CN117381124A - Efficient electron beam welding method for T-section long-short intersection weld joint structure - Google Patents

Efficient electron beam welding method for T-section long-short intersection weld joint structure Download PDF

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Publication number
CN117381124A
CN117381124A CN202311434565.6A CN202311434565A CN117381124A CN 117381124 A CN117381124 A CN 117381124A CN 202311434565 A CN202311434565 A CN 202311434565A CN 117381124 A CN117381124 A CN 117381124A
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China
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welding
electron beam
short
tool
weld
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Inventor
崔洋
吴广东
史吉鹏
高峰
关峰
赵兴旺
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Shenyang Aircraft Industry Group Co Ltd
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Shenyang Aircraft Industry Group Co Ltd
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Priority to CN202311434565.6A priority Critical patent/CN117381124A/en
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K15/00Electron-beam welding or cutting
    • B23K15/06Electron-beam welding or cutting within a vacuum chamber
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K15/00Electron-beam welding or cutting
    • B23K15/0013Positioning or observing workpieces, e.g. with respect to the impact; Aligning, aiming or focusing electronbeams
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K15/00Electron-beam welding or cutting
    • B23K15/0033Preliminary treatment
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K15/00Electron-beam welding or cutting
    • B23K15/0046Welding
    • B23K15/0053Seam welding

Abstract

The invention belongs to the technical field of aircraft structural member manufacturing, and provides a high-efficiency electron beam welding method for a T-section long-short intersection welding seam structure. Clamping the T-section long-short intersection weld joint structure once and vacuumizing once to finish the welding of two weld joints; the welding sequence of the T-section long-short intersection weld joint structure is that the welding sequence is long before short; according to the matching of the double-weld welding tool and the tool shifting mechanism, the welding of the long weld in a horizontal state and the welding of the short weld in a vertical state are ensured; and after the two welding seams are welded, further optimizing treatment is carried out, and the required part is obtained. The invention eliminates unstable welding process and hidden quality trouble caused by two clamping, reduces one disassembly and one clamping, reduces labor intensity in the welding process and reduces manual intervention level. And two welding seams of the parts are welded by the longitudinal gun and the transverse gun respectively, the influence of gravity on a molten pool can be eliminated during the transverse welding of the electron beam, and the heat input of the parts can be reduced and the internal stress level of the parts can be reduced relative to the longitudinal welding.

Description

Efficient electron beam welding method for T-section long-short intersection weld joint structure
Technical Field
The invention relates to the technical field of aircraft structural member manufacturing, in particular to a high-efficiency electron beam welding method of a T-section long-short intersection welding seam structure.
Background
The aviation bearing structure part is manufactured by adopting high-strength steel materials, and because the high-strength steel materials are high in density and large in mass, the characteristics of multiple semi-closed weight-reducing groove cavities, complex structure and the like of the part exist on the structural design in consideration of the weight-reducing requirement of an airplane, and the part is designed into a welding structure in order to improve the processing efficiency of the part, reduce the economic cost and the processing difficulty. Electron beam welding is widely applied to the field of welding of aerospace structural members due to the advantages and characteristics of high energy density, strong penetrating power, relatively small welding deformation, high degree of automation and the like. The welding seam structure with T-shaped cross section and long and short intersection is divided into a left part and a right part before welding, the two welding seams are connected into a whole, and the two welding seams show the characteristic of T-shaped intersection from the cross section direction. The following problems exist in the actual production process of the structure:
1) The welding machine is limited by the space positions of two welding seams and the size of an electron beam vacuum chamber, two sets of different tools are required to be used for positioning and welding respectively for finishing the processing of a part, and the whole process is subjected to the processes of twice assembly, disassembly, cleaning, vacuumizing, heat preservation and the like, so that the problems of low welding efficiency, long processing period, high cost, high labor intensity of workers and great manual intervention exist.
2) Because the tooling needs to be converted when two welding seams are welded in the actual welding process, when the first welding seam is detached from the corresponding tooling after the electron beam welding is completed, the stress state in the part is changed, the part after the stress state change and deformation is clamped for the electron beam welding of the second welding seam again, and the hidden quality trouble that the welding deformation cannot meet the design requirement exists.
3) Stress release, deformation and stress state change caused by repeated clamping can influence the involution state and the internal stress level of the part before the second welding seam welding, so that the defect of unfused is frequently generated after the second welding seam welding of the part, the defect has a large crack tendency level, and the welding quality of the part is seriously influenced. After the unfused defect occurs, the internal stress and deformation of the part are aggravated by the heat input in the repair welding process according to the relevant standard, and the part is scrapped in severe cases.
4) The greater the weld thickness of a part for a welding process, the greater the heat input required during the welding process and the greater its deformation. When the electron beam longitudinal spot gun is used for welding along the direction perpendicular to the ground plane, the welding molten pool is influenced by gravity to prevent the maintenance of a keyhole in the electron beam welding molten pool, so that the penetration capacity of the electron beam welding is reduced, and the electron beam longitudinal welding requires larger heat input relative to the electron beam transverse welding to realize the same penetration depth, and the welding deformation of parts is further aggravated by the multiple heat inputs.
Therefore, aiming at the structure of the T-shaped cross section long and short intersection weld joint, the electron beam welding method which is more efficient, stable and reliable, accurate in positioning, capable of controlling the welding deformation of parts, reducing the tendency of cracks to reduce welding defects, reducing the scrapping risk of the parts and the like is urgently needed to be developed, the problems of long period, low efficiency, high labor intensity of workers, serious deformation, easiness in generating welding defects and the like are solved, the electron beam welding efficiency and the accurate welding level of the parts are improved, and a technical solution is provided for the electron beam welding of aviation structural parts with similar structures.
