WO2016173314A1 - 一种空心主轴与实心轴头的焊接方法 - Google Patents

一种空心主轴与实心轴头的焊接方法 Download PDF

Info

Publication number
WO2016173314A1
WO2016173314A1 PCT/CN2016/074554 CN2016074554W WO2016173314A1 WO 2016173314 A1 WO2016173314 A1 WO 2016173314A1 CN 2016074554 W CN2016074554 W CN 2016074554W WO 2016173314 A1 WO2016173314 A1 WO 2016173314A1
Authority
WO
WIPO (PCT)
Prior art keywords
welding
main shaft
hollow main
shaft head
solid shaft
Prior art date
Application number
PCT/CN2016/074554
Other languages
English (en)
French (fr)
Inventor
崔恒兵
张云彩
张志权
陈曦
袁留兵
Original Assignee
江苏金通灵流体机械科技股份有限公司
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 江苏金通灵流体机械科技股份有限公司 filed Critical 江苏金通灵流体机械科技股份有限公司
Publication of WO2016173314A1 publication Critical patent/WO2016173314A1/zh

Links

Images

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/18—Submerged-arc welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K33/00—Specially-profiled edge portions of workpieces for making soldering or welding connections; Filling the seams formed thereby
    • B23K33/004—Filling of continuous seams
    • B23K33/006—Filling of continuous seams for cylindrical workpieces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/02—Seam welding; Backing means; Inserts
    • B23K9/028—Seam welding; Backing means; Inserts for curved planar seams
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/23—Arc welding or cutting taking account of the properties of the materials to be welded
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/235—Preliminary treatment

