JP7075851B2 - Arc welding method - Google Patents

Description

The present invention relates to an arc welding method using a ceramic end tab.

One of the welding methods is a consumable electrode type gas shielded arc welding method. The gas shield arc welding method is a method in which an arc is generated between the welding wire sent to the welded part of the base metal and the base metal, and the base metal is welded by the heat of the arc, and the temperature becomes particularly high. Welding is performed while injecting an inert gas around the welded portion in order to prevent oxidation of the base metal. By feeding the welding wire at high speed and supplying a large current, one-pass welding of a thick plate of 9 to 30 mm can be realized. Specifically, one-pass welding of a thick plate can be realized by supplying a welding wire at a rate of about 5 to 100 m / min and supplying a large current of 300 A or more. When the welding wire is fed at high speed and a large current is supplied, a concave molten pool is formed in the base metal by the heat of the arc, and the tip of the weld wire enters the space surrounded by the molten pool. When the tip of the welding wire penetrates deeper than the surface of the base metal, the molten pool penetrates to the back surface side in the thickness direction of the base metal, and one-pass welding becomes possible. Hereinafter, the space surrounded by the concave molten pool is referred to as a buried space, and the arc generated between the tip of the welding wire that has entered the buried space and the base metal or the molten pool is appropriately referred to as a buried arc. Welding using a buried arc is called buried arc welding.

Japanese Unexamined Patent Publication No. 6-234074

However, it has been found that when buried arc welding is performed using a ceramic end tab, slag made of a non-metal material such as silicon dioxide is generated at the end portion near the end tab due to a large current, which causes a problem. Specifically, at the end of the welded portion, a large amount of slag is generated due to the buried arc due to a large current and the ceramic end tab, and the generated slag bites into the bead, resulting in deterioration of welding quality. There was a problem. In non-buried arc welding, since the welding current is small, the above-mentioned welding defects caused by the ceramic end tabs did not become a problem.

An object of the present invention is to provide an arc welding method capable of obtaining a good welded portion by preventing the slag from getting caught in the bead at the end portion of the welded portion in the buried arc welding using the ceramic end tab. There is something in it.

In the arc welding method according to this aspect, the welding wire is fed while moving the welding torch from the start end portion to the end portion of the welded portion of the base metal, and the welding current is supplied to the welding wire to perform the welding. A consumable electrode that generates an arc between the tip of the wire and the welded portion and causes the tip to enter the space surrounded by the concave molten pool formed in the base metal by the arc to weld the base metal. In the type of arc welding method, a ceramic end tab having a recess is arranged at the end portion of the welded portion, welding is started, the welding torch is moved to the end portion , and the molten pool is the end tab. Reduce the welding current before entering the recess.

The arc welding method according to this aspect reduces the welding current before the welding wire enters the recess of the end tab.

In the arc welding method according to this aspect, the welding current capable of welding the base metal by allowing the tip portion to enter the space surrounded by the concave molten pool is 300 A or more, and the welding wire is the end tab. Before entering the recess, the welding current is reduced within the range where the welding is possible.

In the arc welding method according to this aspect, the supply of welding current is stopped before the welding wire comes into contact with the end tab.

In the arc welding method according to this aspect, the supply of the welding current is stopped before the welding wire comes into contact with the non-metal substance generated at the end portion.

According to this aspect, the welding current is reduced before the molten pool formed by buried arc welding enters the recess of the end tab. Therefore, it is possible to suppress the generation of slag caused by the large current buried arc and the ceramic end tab, and the welding quality at the end portion is good.

In addition, by stopping the welding current before the welding wire comes into contact with the slag generated at the end and the end tab, the large current buried arc and the generation of slag caused by the ceramic end tab are suppressed, and slag biting is prevented. The welding quality of the end portion can be improved.

In the present invention, in the buried arc welding using the ceramic end tab, it is possible to prevent the slag from getting caught in the bead at the end portion of the welded portion and to obtain a good welded portion.

It is a schematic diagram which shows one configuration example of an arc welding apparatus. It is a flowchart which shows the arc welding method. It is a perspective view which shows the base material and the end tab to be welded. It is a top view which shows the base material and the end tab to be welded. It is a schematic diagram which shows the welding start method. It is explanatory drawing which shows the optimum range of the predetermined time from the receding angle to returning to the plane. It is explanatory drawing which shows the optimum range of the receding angle. It is explanatory drawing which shows the optimum range of the wire protrusion length. It is a schematic diagram which shows the welding end method. It is a schematic diagram which enlarged and showed the end part of the welded part. It is explanatory drawing which shows the optimum range of the distance from the end tab which should reduce or stop a welding current. It is explanatory drawing which showed the bead shape in the terminal part at the time of finishing welding at an appropriate timing. It is explanatory drawing which showed the bead shape at the end part at the time of finishing welding at an inappropriate timing.

