WO2021057307A1 - 一种mag仰对接单面焊双面成型焊接方法 - Google Patents

一种mag仰对接单面焊双面成型焊接方法 Download PDF

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WO2021057307A1
WO2021057307A1 PCT/CN2020/108955 CN2020108955W WO2021057307A1 WO 2021057307 A1 WO2021057307 A1 WO 2021057307A1 CN 2020108955 W CN2020108955 W CN 2020108955W WO 2021057307 A1 WO2021057307 A1 WO 2021057307A1
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welding
groove
sided
arc
mag
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PCT/CN2020/108955
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English (en)
French (fr)
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李晓辉
武永亮
王飞
易冉
陈良江
刘坚
陈建
陈娜娜
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中车株洲车辆有限公司
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Publication of WO2021057307A1 publication Critical patent/WO2021057307A1/zh

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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
    • B23K9/173—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
    • B23K9/235—Preliminary treatment
    • 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
    • B23K9/24—Features related to electrodes
    • B23K9/28—Supporting devices for 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
    • B23K9/32—Accessories

Definitions

  • the present disclosure belongs to the technical field of welding, and in particular relates to a MAG vertical butt-joining single-sided welding and double-sided forming welding method that can be used for plates.
  • Weld forming is to apply welding on one side of the groove, usually by forming a molten hole at the root of the groove in front of the weld pool, so as to achieve single-sided welding and double-sided forming of the weld.
  • Overhead butt joint is the most difficult type of welding joint among all welding positions.
  • the liquid metal is prone to fall under the action of gravity, and the molten hole is prone to become larger by the arc burning. , Thereby forcing the arc to stop for repair.
  • continuous arc welding cannot be used, defects such as depressions and incomplete penetration of the weld will be formed on the back of the weld, making it difficult for the formation of the back weld to meet the requirements.
  • the present disclosure provides a MAG butt-joint single-sided double-sided forming welding method, which does not need to form a molten hole at the root of the groove in front of the weld pool, and can achieve a single side of the weld.
  • a MAG upward butt joint single-side welding and double-sided forming welding method which uses MAG solid welding wire to perform upward butt welding on a plate with a groove, and the assembly gap of the groove is 1.5mm ⁇ 2.5mm; may include the following steps: bottom layer welding: continuous arc welding; in the welding process, the inclination angle of the welding torch to the welding direction is 90°-100°; using the arc force, the welding torch strikes along the thickness of the plate Pass through the blunt edge of the groove, and push part of the molten liquid in the molten pool to the back of the groove, forming a molten pool on both the groove and the back of the groove; the welding torch will melt the melt After the weld at the front groove of the pool penetrates, when there is no molten hole at the front groove of the molten pool, it keeps advancing at a constant speed along the welding direction to complete the bottom welding; filling layer welding: continuous arc welding; cover surface Layer welding: using continuous arc welding
  • positioning welding may be performed on both ends of the groove of the plate.
  • the positioning welding may include: performing positioning welding on the back surfaces of both ends of the groove, and the welding length may be 5 mm to 10 mm.
  • the bottom layer welding may further include: starting an arc at the end of the groove. After the arc is started, the welding torch can be directly advanced in the welding direction at a uniform speed, and the welding wire can always be molten. 1/4 position at the front of the pool.
  • the filling layer welding may include: starting an arc at the end of the groove. After the arc is started, the welding torch can swing as a transport bar, and it can stay 0.5 when the arc runs to both sides of the groove. s ⁇ 1s.
  • the inclination angle of the welding gun to the welding direction may be 80°-90°.
  • the welding of the cover layer may include: starting an arc at the end of the groove, and after the arc is started, the welding torch can swing as a transport bar to back pressure 1/3 of the front end of the molten pool ⁇ 1/2 place; when the arc runs to both sides of the groove, it can stay for 0.5s to 1s, and fuse 1mm to 2mm on both sides of the edges and corners of the groove.
  • the inclination angle of the welding gun to the welding direction may be 80°-90°.
  • the butt joint portion of the plate may be reserved with an anti-deformation angle bent toward the back of the plate, and the reserved anti-deformation angle may not be greater than 3°.
  • the thickness of the blunt side of the groove may be 0 ⁇ 1.5 mm.
  • the MAG upward butt joint single-sided welding and double-sided forming welding method provided by the present disclosure can reduce the assembly gap of the workpiece and improve the operation process by changing the angle of the welding torch, without forming a molten hole at the root of the groove in front of the weld pool.
  • the process principle of the present disclosure is as follows:
  • the MAG vertical butt single-sided welding and double-sided forming welding method changes the angle of the welding torch of the bottom layer, and the inclination angle of the welding torch to the welding direction is 90°-100°, that is, the welding torch is in a forward attitude, pointing to the groove
  • the arc strength of MAG welding can be used to break down the blunt edge of the groove along the thickness of the plate, and part of the molten pool in the molten pool can be pushed to the back of the groove. Both the mouth and the back of the groove form a molten pool, so as to obtain the remaining height of the back.
  • the MAG vertical butt single-sided welding and double-sided forming welding method provided by the present disclosure adopts MAG continuous arc welding.
  • the continuous arc welding is matched with the angle of the welding gun, so that the molten pool can always be kept at a high temperature (the molten iron is in a molten state), so the groove can be reduced.
  • the assembly gap is 1.5mm ⁇ 2.5mm, and the blunt edge of the groove can be penetrated without the molten hole at the front groove of the molten pool, so as to prevent the occurrence of the molten hole from being burned by the arc.
  • the MAG vertical butt joint single-sided welding and double-sided forming welding method reduces the assembly gap of the groove (while the assembly gap in the prior art is 3 mm to 4 mm or greater), so that the slope of the same specification plate
  • the welding speed is increased during the bottoming welding, the thickness of the bottom welding seam is reduced, the welding seam filling amount is reduced, and the welding labor intensity is reduced; in addition, the welding seam deposition efficiency is improved, and the cooling of the weld pool is shortened. Time reduces the amount of anti-deformation of the plate, so that the reserved anti-deformation angle is not more than 3°.