Definitions

  • the invention relates to a welding method, in particular to a welding method of a hollow main shaft and a solid shaft head.
  • the hollow main shaft is generally made of 45 steel or 35CrMo.
  • the carbon equivalent is high and the hardenability is high. Therefore, the weldability is poor. In the welding process, defects such as hot cracks and dense pores are easily generated due to improper welding process.
  • the formed weldment When the hollow main shaft is assembled with the solid shaft head, the formed weldment has a large geometrical size, so it has a very large rigidity and constraint, thereby generating a large internal stress during the welding process, and the entire welding process time is relatively high. Long, during the thermal cycle of welding, the hardened martensite structure is easily generated from high temperature cooling, so strict process measures must be taken when welding the hollow main shaft and the solid shaft.
  • the invention patent application published as CN103521887A discloses a welding process of 45 steel and 35CrMo cast steel.
  • the process adopts the following steps: a. preheating, the core and the disk are placed in the annealing furnace at 40-60 ° C / h.
  • the heating rate is preheated to 300 ° C, the heat is heated for 1 h, and the gas is continuously heated and kept, so that the welding process is always maintained at a preheating temperature of 200-250 ° C;
  • the welding method is adopted, H08Mn2SiA welding wire, 80% Ar + 20% CO2 argon-rich CO2 gas shielded welding; c.
  • welding parameters wire diameter is 1.2mm, welding current is 190-240A, welding voltage is 28-32V, interlayer temperature is 200-250 °C, gas flow rate, 15-20L ⁇ min -1, multi-layer multi-pass welding, the weld bead overlaps each other, the overlap weld is not less than 1/3 of the weld width, and each layer is welded with a shovel to smash the weld to eliminate stress, and the weld is made into the furnace. Stress relief heat treatment, which can greatly reduce the constraint stress, thus effectively controlling the occurrence of cracks.
  • this method still uses argon-rich CO2 gas shielded welding, which cannot be applied to the welding of 45 steel hollow spindle with large groove depth and high carbon equivalent.
  • the publication number CN101856758A discloses a welding method of a hard alloy steel part and a 45 steel part, the pre-weld pretreatment is after the alkali washing, degreasing and pickling activation treatment, in the hard alloy steel.
  • the welding surface is coated with a layer of Ag-Cu-Zn-Sn solder; the welding of the two is performed under the argon protection condition, and is electrically heated to 600-900 °, and the temperature is maintained for 0-20 s, and the welding is performed. Slow cooling is the main feature. It has the characteristics of good process performance, no oxidation on the surface and reliable welding quality.
  • This patent still uses argon-rich gas shielded welding, which cannot be applied to the welding of 45 steel hollow spindles with large groove depth and high carbon equivalent.
  • the present invention provides a welding method of a hollow main shaft and a solid shaft head, comprising the following steps:
  • the welding groove of the hollow main shaft and the solid shaft head is designed as a U+V-shaped groove, and a gap of 2-6 mm is left at the root of the welding groove;
  • the weld zone is partially annealed, and after the temperature is cooled to room temperature, the open heater is removed, and the weldment is completed.
  • the open heater is LCD-Q type, when heating The temperature is 300-400 ° C, and the heating is kept for 0.5-2 h; the temperature is preferably 350 ° C, and the heating is kept for 1 h; after the solid shaft head is inserted into the hollow main shaft, the position of the solid shaft head and the hollow main shaft is adjusted so that the concentricity is less than 3 mm.
  • the starting and ending portions of the tack welding are rounded, and the length between the positioning welding head and the closing end is 80-100 mm, and the welding parameters during the positioning welding are slightly larger than the welding parameters during the normal welding, and the inspection is performed. Whether the welding is intact, defect-free, defective, need to be removed and re-welded.
  • the open heater is an LCD-Q type, and the open heater set is biased.
  • the temperature of the hollow main shaft and the solid shaft head is sensed by the measuring couple during heating.
  • the temperature of the instrument is set at 400-500 ° C, the temperature is kept for 1-3 hours, the temperature of the instrument is preferably 450 ° C, and the temperature is kept for 2 hours;
  • the speed is greater than 100 ° C / h, not more than 125 ° C / h, the preheating temperature is between 200-250 ° C.
  • the manual arc welding is performed by using E5015 (J507) ⁇ 4.0 electrode, current 150-170A, and the electrode is dried at a temperature of 300-400 ° C for 0.5-2 hours before use, preferably in The temperature is 350 ° C for 1 hour; stored in the insulation tube, with the use; the manual arc welding first start the roller, make it slowly rotate, determine the location of the welding point to make the joint slightly uphill; during the welding process
  • the oscillating welding method is adopted to completely weld the deposited metal to both sides of the groove, and it is preferable to use small current welding to reduce the fusion ratio of the base metal in the weld, and the original welding is skipped, but the continuity of the entire weld must be ensured. With smoothness, the surface of the weld is concavely welded, and the weld slag, splash and scale are removed after the bottom layer is welded.
  • the submerged arc welding tooling is debugged to ensure the normal operation of each button of the tooling; the welding line circuit is inspected to ensure that there is no safety hazard at the welding site, the welding material is checked, and the measurement is confirmed.
  • the infrared tracking position is further determined to determine the position of the contact nozzle, and after determining the position of the contact nozzle, the welding wire is closely attached to the center of the bottom weld layer at the bottom of the groove, and the insulation is installed.
  • the paperboard is adjusted, the feeding and unloading buttons are adjusted to start adding flux, the dry elongation of the welding wire is controlled between 15-20mm, and the thickness of the flux covering layer is between 25-30mm.
  • step (5) the process parameters and the stacking sequence are set according to the parameter relationship and the groove size, and the following table 1 is the measured data:
  • B is the melting width
  • I is the welding current
  • U is the arc voltage
  • u is the roller frame motor speed
