CN115283865A

CN115283865A - Wire welding device and method

Info

Publication number: CN115283865A
Application number: CN202211235937.8A
Authority: CN
Inventors: 树西; 万龙
Original assignee: Anhui Wanyu Mechanical Equipment Technology Co ltd
Current assignee: Anhui Wanyu Mechanical Equipment Technology Co ltd
Priority date: 2022-10-10
Filing date: 2022-10-10
Publication date: 2022-11-04
Anticipated expiration: 2042-10-10
Also published as: CN115283865B

Abstract

The invention discloses a wire welding device and a method, comprising a power supply, wherein two poles of the power supply are communicated with a discharge body through two leads or are respectively connected with the discharge body and a welding matrix; the base metal heat affected zone welded by the method is extremely small, almost no heat affected zone exists, and the problems of large heat affected zone and poor joint performance of the traditional welding method are solved; the special-shaped complex structure can be welded in the welding process, and the joint performance is good; the effective connection of the same materials and different materials such as metal, ceramic, polymer-based glass and the like can be realized; the method can realize seam welding and spot welding functions, can also realize defect repair, and can also realize surfacing and additive manufacturing of precise complex structures.

Description

Wire welding device and method

Technical Field

The invention relates to the technical field of welding, in particular to a wire welding device and a wire welding method.

Background

The current welding methods are mainly divided into three categories, namely fusion welding, solid phase welding and brazing. The fusion welding is realized by melting and solidifying a welded material in a heating mode, the material is generally melted by adopting heat sources such as electric arc, laser or electron beam, and the like, and obvious heat affected zones are formed on two sides of a welding seam after welding; the materials are generally not melted in the solid-phase welding process, and the connection is realized in a non-liquid state mode through the action of external force, such as ultrasonic welding, explosion welding, friction welding and the like, and the solid-phase welding is characterized in that the action of larger force is needed in the welding process; the brazing is realized by melting the brazing filler metal between two parts to be brazed and forming mutual diffusion between the two parts and the base metal, the base metal is not melted in the brazing process, and compared with other two welding methods, the strength of a brazed joint is relatively weak;

the above three basic welding methods have the following disadvantages:

(1) The heat affected zone is large: in particular, fusion welding, the joint failure location is often located in the heat affected zone, which is the weak zone of the entire welded joint;

(2) There is a large force effect during the welding process: the application range of solid-phase welding is small due to the defect that a welding seam with a complex structure is not suitable for solid-phase welding particularly.

(3) The strength of the welding seam is low: the defect mainly exists in brazing, the performance of the brazing filler metal is generally lower than that of a base metal in the brazing process, and the high-temperature service performance of a brazed joint is poor.

The surface modification of the material can be realized by an electric spark deposition technology, the electrode is melted by utilizing the heat generated during discharging, the melted electrode material is deposited on the surface of the base material, the electrode and the base material form metallurgical bonding, and the original hardness, wear resistance, corrosion resistance and the like of the base material are optimized to a certain degree; however, the electrode for electric discharge machining is a consumable and cannot weld two materials. Therefore, a novel welding mode is provided, in particular to a wire welding device and a wire welding method.

Disclosure of Invention

In order to solve the above problems, it is an object of the present invention to provide a wire bonding apparatus and method, by which an extremely small welding heat affected zone can be obtained, a large force is not required in the welding process, and the joint strength is high.

The invention can be realized by the following technical scheme: the two poles of the power supply are communicated with the discharge body through two leads or are respectively connected with the discharge body and the welding base body, and the discharge body and the welding base body move relatively in the welding process.

The invention has further technical improvements that: the power supply is one of a direct current power supply, an alternating current power supply or a pulse power supply.

The invention has further technical improvements that: the welding device further comprises a moving assembly for driving the discharge body to move relative to the welding base body, and the moving assembly has freedom degree in at least one direction.

