JP5084277B2 - Large diameter stud for contact type arc stud welding - Google Patents

Large diameter stud for contact type arc stud welding Download PDF

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JP5084277B2
JP5084277B2 JP2007009651A JP2007009651A JP5084277B2 JP 5084277 B2 JP5084277 B2 JP 5084277B2 JP 2007009651 A JP2007009651 A JP 2007009651A JP 2007009651 A JP2007009651 A JP 2007009651A JP 5084277 B2 JP5084277 B2 JP 5084277B2
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JP2008173669A (en
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正之 大垣
喜照 丸山
敏洋 大友
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岡部株式会社
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Description

本発明は、コンタクト方式を採用したアークスタッド溶接に対応した大径のスタッドに関する。   The present invention relates to a large-diameter stud adapted for arc stud welding employing a contact method.

アークスタッド溶接に関しては、大別するとコンタクト方式とギャップ方式が従来から知られている。コンタクト方式は、溶接対象であるスタッドを溶接ガンのチャックに差込み、そのスタッドの溶接側端部を耐熱磁器製のアークシールド（フェルール）で囲んだ状態で母材側に当接させ、パイロット電流を流すと同時に母材から引離してパイロットアークを発生させた後、大電流を流してメインアークを形成して溶接を行うというものである。本発明は、このコンタクト方式を採用したアークスタッド溶接に使用されるスタッドに関する。なお、コンタクト方式を採用したコンタクト方式アークスタッド溶接用のスタッドとして、溶接側端部の中央部に突起を設けるとともに、その外周縁部にテーパ部を形成したものは知られている（特許文献１）が、テーパの角度が小さく大径スタッドには有効ではなかった。
実用新案登録第２５６９００５号公報 As for arc stud welding, a contact method and a gap method are conventionally known. In the contact method, the stud to be welded is inserted into the chuck of the welding gun, and the end of the stud on the welding side is in contact with the base metal side with an arc shield (ferrule) made of heat-resistant porcelain. At the same time, the pilot arc is generated by separating from the base material, and then a large current is passed to form a main arc for welding. The present invention relates to a stud used for arc stud welding employing this contact method. In addition, as a stud for contact method arc stud welding adopting a contact method, there is known one in which a protrusion is provided at the center portion of the welding side end portion and a tapered portion is formed at the outer peripheral edge portion (Patent Document 1). However, the taper angle is small and not effective for large diameter studs.
Utility Model Registration No. 2569005

ところで、コンタクト方式アークスタッド溶接用のスタッドとしては、従来から外径が１９ｍｍ程度までの軸径からなるスタッドが使用されることが多く、これに対応して溶接機も１次側の電圧が２００Ｖで２次側の無負荷時の電圧が６５Ｖ程度の容量のものを使用し、３０〜５０Ｖ程度のアーク電圧によってスタッド溶接を行っているのが実状である。しかしながら、この従来から一般的に使用されている既存の溶接機を用いた場合に、スタッドの軸径が２２ｍｍ程度に増大されると、非常に大きなアーク電流が必要とされることから、それに伴う強力な電磁界によって、スタッドの断面全体で均一なアークエネルギを保持することが難しくなり、アークの偏りにより溶融金属の厚みが不均一になったり溶接余盛が欠けるといった不具合が生じ、溶接の品質を低下させる原因にもなった。因みに、この場合に、アーク電圧を上げて溶接断面内のエネルギ密度を一定に近づける方法もあり得るが、溶接機内の変圧器も一層大がかりなものとなり、また１次側の電源設備としても大きな容量が必要とされるため、設備費用も嵩み実用的ではない。しかも、アーク電圧を高めると、作業者が感電する危険が高くなり、安全上の観点からも問題がある。   By the way, as a stud for contact type arc stud welding, a stud having an outer diameter of about 19 mm is often used conventionally, and the welding machine has a primary voltage of 200 V corresponding to this. In actuality, the secondary side unloaded voltage having a capacity of about 65V is used, and stud welding is performed with an arc voltage of about 30 to 50V. However, when an existing welding machine that is generally used from the past is used, if the shaft diameter of the stud is increased to about 22 mm, a very large arc current is required. The strong electromagnetic field makes it difficult to maintain uniform arc energy across the entire cross-section of the stud, resulting in defects such as non-uniform molten metal thickness and lack of weld overlay due to arc bias. It was also a cause of lowering. Incidentally, in this case, there is a method of increasing the arc voltage to make the energy density in the weld cross section close to a constant value, but the transformer in the welder becomes larger, and the primary side power supply equipment has a large capacity. Therefore, the equipment cost increases and is not practical. In addition, when the arc voltage is increased, the risk of electric shock from the operator increases, and there is a problem from the viewpoint of safety.

