CN117300361B - Air cooler tube plate welding method and system - Google Patents
Air cooler tube plate welding method and system Download PDFInfo
- Publication number
- CN117300361B CN117300361B CN202311600995.0A CN202311600995A CN117300361B CN 117300361 B CN117300361 B CN 117300361B CN 202311600995 A CN202311600995 A CN 202311600995A CN 117300361 B CN117300361 B CN 117300361B
- Authority
- CN
- China
- Prior art keywords
- welding
- laser
- tig
- tube plate
- air cooler
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Active
Links
- 238000003466 welding Methods 0.000 title claims abstract description 474
- 238000000034 method Methods 0.000 title claims abstract description 70
- 239000002131 composite material Substances 0.000 claims abstract description 49
- 238000012544 monitoring process Methods 0.000 claims abstract description 27
- 230000008569 process Effects 0.000 claims abstract description 19
- 238000010891 electric arc Methods 0.000 claims description 38
- 238000004364 calculation method Methods 0.000 claims description 36
- 238000001816 cooling Methods 0.000 claims description 17
- 239000002184 metal Substances 0.000 claims description 14
- 229910052751 metal Inorganic materials 0.000 claims description 14
- 239000000463 material Substances 0.000 claims description 11
- 230000007246 mechanism Effects 0.000 claims description 9
- 230000007613 environmental effect Effects 0.000 claims description 7
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 claims description 6
- 239000007789 gas Substances 0.000 claims description 4
- 230000001133 acceleration Effects 0.000 claims description 3
- 230000001154 acute effect Effects 0.000 claims description 3
- 229910052786 argon Inorganic materials 0.000 claims description 3
- 230000000977 initiatory effect Effects 0.000 claims description 3
- 238000009423 ventilation Methods 0.000 claims description 3
- 230000009286 beneficial effect Effects 0.000 abstract description 6
- 238000007670 refining Methods 0.000 abstract description 4
- 230000000694 effects Effects 0.000 description 10
- 238000003860 storage Methods 0.000 description 9
- 238000004422 calculation algorithm Methods 0.000 description 8
- 230000006870 function Effects 0.000 description 8
- 238000010521 absorption reaction Methods 0.000 description 7
- 230000035515 penetration Effects 0.000 description 7
- 230000009471 action Effects 0.000 description 6
- 238000004517 catalytic hydrocracking Methods 0.000 description 6
- 238000005516 engineering process Methods 0.000 description 6
- 230000008859 change Effects 0.000 description 5
- 238000006243 chemical reaction Methods 0.000 description 5
- 239000013078 crystal Substances 0.000 description 5
- 230000007547 defect Effects 0.000 description 5
- 238000010586 diagram Methods 0.000 description 4
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 3
- 239000010953 base metal Substances 0.000 description 3
- 238000005265 energy consumption Methods 0.000 description 3
- 230000006872 improvement Effects 0.000 description 3
- 229910001338 liquidmetal Inorganic materials 0.000 description 3
- 238000005457 optimization Methods 0.000 description 3
- 238000003756 stirring Methods 0.000 description 3
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- 229910001069 Ti alloy Inorganic materials 0.000 description 2
- 230000008878 coupling Effects 0.000 description 2
- 238000010168 coupling process Methods 0.000 description 2
- 238000005859 coupling reaction Methods 0.000 description 2
- 239000000945 filler Substances 0.000 description 2
- 230000002068 genetic effect Effects 0.000 description 2
- 239000001257 hydrogen Substances 0.000 description 2
- 229910052739 hydrogen Inorganic materials 0.000 description 2
- 238000002844 melting Methods 0.000 description 2
- 230000008018 melting Effects 0.000 description 2
- 210000005036 nerve Anatomy 0.000 description 2
- 230000003287 optical effect Effects 0.000 description 2
- 230000010355 oscillation Effects 0.000 description 2
- 230000001681 protective effect Effects 0.000 description 2
- 238000011160 research Methods 0.000 description 2
- 238000000926 separation method Methods 0.000 description 2
- 229910000838 Al alloy Inorganic materials 0.000 description 1
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 1
- UFWIBTONFRDIAS-UHFFFAOYSA-N Naphthalene Chemical compound C1=CC=CC2=CC=CC=C21 UFWIBTONFRDIAS-UHFFFAOYSA-N 0.000 description 1
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 1
- 150000004945 aromatic hydrocarbons Chemical class 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 239000003054 catalyst Substances 0.000 description 1
- 238000004523 catalytic cracking Methods 0.000 description 1
- 239000007806 chemical reaction intermediate Substances 0.000 description 1
- 239000007795 chemical reaction product Substances 0.000 description 1
- 238000004590 computer program Methods 0.000 description 1
- 238000009833 condensation Methods 0.000 description 1
- 230000005494 condensation Effects 0.000 description 1
- 239000010779 crude oil Substances 0.000 description 1
- 239000002283 diesel fuel Substances 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 150000002431 hydrogen Chemical class 0.000 description 1
- 238000005984 hydrogenation reaction Methods 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 230000000149 penetrating effect Effects 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 239000000047 product Substances 0.000 description 1
- 230000003068 static effect Effects 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 229910052717 sulfur Inorganic materials 0.000 description 1
- 239000011593 sulfur Substances 0.000 description 1
- 230000002195 synergetic effect Effects 0.000 description 1
- 239000010936 titanium Substances 0.000 description 1
- 229910052719 titanium Inorganic materials 0.000 description 1
Classifications
-
- 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
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/346—Working by laser beam, e.g. welding, cutting or boring in combination with welding or cutting covered by groups B23K5/00 - B23K25/00, e.g. in combination with resistance welding
- B23K26/348—Working by laser beam, e.g. welding, cutting or boring in combination with welding or cutting covered by groups B23K5/00 - B23K25/00, e.g. in combination with resistance welding in combination with arc heating, e.g. TIG [tungsten inert gas], MIG [metal inert gas] or 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
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/70—Auxiliary operations or equipment
- B23K26/702—Auxiliary equipment
Abstract
The invention provides a method and a system for welding a tube plate of an air cooler, wherein the method comprises the following steps: monitoring the walking speed and the ambient temperature of a TIG welding gun at the ith welding position of the air cooler tube plate in real time; calculating the optimal walking speed of the energy-saving welding of the TIG welding gun; calculating the laser absorptivity of the air cooler tube plate to the laser emitted by the laser, and constructing a real-time optimal laser with the highest real-time temperature in a laser arc composite heat affected zone at the position of the air cooler tube plate under the limiting condition of temperature balance of a keyhole at the ith welding position of the laser and a TIG welding gun, wherein the real-time optimal laser deviates from a vertical direction angle; and performing laser-TIG composite welding on the air cooler tube plate at an angle deviating from the vertical direction by the calculated real-time optimal walking speed and the calculated real-time optimal laser. According to the invention, in the welding process, the adjustment of the angle of the laser deviating from the vertical direction is beneficial to improving the porosity of the welding seam, refining the welding seam grains and improving the overall performance of the welding seam.
Description
Technical Field
The invention belongs to the technical field of air cooler welding, and particularly relates to an air cooler tube plate welding method and system.
