WO2024159592A1 - 一种预热闪光对焊方法 - Google Patents

一种预热闪光对焊方法 Download PDF

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WO2024159592A1
WO2024159592A1 PCT/CN2023/082656 CN2023082656W WO2024159592A1 WO 2024159592 A1 WO2024159592 A1 WO 2024159592A1 CN 2023082656 W CN2023082656 W CN 2023082656W WO 2024159592 A1 WO2024159592 A1 WO 2024159592A1
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flash
stage
preheating
speed
continuous
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French (fr)
Inventor
董诗慧
苏世杰
高佳贺
翁海波
张升鹤
朱申奥
张建
李文达
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Jiangsu University of Science and Technology
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Jiangsu University of Science and Technology
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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
    • B23K11/00—Resistance welding; Severing by resistance heating
    • B23K11/04—Flash butt 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
    • B23K11/00—Resistance welding; Severing by resistance heating
    • B23K11/34—Preliminary treatment
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/10—Greenhouse gas [GHG] capture, material saving, heat recovery or other energy efficient measures, e.g. motor control, characterised by manufacturing processes, e.g. for rolling metal or metal working

Definitions

  • the invention relates to mechanical processing technology, in particular to a preheating flash butt welding method.
  • Marine anchor chains and mooring chains are chains connecting anchors and hulls or marine engineering equipment.
  • the demand for high-level mooring chains for marine engineering is growing continuously.
  • the commissioning of new offshore platforms and related offshore engineering structures and other mooring units, the demand for high-level mooring chains, which are indispensable safety guarantee components for the fixing of offshore oil and mining equipment, will become increasingly greater.
  • Chinese Patent No. 201080048430.0 discloses a flash butt welding method for rail steel. By specifying the time for current to flow in the preheating process, the heat-affected width of the weld joint head is controlled below 27 mm, so that the subsequent microstructure and performance of the rail will not be greatly affected.
  • Chinese Patent No. 201910407841.7 discloses a flash butt welding connection method for carbide blades. During preheating before welding, the workpiece ports are contacted and separated multiple times, and the power-on time is limited each time until the ports are heated to the rated temperature; during intermittent flash butt welding, the initial velocity and acceleration of the dynamic clamp are set to make it perform accelerated feeding movement, and the top forging speed is used after reaching the predetermined flash reserve.
  • the preheating stage is not regulated according to the actual working conditions, such as the floating of the threshold current, etc., and the preheating process is uncontrollable, resulting in the interruption of the flash stage due to insufficient temperature during the flash process, so that the subsequent flash stage and preheating are alternately performed, and the burning length is uncontrollable.
  • the acceleration stage of the flash is not controlled in combination with the actual burning conditions, which can easily affect the quality of the weld joint.
  • the present invention aims to provide a preheating flash butt welding method which can be regulated according to actual working conditions.
  • the preheating flash butt welding method of the present invention includes clamping, flash leveling stage, preheating stage, continuous flash stage, upsetting stage and resetting stage, wherein in the flash leveling stage, preheating stage and continuous flash stage, the advance and retreat of the movable clamp is controlled according to the relationship between the welding current i and the threshold current I; in the flash leveling stage, the starting point of the flash leveling is determined according to the distance between the movable and static clamps when the welding current is greater than the threshold current for the first time in this stage, and the starting point of the continuous flash in the continuous flash stage is determined similarly.
  • the flash leveling stage includes the following steps:
  • step (2.4) Determine the flash-flat distance. If the current dynamic-static fixture distance l>l′ 0 -L a , return to step (2.3). Otherwise, the flash-flat stage ends, where L a is the flash-flat length.
  • the preheating stage includes the following steps:
  • the continuous flashing stage includes the following steps:
  • the upsetting stage comprises the following steps:
  • the reset stage includes the following steps:
  • the present invention has the following significant advantages: 1.
  • the present invention can automatically determine the starting point of flash leveling according to the electrode position where the first welding current is greater than the gate line current in the flash leveling stage, and can achieve flash leveling more accurately to avoid material waste;
  • the preheating stage is achieved by controlling the advance and retreat of the brake clamp and the additional preheating compression according to the relationship between the welding current i and the threshold current I, which has the advantages of stable preheating and low material consumption;
  • the forward speed in the continuous flash stage is proportional to the flash distance, thereby producing an accelerated flash effect, with the advantages of fast energy accumulation, difficult flash interruption, and low material consumption, and can ensure that the optimal flash speed is reached at the end of the flash; 4.
  • the present invention can automatically identify the starting position of welding to ensure the consistency of the length after welding; 5.
  • the present invention avoids the problems of uneven heating and discontinuous flash caused by uneven or misaligned end faces of the workpieces to be welded through the flash leveling stage; 6.
  • the consistency of the input energy is improved and the loss of material is reduced through the controllable number of preheating stages, thereby ensuring the continuous progress of subsequent continuous flashes.
  • Fig. 1 is a schematic diagram of the process of the present invention
  • Figure 2 is a typical electrode position signal diagram during preheat flash butt welding
  • Figure 3 is a typical current signal diagram during preheating flash butt welding
  • the preheating flash butt welding method of the present invention involves welding parameters including: welding current i, current distance l between dynamic and static clamps, initial distance l′ 0 between dynamic and static clamps at the start of flash flattening, current preheating times n, initial distance l′ 1 between dynamic and static clamps at the start of flash, initial distance l′ 2 between dynamic and static clamps at the start of upset forging, and current time t.
  • Clamping Clamp the paired weldments in a dynamic fixture and a static fixture at a distance of l 0 (80 mm) respectively, and monitor the current distance l between the dynamic and static fixtures and the welding current i in real time during the welding process.
  • step (2.4) Determine the flash-flat distance. If the current dynamic-static fixture distance l>l′ 0 -3 mm, return to step (2.3). Otherwise, the flash-flat stage ends.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Pressure Welding/Diffusion-Bonding (AREA)
  • Arc Welding In General (AREA)