The invention has further technical improvements that: the discharge body between the two welding matrixes is utilized, the power supply is started, pulse discharge is generated between the discharge body and the welding matrixes or the discharge body directly generates resistance heat, and the parts to be welded of the welding matrixes are melted, so that the welding between the two welding matrixes is realized.

The invention has further technical improvements that: when the welding matrix is made of a wire metal material, an alternating current power supply or a pulse power supply is selected to puncture a medium between the discharge body and the welding matrix to form electric sparks, and the instantaneous high temperature of the electric sparks can enable the metal to be welded to be locally molten and form stable connection after solidification.

The invention has further technical improvements that: when the welding matrix is non-conductive polymer material, the DC power supply is selected to heat the discharge body to the softening temperature of the non-conductive polymer material, the heated discharge body directly contacts the welding matrix to melt the local part of the welding matrix, and the stable connection is formed after solidification.

The invention has the further technical improvements that: aiming at hole repair welding, filling filler into the holes, melting the filler at the bottoms of the holes by a discharge body in a pulse discharge mode, and forming welding spots after solidification; when the welding spot is not enough to repair the hole, filling the filler again, and repeating the operations.

The invention has the further technical improvements that: when the holes are through holes, the bottoms of the holes are discharged by the discharge bodies to be changed into blind holes, and then the filling materials are added;

if the holes are spiral, the discharge body is made to reciprocate in the holes, the scanning radius is gradually enlarged, the materials around the holes are melted and solidified to form recesses, and the filling materials are repeatedly added into the recesses and are subjected to discharge melting, so that the hole repair welding is finally realized.

The invention has further technical improvements that: when additive manufacturing needs to be carried out on a welding base body, a layer of additive raw material is uniformly spread on the upper surface of the welding base body, pulse discharging is carried out by using a discharging body, after the welding base body and the additive raw material are stably combined, the spreading and discharging operations are repeated, the additive manufacturing is realized layer by layer, and the discharging body used in the additive manufacturing process is a strip or a module array.

The invention has the further technical improvements that: during welding, the relative motion path of the discharge body and the welding base body comprises linear motion or reciprocating scanning motion along the welding seam.

Compared with the prior art, the invention has the following beneficial effects:

1. the base metal heat affected zone welded by the method is extremely small, almost no heat affected zone exists, and the problems of large heat affected zone and poor joint performance of the traditional welding method are solved.

2. Force is not needed in the welding process, the special-shaped complex structure can be welded, and the joint performance is good.

3. Can realize the effective connection of the same materials and different materials such as metal, ceramic, polymer-based glass and the like.

4. Can weld various joint forms such as butt joint, lap joint, butt lap joint and the like.

5. Can realize seam welding and spot welding functions and can also realize defect repair.

6. Can realize surfacing and can also realize additive manufacturing of precise and complex structures.

Drawings

In order to facilitate understanding for those skilled in the art, the present invention will be further described with reference to the accompanying drawings.

FIG. 1 is a schematic view of a wire bonding method of a conductive metal material according to the present invention;

FIG. 2 is a schematic view of a wire bonding method of a non-conductive polymeric material according to the present invention;

FIG. 3 is a schematic view of the structure of the invention for welding the bottom of a wire/rod flush with the bottom of the material to be welded;

FIG. 4 is a schematic view of the welding structure of the invention in which the bottom of the wire/rod is not flush with the bottom of the material to be welded;

FIG. 5 is a schematic view of a weld structure of a non-conductive polymer material of the present invention;

FIG. 6 is a schematic view of a structure of one end of a heating rod wire leading out from a welding structure according to the present invention;

FIG. 7 is a schematic view of a vertical hole repair/spot welding process of the present invention;

FIG. 8 is a schematic view of a spiral hole repair/spot welding process of the present invention;

FIG. 9 is a schematic view of an additive manufacturing structure of the present invention;

figure 10 is a schematic view of an additive manufactured structure XOZ of the present invention;

fig. 11 is a schematic view of the additive manufacturing structure YOZ of the present invention;

FIG. 12 is a schematic view of an additive manufacturing structure of square conductive wires/rods/bars according to the present invention;

FIG. 13 is a YOZ schematic of an array discharge additive manufacturing structure of the present invention;

FIG. 14 is a schematic diagram of a one-dimensional array of discharge blocks of the present invention;

FIG. 15 is a schematic view of a two-dimensional array of discharge blocks of the present invention;

FIG. 16 is a schematic view of a scan welding state of the present invention.