Background
The high-pressure air cooler system is core equipment in the whole hydrocracking device, has the characteristics of high temperature, high pressure and hydrogen, and belongs to the range of special equipment. When the high-pressure air cooler is widely applied to a hydrocracking device, crude oil is subjected to a series of hydrogenation catalytic cracking reactions in the hydrocracking device under the action of a catalyst, high-pressure hydrogen and reaction temperature, and the high-pressure air cooler is heat exchange equipment for condensing and cooling reaction products of the hydrocracking device and contains reaction intermediate substances such as nitrogen, oxygen, sulfur and the like. The purpose of the reaction in the hydrocracking device is to convert the depressurized diesel oil into aromatic hydrocarbon, naphthene and other products, the reaction temperature is about 400 ℃, and the pressure is up to 15Mpa. In the technological process, the hydrocracking device needs to complete condensation cooling treatment by an air cooling device, and then fluid enters a high-pressure separation system, a low-pressure separation system and the like.
In the preparation process of the air cooler, the tube plate, the side plates, the upper cover plate, the lower cover plate, the supporting plate, the heat exchange tube plate and the like are required to be assembled and then welded and fixed. In the prior art, the welding method of the air cooler tube plate, the side plate, the upper cover plate, the lower cover plate and the supporting plate mostly adopts laser welding, TIG welding or composite welding of the side plate, the upper cover plate, the lower cover plate and the supporting plate, and the prior art for filling wires in the welding process to improve the welding effect is adopted, and because the single laser welding or TIG welding is difficult to achieve the better welding effect, the laser-TIG composite wire filling welding is adopted. An aluminum alloy laser-TIG composite filler wire welding method disclosed in China patent with application number 201410385202.2, a laser TIG composite welding process disclosed in China patent with application number 201811595416. X for improving laser welding undercut of titanium and titanium alloy sheets, and a laser hot wire TIG composite welding system disclosed in China patent with application number 202010942308.3 for titanium alloy.
The researches on the laser TIG composite welding technology in the prior art mainly focus on the combination of a high-power laser and a TIG welding gun for welding. But the high power laser has the following problems: the photoelectric conversion efficiency is low, the larger the laser power is, the larger the energy consumption is, and the energy consumption is increased; the volume is large, the cost and the maintenance cost are high, and the welding cost is increased. These factors are very disadvantageous for the practical application of the technology, so that research on the low-power laser arc hybrid welding technology with low cost and low energy consumption is important. How to provide a welding method and a system which can maintain the optimal welding walking speed by using the energy emitted by a lower TIG welding gun so as to improve the laser absorption efficiency, and simultaneously, under the assistance of the coupling of a laser, realize the improvement of the temperature stability of a key Kong Rongshen and a molten pool of a welding seam by a smaller power function and refine welding seam grains while reducing the porosity of the welding seam under the optimal welding temperature environment by adjusting the angle of the laser deviating from the vertical direction in real time, thereby improving the overall performance of the welding seam is a technical problem to be solved in the field.
Disclosure of Invention
The invention provides a method and a system for welding an air cooler tube plate aiming at the defects. According to the invention, in the welding process, the energy emitted by the laser is combined with the arc energy emitted by the TIG welding gun to jointly act on the surface of the welding seam, the arc with the same energy can reach the deep part of the welding seam through the matching of the laser, so that the penetration depth is increased, the absorption rate of the base metal of the air cooler tube plate to the laser can be increased through the matching of the arc with the action of the laser beam on the air cooler tube plate, the penetration depth is further increased, the groove side wall can be melted and fully fused with the filling metal to form a defect-free welding seam through the adjustment of the laser deviation angle, and in addition, the adjustment of the deviation vertical direction angle of the laser beam is also beneficial to improving the porosity of the welding seam and refining the crystal grains of the welding seam, so that the integral performance of the welding seam is improved.
The invention provides the following technical scheme: the method adopts laser-TIG composite welding to weld gaps among the air cooler tube plate, the side plate, the tube plate, the cover plate and the tube plate and the support plate, and uses laser to weld the gaps before the welding direction of a TIG welding gun, controls the angle of the laser deviating from the vertical direction in real time to be alpha, and controls the angle of the TIG welding gun deviating upwards from the horizontal plane where the gaps are positioned to be fixed to be beta, beta=60 degrees, and the method comprises the following steps:
s1: monitoring the walking speed and the ambient temperature of a TIG welding gun at the ith welding position of the air cooler tube plate in real time;
s2: calculating the optimal walking speed of the energy-saving welding of the TIG welding gun;
s3: according to the optimal walking speed of the energy-saving welding of the TIG welding gun obtained by the step S2, calculating the laser absorptivity of the air cooler tube plate to laser emitted to the air cooler tube plate, constructing a key hole temperature balance limiting condition of the laser and the TIG welding gun at the ith welding position of the air cooler tube plate, and calculating an angle of deviating the real-time optimal laser with the highest real-time temperature of a laser arc composite heat affected zone of the laser and the TIG welding gun from the vertical direction under the condition at the ith welding position of the air cooler tube plate;
s4: and (3) performing laser-TIG composite welding on the air cooler tube plate by the real-time optimal walking speed calculated in the step (S2) and the angle of the real-time optimal laser calculated in the step (S3) deviating from the vertical direction.
Further, the step S2 includes the steps of:
s21: monitoring the ith welding position of a TIG welding gun on an air cooler tube plate in real timeWalking rate at the siteConstructing +.>A formed plasma cloud space equation;
wherein,for monitoring the x-axis coordinate of the obtained welding seam welded by the TIG welding gun at the ith welding position of the air cooling tube plate in real time,/V>For monitoring the y-axis coordinate of the obtained welding seam welded by the TIG welding gun at the ith welding position of the air cooling tube plate in real time,/V>The z-axis coordinate of the welding seam welded by the TIG welding gun at the ith welding position of the air cooling tube plate is obtained through real-time monitoring;
s22: constructing a TIG welding gun arc emission energy minimization model, and calculating the optimal running speed of the TIG welding gun when the energy required by the arc emitted by the TIG welding gun is minimizedWherein->Optimal walking speed of TIG welding gun on x-axis of welding coordinate system, < >>Optimal walking speed of TIG welding gun on y axis of welding coordinate system, < >>The optimal walking speed of the TIG welding gun on the z axis of a welding coordinate system is set;
s23: judging whether the welding speed is within a welding speed threshold range, if so, welding at the obtained optimal walking speed; otherwise, repeating the steps S21-S22; the welding speed threshold range is 2.6 m/min-3.0 m/min.
Further, the step S21 is constructed at the ith welding position of the air cooler tube plateThe resulting plasma cloud space equation is as follows:
wherein,σin order to achieve a dynamic coefficient of viscosity,for monitoring the walking speed of the TIG welding gun in real time on the x axis of a welding coordinate system, the walking speed of the TIG welding gun is +.>The TIG welding gun obtained by real-time monitoring runs along the y axis of a welding coordinate systemWalk rate->The z-axis walking speed of the TIG welding gun in a welding tube plate coordinate system is obtained through real-time monitoring;ρis the density of the welded air cooling plate material metal.
Further, the TIG welding gun arc emission energy minimization model constructed in the step S22 is as follows:
wherein C is M For preparing the specific heat capacity of the metal of the air cooler tube plate material, k is Boltzmann constant, e is electronic charge,the arc charge density of the arc emitted by the TIG welding gun in the x-axis direction of the welding coordinate system, +.>The electric arc charge density of the electric arc emitted by the TIG welding gun in the y-axis direction of the welding coordinate system, +.>Arc charge density in the z-axis direction of the welding coordinate system for the arc emitted by the TIG welding gun.