  • FIG. 1 is a schematic diagram of an implementation of a double-sided forming and welding method for MAG butt butt-joint single-sided welding according to an embodiment of the present disclosure
  • FIG. 2 is a schematic diagram of the structure of plate butting according to an embodiment of the present disclosure
  • Fig. 3 is a groove distribution diagram of a weld seam according to an embodiment of the present disclosure.
  • Fig. 4 is a schematic diagram of a box beam butt welding structure according to an embodiment of the present disclosure.
  • Reference Signs 1-plate; 11-blunt edge; 2-groove; 21-assembly gap; 22-corner; 3-welding wire; 4-welding seam; 41-bottom layer; 42-filling layer; 43- Covering layer; 44- remaining height on the back; 5- welding gun; 6-box beam.
  • FIG. 1 is a schematic diagram of an implementation of a double-sided forming welding method for single-sided butt welding of MAG according to an embodiment of the present disclosure.
  • the MAG vertical butt joint single-sided welding and double-sided forming welding method can be used to perform vertical butt welding on the plate 1 with the groove 2; the plate 1 can Including two plates to be connected, the two plates should be placed horizontally during welding, and they can also have a certain angle, but the misalignment of the two plates should be avoided as far as possible (the amount of misalignment ⁇ 1mm).
  • One end of the two plates to be connected can have a groove 2 for welding, and the groove 2 can be formed by arranging bevels on the adjacent end faces of the two plates (as shown in Figure 2), or it can be made of a single plate.
  • the two plates are formed by arranging inclined surfaces on the adjacent end faces of the two plates.
  • the ungrooved end surface along the thickness direction of the plate 1 (the Z-axis direction in FIG. 1) is called the blunt edge 11, and the thickness of the blunt edge of the groove 2 can be 0 to 1.5 mm;
  • the obtuse angle formed by the slope of the groove extending downward and the lower surface of the plate is called the corner 22, as shown in Figure 2.
  • the opening angle of the groove 2 is related to the thickness of the plate 1, and the conventional opening angle can be 60°.
  • the assembly gap of the groove 2 may be 1.5 mm to 2.5 mm, such as 1.5 mm, 1.8 mm, 2.0 mm, 2.3 mm, 2.5 mm, and so on.
  • the thickness of the blunt edge of the bevel can be increased accordingly.
  • the thickness of the blunt edge of the bevel can be 1 mm to 1.5 mm.
  • the opening of the groove 2 may gradually increase downward along the thickness direction of the plate 1 to facilitate upside welding.
  • an anti-deformation angle bent toward the back of the plate 1 can be reserved at the butt joint of the plate 1 to offset the deformation caused by welding; in some embodiments of the present disclosure, the anti-deformation angle is not greater than 3°.
  • the MAG butt-butt single-sided double-sided forming welding method may adopt MAG welding (Melting Electrode Active Gas Shielded Arc Welding, referred to as gas shielded welding) for the top butt welding with MAG solid wire 3;
  • MAG welding Melting Electrode Active Gas Shielded Arc Welding, referred to as gas shielded welding
  • the MAG butt-butt single-side welding and double-side forming welding method may include the welding of the bottom layer 41, the filling layer 42, and the cover layer 43, which may include:
  • bottom layer 41 welding continuous arc welding can be carried out by the straight-line transport method.
  • the arc is started at the end of the groove 2 (that is, the welding start end a in Figure 1) during arc starting, and there is no need to swing after arc starting.
  • the welding torch can be directly along the welding direction ( Figure 1).
  • the direction indicated by the arrow c in 1) is advanced at a constant speed, and the welding wire 3 can always be at the 1/4 position of the front end of the molten pool (the molten pool is elliptical, the long axis is along the welding direction, and the direction toward the final welding end b is the front end).
  • the inclination angle of the welding gun 5 to the welding direction can be 90°-100°, such as 90°, 92°, 94.5°, 96°, 98°, 100°, etc.;
  • the included angle in the width direction of the slit 4 (the Y-axis direction in FIG. 1) may be 90°.
  • the welding torch can penetrate the blunt edge 11 in the thickness direction of the plate 1 and push part of the molten liquid in the molten pool to the back of the groove 2 by using the arc force. A molten pool is formed.
  • judging whether a molten pool is formed on the back of the groove can be judged by the sound of "puff” (the sound made when the weld penetrates) on the back of the groove.
  • the "puff puff” sound is only an exemplary description, and is only used to illustrate that the blunt edge of the bevel has been melted through, but the sound of the blunt edge of the bevel melted through varies depending on the actual situation.
  • the welding torch can keep advancing at a constant speed along the welding direction, that is, the welding seam at the front groove of the molten pool penetrates After penetration (for example, after hearing the penetration sound of the welding seam), the welding gun can be kept advancing at a uniform speed without waiting for a molten hole at the bevel to complete the welding of the bottom layer 41.
  • the method provided by the present disclosure does not require a molten hole to appear at the front groove of the molten pool to maintain the welding torch forward at a uniform speed, thus preventing the occurrence of a situation where the molten hole is burned by the arc to become larger.
  • Position welding can be performed on the side of the groove (the lower surface of the plate) or on the back of the groove. If tack welding is performed on the groove side, the tack welding will form a certain weld thickness at both ends of the groove 2, which is equivalent to a certain length of bottom welding in advance; during the bottom welding process, it is to control the bottom welding If the thickness and arc starting point are set at the end of the tack welding seam, the arc starting at the end of the groove 2 cannot be achieved. When the arc is started, the plate is in a normal temperature state, so the groove is not easy to burn through, and the back welding seam is not easy to form.
