description 11
- 238000010891 electric arc Methods 0.000 claims description 11
- 230000001681 protective effect Effects 0.000 claims description 10
- 238000005253 cladding Methods 0.000 claims description 8
- 239000000945 filler Substances 0.000 abstract description 24
- 230000015572 biosynthetic process Effects 0.000 description 11
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- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 8
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- 229910052786 argon Inorganic materials 0.000 description 4
- 238000006073 displacement reaction Methods 0.000 description 4
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- 230000006698 induction Effects 0.000 description 3
- 229910052751 metal Inorganic materials 0.000 description 3
- 239000002184 metal Substances 0.000 description 3
- 239000010953 base metal Substances 0.000 description 2
- 229910002092 carbon dioxide Inorganic materials 0.000 description 2
- 239000001569 carbon dioxide Substances 0.000 description 2
- 230000007547 defect Effects 0.000 description 2
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- 238000002474 experimental method Methods 0.000 description 2
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
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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
-
- 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
- B23K10/00—Welding or cutting by means of a plasma
- B23K10/02—Plasma welding
-
- 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
- B23K9/06—Arrangements or circuits for starting the arc, e.g. by generating ignition voltage, or for stabilising the arc
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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
- B23K9/133—Means for feeding electrodes, e.g. drums, rolls, motors
Abstract
The invention belongs to the technical field of welding methods, and particularly relates to a welding method of a current-carrying hot-fill wire. The method comprises the following steps: s1, providing an arc generating signal to the electrode by using the welding power supply, so that an arc is generated between the electrode and at least one workpiece, and a molten pool is generated on the workpiece; s2, generating a heating signal for heating at least one welding wire by using a heating power supply, and reducing the energy required by the filler wire to melt in the molten pool; s3, the electrode and the welding wire move along the set welding direction relative to the workpiece; and S4, before entering the molten pool, the welding wire is continuously contacted with the unmelted part of the at least one workpiece and is fed from front to back along the set welding direction, and moves forward relative to the electrode along the welding direction by the set distance, and finally the welding is finished. The invention has the characteristics of convenience, practicability, contribution to improving the melting speed of the welding wire, reducing the porosity of a welding line and improving the forming of the welding line.
Description
Technical Field
The invention belongs to the technical field of welding methods, and particularly relates to a welding method of a current-carrying hot-fill wire.
Background
In the welding process, the welding wire is heated in advance, so that the stability of the welding wire fed into a welding part can be improved, the energy input for heating the welding wire to be molten is reduced, the melting speed of the welding wire is further improved, the porosity of a welding seam is reduced, and the welding seam forming is improved. The existing method for heating the welding wire mainly adopts induction heating. The heating principle is that the induction coil generates a current in the welding wire, which causes heat to be generated in the welding wire due to the resistivity of the welding wire. The generated heat raises the temperature of the wire just prior to its entry into the arc zone, thereby reducing the energy required by the welding arc to melt the wire metal in the puddle.
Patent literature mixes hot wire arc welding methods and systems using displacement positioning of the wire [ patent wono.2015/124977a 1: a hybrid hot wire arc welding method and a system for displacement positioning using the wire. The inventor: stevens, Peters, Williams, Maries, Williamt, Matthews, Kent Johns, Lincoln Global, Inc. IPC 7B 23K 9/02; year 2015, 8, 27, etc. ] to a system and method (prototype method) for welding using a hot wire and a biased arc. The welding system includes: an arc generating welding power supply providing an arc generating signal to the electrode to generate an arc between the electrode and at least one workpiece to generate a puddle on the at least one workpiece, wherein the arc generating signal comprises a plurality of current pulses; a power source for heating the wire to generate a heating signal for heating at least one of the wires such that the filler wire melts in the puddle when the wire contacts the puddle, wherein the heating signal comprises a plurality of pulsed heating currents; controller-synchronizing said arc generation signal and said heating signal such that a constant phase angle (from 340 to 20 degrees) is maintained between said arc generation signal pulse current and said heating pulse current. But has the disadvantage of requiring the use of complex electronics, i.e. controllers, which increase the cost of the process.