  • v is the main axis.
  • H is the effective superimposed thickness
  • ⁇ is the main shaft angular velocity.
  • the welding wire is located at the center of the joint, and the single layer is formed at the beginning of the welding, and the same layer is welded by two or more passes with the increase of the level, and the superposition sequence is performed. Marking, when welding the weld bead near the side of the groove, the wire should be kept at a certain distance from the side, generally slightly larger than or equal to the diameter of the wire, so that the weld and the side of the groove form a slightly concave smooth transition. Guaranteed penetration is also beneficial for slag removal. Maintain continuous coverage in the welded layer to avoid interruption of the flux and expose the arc. As the level increases, the welding current and arc voltage should be appropriately increased. When the temperature of the welding is too high, it should not be increased, and it should be reduced to 160- The interlayer control temperature of 250 ° C is re-welded.
  • the welding layer When the welding layer is increased by 20 mm, it is used as a stopping point, and the concentricity of the shaft head and the hollow tube is checked and the recording is confirmed.
  • stopping the arc press the stop button in two steps. Do not let go first, then let the wire stop feeding; the arc is gradually elongated, the arc pit is slowly filled, and the button is pressed to the end after the arc is extinguished.
  • the LCD-Q type split heater is used to heat the weld zone, and the bracket is supported by the natural support force and the shaft end, and the heating temperature is 600-700 ° C.
  • the heating rate is not more than 150 ° C / h., and the temperature is maintained at 600-700 ° C for 2-4 hours.
  • the beneficial effects of the invention are as follows: (1) welding the thick-walled hollow main shaft by the combination of semi-automatic submerged arc welding and electrode arc welding, thereby improving the welding of the thick-walled hollow main shaft and the shaft tube once. (2) semi-automatic submerged arc welding of the cover surface, the weld bead is beautifully formed, which can improve the stability of the product; (3) The semi-automatic submerged arc welding of the filling cover surface can effectively improve the welding efficiency.
  • FIG. 1 is a schematic structural view of a preferred group weldment of the present invention.
  • FIG. 2 is a schematic view of a preferred hollow spindle and its groove according to the present invention.
  • Figure 3 is a schematic view of a preferred solid shaft head and its groove according to the present invention.
  • Figure 4 is a general view of a preferred solid shaft head of the present invention inserted into a hollow main shaft;
  • Figure 5 is a positional view of the climbing soldering contact nozzle
  • Figure 6 is a diagram showing the position of the down-weld contact tip.
  • FIG. 1 is a schematic structural view of a preferred group of weldments according to the present invention, including a hollow main shaft 1, a solid shaft head 2 and a joint 3, and includes the following steps during welding:
  • the groove is designed as a U+V-shaped groove and left at the root.
  • the segmented symmetrical positioning welding is used to fix the hollow main shaft and the solid shaft head, and the rounding treatment is performed on the starting and closing ends of the positioning welding.
  • the length between the positioning welding head and the closing end is 80-100mm, and the welding parameters during the positioning welding are slightly larger than Welding parameters during normal welding, check whether the positioning welding is intact and defect-free, and need to be removed and re-welded; and the LCD-Q type open heater is put into the solid spindle joint for heating, and the open heater set is positionally solid.
  • the temperature of the hollow main shaft and the solid shaft head is sensed by the measuring couple during heating.
  • the temperature of the instrument is set at 450 ° C for 2 hours; the heating temperature is higher than 100 ° C / h, not more than 125 ° C / h, preheating temperature Between 200-250 ° C.
  • Infrared tracking positioning determines the position of the contact tip, after determining the position of the contact tip, the wire is closely attached to the center of the bottom weld layer at the bottom of the groove, the insulation block board is installed, the feeding and unloading buttons are adjusted to start adding flux, and the wire is controlled to dry.
  • the length is between 15-20mm and the thickness of the flux coating is between 25-30mm.
  • the welding contact nozzle is in the climbing welding position during filling welding, and the welding nozzle is in the down-slope welding position when the surface is welded, as shown in Fig. 5 for climbing welding.
  • the spindle rotates counterclockwise, the spindle is downhill with respect to the contact tip 7.
  • Table 1 shows the measured data:
  • B is the melt width
  • I is the welding current
  • U is the arc voltage
  • u is the roller frame motor speed
  • v is the spindle outermost end point line speed (only for the outer diameter of 570 spindle)
  • H is the effective stack thickness
  • ⁇ is the spindle angular velocity.
  • the welding wire is located at the center of the joint.
  • the initial welding is carried out in a single layer. With the increase of the level, the same layer is welded by two or more passes, and the stacking marks are made.
  • the welding wire should be kept at a certain distance from the side, which is generally slightly larger than or equal to the diameter of the welding wire, so that the weld seam and the side of the groove form a slightly concave and smooth transition, which not only ensures the penetration but also facilitates the slag removal.
  • the welding layer When the welding layer is increased by 20 mm, it is used as a stopping point, and the concentricity of the shaft head and the hollow tube is checked and the recording is confirmed.
  • stopping the arc press the stop button in two steps. Do not let go first, then let the wire stop feeding; the arc is gradually elongated, the arc pit is slowly filled, and the button is pressed to the end after the arc is extinguished.
  • the weld zone is partially annealed, and after the temperature is cooled to room temperature, the open heater is removed, and the weldment is completed.
  • the LCD-Q type split heater is used to heat the weld zone, and the bracket is supported by the natural support force and the shaft end.
  • the heating temperature is 600-700 ° C, and the heating rate is not more than 150 ° C / h. Maintain the temperature at 600-700 ° C for 2-4 hours.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Arc Welding In General (AREA)