Disclosure of Invention
The invention provides a high-efficiency electron beam welding method for a T-shaped section long-short intersection welding seam structure, which aims to solve the technical problems that the welding period of the aviation T-shaped section long-short intersection welding seam structure is long, the production efficiency is low, the manual intervention is more, the processing cost is high, the risk of out-of-tolerance rejection is generated due to deformation, the stress level is high after welding, the welding defect is extremely easy to generate and the like. The welding of two welding seams can be completed by one clamping and one vacuumizing, the welding deformation of the T-section long-short intersection welding seam structure is controlled, the labor intensity of workers in the welding process is reduced, the manual intervention level is reduced, and the equipment capacity of doubling the electron beam welding processing efficiency is fully utilized. Meanwhile, the risk of defects such as unfused and cracks and the like of the part is reduced, the welding deformation of the part is reduced, the internal stress level of the part is reduced, the defect area of the intersection part of two welding seams is calculated and removed, the influence on the structural strength of the part is greatly reduced, and the service life of the part is prolonged.
The technical scheme of the invention is as follows: a high-efficiency electron beam welding method of a T-shaped section long-short intersection welding seam structure comprises the steps of clamping the T-shaped section long-short intersection welding seam structure once and carrying out vacuum once to finish the welding of two welding seams; the welding sequence of the T-section long-short intersection weld joint structure is that the welding sequence is long before short; according to the matching of the double-weld welding tool 4 and the tool indexing mechanism 5, the welding of the long weld joint 1 in a horizontal state and the welding of the short weld joint 2 in a vertical state are ensured; and after the two welding seams are welded, further optimizing treatment is carried out, and the required part is obtained.
Measuring an included angle A between the short welding line 2 and the long welding line 1 by using three-dimensional modeling software;
when a=90°, directly indexing and welding two welding seams of the parts by using an electron beam vacuum chamber turntable in the welding process; when the long weld joint 1 is welded, the double-weld joint welding tool 4 is horizontally placed in a posture, the weld joint is horizontally along the X axis of the electron beam welding machine, and the surface to be welded faces the positive direction of the Z axis of the electron beam welding machine; the gesture is vertical along the Z-axis direction when the short welding line 2 is welded, and the surface to be welded faces to the Y-axis negative direction of the electron beam welder;
the included angle A between two welding seams of most T-shaped section long-short intersection welding seam structures is not exactly 90 degrees, so that a welding tool indexing mechanism is required to be designed for welding posture conversion of the two welding seams in the welding process. When A is smaller than 90 degrees, the double-weld welding tool 4 and the tool indexing mechanism 5 are matched, the posture of the short weld 2 during welding is adjusted to be a vertical posture, and the electron beam vacuum chamber turntable and the tool indexing mechanism 5 are used for jointly realizing indexing and welding of two welding seams of parts in the welding process;
when the long weld joint 1 is welded, the double-weld joint welding tool 4 is horizontally placed in a posture, the long weld joint 1 is horizontally arranged along the X axis of the electron beam welding machine, and the surface to be welded faces the positive direction of the Z axis of the electron beam welding machine; the tool indexing mechanism 5 adjusts the double-weld welding tool 4 to be in a posture of a horizontal inclination angle B when the short weld 2 is welded, wherein B= (90-A); the short welding line 2 is vertical along the Z-axis direction, and the surface to be welded faces the negative Y-axis direction of the electron beam welder.
The double-weld welding tool 4 comprises a positioning bolt 9, a lateral floating head positioning mechanism 10 and a web floating head positioning mechanism 11; a positioning bolt 9 is arranged at one end of the bottom surface of the double-weld welding tool 4, and lateral floating head positioning mechanisms 10 are arranged at two sides of the bottom surface; the web floating head positioning mechanism 11 is arranged above the structure to be welded; the diameter of the positioning bolt 9 is set according to the aperture size of the structure to be welded, and is used for connecting and positioning the structure to be welded and the double-weld welding tool 4, so that the degree of freedom of the structure to be welded in four directions is limited; the two lateral floating head positioning mechanisms 10 are symmetrically arranged at two sides of the welding line section of the structure to be welded, and the interval is 100-150mm; the two web floating head positioning mechanisms 11 are used for compressing the web of the structure to be welded, are distributed on two sides of the long welding line 1, are spaced by 100-150mm, and the spacing between the web floating head positioning mechanisms 11 on two sides of the welding line is 10-20mm;
polishing, cleaning and repairing the structure to be welded according to the related requirements of the electron beam welding standard of the material of the structure to be welded; checking whether the magnetic flux of the structure to be welded and the double-weld welding tool 4 meets the related standard requirement, and if not, carrying out demagnetization treatment; mounting the demagnetized and cleaned structure to be welded on a double-weld welding tool 4, firstly pre-assembling, positioning by penetrating through the two parts of the structure to be welded by using a positioning bolt 9, and clamping by using a lateral floating head positioning mechanism 10; checking the butt joint gap and the offset of the welding seams according to an electron beam welding standard, and positioning a welding backing plate and an arc striking plate required by two welding seams by using manual argon arc welding after the welding seams are qualified; and then performing formal assembly, and clamping all the positioning and limiting mechanisms.
The operation steps of the lateral floating head positioning mechanism 10 and the web floating head positioning mechanism 11 during clamping are that the floating heads on two sides are placed at the maximum stroke position, then the floating heads on two sides are screwed in synchronously, so that the floating heads on two sides are attached to the parts, and the number of the screwed cycles of each floating head is not more than 1/5 of the circle difference in the process from the attachment of the floating heads to final clamping.