Further, the electric arc charge density of the electric arc emitted by the TIG welding gun in the x-axis direction of a welding coordinate systemThe calculation formula of (2) is as follows:
the electric arc charge density of the electric arc emitted by the TIG welding gun in the y-axis direction of a welding coordinate systemComputing means of (a)The formula is:
the electric arc charge density of the electric arc emitted by the TIG welding gun in the z-axis direction of a welding coordinate systemThe calculation formula of (2) is as follows:
wherein beta is an acute angle deviating from an x-axis in an xz plane, R is a radius of a laser spot emitted by a laser while an arc is emitted by a TIG welding gun, R=0.6 mm,rated power of the TIG welding gun; />For the x-axis coordinate of the welding starting point in the welding coordinate system,/->For the y-axis coordinate of the welding starting point in the welding coordinate system,/->Is the z-axis coordinate of the weld initiation point in the weld coordinate system.
Further, the step S3 includes the following steps:
s31: according to the optimal walking speed of the TIG welding gun calculated in the step S1Calculating the +.A. Of an arc emitted by the laser and the TIG welding gun at the ith welding position of the air cooler tube plate>Laser absorptivity coefficient ∈ ->：
Wherein,for the optimal walking speed of the TIG welding gun in the welding coordinate system,t is the ith welding position of the air cooler tube plate when the TIG welding gun walks toTime of day;
is a Gaussian error function>Wherein, the method comprises the steps of, wherein,Xis an argument of Gaussian error function, +.>In order to take the largest integer not exceeding the value of X, and (2)>To take->Any number in between;
s32: calculating and projecting at the ith welding position of the air cooler tube plateGreen's function of laser on laser spot with radius R>：
Wherein,λλ=1.05 μm to 1.10 μm for the laser wavelength emitted by the laser;
s33: constructing the laser-TIG composite welding at the ith welding position of the air cooler tube plate according to the calculation result of the step S31 and the calculation result of the step S32Real-time temperature of laser arc composite heat affected zone formed at：
Wherein V is the volume of a keyhole formed by a laser arc composite heat affected zone;
s34: constructing a keyhole temperature balance equation:
wherein,is a thermal diffusivity, also called thermal diffusivity,/->Wherein, the method comprises the steps of, wherein,Kis the heat conductivity coefficient of the air cooling plate material metal; />Monitoring the obtained environmental temperature in real time for the step S1;
s35: the key hole temperature balance equation constructed in the step S34Under the limit, the ith welding position of the air cooler tube plate is obtainedReal-time temperature of laser arc composite heat affected zone formed there +.>The real-time optimal laser in the highest case deviates from the vertical direction by an angle +.>：
。
Further, the calculation formula of the keyhole volume V formed by the laser arc composite heat affected zone is as follows:
wherein,is->Is different depending on the position of the ith weld of the air cooler tube sheet at time t,/-, etc.>，/>Gravitational acceleration.
Further, in the step S3, the wire feeding speed of the laser-TIG wire filling welding is controlled to be 0.8 m/min-1.2 m/min; in the welding process, high-purity argon with the purity of more than 99 percent is used for real-time ventilation protection, and the air supply rate is 12L/min-16L/min.
The invention also provides an air cooler tube plate welding system adopting the method, which comprises a laser, a TIG welding gun, a TIG wire filling mechanism, a protective gas supply device and a stepping motor, and further comprises a data acquisition module, an optimal walking speed calculation module, a laser deviation angle calculation module and a main control module;
the data acquisition module is used for monitoring the walking speed and the environmental temperature of the TIG welding gun at the ith welding position of the air cooler tube plate in real time;
the optimal walking speed calculation module is used for calculating the optimal walking speed of the energy-saving welding of the TIG welding gun;
the laser deviation angle calculation module is used for calculating the laser absorptivity of the air cooler tube plate to the laser emitted by the laser according to the optimal travelling speed of the energy-saving welding of the TIG welding gun, which is calculated by the optimal travelling speed calculation module, constructing a key hole temperature balance limiting condition of the laser and the TIG welding gun at the ith welding position of the air cooler tube plate, and calculating a real-time optimal laser deviation vertical direction angle which enables the laser and the TIG welding gun to have the highest real-time temperature of a laser arc composite heat affected zone at the ith welding position of the air cooler tube plate under the condition;
the main control module controls the stepping motor to drive the laser, the TIG welding gun and the TIG wire filling mechanism to move horizontally along the welding direction so as to weld gaps among the air cooler tube plate, the side plate, the tube plate, the cover plate and the tube plate and the support plate, and simultaneously controls the stepping motor to drive the laser to adjust an angle according to the deviation of the real-time optimal laser calculated by the laser deviation angle calculation module from the vertical direction.
Further, the rated power of the laser is 600W, and the welding current of the TIG welding gun is 75A when the TIG welding gun works. The beneficial effects of the invention are as follows:
1. according to the invention, in the welding process, the energy emitted by the laser is combined with the arc energy emitted by the TIG welding gun to jointly act on the surface of the welding seam, the arc with the same energy can reach the deep part of the welding seam through the matching of the laser, so that the penetration depth is increased, the absorption rate of the base metal of the air cooler tube plate to the laser can be increased through the matching of the arc with the action of the laser beam on the air cooler tube plate, the penetration depth is further increased, the groove side wall can be melted and fully fused with the filling metal to form a defect-free welding seam through the adjustment of the laser deviation angle, and in addition, the adjustment of the deviation vertical direction angle of the laser beam is also beneficial to improving the porosity of the welding seam and refining the crystal grains of the welding seam, so that the integral performance of the welding seam is improved.
2. Build at air cooler tube sheet ith weld location by S1 stepThe formed plasma cloud space equation is further constructed, a welding gun electric arc emission energy minimization model is further constructed, the optimal running speed capable of enabling the TIG welding gun to meet the minimum welding energy of the welding seam is further obtained, the fact that the density of electric arc electrons emitted by the TIG welding gun is too low is avoided, the defect of welding seams (the conditions of forming air holes, welding seam virtual welding and the like) caused by insufficient welding energy of the welding seam due to the fact that the formed plasma cloud is too diluted is avoided, meanwhile, the fact that the welding seams are effectively welded is guaranteed, the running speed of the whole welding process is guaranteed to be 2.6-3.0 m/min, and the fact that double requirements of welding speed and welding quality are met is effectively guaranteed.
3. Under the condition that the arc emission energy of a TIG welding gun is minimum, a calculation formula of a laser absorption coefficient is constructed, namely the real-time temperature T of a laser-TIG composite beam at the T moment is highest at the ith welding position of an air cooler tube plate, so that the situation that all positions of a welding gap of the air cooler tube plate can be realized, the laser beam emitted by a laser device is assisted by an arc emitted by the TIG welding gun, the laser absorption rate of the tube plate is improved, and meanwhile, the laser beam is used for assisting the arc to weld the welding wireThe focusing guiding function of the welding point is realized by constructing a laser which deviates from the vertical direction by a certain angle under the condition that the temperature in the heat affected zone is kept balancedThe laser output at rated output power can make the real-time temperature in the heat affected zone be the highest, and further can maintain the temperature balance of uniform melting at the highest temperature in the heat affected zone under the condition that the energy output by the whole welding system is the lowest,
4. the air cooler tube plate welding method provided by the invention adopts the steps that a plasma cloud space equation is firstly constructed, the optimal welding traveling speed for minimizing the energy required by a welding gun for emitting an electric arc is calculated, a laser is driven to travel horizontally along a welding seam under the condition of the optimal speed, the laser absorptivity is further improved, and the real-time temperature of the laser coupling electric arc emitted by the laser to a laser electric arc composite heat affected zone is consideredThe influence of the laser is calculated, the angle of deviation of the laser towards the welding direction when the temperature of the composite heat affected zone reaches the highest is calculated, and then the laser beam deviation direction is changed in real time while the optimal welding walking speed is used for walking welding, so that the composite heat affected zone can avoid the occurrence of air holes and cracks in a welding line area after welding while ensuring the deep penetration of a keyhole under the condition of ensuring the temperature balance (even melting of the parent metal of an air cooler acted by laser and electric arc).