The existing current-carrying filler wire welding method has the following defects: first, the conventional self-resistance generates heat to preheat the welding wire, and the magnetic field generated by the heating current flowing through the welding wire deflects the welding arc uncontrollably; secondly, induction heating hot wire welding lacks the opportunity of dynamically controlling the heat value and the damage of an oxide film of an aluminum welding wire; third, the hybrid hot wire arc welding method and the system using displacement positioning of the wire require the use of complex electronics, increasing the cost of the process. Therefore, it is necessary to design a current-carrying filler wire welding method which is convenient and practical, and can help to improve the melting speed of the welding wire, reduce the porosity of the welding seam and improve the forming of the welding wire.
Disclosure of Invention
The invention aims to overcome the problems in the prior art and provides a current-carrying hot-filler wire welding method which is convenient and practical, can help to improve the melting speed of a welding wire, reduce the porosity of a welding seam and improve the formation of the welding wire.
In order to achieve the purpose, the invention adopts the following technical scheme:
a welding method of a current-carrying hot-fill wire comprises the following steps:
s1, providing an arc generating signal to the electrode by the welding power source to generate an arc between the electrode and at least one workpiece, thereby generating a weld pool on the workpiece;
s2, generating a heating signal for heating at least one welding wire by using a heating power supply, and reducing the energy required by the welding wire to melt in the molten pool;
s3, the electrode and the welding wire move along the set welding direction relative to the workpiece;
s4, before entering the molten pool, the welding wire is continuously contacted with the unmelted part of at least one workpiece and is fed from front to back along the set welding direction, and simultaneously moves forward relative to the electrode along the welding direction by a set distance, finally completing the welding;
wherein the average operating voltage of the heating signal is always less than the arc voltage.
Preferably, when welding steel, the welding wire is heated by direct current or reverse polarity unipolar pulse current or pulsed bipolar current.
Preferably, when welding aluminum alloy, the welding wire is heated by bipolar pulse current; the bipolar pulse current frequency is at least one time lower than or the same as the modulation frequency of the arc current.
Preferably, when the arc generating signal is GMAW or plasma-GMAW hybrid welding and the electrode is a consumable electrode, the ratio of the cladding rate of the electrode to the cladding rate of the welding wire is 2:1 to 8: 1.
Preferably, the electrode comprises a first non-consumable electrode, and in the case of TIG welding or plasma welding using a welding power supply, comprises the steps of:
s101, generating an electric arc between a first non-melting electrode and at least one workpiece to form a molten pool in the workpiece;
s201, protecting the molten pool by protective gas fed through a nozzle; .
S301, before the welding wire enters a molten pool, the welding wire is in contact with the workpiece, is fed from front to back along a set welding direction, and moves forwards relative to the electrode along the welding direction by a set distance;
s401, heating the welding wire to a temperature exceeding the initial temperature by virtue of a self-contained resistor, and then entering a molten pool to finish welding;
wherein a heating signal with the power of 0.3KW-2.5KW is provided between the workpiece and the welding wire by a current carrying nozzle, and the average working voltage of the heating signal is 2V-10V.
Preferably, the electrode comprises a consumable electrode, and in the case of a GMAW process using a welding power supply, comprises the steps of:
s102, generating an electric arc between a consumable electrode and at least one workpiece to form a molten pool in the workpiece;
s202, protecting the molten pool by protective gas fed through a nozzle;
s302, before the welding wire enters a molten pool, the welding wire is in contact with the workpiece and is fed from front to back along a set welding direction, and meanwhile, the welding wire moves forwards relative to the electrode along the welding direction by a set distance;
s402, heating the welding wire to a temperature exceeding the initial temperature by virtue of a self-contained resistor, and then entering a molten pool to finish welding;
wherein a heating signal with the power of 0.3KW-2.5KW is provided between the workpiece and the welding wire by a current carrying nozzle, and the average working voltage of the heating signal is 2V-10V.