  • positioning welding may be performed on the back surfaces of both ends of the groove 2, and the welding length may be 5 mm to 10 mm.
  • the back surfaces of the two ends of the groove 2 are welded by positioning, which is equivalent to forming a redundant height on the back surfaces of the two ends of the groove 2. Since there is no welding seam in the groove, the arc can be started from the end of the groove 2.
  • the welding place of the plate 1 has reached high temperature, so the bottom layer is welded to When positioning the end position of the welding section, the back of the groove can be easily broken down, so that the backing welding and positioning welding on the back are integrated to ensure the quality of the back welding seam.
  • the MAG vertical butt single-side welding and double-side forming welding method may further include: S2, filler layer 42 welding: continuous arc welding is performed by a zigzag striping method.
  • the arc can be started at the end of the groove 2 when starting the arc.
  • the welding torch 5 can swing in a small arc zigzag shape, and the intermediate transition speed during the swing should be fast, and the two sides should be slightly
  • the arc runs to both sides of the groove 2, it can stay for 0.5s to 1s, which can ensure a good fusion between the welds, and avoid the drop of metal on the front of the weld to form a weld bead.
  • the surface of the welding seam of the filling layer 42 can be left with a margin of 1 to 2 mm from the edge of the groove. Take care not to burn the edge 22.
  • the filling layer welding may also adopt crescent-shaped striping methods, reverse crescent-shaped striping methods, and triangular striping methods, which are not limited in the present disclosure.
  • the inclination angle of the welding torch 5 to the welding direction may be 80-90°, and the included angle of the welding torch 5 to the width direction of the welding seam may be 90°.
  • the welding torch can be in a backstroke attitude, pointing to the starting welding end a of the groove, and the angle of the welding torch can control the welding speed; the reverse attitude of the welding torch 5 can control the welding speed of the filling layer 42 to be slower than that of the bottom layer 41.
  • the slower welding speed can prolong the residence time of the molten pool; the residence time can determine the temperature of the molten pool, thus ensuring that both sides of the filler layer weld and the mother The material is fully fused, and the weld between the primer layer 41 and the filler layer 42 is fully fused.
  • the MAG butt-butt single-side welding and double-side forming welding method may further include: S3, welding of the cover layer 43: the crescent-shaped strip method may be used for continuous arc welding.
  • the arc can be started at the end of the groove 2 when the arc is started, and after the arc is started, the welding wire 3 drives the molten pool to rapidly swing to both sides of the weld bead to avoid the formation of weld bead on the front side of the weld.
  • the welding wire 3 can swing in a crescent shape in the molten pool, and the back pressure (arc pressure) is at 1/3 to 1/2 of the front end of the molten pool, that is, the wire 3 swings at 1/3 to 1/2 of the front end of the molten pool; correspondingly Ground, the distance that the electrode moves forward is 1/6 of the length of the molten pool.
  • the transport bar is limited to 1/3 to 1/2 of the front end of the molten pool, that is, the front half of the molten pool, so that the welding seam between the cover layer 43 and the filler layer 42 can be fully fused.
  • the capping layer welding may also adopt a zigzag striping method, a reverse crescent striping method, a triangular striping method, etc., which are not limited by the present disclosure.
  • the arc when the arc runs to both sides of the groove 2, it can stay for 0.5 s to 1 s, and the fusion of the groove 2 is 1 mm to 2 mm on both sides of the corners, which can avoid unfilled grooves on both sides of the weld. Full and undercut defects.
  • the arc When the arc is closed, the arc crater of the welding seam can be filled to prevent the arc crater from being underfilled and cracked, so as to ensure the beautiful shape of the welding seam of the cover layer 43.
  • the inclination angle of the welding gun 5 to the welding direction may be 80° to 90°; in some embodiments of the present disclosure, the welding gun 5 is opposite to the welding direction.
  • the inclination angle of may be 90°; in some embodiments of the present disclosure, the included angle between the welding gun 5 and the width direction of the weld may be 90°, and the corresponding effect is the same as that of the filling layer 42.
  • a company applies the MAG backside butt single-side welding and double-side forming welding method provided in the present disclosure, which is specifically applied to box beam welding.
  • the box girder 6 is used as the main load-bearing part of the vehicle, the groove 2 is located on the bottom plate 1, and the welding seam is required to be fully penetrated.
  • the box-shaped beam 6 is welded, it often occurs that the reverse side of the butt butt weld cannot be cleaned due to the narrow working space, resulting in welding defects in the weld.
  • a better welding seam single-sided welding and double-sided forming effect is achieved.
  • the test plates are all made of high-strength weathering steel Q450NQR1, and the plate thickness is 10mm.
  • Q450NQR1 belongs to high-strength atmospheric corrosion-resistant steel. The superior performance of this material is mainly manifested in the advantages of high strength and good atmospheric corrosion resistance.
  • the chemical composition and mechanical properties of Q450NQR1 are shown in Table 1 and Table 2, respectively.
  • the grade of high-strength welding wire is TH550NQ-II, and the diameter is The chemical composition and mechanical properties of the welding wire are shown in Table 3 and Table 4 respectively.
  • the thickness of the blunt edge of the groove is 0 ⁇ 0.5mm; the position welding is on the opposite side of the groove at both ends of the plate, the length is 5 ⁇ 10mm; the assembly gap is 1.5mm; the reserved anti-deformation amount: 2° ⁇ 3°; the amount of misalignment: ⁇ 1mm.
  • the welding machine uses the gas shielded welding machine KRII-500, and the DC reverse connection is used.
  • the welding machine should be in good condition, able to provide a stable arc within the required current range, with large penetration, small spatter, and safe and reliable.
  • Reasonable welding process parameters are an important guarantee for determining the quality of welding. It not only plays a key role in the formation of the weld, but also has an impact on the structure of the weld.
  • the welding machine must be debugged before welding, and test welding must be performed on the test board.