The tool indexing mechanism 5 is two blocks, and is respectively arranged on two sides of one end of the bottom surface of the double-weld welding tool 4 and positioned on the side of the short weld joint 2; the tool indexing mechanism 5 comprises an indexing mechanism scribing observation surface G6 and an indexing mechanism positioning surface F7 which are mutually perpendicular; the positioning surface F7 of the indexing mechanism is attached to the working table surface of the turntable of the electron beam welding machine, and the double-weld welding tool 4 is in a posture of being inclined horizontally by B degrees; an auxiliary positioning surface E8 is arranged on one side, far away from the tool indexing mechanism 5, of the bottom surface of the double-weld welding tool 4 and forms an included angle A with the bottom surface of the double-weld welding tool 4; the positioning surface F7 and the auxiliary positioning surface E8 of the indexing mechanism are jointly attached and supported with the working table surface of the turntable of the electron beam welding machine, and the short welding seam of the structure to be welded can be welded by using the electron beam welding transverse electron gun under the posture.
The tool indexing mechanism mainly comprises two working positions, when the double-weld welding tool 4 is horizontally placed, the tool indexing mechanism does not participate in positioning of the double-weld welding tool 4, the bottom surface of the double-weld welding tool 4 is attached to the working table surface of the turntable of the electron beam welding machine, and the long weld of a structure to be welded can be welded by using the electron beam welding longitudinal electron gun under the posture; when the tool indexing mechanism rotates to the position below the bottom surface of the tool, the short welding line 2 is in a vertical state; the transverse electron gun is welded by using an electron beam under the gesture, so that the welding of a short welding line of a structure to be welded can be realized; when the indexing mechanism rotates to the position below the bottom surface of the tool, the scribing observation surface G6 of the indexing mechanism is perpendicular to the working table surface of the equipment and parallel to the short weld joint surface.
When the two welding seams are welded, after the structure to be welded is positioned on the double-welding-seam welding tool 4, the double-welding-seam welding tool 4 is positioned on electron beam welding equipment; vacuumizing and welding long weld joints by using an electron beam longitudinal gun; preserving heat and carrying out tool transposition and calibration; welding short welding seams by using an electron beam transverse gun; ventilating after heat preservation to release vacuum, and performing heat treatment annealing;
the double-weld welding tool 4 is positioned on electron beam welding equipment, and specifically comprises the following steps:
hoisting the double-weld welding tool 4 assembled with the structure to be welded onto a turntable of an electron beam welding device, adjusting the angle of the turntable to enable the long weld joint 1 to be in a horizontal state and parallel to the X axis of the electron beam welding device, then adjusting the Z-direction position of a working table, and adjusting the distance from the end face of an electron beam longitudinal gun to the surface of the long weld joint to enable the distance to meet the requirementRecording the working distance requirement in the process file, and recording the X of the electron beam welding equipment at the moment 1 Y 1 Z 1 A coordinate value; the equipment turntable is rotated anticlockwise by 90 degrees, then the tool indexing mechanism 5 is operated, the short welding line is in a vertical state, the position of the scribing line where the scribing line observation surface G6 of the indexing mechanism is positioned at the moment is recorded, the Y-direction and the X-direction positions of the workbench surface are adjusted, the Y-direction meets the requirement of the welding working distance of the short welding line in the process file, the X-direction scribing line is positioned at the center of the welding line, and the X of the equipment at the moment is recorded 2 Y 2 Z 2 A coordinate value; then the tool indexing mechanism 5 is pressed according to the recorded X 1 Y 1 Z 1 Resetting the value adjusting device to a to-be-welded state of the long weld joint of the part to enable the long weld joint to be in the to-be-welded state;
the vacuum pumping and the long welding seam welding by using an electron beam longitudinal gun are specifically as follows;
vacuumizing to reach a preset vacuum degree, wherein the formal welding current of the long welding line is I 1 First using 0.175I 1 Preheating and sealing the long weld joint by using high and low current; then calling a formal welding program to weld the long weld joint 1;
the heat preservation and tool indexing and calibration are specifically carried out;
after the welding of the long welding line 1 is finished and heat preservation is carried out for 20 minutes, a tool indexing mechanism 5 is operated, the short welding line 2 is turned to be in a vertical state, an electron beam longitudinal gun is arranged right above a scribing observation surface of the indexing mechanism, an electron observation window of the electron beam longitudinal gun is utilized to observe whether the scribing position of G is consistent with the recorded scribing position, and after confirmation, a workbench is adjusted to X of the short welding line to meet the requirement of working distance 2 Y 2 Z 2 A coordinate position;
the welding of the short weld joint by using the electron beam transverse gun is specifically as follows;
switching the electron gun to the electron beam transverse gun, and adjusting the focusing of the observation window to enable the surface of the short welding line to be clearly visible; checking whether the vacuum degree of the electron gun and the vacuum chamber meets the welding requirement, wherein the formal welding current of the short welding line is I 2 First using 0.175I 2 Preheating and sealing the short welding line by using high-low current; then calling a formal welding program to weld the short weld;
the heat preservation is carried out, then ventilation is carried out, vacuum is released, and heat treatment annealing is carried out specifically;
and after the welding of the short welding line is finished, preserving heat for 60 minutes, ventilating, taking out, and transferring heat treatment to carry out post-welding annealing.