Preferably, the electrodes include a consumable electrode and a second non-consumable electrode, and in the case of a plasma-GMAW hybrid welding process using a welding power source, include the steps of:
s103, generating an electric arc between the consumable electrode and at least one workpiece;
s203, generating a second arc between the second non-melting electrode and at least one workpiece;
s303, forming a molten pool in the workpiece, wherein the molten pool is protected by protective gas fed through a nozzle;
s403, before the welding wire enters the molten pool, the welding wire is in contact with the workpiece and is fed from front to back along a set welding direction, and meanwhile, the welding wire moves forwards relative to the electrode along the welding direction by a set distance;
s503, heating the welding wire to a temperature exceeding the initial temperature by virtue of the self-contained resistor, and then entering a molten pool to finish welding;
wherein a heating signal with the power of 0.3KW-2.5KW is provided between the workpiece and the welding wire by a current carrying nozzle, and the average working voltage of the heating signal is 2V-10V.
Preferably, the ratio of the heat input into the molten pool by the arc generating signal to the heat provided by the heating signal is 2:1-10: 1.
Compared with the prior art, the invention has the beneficial effects that: (1) compared with the method using the unheated welding wire, the method can improve the welding speed by more than 25 percent by using the heated welding wire; (2) the invention can improve the quality of weld formation and reduce the size of a heat affected zone; (3) the invention can improve the welding productivity and welding quality of steel and aluminum alloy parts, and can be used for the connection of steel and aluminum alloy parts (with or without grooves) in various technical fields by using metal-arc welding (MIG/GMAW), non-metal-arc welding (TIG), plasma welding (PAW) and plasma-metal-arc hybrid welding (PAW-MIG/GMAW).
Drawings
FIG. 1 is a schematic view of a welding method of a current-carrying hot-fill wire according to the present invention in example 1;
FIG. 2 is a schematic view of a welding method of current-carrying hot-fill wire according to the present invention in example 2;
FIG. 3 is a schematic view of a welding method of current-carrying hot-fill wire according to the present invention in example 3;
FIG. 4 is a graph of weld surface shaping effects for GMAW and laser-GMAW hybrid cold and hot wire welding of steel, wherein: FIG. 4 a) cold-fill wire, FIG. 4 b) hot-fill wire;
FIG. 5 is a diagram of the effect of weld surface formation in MIG and plasma-MIG hybrid cold and hot wire welding of aluminum alloys, in which: FIG. 5 a) cold-fill wire, FIG. 5 b) hot-fill wire;
FIG. 6 is a weld cross-sectional profile of a GMAW weld of Q235 steel, wherein: FIG. 6 a) without additional filler wire, FIG. 6 b) cold filler wire, FIG. 6 c) hot filler wire;
FIG. 7 is a cross-sectional profile of a weld using a prototype method and a method of the present invention for Q235 steel welding, wherein: FIG. 7 a) prototype method, FIG. 7 b) patented method of the invention.
In the figure: arc 1, first non-consumable electrode 2, workpiece 3, molten pool 4, shielding gas 5, nozzle 6, welding wire 7, current carrying nozzle 8, consumable electrode 9, second non-consumable electrode 10, second arc 11, and welding direction 12.
Detailed Description
In order to more clearly illustrate the embodiments of the present invention, the following description will explain the embodiments of the present invention with reference to the accompanying drawings. It is obvious that the drawings in the following description are only some examples of the invention, and that for a person skilled in the art, other drawings and embodiments can be derived from them without inventive effort.
Example 1:
the invention provides a welding method of a current-carrying hot-fill wire, which comprises the following steps:
s1, providing an arc generating signal to the electrode by the welding power source to generate an arc between the electrode and a workpiece, thereby generating a weld pool on the workpiece;
s2, generating a heating signal for heating a welding wire by using a heating power supply, and melting the welding wire in a molten pool;
s3, the electrode and the welding wire move along the set welding direction relative to the workpiece;
s4, before entering the molten pool, the welding wire is continuously contacted with the unmelted part of a workpiece and is fed from front to back along the set welding direction, and simultaneously moves forward relative to the electrode along the welding direction by a set distance, finally completing the welding;
wherein the average working voltage of the heating signal is always less than the arc voltage; the electrode includes a first non-melting electrode.