本発明は、以上のような従来の技術的状況に鑑みて研究開発したもので、アーク電圧が３０〜５０Ｖ程度の従来から一般的に使用されている既存の溶接機によっても良好な溶接状態を確保することができる、使い勝手のきわめてよいコンタクト方式アークスタッド溶接用の大径スタッドを提供することを目的とするものである。   The present invention has been researched and developed in view of the above-described conventional technical situation, and a good welding state can be obtained even with an existing welding machine generally used in the past having an arc voltage of about 30 to 50V. It is an object of the present invention to provide a large-diameter stud for contact-type arc stud welding that can be secured and is very easy to use.

本発明では、前記課題を解決するため、種々の実験を通じて得た後述の実験結果に基づいて、コンタクト方式アークスタッド溶接用の大径スタッドとして、溶接側端部がその外周縁部に形成されたテーパ部により先細状に形成され、溶接時にはそのテーパ部により形成された先細状部分全体が溶融する形態のものからなり、前記テーパ部の長さＬが３．５ｍｍ≦Ｌ≦６ｍｍとの条件（１）を満たすとともに、前記テーパ部の先端部側の小径部の断面積Ａａと基端部側の大径部の断面積Ａｂとの面積比Ａａ／Ａｂが０．２５≦（Ａａ／Ａｂ）≦０．５５との条件（２）を満たす、軸径が２２〜２５ｍｍの大径スタッドを採用した。これにより、３０〜５０Ｖ程度のアーク電圧により前記テーパ部により形成された先細状部分全体が的確に溶融する良好な溶接状態が得られる大径スタッドが可能となった。 In the present invention, in order to solve the above-mentioned problem, based on the experimental results described later obtained through various experiments, a welding-side end portion is formed on the outer peripheral edge portion as a large-diameter stud for contact type arc stud welding. is formed in a shape tapered by tapered section, the entire tapered portion formed by the tapered portion at the time of welding is made of the form of melting, the length L of the tapered portion of the 3.5 mm ≦ L ≦ 6 mm conditions ( 1) and the area ratio Aa / Ab between the cross-sectional area Aa of the small-diameter portion on the distal end side and the cross-sectional area Ab of the large-diameter portion on the proximal end side is 0.25 ≦ (Aa / Ab) A large-diameter stud having a shaft diameter of 22 to 25 mm that satisfies the condition (2) of ≦ 0.55 was employed. As a result, a large-diameter stud capable of obtaining a good weld state in which the entire tapered portion formed by the tapered portion is accurately melted by an arc voltage of about 30 to 50 V can be obtained.

本発明によれば、軸径が２２〜２５ｍｍの大径スタッドであるにも拘らず、従来から一般的に使用されている、１次側の電圧が２００Ｖで２次側のアーク電圧が３０〜５０Ｖ程度の既存の溶接機を用いても、溶接時における前記テーパ部により形成された溶接側端部の先細状部分全体の溶融を的確に実現することができ、溶接完了後に溶接部からの破断の原因となる断面欠損を残すことのない良好な溶接状態を得ることができる。 According to the present invention, although it is a large-diameter stud having a shaft diameter of 22 to 25 mm, the primary side voltage generally used in the past is 200 V and the secondary arc voltage is 30 to 30 mm. Even with an existing welding machine of about 50V, it is possible to accurately achieve melting of the entire tapered portion of the welding side end formed by the tapered portion at the time of welding, and breakage from the welded portion after welding is completed. It is possible to obtain a good welded state that does not leave a cross-sectional defect causing the above.

