WO2022257669A1 - 激光-gma电弧复合热源填丝焊脉动送丝方法 - Google Patents

激光-gma电弧复合热源填丝焊脉动送丝方法 Download PDF

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WO2022257669A1
WO2022257669A1 PCT/CN2022/091448 CN2022091448W WO2022257669A1 WO 2022257669 A1 WO2022257669 A1 WO 2022257669A1 CN 2022091448 W CN2022091448 W CN 2022091448W WO 2022257669 A1 WO2022257669 A1 WO 2022257669A1
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wire
welding
arc
gma
laser
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PCT/CN2022/091448
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English (en)
French (fr)
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雷振
徐富家
徐良
杨海锋
王旭友
李�荣
张彦东
李洪伟
孙岩
陈晓宇
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哈尔滨焊接研究院有限公司
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Priority to DE112022000122.4T priority Critical patent/DE112022000122T5/de
Publication of WO2022257669A1 publication Critical patent/WO2022257669A1/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
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/346—Working by laser beam, e.g. welding, cutting or boring in combination with welding or cutting covered by groups B23K5/00 - B23K25/00, e.g. in combination with resistance welding
    • B23K26/348—Working by laser beam, e.g. welding, cutting or boring in combination with welding or cutting covered by groups B23K5/00 - B23K25/00, e.g. in combination with resistance welding in combination with arc heating, e.g. TIG [tungsten inert gas], MIG [metal inert gas] or plasma 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
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/70—Auxiliary operations or equipment
    • 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
    • B23K9/12—Automatic feeding or moving of electrodes or work for spot or seam welding or cutting
    • B23K9/124—Circuits or methods for feeding welding wire
    • 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