Specifically, as shown in fig. 1, when TIG welding or plasma welding is performed using a welding power source, the method includes the steps of:
s101, generating an electric arc 1 between a first non-consumable electrode 2 and a workpiece 3 to form a molten pool 4 in the workpiece 3;
s201, protecting the molten pool 4 by protective gas 5 fed through a nozzle 6;
s301, before the welding wire 7 enters a molten pool, the welding wire is in contact with the workpiece 3 and is fed from front to back along a set welding direction 12, and meanwhile, the welding wire moves forwards 1mm-10mm relative to the electrode along the welding direction 12;
s401, heating the welding wire 7 to a temperature exceeding the initial temperature by virtue of self-contained resistance, and then entering a molten pool 4 to finish welding;
wherein a heating signal with the power of 0.3KW-2.5KW is provided between the workpiece 3 and the welding wire 7 by a current carrying nozzle 8, and the average working voltage of the heating signal is 2V-10V.
Further, when welding steel, the welding wire 7 is heated by direct current or reverse polarity unipolar pulse current or pulse bipolar current.
Further, when welding an aluminum alloy, the welding wire 7 is heated by bipolar pulse current; the bipolar pulse current frequency is at least one time lower than or the same as the modulation frequency of the arc current.
Further, where the signal to generate the arc is GMAW or plasma-GMAW hybrid welding and the electrode is a consumable electrode, the ratio of the deposition rate of the electrode to the deposition rate of the filler wire is 2:1 to 8: 1.
Further, the ratio of the heat input into the molten pool by the electric arc generating signal to the heat provided by the heating signal is 2:1-10: 1.
Example 2:
the difference from embodiment 1 is that the electrode comprises a consumable electrode, as shown in fig. 2, in the case of a GMAW (MIG/MAG) process with a welding power supply, comprising the steps of:
s102, generating an electric arc 1 between a consumable electrode 9 and a workpiece 3 to form a molten pool 4 in the workpiece 3;
s202, protecting the molten pool 4 by protective gas 5 fed through a nozzle 6;
s302, the welding wire 7 is in contact with the workpiece 3 before entering a molten pool, is fed from front to back along a set welding direction 12, and moves forwards 1mm-10mm relative to the electrode along the welding direction 12;
s402, heating the welding wire 7 to a temperature exceeding the initial temperature by virtue of self-contained resistance, and then entering a molten pool 4 to finish welding;
wherein a heating signal with the power of 0.3KW-2.5KW is provided between the workpiece 3 and the welding wire 7 by a current carrying nozzle 8, and the average working voltage of the heating signal is 2V-10V.
Further, in the case where the signal for generating the arc 1 is GMAW and the electrode is the consumable electrode 9, the ratio of the fusion rate of the consumable electrode 9 to the fusion rate of the welding wire 7 is 2:1 to 8: 1.
Further, the ratio of the heat input into the molten pool 4 by the signal for generating the electric arc 1 to the heat provided by the heating signal is 2:1-10: 1.
Example 3:
the difference from the embodiments 1 and 2 is that, as shown in fig. 3, in the case of performing a plasma-GMAW (plasma-MIG) hybrid welding process using a welding power source, the following steps are included:
s103, generating an electric arc 1 between the consumable electrode 9 and a workpiece 3;
s203, generating a second arc 11 between the second non-consumable electrode 10 and a workpiece 3;
s303, forming a molten pool 4 in the workpiece 3, wherein the molten pool 4 is protected by a protective gas 5 fed through a nozzle 6;
s403, the welding wire 7 is in contact with the workpiece 3 before entering the molten pool 4, and is fed from front to back along the set welding direction 12, and meanwhile, the welding wire moves forwards 1mm-10mm relative to the electrode along the welding direction 12;
s503, the welding wire 7 is heated to a temperature exceeding the initial temperature by means of self-contained resistance and then enters the molten pool 4, and welding is completed;
wherein a heating signal with the power of 0.3KW-2.5KW is provided between the workpiece 3 and the welding wire 7 by a current carrying nozzle 8, and the average working voltage of the heating signal is 2V-10V.