  • Reasonably match the welding parameters such as welding current, arc voltage and gas flow. See Table 5 for specific parameters.
  • Shielding gas flow rate 15-20L/min; welding wire extension length: 10-15mm; bottom welding welding speed: 170-190mm/min.
  • the MAG backside butt single-sided welding and double-sided forming welding method includes: welding a bottom layer 41, a filling layer 42 and a cover layer 43, and the specific process is as follows:
  • bottom layer 41 welding use the straight-line transport method for continuous arc welding.
  • the arc When the arc is started, the arc is started at the end of the groove 2, and there is no need to swing after the arc is started.
  • the welding tongs directly advance in the welding direction at a uniform speed, and the welding wire 3 is always at the 1/4 position of the front end of the molten pool.
  • the inclination angle of the welding torch 5 to the welding direction is 90°-100°, and the included angle between the welding torch 5 and the width direction of the weld 4 is 90°; using the arc strength, the welding torch 5 penetrates bluntly in the thickness direction of the plate 1 Side 11, and push part of the molten liquid in the molten pool to the back of the groove 2, so as to form a molten pool on both the groove 2 and the back of the groove 2.
  • the welding tongs 5 is maintained at a constant speed in the welding direction, and the welding of the bottom layer 41 is completed.
  • the MAG vertical butt single-sided welding and double-sided forming welding method provided by the present disclosure may further include: S2, filler layer 42 welding: continuous arc welding is performed by using a zigzag striping method.
  • the welding torch 5 When starting the arc, start the arc at the end of the groove 2. After the arc starts, the welding torch 5 swings in a zigzag shape with a small arc. The intermediate transition speed should be fast during the swing, and the two sides should stop for a while; when the arc runs to both sides of the groove 2. Stay for 0.5s ⁇ 1s at the same time, so as to ensure good fusion between the welds, but also to avoid the drop of the metal on the front of the weld to form weld bead.
  • the inclination angle of the welding gun 5 with the welding direction is 80-90°
  • the included angle with the width direction of the welding seam is 90°.
  • the surface of the welding seam of the filling layer 42 is left with a margin of 1 ⁇ 2mm for the cover layer from the edge of the groove. Be careful not to burn the edge 22.
  • the MAG upward butt single-sided welding and double-sided forming welding method provided by the present disclosure may further include: S3, welding of the cover layer 43: continuous arc welding by using a crescent-shaped strip method.