Definitions

  • the patent of the present invention proposes a laser-GMA arc composite heat source wire-filling welding pulsating wire feeding method, which belongs to the field of laser processing technology, and particularly relates to the phase phase of the pulsed GMA arc waveform under the high-speed welding conditions of laser-GMA arc composite heat source welding.
  • the pulsating wire feeding method with a difference of 180° realizes the wire feeding of the additional filler wire and improves the stability of the additional filler wire filling.
  • Laser-GMA is the abbreviation of gas metal arc welding, including MIG and MAG arc
  • hybrid arc welding technology is an advanced welding technology with high efficiency and high quality.
  • MAG/MIG gas metal arc welding
  • It has technical advantages such as fast welding speed, low welding heat input, small welding deformation, large weld penetration, easy realization of single-sided welding and double-sided forming, refined joint structure, and improved joint performance.
  • this welding method can be used in high-speed welding
  • the characteristics of arc high stability welding under certain conditions make this welding method have significant technical advantages in the welding of medium and thin plates.
  • the characteristics of high-speed welding of this process method should be fully utilized to increase the welding speed as much as possible.
  • the GMA will generally be increased.
  • this method of increasing the amount of deposited metal by increasing the power of the GMA arc tends to overheat the metal in the molten pool, seriously affecting the shape of the weld, and even causing the collapse of the weld , Undercut and other defects, at the same time cause joint performance and tissue damage.
  • the invention patent ZL201410092005.1 proposes a laser-GMA arc composite heat source wire filling welding method.
  • This method makes full use of the composite heat source welding method without increasing the power of the GMA arc.
  • the heat source energy is concentrated and the thermal efficiency is high.
  • the inherent characteristics of high molten pool temperature through the additional filling of welding wire and the use of excess heat in the welding process to achieve the melting of the welding wire, greatly improving the welding wire deposition efficiency in the welding process.
  • the efficiency of deposited metal can be increased by 50%-100%, but the welding heat input energy does not increase significantly. It is a new high-quality and efficient welding method. craft.
  • the feeding mode and reliable stability of the additional filler wire are the key to this welding method.
  • the additional filler wire should be inserted into the welding pool, and the welding wire should be melted by the rich heat of the welding pool.
  • the additional filler wire can be fed into the welding pool from the front, middle, and rear of the two heat sources, but when it is fed into the molten pool from the middle of the two heat sources or the side close to the GMA arc, due to the arc
  • the action range is large, especially when the pulsed GMA arc is used, the arc power is relatively high at the peak current of the pulsed arc, and the additional filler wire is heated, which easily causes the welding wire to melt before it is inserted into the molten pool and form large particles.
  • the phenomenon of falling molten pool leads to unstable welding process and poor weld formation.
  • the present invention proposes a laser-GMA arc composite heat source pulsating wire feeding method.
  • the welding process adopts pulsed GMA arc welding, and the arc welding power supply and the wire feeder are coordinated and synchronously controlled, and the additional filler wire adopts pulsating In the wire feeding mode, the phase difference between the pulsating wire feeding waveform and the pulsed GMA arc waveform is 180°, that is, when the pulsed GMA arc is at the peak current, the wire feeding speed of the additional filler wire is 0, and when the pulsed GMA arc drops to the base value current, the additional filler wire
  • the filler wire is used for wire feeding filling to ensure that the welding wire is inserted into the welding pool and prevent the formation of large particle droplet transfer due to arc heating of the welding wire.
  • the GMA arc adopts the pulse mode, and the communication between the arc welding power supply and the additional filler wire feeding system is realized, and synchronous cooperative control is realized.
  • the additional filler wire also adopts the pulsating wire feeding method, and its pulsating wire feeding waveform is the same as the pulse GMA arc waveform 180° out of phase.
  • the distance between the wire feeding nozzle of the additional filler wire and the surface of the molten pool is 5mm-10mm, and the additional filler wire
  • the wire feeding nozzle is made of ceramic or tungsten, and the hole of the wire feeding nozzle is cooled by argon gas, and the diameter of the welding wire that can be fed is ⁇ 0.8mm-1.6mm.
  • the filled welding wire can swing along a certain frequency and amplitude perpendicular to the welding direction.
  • the swing frequency is 0-100HZ
  • the swing range is 0-5mm
  • the welding speed and swing amplitude need to be reasonably matched with welding speed, wire feeding speed, laser power, arc power and other parameters through process tests.
  • the welding wire can not swing, that is, the swing frequency and swing amplitude are uniform is 0.
  • Fig. 1 is a schematic diagram of a laser-GMA arc composite heat source self-adaptive welding method for wire filling proposed by the present invention.
  • the arrow indicates the welding direction, and the actual welding process can be welded along "welding direction 1" or along "welding direction 2".
  • 1 is the workpiece to be welded
  • 2 is the laser beam
  • 3 is the GMA welding torch
  • 4 is the GMA arc
  • 5 is the filler wire
  • 6 is the weld seam
  • 7 is the high temperature resistant wire feeding nozzle
  • 8 is the welding current waveform
  • 9 is Additional wire pulse feed waveform.
  • Figure 2 shows that when the pulsed GMA arc is at the base current, the additional filler wire is fed at V f ; when the base current of the pulsed GMA arc ends and begins to grow to the peak current, the additional filler wire stops feeding until the pulse GMA When the arc drops to the base value current, the additional filler wire continues to be fed at V f , and this cycle is repeated.
  • Welding parameters used in the implementation process welding speed 3.6m/min, laser power 4500W, average welding current 205A; non-pulsating wire feeding speed 5.0m/min, wire swing frequency 5HZ, swing 2mm; In the pulsating wire feeding mode, the peak wire feeding speed of the welding wire is 10.0m/min, the base wire feeding speed is 0, the welding wire swing frequency is 5HZ, and the swing amplitude is 2mm.
  • the laser used is a fiber laser
  • the protective gas is industrial pure argon
  • the flow rate of the protective gas is 20L/min.
  • the weld formation obtained by filling the welding wire with the pulsating wire feeding method is more uniform, while the weld formation obtained by filling the welding wire with the non-pulsating wire feeding method occasionally has irregular weld formation.
  • Uniform phenomenon which is mainly due to the transfer of large particles of droplet formed by arc melting welding wire during wire feeding.