Further, in the case where the signal for generating the arc is plasma-GMAW hybrid welding and the electrodes are a consumable electrode 9 and a second non-consumable electrode 10, the ratio of the fusion rate of the consumable electrode 9 to the fusion rate of the welding wire 7 is 2:1 to 8: 1.
In order to test the effectiveness of the welding method of the current-carrying hot-fill wire, the invention provides an experimental device, which comprises the following steps: a single axis robot that can be used to move a welding gun with the welding wire fed and positioned, a wire feed and heating system, consumable and non-consumable welding power sources, and a gas blending and feeding system.
Consumable and non-consumable arc welding, plasma-GMAW hybrid welding (plasma-MIG) experiments were performed on Q235 steel (mixed gas shield, 82% argon +18% carbon dioxide), Al1516 aluminum alloy (argon shield) with the aid of the experimental setup described above. The flow of protective gas during butt weld and fillet weld welding is 20L/min. The samples used were of dimensions 100X 50X delta-100X 400X delta mm and had plate thicknesses of: butt joint δ =4, 5, 8, 10 mm; t-joint δ =4 mm. The wire is fed from front to back in the direction of movement (welding) and is at a distance of 1mm to 10mm in the welding direction relative to the electrode. The filler wire can be heated by bipolar and unipolar pulsed current and reverse polarity direct current at an electrical power of 300W-2500W and a frequency of 75Hz-200 Hz.
The experimental results are as follows:
the use of heated wire can increase welding speed by as much as 25% compared to the use of unheated wire. The ratio of the cladding rate of the melting electrode to the cladding rate of the wire filling is 2:1-8: 1.
In TIG (plasma) welding without filler wire, the observed defect is that the cap bead has no weld bead reinforcement. In GMAW (MIG) welding without filler wire and hybrid plasma-MIG welding, the consumable of the consumable electrode must be increased, which results in increased welding current, input of additional energy into the sample to be welded, overheating of the consumable electrode, increased residual distortion, burn-through and collapse formation.
In GMAW welding and composite laser-GMAW welding of steel with filler wire without heating (so-called "cold wire"), poor formation of weld head weld bead height was observed, and as shown in fig. 4 (a), non-fusion of the weld metal and the base metal was likely to occur. In both GMAW and hybrid plasma-GMAW welding of steel with hot filler wire, improved formation of the weld head height of the weld bead was observed due to increased metal spreading and slight reduction in weld pool length, as shown in fig. 4 (b). In the case of MIG and plasma-MIG welding of aluminum alloy with a cold filler wire, as in the case of welding steel, poor formation of the topping bead weld bead height was observed as shown in fig. 5 (b) as compared with the case of using a hot filler wire, as shown in fig. 5 (a).
For more detailed study, the structure of the weld section was observed. For example, without additional filler wire in the GMAW welding of Q235 steel, the sample was significantly overheated, and the heat affected zone was observed to have a range of about 4mm wide along the surface (from the top edge of the weld), with grain coarsening occurring in the weld and heat affected zone, as shown in fig. 6 (a). When GMAW welding of Q235 steel with filler wire was performed without heating, the heat affected zone of the joint surface hardly exceeded the weld boundary, the grain size in the weld and the heat affected zone was small (compared with the former case), but no fusion between the weld and the base material was observed, as shown in fig. 6 (b). In the case of GMAW welding of Q235 steel with hot filler wire, a high quality weld was observed, with good fusion with the base metal, a heat affected zone that ranged less than 2mm across the surface (from the top edge of the weld), and grain size in the weld and heat affected zone was about the same as the grain size of the weld without the hot filler wire, as shown in fig. 6 (c).
