CN115026398A - Dynamic preheating welding method for aluminum alloy spot welding - Google Patents
Dynamic preheating welding method for aluminum alloy spot welding Download PDFInfo
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- CN115026398A CN115026398A CN202210660642.9A CN202210660642A CN115026398A CN 115026398 A CN115026398 A CN 115026398A CN 202210660642 A CN202210660642 A CN 202210660642A CN 115026398 A CN115026398 A CN 115026398A
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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
- B23K11/10—Spot welding; Stitch welding
- B23K11/11—Spot welding
- B23K11/115—Spot welding by means of two electrodes placed opposite one another on both sides of the welded parts
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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
- B23K11/24—Electric supply or control circuits therefor
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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
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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Abstract
The invention provides a dynamic preheating welding method for aluminum alloy spot welding, which adopts a dynamic preheating process method, wherein the preheating time is not a fixed value any more, but is dynamically changed, namely when the real-time resistance value between two electrodes reaches a set value, the preheating process is finished, so that the welding heat input in the preheating process is accurate and controllable, the preheating process is finished when an oxide layer on the surface of aluminum alloy is punctured, and the main welding process is started, thereby effectively reducing the interface resistance of the electrodes and the aluminum alloy and improving the heat conduction capability of the electrodes and the aluminum alloy, reducing the interface heat, remarkably improving the firmness of the process, eliminating the external splashing phenomenon, improving the quality of welding spot nugget of an aluminum alloy plate, and realizing the stability of the welding quality.
Description
Technical Field
The invention belongs to the field of aluminum alloy welding, and particularly relates to a dynamic preheating welding method for aluminum alloy spot welding.
Background
In the process of automobile light weight, the aluminum alloy has the characteristics of high specific strength, corrosion resistance, low recycling cost and the like, and has wide application prospects in the automobile industry.
The chemical activity of the aluminum alloy is very strong, a compact oxide film is easily generated on the surface of the aluminum alloy, the high-resistance oxide film is randomly distributed on the surface of a plate, the resistivity of the oxide film is high, and a large welding current needs to be instantly applied during welding to form a qualified nugget, so that the local current density on the surface of a workpiece is too high, the workpiece is instantly melted, early splashing is generated, and the quality of a welding spot is influenced.
In order to destroy the oxide film on the surface of the aluminum alloy plate, the conventional spot welding process is to add a preheating process before the main welding process, wherein the preheating current is usually 10kA-15kA, and the preheating time is usually 100ms-200ms, so as to improve the quality of the nugget. However, since the distribution of the oxide film on the surface of the aluminum alloy plate is generally uneven, as shown on a microscopic scale, the morphology is random. When the aluminum alloy plate is subjected to spot welding, the microcosmic contact part on the surface of the plate causes the cracking of an oxide film under the action of pressure to form a loop required by welding, if the high-random welding loop adopts fixed preheating time in the welding process, each welding spot causes insufficient or excessive heat input in the preheating stage due to different resistances between two electrodes, so that the change of a welding result is brought, namely, the size of a nugget of the welding spot is insufficient or the surface of the welding spot is splashed, and finally the quality of a continuous welding spot of the resistance spot welding of the aluminum alloy plate is unstable. On the other hand, due to the fact that the temperature of the local contact surface of the electrode and the material is high due to the random distribution of the thickness of the oxide film and the high resistance, the Cu/Al alloying on the surface of the electrode is serious, the electrode adhesion is generated, the electrode pitting corrosion is serious, the service life is short, the subsequent continuous damage of a welding point is further caused, the nugget diameter fluctuates, the joint strength is extremely unstable, and great process uncertainty is brought.
Disclosure of Invention
In view of the above, the present invention aims to provide a dynamic preheating welding method for aluminum alloy spot welding, so as to solve the problem that the quality of continuous welding spots of aluminum alloy resistance spot welding is unstable due to insufficient or excessive heat input in the preheating stage and damage of electrode tips under the condition of a certain welding preheating time.
