CN210848805U - Welding torch for laser and photoelectric arc composite welding - Google Patents
Welding torch for laser and photoelectric arc composite welding Download PDFInfo
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- CN210848805U CN210848805U CN201921102231.8U CN201921102231U CN210848805U CN 210848805 U CN210848805 U CN 210848805U CN 201921102231 U CN201921102231 U CN 201921102231U CN 210848805 U CN210848805 U CN 210848805U
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Abstract
The utility model provides a welding torch of laser and light electric arc hybrid welding includes: a torch body having an input end, an output end, and a hollow interior between the input end and the output end; the torch body has a central axis through which the laser beam passes; the input end is provided with an incident ray lens for focusing laser beams; the output end comprises an insulating bush, a compression nozzle, a protection nozzle and a first non-melting electrode; the insulating bush surrounds the lower end of the hollow inner cavity; the compression nozzle is positioned at the output end of the insulation bushing; the first non-melting electrode is embedded in the insulating bush and arranged in an oblique angle with the central axis, the bottom end of the first non-melting electrode is positioned above the through hole of the compression nozzle, the distance from the bottom end of the first non-melting electrode to the upper surface of the through hole of the compression nozzle is h, and the distance between the bottom ends of the first non-melting electrode is d; the radius of the laser beam passing through the through hole of the compression nozzle is r1, and the radius of the through hole is larger than r 1.
Description
Technical Field
The utility model relates to a welding torch device that is used for welding of metal material, coating, exactly, is the welding torch that relates to laser and light electric arc hybrid welding, and adopts the utility model discloses a laser and light electric arc hybrid welding method.
Background
Welding is a processing and manufacturing technology which is vital in various metal manufacturing industries and cannot be completely replaced up to now. Welding operations refer to the creation of high energy densities on a workpiece to form a weld pool and to move the weld pool. Therefore, if the energy coupling efficiency between the bonding tool and the workpiece, i.e., the energy density incident on the workpiece, can be improved, significant economic benefits can be obtained, depending on the materials used and the bonding technique.
One of them is plasma welding with high energy coupling density, plasma welding is a process technology using plasma arc as energy source to melt workpiece and weld, plasma arc is plasma with higher energy density obtained by non-melting electrode arc after compression strengthening, also called compression arc, energy density can reach 105--106w/cm2. The plasma welding torch mainly comprises a non-melting electrode, a water-cooling nozzle and the like, when welding starts, a pilot arc with small current is firstly established between a tungsten electrode and the nozzle, and the pilot arc does not actually participate in welding; during welding, a pilot arc is used to establish a plasma arc between a tungsten electrode and a workpiece, the energy density of the plasma arc between the nozzle and the workpiece is increased after the non-consumable electrode arc is compressed by the nozzle, and the higher energy plasma arc generates dynamic pressure on the surface of the workpiece, so that the arc can penetrate through a molten liquid pool, and the welding is also called as 'small hole' welding. The main advantage of plasma welding is the ability to perform a one-pass, relatively fast material weld with minimal joint preparation. In addition, because the plasma arcs are concentrated within the "keyhole," stresses or deformations within the workpiece are reduced.
Despite the many important advantages of plasma welding, several serious limitations remain.
First, plasma arc starting techniques, plasma welding, often require high frequency high voltage to break down the shielding gas between the electrode and the nozzle to form a non-transferred plasma arc, which can result in damage to nearby electronic equipment. In addition, the insufficient energy density of the plasma arc limits the penetration depth of the "keyhole", the thickness of the weldable material and the welding speed, and in addition, the plasma welded "keyhole" may collapse under certain operating conditions, thereby causing a reduction in weld quality.
In plasma welding, the energy density incident on the workpiece is the most important parameter for forming a "keyhole". In conventional plasma arc welding processes, radiative heat transfer is the dominant factor for currents of about 200A-250A and plasma power densities of about 3-3.5KW, and thus, higher plasma welding power densities are not practically achievable with the prior art, and any attempt to increase power density by increasing torch power consumption reduces welding efficiency; if attempts are made to increase the welding speed, the plasma arc can become unstable and hot spots on the workpiece can fall behind the torch axis, a cause of poor weld quality.