In the figure: 1. welding wires/wires; 2. a material to be welded; 3. a conducting wire; 4. a conductive block; 5. a motion structure; 6. a clamp; 7. a work table; 9. heating the melting zone; 10. a filler material; 11. a discharge wire; 12. adding materials; 13. a base; 11-1, a discharge block fixing base; 11-2 and a discharge block.

Detailed Description

To further illustrate the technical means and effects of the present invention adopted to achieve the predetermined objects, the following detailed description of the embodiments, structures, features and effects according to the present invention will be given with reference to the accompanying drawings and preferred embodiments.

Referring to fig. 1 to 16, a wire bonding apparatus includes a power source, a discharge body and a motion assembly, wherein the power source may be a pulse power source, a dc power source or an ac power source, and different power sources are required to be used in cooperation with different materials to be bonded, and the specific correspondence relationship is as follows: aiming at the conductive metal material, a pulse or alternating current power supply is required, but a direct current power supply cannot be used; aiming at non-conductive polymer materials, the three power supplies are used, the wire welding device realizes the welding of two materials to be welded by using wires/wires positioned between the two materials to be welded in a pulse discharge or resistance heat mode, and it is noted that a discharge body in the application can select wires or even bars with corresponding diameters according to different volumes of the materials to be welded and different welding scenes, a motion assembly in the application can be a single-degree-of-freedom translation assembly, a double-degree-of-freedom motion assembly or a multi-degree-of-freedom motion assembly, and the motion assembly can be realized based on a sliding module or a gear-rack meshing transmission structure;

the present application describes a welding method using the above wire welding device in different application scenarios by using a plurality of embodiments:

the first embodiment is as follows: welding of conductive metal materials

When conducting metal materials are welded, the wire welding device further comprises a workbench 7 and a clamp 6, the clamp 6 is fixedly mounted on the workbench 7, two materials 2 to be welded are fixedly mounted on the clamp 6, a welding wire/wire 1 is connected with a conductive block 4 and is fixedly connected with a moving structure 5 through the conductive block 4, two electrodes of a power supply are respectively connected with the conductive block 4 and the materials 2 to be welded through two conducting wires 3, and the welding wire/wire 1 can move in a three-dimensional space under the driving of the moving structure 5 to complete welding;

if the current can be conducted between the clamp 6 and the material 2 to be welded, the conducting wire 3 connected with one electrode of the power supply is directly connected with the clamp 6; the moving structure 5 can be a guide rail sliding block structure or a gear rack structure;

during welding, the welding wire/wire 1 is not in contact with the material 2 to be welded, a certain gap exists between the welding wire/wire and the material 2 to be welded, a gap medium (such as air) can be punctured under the action of a pulse power supply or an alternating current power supply, discharging is realized, electric sparks are formed, the material 2 to be welded can be melted by the instantaneous high temperature of the electric sparks, and a welding seam is formed after solidification;

the lower end of the welding wire/wire 1 can be flush with the lower surface of the material to be welded, and can also protrude or retract into the lower surface of the material to be welded 2 so as to meet the quality requirements and working conditions of different welding joints;

in addition, the lower end of the weld wire/rod 1 may be rounded or other non-pointed shape to prevent poor quality welds from occurring due to point discharge.

