WO2020052049A1 - 一种三丝气体保护间接电弧焊方法、装置及其应用 - Google Patents

一种三丝气体保护间接电弧焊方法、装置及其应用 Download PDF

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Publication number
WO2020052049A1
WO2020052049A1 PCT/CN2018/115249 CN2018115249W WO2020052049A1 WO 2020052049 A1 WO2020052049 A1 WO 2020052049A1 CN 2018115249 W CN2018115249 W CN 2018115249W WO 2020052049 A1 WO2020052049 A1 WO 2020052049A1
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Prior art keywords
welding
wire
arc
wires
indirect
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English (en)
French (fr)
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刘黎明
宋刚
张兆栋
胡成辉
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Dalian University of Technology
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Dalian University of Technology
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Priority to US17/272,927 priority Critical patent/US20210316385A1/en
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    • 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
    • B23K9/16—Arc welding or cutting making use of shielding gas
    • B23K9/164—Arc welding or cutting making use of shielding gas making use of a moving fluid
    • 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
    • B23K9/025—Seam welding; Backing means; Inserts for rectilinear 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
    • B23K9/16—Arc welding or cutting making use of shielding gas
    • 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
    • B23K9/04—Welding for other purposes than joining, e.g. built-up 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
    • B23K9/00—Arc welding or cutting
    • B23K9/16—Arc welding or cutting making use of shielding gas
    • B23K9/173—Arc welding or cutting making use of shielding gas and of a consumable electrode
    • B23K9/1735—Arc welding or cutting making use of shielding gas and of a consumable electrode making use of several electrodes
    • 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
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/02—Iron or ferrous alloys
    • B23K2103/04—Steel or steel alloys

Definitions

  • the invention belongs to the technical field of material processing, and relates to an indirect arc welding method, in particular, to a three-wire gas shielded indirect arc welding method, device and application thereof.
  • the indirect arc welding method is proposed, which is different from the traditional arc welding in that the workpiece does not contact the power source, and the arc is generated only between the electrodes.
  • the indirect arcs currently studied are mainly two-wire indirect arcs [1-3] .
  • the existing two-wire indirect arc welding has obvious limitations. As shown in Figure 1, the two-wire indirect arc welding, especially its power connection method and The wire distribution method makes the double-wire indirect arc welding arc dispersion phenomenon under the electromagnetic effect when the current increases to a certain value, which can not guarantee the stability of the welding process, and the deposition efficiency and welding efficiency are limited. Therefore, there are disadvantages such as insufficient heat input to the base material and narrow selection of welding parameters.
  • the invention patent (application number 201510145041.4) proposed a three-wire gas-shielded indirect arc welding method, as shown in Figures 2 and 3, which are the principles of three-wire indirect arc welding and four types of welding wires.
  • a is three welding wires distributed on a plane; b is edge wire on each side of the middle wire; c is edge wire at the same time on one side of the middle wire; d is the middle wire inclined with the horizontal line At a certain angle, etc., z is the main wire, that is, the middle wire, and b is the side wire.
  • the two sides of the wire are symmetrical about the center of the main wire, so that the magnetic field between the main wire and the side wire is symmetric about the center of the main wire, which causes the two indirect arcs to be independent of each other and offset at the tail, which causes the arc
  • the area acting on the base material increases, the energy density of the arc decreases, and the penetrating power of the arc decreases, resulting in insufficient heat input to the workpiece.
  • the large distribution space of the three welding wires causes the welding torch to be too large, which is not conducive to the popularization and application of the technology.
  • the present invention mainly adopts the mirror symmetrical welding wire arrangement method and a specific welding wire connection method (that is, the main wire is connected to the positive electrode of the power supply and the side wire is connected to the negative electrode of the power supply), which optimizes the spatial distribution of the magnetic field between indirect arcs and enhances the welding wire.
  • the magnetic field strength between the arcs has solved the problem of deflection of the two indirect arc tails during the welding process, and the arc energy density and arc stiffness have been improved.
  • the welding heat input of the workpiece can be effectively designed and regulated, thereby increasing the application range of the technology. .
  • the technical means adopted by the present invention are as follows:
  • a three-wire gas-shielded indirect arc welding method performs a welding process by using three welding wires and two electric arc power sources.
  • the method is characterized in that:
  • one of the three welding wires is connected to the positive poles of the two arc power sources, and the remaining two welding wires are respectively connected to the negative poles of the two arc power sources.
  • the welding workpiece is not connected with the arc power source. Connect; then arrange the above welding wire connecting the two positive poles of the arc power source in the middle, and call the welding wire as the main wire; the remaining two welding wires are respectively arranged on both sides of the main wire, and the two welding wires are called side wires;
  • the two side wires form an angle of 20 ° to 60 ° with the main wire, the two side wires intersect with the extension line of the main wire and the two intersection points are on the same horizontal line; the side wire and the The orthographic projection of the main wire in a plane perpendicular to the welding direction satisfies the following conditions: the angle between the side wire and the main wire is 0 ° to 5 °, and the two side wires are mirror-symmetrical with respect to the main wire;
  • the two arc power sources are output at the same time, so that an indirect arc coupled at the intersection between the main wire and the side wire and concentrated in the form of the arc (due to the use of the wire arrangement method, The magnetic field distribution is optimized, and the two indirect arc shapes become concentrated.)
  • the welding wire polarity is used, the two indirect arcs are deflected toward the main wire at the same time and coupled into a single arc with increased current density and enhanced penetration ability;
  • the coupled indirect arc processes the base metal, and according to a preset welding process, the welding wire metal and a part of the base metal are melted, and a welded joint can be formed after cooling and solidification, thereby realizing a welding process with a high deposition rate and a large penetration depth. .
  • the total welding current refers to the total welding current during the welding process, because the total welding current before and after the coupling does not change, so the total welding current after the coupling is equivalent to the total welding current
  • range is maintained between 250A to 600A, the main The wire feeding speed is controlled at 3.5m / min ⁇ 15m / min, and the welding speed is controlled at 0.3m / min ⁇ 2m / min; the welding torch composed of the three welding wires can be arranged vertically downward or inclined to a certain level with the horizontal line Angle arrangement, its inclination range is 20 ° ⁇ 120 °.
  • the two arc power sources are selected from a combination of two DC power sources, two pulse power sources, one DC power source, and one pulse power source.
  • the welding method is arc welding process may be employed as CO 2, Ar or one kind of a mixed gas of CO 2 and Ar, the protective gas flow are 0.1 ⁇ 50 L / min.