Abstract

提供一种激光-GMA电弧复合热源脉动送丝方法，包括：在激光-GMA电弧复合热源填丝焊接过程中，GMA电弧（4）采用脉冲模式，并将弧焊电源与送丝机协调同步控制，附加填充焊丝（5）采用脉动送丝方式，其脉动送丝波形（9）与脉冲GMA电弧（4）波形（8）相位相差180°，在脉冲GMA电弧（4）降至基值电流时，附加填充焊丝（5）进行送丝填充，在脉冲GMA电弧（4）处于峰值电流时不填充焊丝（5），确保焊丝（5）插入焊接熔池，防止因电弧（4）加热焊丝（5）而形成大颗粒熔滴过渡导致焊缝（6）成形不均匀现象。

Description

激光-GMA电弧复合热源填丝焊脉动送丝方法 所属技术领域：
本发明专利提出一种激光-GMA电弧复合热源填丝焊脉动送丝方法，属于激光加工技术领域，特别涉及到在激光-GMA电弧复合热源焊接的高速焊接条件下，通过与脉冲GMA电弧波形相位相差180°的脉动送丝方式实现附加填充焊丝的送丝，提高附加焊丝填充的稳定性。
背景技术：
激光-GMA(GMA是熔化极气体保护焊电弧的简称，包括MIG和MAG电弧)电弧复合焊接技术是一种高效优质的先进焊接技术，与传统熔化极气体保护焊(MAG/MIG)相比，具有焊接速度快、焊接热输入低、焊接变形小、焊缝熔深大、易于实现单面焊双面成形、细化接头组织、提高接头性能等技术优点，特别是该焊接方法可在高速焊接条件下实现电弧高稳定焊接的特性使得该焊接方法在中薄板的焊接中具有显著的技术优势。利用该工艺方法进行工件焊接时，为了有效地控制焊接变形，应当充分利用该工艺方法高速焊接的特点，尽可能提高焊接速度，但是在高速焊接条件下为了提高熔敷效率，一般会增大GMA电弧的功率以获得更大的焊丝熔敷量，然而这种通过增大GMA电弧功率来提高熔敷金属量的方法往往会使得熔池金属过热，严重影响焊缝成形，甚至造成焊缝的塌陷、咬边等缺陷，同时造成接头性能和组织的损伤。针对上述问题，发明专利ZL201410092005.1提出了一种激光-GMA电弧复合热源填丝焊接方法，该方法在不增大GMA电弧功率的前提下，充分利用了复合热源焊接方法热源能量集中、热效率高、熔池温度高的固有特点，通过额外填充焊丝并利用焊接过程的富余热量来实现焊丝的熔化，大幅提高焊接过程的焊丝熔敷效率。该方法与传统激光-GMA电弧复合热源焊接方法相比，在相同焊接速度下，熔敷金属效率可提高50％-100％，但焊接热输入能量并没有显著增加，是一种优质高效焊接新工艺。附加填充焊丝的送进方式和可靠稳定性是该焊接方法的关键，为确保焊接过程稳定性，附加填充焊丝应当插入焊接熔池，靠焊接熔池的富裕热量来熔化焊丝。根据发明专利ZL201410092005.1，附加填充焊丝可以从两热源的前方、中间、后方三个位置送入焊接熔池，但是从两热源中间位置或靠近GMA电弧一侧送入熔池时，由于电弧的作用区间较大，尤其是采用脉冲GMA电弧时，脉冲电弧在峰值电流时电弧功率较大，对附加填充焊丝进行了加热，容易使得焊丝尚未插入熔池便产生了熔化并形成大颗粒熔滴掉落熔池的现象，导致焊接过程不稳定和焊缝成形不良问题。
发明内容：
针对技术背景提到的突出问题，本发明提出一种激光-GMA电弧复合热源脉动送丝方法，焊接过程采用脉冲GMA电弧焊，将弧焊电源与送丝机协调同步控制，附加填充焊丝采用脉动送丝方式，其脉动送丝波形与脉冲GMA电弧波形相位相差180°，即在脉冲GMA电弧处于峰值电流时，附加填充焊丝送丝速度为0，在脉冲GMA电弧降至基值电流时，附加填充焊丝进行送丝填充，确保焊丝插入焊接熔池，而防止因电弧加热焊丝而形成大颗粒熔滴过渡。
本发明的技术方案如下：
(1)将激光束()与GMA电弧()按照旁轴复合的方式进行复合，并额外填充一根附加焊丝至复合焊熔池，消耗熔池的富余热量来熔化填充焊丝。
(2)GMA电弧采用脉冲模式，弧焊电源与附加填充焊丝送丝系统之间实现通讯，并实现同步协同控制，附加填充焊丝同样采用脉动送丝方式，其脉动送丝波形与脉冲GMA电弧波形相位相差180°。在脉冲GMA电弧处于基值电流时，附加填充焊丝以V f送进；在脉冲GMA电弧的基值电流结束并且开始逐渐长大为峰值电流时，附加填充焊丝停止送丝，直至脉冲GMA电弧降至基值电流时附加填充焊丝在继续以V f送进，以此循环。