Furthermore, according to the prototype method, TIG, plasma, MIG/GMAW, plasma-MIG/plasma-GMAW welding experiments were performed in which the displacement of the welding electrode relative to the current-carrying filler wire (consumable) was perpendicular to the welding direction, at a distance in the range of 2mm to 5 mm. In this case, the power supply and the control of the hot carrier wire have a feedback of the heating signal, which is advantageous in that the electrical signal applied to the wire can be compared with the arc formation threshold. When the heating signal reaches a specified arc formation threshold level, the hot wire power supply will turn off the heating signal according to a feedback command. In GMAW/MIG and plasma-GMAW/plasma-MIG welding processes, the ratio of the cladding rate of a welding electrode to the cladding rate of a welding wire consumable is 0.85:1-1.15: 1. The results are shown in tables 1 and 2 below:
table 1 welding specification for Q235 steel (δ =4 mm) coupon fillet using ER70S for electrode and wire welding using GMAW welding with mixed gas (82% argon +18% carbon dioxide) shielding in accordance with the method of the present invention as prototype
Wherein, for the Q235 steel weld (δ =4 mm), the actual welding effect using the prototype method is shown in fig. 7 (a); the actual welding effect using the method of the present invention is shown in fig. 7 (b). TABLE 2 electrode and wire fillet weld specification for 1561 aluminum alloy (δ =4 mm) specimens using ER5356, MIG welding with argon shield, prototype method, method of the invention
As can be seen from Table 1 and FIG. 7, compared with the prototype method, the electric power for heating the welding wire is reduced by 51.4%, the size of the heat affected zone is reduced from 300% to 50%, and the welding speed is improved by 28.6%. As can be seen from table 2, compared with the prototype method, the electric power for heating the welding wire is reduced by 61.5% and the welding speed is increased by 30.0%.
Thus, it was determined that a current-carrying hot-fill wire welding method as proposed by the present invention improves the quality of weld formation and helps to increase the welding speed, as compared to conventional methods and prototype methods that use a non-heated filler wire.
Compared with the method using the unheated filler wire, the method can improve the welding speed by more than 25 percent by using the heated filler wire; the invention can improve the quality of weld formation and reduce the size of a heat affected zone; the invention can improve the welding productivity and welding quality of steel and aluminum alloy parts, and can be used for the connection of steel and aluminum alloy parts (with or without grooves) in various technical fields by using metal-arc welding (MIG/GMAW), non-metal-arc welding (TIG), plasma welding (PAW) and plasma-metal-arc hybrid welding (PAW-MIG/GMAW).
The foregoing has outlined rather broadly the preferred embodiments and principles of the present invention and it will be appreciated that those skilled in the art may devise variations of the present invention that are within the spirit and scope of the appended claims.
Claims (8)
1. A welding method of a current-carrying hot-fill wire is characterized by comprising the following steps:
s1, providing an arc generating signal to the electrode by the welding power source to generate an arc between the electrode and at least one workpiece, thereby generating a weld pool on the workpiece;
s2, generating a heating signal for heating at least one welding wire by using a heating power supply, and reducing the energy required by the welding wire to melt in the molten pool;
s3, the electrode and the welding wire move along the set welding direction relative to the workpiece;
s4, before entering the molten pool, the welding wire is continuously contacted with the unmelted part of at least one workpiece and is fed from front to back along the set welding direction, and simultaneously moves forward relative to the electrode along the welding direction by a set distance, finally completing the welding;
wherein the average operating voltage of the heating signal is always less than the arc voltage.
2. A method of welding a current-carrying hot-fill wire as in claim 1 wherein said wire is heated by direct current or reverse polarity unipolar pulsed current or pulsed bipolar current when welding steel.
3. A method of welding a current-carrying hot-fill wire as in claim 1 wherein said wire is heated by bipolar pulsed current when welding aluminum alloys; the bipolar pulse current frequency is at least one time lower than or the same as the modulation frequency of the arc current.