  • the invention discloses a device for realizing the above-mentioned three-wire gas shielded indirect arc welding method, which is characterized in that the device is composed of three welding wires and two arc power sources;
  • one of the three welding wires is connected to the positive electrodes of the two arc power sources, and the welding wire is arranged at the middle position of the three welding wires, and the welding wire is called a main wire;
  • the remaining two welding wires are connected to the negative electrodes of the two arc power sources and are arranged on both sides of the main wire, respectively, and these two welding wires are called side wires;
  • the two side wires form an angle of 20 ° to 60 ° with the main wire, and the orthographic projection of the side wire and the main wire in a plane perpendicular to the welding direction satisfies the following conditions:
  • An included angle of the main wire is 0 ° to 5 °, and the two side wires are mirror-symmetrical with respect to the main wire;
  • the welding workpiece is not connected to the arc power source; the two side wires and the extension lines of the main wire intersect respectively and the two intersection points are on the same horizontal line;
  • the two arc power sources are output at the same time, so that an indirect arc coupled with indirect arcs and concentrated in the form of the arc is generated at the intersection between the main wire and the side wires, and the two indirect arcs are directed to the main wire.
  • a welded joint can be formed, and a welding process with a high deposition rate and a large penetration depth can be realized.
  • the integrated welding torch composed of the three welding wires may be arranged vertically downward or at a certain inclined angle with the horizontal line, and the inclination angle thereof ranges from 20 ° to 120 °.
  • the two arc power sources are selected from a combination of two DC power sources, two pulse power sources, one DC power source, and one pulse power source.
  • the welding method is arc welding process may be employed as CO 2, Ar or one kind of a mixed gas of CO 2 and Ar, the protective gas flow are 0.1 ⁇ 50 L / min.
  • the invention also discloses a surfacing method based on three-wire gas protection indirect arc, which comprises adopting the above-mentioned method, and in implementing the surfacing process, the welding process is performed parallel to the vertical plane where the welding wire is located and perpendicular to the The vertical plane where the welding wire is located is the overlay welding direction, and the three welding wires are used as the filler metal, and the welding of the filler metal and the welding workpiece is realized by using the heat of the arc column coupled with the indirect arc and the heat carried by the droplet transfer.
  • the invention also discloses a high-efficiency welding process based on three-wire gas shielded indirect arc, which is characterized by including using the above-mentioned method, and during the welding process, the welding plane is parallel to the vertical plane where the welding wire is located, and mirror images are used. Symmetric welding wire arrangement to achieve a single-pass welding penetration depth of 10mm or more when the groove angle is less than 20 °.
  • the present invention has the following advantages:
  • the three-wire gas-shielded indirect arc welding workpiece provided by the present invention is not connected to a power source, the arc forms an indirect arc only at the end of the welding wire, the workpiece heat input is increased, the welding wire deposition coefficient is high, and electrical energy is saved.
  • the present invention realizes the optimization of the spatial distribution of the magnetic field between the indirect arcs by adopting the mirror symmetrical welding wire arrangement method, enhances the magnetic field strength between the welding wires, and solves the problem of the welding process while concentrating the two indirect arc shapes.
  • the present invention uses a specific welding wire connection method (that is, the main wire is connected to the positive pole of the power supply and the side wire is connected to the negative pole of the power supply) to directly couple the two indirect arcs into a single arc, which improves the arc energy density and arc stiffness, and the penetration of the arc Increased capacity.
  • the method of the present invention can effectively compress the distribution space of the three welding wires, reduce the volume of the composite welding torch, and is beneficial to the popularization and application of the technology.
  • FIG. 1 is a schematic diagram of the principle of twin wire indirect arc welding in the prior art.
  • FIG. 2 is a schematic diagram of the principle of three-wire indirect arc welding in the prior art.
  • FIG. 3 is a schematic diagram of a three-wire indirect arc welding wire arrangement method in the prior art.
  • FIG. 4 is a schematic diagram of the three-wire indirect arc welding principle of the present invention.
  • FIG. 5 is a schematic diagram of the distribution mode of the three-wire indirect arc welding wire according to the present invention
  • (I) is a schematic view of a line of sight perpendicular to the welding direction
  • (II) is a schematic view of a line of sight parallel to the welding direction.
  • FIG. 6 is a comparison chart of the effect of surfacing welding of the present invention and the effect of three-wire indirect arc surfacing welding in the prior art.
  • FIG. 7 is a schematic diagram of an embodiment of three-wire gas shielded indirect arc welding in the present invention.
  • First arc power source 2. Second arc power source; 3. Main wire; 4. First edge wire; 5. Second edge wire; 6. Base material to be welded; 7. Ceramic gasket.
  • orientation words such as “front, back, up, down, left, right", “horizontal, vertical, vertical, horizontal”, “top, bottom” and the like indicate the orientation Or the positional relationship is usually based on the orientation or positional relationship shown in the drawings, only for the convenience of describing the present invention and simplifying the description. Unless otherwise stated, these orientation words do not indicate and imply the device or element referred to. It must have a specific orientation or be constructed and operated in a specific orientation, so it cannot be understood as a limitation on the scope of protection of the present invention: the orientation words “inside and outside” refer to the inside and outside relative to the outline of each component itself.
  • spatially relative terms such as “above”, “above”, “above”, “above”, etc. can be used here to describe as shown in the figure Shows the spatial position relationship between one device or feature and other devices or features. It should be understood that spatially relative terms are intended to encompass different orientations in use or operation in addition to the orientation of the device as described in the figures. For example, if a device in the figure is turned over, devices described as “above” or “above” other devices or constructions will be positioned “below the other devices or constructions” or “below” Under its device or structure. " Thus, the exemplary term “above” may include both directions “above” and “below”. The device can also be positioned in other different ways (rotated 90 degrees or at other orientations), and the relative description of space used here is explained accordingly.
  • the invention discloses a three-wire gas-shielded indirect arc welding method.
  • a magnetic field intensity acting on an indirect arc is improved.
  • the arc energy density and welding heat input are greatly improved, the arc penetration ability is enhanced, and the stability of the indirect arc is effectively improved.
  • the distribution space of the three welding wires is greatly reduced, and the torch head is greatly reduced, which improves the practical performance of the technology.
  • the method uses three welding wires and two arc power sources to perform the welding process; specifically, it includes:
  • one of the three welding wires is connected to two of the arc power sources (ie, the positive poles of the first arc power source 1 and the second arc power source 2, and the remaining two welding wires are respectively connected to the first arc power source 1).