(3)为防止在停止送丝后因电弧脉冲峰值电流对裸漏出送丝嘴的焊丝加热而导致焊丝熔化或弯曲，附加填充焊丝的送丝嘴距熔池表面距离5mm-10mm，附加填充焊丝送丝嘴采用陶瓷或钨制造，送丝嘴孔内通氩气冷却，可送焊丝直径Φ0.8mm-1.6mm。
(4)为了确保填充焊丝后的焊缝金属铺展性，填充的焊丝在垂直于焊接方向上可以沿一定频率和摆幅进行摆动，摆动频率在0～100HZ，摆幅在0-5mm，摆动频率和摆幅需要通过工艺试验来实现与焊接速度、送丝速度、激光功率、电弧功率等参数合理匹配，当填充焊丝的送丝速度相对较小时，焊丝可以不摆动，即摆动频率、摆幅均为0。
本发明的突出优点是：(1)附加填充焊丝的送丝采用脉动送丝方式，送丝速度波形与脉冲电弧波形相匹配，确保附加填充焊丝在脉冲基值电流时填充至熔池，解决了因GMA电弧对附加填充焊丝加热导致大颗粒熔滴过渡问题。(2)附加填充焊丝的填充过程更加可靠，焊接过程更加稳定，焊缝成形的均匀一致性更好。(3)与传统激光-GMA电弧复合焊相比，采用该发明专利的脉动送丝方法获得的激光-GMA电弧复合热源填丝焊缝的熔敷金属效率提高0.5-1倍。
附图说明
图1为本发明提出的一种激光-GMA电弧复合热源填丝自适应焊接方法示意图。箭头表 示焊接方向，实际焊接过程可以沿“焊接方向1”焊接，也可以沿“焊接方向2”焊接。图1中1为待焊接工件，2为激光束，3为GMA焊枪，4为GMA电弧，5为填充焊丝，6为焊缝，7为耐高温送丝嘴，8为焊接电流波形，9为附加焊丝脉动送丝波形。
图2为脉冲GMA电弧处于基值电流时，附加填充焊丝以V f送进；在脉冲GMA电弧的基值电流结束并且开始逐渐长大为峰值电流时，附加填充焊丝停止送丝，直至脉冲GMA电弧降至基值电流时附加填充焊丝在继续以V f送进，以此循环。
具体实施方式：
(1)、6005A铝合金型材实施案例
利用上述专利方法进行了6005A铝合金型材的激光-MIG电弧复合热源填丝焊接试验，并将脉动送丝和非脉动送丝两种焊缝成形结果作对比。试验母材为6005A铝合金型材，型材状态为T6状态，型材规格为1000×500×120mm，焊接区域的板厚为4mm，接头形式为对接接头，开设30°坡口。所用焊丝为直径Φ1.2mm的ER5087铝合金焊丝，焊接过程采用脉冲MIG电弧，复合时激光在前，电弧在后，激光和电弧的热源间距5mm，附加填充焊丝从两热源中间送进。实施过程中采用的焊接参数：焊接速度3.6m/min，激光功率4500W，焊接平均电流205A；采用非脉动送丝方式的焊丝送丝速度5.0m/min，焊丝摆动频率5HZ，摆幅2mm；采用脉动送丝方式时，焊丝峰值送丝速度为10.0m/min，基值送丝速度为0，焊丝摆动频率5HZ，摆幅2mm。所用激光器为光纤激光器，保护气体为工业纯氩，保护气体流量20L/min。焊后对比分析两种焊缝的焊缝形成，其中采用脉动送丝方式填充焊丝获得的焊缝成形更加均匀，而采用非脉动送丝方式填充焊丝获得的焊缝成形偶尔会有焊缝成形不均匀现象，这主要是因为焊丝送进过程中电弧熔化焊丝形成大颗粒熔滴过渡所致。
(2)、Q235钢对接试验实施案例
利用上述专利所述的脉动送丝方法进行了Q235钢激光-MAG复合热源填丝对接焊试验。试验母材为Q235低碳钢，试板规格为450×120×8mm，坡口角度30°,钝边4mm，所用焊丝为直径Φ1.2mm的ER50-6气保焊焊丝，焊接过程采用脉冲MAG电弧，复合时电弧在前，激光在后，光丝间距6mm。所用激光器为光纤激光器，保护气体为80％Ar+20％CO 2，保护气体流量20L/min。焊接参数：焊接速度1.2m/min，激光功率P＝6800W，焊接电流200A，焊丝峰值送丝速度为7.0m/min，基值送丝速度为0，焊丝摆动频率5HZ，摆幅3mm。焊后获得的激光-MAG复合热源填丝焊缝具有良好的焊缝成形，焊缝成形均匀。