In order to achieve the purpose, the technical scheme of the invention is realized as follows:
a dynamic preheating welding method for aluminum alloy spot welding comprises the following specific steps:
s1, mounting a current feedback coil on the secondary side of a transformer of the resistance welding tongs to obtain an actually measured current value Ia and mounting a voltage detection line near the two electrodes to obtain a secondary voltage value Ua;
s2, setting welding parameters in the welding controller: inputting preheating current I1, threshold resistance Rf, welding current I2 and welding time T;
s3, enabling the electrode holders to be electrified to enter a preheating stage, controlling the corresponding workpieces to apply preheating current I1 by the controller, calculating and obtaining a dynamic resistance Rd in the welding process through an actually measured current value Ia and a secondary voltage value Ua, and finishing the preheating stage when the dynamic resistance Rd is reduced to a preset threshold resistance Rf;
and S4, ending the non-power-off cooling process in the preheating stage, directly entering a main welding stage, wherein in the main welding stage, the current is increased from the preheating current value to a welding current value I2, entering the main welding stage, and ending the main welding stage after the welding time is set for a time period T.
Further, the calculation formula of the dynamic resistance Rd in the welding process obtained by calculating the actually measured current value Ia and the secondary voltage value Ua is as follows:
Rd＝Ua/Ia。
further, the dynamic resistance Rd includes a contact resistance Rc between two weldments, a contact resistance 2Rcw between the electrode and the adjacent weldments, and an internal resistance 2Rw of the two weldments themselves, that is
Rd＝Rc+2Rcw+2Rw，
After the welding workpiece material is determined, the internal resistance Rw of the weldment per se is kept unchanged;
in the preheating stage of the aluminum spot welding, the welded workpiece is pressed by the electrode, and with the increase of the preheating current, the interface pressure generated by the extrusion of the electrode destroys irregular convex parts and concave parts between contact surfaces, which is represented as the continuous increase of microscopic contact surfaces, so that the contact resistance Rcw on the surface is rapidly reduced;
meanwhile, welding current flows through the electrode and the workpiece, and because the resistance of the oxide film on the surface of the aluminum alloy workpiece is higher, the oxide film is melted before the workpiece, and the melting of the oxide film increases the contact area between the electrode and the workpiece, so that the contact resistance Rcw between the electrode and the workpiece is reduced;
the total dynamic resistance value Rd gradually decreases; the Rd monitoring resistance is calculated by the controller, the time point of oxide film rupture can be determined, namely Rf is shown when the dynamic resistance is reduced to a certain value, namely the preset threshold resistance, the oxide film on the surface of the aluminum alloy is melted and broken, so that the current is rapidly increased to the main welding current, the heat input quantity in the spot welding preheating process can be accurately controlled, and finally the qualified welding spot is obtained.
Further, the preheat current value I1 is 15 kA.
Further, the resistance values of the aluminum alloy workpieces with different grades and thicknesses are different, and the setting ranges of the aluminum alloy materials and the plate thickness are as follows: 70 mu omega-150 mu omega;
the threshold resistance value Rf is determined by adopting a welding test, namely, the spot welding test is carried out by setting different threshold resistance values Rf in the welding process, the metallographic analysis is carried out on the welded welding spot nugget, and finally the most appropriate threshold resistance value Rf is determined to be used as the setting value in the batch production process, so that the qualified aluminum alloy welding spot with good consistency is obtained.
Further, in the main welding stage, the welding current value I2 is 35kA-50kA, and the welding time T is 60ms-120 ms.
Compared with the prior art, the dynamic preheating welding method for aluminum alloy spot welding has the following beneficial effects:
the spot welding of the aluminum alloy plate is divided into a preheating stage and a main welding stage, the voltage and the current between two electrodes of a resistance welding tongs are measured in the welding process, so that the real-time dynamic resistance between the two electrodes is calculated, the dynamic resistance is used as the basis for judging the damage of an oxide film on the surface of the aluminum alloy plate, and the preheating current electrifying time is adjusted, so that the contact surface state of the plate is improved, and the stability of the welding process is improved.
Drawings
The accompanying drawings, which are included to provide a further understanding of the invention, illustrate embodiments of the invention and together with the description serve to explain the invention and do not constitute a limitation of the invention. In the drawings:
FIG. 1 is a schematic diagram illustrating a principle of a dynamic preheating welding method for spot welding of aluminum alloy according to an embodiment of the present invention;
FIG. 2 is a schematic diagram of the dynamic resistor composition distribution according to an embodiment of the present invention;
FIG. 3 is a schematic diagram of a phase diagram of a 5182 aluminum alloy welding spot welded according to an embodiment of the present invention.
Detailed Description
It should be noted that the embodiments and features of the embodiments may be combined with each other without conflict.