Abstract

一种空心主轴与实心轴头的焊接方法，包括如下步骤：(1)设计U+V形坡口，在根部留有2-6mm的间隙；(2)将空心主轴置于焊接辊轮上，加热后将实心轴头套入空心主轴内；(3)采用分段对称定位焊点固，并将开式加热器套入实心轴头和空心主轴接头进行加热；(4)用手工电弧焊进行封底焊接；(5)半自动埋弧焊，填充焊采用爬坡焊位置，盖面焊采用下坡焊位置；(6)焊接完成后对焊缝区域进行局部退火，缓冷至室温后拆下加热器，得到组焊件完成焊接。该焊接方法利用半自动埋弧焊和焊条电弧焊相结合，选取合适的焊接材料和焊剂，调整焊接工艺参数及对焊接过程进行控制，解决了厚壁45钢空心主轴的焊接难题。

Description

一种空心主轴与实心轴头的焊接方法 技术领域
本发明涉及一种焊接方法，尤其涉及一种空心主轴与实心轴头的焊接方法。
背景技术
目前空心主轴一般采用45钢或35CrMo等材料，其碳当量较高，淬硬性较高，因此焊接性较差，在焊接过程中极易因为焊接工艺制定不当而产生热裂纹、密集性气孔等缺陷，目前行业内对空心主轴焊接时，多数用氩弧焊打底，焊条电弧焊或二氧焊填充盖面的方法，但当对坡口深度大于等于70mm的碳当量较高的45钢空心主轴进行焊接时，氩弧焊打底已经很难做到，而用焊条电弧焊及二氧焊对之进行焊接更容易产生焊接缺陷，且焊缝成形较差，焊接效率低，焊材利用率低。当空心主轴与实心轴头组合装配时，形成的组焊件几何尺寸较大，因此具有非常大的刚性和约束，从而在焊接过程中产生较大的内应力，再加上整个焊接过程时间较长，在焊接热循环过程中，从高温冷却时极易产生淬硬的马氏体组织，因此在空心主轴与实心轴头焊接时必须采取严格的工艺措施。
如公开号为CN103521887A的发明专利申请，公开了一种45钢与35CrMo铸钢的焊接工艺，工艺采用如下步骤：a.预热，盘芯和盘片置退火炉内以40-60℃/h的升温速度预热到300℃，保温1h出炉组对，并用煤气继续加热保温，使焊接过程始终保持200-250℃的预热温度；b.焊接方式，采用H08Mn2SiA焊丝，80％Ar+20％CO2的富氩CO2气体保护焊；c.焊接参数，焊丝直径为1.2mm，焊接电流为190-240A，焊接电压为28-32V，层间温度200-250℃，气体流量，15-20L×min-1,采用多层多道焊，焊道彼此重叠，重叠焊缝不少于焊缝宽度的1/3，同时每焊完一层用风铲捶击焊缝以消除应力，焊后进炉作消除应力热处理，其可大大降低约束应力，从而有效地控制了裂纹的出现。但是该方法仍采用的是富氩CO2气体保护焊，无法适用于坡口深度较大、碳当量较高的45钢空心主轴的焊接。
如公开号为CN101856758A公开了一种硬质合金钢制件与45钢制件的焊接方法，以其焊前预处理是在碱洗除油、脱脂和酸洗活化处理后，在硬质合金钢制件 焊接面镀上一层Ag-Cu-Zn-Sn钎料；而两者的焊接，是在氩气保护条件下，经电感应加热至600～900°，保温0～20s实施焊接的，且焊后实现缓慢冷却为主要特征。具有工艺性能良好，表面不会产生氧化，焊接质量可靠等特点。该专利采用的仍是富氩气体保护焊，无法适用于坡口深度较大、碳当量较高的45钢空心主轴的焊接。
发明内容
为克服现有技术中存在的厚壁45钢空心主轴与实心轴头的焊接问题，本发明提供了一种空心主轴与实心轴头的焊接方法，包括如下步骤：
(1)将空心主轴和实心轴头的焊接坡口设计成U+V形坡口，并使焊接坡口的根部留有2-6mm的间隙；
(2)将空心主轴置于焊接辊轮上，用开式加热器对空心主轴进行加热，然后将实心轴头套入空心主轴内；
(3)采用分段对称定位焊将空心主轴与实心轴头固定，并将开式加热器套入实心主轴接头进行加热；
(4)采用手工电弧焊对坡口进行封底焊接；
(5)采用半自动埋弧焊对坡口进行填充焊和盖面焊，填充焊时焊接导电嘴处于爬坡焊位置，盖面焊时导电嘴处于下坡焊位置；
(6)焊接完成后对焊缝区域进行局部退火，缓冷至室温后拆下开式加热器，得到组焊件完成焊接。
进一步，所述步骤(2)中将空心主轴置于焊接辊轮上之前，先将空心主轴坡口及管壁内外油污、锈斑、杂质清理干净，开式加热器为LCD-Q型，加热时温度为300-400℃，保持加热0.5-2h；优选温度为350℃，保持加热1h；将实心轴头套入空心主轴后，调整实心轴头与空心主轴位置，使其同心度小于3mm。
进一步，所述步骤(3)中对定位焊的起头和收尾处进行圆滑处理，定位焊起头和收尾之间长度为80-100mm，定位焊时焊接参数稍大于正常焊接时的焊接参数，检查定位焊是否完好无缺陷，有缺陷需铲除并重新焊接。
进一步，所述步骤(3)中开式加热器为LCD-Q型，开式加热器套装位置偏 实心轴头一侧，加热时用测电偶传感空心主轴和实心轴头的温度，仪表设置温度400-500℃，保温1-3小时，仪表设置温度优选450℃，保温2小时；加热升温速度大于100℃/h，不大于125℃/h，预热温度在200-250℃之间。
进一步，所述步骤(4)中手工电弧焊选用E5015(J507)φ4.0焊条，电流150-170A，焊条使用前先在温度为300-400℃的条件下烘干0.5-2小时，优选在温度为350℃的条件下烘干1小时；存放于保温筒，随用随取；手工电弧焊时先启动滚轮，使其缓慢转动，确定焊接点位置使接头呈微上坡状；焊接过程中采用摆动焊法，使熔敷金属与坡口两侧边缘完全熔合，优选采用小电流焊接以减少焊缝中母材金属的熔合比，原点固焊跳过，但必须保证整条焊缝的连贯与平滑，焊缝表面呈内凹船形焊焊缝，底层焊接结束后去除焊渣、飞溅、氧化皮。
进一步，所述步骤(5)中进行半自动埋弧焊之前，调试埋弧焊焊接工装，确保工装各按钮正常运行；检查焊接现场线路管路，确保焊接现场无安全隐患，核对焊接材料，测量确认轴头与轴管的同心度，跳动误差值＜3mm，调整坡口两侧150-200mm范围温度，使其保持在200-250℃之间。
进一步，所述步骤(5)中进行半自动埋弧焊之前，还进行红外线跟踪定位确定导电嘴位置，确定导电嘴位置后，将焊丝紧贴于坡口底部打底焊层中心位置，安装好绝缘挡料纸板，调节送料、下料按钮开始添加焊剂，控制焊丝干伸长度在15-20mm之间，焊剂覆盖层厚度在25-30mm之间。
进一步，所述步骤(5)中根据参数关系及坡口大小设置工艺参数及层道叠加顺序，下表表1为试验所测得数据：
表1焊接工艺参数
I(A) 500～510 500～510 500～510 500～510
U(V) 30～32 30～32 30～32 30～32
u(r/min) 300～340 400 560 590～600
B(mm) 20 18 15 12
V(m/h) 22.77 26.85 37.24 40.28
H(mm) 3 3 3 3
ω(1/h) 79.89 94.21 130.67 141.33
其中B为熔宽、I为焊接电流、U为电弧电压、u为滚轮架电机速度、v为主轴 最外缘端点线速度(仅对于外径为570的主轴而言)、H为有效叠加厚度、ω为主轴角速度。