Laser beam welding is an efficient precision machining method that uses a laser beam as a heat source for welding. Laser beam welding, dominated by the "keyhole" mode, which provides relatively large penetration depths, has a high energy density (typically 10 a) compared to other fusion welding methods6～108W/cm2) The heat input is less, the residual stress and deformation of a joint area are small, a melting area and a heat affected area are narrow, the fusion depth is large, a welding seam structure is fine, the joint performance is good, and the like. In addition, compared with the electron beam technology, the laser beam welding does not need vacuum conditions, the type and the pressure range of the protective gas can be conveniently selected, the laser beam can be guided to the position which is difficult to access by means of a deflection prism or an optical fiber for welding, the operation is flexible, the laser beam can pass through the focusing welding of a transparent material and the like, the laser beam can be flexibly controlled, and the three-dimensional automatic welding of workpieces is easy to realize.
Laser beam welding also has several significant constraints. Since the weldable material thickness and penetration depth are limited by the power and heat of the laser beam coupled to the workpiece, improved welding results can generally only be achieved by increasing the laser power. Laser beam welding typically requires large, high power gas, solid state, or diode lasers to generate and maintain a "keyhole" weld pattern.
It is well known that the pressure generated by the metal plasma against the inner wall of the "keyhole" is important to maintain the "keyhole" welding mode during welding. However, if the plasma density is too high, laser beam reflection may occur; in fact, the plasma density becomes too low or too high, which can result in a reduction in the efficiency of the welding operation. In addition, laser beam welding on materials such as metals requires the use of higher laser beam power to form the "keyhole," but the power conversion efficiency of the laser beam is low.
In general, the following typical limitations exist for laser beam welding techniques:
(1) very precise weldment positions (within the focus of the laser beam) are required, and relatively complex clamping fixtures are required for the weldments to ensure that the laser beam hot spots are aligned with the final positions of the weldments; for workpieces with a thickness greater than 19mm, laser welding is not suitable for use in a production line.
(2) The application of laser beam welding is limited for highly reflective and highly thermally conductive materials such as aluminum, copper and alloys thereof. When high energy welding is performed, the performance of laser beam welding is affected by plasma.
(3) Energy conversion efficiency is typically less than 10%; the weld bead is solidified quickly, and is easy to generate air holes and embrittle.
(4) The equipment is expensive.
To eliminate or reduce the drawbacks of laser welding, new techniques for hybrid welding with laser beams using other heat sources have now begun some industrial applications. The most typical of the hybrid welding techniques that have been used are laser beam and arc paraxial arrangements.
The basic feature of this laser-arc hybrid welding technique is that the energy of the laser beam is applied directly to the workpiece surface and is combined with the consumable electrode arc (GMAW) or TIG arc to produce a certain "hybrid welding" effect, but this "hybrid welding" effect is limited because the energy density of the GMAW or TIG arc is much lower than that of the laser beam.
In general, laser beam and arc hybrid welding has the following "hybrid welding" advantages:
1) has certain 'composite welding' effect, and can improve the welding speed, increase the fusion depth and improve the 'bridging' capability of welding compared with single laser welding.
2) The combined heat source of the laser beam and the electric arc can increase the welding speed compared to arc welding alone.
Although laser beam arc hybrid welding has many important advantages, there are some limitations that affect the application of laser beam arc hybrid welding process technology in the industrial field. For example, one of the most important disadvantages of the hybrid welding method is the paraxial arrangement of the laser beam and the arc, because the working areas of the two welding heat sources on the workpiece are asymmetrical, and the control system is difficult to realize stable operation; another disadvantage is that the difference in energy density levels between the laser beam and the arc is large, reducing the "hybrid" welding effect of the dual heat sources, for example, when the arc current increases to a certain value, the energy of the laser beam is reduced by continuing to increase the arc current. In addition, in practical application, the laser beam and arc hybrid welding torch adopting the paraxial arrangement mode still has many problems of insufficient practicability, such as large arrangement space, relatively complex welding system, high welding groove precision and the like.
The composite welding technology of the laser beam and other welding heat sources in a paraxial arrangement mode, which is similar to the technology, also comprises a laser and TIG electric arc composite welding mode, and the double heat source arrangement mode is similar, so the technical defects still exist.