本発明においては、コンタクト方式アークスタッド溶接においてスタッドの溶接側の外周縁部にテーパ部を形成した場合の溶接状態すなわち溶接結果に対する影響に関して実験を進めたところ、そのテーパ部の傾斜角度や大きさが溶接状態に大きく影響することを突止めることができた。とりわけ、テーパ部の形態によっては、３０〜５０Ｖ程度のアーク電圧によってスタッド溶接を行う、従来から一般的に使用されている既存の溶接機では溶接状態に不具合が生じやすい軸径が２２ｍｍ以上の大径スタッドに対して有効であることが判明した。そこで、試験体として、一般構造用圧延鋼材に属するＳＳ４９０や冷間圧造用炭素鋼線材に属するＳＷＲＣＨ１６で外径が２２ｍｍ及び２５ｍｍの軸径からなる丸鋼と、鉄筋コンクリート棒鋼に属するＳＤ３４５で呼び径が２２ｍｍ及び２５ｍｍの軸径からなる異形棒鋼を用いて、従来からの既存の溶接機を使用して前記テーパ部の具体的形態を変化させながら溶接実験を行い、その溶接状態に対する影響を調べたところ、図１に示したような実験結果を得ることができた。すなわち、前記各種の素材を用い、図２に示したように大径スタッド１の溶接側の外周縁部に形成したテーパ部２の長さＬと、そのテーパ部２の先端部側の外径がＤａからなる小径部３の断面積Ａａと基端部側の外径がＤｂからなる大径部４の断面積Ａｂとの面積比Ａａ／Ａｂを変化させながら実際に溶接を行い、それらの個々の溶接結果について、引張試験や溶融金属の厚みの状況などから使用に適合し得るか否か、その合否を評価するという実験を行った。因みに、溶接後の引張試験において軸部から破断し、かつマクロ試験により溶融金属の厚みが均一で溶接状態に特段の不具合がない場合は適合と評価し、前記引張試験において溶接部から破断した場合や、溶接部からではなく軸部から破断した場合であっても溶融金属の厚みが不均一であったり、溶け込み不良、融合不良などの周縁部の不具合や、溶接部の内部に収縮孔や割れなどが認められる場合には不適合と評価した。図１は、その実験結果を横軸に前記面積比Ａａ／Ａｂをとり、縦軸に前記テーパ部２の長さＬをとって表したもので、図中○印は溶接状態が良好で適合と評価された場合を示し、×印は不適合と評価された場合を示したものである。   In the present invention, in the contact-type arc stud welding, an experiment was carried out regarding the influence on the welding state, that is, the welding result when the tapered portion was formed on the outer peripheral edge portion on the welding side of the stud. Has been able to ascertain that it significantly affects the welding state. In particular, depending on the shape of the tapered portion, stud welding is performed with an arc voltage of about 30 to 50 V, and a shaft diameter of 22 mm or more is likely to cause a problem in the welding state in the existing welding machines that are generally used conventionally. It has been found effective against a diameter stud. Therefore, as test specimens, SS490, which belongs to general structural rolled steel, and SWRCH16, which belongs to carbon steel wire for cold heading, round steel having an outer diameter of 22 mm and 25 mm, and nominal diameter, which is SD345, which belongs to reinforced concrete steel bar. Using a deformed steel bar with a shaft diameter of 22 mm and 25 mm, a welding experiment was conducted while changing the specific form of the tapered portion using a conventional existing welding machine, and the influence on the welding state was examined. The experimental results as shown in FIG. 1 could be obtained. That is, using the above-mentioned various materials, as shown in FIG. 2, the length L of the tapered portion 2 formed on the outer peripheral edge portion on the welding side of the large-diameter stud 1 and the outer diameter on the distal end side of the tapered portion 2 Are actually welded while changing the area ratio Aa / Ab between the cross-sectional area Aa of the small-diameter portion 3 made of Da and the cross-sectional area Ab of the large-diameter portion 4 whose outer diameter on the base end side is made of Db, For each welding result, an experiment was conducted to evaluate whether or not it could be adapted for use from the tensile test and the thickness of the molten metal. By the way, when it breaks from the shaft part in the tensile test after welding and the thickness of the molten metal is uniform by the macro test and there is no particular defect in the welded state, it is evaluated as conforming, and when it breaks from the welded part in the tensile test Even when the fracture occurs from the shaft rather than from the welded part, the thickness of the molten metal is uneven, defects in the peripheral part such as poor penetration and poor fusion, shrinkage holes and cracks inside the welded part It was evaluated as non-conformity when such as Fig. 1 shows the experimental results with the area ratio Aa / Ab on the horizontal axis and the length L of the tapered portion 2 on the vertical axis. X indicates the case where it was evaluated as non-conforming.