Drawings
The invention will be described in more detail hereinafter on the basis of embodiments and with reference to the accompanying drawings. Wherein:
FIG. 1 is a schematic flow chart of a method for welding an air cooler tube plate provided by the invention;
FIG. 2 is a schematic diagram of an air cooler tube sheet welding system employing the method provided by the invention;
FIG. 3 is a schematic flow chart of the step S2 of the welding method of the air cooler tube plate provided by the invention;
FIG. 4 is a schematic flow chart of the step S3 of the welding method of the air cooler tube plate provided by the invention;
FIG. 5 is a schematic view of a laser arc composite heat affected zone formed at a weld location in accordance with the air cooler tube sheet welding method provided by the present invention;
FIG. 6 is a diagram of a spoon Kong Duibi employing the method provided by the present invention and a laser-TIG hybrid welding technique of the prior art;
FIG. 7 is a graph comparing the welding method with step S3 provided by the present invention with the prior art optimization algorithm to control the temperature in the molten pool area.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
As shown in fig. 1, a flow chart of a welding method of an air cooler tube plate provided by the invention is shown, the method provided by the invention adopts laser-TIG composite welding to weld gaps among the air cooler tube plate, a side plate, a tube plate, a cover plate and a tube plate and a support plate, and as shown in fig. 2, the air cooler tube plate welding system adopting the method provided by the invention welds the gaps in a welding direction of a laser before a TIG welding gun, namely, the laser emitted by the laser contacts a welding gap before an electric arc emitted by the TIG welding gun, the laser is controlled to deviate from a vertical direction in real time to an angle alpha, and the TIG welding gun is controlled to deviate upwards from a horizontal plane angle of the gap to be fixed as beta, beta=60 degrees, and the method comprises the following steps:
s1: monitoring the walking speed and the ambient temperature of a TIG welding gun at the ith welding position of the air cooler tube plate in real time;
s2: calculating the optimal walking speed of the energy-saving welding of the TIG welding gun;
s3: according to the optimal walking speed of the energy-saving welding of the TIG welding gun obtained by the step S2, calculating the laser absorptivity of the air cooler tube plate to the laser emitted by the laser, constructing a key hole temperature balance limiting condition of the laser and the TIG welding gun at the ith welding position of the air cooler tube plate, and calculating the laser arc combined heat of the laser and the TIG welding gun at the ith welding position of the air cooler tube plate under the conditionReal-time temperature of affected areaThe highest real-time optimal laser deviates from the vertical direction by an angle +.>；
In the S3 step, firstly calculating the laser absorptivity of the air cooler tube plate to the laser emitted by the laser, then constructing a key hole temperature balance limiting condition at the ith welding position of the air cooler tube plate between the laser and the TIG welding gun, and further calculating the angle of the real-time optimal laser under the limiting condition deviating from the vertical directionThe real-time optimal laser deviates from the vertical direction by an angle +.>The real-time temperature of the laser arc composite heat affected zone of the laser and the TIG welding gun at the ith welding position of the air cooler tube plate can be increased>The highest;
s4: and (3) performing laser-TIG composite welding on the air cooler tube plate according to the real-time optimal walking speed calculated in the step (S2) and the angle of the real-time optimal laser calculated in the step (S3) deviating from the vertical direction.
According to the invention, the angle of the TIG welding gun which emits the electric arc, which deviates upwards from the horizontal plane where the gap is positioned, is controlled to be fixed to be beta, beta=60 DEG, the angle of the laser which deviates from the vertical direction in real time is controlled to be adjustable alpha, and the travelling speed and the environmental temperature of the TIG welding gun at the ith welding position of the air cooler tube plate are monitored in real time, so that the ith welding position of the air cooler tube plate is controlledThe laser deflection angle of the laser is adjusted to realize the adjustment of the laser beam matched with the welding arc, so that the laser has certain workThe light spots with the rate density can be focused on different positions of a workpiece, so that the arc emitted by the TIG welding gun can be matched with laser emitted by a laser with the rated power of 600W, the technical effect of larger penetration can be obtained, the welding process is finished, and in the welding process, the side wall of a groove can be melted and fully fused with filling metal to form a defect-free welding line through the adjustment of the laser deviation angle; and meanwhile, the adjustment of the angle of the light beam deviating from the vertical direction is also beneficial to improving the porosity of the welding seam, refining the crystal grains of the welding seam and improving the integral performance of the welding seam.
The arc which is emitted by the laser and is emitted by the TIG welding gun before the arc which is emitted by the TIG welding gun is arranged in the welding direction, so that the arc which is emitted by the TIG welding gun can be effectively compressed in the keyhole by heat scattering electrons generated by the laser, the synergistic effect of the laser and the arc is enhanced, and the absorptivity and the energy utilization rate of the material to the laser are improved; the diameter of the keyhole is larger than that of pure laser welding, which is also beneficial to gas escape and further reduces air holes.
As another preferred embodiment of the present invention, as shown in fig. 3, the S2 step includes the steps of:
s21: monitoring the ith welding position of a TIG welding gun on an air cooler tube plate in real timeWalking rate at the siteConstructing +.>A formed plasma cloud space equation;
wherein,for monitoring the x-axis coordinate of the obtained welding seam welded by the TIG welding gun at the ith welding position of the air cooling tube plate in real time,/V>Obtained for real-time monitoringThe y-axis coordinate of the welding seam welded by the TIG welding gun at the ith welding position of the air cooling tube plate,/->In order to monitor the z-axis coordinate of the obtained welding seam welded by the TIG welding gun at the ith welding position of the air-cooled tube plate in real time, the welding coordinate system takes the vertical direction of the plane of the air-cooled tube plate as the z-axis, the welding plane of the air-cooled tube plate as the xy-plane, the opposite direction of the welding direction as the x-axis (the welding direction extends along the welding seam), and the direction vertical to the welding seam as the y-axis;
s22: constructing a TIG welding gun arc emission energy minimization model, and calculating the optimal running speed of the TIG welding gun when the energy required by the arc emitted by the TIG welding gun is minimizedWherein->Optimal walking speed of TIG welding gun on x-axis of welding coordinate system, < >>Optimal walking speed of TIG welding gun on y axis of welding coordinate system, < >>The optimal walking speed of the TIG welding gun on the z axis of a welding coordinate system is set;
s23: judging whether the welding speed is within a welding speed threshold range, if so, welding at the obtained optimal walking speed; otherwise, repeating the steps S21-S22; the welding speed threshold range is 2.6 m/min-3.0 m/min.