  • the negative electrode of the second arc power source 2 the welding workpiece is not connected to the arc power source;
  • the two arc power sources are selected from a combination of two DC power sources, two pulse power sources, one DC power source, and one pulse power source.
  • the above welding wires connecting the two arc power source positive electrodes are arranged in the middle, and the welding wire is called the main wire 3; the remaining two welding wires are respectively arranged on both sides of the main wire, and the two welding wires are called side wires, that is, First side wire 4 and second side wire 5;
  • an angle of 20 ° to 60 ° is formed between the first edge wire 4 and the main wire 3 and between the second edge wire 5 and the main wire 3.
  • the extension lines intersect and the two intersections are on the same horizontal line; as shown in FIG. 5, the orthographic projection of the edge wire and the main wire 3 in a plane perpendicular to the welding direction satisfies the following conditions: the first edge wire 4
  • the angle between the main wire 3 and the second side wire 5 and the main wire 3 is 0 ° to 5 °, and the two side wires are mirror-symmetrical with respect to the main wire 3;
  • the two arc power sources are output simultaneously, so that a coupling indirect arc is generated at the intersection between the main wire 3 and the side wire, and the two indirect arcs are deflected toward the main wire 3 at the same time and coupled as a current.
  • a single electric arc with increased density and enhanced penetration capability; the coupled indirect arc is used to process the base metal 6 to be welded, and the main wire 3 is adjusted according to a preset welding process under the condition that the welding current is maintained.
  • the wire feed speed controls the arc energy, so that the welding wire metal and part of the base metal 6 to be welded are melted, and the welded joint can be formed after cooling and solidification, realizing a welding process with high deposition rate and large penetration depth.
  • the total welding current range is maintained at 250A to 600A, the wire feed speed of the main wire 3 is controlled at 3.5m / min to 15m / min, and the welding speed is controlled at 0.3m / min to 2m / min;
  • the torches can be arranged vertically downward or at a certain inclination angle with the horizontal line, and the inclination angle ranges from 20 ° to 120 °.
  • the welding method a shielding gas welding process employed may be CO 2, Ar or in a mixed gas of CO 2 and Ar, the protective gas flow are 0.1 ⁇ 50 L / min.
  • the invention discloses a device for realizing the above-mentioned three-wire gas shielded indirect arc welding method.
  • the device is composed of three welding wires and two arc power sources.
  • one of the three welding wires is connected to the positive electrodes of the two arc power sources, and the welding wire is arranged at the middle position of the three welding wires, and the welding wire is referred to as the main wire 3;
  • the remaining two welding wires are connected to the negative electrodes of the two arc power sources and are arranged on both sides of the main wire, respectively, and these two welding wires are called side wires;
  • the two side wires form an angle of 20 ° to 60 ° with the main wire 3, and the orthographic projection of the side wire and the main wire 3 in a plane perpendicular to the welding direction satisfies the following conditions:
  • the angle between the wire and the main wire 3 is 0 ° to 5 °, and the two side wires are mirror-symmetrical with respect to the main wire 3;
  • the welding workpiece is not connected to the arc power source; the two side wires intersect the extension lines of the main wire 3 and the two intersection points are on the same horizontal line;
  • the two arc power sources are output simultaneously, so that a coupling indirect arc is generated at the intersection between the main wire 3 and the side wire, and the two indirect arcs are deflected toward the main wire at the same time and coupled to a current density.
  • Increased single arc with enhanced penetration ability; the coupled indirect arc is used to process the base metal 6 to be welded, and the welding current is maintained, and according to a preset welding process, the main wire 3 is adjusted by adjusting The wire feed speed controls the arc energy, and the metal in the thickness direction of the base metal 6 to be welded is melted. After cooling and solidifying, a weld joint can be formed, and a welding process with a high deposition rate and a large penetration depth is achieved.
  • the invention also discloses a surfacing method based on three-wire gas protection indirect arc, which comprises adopting the above-mentioned method, and in the process of implementing surfacing, respectively, parallel to the vertical plane where the welding wire is located and vertical to the where the welding wire is vertical.
  • the surface is in the direction of overlay welding, and the three welding wires are used as the filler metal, and the welding of the filler metal and the welding workpiece is realized by using the arc column heat coupled with the heat transferred by the droplet transfer of the indirect arc.
  • the present invention also discloses a high-efficiency welding process based on a three-wire gas shielded indirect arc.
  • the method includes the method described above, and during the welding process, the welding direction is parallel to the vertical plane where the welding wire is located.
  • the mirror-symmetrical wire arrangement is adopted to achieve a single-pass welding penetration greater than or equal to 10mm when the groove angle is less than 20 °. It can be seen that the angle of the groove used in the present invention is smaller and can be reduced to less than 10 °, which can meet the single-pass welding of high-speed thin plates and medium-thick plates.
  • the present invention realizes arc shape concentration and arc energy controllability in indirect arc welding by adopting a mirror-symmetrical wire arrangement method, a specific wire connection method, and control of the wire feeding speed of the main wire 3.
  • Adopting mirror symmetrical welding wire arrangement and specific welding wire connection method main wire is connected to the positive pole of the power supply and side wire is connected to the negative pole of the power supply
  • the spatial distribution of the magnetic field between the indirect arcs is optimized, and the magnetic field strength between the welding wires is increased; meanwhile,
  • the indirect arcs formed between the main wire 3 and the two side wires are deflected toward the main wire at the same time, and the two indirect arcs are directly coupled into a single arc with a large current density.
  • the obtained indirect arc form is concentrated, the energy density of the arc is increased, the stiffness is increased, and the penetration ability is enhanced.
  • the indirect arc arc voltage is controlled by adjusting the wire feeding speed of the main wire 3 to achieve the purpose of controlling the amount of indirect arc energy.
  • the invention utilizes a coupled single arc to improve the indirect arc penetration ability while controlling the arc energy size, and meets the high-efficiency welding requirements such as flat-plate surfacing and single-pass forming of thin and medium-thick plates.
  • Example 1 Three-wire gas shielded indirect arc parallel surfacing.
  • the angle between the main wire 3 and the horizontal direction is 45 °
  • the angle between the first side wire 4 and the second side wire 5 and the main wire 3 is 30 °
  • the two side wires are distributed on the main Both sides of the wire 3 are mirror-symmetrical with respect to the main wire, and the two sides of the wire are in contact with the main wire 3 respectively, and the two contact points are on the same horizontal line.