The research results of the laser beam and other common welding heat sources adopting a coaxial arrangement mode comprise: a laser beam and MIG arc (consumable electrode arc) coaxial hybrid torch, and a laser beam and TIG arc (non-consumable electrode) coaxial hybrid torch (e.g., US4,689,466). The above-mentioned technology has a limited "hybrid welding" effect because the energy density grade difference between the laser beam and the electric arc is too large, and from the practical effect, the effect of the coaxial hybrid welding method of the laser beam and the electric arc (consumable electrode electric arc) is limited from the previous paraxial hybrid welding effect, and the coaxial hybrid welding method of the laser beam and the non-consumable electrode (TIG electric arc, uncompressed plasma) is difficult to be put into practical use because the technology needs to adopt a ring-shaped or hollow non-consumable electrode, but the special-shaped non-consumable electrode is difficult to be manufactured and is easy to be burnt.
The core of the technology of welding by combining laser beam and plasma arc (compressed arc) as described in US5,705,785 and US6,388,227 is that part of the laser beam is directly projected on the non-melting electrode, and the rest passes through the center of the non-melting electrode arc and is combined with the arc. The main drawbacks of these techniques include: only part of laser beams pass through the plasma arc for composite welding, so that the energy utilization rate is low; plasma is excited by adopting a mode of radiating heat by partial laser beams to electrodes, so that burning loss of the electrodes is inevitably aggravated; in addition, both the conical hollow electrode and the combined electrode have the problems of low reliability, high requirements on manufacturing and mounting precision, difficulty in electrode replacement and the like, and the popularization and application of the technology are directly limited.
SUMMERY OF THE UTILITY MODEL
In order to overcome the technical defects, the embodiment of the utility model provides a welding torch for performing hybrid welding by using laser beams and plasma arcs and a using method thereof.
In order to achieve the purpose, the utility model adopts the technical proposal that:
a torch for hybrid welding using a laser beam and a plasma arc includes a torch body having a hollow interior with an input end through which the laser beam passes and an output end through which the laser beam is incident and exits. The welding torch comprises a lens at an input end for focusing incident rays of a laser beam, a first non-melting electrode and an insulating bush for insulating the electrode from the welding torch, wherein the insulating bush surrounds the lower end of a hollow inner cavity, a compression nozzle and a protection nozzle for compressing an electric arc are arranged at the lower part of the welding torch, the protection nozzle surrounds the outside of the compression nozzle, the compression nozzle is provided with a through hole taking the central axis of a welding torch body as a center, and the bottom surface is perpendicular to the central axis of the welding torch body.
The first non-melting electrode is embedded in an insulating bushing and the laser beam passes through a compression nozzle through-hole having a radius r1, which is greater than r 1.
Further, the first non-consumable electrode and the torch body central axis are disposed at an oblique angle, and the intersection angle of the electrode and the torch body central axis ranges from 0 to 90 degrees.
Further, the bottom end of the first non-melting electrode is located at a distance h of 1 to 5mm from the upper surface of the opening of the compression nozzle, which is used for forming a pilot arc (non-transferred arc).
Furthermore, protective gas is input between the compression nozzle and the protective nozzle.
Further, the number of non-consumable electrodes in the torch may be 1, 2, 3, or 4.
The technical scheme has the following beneficial effects:
1. the first non-melting electrode establishes a plasma working arc between the tip and the workpiece, the laser beam interacts with the plasma arc to form a light arc having a higher energy density, the light arc interacts with the laser beam at a weld spot on the surface of the workpiece, and thus a higher combined heat source coupling efficiency than conventional laser beam and arc combining can be achieved.
2. A less costly welding method is provided that achieves the same welding capacity and efficiency as a higher power laser beam, and achieves quality and efficiency over welding with a single laser beam, while eliminating the drawbacks of the prior art laser and plasma hybrid welding techniques.
3. The electrode structure of the composite welding torch is simplified, the manufacturing, the installation and the operation are convenient, the electrode is replaced, and the electrode is not easy to burn. Adopt the utility model discloses a welding torch is probably further reduced size, and this welding construction of being convenient for more is favorable to reducing the cost of the compound welding torch of laser and photoelectric arc moreover.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to these drawings without creative efforts.