Claims (3)

  1. 一种激光-GMA电弧复合热源填丝焊脉动送丝方法，其特征在于：将激光束与脉冲GMA电弧按照旁轴复合的方式进行复合，并额外填充一根附加焊丝至复合焊熔池，消耗熔池的富余热量来熔化填充焊丝，弧焊电源与附加填充焊丝送丝系统之间实现通讯并同步协同控制，附加填充焊丝采用脉动送丝方式，其脉动送丝波形与脉冲GMA电弧波形相位相差180°，在脉冲GMA电弧处于基值电流时，附加填充焊丝以V f送进；在脉冲GMA电弧的基值电流结束时，附加填充焊丝停止送丝，直至脉冲GMA电弧由峰值电流降至基值电流时附加填充焊丝再继续以V f送进，以此循环。
  2. 根据权利要求1所述的一种激光-GMA电弧复合热源填丝焊脉动送丝方法，为防止在停止送丝后因电弧脉冲峰值电流对裸漏出送丝嘴的焊丝加热而导致焊丝熔化或弯曲，附加填充焊丝的送丝嘴距熔池表面距离5mm-10mm，附加填充焊丝送丝嘴采用陶瓷或钨制造，送丝嘴孔内通氩气冷却，可送焊丝直径Φ0.8mm-1.6mm。
  3. 根据权利要求1所述的一种激光-GMA电弧复合热源填丝焊脉动送丝方法，为了确保填充焊丝后的焊缝金属铺展性，填充的焊丝在垂直于焊接方向上可以沿一定频率和摆幅进行摆动，摆动频率在0～100HZ，摆幅在0-5mm，摆动频率和摆幅需要通过工艺试验来实现与焊接速度、送丝速度、激光功率、电弧功率等参数合理匹配，当填充焊丝的送丝速度相对较小时，焊丝可以不摆动，即摆动频率、摆幅均为0。
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