4. The method of claim 1, wherein when the signal to generate the arc is GMAW or plasma-GMAW hybrid welding and the electrode is a consumable electrode, the ratio of the electrode's cladding rate to the welding wire's cladding rate is 2:1-8: 1.
5. A method of welding a current-carrying hot-fill wire as recited in claim 1, said electrode comprising a first non-consumable electrode, and wherein in the case of TIG welding or plasma welding with a welding power supply, comprising the steps of:
s101, generating an electric arc between a first non-melting electrode and at least one workpiece to form a molten pool in the workpiece;
s201, protecting the molten pool by protective gas fed through a nozzle;
s301, before the wire is filled into a molten pool, the wire is in contact with the workpiece, is fed from front to back along a set welding direction, and moves forwards relative to the electrode along the welding direction by a set distance;
s401, heating the welding wire to a temperature exceeding the initial temperature by virtue of a self-contained resistor, and then entering a molten pool to finish welding;
wherein a heating signal with the power of 0.3kW-2.5kW is provided between the workpiece and the welding wire by means of the carrier nozzle, and the average working voltage of the heating signal is 2V-10V.
6. A method of current carrying hot wire welding as set forth in claim 1 wherein said electrode comprises a consumable electrode, and wherein in the case of a GMAW process using a welding power source, comprising the steps of:
s102, generating an electric arc between a consumable electrode and at least one workpiece to form a molten pool in the workpiece;
s202, protecting the molten pool by protective gas fed through a nozzle;
s302, before the welding wire enters a molten pool, the welding wire is in contact with the workpiece and is fed from front to back along a set welding direction, and meanwhile, the welding wire moves forwards relative to the electrode along the welding direction by a set distance;
s402, heating the welding wire to a temperature exceeding the initial temperature by virtue of a self-contained resistor, and then entering a molten pool to finish welding;
wherein a heating signal with the power of 0.3KW-2.5KW is provided between the workpiece and the welding wire by a current carrying nozzle, and the average working voltage of the heating signal is 2V-10V.
7. A method of welding a current-carrying hot-fill wire as recited in claim 1, said electrodes comprising a consumable electrode and a second non-consumable electrode, wherein in the case of a plasma-GMAW hybrid welding process using a welding power source, comprising the steps of:
s103, generating an electric arc between the consumable electrode and at least one workpiece;
s203, generating a second arc between the second non-melting electrode and at least one workpiece;
s303, forming a molten pool in the workpiece, wherein the molten pool is protected by protective gas fed through a nozzle;
s403, before the welding wire enters the molten pool, the welding wire is in contact with the workpiece and is fed from front to back along a set welding direction, and meanwhile, the welding wire moves forwards relative to the electrode along the welding direction by a set distance;
s503, heating the welding wire to a temperature exceeding the initial temperature by virtue of the self-contained resistor, and then entering a molten pool to finish welding;
wherein a heating signal with the power of 0.3KW-2.5KW is provided between the workpiece and the welding wire by a current carrying nozzle, and the average working voltage of the heating signal is 2V-10V.
8. A method of welding as defined in any of claims 1 to 7 wherein the ratio of the amount of heat input to the weld puddle by the arc-generating signal to the amount of heat provided by the heating signal is from 2:1 to 10: 1.
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| CN202111507404.6A CN114101856A (en) | 2021-12-10 | 2021-12-10 | Welding method of current-carrying hot-fill wire |
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| CN202111507404.6A CN114101856A (en) | 2021-12-10 | 2021-12-10 | Welding method of current-carrying hot-fill wire |
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| CN111168263A (en) * | 2020-01-09 | 2020-05-19 | 哈尔滨工程大学 | Device and method for bypass hot wire consumable electrode plasma arc gradient material additive manufacturing |
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| GB1370217A (en) * | 1971-06-17 | 1974-10-16 | Esab Ltd | Electric arc welding |
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