FIG. 1 is a schematic view of a laser and light arc hybrid welding torch;
the reference numerals are represented as: 1. an input end; 2. an output end; 3. a hollow interior cavity; 11. a lens; 21. an insulating bushing; 22. Compressing the nozzle; 23. protecting the nozzle; 24. a first non-melting electrode; 211. a central axis; 221. and a through hole.
Detailed Description
The technical solutions in the embodiments of the present invention will be described clearly and completely with reference to the accompanying drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments in the present invention, all other embodiments obtained by a person skilled in the art without creative work belong to the protection scope of the present invention.
The utility model discloses an utilize laser beam and plasma arc to carry out hybrid welding's welding torch, include: the welding torch comprises a welding torch body and a welding torch body, wherein the welding torch body is provided with an input end 1, an output end 2 and a hollow inner cavity 3 positioned between the input end 1 and the output end 2, and a laser beam is incident from the input end 1 and is emitted from the output end 2; the torch body has a central axis 211, the central axis 211 being a laser beam passing direction;
the input end 1 comprises a lens 11 for focusing the incident rays of the laser beam so that the beam is collinear with the central axis 211 of the torch body and is focused to a focal point located outside the torch.
The output end 2 comprises an insulating bush 21, a compression nozzle 22, a protection nozzle 23 and a first non-melting electrode 24;
the insulating bush 21 surrounds the lower end of the hollow inner cavity 3 to ensure that the non-melting electrode is insulated from the welding torch;
the compression nozzle 22 is positioned at the output end of the insulation bushing 31, the compression nozzle 22 is provided with a through hole 221 which is centered on the central axis 211 of the welding torch body, and the bottom surface of the compression nozzle 22 is perpendicular to the central axis 211 of the welding torch body;
a protection nozzle 23 surrounding the outside of the compression nozzle 22 for protecting the compression nozzle 22;
the first non-melting electrode 24 is embedded in the insulating bush 21 and is obliquely arranged with the central axis 211, the bottom end of the first non-melting electrode 24 is positioned above the through hole of the compression nozzle and is at a distance h from the upper surface of the through hole of the compression nozzle 22, the range of h is 1mm to 5mm, the range depends on the output current range of the plasma power supply of the welding torch, and the welding torch with larger output current is larger in h, and is smaller in the opposite direction.
The laser beam passes through a radius r1 at the through hole 221 of the compression nozzle 22; the radius of the through hole (221) is larger than r 1.
The first non-melting electrode 24 forms a pilot arc between the electrode tip and the compression nozzle 22, which establishes a main working plasma arc in the space between the first non-melting electrode 24 and the workpiece when welding is performed;
the laser beam travels collinearly along the central axis 211 of the torch body through the lens 11, is coaxial with and interacts through the center of the plasma arc to form a photoelectric arc distinct from the laser beam and the plasma arc, and is focused to a focal point outside the torch body, which interacts with the metal vapor and plasma cloud created by the laser as it burns a small hole in the workpiece to form a weld-melted spot on the workpiece material.
The first non-consumable electrode 24 is disposed along the central axis of the torch body at an oblique angle ranging from 0 to 90 degrees, which is suitable for a wide range of applications, and also facilitates the design of torches of different forms and functions, preferably ensuring that the electrode is easy to install and does not make the torch too bulky in size.
Further, the distance h from the bottom end of the first non-melting electrode 24 to the upper surface of the opening of the compression nozzle 22 is 1 to 5mm, and thus a stable non-transferred arc is easily formed between the first non-melting electrode 24 and the compression nozzle 22.
Further, a shielding gas is introduced between the compression nozzle 22 and the shield nozzle 23.
Further, the number of non-consumable electrodes in the torch may be 1, 2, 3, or 4. Adopting 2 rod-shaped non-melting electrodes which are symmetrically arranged along the central line of the welding torch; 3 electrodes which are uniformly arranged can also be adopted, 4 electrodes which are oppositely arranged in pairs can also be adopted, and the plasma arc power formed by a plurality of electrodes is higher.