  • the welding wire 3 drives the molten pool to rapidly swing to both sides of the weld bead, so as to avoid the formation of weld bead on the front of the weld.
  • the welding wire 3 swings in a crescent shape in the molten pool, and the back pressure (arc pressure) is 1/3 to 1/2 at the front end of the molten pool.
  • the arc runs to both sides of the groove 2, it stays for 0.5s to 1s, and the groove 2 is fused.
  • the edges and corners are 1mm ⁇ 2mm, which can avoid the under-groove and undercut defects on both sides of the weld.
  • the inclination angle of the welding gun 5 to the welding direction is 90°
  • the included angle to the width direction of the welding seam is 90°.
  • the height and width of the weld on the front face of the groove are uniform, without undercut, and the shape is beautiful; the remaining height of the weld on the back is 0.5 to 1mm, and the welding quality is guaranteed.
  • the MAG backside butt single-sided welding and double-sided forming welding method provided by the present disclosure has been successfully used in the production of long and large special vehicles and the welding of box-shaped beams whose back surface cannot be cleaned.
  • this welding method can be simplified
  • the operation action reduces the operation difficulty and labor intensity; it can greatly reduce the operation difficulty of the electric welder, so that the operator can be familiar with and master the operation method in a short time.
  • the MAG butt-butt single-sided welding and double-sided forming welding method provided by the present disclosure can be popularized.

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Abstract

一种MAG仰对接单面焊双面成型焊接方法，采用MAG实心焊丝对具有坡口的板件进行仰对接焊接，坡口的装配间隙为1.5mm～2.5mm；包括打底层焊接、填充层焊接、盖面层焊接；其中打底层焊接过程中，焊枪(5)与焊接方向的倾角为90°～100°，利用电弧挺力，沿板件(1)厚度方向击穿坡口(2)的钝边(11)，并将熔池内的部分熔液顶向坡口背面，在坡口和坡口的背面均形成熔池；熔池前方的坡口处焊缝(4)穿透后，在熔池前方的坡口处未出现熔孔时沿焊接方向保持匀速推进，完成打底层的焊接。该焊接方法通过减小工件装配间隙，改变焊枪角度及操作方法，无需在焊缝熔池前方的坡口根部形成熔孔，可达到焊缝单面焊双面成型的技术效果。

Description

一种MAG仰对接单面焊双面成型焊接方法
相关申请的交叉引用
本申请要求于2019年9月27日提交、申请号为201910924871.5且名称为“一种MAG对接单面焊双面成型焊接方法”的中国专利申请的优先权，其全部内容通过引用合并于此。
技术领域
本公开内容属于焊接技术领域，具体涉及一种可用于板件的MAG仰对接单面焊双面成型焊接方法。
背景技术
焊缝成型是在坡口一侧施焊，通常采用在焊缝熔池前方的坡口根部形成熔孔的操作方法，以此达到焊缝单面焊双面成型。
仰对接是所有焊接位置中操作难度最大的一种焊接接头形式。在仰对接实际操作过程中，由于工件钝边薄、间隙大，加之熔滴自身重力及表面张力减小，液态金属受重力作用容易下坠，并容易出现熔孔处被电弧烧损变大的情况，从而迫使停弧去进行修补。由于不能采取连弧焊接，会造成焊缝背面形成凹陷、未焊透等缺陷，使得背面焊缝成型难以达到要求。此外，填充层内部难以控制，而且层间不易熔合，容易形成密集气孔和夹渣等缺陷。而盖面层焊缝外观成型难以控制，则容易形成表面成型不良、接头过高、脱节以及咬边等缺陷。因此，焊接质量得不到保障，造成极大浪费。
因此，需对现有技术进行改进，以实现仰对接焊缝单面焊双面成型。
发明内容
针对上述现有技术存在的问题，本公开内容提供了一种MAG仰对 接单面焊双面成型焊接方法，其无需在焊缝熔池前方的坡口根部形成熔孔，可达到焊缝单面焊双面成型的技术效果。