In the description of the present invention, it is to be understood that the terms "center", "longitudinal", "lateral", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", and the like, indicate orientations or positional relationships based on those shown in the drawings, and are used only for convenience in describing the present invention and for simplicity in description, and do not indicate or imply that the referenced devices or elements must have a particular orientation, be constructed and operated in a particular orientation, and thus, are not to be construed as limiting the present invention. Furthermore, the terms "first", "second", etc. are used for descriptive purposes only and are not to be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defined as "first," "second," etc. may explicitly or implicitly include one or more of that feature. In the description of the present invention, "a plurality" means two or more unless otherwise specified.
In the description of the present invention, it should be noted that, unless otherwise explicitly specified or limited, the terms "mounted," "connected," and "connected" are to be construed broadly, e.g., as meaning either a fixed connection, a removable connection, or an integral connection; can be mechanically or electrically connected; they may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meaning of the above terms in the present invention can be understood by those of ordinary skill in the art through specific situations.
The present invention will be described in detail below with reference to the accompanying drawings in conjunction with embodiments.
As shown in FIG. 1, the dynamic preheating welding method for aluminum alloy spot welding comprises the following specific steps:
s1, mounting a current feedback coil on the secondary side of a transformer of the resistance welding tongs to obtain an actually measured current value Ia and mounting a voltage detection line near the two electrodes to obtain a secondary voltage value Ua;
s2, setting welding parameters in the welding controller: inputting preheating current I1, threshold resistance Rf, welding current I2 and welding time T;
s3, electrifying the welding tongs to enter a preheating stage, controlling the corresponding workpiece to apply preheating current I1 by the controller, calculating and obtaining a dynamic resistance Rd in the welding process through an actually measured current value Ia and a secondary voltage value Ua, and when the dynamic resistance Rd is reduced to a preset threshold resistance, finishing the preheating stage;
and S4, ending the non-power-off cooling process in the preheating stage, directly entering a main welding stage, wherein in the main welding stage, the current is increased from the preheating current value to a welding current value I2, entering the main welding stage, and ending the main welding stage after the welding time is set for a time period T.
The controller is prior art and adopts model GID 71600.
As shown in fig. 1, the calculation formula of the dynamic resistance Rd in the welding process obtained by calculating the measured current value Ia and the secondary voltage value Ua is as follows:
Rd＝Ua/Ia。
as shown in fig. 1 and 2, the dynamic resistance Rd includes a contact resistance Rc between two weldments, a contact resistance 2Rcw between an electrode and an adjacent weldment, and an internal resistance 2Rw of two weldments themselves, that is, the dynamic resistance Rd is
Rd＝Rc+2Rcw+2Rw，
After the welding workpiece material is determined, the internal resistance Rw of the weldment per se is kept unchanged;
in the preheating stage of the aluminum spot welding, the welded workpiece is pressed by the electrode, and with the increase of the preheating current, the interface pressure generated by the extrusion of the electrode destroys irregular convex parts and concave parts between contact surfaces, which is represented as the continuous increase of microscopic contact surfaces, so that the contact resistance Rcw on the surface is rapidly reduced;
meanwhile, welding current flows through the electrode and the workpiece, and because the resistance of the oxide film on the surface of the aluminum alloy workpiece is larger, the oxide film is melted before the workpiece, and the melting of the oxide film increases the contact area between the electrode and the workpiece, so that the contact resistance Rcw between the electrode and the workpiece is reduced;
the total dynamic resistance value Rd gradually decreases; the Rd monitoring resistance is calculated by the controller, the time point of oxide film rupture can be determined, namely Rf is shown when the dynamic resistance is reduced to a certain value, namely the preset threshold resistance, the oxide film on the surface of the aluminum alloy is melted and broken, so that the current is rapidly increased to the main welding current, the heat input quantity in the spot welding preheating process can be accurately controlled, and finally the qualified welding spot is obtained.
In the preheating process, the preheating time is not a fixed value any more, but is dynamically changed, namely when the real-time resistance value between two electrodes reaches a set threshold resistance, Rf, the preheating process is completed, and the dynamic resistance is used as the basis for judging the damage of the oxide film on the surface of the aluminum alloy plate.
As shown in fig. 1, the preheat current value I1 is 15 kA.