  • the three steel welding wire model is ER50-6
  • the diameter of the main wire 3 is 1.6mm
  • the diameter of both sides of the wire is 1.2mm
  • the power source uses a DC power source as the first arc power source 1 and a pulsed DC power source as the second arc power source 2
  • the corresponding shielding gas is a mixture of 80% CO 2 and 20% Ar
  • plane overlay welding is performed on the Q235 steel plate as the base material, and the direction of the overlay welding is parallel to the vertical plane where the wire is located (parallel overlay welding).
  • the plate size is 200mm ⁇ 100mm ⁇ 6mm
  • welding torch height is 5mm
  • total welding current is 320A
  • welding speed is 600mm / min.
  • FIG. 6 it is a comparison of surfacing morphology under different welding currents before and after the improvement of three-wire indirect arc welding. From the figure, it can be seen that the above-mentioned wire arrangement method and specific wire connection method (the main wire is connected to the positive electrode of the power supply, The side wire is connected to the negative electrode of the power supply), and the penetration depth and melting amount of the base material are greatly improved, thereby demonstrating that the three-wire gas-shielded indirect arc surfacing welding has the advantages of achieving a high deposition rate and a large penetration depth.
  • Example 2 Three-wire gas shielded indirect arc vertical overlay welding.
  • the angle between the main wire 3 and the horizontal direction is 45 °
  • the angle between the two side wires and the main wire 3 is 30 °
  • the two side wires are distributed on both sides of the main wire 3 and are about the main
  • the filaments are mirror-symmetric, and the two filaments are in contact with the main filament 3 respectively, and the two contact points are on the same horizontal line.
  • the three steel welding wire model is ER50-6, the diameter of the main wire 3 is 1.6mm, the diameter of both sides of the wire is 1.2mm, the power source uses a DC power supply and a pulsed DC power supply, and the corresponding shielding gas is 80% CO 2 and 20% Ar mixed gas; plane surfacing welding is performed on the Q235 steel plate as the base material, and the direction of surfacing is perpendicular to the vertical plane where the wire is located (vertical surfacing), the plate size is 200mm ⁇ 100mm ⁇ 6mm, the welding gun height is 5mm, and the total welding current The welding speed is 360A and the welding speed is 650mm / min. The results show that the welding joint is smooth and uniform, combines well with the base metal, has no defects, and has a wide welding width. This proves that the three-wire gas shielded indirect arc surfacing welding has deposition. High efficiency, high welding efficiency.
  • Example 3 Single-pass forming gas shielded three wire indirect arc welding.
  • the distribution of the welding wire used is shown in Figure 5.
  • the angle between the main wire 3 and the side wire is 30 degrees.
  • the wire with a main wire diameter of 1.6mm and a diameter of 1.2mm on both sides is used.
  • the welding wire model is ER50-6.
  • the base material is Q235 low carbon steel, the plate size is 300mm ⁇ 150mm ⁇ 10mm, the bevel angle is 20 °, there is no blunt edge, the back side uses ceramic gasket 7, the butt gap is 2mm, the total welding current used is 320A, and the welding speed At 735 mm / min, a single-pass welded joint was obtained. Due to its smaller bevel angle, higher welding wire deposition rate and faster welding speed, it has the characteristics of high efficiency.

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Abstract

一种三丝气体保护间接电弧焊方法、装置及其应用，焊接前，先将三根焊丝中的一根焊丝连接至第一电弧电源（1）和第二电弧电源（2）的正极，其余两根焊丝分别连接第一电弧电源（1）和第二电弧电源（2）的负极，焊接工件不与电弧电源连接，将连接两个电弧电源正极的焊丝排布在中间，其余的两根焊丝分别排布在两边；装置由三根焊丝以及两个电弧电源组成；焊接方法用来实施堆焊。

Description

一种三丝气体保护间接电弧焊方法、装置及其应用 技术领域
本发明属于材料加工技术领域，涉及一种间接电弧焊方法，具体而言，尤其涉及一种三丝气体保护间接电弧焊方法、装置及其应用。
背景技术
目前，熔化极气体保护焊已在各行各业中广泛应用，但仍难已满足现代制造业飞速发展的需求。
近年来，一些高效的熔化极气体保护焊陆续被提出和推广应用。在这些方法中，提高焊接效率的关键是提高焊丝熔覆效率，也就是增加焊接电流。但由于电源、工件以及焊丝三者之间形成一个回路，流经焊丝和工件的电流势必相等。因此，通过增大焊接电流来增加焊丝熔覆率势必会增加工件的热输入，而过大的热输入会导致焊接接头性能下降、焊接变形增加等一系列问题。
由此，间接电弧焊方法被提出，其与传统电弧焊的区别在于工件不接触电源，电弧只产生于电极之间。目前研究的间接电弧主要为双丝间接电弧 [1-3]，然而现有的双丝间接电弧焊存在明显的局限性，如图1所示，双丝间接电弧焊特别是其电源连接方式和焊丝分布方式，使得双丝间接电弧焊在电流增大到一定值时，在电磁作用下会发生电弧分散现象，无法保证焊接过程的稳定性，且熔敷效率和焊接效率都受限制。因此存在对母材热输入不足、焊接参数选择狭窄等缺点。
针对双丝间接电弧的不足，发明专利(申请号为201510145041.4)提出了一种三丝气体保护间接电弧焊接的方法，如图2、图3所示，为三丝间接电弧焊原理及四种焊丝排布方式(如图3中，a为三根焊丝分布在一个平面上；b为边丝分别在中间焊丝的两侧；c为边丝同时在中间焊丝的一侧；d为中间焊丝与水平线倾斜一定角度等等，图中z为主丝即中间焊 丝，b为边丝。)通过采用不同的电源模式组合和焊丝排布方式，其有效提升了焊丝熔化效率以及扩大了间接电弧焊接参数的可调范围。但是该技术方案仍有些许不足，结构中两边丝关于主丝中心对称使得主丝与边丝之间的磁场关于主丝中心对称，致使两间接电弧相互独立并且在尾部发生偏移，这样造成电弧作用于母材的面积增大，电弧能量密度降低，电弧的穿透力下降，导致对工件的热输入仍显不足。除此之外，三根焊丝分布空间较大，造成焊炬体积过大，不利于该技术的推广应用。
基于上述间接电弧焊存在的缺陷及其产生的原因，有必要提供一种的三丝气体保护间接电弧焊的方法及装置用以解决上述问题。
参考文献：
[1].曹梅青，邹增大，王春茂，等.焊接电流对双丝间接电弧焊电弧特性的影响[J].焊接学报，2005，26(12):47－50.