The further optimization treatment specifically comprises the following steps:
calculating and removing an arc-collecting and spike-tip intersection region P, taking out the welded part, and then performing numerical control drilling to remove defects; the arc-collecting and spike-tip-collecting intersection area P is an intersection area of two welding lines, a long welding line is collected at the intersection area, and spike defects of a short welding line are in the intersection area; the transitional arc at the crossing part of the welding seam of the part is R, the arc-collecting length of the long welding seam is K, the defect control area of the electron beam nail tip of the short welding seam is L, and L=R×cos (A/2); then the arc and spike intersection region p=l+k+1; transferring the part to numerical control processing to carry out numerical control drilling to remove the intersection area of the defects of the two welding lines; firstly, removing backing plates, arc starting and arc collecting plates of long and short welding lines of a part by using a numerical control machine tool, then drilling a hole with the diameter of D at the intersection position of T-shaped sections of two welding lines in parallel to the direction of the short welding line according to the calculated arc collecting and spike intersection region P, rounding up the hole with the diameter of D as P, positioning the center of the hole on the joint line of the long welding line, enabling the periphery of the hole to be tangent to the back surface of the short welding line, and removing the arc collecting and spike defect intersection region P of the long welding line of the part by a drilling mode; and carrying out subsequent detection work, and completing electron beam welding of the T-section long-short intersection weld joint structure.
The invention has the beneficial effects that: 1. the high-efficiency electron beam welding method for completing the long-short intersection weld joint structure of the T-shaped section at one time is designed, welding is performed on the same tool in the same constraint force state by using one-time clamping, and electron beam welding of two welding joints is completed successively, so that the deformation control of the long-short intersection weld joint structure of the T-shaped section can be realized;
2. the tool and the tool indexing mechanism are suitable for electron beam welding of the T-shaped section long and short intersection welding line structure, and can realize once clamping and once vacuumizing to finish welding of two welding lines, so that unstable welding process and hidden quality hazards caused by twice clamping are eliminated, once disassembly and once clamping are reduced, labor intensity of the welding process is reduced, and manual intervention level is reduced.
3. The electron beam welding of the two vacuum furnaces with the T-shaped section long and short intersection welding seam structure is reduced to be completed by one vacuum furnace, and the processing efficiency of parts is doubled.
4. The two welding seams of the parts are welded by the longitudinal gun and the transverse gun respectively, so that the equipment capacity is fully utilized, meanwhile, the electron beam transverse gun is used for welding the second welding seam with larger constraint stress, the influence of gravity on a molten pool can be eliminated during electron beam transverse welding, the characteristic of the penetration capacity of electron beam welding is improved, compared with the longitudinal welding, the heat input of the parts can be reduced, the internal stress level of the parts is reduced, the risks of defects such as unfused and cracks of the parts are reduced, and meanwhile, the welding deformation of the parts is reduced.
5. The defects of the intersection parts of the two welding lines of the T-shaped section long-short intersection welding line structure are controlled in a reasonable area through reasonably designing the arc-collecting length of the long welding line and the electron beam nail tip control area of the short welding line, and the characteristics that the strength influence of a round hole on the original structure is minimum and stress concentration is not caused are combined with the strength gain of the corner of the part structure, the defects are thoroughly removed in a drilling mode at the position of the back of the joint short welding line, the influence of the defects on the structural strength of the part is greatly reduced, and the service life of the part is prolonged.
Drawings
FIG. 1 is a schematic diagram of a typical T-section long and short intersection weld;
FIG. 2 is a schematic diagram of a dual weld welding tool and tool indexing mechanism;
FIG. 3 is a schematic view of the arc of collection and spike intersection region P;
FIG. 4 is a schematic illustration of a borehole to remove defects at the weld intersection.
In the figure: 1. a long weld; 2. short welds; 3. typical T-shaped section long and short intersection weld structures; 4. double-weld welding tool; 5. tool indexing mechanism; 6. indexing mechanism lines the observation surface G; 7. a tool indexing mechanism positioning surface F; 8. an auxiliary positioning surface E; 9. positioning a bolt by a tool; 10. a lateral floating head positioning mechanism; 11. a web floating head positioning mechanism; 12. arc collection and spike intersection areas; 13. and (3) a hole.
Detailed Description
In the embodiment of fig. 1, a typical T-shaped section long and short intersection welding seam structure 3 is formed, the material of the part is AF1410, the welding thickness of a long welding seam 1 of the part is 6mm, the welding thickness of a short welding seam 2 is 12mm, and the specific structural form is shown in fig. 1. The specific electron beam welding implementation process of a typical T-shaped section long and short intersection weld joint structural part is as follows:
(1) Determining a welding posture according to the position relation of the two welding seams;
the two weld sections of the typical T-section long-short intersection weld structure 3 exhibit a T-intersection shape, with an angle between the long weld 1 and the short weld 2 of a=83°. A < 90 DEG judges that the welding tool needs to be designed with an indexing mechanism to adjust the short welding line 2 into a vertical posture, so that the welding is conveniently performed by using an electron beam transverse gun, and the indexing and welding of two welding lines of parts are jointly realized by using an electron beam vacuum chamber turntable and the tool indexing mechanism in the welding process. When the long welding line 1 is welded, the welding tool is horizontally placed in a posture, the welding line is horizontally along the X axis of the electron beam welding machine, and the surface to be welded faces the Z+ direction of the electron beam welding machine. When welding a short welding line, the tool indexing mechanism adjusts the tool to be in a posture of a horizontal inclination angle B=7 degrees, and the welding line is vertical along the Z-axis direction. And the surface to be welded is adjusted to face the Y-direction of the electron beam welding machine by the electron beam vacuum chamber turntable, and the gesture of the part welding process is determined.