进一步，所述步骤(5)中进行半自动埋弧焊时，焊丝位于接头中心，起始焊时单层一道，随着层次的增加同一层采用两道或多道焊焊接，并做好叠加顺序记号，当焊接接近坡口侧边的焊道时，焊丝应与侧边保持一定距离，一般稍大于或等于焊丝的直径，使焊缝与坡口侧边形成稍具凹形的圆滑过渡，既保证熔深又利于脱渣。在焊接过层中保持连续覆盖，以免焊剂中断，露出电弧，随着层次的增加焊接电流和电弧电压应适当增大，当焊接的温度过高时，不宜增大，并稍待降至160-250℃的层间控制温度再焊接。
焊层每增高20mm时作为停止点，对轴头与空心管的同心度检查并确认记录。停弧时，按停止按钮分两步进行，先按下一半不要松手，使焊丝停止送进；电弧逐渐拉长，弧坑慢慢被填满，待电弧熄灭后将按钮按到底。
进一步，所述步骤(6)中局部退火时，用LCD-Q型对开式加热器对焊缝区进行加热，采用托架自然托力支撑与轴头端，加热温度为600-700℃，升温速率不大于150℃/h.，并保持温度在600-700℃条件下2-4小时。
与现有技术相比，本发明的有益效果是：(1)利用半自动埋弧焊和焊条电弧焊相结合的方法对厚壁空心主轴进行焊接，提高了厚壁空心主轴与轴管焊接的一次合格率；(2)盖面采用半自动埋弧焊，焊缝成形美观，可提高产品的稳定性；(3)填充盖面采用半自动埋弧焊，可有效提高焊接效率。
附图说明
图1是本发明较佳之组焊件结构示意图；
图2是本发明较佳之空心主轴及其坡口示意图；
图3是本发明较佳之实心轴头及其坡口示意图；
图4是本发明较佳之实心轴头套入空心主轴的整体图；
图5是爬坡焊导电嘴位置图；
图6是下坡焊导电嘴位置图。
具体实施方式
以下结合附图和实施例，对本发明进行进一步详细说明。应当理解，此处所描述的具体实施例仅用以解释本发明，并不用于限定本发明。
如图1所示是本发明较佳之组焊件结构示意图，包括空心主轴1、实心轴头2和连接处3，在焊接时包括如下步骤：
(1)设计U+V形坡口，在对坡口进行设计时，需考虑到焊缝根部的熔透情况，因此将坡口设计成U+V形的坡口形式，并在根部留有4mm的间隙距离；如图2所示为本发明较佳之空心主轴及其坡口，其中坡口4下部为圆弧段，半径R1＝10mm，上部为直线段，其与竖直方向的夹角a＝100,如图3所示为本发明较佳之实心轴头及其坡口示意图，其中坡口5下部为圆弧段，半径R2＝10mm，上部为直线段，其与竖直方向的夹角b＝100,如图4所示为本发明较佳之实心轴头套入空心主轴的整体图，此时空心主轴和实心轴头形成的坡口6左右对称，坡口根部留有空隙L＝2-6mm。
(2)将空心主轴坡口及管壁内外油污、锈斑、杂质清理干净，再将空心主轴置于焊接辊轮上，用LCD-Q型开式加热器对空心主轴进行加热，加热时温度为350℃，保持加热1h；然后将实心轴头套入空心主轴内，检查实心轴头与空心主轴的同心度，保证同心度小于3mm。
(3)采用分段对称定位焊将空心主轴与实心轴头固定，对定位焊的起头和收尾处进行圆滑处理，定位焊起头和收尾之间长度为80-100mm，定位焊时焊接参数稍大于正常焊接时的焊接参数，检查定位焊是否完好无缺陷，有缺陷需铲除并重新焊接；并将LCD-Q型开式加热器套入实心主轴接头进行加热，开式加热器套装位置偏实心轴头一侧，加热时用测电偶传感空心主轴和实心轴头的温度，仪表设置温度450℃，保温2小时；加热升温速度大于100℃/h，不大于125℃/h，预热温度在200-250℃之间。
(4)采用手工电弧焊对坡口进行封底焊接，选用E5015(J507)φ4.0焊条，电流150-170A，焊条使用前先在温度为350℃的条件下烘干1小时；存放于保温筒，随用随取；手工电弧焊时先启动滚轮，使其缓慢转动，确定焊接点位置使接头呈微上坡状；焊接过程中采用摆动焊法，使熔敷金属与坡口两侧边缘完全熔合，优选采用小电流焊接以减少焊缝中母材金属的熔合比，原点固焊跳过，但必须保证整条焊缝的连贯与平滑，焊缝表面呈内凹船形焊焊缝，底层焊接结束后去除焊 渣、飞溅、氧化皮。
(5)调试埋弧焊焊接工装，确保工装各按钮正常运行；检查焊接现场线路管路，确保焊接现场无安全隐患，核对焊接材料，测量确认轴头与轴管的同心度，跳动误差值＜3mm，调整坡口两侧150-200mm范围温度，使其保持在200-250℃之间。
红外线跟踪定位确定导电嘴位置，确定导电嘴位置后，将焊丝紧贴于坡口底部打底焊层中心位置，安装好绝缘挡料纸板，调节送料、下料按钮开始添加焊剂，控制焊丝干伸长度在15-20mm之间，焊剂覆盖层厚度在25-30mm之间。
采用半自动埋弧焊对坡口进行填充焊和盖面焊，填充焊时焊接导电嘴处于爬坡焊位置，盖面焊时导电嘴处于下坡焊位置，如图5所示为爬坡焊导电嘴位置图，导电嘴7设在靠左侧方向，S＝3-5mm，当主轴逆时针旋转时，主轴相对于导电嘴7呈爬坡方式，如图6所示下坡焊导电嘴位置图，导电嘴7设在靠右侧方向，S＝3-5mm，当主轴逆时针旋转时，主轴相对于导电嘴7呈下坡方式。根据参数关系及坡口大小设置工艺参数及层道叠加顺序，下表表1为试验所测得数据：
表1焊接工艺参数
I(A) 500～510 500～510 500～510 500～510
U(V) 30～32 30～32 30～32 30～32
u(r/min) 300～340 400 560 590～600
B(mm) 20 18 15 12
V(m/h) 22.77 26.85 37.24 40.28
H(mm) 3 3 3 3
ω(1/h) 79.89 94.21 130.67 141.33
其中B为熔宽、I为焊接电流、U为电弧电压、u为滚轮架电机速度、v为主轴最外缘端点线速度(仅对于外径为570的主轴而言)、H为有效叠加厚度、ω为主轴角速度。
进行半自动埋弧焊时，焊丝位于接头中心，起始焊时单层一道，随着层次的增加同一层采用两道或多道焊焊接，并做好叠加顺序记号，当焊接接近坡口侧边的焊道时，焊丝应与侧边保持一定距离，一般稍大于或等于焊丝的直径，使焊缝与坡口侧边形成稍具凹形的圆滑过渡，既保证熔深又利于脱渣。在焊接过程中保 持连续覆盖，以免焊剂中断，露出电弧，随着层次的增加焊接电流和电弧电压应适当增大，当焊接的温度过高时，不宜增大，并稍待降至160-250℃的层间控制温度再焊接。
焊层每增高20mm时作为停止点，对轴头与空心管的同心度检查并确认记录。停弧时，按停止按钮分两步进行，先按下一半不要松手，使焊丝停止送进；电弧逐渐拉长，弧坑慢慢被填满，待电弧熄灭后将按钮按到底。
(6)焊接完成后对焊缝区域进行局部退火，缓冷至室温后拆下开式加热器，得到组焊件完成焊接。
退火时用LCD-Q型对开式加热器对焊缝区进行加热，采用托架自然托力支撑与轴头端，加热温度为600-700℃，升温速率不大于150℃/h.，并保持温度在600-700℃条件下2-4小时。
上述说明示出并描述了本发明的优选实施例，如前所述，应当理解本发明并非局限于本文所披露的形式，不应看作是对其他实施例的排除，而可用于各种其他组合、修改和环境，并能够在本文所述发明构想范围内，通过上述教导或相关领域的技术或知识进行改动。而本领域人员所进行的改动和变化不脱离本发明的精神和范围，则都应在本发明所附权利要求的保护范围内。