[2].曹梅青，邹增大，曲仕尧.双丝间接电弧氩气保护焊的熔滴过渡与电弧形态[J].焊接学报，2012，33(6):47－50.
[3].张顺善，邹勇，邹增大.磁场对双丝间接电弧焊熔滴过渡的影响[J].焊接学报，2011,32(6)：69-72.
发明内容
根据上述提出现有的三丝间接电弧焊方法存在的电弧分别向两侧偏转的技术问题，而提供一种的三丝气体保护间接电弧焊接方法、装置及其应用。本发明主要通过采用镜像对称式焊丝排布方式和特定的焊丝连接方式(即主丝接电源正极、边丝接电源负极)，在对间接电弧之间的磁场空间分布优化的同时增强了焊丝之间的磁场强度，从而解决了焊接过程中的两间接电弧尾部偏转的问题，提高了电弧能量密度以及电弧挺度，可以实现工件的焊接热输入的有效设计和调控，进而提升该技术的应用范围。本发明采用的技术手段如下：
一种三丝气体保护间接电弧焊方法，所述方法通过三根焊丝以及两个电弧电源实施焊接过程；其特征在于，具体包括：
焊接前，先将三根所述焊丝中的一根焊丝连接至两个所述电弧电源的正极，其余的两根焊丝分别连接至两个所述电弧电源的负极，焊接工件不与所述电弧电源连接；随后将上述连接两个电弧电源正极的焊丝排布在中间，称该焊丝为主丝；其余的两根焊丝分别排布在所述主丝的两边，称这两根焊丝为边丝；
两所述边丝分别与所述主丝构成20°～60°的夹角，两所述边丝与所述主丝的延长线分别相交且两交点在同一水平线上；所述边丝与所述主丝在垂直于焊接方向的平面内的正投影满足如下条件：所述边丝与所述主丝的夹角为0°～5°且两所述边丝关于所述主丝镜像对称；
焊接时，令所述两个电弧电源同时输出，使得所述主丝以及所述边丝之间的交点上产生耦合的、且电弧形态集中的间接电弧(由于采用了所述焊丝排布方式，磁场分布得到优化，两间接电弧形态变的集中)，当采用所述焊丝极性，两间接电弧向所述主丝同时偏转并耦合为电流密度增大的、穿透能力增强的单个电弧；采用该耦合间接电弧对母材进行加工，根据预设的焊接工艺，使焊丝金属和部分母材金属熔化，冷却凝固后即可形成焊接接头，实现高熔敷率且具有较大熔深的焊接过程。
进一步地，焊接总电流(是指焊接过程中总的焊接电流，由于耦合前后总焊接电流是没有变化的，所以耦合后焊接总电流等同于焊接总电流)范围保持在250A～600A，所述主丝的送丝速度控制在3.5m/min～15m/min，焊接速度控制在0.3m/min～2m/min；三根所述焊丝组成的焊炬可垂直向下排布或者与水平线成一定的倾斜角排布，其倾角范围为20°～120°。
进一步地，两个所述电弧电源选用两个直流电源、两个脉冲电源、一个直流电源和一个脉冲电源的组合中的一种。
进一步地，所述焊接方法进行焊接过程中所采用的保护气体可以为CO 2、Ar中的一种或CO 2和Ar的混合气，保护气流均为0.1～50 L/min。
本发明公开了一种实现上述的三丝气体保护间接电弧焊方法的装置，其特征在于，所述装置由三根焊丝以及两个电弧电源组成；
其中，三根所述焊丝中的一根焊丝连接至两个所述电弧电源的正极上，且使得该焊丝排布在三根焊丝中间位置处，称该焊丝为主丝；
其余的两根焊丝连接至两个所述电弧电源的负极上，且分别排布在所述主丝的两边，称这两根焊丝为边丝；
两所述边丝分别与所述主丝构成20°～60°的夹角，所述边丝与所述主丝在垂直于焊接方向的平面内的正投影满足如下条件：所述边丝与所述主丝的夹角为0°～5°且两所述边丝关于所述主丝镜像对称；
焊接工件不与所述电弧电源连接；两所述边丝与所述主丝的延长线分别相交且两交点在同一水平线上；
焊接时，令所述两个电弧电源同时输出，使得所述主丝以及所述边丝之间的交点上产生耦合间接电弧的、且电弧形态集中的间接电弧，两间接电弧向所述主丝同时偏转并耦合为电流密度增大的、穿透能力增强的单个电弧；采用该耦合间接电弧对母材进行加工，根据预设的焊接工艺，使焊丝金属和部分母材金属熔化，冷却凝固后即可形成焊接接头，实现高熔敷率且具有较大熔深的焊接过程。
进一步地，三根所述焊丝组成的整体焊炬可垂直向下排布或者与水平线成一定的倾斜角排布，其倾角范围为20°～120°。
进一步地，两个所述电弧电源选用两个直流电源、两个脉冲电源、一个直流电源和一个脉冲电源的组合中的一种。
进一步地，所述焊接方法进行焊接过程中所采用的保护气体可以为CO 2、Ar中的一种或CO 2和Ar的混合气，保护气流均为0.1～50 L/min。
本发明还公开了一种基于三丝气体保护间接电弧的堆焊方法，其特征在于，包括采用上述的方法，并在实施堆焊过程中，分别以平行于焊丝所在竖直面和以垂直于焊丝所在竖直面为堆焊方向，以三根所述焊丝为填充金属，利用所述耦合间接电弧的弧柱热量和熔滴过渡所携带的热量，实现填充金属与焊接工件的焊接。
本发明还公开了一种基于三丝气体保护间接电弧的高效焊接工艺，其特征在于：包括采用上述的方法，并在实施焊接过程中，以平行于焊丝所在竖直面为焊接方向，采用镜像对称式焊丝排布方式，以实现坡口角度小于20°条件下获得大于或等于10mm单道焊接熔深。
较现有技术相比，本发明具有以下优点：
1)本发明提供的三丝气体保护间接电弧焊工件不接电源，电弧只在焊丝端部形成间接电弧，工件热输入增大、焊丝熔敷系数高、节约电能。
2)本发明通过采用镜像对称式焊丝排布方式，实现了间接电弧之间的磁场空间分布优化，增强了焊丝之间的磁场强度，在使两间接电弧形态集中的同时解决了焊接过程中的两间接电弧尾部分别向两侧偏转的问题。
3)本发明通过采用特定的焊丝连接方式(即主丝接电源正极、边丝接电源负极)，使两间接电弧直接耦合为单个电弧，提高了电弧能量密度以及电弧挺度，电弧的穿透能力增大。