The utility model adopts a mature 'soft start' mode to ignite a non-transferred arc between an electrode and a nozzle, and the 'soft start' of plasma arc refers to a plasma arc striking technology which does not need high frequency and high pressure when plasma arc striking; when implementing the welding, the utility model provides an establish transfer electric arc (plasma electric arc) between non-melting electrode and the work piece, the laser beam passes plasma arc and interact with it, forms the higher photoelectric arc of energy density, on the work piece solder joint, passes the laser beam of photoelectric arc and photoelectric arc combined action, has formed photoelectric arc-laser discharge to furthest has improved the energy density at the work piece solder joint.
Utilize the utility model discloses, electric arc energy density lasts the improvement under coupling and photoelectricity combined action, has formed the photoelectric arc higher than plasma arc energy density:
1. first, a first non-melting electrode forms a pilot arc (non-transferred arc) between the electrode and the nozzle;
2. when welding is carried out, a compressed plasma arc ("transferred arc") is formed between the electrode and the workpiece, achieving a first step of energy enhancement;
3. the laser beam passing through the plasma arc interacts with the plasma arc, so that the plasma arc forms a photoelectric arc with higher energy density, and the second step of energy enhancement is realized;
4. the laser beam interacts with the photoelectric arc to form a welding point with higher energy density on the workpiece, and the third step of energy enhancement is realized, so that the absorption rate of the material to the welding energy is improved.
The use method of the welding torch comprises the following steps:
the first non-consumable electrode 24 forms a pilot arc between the tip of the electrode and the nozzle 22 that is transferred to a compressed plasma arc between the electrode and the workpiece as the weld is being performed, and the laser beam passes through the center of the plasma arc and interacts with the plasma arc to form a photoelectric arc that cooperates with the laser beam to form a high energy density weld joint on the workpiece.
Compare solitary laser beam or plasma arc, the utility model discloses the welding torch has increased substantially workpiece surface's energy density, and then has improved welding efficiency. Utilize the utility model discloses, the penetration that adopts 1KW laser instrument to obtain is equivalent to 2KW-3KW laser instrument effect of welding alone.
The laser beam and photoelectric arc hybrid welding torch of the utility model utilizes the combined action of the laser beam and the photoelectric arc to improve the energy density on the welding spot of the workpiece; by utilizing the device of the utility model, a laser with small power can be adopted to obtain high composite heat source coupling efficiency on a welding spot of a workpiece, and the defects of laser beam welding are eliminated, including that the workpiece has very accurate size, the welding bead is solidified quickly, the equipment is expensive, and the like; by utilizing the device of the utility model, the defects of plasma welding, including lower welding efficiency, small fusion depth and the like, are eliminated; utilize the utility model discloses a device has still eliminated some current laser beam plasma hybrid welding device's defect simultaneously, including that the welding torch structure is complicated, the electrode is very easily burnt and is decreased, the manufacturing and installation degree of difficulty are big, the range of application is narrower etc..
Laser beam light electric arc hybrid welding torch also is applicable to the condition that adopts pulsed plasma welding.
The utility model discloses in welding aluminum alloy, magnesium alloy or other occasions that need adopt the plasma power supply of change polarity, the utility model discloses it is equally suitable. Meanwhile, thorium, lanthanum, zirconium and other alloys are coated on the end part of the plasma electrode, so that the service life of the electrode is prolonged, and the stability of the welding process is improved.
According to the utility model human research, the main physical effects that occur in the enhanced interaction between the laser beam and the plasma arc include:
1. the plasma arc undergoes a significant pinch effect, producing a higher energy density, i.e. the formation of the said photoelectric arc, which is characterized by a diameter of the photoelectric arc which is smaller than that of the plasma arc alone, and by a temperature which is also significantly higher than that of the plasma arc. According to research and comparison, the photoelectric arc can promote the absorption rate of the material to the laser energy, for example, the absorption efficiency of the aluminum alloy material to the laser can be improved from 5% to 90%, and for example, because the reflectivity of the copper material to laser is higher than 99 percent, the laser welding can not be generally used, but by utilizing the utility model, on one hand, the copper material can absorb more laser energy to melt the copper material under the action of the light electric arc, therefore, the utility model can be used for welding copper alloy materials, which greatly improves the application field and application capability of laser, on the other hand, the utility model embodies that the absorption rate of the materials to laser energy is greatly improved, and the emitted laser beam has no direct reflection phenomenon under the surrounding of the plasma arc, thereby not influencing the laser, because the laser is located inside the plasma nozzle, spatter generated during welding does not contaminate the laser.