上記溶接実験の結果、前記テーパ部２の具体的形態すなわちテーパ部２の傾斜角度や大きさと、溶接状態すなわち溶接結果の良否との間には重要な関連があり、とりわけ軸径が２２〜２５ｍｍの大径スタッドを、アーク電圧が３０〜５０Ｖ程度の従来から一般的に使用されている既存の溶接機を用いてコンタクト方式アークスタッド溶接を行った場合に、使用に十分適合し得る良好な溶接状態を確保し得るか、あるいは溶接状態に不具合が生じやすいか、その条件を見出すことができた。すなわち、図１に示した実験結果に基づいて説明すると、○印で表したテーパ部２の長さＬが３．５ｍｍ≦Ｌ≦６ｍｍとの条件（１）と、テーパ部２の先端部側の小径部３の断面積Ａａと基端部側の大径部４の断面積Ａｂとの面積比Ａａ／Ａｂが０．２５≦（Ａａ／Ａｂ）≦０．５５との条件（２）を満たす範囲では、溶接後の引張試験において溶接部から破断せずに軸部から破断し、かつ溶融金属の厚みが均一で溶接状態に特段の不具合がない、使用に充分適合し得る良好な溶接状態が得られることが判明した。 As a result of the above welding experiment, there is an important relationship between the specific form of the tapered portion 2, that is, the inclination angle and size of the tapered portion 2, and the welding state, that is, the quality of the welding result, and in particular, the shaft diameter is 22 to 25 mm. Good welding that can be adequately adapted for use when contact type arc stud welding is performed on existing large-diameter studs using an existing welding machine that has been generally used in the past with an arc voltage of about 30-50V. It was possible to find out whether the condition could be ensured or whether the welded state was likely to cause defects. That is, based on the experimental results shown in FIG. 1, the condition (1) that the length L of the tapered portion 2 represented by a circle is 3.5 mm ≦ L ≦ 6 mm, and the tip end side of the tapered portion 2 The area ratio Aa / Ab of the cross-sectional area Aa of the small-diameter portion 3 and the cross-sectional area Ab of the large-diameter portion 4 on the base end side is 0.25 ≦ (Aa / Ab) ≦ 0.55. In the range to satisfy, in the tensile test after welding, it does not break from the welded part but breaks from the shaft part, the molten metal thickness is uniform and there is no particular defect in the welded state, good welding state that can be adequately adapted for use Was found to be obtained.

以上のように、前記テーパ部２の長さＬが３．５ｍｍ≦Ｌ≦６ｍｍの範囲で、かつ前記面積比Ａａ／Ａｂが０．２５≦（Ａａ／Ａｂ）≦０．５５の範囲であれば、良好な溶接状態が得られるのは、この範囲内であれば、前記テーパ部２の形成により、テーパ部２の先端の小径部３から初期のアークが発生し、アーク柱の中心が常にスタッド断面の中心と一致したままスタッド１の溶融が進行するとともにエネルギ密度の偏りが抑制され、テーパ部２の先端の小径部３を最大限とする同心円状に一様に分布する安定したアークを維持しながらスタッド１の溶融が進むとともに、溶融時においてスタッド１の先端に形成した適度の凸状がほぼ維持されることに基づくものと推測される。その結果、溶接部のマクロ断面では溶融金属層の厚さが薄く均一化され、溶融金属の凝固時に内部応力の発生が緩和されるとともに、収縮孔や高温割れ等の不具合が大幅に軽減される。また、アークの安定化により磁気吹きによるアークの偏りが軽減され、余盛が全周にわたって的確に形成できるようになったものと考えられる。   As described above, the length L of the tapered portion 2 is in the range of 3.5 mm ≦ L ≦ 6 mm, and the area ratio Aa / Ab is in the range of 0.25 ≦ (Aa / Ab) ≦ 0.55. For example, if it is within this range that a good welded state can be obtained, the formation of the tapered portion 2 generates an initial arc from the small diameter portion 3 at the tip of the tapered portion 2, and the center of the arc column is always at the center. A stable arc that is uniformly distributed in a concentric circle maximizing the small-diameter portion 3 at the tip of the tapered portion 2 while the melting of the stud 1 proceeds while keeping the center of the stud cross-section and the bias of the energy density is suppressed. It is presumed that the melting of the stud 1 proceeds while maintaining, and the moderate convex shape formed at the tip of the stud 1 at the time of melting is substantially maintained. As a result, the thickness of the molten metal layer is made thin and uniform in the macro section of the welded portion, and the occurrence of internal stress during solidification of the molten metal is alleviated, and defects such as shrinkage holes and hot cracks are greatly reduced. . Further, it is considered that the arc stabilization due to the magnetic blowing is reduced by the stabilization of the arc, and the surplus can be formed accurately over the entire circumference.