除此之外，本发明方法可以有效压缩三根焊丝分布空间，减少复合焊炬体积，有利于该技术的推广应用。
附图说明
为了更清楚地说明本发明实施例或现有技术中的技术方案，下面将对实施例或现有技术描述中所需要使用的附图做以简单地介绍，显而易见地，下面描述中的附图是本发明的一些实施例，对于本领域普通技术人员来讲，在不付出创造性劳动性的前提下，还可以根据这些附图获得其他的附图。
图1为现有技术中双丝间接电弧焊原理示意图。
图2为现有技术中三丝间接电弧焊原理示意图。
图3为现有技术中三丝间接电弧焊焊丝排布方式示意图。
图4为本发明三丝间接电弧焊原理示意图。
图5为本发明三丝间接电弧焊焊丝分布方式示意图，(Ⅰ)为视线垂直于焊接方向的示意图，(Ⅱ)为视线平行于焊接方向的示意图。
图6为本发明堆焊效果与现有技术中三丝间接电弧堆焊效果对比图。
图7为本发明中三丝气体保护间接电弧焊实施例示意图。
图中：1、第一电弧电源；2、第二电弧电源；3、主丝；4、第一边丝；5、第二边丝；6、待焊母材；7、陶瓷衬垫。
具体实施方式
需要说明的是，在不冲突的情况下，本发明中的实施例及实施例中的特征可以相互组合。下面将参考附图并结合实施例来详细说明本发明。
为使本发明实施例的目的、技术方案和优点更加清楚，下面将结合本发明实施例中的附图，对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。以下对至少一个示例性实施例的描述实际上仅仅是说明性的，决不作为对本发明及其应用或使用的任何限制。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。
需要注意的是，这里所使用的术语仅是为了描述具体实施方式，而非意图限制根据本发明的示例性实施方式。如在这里所使用的，除非上下文另外明确指出，否则单数形式也意图包括复数形式，此外，还应当理解的是，当在本说明书中使用术语“包含”和/或“包括”时，其指明存在特征、步骤、操作、器件、组件和/或它们的组合。
除非另外具体说明，否则在这些实施例中阐述的部件和步骤的相对布置、数字表达式和数值不限制本发明的范围。同时，应当清楚，为了便于描述，附图中所示出的各个部分的尺寸并不是按照实际的比例关系绘制的。对于相关领域普通技术人员己知的技术、方法和设备可能不作详细讨论，但在适当情况下，所述技术、方法和设备应当被视为授权说明书的一部分。在这里示出和讨论的所有示例中，任向具体值应被解释为仅仅是示例性的，而不是作为限制。因此，示例性实施例的其它示例可以具有不同的值。应注意到：相似的标号和字母在下面的附图中表示类似项，因此，一旦某一项在一个附图中被定义，则在随后的附图中不需要对其进行进一步讨论。
在本发明的描述中，需要理解的是，方位词如“前、后、上、下、左、右”、“横向、竖向、垂直、水平”和“顶、底”等所指示的方位或位置关系通常是基于附图所示的方位或位置关系，仅是为了便于描述本发明和简化描述，在未作相反说明的情况下，这些方位词并不指示和暗示所指的装置或元件必须具有特定的方位或者以特定的方位构造和操作，因此不能理解为对 本发明保护范围的限制：方位词“内、外”是指相对于各部件本身的轮廓的内外。
为了便于描述，在这里可以使用空间相对术语，如“在……之上”、“在……上方”、“在……上表面”、“上面的”等，用来描述如在图中所示的一个器件或特征与其他器件或特征的空间位置关系。应当理解的是，空间相对术语旨在包含除了器件在图中所描述的方位之外的在使用或操作中的不同方位。例如，如果附图中的器件被倒置，则描述为“在其他器件或构造上方”或“在其他器件或构造之上”的器件之后将被定位为“在其他器件或构造下方”或“在其位器件或构造之下”。因而，示例性术语“在……上方”可以包括“在……上方”和“在……下方”两种方位。该器件也可以其他不同方式定位(旋转90度或处于其他方位)，并且对这里所使用的空间相对描述作出相应解释。
此外，需要说明的是，使用“第一”、“第二”等词语来限定零部件，仅仅是为了便于对相应零部件进行区别，如没有另行声明，上述词语并没有特殊含义，因此不能理解为对本发明保护范围的限制。
本发明公开了一种三丝气体保护间接电弧焊方法，通过采用镜像对称式焊丝排布方式和主丝接电源正极、边丝接电源负极的焊丝连接方式，提高了作用于间接电弧的磁场强度，有效解决了三丝气体保护间接电弧焊接方法中的两间接电弧尾部偏移的问题，同时在保持焊接电流不变的条件下，通过调节主丝送丝速度提高了间接电弧弧压，使得间接电弧能量密度和焊接热输入均大幅提高，电弧穿透能力增强，间接电弧的稳定性也得到有效提升。除此之外，三根焊丝的分布空间大幅减小，焊枪枪头大幅减小，提高了该技术的实用性能。
如图4所示，所述方法通过三根焊丝以及两个电弧电源实施焊接过程；具体包括：
焊接前，先将三根所述焊丝中的一根焊丝连接至两个所述电弧电源(即第一电弧电源1和第二电弧电源2的正极，其余的两根焊丝分别连接第一电弧电源1和第二电弧电源2的负极，焊接工件不与所述电弧电源连接；两个所述电弧电源选用两个直流电源、两个脉冲电源、一个直流电源和一个脉冲 电源的组合中的一种。
随后将上述连接两个电弧电源正极的焊丝排布在中间，称该焊丝为主丝3；其余的两根焊丝分别排布在所述主丝的两边，称这两根焊丝为边丝，即第一边丝4和第二边丝5；
在空间范围内，第一边丝4与主丝3之间以及第二边丝5与主丝3之间构成20°～60°的夹角，两所述边丝与所述主丝3的延长线分别相交且两交点在同一水平线上；如图5所示，所述边丝与所述主丝3在垂直于焊接方向的平面内的正投影满足如下条件：所述第一边丝4与所述主丝3以及第二边丝5与所述主丝3之间的夹角为0°～5°且两所述边丝关于所述主丝3镜像对称；