Abstract

一种预热闪光对焊方法，包括装夹、闪平阶段、预热阶段、连续闪光阶段、顶锻阶段和复位阶段，其中，在闪平阶段、预热阶段和连续闪光阶段中均是根据焊接电流与门限电流关系控制动夹具进退；在闪平阶段，根据焊接电流在该阶段首次大于门限电流时动-静夹具的距离确定闪平起点，同理确定连续闪光阶段的连续闪光起点。本闪光对焊方法能够自动判断闪平起点，更精确的实现闪平，避免材料的浪费；预热阶段预热稳定，材料消耗少；连续闪光阶段具有能量积累快、闪光不易中断、材料消耗小的优势，保证到闪光末期达到最佳闪光速度。

Description

一种预热闪光对焊方法 技术领域
本发明涉及机械加工技术，尤其涉及一种预热闪光对焊方法。
背景技术
船用锚链和系泊锚链是连接锚和船体或海洋工程设备之间的链条，随着世界各国对海洋资源需求量的加大，以及近年来海啸、飓风、海域频繁发生的地震等恶劣海况与自然气象对海洋资源勘探开采油设施及系泊单元的破坏，海洋工程用的高级别系泊链需求量在不断地增长。随着海洋开发的进行，新式海洋平台及相关海洋工程结构等系泊单元的投入运营，作为海洋采油、采矿装置固定装置所不可或缺的安全保障部件的高级别系泊链，其需求将愈来愈大。
中国专利201080048430.0公开了一种钢轨钢的闪光对焊方法，通过规定预热工序中电流流通的时间，从而使焊接接头头部的热影响宽度控制在27mm以下，以便后续对钢轨的组织性能不会产生太大影响。中国专利201910407841.7公开了一种用于硬质合金刀刃的闪光对焊连接方法，在焊前预热时，通过将工件端口多次接触与分开，并限制每次的通电时间，直至端口均被加热至额定温度；在断续闪光对焊时，通过设定动夹钳的初速度和加速度使其做加速进给运动，达到预定的闪光留量后再采用顶锻速度。但其预热阶段没有根据实际的工况进行调控，如针对门限电流的浮动等，预热工序不可控，导致在进行闪光工序时因温度不足而导致闪光阶段中断，使后续的闪光阶段与预热交替进行，进而使烧化长度不可控。闪光的加速阶段并未结合实际的烧化情况进行控制，易影响焊接接头的质量。
发明内容
发明目的：本发明旨在提供一种根据实际的工况进行调控的预热闪光对焊方法。
技术方案：本发明所述预热闪光对焊方法，包括装夹、闪平阶段、预热阶段、连续闪光阶段、顶锻阶段和复位阶段，其中，在闪平阶段、预热阶段和连续闪光阶段中均是根据焊接电流i与门限电流I关系控制动夹具进退；在闪平阶段，根据焊接电流在该阶段首次大于门限电流时动-静夹具的距离确定闪平起点，同理确定连续闪光阶段的连续闪光起点。
进一步的，所述闪平阶段包括如下步骤：
(2.1)电极通电；
(2.2)判断闪平起点：动夹具以v0的速度前进，直至第一次焊接电流i＞I时，动夹具停止，确定闪平起点，此时令闪平开始时动-静夹具距离l′0＝l；
(2.3)当i＞I时，动夹具以-v0的速度后退，直至i≤I；当i≤I时，动夹具以v0的速度前进闪平，直至i＞I；
(2.4)判断闪平距离，若当前动-静夹具距离l＞l′0-La，则返回步骤(2.3)，反之闪平阶段结束，其中La为闪平长度。
进一步的，所述预热阶段包括如下步骤：
(3.1)n＝0；
(3.2)动夹具以v1的速度前进，直至i＞I，继续以v1的速度前进预热压缩量Δp，让两个待焊工件端面接触更加紧密；
(3.3)动夹具停止t1时间；
(3.4)动夹具以-v1的速度后退，直至i≤I；
(3.5)动夹具停止t2时间；
(3.6)n：＝n+1，若n＜N，返回(3.2)，反之预热阶段结束，其中N为额定预热次数。
进一步的，所述连续闪光阶段包括如下步骤：
(4.1)判断连续闪光起点：动夹具以v3的速度前进，直至i＞I时，动夹具停止，确定连续闪光起点，此时令连续闪光开始时动-静夹具距离l′1＝l；
(4.2)当i＞I时，动夹具以的速度后退，直至i≤I；当i≤I时，动夹具以的速度前进连续闪光，直至i＞I；
(4.3)判断连续闪光距离，若l＞l′1-Lb+L′b，则返回(4.2)；若l≤l′1-Lb+L′b，动夹具以v3的速度做匀速前进，直至l≤l′1-Lb，动夹具停止，连续闪光阶段结束；其中，Lb为烧化长度，L′b为最短连续闪光长度。
进一步的，所述顶锻阶段包括如下步骤：
(5.1)令t＝0，顶锻开始时动-静夹具初始的距离l′2＝l；
(5.2)动夹具以v4的速度前进，进行带电顶锻，此时不断记录当前经历的时间t，直至t≥tu，其中tu为带电顶锻时间；
(5.3)切断焊接电流；
(5.4)动夹具以v4的速度继续前进至l′2-Lc处，其中Lc为顶锻长度；
(5.5)动夹具维持在l′2-Lc处不动，保持tm时间，其中tm为顶锻保持时间。
进一步的，所述复位阶段包括如下步骤：
(6.1)动夹具、静夹具松开；
(6.2)动夹具退回至初始位置，焊接过程结束。