(2) Designing a double-weld welding tool 4 and a tool indexing mechanism 5;
the welding fixture mainly comprises a fixture positioning bolt 9, a lateral floating head positioning mechanism 10 and a web floating head positioning mechanism 11, and a fixture bottom plate is connected with the fixture indexing mechanism 5, as shown in fig. 2. The diameter of the fixture positioning bolt 9 is phi 65mm, and 6 groups of lateral floating head positioning mechanisms 10 are arranged on two sides of the T-shaped section of the welding seam, and the distance is 120mm. The 4 groups of web floating head positioning mechanisms 11 are arranged for pressing the web of the structure to be welded, and the floating heads are 10mm away from the welding line and 120mm apart. The tool indexing mechanism 5 is arranged on one side of the short welding line 2 of the welding tool 4, the tool indexing mechanism 5 has two working positions, the first working position is horizontally placed, and the second working position is rotated to the position below the bottom surface of the tool; and the welding postures of the parts are converted by rotating and switching the form of the positioning surface. When the transposition mechanism is positioned at one position, the long weld joint 1 of the part is positioned at a horizontal posture, the transposition mechanism does not participate in positioning of the double-weld joint welding tool 4, the bottom surface of the double-weld joint welding tool 4 is attached to the working table surface of the turntable of the electron beam welding machine, and the long weld joint 1 of the structure to be welded can be welded by using the electron beam welding longitudinal electron gun under the posture. When the tooling indexing mechanism 5 is in the second position, the short weld 2 is in a vertical state. At the moment, the positioning surface 7 of the indexing mechanism is attached to the working table surface of the turntable of the electron beam welding machine, and the tool is in a posture of being inclined horizontally by 7 degrees. And an auxiliary positioning surface 8 is arranged on one side, far away from the indexing mechanism 5, of the bottom plane of the double-weld welding tool 4 and forms an included angle of 83 degrees with the bottom plane of the tool. The positioning surface 7 and the auxiliary positioning surface 8 of the indexing mechanism are attached to the working table surface of the turntable of the electron beam welding machine to jointly support the tool, and the short welding seam 2 of the structure to be welded can be welded by using the electron beam welding transverse electron gun in the posture. And a scribing observation surface 6 is manufactured on the indexing mechanism, the surface is perpendicular to the positioning surface 7 of the indexing mechanism, and when the indexing mechanism is positioned at the second position, the scribing observation surface 6 of the indexing mechanism is perpendicular to the working table surface of the equipment and is parallel to the surface of the short weld joint 2.
(3) Positioning a structure to be welded on a welding tool 4;
polishing and repairing the structure to be welded, ensuring that the roughness of the matching surface is not more than Ra3.2, keeping the edge of the butt joint surface of the welding line, wiping and cleaning the structure to be welded and the tool by dipping the white cotton cloth in acetone, and ensuring that the joint after cleaning has no trace such as knocked, scratched, pressed, rust, greasy dirt, oxide and other dirt. And checking that the magnetic flux of the typical T-shaped section long and short intersection weld joint structure 3 and the double weld joint welding fixture 4 is not more than 2Gs, and if the magnetic flux is not satisfied, carrying out demagnetization treatment. The demagnetized and cleaned typical T-section long and short intersection weld structure 3 is mounted on a welding tool 4. Firstly, preassembling, inserting a tool positioning bolt 9 into a typical T-shaped section long and short intersection weld joint structure 3 and a double-weld joint welding tool 4 on two sides in a penetrating manner, positioning two parts, and then clamping a tool lateral floating head positioning mechanism 10. Checking gaps and offset edges of the welding joint surfaces of the structures to be welded, wherein the gaps of the welding joints are smaller than 0.12mm, the offset edges are not larger than 0.2mm, and locating all welding backing plates and arc striking plates by using manual argon arc welding after the welding joint surfaces are qualified. And finally, performing formal assembly, and clamping and laminating the parts by using a web floating head positioning mechanism 11 for limiting all webs and rotating and compacting. The operation steps of all floating heads during clamping are that the floating heads on two sides are placed at the maximum stroke position, then the floating heads are screwed in synchronously, so that the floating heads on two sides are attached to the parts, and the number of the screwed cycles of each floating head is not more than 1/5 of the number of cycles in the process from attaching to final clamping.
(4) Positioning the tooling and the parts on the electron beam welding equipment;
hoisting the assembled long and short intersection weld structures 3 with typical T-shaped cross sections and the double weld welding tool 4 on a rotary workbench of an electron beam welding device, adjusting the angle of a turntable of the device to enable the long weld 1 to be in a horizontal state and parallel to the X axis of the electron beam welding device, then adjusting the Z-direction position of a workbench surface, adjusting the distance from the end face of an electron beam longitudinal gun to the surface of the long weld 1 to 400mm, and recording the X axis of the electron beam welding device at the moment 1 Y 1 Z 1 And (5) coordinate values. And (3) rotating the equipment turntable anticlockwise by 90 degrees, then operating the indexing mechanism to enable the short welding line 2 to be in a vertical state, and recording the position of the scribing line of the scribing observation surface 6 of the indexing mechanism at the moment. And adjusting the X-direction position of the workbench surface to enable the X-direction scribing line to be positioned at the center of the welding line. Adjusting the Y axis of the equipment, adjusting the distance between the surface of the short welding seam 2 and the muzzle of the electron beam transverse gun to 400mm, and recording the coordinate value X of the equipment at the moment 2 Y 2 Z 2 . Resetting the tool indexing mechanism according to the recorded X 1 Y 1 Z 1 The value adjusting device is reset to the state to be welded of the long welding line 1 of the part, so that the long welding line 1 of the part is in the state to be welded.