Hereinafter, the present invention will be described in detail with reference to the drawings showing the embodiments thereof.
FIG. 1 is a schematic view showing a configuration example of an arc welding device. The arc welding apparatus according to the present embodiment is a consumable electrode type gas shielded arc welder capable of large current buried arc welding of 300 A or more, and is a welding robot 1 to which a welding torch 11 and a wire feeding unit 12 are attached. A welding power supply 2, a control device 3, and a shield gas supply unit (not shown) are provided. In FIG. 1, the thick wire is the power supply cable L, and the thin wire is the control communication line. The control device 3 controls the operations of the welding robot 1 and the welding power supply 2 by outputting the operation control signal to the welding robot 1 and outputting the welding control signal to the welding power supply 2 at a predetermined timing.

The welding robot 1 includes a base portion 13 fixed at an appropriate position on the floor surface. A plurality of arms 14 are rotatably connected to the base portion 13 via a shaft portion. A welding torch 11 is held at the tip portion of the arm 14 connected to the tip side. A servomotor is provided at the connecting portion of the arms 14, and each arm 14 rotates about the shaft portion by the rotational driving force of the servomotor. The rotation of the servomotor is controlled by the control device 3. The control device 3 can move the welding torch 11 up, down, front, back, left, and right with respect to the base metal 4 by rotating each arm 14. An encoder that outputs a signal indicating the rotation position of the arm 14 to the control device 3 is provided at the connecting portion of each arm 14, and the control device 3 bases the welding torch 11 based on the signal output from the encoder. Recognize the position of. Further, the control device 3 communicates with the welding power source 2 to control the feeding of the welding wire W and the supply of the welding current.

The shield gas supply unit supplies the shield gas to the welding torch 11. The shield gas is for preventing oxidation of the base metal 4 and the welding wire W melted by the arc. The shield gas is, for example, a mixed gas of argon Ar, carbon dioxide CO ₂ and helium He, or a mixed gas of argon Ar and helium He.

The welding torch 11 is made of a conductive material such as a copper alloy, and has a cylindrical contact tip that guides the welding wire W to the welded portion of the base metal 4 and supplies the welding current required for generating an arc. The contact tip contacts the welding wire W penetrating the inside thereof and supplies a welding current to the welding wire W. Further, the welding torch 11 has a hollow cylindrical shape surrounding the contact tip, and has a nozzle for injecting the shield gas supplied from the shield gas supply unit to the welded portion.

The welding wire W is, for example, a solid wire, a metal cored wire, or a flux cored wire, and functions as a consumable electrode. The diameter of the welding wire W is 0.8 mm or more and 1.6 mm or less. The welding wire W is, for example, a pack wire housed in a pail pack in a spirally wound state, or a reel wire wound around a wire reel.

The wire feeding unit 12 has a feeding roller that feeds the welding wire W to the welding torch 11, and a motor that rotates the feeding roller. The wire feeding unit 12 pulls out the welding wire W from the pail pack or the wire reel by rotating the feeding roller, and supplies the drawn welding wire W to the welding torch 11 at a constant speed. The feeding speed of the welding wire W is, for example, about 5 to 100 m / min. The feeding method of the welding wire W is an example, and is not particularly limited.

The welding power supply 2 is a power supply having a constant voltage characteristic, and includes a power supply circuit connected to a contact tip of the welding torch 11 and a base material 4 via a power feeding cable L. The power supply circuit is a circuit that outputs a PWM-controlled direct current, and supplies a welding current by applying a welding voltage between the welding wire W and the base metal 4. In particular, the welding power source 2 according to the present embodiment supplies a welding current of 300 A. The welding current is preferably a direct current or a direct current pulse, but is not particularly limited and may be an alternating current or an alternating current pulse. When the welding current fluctuates, 300A means the average value of the welding current.

According to the arc welding apparatus configured as described above, the welding wire W is supplied while supplying the shield gas to the welded portion of the base metal 4, and the welding current is supplied to the welding wire W to supply the welding wire. An arc can be generated between the tip of W and the welded portion, and the tip can be made to enter the space surrounded by the concave molten pool formed in the base material 4 by the arc to weld the base material 4. ..