有益效果：本发明与现有技术相比，其显著优点是：1、本发明根据闪平阶段第一次焊接电流大于门线电流的电极位置，能够自动判断闪平起点，能够更精确的实现闪平，避免材料的浪费；2、预热阶段根据焊接电流i与门限电流I关系控制动夹具进退及附加的预热压缩量实现，具有预热稳定，材料消耗少的优点；3、连续闪光阶段的前进速度与闪光距离成正比，从而产生加速闪光的效果，具有能量积累快、闪光不易中断、材料消耗小的优势，能够保证到闪光末期达到最佳闪光速度；4、本发明能够自动识别焊接起始位置，保证了焊后长度的一致；5、本发明通过闪平阶段避免了因待焊工件端面不平整或不对齐造成的加热不均匀及闪光不连续的问题；6、通过可控次数的预热阶段提高了输入能量的一致性，并减少了材料的损失，保障后续的连续闪光的持续进行。
附图说明
图1为本发明的流程示意图；
图2为预热闪光对焊过程中典型的电极位置信号图；
图3为预热闪光对焊过程中典型的电流信号图；
图中：s1-前进，s2-加热，s3-后退，s4-均衡，s5-有电顶锻，s6-无电顶锻。
具体实施方式
下面结合附图对本发明作进一步说明。
本发明所述预热闪光对焊方法，涉及的焊接参数有：焊接电流i，动-静夹具当前距离l，闪平开始时动-静夹具初始的距离l′0，当前预热次数n，闪光开始时动-静夹具初始的距离l′1，顶锻开始时动-静夹具初始的距离l′2，当前时间t。焊接工艺参数设定为：门限电流I＝4504，动-静夹具初始距离l0＝80mm，闪平速度v0＝1mm/s，闪平长度La＝3mm，预热速度v1＝10mm/s，额定预热次数N＝9次，预热压缩量Δp＝0.5mm，加热时间t1＝2s，冷却时间t2＝1s，闪光初速度v2＝0.4mm/s，闪光末速度v3＝2mm/s，烧化长度Lb＝12mm，最短连续闪光长度L′b＝2mm，带电顶锻时间tu＝0.2s，顶锻保持时间tm＝30s，顶端速度v4＝35mm/s，顶锻长度Lc＝15mm。
具体步骤如下：
(1)装夹：将成对焊件分别夹持在相距l0(80mm)的动夹具与静夹具内，并对焊接过程中动-静夹具当前距离l、焊接电流i进行实时监测。
(2)闪平阶段：
(2.1)电极通电；
(2.2)判断闪平起点：动夹具以v0(1mm/s)的速度进给，直至第一次焊接电流 i＞I(450A)，动夹具停止，确定闪平起点，此时令闪平开始时动-静夹具距离l′0＝l；
(2.3)当i＞I(450A)时，动夹具以-v0(-1mm/s)的速度后退，直至i≤I(450A)；当i≤I(450A)时，动夹具以v0(1mm/s)的速度前进开始闪平，直至i＞I(450A)；
(2.4)判断闪平距离，若当前动-静夹具距离l＞l′0-3mm，则返回步骤(2.3)，反之闪平阶段结束。
(3)预热阶段：
(3.1)n＝0；
(3.2)动夹具以v1(10mm/s)的速度做进给运动，直至i＞I(450A)，继续以v1(10mm/s)的速度前进Δp(0.5mm)，让两个待焊工件端面接触更加紧密，如图2中s1所示；
(3.3)动夹具停止t1(2s)时间，如图2中s2所示；
(3.4)动夹具以-v1(-10mm/s)的速度后退，直至i≤I(450A)，如图2中s3所示；
(3.5)动夹具停止t2(1s)时间，如图2中s4所示；
(3.6)n：＝n+1，若n＜N(9)，则返回(3.2)，反之预热阶段结束。
(4)连续闪光阶段：
(4.1)判断连续闪光起点：动夹具以v3(2mm/s)的速度做进给运动，直至i＞I(450A)，动夹具停止，确定连续闪光起点，此时令连续闪光开始时动-静夹具初始的距离l′1＝l；
(4.2)当i＞I(450A)时，动夹具以-[0.16×(l-l′1)+0.4]mm/s的速度后退，直至i≤I(450A)；当i≤I(450A)时，动夹具以[0.16×(l-l′1)+0.4]mm/s的速度前进连续闪光，直至i＞I(450A)；
(4.3)判断连续闪光距离，若l＞l′1-10mm，则返回(4.2)；若l≤l′1-10mm，动夹具以v3(2mm/s)的速度做匀速进给运动，直至l≤l′1-12mm，动夹具停止，连续闪光阶段结束。
(5)顶锻阶段：
(5.1)令t＝0，顶锻开始时动-静夹具初始的距离l′2＝l；
(5.2)动夹具以v4(35mm/s)的顶锻速度前进，进行带电顶锻，此时不断记录当前经历的时间t，直至t≥tu(0.2s)，如图2中s5所示；
(5.3)切断焊接电流；
(5.4)动夹具以v4(35mm/s)的顶锻速度继续前进至l′2-15mm处；
(5.5)动夹具维持在l′2-15mm处不动，并保持tm(30s)，如图2中s6所示。
(6)复位阶段：
(6.1)动夹具、静夹具松开；
(6.2)动夹具退回至初始距离l0(80mm)处，焊接过程结束。