Example two: welding of non-conductive polymer materials

The wire bonding device under the welding scene has the same composition as the device in the first embodiment, and similarly comprises a workbench 7 and a clamp 6, wherein the clamp 6 is fixedly arranged on the workbench 7, two materials 2 to be welded are fixedly arranged on the clamp 6, a welding wire/wire 1 is connected with a conductive block 4 and is fixedly connected with a moving structure 5 through the conductive block 4, two electrodes of a power supply are respectively connected with the conductive block 4 and the materials 2 to be welded through two conductive wires 3, and the welding wire/wire 1 can perform spatial three-dimensional motion under the driving of the moving structure 5 to match the completion of welding;

when welding, the welding wire/wire 1 is kept in contact with the material 2 to be welded, the welding wire/wire 1 is heated to a certain temperature under the action of a power supply, the temperature is higher than the softening temperature of the material 2 to be welded and lower than the melting point of the welding wire/wire 1, the material 2 to be welded is melted under the action of contact heat conduction, and a welding line is formed after solidification;

the mode can weld materials such as non-conductive polymers and the like, and can also weld amorphous materials such as glass and the like, for example, when glass is welded, the welding wire/wire 1 is heated to reach a softening temperature of the glass to be welded, and the contact area of the glass and the welding wire/wire 1 is softened and then solidified in a contact heat transfer mode, so that the glass is welded;

in the welding mode, the resistance heating rod can be used for replacing the welding wire material/wire material 1, and two conducting wires 3 which are contacted with a power supply are led out from one end of the resistance heating rod, so that the upper end and the lower end of the welding wire material/wire material 1 are prevented from being connected with conducting wires.

Example three: hole repair or spot welding

Compared with the two welding methods in the first embodiment and the second embodiment, the hole repairing/spot welding method has the advantages that the used welding device is the same, but the welding method has two differences from the two methods, and firstly, material filling is needed; secondly, the welding is not seam welding but spot welding at a certain fixed position;

the hole repair/spot welding has different specific welding steps for different hole forms:

(1) Hole repairing/spot welding method for vertical hole

Step one, if the current hole is of a through hole structure, firstly discharging by utilizing the end part of the lower end of a welding wire/wire 1, and melting and solidifying a material 2 to be welded to form a blind hole structure; if the current hole is directly the blind hole structure, directly adjusting to the second step;

step two, removing the welding wire/wire 1, and putting a certain amount of filling materials 10 into the blind hole structure;

thirdly, putting the welding wire/wire 1 into the blind hole again, melting the filling material 10 through the discharge between the welding wire/wire 1 and the filling material 10, and enabling the welding wire/wire 1 and the material 2 to be welded to be effectively combined;

and step four, repeating the step two and the step three, and realizing layer-by-layer spot welding, thereby completing hole repairing/spot welding, wherein after repairing is completed, a welding line of the spot welding is vertical.

(2) Repair/spot welding method for spiral hole

Firstly, discharging by utilizing the end part of the lower end of a welding wire/wire 1 if the current hole is of a through hole structure, and melting and solidifying a material 2 to be welded to form a blind hole structure; if the current hole is directly the blind hole structure, directly adjusting to the second step;

step two, enabling the welding wire/wire 1 to do reciprocating scanning motion in the blind hole structure, melting materials around the blind hole to the bottom of the blind hole and finally solidifying the materials to realize filling of the bottom of the blind hole, wherein the diameter of the blind hole is enlarged;

step three: repeating the process of the second step, wherein the diameter of the blind hole is continuously enlarged, so that the amplitude of the reciprocating scanning motion of the welding wire/wire 1 in the blind hole structure needs to be increased, the materials around the blind hole are continuously melted to the bottom of the blind hole, and finally a recess is formed on the surface of the material 2 to be welded;

step four: filling a certain amount of filling material 10 into the recess formed in the step three, moving the welding wire/wire 1 to the position of the filling material 10, melting the filling material 10 through electric discharge between the tail end of the welding wire/wire 1 and the filling material 10, and enabling the filling material to be effectively combined with the material 2 to be welded;

step five: and repeating the step four, so that the spot welding layer by layer can be realized, the hole repairing/spot welding is realized, and the welding line of the spot welding after the repairing is in a horn shape.