Further preferably, the step S21 is performed at the ith welding position of the air cooler tube plateThe resulting plasma cloud space equation is as follows:
wherein,σin order to achieve a dynamic coefficient of viscosity,for monitoring the walking speed of the TIG welding gun in real time on the x axis of a welding coordinate system, the walking speed of the TIG welding gun is +.>For monitoring the walking speed of the TIG welding gun in real time on the y axis of a welding coordinate system, the walking speed of the TIG welding gun is +.>The z-axis walking speed of the TIG welding gun in a welding tube plate coordinate system is obtained through real-time monitoring;ρis the density of the welded air cooling plate material metal.
Further preferably, the TIG welding gun arc emission energy minimization model constructed in the step S22 is as follows:
wherein C is M To prepare the specific heat capacity of the metal of the air cooler tube sheet material, k is boltzmann constant, k=1.38x10 -23 J/K, e is electron charge, e=1.60×10 -19 The coulomb of the sample,the arc charge density of the arc emitted by the TIG welding gun in the x-axis direction of the welding coordinate system, +.>Arc charge density in the y-axis direction of the welding coordinate system for an arc emitted by a TIG welding gun，/>Arc charge density in the z-axis direction of the welding coordinate system for the arc emitted by the TIG welding gun.
Wherein, the electric arc charge density of the electric arc emitted by the TIG welding gun in the x-axis direction of a welding coordinate systemThe calculation formula of (2) is as follows:
arc charge density of arc emitted by TIG welding gun in y-axis direction of welding coordinate systemThe calculation formula of (2) is as follows:
arc charge density of arc emitted by TIG welding gun in z-axis direction of welding coordinate systemThe calculation formula of (2) is as follows:
wherein beta is an acute angle deviating from the x-axis in the xz plane, and is a fixed value, R is a radius of a laser spot emitted by a laser while the TIG welding gun emits an electric arc, R=0.6 mm,rated power of the TIG welding gun; />X-axis seat in welding coordinate system for welding starting pointMark (I) of->For the y-axis coordinate of the welding starting point in the welding coordinate system,/->Is the z-axis coordinate of the weld initiation point in the weld coordinate system.
According to the air cooler tube plate welding method adopting the laser-TIG composite welding, when the welding of the laser beam emitted by the laser to each position of the air cooler tube plate welding seam by matching with the electric arc emitted by the TIG welding gun is fully considered in the step S21, due to the matching of the laser beam, the electron density emitted by the TIG welding gun is reduced, so that the plasma cloud generated by the electric arc at the ith position of the air cooler tube plate is diluted, and the air cooler tube plate welding method is constructed at the ith welding position of the air cooler tube plate in the step S1The formed plasma cloud space equation is further constructed, a welding gun electric arc emission energy minimization model is further constructed, the optimal running speed capable of enabling the TIG welding gun to meet the minimum welding energy of the welding seam is further obtained, the fact that the density of electric arc electrons emitted by the TIG welding gun is too low is avoided, the defect of welding seams (the conditions of forming air holes, welding seam virtual welding and the like) caused by insufficient welding energy of the welding seam due to the fact that the formed plasma cloud is too diluted is avoided, meanwhile, the fact that the welding seams are effectively welded is guaranteed, the running speed of the whole welding process is guaranteed to be 2.6-3.0 m/min, and the fact that double requirements of welding speed and welding quality are met is effectively guaranteed.
Meanwhile, when the electric arc emitted by the TIG welding gun irradiates the air cooler tube plate, the absorption rate of the air cooler tube plate base metal to the laser is greatly increased, so as to further clarify the improvement of the laser absorption efficiency under the condition of the electric arc cooperation emitted by the TIG welding gun and the conditions of the penetration and the keyhole in the heat affected zone caused by the improvement, and how to deviate the laser by a certain angle under the condition of keeping the temperature in the heat affected zone balanced, and further realize that the laser output under the rated output power makes the real-time temperature in the heat affected zone highest, as another preferred embodiment of the invention, as shown in fig. 4, the step S3 comprises the following steps:
s31: according to the optimal walking speed of the TIG welding gun calculated in the step S1Calculating the +.A. Of an arc emitted by the laser and the TIG welding gun at the ith welding position of the air cooler tube plate>Laser absorptivity coefficient ∈ ->：
Wherein,for the optimal walking speed of the TIG welding gun in the welding coordinate system,t is the ith welding position of the air cooler tube plate when the TIG welding gun walks toTime of day;
is a Gaussian error function>Wherein, the method comprises the steps of, wherein,Xis an argument of Gaussian error function, +.>In order to take the largest integer not exceeding the value of X, and (2)>To take->Any number in between;
s32: calculating and projecting at the ith welding position of the air cooler tube plateGreen's function of laser on laser spot with radius R>：
Wherein,λλ=1.05 μm to 1.10 μm for the laser wavelength emitted by the laser;
s33: constructing the laser-TIG composite welding at the ith welding position of the air cooler tube plate according to the calculation result of the step S31 and the calculation result of the step S32Real-time temperature of laser arc composite heat affected zone formed there +.>：
Wherein V is the volume of a keyhole formed by a laser arc composite heat affected zone; the resulting laser-arc composite heat affected zone is shown in fig. 5;
s34: constructing a keyhole temperature balance equation:
wherein,is a thermal diffusivity, also called thermal diffusivity,/->Wherein, the method comprises the steps of, wherein,Kthe heat conductivity coefficient of the metal which is the material of the air cooling plate can be obtained by looking up a table according to different materials used; />The environmental temperature obtained in the step S1 is monitored in real time;
s35: under the limitation of the key hole temperature balance equation constructed in the step S34, the ith welding position of the air cooler tube plate is obtainedReal-time temperature of laser arc composite heat affected zone formed there +.>The real-time optimal laser in the highest case deviates from the vertical direction by an angle +.>：
。
The calculation formula of the keyhole volume V formed by the laser arc composite heat affected zone is as follows:
wherein,is->Abbreviations of (a)Which varies with the moment t at the ith weld location of the air cooler tube sheet,/->，/>Gravitational acceleration.
According to the air cooler tube plate welding method based on the laser-TIG composite welding technology, the laser and the TIG welding gun can be started simultaneously to respectively emit the laser beam (emitted by the laser welding head) and the electric arc, the laser beam emitted by the laser can attract the electric arc and compress the electric arc at a welding part, so that the energy density of the electric arc is improved, the penetrating capacity of a heat source is increased, wider gaps and thicker plates can be welded, compared with the electric arc welding, the heat input is reduced, the energy density of the electric arc and the stability of the electric arc are improved, and therefore, the welding efficiency is higher, and the welding defects are fewer; compared with laser welding, the laser welding device has the advantages that the wire is synchronously fed through the TIG wire feeding mechanism, so that molten pool crystal nuclei can be increased in a laser arc composite heat affected zone, the structure crystal grain size of a welding joint is smaller, the mechanical property is higher, and meanwhile, the requirement on the assembly precision of a laser gun head is reduced.