As shown in figure 1, the resistance values of aluminum alloy workpieces with different grades and thicknesses are different, and the setting ranges of the aluminum alloy materials and the plate thicknesses are as follows: 70 mu omega-150 mu omega;
the threshold resistance value Rf is determined by adopting a welding test, namely, a spot welding test is carried out by setting different threshold resistance values Rf in the welding process, metallographic analysis is carried out on the welded welding spot nugget, and finally the most appropriate threshold resistance value Rf is determined to be used as a setting value in the batch production process so as to obtain the qualified welding spot of the aluminum alloy with good consistency.
The metallographic analysis image analysis obtained by the different threshold resistance values Rf can analyze the nugget diameter, the air holes and the crack length, and the nugget diameter is larger than the nugget diameter
On the premise of (1), the smaller the size is, the better the size is, and t is the plate thickness; the smaller the pores, the better; the shorter the crack length, the better.
As shown in FIG. 1, in the main welding stage, the welding current value I2 is 35kA-50kA, and the welding time T is 60ms-120 ms.
The preheating time is not a fixed value any more but is dynamically changed, namely when the real-time resistance value between two electrodes reaches a set value, the preheating process is completed, so that the welding heat input in the preheating process is accurate and controllable, the preheating process is finished when an oxide layer on the surface of the aluminum alloy is punctured, and the main welding process is started, so that the interface resistance of the electrodes and the aluminum alloy can be effectively reduced, the heat conduction capability of the electrodes and the aluminum alloy is improved, the interface heat can be reduced, the firmness of the process is remarkably improved, the external splashing phenomenon is eliminated, the quality of a welding spot nugget of the aluminum alloy plate is improved, and the stability of the welding quality is realized.
For example, a 1.5mm +1.5mm 5182 double-layer aluminum alloy plate is welded, and the chemical element composition is shown in the following table.
5182 chemical element composition (mass fraction,%)
| Si | Fe | Cu | Mn | Mg | Cr | Zn | Al |
| 0.2 | 0.35 | 0.15 | 0.20-0.50 | 4.0-5.0 | 0.1 | 0.25 | Balance of |
Through test analysis and simulation verification, the threshold resistance value is set to be 120 mu omega, better nugget quality can be obtained in the spot welding process specification interval as shown in the following table, and welding consistency is good.
As shown in fig. 3, the phase diagram of 5182 aluminum alloy welding spot welded by using the dynamic preheating process is that the diameter of the welding spot reaches 7.55mm and is larger than that of the welding spot
Namely, it is
And no shrinkage cavity and crack, and good welding quality.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, and any modifications, equivalents, improvements and the like that fall within the spirit and principle of the present invention are intended to be included therein.
Claims (6)
1. A dynamic preheating welding method for aluminum alloy spot welding is characterized in that: the method comprises the following specific steps:
s1, mounting a current feedback coil on the secondary side of a transformer of the resistance welding tongs to obtain an actually measured current value Ia and mounting a voltage detection line near the two electrodes to obtain a secondary voltage value Ua;
s2, setting welding parameters in the welding controller: inputting preheating current I1, threshold resistance Rf, welding current I2 and welding time T;
s3, enabling the electrode holders to be electrified to enter a preheating stage, controlling the corresponding workpieces to apply preheating current I1 by the controller, calculating and obtaining a dynamic resistance Rd in the welding process through an actually measured current value Ia and a secondary voltage value Ua, and finishing the preheating stage when the dynamic resistance Rd is reduced to a preset threshold resistance Rf;
and S4, ending the non-power-off cooling process in the preheating stage, directly entering a main welding stage, wherein in the main welding stage, the current is increased from the preheating current value to a welding current value I2, entering the main welding stage, and ending the main welding stage after the welding time is set for a time period T.