For the spot welding/repairing process of the hole, it should be noted that:

the filler material 10 in the spot welding process may be a powder, granular sphere or flake material;

in the spot welding process, the free end (i.e. the end which is not connected with the lead) of the welding wire/wire 1 can adopt a round structure, an arc structure and the like, so that the condition of uneven discharge caused by point discharge is avoided; and the other parts except the discharge part at the lower end can be wrapped by insulating materials;

in the spot welding process, the size of the lower end discharge part of the welding wire/wire 1 or the part in contact with the material 2 to be welded (when the material 2 to be welded is a non-conductive polymer material) is not smaller than that of the other parts.

Example four: build-up welding/additive manufacturing

For the surfacing/additive manufacturing process, as shown in the figure, the raw material 12 to be added is uniformly laid on the base 13, the discharge wire 11 is connected with a power supply through a lead, the base 13 is also connected with the power supply through a lead, the discharge wire 11 is placed right above the raw material 12 to be added and keeps a certain distance between the two, and it should be noted that the uniform laying means that the density is uniform and the thickness is consistent;

during surfacing/additive manufacturing, the discharge wire 11 is enabled to move relative to the raw material 12 to be added through an external moving assembly, electric sparks are formed between the discharge wire 11 and the raw material 12 to be added through pulse or alternating current, so that the raw material 12 to be added is melted and is effectively connected with the base body 13 after being solidified;

after each layer of the raw material to be added 12 is melted and solidified, uniformly spreading a layer of the raw material to be added 12 on the melted and solidified substrate 13, and then continuing the electric discharge machining;

and repeating the steps, and realizing surfacing/additive manufacturing by melting and solidifying the raw materials to be additivated layer by layer.

The discharge wire 11 may also be a wire or a rod, and the cross-sectional shape thereof may be circular or square, and if it is square, one side of the square is parallel to the upper surface of the substrate 13, as shown in the figure;

it should be noted that, not only simple material increase layer by layer can be performed by spreading the material 12 to be increased layer by layer, but also the discharge wire 11 can be replaced by a one-dimensional/two-dimensional array type discharge module, and different discharge blocks are regularly electrified, so that the melting and solidification of the material 12 to be increased locally are realized, and further, the material increase manufacturing of a complex precise structural member can be realized, wherein the one-dimensional/two-dimensional array type discharge module comprises a discharge block fixing base 11-1, and a plurality of rectangular discharge blocks 11-2 are uniformly and fixedly installed at the bottom of the discharge block fixing base 11-1.

In the above embodiments, vacuum or inert gas protection may be adopted in the welding or additive process, and welding may also be performed directly in an air environment; under different working conditions such as the type and the thickness of the material 2 to be welded, wires/wires of different materials and different diameters can be selected;

in front of the movement of the wire/rod, a guide structure can be adopted to ensure that the clearance between the two materials 2 to be welded is consistent, so that the relative clearance between the wire/rod and the surfaces of the two materials 2 to be welded is consistent in the welding process;

in order to prevent the molten material to be welded from collapsing downwards under the action of gravity, the wire/wire can move up and down regularly in the welding process, for example, a pulse power supply is adopted to weld metal, the metal to be welded is locally molten at the pulse time, the wire/wire moves towards the Z positive direction (the gravity direction is Z negative direction), at the non-pulse time, the wire/wire moves towards the Z negative direction, the distances between two adjacent times are equal, and the wire/wire returns to the original position;

in the welding process, the wire/wire rod can only walk along the welding line and can also do reciprocating scanning movement, such as the shapes of a circle, a crescent or a triangle, and the like, the edge of the wire/wire rod walks along the welding line and does reciprocating scanning movement at the same time, as shown in fig. 16, the welding area is increased, the stirring of liquid metal in the heating melting area 9 is also increased, and the quality of a welded joint is improved;

in the welding process, the material 2 to be welded is not moved, and the wire/wire moves along the welding line; the wire/wire can also be fixed, and the material 2 to be welded moves, so that the wire/wire is always in the weld joint; and the wire/wire and the material 2 to be welded can move to realize welding.