The welding method of the air cooler tube plate provided by the invention is simultaneously and respectively welded with the same air cooler tube plate gap with the common laser-TIG composite welding in the prior art, the result is shown in fig. 6, and as compared with fig. 6 (a) and 6 (b), fig. 6 (a) is a keyhole diagram in the welding process of the air cooler tube plate welding method provided by the invention, and fig. 6 (b) is a keyhole diagram in the welding process of the common laser-TIG composite welding in the prior art;
the keyhole in fig. 6 (a) has fewer air holes than the keyhole in fig. 6 (b), the molten pool is stirred by laser oscillation in the welding process, the stirring effect promotes the up-down convection effect of liquid metal around the keyhole, when the oscillation frequency is low, the stirring effect of light beams on the molten pool is mild, the convection effect in the vertical direction is weak, most of generated air bubbles are wrapped by the liquid metal and rapidly flow to the rear of the molten pool, and the air holes are formed without timely escaping. By adjusting the angle of the laser beam deviating from the vertical direction in real time, the stirring effect of the laser beam on the molten pool can be enhanced, most generated bubbles are surrounded nearby the liquid metal convection effect in the vertical direction of the periphery of the keyhole and quickly float upwards to escape from the molten pool, when the angle of the laser beam deviating from the vertical direction is optimal, the influence of the vertical convection mechanism on the bubbles is completely over the wrapping effect of the metal liquid flow in the horizontal direction, and the air hole defects are completely eliminated.
In addition, as shown in fig. 7, in order to optimize the real-time temperature of the laser-TIG filler wire welding in the laser arc composite heat affected zone of the keyhole by adopting the ANN algorithm, the genetic nerve optimization algorithm (GA algorithm) and the CNN algorithm in the air cooler tube plate welding method and the prior art respectively, as shown in fig. 7, the number 4 is a real-time temperature change curve optimized by adopting the ANN algorithm, the number 3 is a real-time temperature change curve optimized by adopting the genetic nerve optimization algorithm, the number 2 is a real-time temperature change curve optimized by adopting the CNN algorithm, and as shown in fig. 7, compared with the prior art, the air cooler tube plate welding method provided by the application can enable the real-time temperature change to slowly rise to the highest temperature range, and can enable the welding temperature to be kept in the higher temperature range of 400-680 ℃ for a longer time, thereby ensuring that the welding system is horizontally moved towards the welding direction of the fast optimal running speed, and ensuring that the welding quality of the welding seam (namely the temperature in the composite heat affected zone) is higher, and further ensuring the welding quality of the welding seam.
As another preferred embodiment of the invention, in the step S3, controlling the wire feeding speed of laser-TIG wire filling welding (TIG wire filling mechanism) to be 0.8 m/min-1.2 m/min; the device is controlled to be opened in the welding process, high-purity argon with the purity of more than 99% is used for real-time ventilation protection, and the air supply rate is 12L/min-16L/min.
The invention also provides an air cooler tube plate welding system adopting the method, as shown in fig. 2, the system comprises a laser, a TIG welding gun, a TIG wire filling mechanism, a protective gas supply device and a stepping motor, and the system also comprises a data acquisition module, an optimal walking speed calculation module, a laser deviation angle calculation module and a main control module;
the data acquisition module is used for monitoring the walking speed and the environmental temperature of the TIG welding gun at the ith welding position of the air cooler tube plate in real time;
the optimal walking speed calculation module is used for calculating the optimal walking speed of the energy-saving welding of the TIG welding gun;
the laser deviation angle calculation module is used for calculating the laser absorptivity of the air cooler tube plate to the laser emitted by the laser according to the optimal walking speed of the energy-saving welding of the TIG welding gun calculated by the optimal walking speed calculation module, constructing a key hole temperature balance limiting condition of the laser and the TIG welding gun at the ith welding position of the air cooler tube plate, and calculating the real-time temperature of a laser arc composite heat affected zone of the laser and the TIG welding gun at the ith welding position of the air cooler tube plate under the conditionThe highest real-time optimal laser deviates from the vertical direction by an angle +.>；
The main control module controls the stepping motor to drive the laser, the TIG welding gun and the TIG wire filling mechanism to move horizontally along the welding direction to weld gaps among the air cooler tube plate, the side plate, the tube plate, the cover plate and the tube plate and the support plate according to the real-time optimal walking speed calculated by the optimal walking speed calculation module, and simultaneously controls the stepping motor to drive the laser to adjust the angle according to the angle of the laser deviating from the vertical direction according to the angle of the laser deviating from the angle calculated by the laser calculating module, so as to perform laser-TIG composite welding on the air cooler tube plate.
Further preferably, the rated power of the laser is 600W, and the welding current of the TIG welding gun during working is 75A.
The heat exchanger tube sheet welding methods provided herein may take the form of a computer program product embodied on one or more storage media (including, but not limited to, disk storage, CD-ROM, optical storage, etc.) having program code embodied therein. Machine-readable storage media include both permanent and non-permanent, removable and non-removable media, and information storage may be implemented by any method or technology. The information may be computer readable instructions, data structures, modules of a program, or other data. Examples of machine-readable storage media include, but are not limited to: phase change memory (PRAM), static Random Access Memory (SRAM), dynamic Random Access Memory (DRAM), other types of Random Access Memory (RAM), read Only Memory (ROM), electrically Erasable Programmable Read Only Memory (EEPROM), flash memory or other memory technology, compact disc read only memory (CD-ROM), digital Versatile Disks (DVD) or other optical storage, magnetic cassettes, magnetic tape magnetic disk storage or other magnetic storage devices, or any other non-transmission medium, may be used to store information that may be accessed by the computing device.
It should be noted that, the foregoing reference numerals of the embodiments of the present invention are merely for describing the embodiments, and do not represent the advantages and disadvantages of the embodiments. Relational terms such as "first" and "second", and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. And the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, apparatus, article, or method that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, apparatus, article, or method. Without further limitation, an element defined by the phrase "comprising one … …" does not exclude the presence of other like elements in a process, apparatus, article or method that comprises the element.