在本公开内容的一个方面，提供了一种MAG仰对接单面焊双面成型焊接方法，采用MAG实心焊丝对具有坡口的板件进行仰对接焊接，所述坡口的装配间隙为1.5mm～2.5mm；可以包括如下步骤：打底层焊接：采用连弧焊接；在焊接过程中，焊枪与焊接方向的倾角为90°～100°；利用电弧挺力，所述焊枪沿板件厚度方向击穿所述坡口的钝边，并将熔池内的部分熔液顶向所述坡口的背面，在所述坡口和所述坡口的背面均形成熔池；所述焊枪将所述熔池的前方坡口处焊缝穿透后，在所述熔池前方坡口处未出现熔孔时沿焊接方向保持匀速推进，完成打底层的焊接；填充层焊接：采用连弧焊接；盖面层焊接：采用连弧焊接。
在一些实施方式中，所述打底层焊接前，首先可以在所述板件的坡口两端进行定位焊接。
在一些实施方式中，所述定位焊接可以包括：在所述坡口两端的背面进行定位焊接，焊接长度可以为5mm～10mm。
在一些实施方式中，所述打底层焊接，还可以包括：在所述坡口的端头起弧，起弧后所述焊枪可以直接沿所述焊接方向匀速推进，所述焊丝可以始终处于熔池前端1/4位置。
在一些实施方式中，所述填充层焊接，可以包括：在所述坡口的端头起弧，起弧后所述焊枪可以作运条摆动，当电弧运行到坡口两侧时可以停留0.5s～1s。
在一些实施方式中，所述填充层焊接的过程中，所述焊枪与焊接方向的倾角可以为80°～90°。
在一些实施方式中，所述盖面层焊接，可以包括：在所述坡口的端头起弧，起弧后所述焊枪可以作运条摆动，回压所述熔池的前端1/3～1/2处；当电弧运行到所述坡口的两侧时可以停留0.5s～1s，熔合所述坡口的棱角两侧1mm～2mm。
在一些实施方式中，所述盖面层焊接的过程中，所述焊枪与焊接方向的倾角可以为80°～90°。
在一些实施方式中，所述板件的对接部位可以预留有向所述板件背面弯曲的反变形角，且预留的所述反变形角可以不大于3°。
在一些实施方式中，所述坡口的钝边的厚度可以为0～1.5mm。
本公开内容提供的MAG仰对接单面焊双面成型焊接方法，通过改变焊枪角度，减小工件装配间隙以及改进操作工艺，无需在焊缝熔池前方的坡口根部形成熔孔，即可达到焊缝单面焊双面成型的技术效果。本公开内容的工艺原理如下：
首先，本公开内容提供的MAG仰对接单面焊双面成型焊接方法改变了打底层的焊枪角度，焊枪与焊接方向的倾角为90°～100°，即焊枪处于前冲姿态，指向坡口的终焊端，可以利用MAG焊接(熔化极活性气体保护电弧焊)的电弧挺力，沿板件厚度方向击穿坡口钝边，将熔池内的部分熔液顶向坡口背面，以在坡口和坡口背面均形成熔池，从而得到背面余高。
再者，本公开内容提供的MAG仰对接单面焊双面成型焊接方法采用MAG连弧焊接，连弧焊接配合焊枪角度，可以使得熔池始终保持高温(铁水熔化状态)，因此可以缩小坡口的装配间隙至1.5mm～2.5mm，且不要求熔池前方坡口处出现熔孔即可穿透坡口钝边，从而杜绝出现熔孔处被电弧烧损变大的情况。
最后，本公开内容提供的MAG仰对接单面焊双面成型焊接方法缩小了坡口的装配间隙(而现有技术中装配间隙为3mm～4mm，或更大)，使得在相同规格板材的坡口打底焊时提高了焊接速度，减小了打底层焊缝厚度，减少了焊缝填充量以及降低了焊接劳动强度；此外还提高了焊缝熔敷效率，缩短了焊缝熔池的冷却时间，减小了板件的反变形量，使得预留的反变形角不大于3°。
附图说明
图1为依据本公开内容实施例的MAG仰对接单面焊双面成型焊接方法的实施示意图；
图2为依据本公开内容实施例的板件对接的结构示意图；
图3为依据本公开内容实施例的焊缝的坡口分布图；以及
图4为依据本公开内容实施例的箱型梁仰对接焊接结构示意图。
附图标记说明：1-板件；11-钝边；2-坡口；21-装配间隙；22-棱角；3-焊丝；4-焊缝；41-打底层；42-填充层；43-盖面层；44-背面余高；5-焊枪；6-箱型梁。
具体实施方式
为了使本申请所属技术领域中的技术人员更清楚地理解本申请，下面结合附图，通过具体实施例对本申请技术方案作详细描述。
图1为依据本公开内容实施例的MAG仰对接单面焊双面成型焊接方法的实施示意图。如图1所示，在在本公开内容的一些实施例中，MAG仰对接单面焊双面成型焊接方法，可以用于对具有坡口2的板件1进行仰对接焊接；板件1可以包括两块待连接的板件，焊接时两块板件应水平放置，也可具有一定的夹角，但是应该尽量避免两块板件错位(错边量≤1mm)。两块板件待连接的一端可以具有焊接用坡口2，并且该坡口2可以通过在两块板件临近的端面均设置斜面而形成(如图2所示)，也可以由单块板件在两块板件临近的端面设置斜面而形成。
在本公开内容的一些实施例中，沿板件1厚度方向(图1中Z轴方向)未开坡口的端面称为钝边11，并且坡口2的钝边的厚度可以为0～1.5mm；坡口斜面向下延伸与板件下表面形成的钝角称为棱角22，如图2所示。坡口2的开口角度与板件1的板厚有关，常规开角可以为60°。
在本公开内容的一些实施例中，坡口2的装配间隙可以为1.5mm～2.5mm，例如1.5mm、1.8mm、2.0mm、2.3mm、2.5mm等。当装配 间隙较大时，坡口的钝边的厚度可相应增加，例如可以采用2.5mm的装配间隙时，坡口的钝边的厚度可以为1mm～1.5mm。
如图2所示，在本公开内容的一些实施例中，坡口2的开口沿板件1厚度方向向下可以逐渐增大，以便于进行仰位焊接。板件1在焊接前，可以在板件1的对接部位预留向板件1背面弯曲的反变形角，以抵消焊接造成的变形；在本公开内容的一些实施例中，反变形角不大于3°。
在本公开内容的一些实施例中，MAG仰对接单面焊双面成型焊接方法，可以采用MAG焊(熔化极活性气体保护电弧焊，简称气保焊)配合MAG实心焊丝3进行仰对接焊接；如图3所示，在本公开内容的一些实施例中，MAG仰对接单面焊双面成型焊接方法，可以包括打底层41、填充层42和盖面层43的焊接，可以包括：
S1、打底层41焊接：可以采用直线运条方法进行连弧焊接。
在本公开内容的一些实施例中，起弧时在坡口2的端头(即图1中始焊端a)起弧，起弧后不需摆动，所述焊枪可以直接沿焊接方向(图1中箭头c所指方向)匀速推进，并且焊丝3可以始终处于熔池前端1/4位置(熔池呈椭圆形，长轴沿焊接方向，朝向终焊端b的方向为前端)。如图1所示，在焊接过程中，焊枪5与焊接方向的倾角可以为90°～100°，例如90°、92°、94.5°、96°、98°、100°等；焊枪5与焊缝4宽度方向(图1中Y轴方向)的夹角可以为90°。起弧后，利用电弧挺力，所述焊枪可以沿板件1厚度方向击穿钝边11，并将熔池内的部分熔液顶向坡口2背面，以在坡口2和坡口背面均形成熔池。其中，判断坡口背面是否形成熔池可以通过坡口背面发出“噗噗”声音(焊缝穿透时发出的声音)来判断。该“噗噗”的声音仅是示例性的说明，仅是用以说明坡口钝边已经熔透，但坡口钝边熔透的声音因实际情况而异。