焊接时，令所述两个电弧电源同时输出，使得所述主丝3以及所述边丝之间的交点上产生耦合间接电弧，两间接电弧会向所述主丝3同时偏转并耦合为电流密度增大的、穿透能力增强的单个电弧；采用该耦合间接电弧对待焊母材6进行加工，在保持焊接电流不变的条件下，根据预设的焊接工艺，通过调节所述主丝3的送丝速度控制电弧能量，使焊丝金属和部分待焊母材6金属熔化，冷却凝固后即可形成焊接接头，实现高熔敷率且具有较大熔深的焊接过程。
焊接总电流范围保持在250A～600A，所述主丝3的送丝速度控制在3.5m/min～15m/min，焊接速度控制在0.3m/min～2m/min；三根所述焊丝组成的焊炬可垂直向下排布或者与水平线成一定的倾斜角排布，其倾角范围为20°～120°。所述焊接方法进行焊接过程中所采用的保护气体可以为CO 2、Ar中的一种或CO 2和Ar的混合气，保护气流均为0.1～50 L/min。
本发明公开了一种实现上述的三丝气体保护间接电弧焊方法的装置，所述装置由三根焊丝以及两个电弧电源组成；
其中，三根所述焊丝中的一根焊丝连接至两个所述电弧电源的正极上，且使得该焊丝排布在三根焊丝中间位置处，称该焊丝为主丝3；
其余的两根焊丝连接至两个所述电弧电源的负极上，且分别排布在所述主丝的两边，称这两根焊丝为边丝；
两所述边丝分别与所述主丝3构成20°～60°的夹角，所述边丝与所述 主丝3在垂直于焊接方向的平面内的正投影满足如下条件：所述边丝与所述主丝3的夹角为0°～5°且两所述边丝关于所述主丝3镜像对称；
焊接工件不与所述电弧电源连接；两所述边丝与所述主丝3的延长线分别相交且两交点在同一水平线上；
焊接时，令所述两个电弧电源同时输出，使得所述主丝3以及所述边丝之间的交点上产生耦合间接电弧，两间接电弧会向所述主丝同时偏转并耦合为电流密度增大的、穿透能力增强的单个电弧；采用该耦合间接电弧对待焊母材6进行加工，在保持焊接电流不变的条件下，根据预设的焊接工艺，通过调节所述主丝3的送丝速度控制电弧能量，待焊母材6厚度方向金属熔化，冷却凝固后即可形成焊接接头，实现高熔敷率且具有较大熔深的焊接过程。
本发明还公开了一种基于三丝气体保护间接电弧的堆焊方法，包括采用上述的方法，并在实施堆焊过程中，分别以平行于焊丝所在竖直面和以垂直于焊丝所在竖直面为堆焊方向，以三根所述焊丝为填充金属，利用所述耦合间接电弧的弧柱热量和熔滴过渡所携带的热量，实现填充金属与焊接工件的焊接。
如图7所示，本发明还公开了一种基于三丝气体保护间接电弧的高效焊接工艺，包括采用上述的方法，并在实施焊接过程中，以平行于焊丝所在竖直面为焊接方向，采用镜像对称式焊丝排布方式，以实现坡口角度小于20°条件下获得大于或等于10mm单道焊接熔深。可以看到本发明采用的坡口角度更小，可降至10°以下，满足薄板高速及中厚板的单道完成焊接。
本发明具体工作原理为：
本发明通过采用镜像对称式的焊丝排布方式和特定的焊丝连接方式以及对主丝3送丝速度的控制实现了间接电弧焊中的电弧形态集中及电弧能量可控。采用镜像对称式焊丝排布方式和特定的焊丝连接方式(主丝接电源正极、边丝接电源负极)，间接电弧之间的磁场空间分布得到优化，焊丝之间的磁场强度得到提高；同时，主丝3和两个边丝之间分别形成的间接电弧会同时向主丝偏转，两间接电弧直接耦合为一个电流密度较大的单电弧。因此，所获得的间接电弧形态集中，电弧的能量密度增加，挺度增大，穿透能力增强。除此之外，在保持焊接电流不变的条件下，通过调节主丝3送丝速 度使得间接电弧弧压受控，达到控制间接电弧能量大小的目的。本发明利用耦合的单电弧在提升间接电弧穿透能力的同时使电弧能量大小可控，满足平板堆焊以及薄板、中厚板单道成形等高效焊接需求。
实施例1：三丝气体保护间接电弧平行式堆焊。
采用图5中所示焊丝分布方式，主丝3与水平方向的夹角为45°，第一边丝4和第二边丝5分别与主丝3夹角为30°，两边丝分布于主丝3的两侧并且关于主丝镜像对称，并且两边丝分别与主丝3接触，两接触点在同一水平线上。其中，三根钢焊丝型号为ER50-6，主丝3直径为1.6mm，两边丝直径均为1.2mm，电源采用一个直流电源作为第一电弧电源1和一个脉冲直流电源作为第二电弧电源2，对应的保护气体为80％CO 2和20％Ar混合气；在Q235钢板为母材进行了平面堆焊，堆焊方向与焊丝所在竖直面平行(平行式堆焊)，板材尺寸为200mm×100mm×6mm，焊枪高度为5mm，焊接总电流为320A，焊接速度为600mm/min，结果得到了表明光滑均匀一致，和母材结合良好，没有缺陷的焊接接头。
如图6所示，为三丝间接电弧焊改进前后不同焊接电流下的堆焊形貌对比，从图中可以看到采用上述焊丝排布方式及特定的焊丝连接方式(主丝接电源正极、边丝接电源负极)，母材的熔深及熔化量都有较大提升，从而论证了本三丝气体保护间接电弧堆焊具有实现高熔敷率且较大熔深的优点。
实施例2：三丝气体保护间接电弧垂直式堆焊。
采用图5中所示焊丝分布方式，主丝3与水平方向的夹角为45°，两个边丝与主丝3夹角为30°，两边丝分布于主丝3的两侧并且关于主丝镜像对称，并且两边丝分别与主丝3接触，两接触点在同一水平线上。其中，三根钢焊丝型号为ER50-6，主丝3直径为1.6mm，两边丝直径均为1.2mm，电源采用一个直流电源和一个脉冲直流电源，对应的保护气体为80％CO 2和20％Ar混合气；在Q235钢板为母材进行了平面堆焊，堆焊方向与焊丝所在竖直面垂直(垂直式堆焊)，板材尺寸为200mm×100mm×6mm，焊枪高度为5mm，焊接总电流为360A，焊接速度为650mm/min，结果得到了表明光滑均匀一致，和母材结合良好，没有缺陷、熔宽较宽的焊接接头；从而论证了本三丝气体保护间接电弧堆焊具有熔敷效率高、堆焊效率高的优点。