The foregoing is merely a specific embodiment of the disclosure to enable one skilled in the art to understand or practice the disclosure. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the disclosure. Thus, the present disclosure is not intended to be limited to the embodiments shown and described herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
Claims (7)
1. The air cooler tube plate welding method adopts laser-TIG composite welding to weld gaps among the air cooler tube plate, a side plate, a tube plate, a cover plate and a tube plate and a support plate, and uses laser to weld the gaps before the welding direction of a TIG welding gun, and is characterized in that the laser is controlled to deviate from the vertical direction in real time to be alpha, and the TIG welding gun is controlled to deviate upwards to be fixed to be beta at the angle of the horizontal plane where the gaps are positioned, and the beta=60 degrees, and the method comprises the following steps:
s1: monitoring the walking speed and the ambient temperature of a TIG welding gun at the ith welding position of the air cooler tube plate in real time;
s2: calculating the optimal walking speed of the energy-saving welding of the TIG welding gun;
s3: according to the optimal walking speed of the energy-saving welding of the TIG welding gun obtained by the step S2, calculating the laser absorptivity of the air cooler tube plate to laser emitted to the air cooler tube plate, constructing a key hole temperature balance limiting condition of the laser and the TIG welding gun at the ith welding position of the air cooler tube plate, and calculating an angle of deviating the real-time optimal laser with the highest real-time temperature of a laser arc composite heat affected zone of the laser and the TIG welding gun from the vertical direction under the condition at the ith welding position of the air cooler tube plate;
s4: performing laser-TIG composite welding on the air cooler tube plate according to the real-time optimal walking speed calculated in the step S2 and the angle of the real-time optimal laser calculated in the step S3 deviating from the vertical direction;
the step S2 comprises the following steps:
s21: monitoring the ith welding position of a TIG welding gun on an air cooler tube plate in real timeWalking rate at the siteConstructing +.>A formed plasma cloud space equation;
wherein,in order to monitor the x-axis coordinate of the obtained welding seam welded by the TIG welding gun at the ith welding position of the air cooling tube plate in real time,for monitoring the y-axis coordinate of the obtained welding seam welded by the TIG welding gun at the ith welding position of the air cooling tube plate in real time,/V>The z-axis coordinate of the welding seam welded by the TIG welding gun at the ith welding position of the air cooling tube plate is obtained through real-time monitoring;
s22: constructing a TIG welding gun arc emission energy minimization model, and calculating the optimal running speed of the TIG welding gun when the energy required by the arc emitted by the TIG welding gun is minimizedWherein->Optimal walking speed of TIG welding gun on x-axis of welding coordinate system, < >>Optimal walking speed of TIG welding gun on y axis of welding coordinate system, < >>Optimal walking of TIG welding gun in welding coordinate system z-axisA rate;
s23: judging whether the welding speed is within a welding speed threshold range, if so, welding at the obtained optimal walking speed; otherwise, repeating the steps S21-S22; the welding speed threshold range is 2.6 m/min-3.0 m/min;
the S21 step is constructed at the ith welding position of the air cooler tube plateThe resulting plasma cloud space equation is as follows:
wherein,σin order to achieve a dynamic coefficient of viscosity,for monitoring the walking speed of the TIG welding gun in real time on the x axis of a welding coordinate system, the walking speed of the TIG welding gun is +.>For monitoring the walking speed of the TIG welding gun in real time on the y axis of a welding coordinate system, the walking speed of the TIG welding gun is +.>The z-axis walking speed of the TIG welding gun in a welding tube plate coordinate system is obtained through real-time monitoring;ρthe density of the air cooling plate material metal to be welded;
the TIG welding gun arc emission energy minimization model constructed in the step S22 is as follows:
wherein C is M For preparing the specific heat capacity of the metal of the air cooler tube plate material, k is Boltzmann constant, e is electronic charge,the arc charge density of the arc emitted by the TIG welding gun in the x-axis direction of the welding coordinate system, +.>The electric arc charge density of the electric arc emitted by the TIG welding gun in the y-axis direction of the welding coordinate system, +.>Arc charge density in the z-axis direction of the welding coordinate system for the arc emitted by the TIG welding gun.
2. The air cooler tube sheet welding method as set forth in claim 1, wherein said TIG welding gun emits an arc having an arc charge density in an x-axis direction of a welding coordinate systemThe calculation formula of (2) is as follows:
the electric arc charge density of the electric arc emitted by the TIG welding gun in the y-axis direction of a welding coordinate systemThe calculation formula of (2) is as follows:
the electric arc charge density of the electric arc emitted by the TIG welding gun in the z-axis direction of a welding coordinate systemThe calculation formula of (2) is as follows:
wherein beta is an acute angle deviating from an x-axis in an xz plane, R is a radius of a laser spot emitted by a laser while an arc is emitted by a TIG welding gun, R=0.6 mm,rated power of the TIG welding gun; />For the x-axis coordinate of the welding starting point in the welding coordinate system,/->For the y-axis coordinate of the welding starting point in the welding coordinate system,/->Is the z-axis coordinate of the weld initiation point in the weld coordinate system.
3. The air cooler tube sheet welding method according to claim 1, wherein said step S3 includes the steps of:
s31: according to the optimal walking speed of the TIG welding gun calculated in the step S1Calculating the +.A. Of an arc emitted by the laser and the TIG welding gun at the ith welding position of the air cooler tube plate>Laser absorptivity coefficient ∈ ->：
Wherein,for the optimal walking speed of the TIG welding gun in the welding coordinate system,t is the ith welding position of the air cooler tube plate when the TIG welding gun walks toTime of day;
is a Gaussian error function>Wherein, the method comprises the steps of, wherein,Xis an argument of Gaussian error function, +.>In order to take the largest integer not exceeding the value of X, and (2)>To take->Any number in between;
s32: calculating and projecting at the ith welding position of the air cooler tube plateGreen's function of laser on laser spot with radius R>：
Wherein,λλ=1.05 μm to 1.10 μm for the laser wavelength emitted by the laser;
s33: constructing the laser-TIG composite welding at the ith welding position of the air cooler tube plate according to the calculation result of the step S31 and the calculation result of the step S32Real-time temperature of laser arc composite heat affected zone formed at：
Wherein V is the volume of a keyhole formed by a laser arc composite heat affected zone;
s34: constructing a keyhole temperature balance equation:
wherein,is a thermal diffusivity, also called thermal diffusivity,/->Wherein, the method comprises the steps of, wherein,Kis the heat conductivity coefficient of the air cooling plate material metal; />Monitoring the obtained environmental temperature in real time for the step S1;
s35: constructed in the step S34Under the limitation of a key hole temperature balance equation, the ith welding position of the air cooler tube plate is obtainedReal-time temperature of laser arc composite heat affected zone formed there +.>The real-time optimal laser in the highest case deviates from the vertical direction by an angle +.>：
。
4. The air cooler tube sheet welding method according to claim 3, wherein the calculation formula of the keyhole volume V formed by the laser arc composite heat affected zone is as follows:
wherein,is->Is different depending on the position of the ith weld of the air cooler tube sheet at time t,/-, etc.>，/>Gravitational acceleration.
5. The method for welding the tube plate of the air cooler according to claim 1, wherein in the step S3, the wire feeding speed of the laser-TIG wire filling welding is controlled to be 0.8 m/min-1.2 m/min; in the welding process, high-purity argon with the purity of more than 99 percent is used for real-time ventilation protection, and the air supply rate is 12L/min-16L/min.
6. The air cooler tube plate welding system adopting the method as defined in any one of claims 1-5, wherein the system comprises a laser, a TIG welding gun, a TIG wire filling mechanism, a shielding gas supply device and a stepping motor, and is characterized by further comprising a data acquisition module, an optimal walking speed calculation module, a laser deviation angle calculation module and a main control module;
the data acquisition module is used for monitoring the walking speed and the environmental temperature of the TIG welding gun at the ith welding position of the air cooler tube plate in real time;
the optimal walking speed calculation module is used for calculating the optimal walking speed of the energy-saving welding of the TIG welding gun;
the laser deviation angle calculation module is used for calculating the laser absorptivity of the air cooler tube plate to the laser emitted by the laser according to the optimal travelling speed of the energy-saving welding of the TIG welding gun, which is calculated by the optimal travelling speed calculation module, constructing a key hole temperature balance limiting condition of the laser and the TIG welding gun at the ith welding position of the air cooler tube plate, and calculating a real-time optimal laser deviation vertical direction angle which enables the laser and the TIG welding gun to have the highest real-time temperature of a laser arc composite heat affected zone at the ith welding position of the air cooler tube plate under the condition;
the main control module controls the stepping motor to drive the laser, the TIG welding gun and the TIG wire filling mechanism to move horizontally along the welding direction so as to weld gaps among the air cooler tube plate, the side plate, the tube plate, the cover plate and the tube plate and the support plate, and simultaneously controls the stepping motor to drive the laser to adjust an angle according to the deviation of the real-time optimal laser calculated by the laser deviation angle calculation module from the vertical direction.