因みに、前記面積比Ａａ／Ａｂは、０．５程度が最適であるが、０．２５〜０．５５の範囲であれば、前述のアークの安定化と溶融時におけるスタッドの先端形状に基づく作用効果を得ることができ、良好な溶接状態が得られる。これに対して、面積比Ａａ／Ａｂが０．２５より小さい場合には、初期のアーク発生時におけるガスシールド効果が弱く溶融金属の内部に大気を巻込んで溶融金属内にブローホールができやすくなるといった不具合があった。また、初期のアークが不安定になり、スパッタが多量に発生して溶接性を低下させるという欠点もあった。逆に面積比Ａａ／Ａｂが０．５５より大きい場合には、前述のテーパ部２に基づく作用効果が弱く、溶接部の内部に収縮割れ等の欠陥が生じやすくなるといった不具合があった。   Incidentally, the area ratio Aa / Ab is optimally about 0.5, but if it is in the range of 0.25 to 0.55, it is based on the stabilization of the aforementioned arc and the shape of the tip of the stud during melting. An effect can be acquired and a favorable welding state is obtained. On the other hand, when the area ratio Aa / Ab is smaller than 0.25, the gas shielding effect at the time of initial arc generation is weak, and it is easy to blow air into the molten metal by entraining the atmosphere inside the molten metal. There was a problem of becoming. In addition, the initial arc becomes unstable and a large amount of spatter is generated, resulting in a decrease in weldability. On the contrary, when the area ratio Aa / Ab is larger than 0.55, there is a problem that the effect based on the tapered portion 2 described above is weak and defects such as shrinkage cracks are likely to occur inside the welded portion.

また、テーパ部２の長さＬが３．５ｍｍより小さい場合には、前述のテーパ部２に基づく作用効果が低減して、従来のスタッドとの差異が見られなくなり、良好な溶接状態の確保が困難となった。逆にテーパ部２の長さＬが６ｍｍを超えて大きくなると、テーパ部２の全体が溶融せずに、溶接完了後に断面欠損として残り、溶接部からの破断の原因になるといった不具合が生じた。すなわち、この場合には、アーク電圧が３０〜５０Ｖ程度の従来から一般的に使用されている既存の溶接機を用いて軸径が２２〜２５ｍｍの大径スタッドのコンタクト方式アークスタッド溶接を行った場合に、溶接時に前記テーパ部２により形成された先細状部分全体が的確に溶融することにより良好な溶接状態を実現し、溶接完了後に断面欠損として残さないという、本発明の本来の目的が達成できなくなってしまうことになる。


Moreover, when the length L of the taper part 2 is smaller than 3.5 mm, the effect based on the above-mentioned taper part 2 reduces, a difference with the conventional stud is not seen, and a favorable welding state is ensured. Became difficult. Conversely, when the length L of the taper portion 2 exceeds 6 mm, the entire taper portion 2 does not melt and remains as a cross-sectional defect after completion of welding, which causes a failure from the welded portion. . That is, in this case, contact-type arc stud welding of a large-diameter stud having a shaft diameter of 22 to 25 mm was performed using an existing welding machine generally used in the past with an arc voltage of about 30 to 50V. In this case, the entire tapered portion formed by the tapered portion 2 at the time of welding is accurately melted to achieve a good welded state, and the original object of the present invention is not left as a cross-sectional defect after completion of welding. It will be impossible.