实施例3：单道成形气体保护三丝间接电弧焊。
如图7，其采用的焊丝分布见图5所示，主丝3和边丝夹角为30度，采用主丝直径1.6mm，两边丝直径1.2mm的焊丝，焊丝型号为ER50-6，焊接母材为Q235低碳钢，板材尺寸为300mm×150mm×10mm，坡口角度为20°，无钝边，背面使用陶瓷衬垫7，对接间隙为2mm，采用的总焊接电流为320A，焊接速度为735 mm/min，得到了单道成形很好的焊接接头。由于其坡口角度较小，焊丝熔敷率较高，焊接速度较快，因此具有高效的特点。
最后应说明的是：以上各实施例仅用以说明本发明的技术方案，而非对其限制；尽管参照前述各实施例对本发明进行了详细的说明，本领域的普通技术人员应当理解：其依然可以对前述各实施例所记载的技术方案进行修改，或者对其中部分或者全部技术特征进行等同替换；而这些修改或者替换，并不使相应技术方案的本质脱离本发明各实施例技术方案的范围。

Claims (10)

  1. 一种三丝气体保护间接电弧焊方法，所述方法通过三根焊丝以及两个电弧电源实施焊接过程；其特征在于，具体包括：
    焊接前，先将三根所述焊丝中的一根焊丝连接至两个所述电弧电源的正极，其余的两根焊丝分别连接至两个所述电弧电源的负极，焊接工件不与所述电弧电源连接；随后将上述连接两个电弧电源正极的焊丝排布在中间，称该焊丝为主丝；其余的两根焊丝分别排布在所述主丝的两边，称这两根焊丝为边丝；
    两所述边丝分别与所述主丝构成20°～60°的夹角，两所述边丝与所述主丝的延长线分别相交且两交点在同一水平线上；所述边丝与所述主丝在垂直于焊接方向的平面内的正投影满足如下条件：所述边丝与所述主丝的夹角为0°～5°且两所述边丝关于所述主丝镜像对称；
    焊接时，令所述两个电弧电源同时输出，使得所述主丝以及所述边丝之间的交点上产生耦合的、且电弧形态集中的间接电弧，两间接电弧向所述主丝同时偏转并耦合为电流密度增大的、穿透能力增强的单个电弧；采用该耦合间接电弧对母材进行加工，根据预设的焊接工艺，使焊丝金属和部分母材金属熔化，冷却凝固后即可形成焊接接头，实现高熔敷率且具有较大熔深的焊接过程。
  2. 根据权利要求1所述的三丝气体保护间接电弧焊方法，其特征在于，焊接总电流范围保持在250A～600A，所述主丝的送丝速度控制在3.5m/min～15m/min，焊接速度控制在0.3m/min～2m/min；三根所述焊丝组成的焊炬可垂直向下排布或者与水平线成一定的倾斜角排布，其倾角范围为20°～120°。
  3. 根据权利要求1所述的三丝气体保护间接电弧焊方法，其特征在于，两个所述电弧电源选用两个直流电源、两个脉冲电源、一个直流电源和一个脉冲电源的组合中的一种。
  4. 根据权利要求1所述的三丝气体保护间接电弧焊方法，其特征在于，所述焊接方法进行焊接过程中所采用的保护气体可以为CO 2、Ar中的一种或CO 2和Ar的混合气，保护气流均为0.1～50L/min。
  5. 一种实现如权利要求1-4任意一项权利要求所述的三丝气体保护间接电弧焊方法的装置，其特征在于，
    所述装置由三根焊丝以及两个电弧电源组成；
    其中，三根所述焊丝中的一根焊丝连接至两个所述电弧电源的正极上，且使得该焊丝排布在三根焊丝中间位置处，称该焊丝为主丝；
    其余的两根焊丝连接至两个所述电弧电源的负极上，且分别排布在所述主丝的两边，称这两根焊丝为边丝；
    两所述边丝分别与所述主丝构成20°～60°的夹角，所述边丝与所述主丝在垂直于焊接方向的平面内的正投影满足如下条件：所述边丝与所述主丝的夹角为0°～5°且两所述边丝关于所述主丝镜像对称；
    焊接工件不与所述电弧电源连接；两所述边丝与所述主丝的延长线分别相交且两交点在同一水平线上；
    焊接时，令所述两个电弧电源同时输出，使得所述主丝以及所述边丝之间的交点上产生耦合的、且电弧形态集中的间接电弧，两间接电弧向所述主丝同时偏转并耦合为电流密度增大的、穿透能力增强的单个电弧；采用该耦合间接电弧对母材进行加工，根据预设的焊接工艺，使焊丝金属和部分母材金属熔化，冷却凝固后即可形成焊接接头，实现高熔敷率且具有较大熔深的焊接过程。
  6. 根据权利要求5所述的装置，其特征在于，三根所述焊丝组成的整体焊炬可垂直向下排布或者与水平线成一定的倾斜角排布，其倾角范围为20°～120°。
  7. 根据权利要求5所述的装置，其特征在于，两个所述电弧电源选用 两个直流电源、两个脉冲电源、一个直流电源和一个脉冲电源的组合中的一种。
  8. 根据权利要求5所述的装置，其特征在于，所述焊接方法进行焊接过程中所采用的保护气体可以为CO 2、Ar中的一种或CO 2和Ar的混合气，保护气流均为0.1～50L/min。
  9. 一种基于三丝气体保护间接电弧的堆焊方法，其特征在于，包括如权利要求1-4任意一项所述的方法，并在实施堆焊过程中，分别以平行于焊丝所在竖直面和以垂直于焊丝所在竖直面为堆焊方向，以三根所述焊丝为填充金属，利用所述耦合间接电弧的弧柱热量和熔滴过渡所携带的热量，实现填充金属与焊接工件的焊接。
  10. 一种基于三丝气体保护间接电弧的高效焊接工艺，其特征在于：包括如权利要求1-4任意一项所述的方法，并在实施焊接过程中，以平行于焊丝所在竖直面为焊接方向，采用镜像对称式焊丝排布方式，以实现坡口角度小于20°条件下获得大于或等于10mm单道焊接熔深。
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