7. The air cooler tube sheet welding system of claim 6, wherein the laser has a rated power of 600w and the tig welding gun operates with a welding current of 75A.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202311600995.0A CN117300361B (en) | 2023-11-28 | 2023-11-28 | Air cooler tube plate welding method and system |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202311600995.0A CN117300361B (en) | 2023-11-28 | 2023-11-28 | Air cooler tube plate welding method and system |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN117300361A CN117300361A (en) | 2023-12-29 |
| CN117300361B true CN117300361B (en) | 2024-02-27 |
Family
ID=89288755
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202311600995.0A Active CN117300361B (en) | 2023-11-28 | 2023-11-28 | Air cooler tube plate welding method and system |
Country Status (1)
| Country | Link |
|---|---|
| CN (1) | CN117300361B (en) |
Citations (10)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2005238282A (en) * | 2004-02-26 | 2005-09-08 | Matsushita Electric Ind Co Ltd | Compound welding equipment, its welding method, and compound welding system |
| CN102717173A (en) * | 2012-06-08 | 2012-10-10 | 江苏科技大学 | Detectors for movement speeds of semi-automatic consumable electrode and non-consumable electrode electric-arc welding molten baths |
| CN105252203A (en) * | 2015-10-19 | 2016-01-20 | 浙江大学宁波理工学院 | Restoration method for mold fractures |
| CN109604831A (en) * | 2018-12-25 | 2019-04-12 | 上海交通大学 | For improving the laser TIG Combined Welding welding procedure of titanium or titanium alloy sheet laser weldering undercut |
| CN110170746A (en) * | 2019-07-02 | 2019-08-27 | 辽宁工业大学 | A kind of coaxial double focus laser-TIG arc hybrid welding method |
| CN110280872A (en) * | 2019-07-23 | 2019-09-27 | 上海工程技术大学 | Automatic welding equipment and welding method applied to large scale Invar steel mold |
| CN111515541A (en) * | 2020-04-26 | 2020-08-11 | 华北水利水电大学 | Thick plate narrow gap laser-TIG composite filler wire welding device and method |
| CN112192028A (en) * | 2020-09-09 | 2021-01-08 | 中国船舶重工集团公司第七一六研究所 | Laser hot wire TIG hybrid welding system suitable for titanium alloy |
| CN112496544A (en) * | 2020-09-30 | 2021-03-16 | 上海交通大学 | Efficient welding method and device for thin-wall welding titanium tube by arc-assisted laser |
| WO2022262788A1 (en) * | 2021-06-16 | 2022-12-22 | 哈尔滨焊接研究院有限公司 | Narrow gap laser-tig arc hybrid welding apparatus and welding method |
-
2023
- 2023-11-28 CN CN202311600995.0A patent/CN117300361B/en active Active
Patent Citations (10)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2005238282A (en) * | 2004-02-26 | 2005-09-08 | Matsushita Electric Ind Co Ltd | Compound welding equipment, its welding method, and compound welding system |
| CN102717173A (en) * | 2012-06-08 | 2012-10-10 | 江苏科技大学 | Detectors for movement speeds of semi-automatic consumable electrode and non-consumable electrode electric-arc welding molten baths |
| CN105252203A (en) * | 2015-10-19 | 2016-01-20 | 浙江大学宁波理工学院 | Restoration method for mold fractures |
| CN109604831A (en) * | 2018-12-25 | 2019-04-12 | 上海交通大学 | For improving the laser TIG Combined Welding welding procedure of titanium or titanium alloy sheet laser weldering undercut |
| CN110170746A (en) * | 2019-07-02 | 2019-08-27 | 辽宁工业大学 | A kind of coaxial double focus laser-TIG arc hybrid welding method |
| CN110280872A (en) * | 2019-07-23 | 2019-09-27 | 上海工程技术大学 | Automatic welding equipment and welding method applied to large scale Invar steel mold |
| CN111515541A (en) * | 2020-04-26 | 2020-08-11 | 华北水利水电大学 | Thick plate narrow gap laser-TIG composite filler wire welding device and method |
| CN112192028A (en) * | 2020-09-09 | 2021-01-08 | 中国船舶重工集团公司第七一六研究所 | Laser hot wire TIG hybrid welding system suitable for titanium alloy |
| CN112496544A (en) * | 2020-09-30 | 2021-03-16 | 上海交通大学 | Efficient welding method and device for thin-wall welding titanium tube by arc-assisted laser |
| WO2022262788A1 (en) * | 2021-06-16 | 2022-12-22 | 哈尔滨焊接研究院有限公司 | Narrow gap laser-tig arc hybrid welding apparatus and welding method |
Also Published As
| Publication number | Publication date |
|---|---|
| CN117300361A (en) | 2023-12-29 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| Zhao et al. | Optimization of laser welding thin-gage galvanized steel via response surface methodology | |
| EP2546020B1 (en) | Laser/arc hybrid welding method and method for producing welded member using same | |
| Yang et al. | Porosity suppressing and grain refining of narrow-gap rotating laser-MIG hybrid welding of 5A06 aluminum alloy | |
| CN111266740A (en) | Ultrafast laser cleaning and fine polishing equipment for inner wall of component and control method | |
| CN112518109A (en) | High-frequency laser pulse method applied to dissimilar metal composite heat source welding | |
| CN107584211B (en) | High-power laser welding system based on high-speed scanning galvanometer and welding method thereof | |
| CN1298486C (en) | Rotary double focus laser-MIG electric arc composite welding head | |
| Xiong et al. | Arc plasma, droplet, and forming behaviors in bypass wire arc-directed energy deposition | |
| CN103501955B (en) | The manufacture method of laser welding steel pipe | |
| CN111168241B (en) | Method for double-beam pulse laser time-sharing induction MAG electric arc directional swinging surfacing | |
| Chen et al. | Influence of welding angle on the weld morphology and porosity in laser-arc hybrid welding of AA2219 aluminum alloy | |
| Xu et al. | Effect of distance between the heat sources on energy transfer behavior in keyhole during laser-GTA welding titanium alloy | |
| CN117300361B (en) | Air cooler tube plate welding method and system | |
| CN110340529B (en) | Groove width calculation method for narrow-gap laser filler wire welding plate | |
| Fu et al. | Influence of the magnetic field on the melting and solidification behavior of narrow-gap laser welding with filler wire | |
| US20140305910A1 (en) | System and Method Utilizing Fiber Lasers for Titanium Welding Using an Argon Cover Gas | |
| Ma et al. | Characteristic of keyhole, molten pool and microstructure of oscillating laser TIG hybrid welding | |
| Liu et al. | Analysis of metal transfer and weld forming characteristics in triple-wire gas indirect arc welding | |
| Chen et al. | Achieving high strength joint of pure copper via laser-cold metal transfer arc hybrid welding | |
| Gong et al. | Study on stability and microstructure properties of oscillating laser welded 5A06 alloy with narrow gap | |
| CN105603416A (en) | Gear repair apparatus | |
| CN111604593A (en) | Laser mirror image welding method | |
| Li et al. | Effect of liquid column on process stability and weld formation under ultra-high power fiber laser-arc hybrid welding of thick plates | |
| CN207372497U (en) | A kind of high power laser welding system based on high-velocity scanning galvanometer | |
| Li et al. | Numerical analysis of the dynamic behavior of arc by rotating laser-GMAW hybrid welding of T-joints |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| PB01 | Publication | ||
| PB01 | Publication | ||
| SE01 | Entry into force of request for substantive examination | ||
| SE01 | Entry into force of request for substantive examination | ||
| GR01 | Patent grant | ||
| GR01 | Patent grant |