(5) Vacuumizing and welding a first long and thin welding line by using an electron beam longitudinal gun;
vacuumizing to 5.0X10 -3 The welding voltage is 150kV, the focusing current is 2455mA, the welding speed is 800mm/min, the electron beam scanning waveform is circular, the scanning amplitude is 0.7mm, and the scanning frequency is 200Hz. Adjusting the position of a workpiece to make the focus aligned with a long welding line 1 to be welded, performing electron beam positioning welding on the welding part, wherein the formal welding current of the long welding line 1 is I 1 =40ma, first with 0.175I 1 Welding current of =7ma for long weld 1 electron beam fixationAnd (5) performing position welding, namely preheating and sealing welding on the parts. And then, a welding program is called, other parameters are unchanged, and 40mA current is used for welding the long welding line 1 of the long and short intersection welding line structure with the typical T-shaped section.
(6) Indexing and calibrating the tool;
and after the welding of the long welding line 1 is finished and the heat preservation is carried out for 20 minutes, the equipment turntable and the tool indexing mechanism are operated, the short welding line 2 is turned to a vertical state, the position of the platform is adjusted to enable the electron beam longitudinal gun to be arranged right above the scribing observation surface of the indexing mechanism, and whether the scribing position of the scribing observation surface 6 of the indexing mechanism is located on the recorded scribing position is observed by utilizing the electron observation window of the electron beam longitudinal gun. If there is a deviation, the Y position of the adjusting device is corrected. After the confirmation and correction, the workbench is adjusted to the position with the working distance of 400mm of the short welding line 2 in the step (4), so that the focus is aligned with the welding joint of the short welding line 2.
(7) Welding the short welding line 2 of the part by using an electron beam transverse gun;
and after the high voltage of the electron beam longitudinal gun is released, an electron gun conversion program is operated, the electron gun is switched from the longitudinal gun to the transverse gun, and the focusing of an observation window of equipment is adjusted, so that the surface of the short welding seam 2 is clearly visible. Checking the vacuum degree of the electron gun and the vacuum chamber, wherein the vacuum degree of the electron gun reaches 5.0X10 -5 mbar, vacuum degree of the vacuum chamber reaches 5.0X10 -3 mbar. The formal welding current of the short welding line 2 is I 2 =77 mA, tack welding current 0.175×i 2 =13 mA, welding voltage of 150kV, focusing current of 2593mA, welding speed of 800mm/min, electron beam scanning waveform of circular shape, scanning amplitude of 1.3mm, and scanning frequency of 200Hz. And (3) adjusting the position of the workpiece, enabling the focus to be aligned with the joint of the short welding line 2, and performing electron beam localized welding of the short welding line 2 by using a welding current of 13 mA. And then, a welding program is called, 77mA current is used for welding the short welding line 2 of the typical T-shaped section long-short intersection welding line structure, and the welding of the parts is completed.
(8) Vacuum is released after heat preservation, and heat treatment annealing is carried out;
and (5) after the heat preservation is carried out for 60 minutes, the part is taken out and transferred to heat treatment for post-welding annealing after being inflated in the vacuum chamber.
(9) Calculating a region 12 for removing arc collection and spike intersection, and taking out the part and then removing defects by using a numerical control drilling hole 13;
the arc and spike intersection region 12 is the intersection region of two welds, as shown in fig. 3. The long weld 1 arcs here and the short weld 2 leaves a weld spike defect in this area. The transitional arc at the crossing part of the welding seam of the part is 10mm, and the length K of the arc-receiving section of the long welding seam 1 is set to be 10mm because the thickness to be welded of the long welding seam 1 is smaller, and the electron beam keyhole is small and the penetration depth is small. The short weld 2 electron beam tip defect control zone was l=r×cos (a/2) =7.49 mm. The long weld 1 arc of collection and short weld 2 spike control intersection region p=l+k+1=18.49 mm. And (3) transferring the part to a numerical control machine tool for numerical control machining and drilling, and firstly removing a backing plate, an arc striking plate and an arc receiving plate of long and short welding seams of the part by using the numerical control machine tool. And then, the calculated arc-collecting and spike-tip-intersecting area P=18.49 mm is parallel to the direction of the short welding line 2, a hole 13 with the diameter of D=19 mm is drilled at the intersecting position of the T-shaped section, the center of the hole 13 is positioned on the joining line of the long welding line 1, the hole periphery is tangential to the back surface of the short welding line 2, and the arc-collecting and spike-tip-defect-intersecting area 12 of the long welding line 1 of the part and the short welding line 2 is removed through the drilling hole 13, as shown in fig. 4.
(10) And (3) detecting the internal quality of the welding by X-ray, and completing the electron beam welding of the T-section long-short intersection welding line structure.

Claims (8)

1. A high-efficiency electron beam welding method of a T-shaped section long-short intersection welding seam structure is characterized in that the T-shaped section long-short intersection welding seam structure is clamped once and vacuumized once, and welding of two welding seams is completed; the welding sequence of the T-section long-short intersection weld joint structure is that the welding sequence is long before short; according to the matching of the double-weld welding tool (4) and the tool indexing mechanism (5), the welding of the long weld joint (1) in a horizontal state and the welding of the short weld joint (2) in a vertical state are ensured; and after the two welding seams are welded, further optimizing treatment is carried out, and the required part is obtained.