なお、テーパ部２に基づく上述の作用効果に関しては、図３に示した頭付の大径スタッド５の場合だけに限らず、図４に示した異形棒鋼からなる大径スタッド６の形態の場合にも同様の作用効果が確認された。因みに、図４に示した異形棒鋼からなる大径スタッド６の場合には、呼び径が２２〜２５ｍｍのものに適用が可能であり、図示のように溶接側端部に前記大径スタッド６の外周部に形成された節７を潰したり、あるいは節７を切削するなどして短い円柱部８を形成し、その円柱部８の溶接側の外周縁部に前記条件（１）及び（２）を満たすテーパ部９を形成することにより同様の作用効果を得ることができる。この場合の面積比Ａａ／Ａｂは、前記テーパ部９の先端の小径部と前記円柱部８の外径から求めることはいうまでもない。

The above-described operation and effect based on the tapered portion 2 is not limited to the case of the large-diameter stud 5 with a head shown in FIG. 3, but in the case of the large-diameter stud 6 made of a deformed steel bar shown in FIG. The same effect was also confirmed. Incidentally, in the case of the large-diameter stud 6 made of the deformed steel bar shown in FIG. 4, it can be applied to those having a nominal diameter of 22 to 25 mm. The short cylindrical portion 8 is formed by crushing the node 7 formed on the outer peripheral portion or cutting the node 7, and the above conditions (1) and (2) are formed on the outer peripheral edge portion of the cylindrical portion 8 on the welding side. The same effect can be obtained by forming the tapered portion 9 that satisfies the above. Needless to say, the area ratio Aa / Ab in this case is obtained from the small-diameter portion at the tip of the tapered portion 9 and the outer diameter of the cylindrical portion 8.

実験結果を示した図表である。It is the chart which showed the experimental result. 大径スタッドの要部を示した拡大説明図である。It is the expansion explanatory view which showed the principal part of the large diameter stud. 本発明の一実施例を示した正面図である。It is the front view which showed one Example of this invention. 本発明の他の実施例を示した正面図である。It is the front view which showed the other Example of this invention.

符号の説明Explanation of symbols

１…大径スタッド、２…テーパ部、３…小径部、４…大径部、５，６…大径スタッド、７…節、８…円柱部、９…テーパ部   DESCRIPTION OF SYMBOLS 1 ... Large diameter stud, 2 ... Tapered part, 3 ... Small diameter part, 4 ... Large diameter part, 5, 6 ... Large diameter stud, 7 ... Node, 8 ... Cylindrical part, 9 ... Tapered part

Claims (1)

軸径が２２〜２５ｍｍであり、溶接側端部がその外周縁部に形成されたテーパ部により先細状に形成され、溶接時にはそのテーパ部により形成された先細状部分全体が溶融する大径スタッドであって、前記テーパ部の長さＬが次の条件（１）を満たすとともに、前記テーパ部の先端部側の小径部の断面積Ａａと基端部側の大径部の断面積Ａｂとの面積比Ａａ／Ａｂが次の条件（２）を満たし、３０〜５０Ｖのアーク電圧により、前記テーパ部により形成された先細状部分全体が的確に溶融する良好な溶接状態を可能にしたことを特徴とするコンタクト方式アークスタッド溶接用の大径スタッド。
（１）３．５ｍｍ≦Ｌ≦６ｍｍ
（２）０．２５≦（Ａａ／Ａｂ）≦０．５５ Shaft diameter is 22～25Mm, large diameter studs welded end portion is formed on a tapered by tapered portion formed at its outer peripheral edge, the entire tapered portion formed by the tapered portion during welding melts a is, with the length L of the tapered portion satisfies the following condition (1), the cross-sectional area Ab of the larger diameter portion of the cross-sectional area Aa and a proximal end side of the small diameter portion of the front end portion of the tapered portion area ratio Aa / Ab satisfies the following condition (2), Ri by the arc voltage 30～50V, good welding state can entirely tapered portion formed by the tapered portion you melt accurately Large diameter stud for contact type arc stud welding.
(1) 3.5mm ≦ L ≦ 6mm
(2) 0.25 ≦ (Aa / Ab) ≦ 0.55
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