在本公开内容的一些实施例中，打底层41焊接过程中，在熔池前方坡口2处未出现熔孔时，焊枪可以沿焊接方向保持匀速推进，即熔池前方坡口处焊缝穿透后(例如听到焊缝穿透声后)，无需待坡口处出现熔 孔就可以保持焊枪向前匀速推进，直至完成打底层41的焊接。本公开内容提供的方法不需要待熔池前方坡口处出现熔孔就可以保持焊枪向前匀速推进，因此也杜绝出现熔孔处被电弧烧损变大的情况。
在本公开内容的一些实施例中，在打底层41焊接前，需要在坡口2两端进行定位焊接。定位焊接可以在坡口侧(板件下表面)进行，也可以在坡口背面进行。若在坡口侧进行定位焊接，则定位焊接会在坡口2两端形成一定焊缝厚度，相当于预先进行了一定长度的打底焊；在进行打底焊工序时，为控制打底焊厚度，起弧点如果设置在定位焊接焊缝的末端，这样就无法实现坡口2端头起弧。而在起弧时，板件是常温状态，因此坡口不容易烧透，背面焊缝不易成型。
在本公开内容的一些实施例中，可以在坡口2两端的背面进行定位焊接，焊接长度可以为5mm～10mm。坡口2两端的背面进行定位焊接，相当于在坡口2两端的背面形成余高。由于坡口中并无焊缝，因此可以从坡口2端头起弧，在打底层焊接在5mm～10mm定位焊接段进行的过程中，板件1焊接处已达到高温，因此在打底层焊接至定位焊接段末端位置时，可以轻易将坡口背面击穿，使得背面的打底焊与定位焊接融为一体，以保证背面焊缝成型质量。
在本公开内容的一些实施例中，MAG仰对接单面焊双面成型焊接方法还可以包括：S2、填充层42焊接：采用锯齿形运条方法进行连弧焊接。
在本公开内容的一些实施例中，起弧时可以在坡口2的端头起弧，起弧后焊枪5可以作小弧度锯齿形运条摆动，摆动时中间过渡速度要快，两边要稍作停留；当电弧运行到坡口2两侧时可以停留0.5s～1s，这样既能保证焊缝之间熔合良好，又能避免焊缝正面金属液滴下坠形成焊瘤。填充层42焊缝表面距离坡口棱角处可以留有1～2mm的盖面层余量，注意不要将棱角22烧损。
在本公开内容的一些实施例中，填充层焊接也可采用月牙形运条 方法、反月牙形运条方法、三角形运条方法等运条方法，本公开内容不做限制。
在本公开内容的一些实施例中，在填充层42焊接过程中，焊枪5与焊接方向的倾角可以为80～90°，并且焊枪5与焊缝宽度方向的夹角可以为90°。焊枪可以处于后冲姿态，指向坡口的始焊端a，并且焊枪的角度可以控制焊接速度；焊枪5反向姿态可以控制填充层42的焊接速度慢于打底层41。由于越靠近坡口棱角22，坡口面越宽、板厚越厚，则焊接速度慢可以延长熔池停留时间；而停留时间可以决定熔池温度，因而可以保证填充层焊缝两侧与母材充分熔合，以及打底层41与填充层42焊缝之间充分熔合。
在本公开内容的一些实施例中，MAG仰对接单面焊双面成型焊接方法还可以包括：S3、盖面层43焊接：可以采用月牙形运条方法进行连弧焊接。
在本公开内容的一些实施例中，起弧时可以在坡口2的端头起弧，并且起弧后焊丝3带动熔池快速向焊道两侧摆动，以避免焊缝正面形成焊瘤。焊丝3在熔池内可以作月牙形运条摆动，回压(压弧)熔池前端1/3～1/2处，即焊丝3摆动始终在熔池前端1/3～1/2处；相应地，焊条向前推移距离即为熔池长度的1/6。由于熔池表面在焊接方向上呈斜面，即熔池厚度从前(终焊端b侧)往后(始焊端a侧)递增，该熔池与已凝固焊缝相接处厚度最大，因此将运条限制在熔池前端1/3～1/2处，即熔池前半部分，可使得盖面层43与填充层42焊缝之间充分熔合。
在本公开内容的一些实施例中，盖面层焊接也可采用锯齿形运条方法、反月牙形运条方法、三角形运条方法等运条方法，本公开内容不做限制。
在本公开内容的一些实施例中，当电弧运行到坡口2两侧时可以停留0.5s～1s，并且熔合坡口2棱角两侧1mm～2mm，能避免焊缝两侧产生坡口未填满和咬边缺陷。收弧时，可以填满焊缝收弧弧坑，以防 止产生弧坑未填满和裂纹，从而保证盖面层43焊缝成型美观。
在本公开内容的一些实施例中，在盖面层43焊接的过程中，焊枪5与焊接方向的倾角可以为80°～90°；在本公开内容的一些实施例中，焊枪5与焊接方向的倾角可以为90°；在本公开内容的一些实施例中，焊枪5与焊缝宽度方向的夹角可以为90°，其相应效果同填充层42。
应用实例：
某公司在长大型特种车辆生产过程中应用本公开内容提供的的MAG仰对接单面焊双面成型焊接方法，具体应用于箱型梁焊接。如图4所示，箱型梁6作为车辆主要承载部分，坡口2位于底部板件1上，焊缝要求全熔透。现有技术在箱型梁6焊接时，常出现因作业空间狭小造成仰对接焊缝反面无法清根，导致焊缝出现焊接缺陷。采用本公开内容提供的的MAG仰对接单面焊双面成型焊接方法后，达到较好的焊缝单面焊双面成型效果。
具体工艺方法及工艺参数如下：
(一)试板母材性能分析
试板均为高强度耐候钢Q450NQR1的材料，板厚均为10mm。Q450NQR1属于高强度耐大气腐蚀钢，该材料性能优越主要表现在强度高，耐大气腐蚀强度好的优点。Q450NQR1的化学成分与力学性能分别见表1和表2。
表1 Q450NQR1化学成分(％)
Figure PCTCN2020108955-appb-000001
表2 Q450NQR1力学性能
Figure PCTCN2020108955-appb-000002
(二)焊材性能分析
为了使焊接接头具有与母材相匹配的力学性能，选用高强度焊丝牌号为TH550NQ-Ⅱ，直径为
Figure PCTCN2020108955-appb-000003
焊丝的化学成分及力学性能分别见表3和表4。
表3 TH550NQ-Ⅱ化学成分(％)
Figure PCTCN2020108955-appb-000004
表4 TH550NQ-Ⅱ力学性能
Figure PCTCN2020108955-appb-000005
(三)装配工艺要求
坡口的钝边厚度0～0.5mm；定位焊在板件两端坡口反面，长度5～10mm；装配间隙1.5mm；预留的反变形量：2°～3°；错边量：≤1mm。
(四)焊接技术介绍
1、焊接设备：焊机选用气体保护焊机KRⅡ-500，选用直流反接的连接方式。焊机状态应良好，能在所要求的电流范围内提供稳定的电弧，熔深大，飞溅小，而且安全可靠。
2、焊前清理：将工件正、反面两侧20mm范围内，及坡口表面的油、锈、水和氧化物等杂质彻底清除干净，直至露出金属光泽。将坡口内侧点固焊打磨平整，靠工件中心一端打磨至斜坡状，焊枪上焊丝前端小球状氧化物剪除。
3、焊接工艺参数：