2. The efficient electron beam welding method of the T-section long-short intersection weld joint structure according to claim 1, wherein an included angle between the short weld joint (2) and the long weld joint (1) is A;
when a=90°, directly indexing and welding two welding seams of the parts by using an electron beam vacuum chamber turntable in the welding process; when a long welding line (1) is welded, the double-welding line welding tool (4) is horizontally placed in a posture, the welding line is horizontally along the X axis of the electron beam welding machine, and the surface to be welded faces the positive direction of the Z axis of the electron beam welding machine; the gesture of the short welding line (2) is vertical along the Z-axis direction when in welding, and the surface to be welded faces to the Y-axis negative direction of the electron beam welding machine;
when A is smaller than 90 degrees, the double-weld welding tool (4) is matched with the tool indexing mechanism (5), the posture of the short weld (2) during welding is adjusted to be a vertical posture, and the electron beam vacuum chamber turntable and the tool indexing mechanism (5) are used for jointly realizing indexing and welding of two welding seams of the part in the welding process;
when the long welding line (1) is welded, the double-welding line welding tool (4) is horizontally placed in a posture, the long welding line (1) is horizontally arranged along the X axis of the electron beam welding machine, and the surface to be welded faces to the positive direction of the Z axis of the electron beam welding machine; the tool indexing mechanism (5) adjusts the double-weld welding tool (4) to be in a posture of a horizontal inclination angle B when the short weld (2) is welded, wherein B= (90-A); the short welding line (2) is vertical along the Z-axis direction, and the surface to be welded faces the Y-axis negative direction of the electron beam welder.
3. The efficient electron beam welding method of the T-section long-short intersection weld joint structure according to claim 2, wherein the double-weld joint welding fixture (4) comprises a positioning bolt (9), a lateral floating head positioning mechanism (10) and a web floating head positioning mechanism (11); one end of the bottom surface of the double-weld welding tool (4) is provided with a positioning bolt (9), and two sides of the bottom surface are provided with lateral floating head positioning mechanisms (10); the web floating head positioning mechanism (11) is arranged above the structure to be welded; the diameter of the positioning bolt (9) is set according to the aperture size of the structure to be welded, and the positioning bolt is used for connecting and positioning the structure to be welded and the double-weld welding tool (4) to limit the freedom degrees of the structure to be welded in four directions; the two lateral floating head positioning mechanisms (10) are symmetrically arranged at two sides of the welding line section of the structure to be welded, and the interval is 100-150mm; the two web floating head positioning mechanisms (11) are used for compressing the web of the structure to be welded, are distributed on two sides of the long welding line (1) at intervals of 100-150mm, and the spacing between the web floating head positioning mechanisms (11) on two sides of the welding line is 10-20mm;
polishing, cleaning and repairing the structure to be welded according to the related requirements of the electron beam welding standard of the material of the structure to be welded; checking whether the magnetic flux of a structure to be welded and the double-weld welding tool (4) meets the related standard requirement, and if not, carrying out demagnetization treatment; mounting the demagnetized and cleaned structure to be welded on a double-weld welding tool (4), firstly pre-assembling, positioning by penetrating through the two parts of the structure to be welded by using a positioning bolt (9), and clamping by using a lateral floating head positioning mechanism (10); checking the butt joint gap and the offset of the welding seams according to an electron beam welding standard, and positioning a welding backing plate and an arc striking plate required by two welding seams by using manual argon arc welding after the welding seams are qualified; and then performing formal assembly, and clamping all the positioning and limiting mechanisms.
4. A method of high efficiency electron beam welding of T-section long and short intersection weld structures according to claim 3, wherein the lateral floating head positioning mechanism (10) and the web floating head positioning mechanism (11) are operated when clamped by the two side floating heads at the maximum stroke position, and then screwed in synchronously to attach the two side floating heads to the part, and the number of screwed cycles of each floating head is not more than 1/5 week from the attachment of the floating heads to the final clamping.
5. The efficient electron beam welding method of the T-shaped section long-short intersection welding seam structure according to claim 3 or 4, wherein the tool indexing mechanism (5) is two blocks which are respectively arranged on two sides of one end of the bottom surface of the double-welding seam welding tool (4) and are positioned on the side of the short welding seam (2); the tool indexing mechanism (5) comprises an indexing mechanism scribing observation surface G (6) and an indexing mechanism positioning surface F (7) which are mutually perpendicular; the positioning surface F (7) of the indexing mechanism is attached to the working table surface of the turntable of the electron beam welding machine, and the double-weld welding tool (4) is in a posture of being inclined horizontally by an angle B; an auxiliary positioning surface E (8) is arranged on one side, far away from the tool indexing mechanism (5), of the bottom surface of the double-weld welding tool (4) and forms an included angle A with the bottom surface of the double-weld welding tool (4); the positioning surface F (7) and the auxiliary positioning surface E (8) of the indexing mechanism are jointly attached and supported with the working table surface of the turntable of the electron beam welding machine, and the short welding seam of the structure to be welded can be welded by using the electron beam welding transverse electron gun under the posture.
6. The efficient electron beam welding method of the T-shaped section long-short intersection welding seam structure according to claim 5, wherein the tool indexing mechanism mainly has two working positions, when the double-welding seam welding tool (4) is horizontally placed, the tool indexing mechanism does not participate in positioning of the double-welding seam welding tool (4), the bottom surface of the double-welding seam welding tool (4) is attached to a turntable working table of an electron beam welding machine, and the long welding seam of the structure to be welded can be welded by using an electron beam welding longitudinal electron gun in the posture; when the tool indexing mechanism rotates to the position below the bottom surface of the tool, and the short welding line (2) is in a vertical state; the transverse electron gun is welded by using an electron beam under the gesture, so that the welding of a short welding line of a structure to be welded can be realized; when the indexing mechanism is positioned below the bottom surface of the tool, the indexing mechanism score line observation surface G (6) is perpendicular to the working table surface of the equipment and parallel to the short weld joint surface.