2. The heat affected zone or hot spot on the workpiece is reduced.
3. The plasma temperature is increased.
4. And the stability of the coupled plasma arc is improved.
5. And the energy consumption is reduced. The welding effect that the plasma heat source that only needs the laser beam of less power and lower output just can reach great power laser beam, higher output could have, and total net effect produces higher energy density spot on the work piece, for example, compares with the plasma welding of equal power laser welding, equal electric current, the utility model discloses higher welding speed and the bigger depth of fusion have.
In the foregoing detailed description, various features are grouped together in a single embodiment for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed embodiments of the subject matter require more features than are expressly recited in each claim. Rather, as the following claims reflect, the invention lies in less than all features of a single disclosed embodiment. Thus, the following claims are hereby expressly incorporated into the detailed description, with each claim standing on its own as a separate preferred embodiment of the invention.
Claims (6)
1. A torch for a hybrid laser and light arc weld, the torch comprising:
the welding torch comprises a welding torch body and a welding torch body, wherein the welding torch body is provided with an input end (1), an output end (2) and a hollow inner cavity (3) positioned between the input end (1) and the output end (2), and laser beams are incident from the input end (1) and are emitted from the output end (2); the torch body has a central axis (211), the central axis (211) being a laser beam passing direction;
the input end (1) comprises a lens (11) for focusing the incident light of the laser beam;
the output end (2) comprises an insulating bush (21), a compression nozzle (22), a protection nozzle (23) and a first non-melting electrode (24);
the insulating bush (21) surrounds the lower end of the hollow inner cavity (3) to ensure that the non-melting electrode is insulated from the welding torch;
the compression nozzle (22) is positioned at the output end of the insulation bushing (21), the compression nozzle (22) is provided with a through hole (221) taking the central axis (211) of the welding torch body as the center, and the bottom surface of the compression nozzle (22) is vertical to the central axis (211) of the welding torch body;
the protection nozzle (23) surrounds the outside of the compression nozzle (22) and is used for protecting the compression nozzle (22);
the first non-melting electrode (24) is embedded in the insulating bush (21) and is arranged at an oblique angle with the central axis (211), and the bottom end of the first non-melting electrode (24) is positioned above the through hole of the compression nozzle and is at a distance h from the upper surface of the through hole of the compression nozzle (22);
the laser beam passes through a through hole (221) of the compression nozzle (22) with a radius r1, the radius of the through hole (221) being greater than r 1.
2. A torch for a hybrid laser and light arc weld as defined in claim 1, wherein:
the first non-melting electrode (24) is disposed at an oblique angle to the central axis (211) in the range of 0 to 90 degrees.
3. A torch for a hybrid laser and light arc weld as defined in claim 1, wherein:
protective gas is input between the compression nozzle (22) and the protective nozzle (23).
4. A torch for a hybrid laser and light arc weld as defined in claim 1, wherein:
and a second non-melting electrode embedded in the insulating bush (21), the second non-melting electrode and the first non-melting electrode (24) being arranged symmetrically outside the central axis (211) along the central axis (211).
5. A torch for a hybrid laser and light arc weld as defined in claim 4, wherein: further comprising:
a third non-melting electrode embedded in the insulating bush (21), the third non-melting electrode being arranged uniformly outside the central axis (211) with the first non-melting electrode (24) and the second non-melting electrode.
6. A torch for a hybrid laser and light arc weld as defined in claim 5, wherein: further comprising:
a fourth non-melting electrode embedded in the insulating bush (21), the fourth non-melting electrode being arranged uniformly outside the central axis (211) with the first non-melting electrode (24), the second non-melting electrode and the third non-melting electrode.
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| WO2021008487A1 (en) * | 2019-07-15 | 2021-01-21 | 成都智见复合科技有限公司 | Laser and photoelectric arc hybrid welding torch |
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| WO2021008487A1 (en) * | 2019-07-15 | 2021-01-21 | 成都智见复合科技有限公司 | Laser and photoelectric arc hybrid welding torch |
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