FIG. 2 is a flowchart showing an arc welding method, FIG. 3 is a perspective view showing a base metal 4 and end tabs 5 and 6 to be welded, and FIG. 4 is a plan view showing a base metal 4 and end tabs 5 and 6 to be welded. , FIG. 5 is a schematic view showing a welding start method. First, a pair of plate-shaped base materials 4 to be joined by welding are prepared (step S11). Specifically, as shown in FIGS. 3 and 4, a first base material 41 and a second base material 42 on which a re-shaped groove is formed are prepared, and the jointed portions are arranged so as to be butted against each other. The first base material 41 and the second base material 42 are steel plates such as mild steel, carbon steel for machine structure, and alloy steel for machine structure, and have a thickness of 9 mm or more and 30 mm or less. In the examples shown in FIGS. 3 and 4, the first base material 41 has, for example, a square plate shape, and the second base material 42 has a rectangular plate shape whose short side is shorter than the side of the first base material 41. The short side of the second base material 42 is butted against one side of 41. The first base material 41 is, for example, a steel plate constituting one end surface in the longitudinal direction of a column, and the second base material 42 is a steel plate constituting a beam. In the present embodiment, the thickness of the first base material 41 and the second base material 42 is 12 mm. The groove angle is, for example, 35 degrees.

Next, as shown in FIG. 5A, ceramic end tabs 5 and 6 are arranged at the start end portion 4a and the end portion 4b of the welded portion of the base metal 4 (step S12). The end tabs 5 and 6 are for allowing welding defects that are likely to occur in the start end portion 4a and the end portion 4b of the welded portion to escape to the outside.
The end tabs 5 and 6 have a plate shape having dimensions capable of covering the start end portion 4a and the end portion 4b of the welded portion from the side surface side, and have recesses that follow the shape of the groove. The depth of the recesses of the end tabs 5 and 6 is, for example, 3 mm or more and 5 mm or less. 3 and 4 show a state in which the end tabs 5 and 6 are arranged at the start end portion 4a and the end end portion 4b of the welded portion formed on the first base material 41 and the second base material 42. The end tabs 5 and 6 are fixed by a clamp or the like.

<Welding start method>
As shown in FIG. 5B, the welding robot 1 moves the welding torch 11 to the start end portion 4a in a state of a receding angle (step S13). The range of the receding angle is such that the inclination angle of the welding torch 11 with respect to the normal direction of the base metal 4 is 5 degrees or more and 25 degrees or less. Further, it is appropriate that the protrusion length of the welding wire W is 15 mm or more and 30 mm or less. In this embodiment, welding is started with a receding angle of 20 degrees and a protrusion length of 25 mm.

Next, the welding power supply 2 starts welding with a low current while keeping the welding torch 11 in the state of the receding angle (step S14). For example, when the welding current (main current) of buried arc welding is 520 A, welding is started at a welding current of 416 A, which is about 80% of the main current. It may start with a welding current of about 400 A. The welding voltage is, for example, 43.5V.

Then, while increasing the welding current (step S15), the welding torch 11 is moved to the end side of the welded portion along the linear welded portion (step S16). The moving speed of the welding torch 11 is, for example, 30 cm / min. The welding current may be increased to the main current at the start of movement of the welding torch 11, or the welding current may be gradually increased until the predetermined time described later elapses.

Then, as shown in FIG. 5C, the welding torch 11 is gradually returned from the receding angle state to the upright state after the start of welding until a predetermined time elapses (step S17). The planatic state is a state in which the inclination angle of the welding torch 11 with respect to the normal direction of the base metal 4 is 0 degrees, that is, a state in which the feeding direction of the welding wire W is in the vertical direction. When a predetermined time has elapsed after the start of welding, the welding torch 11 is in an upright state. The predetermined time is the time required for the slag caused by the end tab 5 to float on the surface of the molten pool. The predetermined time is, for example, more than 0 seconds and within 5 seconds. In the present embodiment, the welding torch 11 is straightened in a predetermined time of 4 seconds. Then, the protruding length of the welding wire W when it becomes straight is set to 20 mm.

After the start of the above welding, the buried arc welding is continued while the welding torch 11 is moved to the terminal side in a state of being straight (step S18).