7. The efficient electron beam welding method of the T-section long-short intersection weld joint structure according to claim 6, wherein when the two weld joints are welded, after the structure to be welded is positioned on the double-weld joint welding tool (4), the double-weld joint welding tool (4) is positioned on the electron beam welding equipment; vacuumizing and welding long weld joints by using an electron beam longitudinal gun; preserving heat and carrying out tool transposition and calibration; welding short welding seams by using an electron beam transverse gun; ventilating after heat preservation to release vacuum, and performing heat treatment annealing;
the double-weld welding tool (4) is positioned on electron beam welding equipment and comprises the following components:
hoisting a double-weld welding tool (4) assembled with a structure to be welded onto a turntable of electron beam welding equipment, adjusting the angle of the turntable to enable a long weld joint (1) to be in a horizontal state and parallel to the X axis of the electron beam welding equipment, then adjusting the Z-direction position of a working table, adjusting the distance from the end face of an electron beam longitudinal gun to the surface of the long weld joint to enable the distance to meet the requirement of working distance in a process file, and recording the X of the electron beam welding equipment at the moment 1 Y 1 Z 1 A coordinate value; the equipment turntable is rotated anticlockwise by 90 degrees, then a tool indexing mechanism (5) is operated, a short welding line is in a vertical state, the position of a scribing line where a scribing line observation surface G (6) of the indexing mechanism is positioned at the moment is recorded, the Y-direction and the X-direction positions of the workbench surface are adjusted, the Y-direction meets the requirement of the welding working distance of the short welding line in a process file, an X-direction scribing line is positioned at the center of the welding line, and the X of the equipment at the moment is recorded 2 Y 2 Z 2 A coordinate value; then the tool indexing mechanism (5) is pressed according to the recorded X 1 Y 1 Z 1 Resetting the value adjusting device to a to-be-welded state of the long weld joint of the part to enable the long weld joint to be in the to-be-welded state;
the vacuum pumping and the long welding seam welding by using an electron beam longitudinal gun are specifically as follows;
vacuumizing to reach a preset vacuum degree, wherein the formal welding current of the long welding line is I 1 First using 0.175I 1 Preheating and sealing the long weld joint by using high and low current; then calling a formal welding program to weld the long weld joint (1);
the heat preservation and tool indexing and calibration are specifically carried out;
after the welding of the long welding line (1) is finished and the heat preservation is carried out for 20 minutes, a tool transposition mechanism (5) is operated, the short welding line (2) is turned to a vertical state, an electron beam longitudinal gun is arranged right above a scribing observation surface of the transposition mechanism, an electron observation window of the electron beam longitudinal gun is utilized to observe whether the scribing position of G is consistent with the recorded scribing position, and after confirmation, a workbench is adjusted to X of the short welding line to meet the requirement of working distance 2 Y 2 Z 2 A coordinate position;
the welding of the short weld joint by using the electron beam transverse gun is specifically as follows;
switching the electron gun to the electron beam transverse gun, and adjusting the focusing of the observation window to enable the surface of the short welding line to be clearly visible; checking whether the vacuum degree of the electron gun and the vacuum chamber meets the welding requirement, wherein the formal welding current of the short welding line is I 2 First using 0.175I 2 Preheating and sealing the short welding line by using high-low current; then calling a formal welding program to weld the short weld;
the heat preservation is carried out, then ventilation is carried out, vacuum is released, and heat treatment annealing is carried out specifically;
and after the welding of the short welding line is finished, preserving heat for 60 minutes, ventilating, taking out, and transferring heat treatment to carry out post-welding annealing.
8. The method for high-efficiency electron beam welding of a T-section long and short intersection weld structure according to claim 7, wherein the further optimization process is specifically:
calculating and removing an arc-collecting and spike-tip intersection region P, taking out the welded part, and then performing numerical control drilling to remove defects; the arc-collecting and spike-tip-collecting intersection area P is an intersection area of two welding lines, a long welding line is collected at the intersection area, and spike defects of a short welding line are in the intersection area; the transitional arc at the crossing part of the welding seam of the part is R, the arc-collecting length of the long welding seam is K, the defect control area of the electron beam nail tip of the short welding seam is L, and L=R×cos (A/2); then the arc and spike intersection region p=l+k+1; transferring the part to numerical control processing to carry out numerical control drilling to remove the intersection area of the defects of the two welding lines; firstly, removing backing plates, arc starting and arc collecting plates of long and short welding lines of a part by using a numerical control machine tool, then drilling a hole with the diameter of D at the intersection position of T-shaped sections of two welding lines in parallel to the direction of the short welding line according to the calculated arc collecting and spike intersection region P, rounding up the hole with the diameter of D as P, positioning the center of the hole on the joint line of the long welding line, enabling the periphery of the hole to be tangent to the back surface of the short welding line, and removing the arc collecting and spike defect intersection region P of the long welding line of the part by a drilling mode; and carrying out subsequent detection work, and completing electron beam welding of the T-section long-short intersection weld joint structure.
CN202311434565.6A 2023-11-01 2023-11-01 Efficient electron beam welding method for T-section long-short intersection weld joint structure Pending CN117381124A (en)

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