Claims (10)

  1. 一种空心主轴与实心轴头的焊接方法，其特征在于包括如下步骤：
    (1)将空心主轴和实心轴头的焊接坡口设计成U+V形坡口，并使焊接坡口的根部留有2-6mm的间隙；
    (2)将空心主轴置于焊接辊轮上，用开式加热器对空心主轴进行加热，然后将实心轴头套入空心主轴内；
    (3)采用分段对称定位焊将空心主轴与实心轴头固定，并将开式加热器套入实心主轴接头进行加热；
    (4)采用手工电弧焊对坡口进行封底焊接；
    (5)采用半自动埋弧焊对坡口进行填充焊和盖面焊，填充焊时焊接导电嘴处于爬坡焊位置，盖面焊时导电嘴处于下坡焊位置；
    (6)焊接完成后对焊缝区域进行局部退火，缓冷至室温后拆下开式加热器，得到组焊件完成焊接。
  2. 根据权利要求1所述的一种空心主轴与实心轴头的焊接方法，其特征在于：所述步骤(2)中将空心主轴置于焊接辊轮上之前，先将空心主轴坡口及管壁内外油污、锈斑、杂质清理干净，开式加热器为LCD-Q型，加热时温度为300-400℃，保持加热0.5-2h，将实心轴头套入空心主轴后，调整实心轴头与空心主轴位置，使其同心度小于3mm。
  3. 根据权利要求1所述的一种空心主轴与实心轴头的焊接方法，其特征在于：所述步骤(3)中对定位焊的起头和收尾处进行圆滑处理，定位焊起头和收尾之间长度为80-100mm，检查定位焊是否完好无缺陷，有缺陷需铲除并重新焊接。
  4. 根据权利要求1所述的一种空心主轴与实心轴头的焊接方法，其特征在于：所述步骤(3)中开式加热器为LCD-Q型，开式加热器套装位置偏实心轴头一侧，加热时用测电偶传感空心主轴和实心轴头的温度，仪表设置温度400-500℃，保温1-3小时，加热升温速度大于100℃/h，不大于125℃/h，预热温度在200-250℃之间。
  5. 根据权利要求1所述的一种空心主轴与实心轴头的焊接方法，其特征在于：所述步骤(4)中手工电弧焊选用E5015(J507)φ4.0焊条，电流150-170A，焊条使用前先在温度为300-400℃的条件下烘干0.5-2小时，存放于保温筒，随用 随取；手工电弧焊时先启动滚轮，使其缓慢转动，确定焊接点位置使接头呈微上坡状；焊接过程中采用摆动焊法，使熔敷金属与坡口两侧边缘完全熔合，焊缝表面呈内凹船形焊焊缝，底层焊接结束后去除焊渣、飞溅、氧化皮。
  6. 根据权利要求1所述的一种空心主轴与实心轴头的焊接方法，其特征在于：所述步骤(5)中进行半自动埋弧焊之前，调整坡口两侧150-200mm范围温度，使其保持在200-250℃之间。
  7. 根据权利要求6所述的一种空心主轴与实心轴头的焊接方法，其特征在于：所述步骤(5)中进行半自动埋弧焊之前，还进行红外线跟踪定位确定导电嘴位置，确定导电嘴位置后，将焊丝紧贴于坡口底部打底焊层中心位置，安装好绝缘挡料纸板，调节送料、下料按钮开始添加焊剂，控制焊丝干伸长度在15-20mm之间，焊剂覆盖层厚度在25-30mm之间。
  8. 根据权利要求1所述的一种空心主轴与实心轴头的焊接方法，其特征在于：所述步骤(5)中根据参数关系及坡口大小设置工艺参数及层道叠加顺序。
  9. 根据权利要求1所述的一种空心主轴与实心轴头的焊接方法，其特征在于：所述步骤(5)中进行半自动埋弧焊时，焊丝位于接头中心，起始焊时单层一道，随着层次的增加同一层采用两道或多道焊焊接，并做好叠加顺序记号；停弧时，按停止按钮分两步进行，先按下一半不要松手，使焊丝停止送进；电弧逐渐拉长，弧坑慢慢被填满，待电弧熄灭后将按钮按到底。
  10. 根据权利要求1所述的一种空心主轴与实心轴头的焊接方法，其特征在于：所述步骤(6)中局部退火时，用LCD-Q型对开式加热器对焊缝区进行加热，加热温度为600-700℃，升温速率不大于150℃/h.，并保持温度在600-700℃条件下2-4小时。
PCT/CN2016/074554 2015-04-27 2016-02-25 一种空心主轴与实心轴头的焊接方法 WO2016173314A1 (zh)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
CN201510205035.3A CN104785911A (zh) 2015-04-27 2015-04-27 一种空心主轴与实心轴头的焊接方法
CN201510205035.3 2015-04-27

Publications (1)

Publication Number Publication Date
WO2016173314A1 true WO2016173314A1 (zh) 2016-11-03