FIG. 6 shows a welding current of 520 A, which is an appropriate welding condition for the construction target specified in the "Building Work Standard Specification JASS6 Steel Frame Work", which is a plate thickness of 12 mm, a re-shaped groove, a groove angle of 35 degrees, and downward butt welding. It is explanatory drawing which shows the optimum range of the predetermined time from the receding angle to returning to the plane when welding is performed at a welding voltage of 43.5V and a welding speed of 30cm / min. The following explanatory drawings showing the optimum range are for the case where the welding conditions are used for the construction target. The horizontal axis represents a predetermined time used to return the welding torch 11 from the receding angle state to the upright state. When the experiment was conducted with a predetermined time of 0 seconds, 1 second, 2 seconds, 3 seconds, 4 seconds, 5 seconds, and 6 seconds, slag was caught in the predetermined time of 0 seconds, resulting in poor fusion and insufficient penetration. occured. When the predetermined time was 1 second or more and 5 seconds or less, the welded state of the starting end portion 4a was good. However, when the predetermined time exceeds 5 seconds, the bead width becomes irregular and the welding quality deteriorates.

FIG. 7 is an explanatory diagram showing an optimum range of the receding angle. The horizontal axis shows the magnitude of the receding angle. Experiments were conducted with a receding angle of 0 degrees, 5 degrees, 10 degrees, 15 degrees, 20 degrees, 25 degrees, and 30 degrees. The welding quality of 4a was poor. When the receding angle was 5 degrees or more and 25 degrees or less, the welding quality of the start end portion 4a was good. When the receding angle exceeds 25 degrees, the bead width becomes irregular and the welding quality deteriorates.

FIG. 8 is an explanatory diagram showing an optimum range of wire protrusion lengths. The horizontal axis indicates the protrusion length of the welding wire W. Experiments were conducted with protrusion lengths of 5 mm, 10 mm, 15 mm, 20 mm, 25 mm, 30 mm, and 35 mm. When the protrusion length was less than 15 mm, there was a problem that molten metal adhered to the tip of the welding torch 11. do. When the protrusion length was 15 mm or more and 30 mm or less, the welding quality of the starting end portion 4a was good. When the protrusion length exceeds 30 mm, the welded state becomes unstable.

<Welding end method>
FIG. 9 is a schematic view showing a welding end method, and FIG. 10 is a schematic view showing an enlarged end portion 4b of the welded portion. When the welding torch 11 approaches the terminal side, the following termination process is executed. When the welding wire W supplied from the welding torch 11 reaches the first predetermined distance d before the end tab 6 on the terminal side, the welding current is reduced (step S19). The first predetermined distance d is the distance from the end surface of the recess of the end tab 6, that is, the surface orthogonal to the welding line direction to the center line of the welding wire W. The first predetermined distance d is a distance that can prevent the molten pool from entering the recess of the end tab 6. Further, the first predetermined distance d is a distance capable of preventing the welding wire W from entering the recess of the end tab 6. The first predetermined distance d is, for example, more than 3 mm and 10 mm or less.
The degree of decrease in the welding current may be arbitrarily set within a range in which the buried arc can be maintained. For example, the welding current may be reduced within the range of 300 A or more and less than 520 A.

Then, the welding apparatus continues welding with a low welding current (step S20), and when the welding wire W reaches a second predetermined distance a before the end tab 6 on the terminal side, welding is stopped (step S21). , Finish welding. The second predetermined distance a is the distance from the end surface of the recess of the end tab 6, that is, the surface orthogonal to the welding line direction to the center line of the welding wire W. The second predetermined distance a is a distance that can prevent the welding wire W from coming into contact with the end tab 6. Further, the second predetermined distance a is a distance capable of preventing the welding wire W from coming into contact with the slag pool 7 generated at the terminal portion 4b. Specifically, the second predetermined distance a is immediately before the end surface of the recess of the end tab 6, for example, 1 mm or more and 3 mm or less.

11 is an explanatory diagram showing the optimum range of the distance from the end tab 6 where the welding current should be reduced or stopped, and FIG. 12 is an explanatory diagram showing the bead shape at the end portion 4b when welding is completed at an appropriate timing. FIG. 13 is an explanatory diagram showing the bead shape at the end portion 4b when welding is completed at an inappropriate timing.
12A and 13A are photographs showing the appearance of the bead formed on the terminal portion 4b, and FIGS. 12B and 13B are schematic views showing the appearance of the bead formed on the terminal portion 4b.