合理的焊接工艺参数是决定焊接质量优劣的重要保证，不仅对焊缝的成形起到关键作用，而且对焊缝组织产生影响。焊前必须对焊机进行调试，在试板上试焊。将焊接电流、电弧电压和气体流量等焊接参数 合理匹配，具体参数见表5。
表-5焊接工艺参数
焊接层次 焊接电流I/A 电弧电压U/V
打底焊 110～120 17～18
填充焊 130～140 18～19
盖面焊 120～130 18～19
保护气体流量：15～20L/min；焊丝伸出长度：10～15mm；打底焊焊接速度：170～190mm/min。
(五)焊接流程
如图1所示，本公开内容提供的MAG仰对接单面焊双面成型焊接方法包括：打底层41、填充层42和盖面层43的焊接，具体工艺如下：
S1、打底层41焊接：采用直线运条方法进行连弧焊接。
起弧时在坡口2的端头起弧，起弧后不需摆动，所述焊钳直接沿焊接方向匀速推进，并且焊丝3始终处于熔池前端1/4位置。在焊接过程中，焊枪5与焊接方向的倾角为90°～100°，焊枪5与焊缝4宽度方向的夹角为90°；利用电弧挺力，焊枪5沿板件1厚度方向击穿钝边11，并将熔池内的部分熔液顶向坡口2背面，以在坡口2和坡口2背面均形成熔池。打底层41焊接过程中，在熔池前方坡口2处未出现熔孔时沿焊接方向保持焊钳5匀速推进，完成打底层41的焊接。
本公开内容提供的MAG仰对接单面焊双面成型焊接方法还可以包括：S2、填充层42焊接：采用锯齿形运条方法进行连弧焊接。
起弧时在坡口2的端头起弧，起弧后焊枪5作小弧度锯齿形运条摆动，摆动时中间过渡速度要快，两边要稍作停留；当电弧运行到坡口2两侧时停留0.5s～1s，这样既能保证焊缝之间熔合良好，又能避免焊缝正面金属液滴下坠形成焊瘤。在填充层42焊接过程中，焊枪5与焊接方向的倾角为80～90°，与焊缝宽度方向的夹角为90°。填充层42焊缝表面 距离坡口棱角处留有1～2mm的盖面层余量，注意不要将棱角22烧损。
本公开内容提供的MAG仰对接单面焊双面成型焊接方法还可以包括：S3、盖面层43焊接：采用月牙形运条方法进行连弧焊接。
起弧时在坡口2的端头起弧，起弧后焊丝3带动熔池快速向焊道两侧摆动，避免焊缝正面形成焊瘤。焊丝3在熔池内作月牙形运条摆动，回压(压弧)熔池前端1/3～1/2处，当电弧运行到坡口2两侧时停留0.5s～1s，熔合坡口2棱角1mm～2mm，能避免焊缝两侧产生坡口未填满和咬边缺陷。收弧时，要填满焊缝收弧弧坑，防止产生弧坑未填满和裂纹，从而保证盖面层43焊缝成型美观。在盖面层43焊接的过程中，焊枪5与焊接方向的倾角90°，与焊缝宽度方向的夹角为90°。
经测定，坡口正面焊缝焊缝高低和宽窄均匀一致，无咬边，成型美观；焊缝背面余高0.5～1mm，焊接质量得到保证。
本公开内容提供的MAG仰对接单面焊双面成型焊接方法至少具有以下有益效果：
本公开内容提供的MAG仰对接单面焊双面成型焊接方法，在长大型特种车辆生产及反面无法清根的箱型梁焊接时得到成功运用。其中，通过减小工件装配间隙，改变焊枪角度及操作方法，无需在焊缝熔池前方的坡口根部形成熔孔，可达到焊缝单面焊双面成型的技术效果；该焊接方法可简化操作动作，降低操作难度和劳动强度；可大幅降低电焊工的操作难度，能让操作工在较短时间熟悉并掌握该操作方法。本公开内容提供的MAG仰对接单面焊双面成型焊接方法可向大众化方向推进。
尽管已描述了本申请的优选实施例，但本领域内的普通技术人员一旦得知了基本创造性概念，则可对这些实施例作出另外的变更和修改。所以，所附权利要求意欲解释为包括优选实施例以及落入本申请范围的所有变更和修改。
显然，本领域的技术人员可以对本申请进行各种改动和变型而不脱离本申请的精神和范围。这样，倘若本申请的这些修改和变型属于本 申请权利要求及其等同技术的范围之内，则本申请也意图包含这些改动和变型在内。

Claims (10)

  1. 一种MAG仰对接单面焊双面成型焊接方法，采用MAG实心焊丝对具有坡口的板件进行仰对接焊接，所述坡口的装配间隙为1.5mm～2.5mm；包括如下步骤：
    打底层焊接：采用连弧焊接；在焊接过程中，焊枪与焊接方向的倾角为90°～100°；利用电弧挺力，所述焊枪沿板件厚度方向击穿所述坡口的钝边，并将熔池内的部分熔液顶向所述坡口的背面，在所述坡口和所述坡口的背面均形成熔池；所述焊枪将所述熔池的前方坡口处焊缝穿透后，在所述熔池前方坡口处未出现熔孔时沿焊接方向保持匀速推进，完成打底层的焊接；
    填充层焊接：采用连弧焊接；
    盖面层焊接：采用连弧焊接。
  2. 如权利要求1所述的MAG仰对接单面焊双面成型焊接方法，其中：所述打底层焊接前，首先在所述板件的坡口两端进行定位焊接。
  3. 如权利要求2所述的MAG仰对接单面焊双面成型焊接方法，其中：所述定位焊接包括：在所述坡口两端的背面进行所述定位焊接，焊接长度为5mm～10mm。
  4. 如权利要求1至3中任一项所述的MAG仰对接单面焊双面成型焊接方法，其中：所述打底层焊接，还包括：
    在所述坡口的端头起弧，起弧后所述焊枪直接沿所述焊接方向匀速推进，所述焊丝始终处于所述熔池前端1/4位置。
  5. 如权利要求1至3中任一项所述的MAG仰对接单面焊双面成型焊接方法，其中：所述填充层焊接，包括：
    在所述坡口的端头起弧，起弧后所述焊枪作运条摆动，当电弧运行到坡口两侧时停留0.5s～1s。
  6. 如权利要求5所述的MAG仰对接单面焊双面成型焊接方法，其中：所述填充层焊接的过程中，所述焊枪与焊接方向的倾角为80°～ 90°。
  7. 如权利要求1至3中任一项所述的MAG仰对接单面焊双面成型焊接方法，其中：所述盖面层焊接，包括：
    在所述坡口的端头起弧，起弧后所述焊枪作运条摆动，回压所述熔池前端1/3～1/2处，当电弧运行到所述坡口的两侧时停留0.5s～1s，熔合所述坡口的棱角两侧1mm～2mm。
  8. 如权利要求7所述的MAG仰对接单面焊双面成型焊接方法，其中：所述盖面层焊接的过程中，所述焊枪与焊接方向的倾角为80°～90°。
  9. 如权利要求1至3中任一项所述的MAG仰对接单面焊双面成型焊接方法，其中：所述板件的对接部位预留有向所述板件背面弯曲的反变形角，且预留的所述反变形角不大于3°。
  10. 如权利要求1至3中任一项所述的MAG仰对接单面焊双面成型焊接方法，其中：所述坡口的钝边的厚度为0～1.5mm。
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