Family

ID=53551335

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/CN2016/074554 WO2016173314A1 (zh) 2015-04-27 2016-02-25 一种空心主轴与实心轴头的焊接方法

Country Status (2)

Country Link
CN (1) CN104785911A (zh)
WO (1) WO2016173314A1 (zh)

Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN107639324A (zh) * 2017-08-08 2018-01-30 上海宝冶集团有限公司 厚壁管道坡口的组对方法
CN111872587A (zh) * 2019-12-09 2020-11-03 中铁宝桥集团有限公司 一种超厚壁板钢塔节段现场环缝焊接方法
CN112338401A (zh) * 2020-11-27 2021-02-09 广州诺星智能科技有限公司 一种带有烘干功能的焊条切割设备
CN113857640A (zh) * 2021-10-26 2021-12-31 中国航发贵州黎阳航空动力有限公司 一种用于航空发动机内隔热筒与外隔热筒的套装焊接方法
CN114166857A (zh) * 2021-10-29 2022-03-11 中国船舶重工集团公司第七二五研究所 一种金属材料焊接接头抗裂性测试方法及焊接方法
CN114160934A (zh) * 2021-11-12 2022-03-11 四川川锅锅炉有限责任公司 一种汽包导气接管的埋弧焊工艺方法
CN114192942A (zh) * 2021-11-02 2022-03-18 海洋石油工程股份有限公司 一种埋弧自动焊焊接2fr节点形式工艺
CN114589379A (zh) * 2022-04-18 2022-06-07 山东蓬翔汽车有限公司 一种车桥本体纵焊缝根部间隙局部超差焊接方法
CN114682892A (zh) * 2020-12-28 2022-07-01 无锡苏嘉法斯特汽车零配件有限公司 一种汽车传动轴用焊接钢管制造方法
CN114769803A (zh) * 2022-05-31 2022-07-22 武昌船舶重工集团有限公司 一种铁白铜管焊接工艺及一种焊接辅助工具
CN114769809A (zh) * 2022-05-12 2022-07-22 威海众合机电科技有限公司 一种铝合金薄壁管件与厚壁管件的焊接工艺
CN115041785A (zh) * 2022-05-30 2022-09-13 河南北方红阳机电有限公司 一种基于低合金高强异种钢涂胶套接组件的手工tig焊接方法
CN115351451A (zh) * 2022-08-18 2022-11-18 东方电气集团东方锅炉股份有限公司 一种多喷嘴气化炉侧壁烧嘴接管的装焊方法
CN115846877A (zh) * 2022-12-31 2023-03-28 中联重科股份有限公司 工件焊接方法及焊接结构件
CN116213887A (zh) * 2023-05-08 2023-06-06 中南大学 一种1.2738钢塑胶模具的氩弧焊修复方法

Families Citing this family (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN104785911A (zh) * 2015-04-27 2015-07-22 江苏金通灵流体机械科技股份有限公司 一种空心主轴与实心轴头的焊接方法
CN107598342B (zh) * 2017-11-08 2020-02-14 东方电气集团东方电机有限公司 一种大型抽水蓄能发电机整体瓶形轴焊接制造方法
CN107900496A (zh) * 2017-11-27 2018-04-13 江苏金通灵流体机械科技股份有限公司 一种45#钢主轴与45#钢法兰盘焊接方法
CN108971792B (zh) * 2018-09-19 2024-04-19 隆华科技集团（洛阳）股份有限公司 一种用于角接头对接缝单面焊双面成形的坡口工艺
CN109352283A (zh) * 2018-11-29 2019-02-19 武汉武船重型装备工程有限责任公司 一种回转轴的制造方法
CN116638256B (zh) * 2023-07-16 2024-05-10 江苏亚太特种铸钢厂有限公司 一种具有机械安全保护结构的稳定辊加工工艺

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7507933B2 (en) * 2005-11-23 2009-03-24 General Electric Company Method for fabricating a rotor shaft
CN101879666A (zh) * 2010-07-15 2010-11-10 湘潭电机股份有限公司 一种电机转轴的筋板与光轴的焊接方法
CN101898271A (zh) * 2010-08-18 2010-12-01 中信重工机械股份有限公司 一种实心轴装焊方法
CN102430893A (zh) * 2011-09-15 2012-05-02 东方电气集团东方电机有限公司 一种小内径空心主轴的制造方法
CN104785911A (zh) * 2015-04-27 2015-07-22 江苏金通灵流体机械科技股份有限公司 一种空心主轴与实心轴头的焊接方法

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN2611647Y (zh) * 2003-04-04 2004-04-14 沈阳鼓风机股份有限公司 大型风机主轴
CN2799925Y (zh) * 2005-06-14 2006-07-26 南通金通灵风机有限公司 叶轮空心轴

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7507933B2 (en) * 2005-11-23 2009-03-24 General Electric Company Method for fabricating a rotor shaft
CN101879666A (zh) * 2010-07-15 2010-11-10 湘潭电机股份有限公司 一种电机转轴的筋板与光轴的焊接方法
CN101898271A (zh) * 2010-08-18 2010-12-01 中信重工机械股份有限公司 一种实心轴装焊方法
CN102430893A (zh) * 2011-09-15 2012-05-02 东方电气集团东方电机有限公司 一种小内径空心主轴的制造方法
CN104785911A (zh) * 2015-04-27 2015-07-22 江苏金通灵流体机械科技股份有限公司 一种空心主轴与实心轴头的焊接方法