In FIG. 11, the horizontal axis indicates the distance from the ceramic tab. When the experiment was conducted with the distance from the ceramic tab, which is the timing to stop the welding current, at 6 mm, 5 mm, 4 mm, 3 mm, 2 mm, 1 mm and 0 mm, the welding current was stopped more than 3 mm in front of the recess of the end tab 6. In this case, the molten metal at the end portion 4b is insufficient, and the bead end formation becomes poor. When the welding current was stopped 1 mm or more and 3 mm or less in front of the recess of the end tab 6, the welding quality at the end portion 4b was good as shown in FIG. Beads are formed without excess or deficiency up to the end portion 4b of the welded portion. When the welding current is stopped less than 1 mm in front of the recess of the end tab 6, a large amount of slag generated at the end portion 4b due to the ceramic end tab 6 bites into the bead as shown in FIG. 13, and the welding quality is improved. It got worse. A large amount of slag generated at the end portion 4b of the welded portion overflows to the base metal 4 side, and slag biting occurs.

As described above, according to the arc welding method according to the present embodiment, in the buried arc welding using the ceramic end tab 5, non-metal substances do not remain in the start end portion 4a of the welded portion, and a good welded portion can be obtained. Obtainable.

Specifically, as shown in FIG. 6, good welding at the start end portion 4a is performed by gradually returning the welding torch 11 from the receding angle state to the upright state over a time of 1 second or more and 5 seconds or less. You can get the result.

Further, by gradually increasing the welding current in the process of returning the welding torch 11 from the state of the receding angle to the state of being straight, a good welding result at the start end portion 4a can be obtained. Further, by gradually shifting to a welding current suitable for welding a portion other than the start end portion 4a and the end portion 4b, good welding results can be obtained even from the start end portion 4a to the portion.

Further, as shown in FIG. 7, by starting welding with the receding angle set to 5 degrees or more and 25 degrees or less, good welding results at the start end portion 4a can be obtained.

Furthermore, as shown in FIG. 8, by starting welding with the wire protrusion length set to 15 mm or more and 30 mm or less, good welding results at the start end portion 4a can be obtained.

Furthermore, by reducing the welding current before the molten pool formed by buried arc welding enters the recess of the end tab 6, the large current buried arc and the generation of slag caused by the ceramic end tabs 5 and 6 are generated. It can be suppressed and the welding quality of the terminal portion 4b becomes good.
Specifically, by reducing the welding current before the welding wire W comes into contact with the end tab 6, preferably before the welding wire W enters the recess of the end tab 6, a large current buried arc and a ceramic end tab 5 are used. It is possible to suppress the generation of slag caused by, 6.

Furthermore, by stopping the welding current before the welding wire W comes into contact with the slag and the end tab 6, the generation of a large current buried arc and the slag caused by the ceramic end tabs 5 and 6 is suppressed, and the slag is caught. This can be prevented and the welding quality of the terminal portion 4b becomes good.

The embodiments disclosed this time should be considered to be exemplary in all respects and not restrictive. The scope of the present invention is indicated by the scope of claims, not the above-mentioned meaning, and is intended to include all modifications within the meaning and scope equivalent to the scope of claims.

1 Welding robot 2 Welding power supply 3 Control device 4 Base material 4a Start end part 4b End part 5, 6 End tab 7 Slag pool 11 Welding torch 12 Wire feeding part 13 Base 14 Arm 41 1st base material 42 2nd base material L cable W Welding wire

Claims (5)

The tip of the weld wire and the welded portion are supplied by feeding the weld wire while moving the weld torch from the start end to the end of the welded portion of the base metal and supplying a welding current to the weld wire. It is a consumable electrode type arc welding method in which an arc is generated between the arcs and the tip portion is made to enter the space surrounded by the concave molten pool formed in the base metal to weld the base metal.
A ceramic end tab having a recess is placed at the end of the welded portion.
Welding is started and the welding torch is moved to the end portion .
An arc welding method in which the welding current is reduced before the molten pool enters the recess of the end tab. The arc welding method according to claim 1, wherein the welding current is reduced before the welding wire enters the recess of the end tab. The welding current capable of welding the base metal by allowing the tip portion to enter the space surrounded by the concave molten pool is 300 A or more, and the welding wire is said to have entered the recess of the end tab before the welding wire enters the concave portion of the end tab. The arc welding method according to claim 1 or 2, wherein the welding current is reduced within a range where welding is possible. The arc welding method according to any one of claims 1 to 3, wherein the supply of welding current is stopped before the welding wire comes into contact with the end tab. The arc welding method according to any one of claims 1 to 4, wherein the supply of the welding current is stopped before the welding wire comes into contact with the non-metal substance generated at the terminal portion.

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