2. The aluminum alloy spot welding dynamic preheating welding method according to claim 1, characterized in that: the calculation formula of the dynamic resistance Rd in the welding process obtained by calculating the actually measured current value Ia and the secondary voltage value Ua is as follows:
Rd＝Ua/Ia。
3. the aluminum alloy spot welding dynamic preheating welding method according to claim 2, characterized in that: the dynamic resistance Rd comprises a contact resistance Rc between two weldments, a contact resistance 2Rcw between the electrode and the adjacent weldment, and an internal resistance 2Rw of the two weldments, namely
Rd＝Rc+2Rcw+2Rw，
After the welding workpiece material is determined, the internal resistance Rw of the weldment per se is kept unchanged;
in the preheating stage of the aluminum spot welding, a welded workpiece is pressed by the electrode, and with the increase of the preheating current, the interface pressure generated by the extrusion of the electrode destroys irregular convex parts and concave parts between contact surfaces, which is represented as the continuous increase of microscopic contact surfaces, so that the contact resistance Rcw on the surface is rapidly reduced;
meanwhile, welding current flows through the electrode and the workpiece, and because the resistance of the oxide film on the surface of the aluminum alloy workpiece is larger, the oxide film is melted before the workpiece, and the melting of the oxide film increases the contact area between the electrode and the workpiece, so that the contact resistance Rcw between the electrode and the workpiece is reduced;
the total dynamic resistance value Rd gradually decreases; the Rd monitoring resistance is calculated by the controller, the time point of oxide film rupture can be determined, namely when the dynamic resistance is reduced to a certain value, namely the preset threshold resistance Rf shows that the oxide film on the surface of the aluminum alloy is melted and broken, so that the current is rapidly increased to the main welding current, the heat input quantity in the spot welding preheating process can be accurately controlled, and finally the qualified welding spot is obtained.
4. The aluminum alloy spot welding dynamic preheating welding method according to claim 1, characterized in that: the preheat current value I1 was 15 kA.
5. The aluminum alloy spot welding dynamic preheating welding method according to claim 3, characterized in that: the resistance values of the aluminum alloy workpieces with different grades and thicknesses are different, and the setting ranges of the aluminum alloy materials and the plate thickness are as follows: 70 mu omega-150 mu omega;
the threshold resistance value Rf is determined by adopting a welding test, namely, the spot welding test is carried out by setting different threshold resistance values Rf in the welding process, the metallographic analysis is carried out on the welded welding spot nugget, and finally the most appropriate threshold resistance value Rf is determined to be used as the setting value in the batch production process, so that the qualified aluminum alloy welding spot with good consistency is obtained.
6. The aluminum alloy spot welding dynamic preheating welding method according to claim 1, characterized in that: in the main welding stage, the welding current value I2 is 35kA-50kA, and the welding time T is 60ms-120 ms.
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| CN202110745308.9A CN113385799A (en) | 2021-06-30 | 2021-06-30 | Dynamic preheating welding method for aluminum alloy spot welding |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN1098672A (en) * | 1993-07-16 | 1995-02-15 | 小原株式会社 | Resistance weld control method |
| KR20180006154A (en) * | 2016-07-08 | 2018-01-17 | 헤베이 리신 테크놀로지 컴퍼니 리미티드 | Metal Sheets Spot Welding with Inoculation Agents |
| CN108971722A (en) * | 2018-07-17 | 2018-12-11 | 上海空间推进研究所 | The process of accurate control band resistance spot welding process characteristic and joint quality |
| CN110253129A (en) * | 2019-07-18 | 2019-09-20 | 天津七所高科技有限公司 | The system and method for spot welding aluminum is used for based on high-frequency inversion direct current resistance welding power source |
| CN112548296A (en) * | 2020-12-23 | 2021-03-26 | 上海梅达焊接设备有限公司 | Aluminum spot welding anti-explosion point control method |
-
2021
- 2021-06-30 CN CN202110745308.9A patent/CN113385799A/en not_active Withdrawn
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- 2022-06-13 CN CN202210660642.9A patent/CN115026398B/en active Active
Patent Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN1098672A (en) * | 1993-07-16 | 1995-02-15 | 小原株式会社 | Resistance weld control method |
| KR20180006154A (en) * | 2016-07-08 | 2018-01-17 | 헤베이 리신 테크놀로지 컴퍼니 리미티드 | Metal Sheets Spot Welding with Inoculation Agents |
| CN108971722A (en) * | 2018-07-17 | 2018-12-11 | 上海空间推进研究所 | The process of accurate control band resistance spot welding process characteristic and joint quality |
| CN110253129A (en) * | 2019-07-18 | 2019-09-20 | 天津七所高科技有限公司 | The system and method for spot welding aluminum is used for based on high-frequency inversion direct current resistance welding power source |
| CN112548296A (en) * | 2020-12-23 | 2021-03-26 | 上海梅达焊接设备有限公司 | Aluminum spot welding anti-explosion point control method |
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