Cited By (21)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN107639324B (zh) * 2017-08-08 2023-07-14 上海宝冶集团有限公司 厚壁管道坡口的组对方法
CN107639324A (zh) * 2017-08-08 2018-01-30 上海宝冶集团有限公司 厚壁管道坡口的组对方法
CN111872587A (zh) * 2019-12-09 2020-11-03 中铁宝桥集团有限公司 一种超厚壁板钢塔节段现场环缝焊接方法
CN112338401A (zh) * 2020-11-27 2021-02-09 广州诺星智能科技有限公司 一种带有烘干功能的焊条切割设备
CN112338401B (zh) * 2020-11-27 2022-07-15 新乡市七星钎焊科技有限公司 一种带有烘干功能的焊条切割设备
CN114682892A (zh) * 2020-12-28 2022-07-01 无锡苏嘉法斯特汽车零配件有限公司 一种汽车传动轴用焊接钢管制造方法
CN113857640A (zh) * 2021-10-26 2021-12-31 中国航发贵州黎阳航空动力有限公司 一种用于航空发动机内隔热筒与外隔热筒的套装焊接方法
CN113857640B (zh) * 2021-10-26 2023-11-21 中国航发贵州黎阳航空动力有限公司 一种用于航空发动机内隔热筒与外隔热筒的套装焊接方法
CN114166857A (zh) * 2021-10-29 2022-03-11 中国船舶重工集团公司第七二五研究所 一种金属材料焊接接头抗裂性测试方法及焊接方法
CN114192942A (zh) * 2021-11-02 2022-03-18 海洋石油工程股份有限公司 一种埋弧自动焊焊接2fr节点形式工艺
CN114160934A (zh) * 2021-11-12 2022-03-11 四川川锅锅炉有限责任公司 一种汽包导气接管的埋弧焊工艺方法
CN114589379A (zh) * 2022-04-18 2022-06-07 山东蓬翔汽车有限公司 一种车桥本体纵焊缝根部间隙局部超差焊接方法
CN114769809A (zh) * 2022-05-12 2022-07-22 威海众合机电科技有限公司 一种铝合金薄壁管件与厚壁管件的焊接工艺
CN115041785A (zh) * 2022-05-30 2022-09-13 河南北方红阳机电有限公司 一种基于低合金高强异种钢涂胶套接组件的手工tig焊接方法
CN115041785B (zh) * 2022-05-30 2024-03-15 河南北方红阳机电有限公司 一种基于低合金高强异种钢涂胶套接组件的手工tig焊接方法
CN114769803A (zh) * 2022-05-31 2022-07-22 武昌船舶重工集团有限公司 一种铁白铜管焊接工艺及一种焊接辅助工具
CN114769803B (zh) * 2022-05-31 2023-09-22 武昌船舶重工集团有限公司 一种铁白铜管焊接工艺及一种焊接辅助工具
CN115351451A (zh) * 2022-08-18 2022-11-18 东方电气集团东方锅炉股份有限公司 一种多喷嘴气化炉侧壁烧嘴接管的装焊方法
CN115846877A (zh) * 2022-12-31 2023-03-28 中联重科股份有限公司 工件焊接方法及焊接结构件
CN116213887A (zh) * 2023-05-08 2023-06-06 中南大学 一种1.2738钢塑胶模具的氩弧焊修复方法
CN116213887B (zh) * 2023-05-08 2023-08-11 中南大学 一种1.2738钢塑胶模具的氩弧焊修复方法

Also Published As

Publication number Publication date
CN104785911A (zh) 2015-07-22

Similar Documents

Publication Publication Date Title
WO2016173314A1 (zh) 一种空心主轴与实心轴头的焊接方法
CN104384677B (zh) 一种特厚钢板焊接方法
CN104084678B (zh) 接管与安全端环缝全位置钨极惰性气体保护焊焊接方法
JP5318749B2 (ja) ステンレス鋼管の溶接装置及び溶接方法
CN108480825B (zh) 一种核电主管道窄间隙自动焊焊缝熔穿缺陷的修复方法
WO2015132651A2 (en) Method and system to start and use combination filler wire feed and high intensity energy source for root pass welding of the inner diameter of clad pipe
CN105414878B (zh) 一种高耐热合金钢铸件缺陷的返修方法
CN107900496A (zh) 一种45#钢主轴与45#钢法兰盘焊接方法
CN104816093B (zh) 一种阀体零件深孔底部密封面激光熔覆的制造方法
CN112719515A (zh) 一种黑白管的轨道tig焊焊接方法
CN101700599A (zh) Sa335p91钢埋弧自动焊焊接方法
CN109986279A (zh) 一种裂解炉高压蒸汽锅炉给水阀焊接修复方法
CN110860769A (zh) Ap1000核电站主蒸汽管道窄间隙自动焊接工艺
CN115007966A (zh) 一种铁路辗钢车轮的表面耐磨堆焊的方法
CN109530857B (zh) 一种粗丝单电源浅熔深高效埋弧自动堆焊工艺方法
JP3198817B2 (ja) 固定管の狭開先突合せ溶接における積層溶接方法
JP4951488B2 (ja) 蒸気タービンロータ及びその製造方法
JP4632428B2 (ja) 鋼管の高周波誘導加熱造管方法
CN110977099A (zh) 钢结构桁架管柱对接方法
CN105195866B (zh) 一种双金属复合管的管端全自动根焊方法
JPH08243739A (ja) ボイラーチューブの連続溶接法
CN106041270A (zh) 一种管道自动焊接方法
CN105499763A (zh) 一种厚壁空心导电磷脱氧铜轴的焊接方法
CN117066657A (zh) 一种镍基合金管ht700p的焊接工艺
CN114734124B (zh) 一种气电立焊接头处理方法

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 16785745

Country of ref document: EP

Kind code of ref document: A1

NENP Non-entry into the national phase

Ref country code: DE

122 Ep: pct application non-entry in european phase

Ref document number: 16785745

Country of ref document: EP

Kind code of ref document: A1