In order to prevent the wires/wires from being melted or burnt due to overheating in the process of welding conductive metals, hollow wires/wires can be adopted, a liquid medium such as cooling water is introduced in the welding process to absorb heat on the wires/wires, and the temperature of the wires/wires is ensured to be constant in the welding process and is far lower than the melting point of the wires/wires;

the welding method can weld butt weld seams, lap weld seams and butt lap weld seams, and only needs to ensure that the shape of the wire/rod is consistent with the shape of the gap of the metal weld seams to be welded; lateral pressure can be applied in the direction vertical to the plane of the welding seam, and the welding quality is improved.

The welding method can melt metal materials on two sides to realize melt welding, and can realize welding of metal and ceramic, metal and plastic and ceramic and plastic to realize melt brazing. For example, when welding metal and ceramic, the method for welding conductive metal material according to the first embodiment is adopted, two electrodes of the power supply are respectively connected with the wire/rod and the metal base material, and the molten metal base material is in contact with the ceramic and is solidified, thereby realizing the fusion soldering. When metal and plastic or ceramic and plastic are welded, the non-conductive polymer and other materials are welded, two electrodes of a power supply are connected with two ends of a wire/wire, the wire/wire is heated under the action of current, so that the plastic is heated, and the molten plastic is contacted with the metal or ceramic and is solidified, so that the fusion brazing is realized.

Although the present invention has been described with reference to the preferred embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the present invention.

Claims

1. A wire bonding apparatus characterized by: the welding device comprises a power supply, a discharge body and a welding base body, wherein two poles of the power supply are communicated with the discharge body through two leads or are respectively connected with the discharge body and the welding base body, and the discharge body and the welding base body move relatively in the welding process.

2. The wire bonding apparatus of claim 1 wherein the power source is one of a dc power source, an ac power source, or a pulsed power source.

3. The wire bonding apparatus of claim 1, further comprising a motion assembly for moving the discharge body relative to the bonding substrate, the motion assembly having freedom in at least one direction.

4. A welding method using the wire bonding apparatus according to claim 2, wherein the welding between the two bonding substrates is performed by using the discharge body between the two bonding substrates, turning on the power source, generating a pulse discharge between the discharge body and the bonding substrates or directly generating resistance heat from the discharge body, and melting the portion to be bonded of the bonding substrates.

5. A welding method as claimed in claim 4, characterized in that, when the welding base is made of a metallic material, an AC power supply or a pulse power supply is used to break down the medium between the discharge body and the welding base to form an electric spark, the instantaneous high temperature of the electric spark can locally melt the metal to be welded, and a stable connection is formed after solidification.

6. A welding method as claimed in claim 4, characterized in that, when the welding substrate is of a non-conductive polymer material, a direct current source is used to heat the discharge to a temperature above the softening temperature of the non-conductive polymer material, and the heated discharge is brought into direct contact with the welding substrate to melt it locally and form a stable connection after solidification.

7. The welding method of claim 5, wherein for hole repair welding, filling filler in the holes, and using pulse discharge to melt the filler at the bottom of the holes by the discharge body, and forming welding spots after solidification; and when the welding spots are not enough to repair the holes, filling the filler again, and repeating the operations.

8. A welding method according to claim 7, wherein the holes comprise through holes or blind holes, and when the holes are through holes, the bottoms of the holes are discharged by the discharge body to become blind holes and then the filling material is added;

9. The welding method according to claim 4, wherein when additive manufacturing is required to be performed on the welding substrate, a layer of additive material is uniformly spread on the upper surface of the welding substrate, pulse discharging is performed by using a discharging body, after the substrate to be welded and the additive material are stably combined, the spreading and discharging operations are repeated to achieve additive manufacturing layer by layer, and the discharging body used in the additive manufacturing process is a strip or a module array.

10. A welding method according to claim 4, wherein the path of relative movement of the discharge body and the welding substrate during welding comprises a linear movement or a reciprocating scanning movement along the weld seam.