Claims (6)

  1. 一种预热闪光对焊方法，其特征在于，包括装夹、闪平阶段、预热阶段、连续闪光阶段、顶锻阶段和复位阶段，其中，在闪平阶段、预热阶段和连续闪光阶段中均是根据焊接电流i与门限电流I关系控制动夹具进退；在闪平阶段，根据焊接电流在该阶段首次大于门限电流时动-静夹具的距离确定闪平起点，同理确定连续闪光阶段的连续闪光起点。
  2. 根据权利要求1所述预热闪光对焊方法，其特征在于，所述闪平阶段包括如下步骤：
    (2.1)电极通电；
    (2.2)判断闪平起点：动夹具以v0的速度前进，直至第一次焊接电流i＞I时，动夹具停止，确定闪平起点，此时令闪平开始时动-静夹具距离l′0＝l；
    (2.3)当i＞I时，动夹具以-v0的速度后退，直至i≤I；当i≤I时，动夹具以v0的速度前进闪平，直至i＞I；
    (2.4)判断闪平距离，若当前动-静夹具距离l＞l′0-La，则返回步骤(2.3)，反之闪平阶段结束，其中La为闪平长度。
  3. 根据权利要求1所述预热闪光对焊方法，其特征在于，所述预热阶段包括如下步骤：
    (3.1)n＝0；
    (3.2)动夹具以v1的速度前进，直至i＞I，继续以v1的速度前进预热压缩量Δp，让两个待焊工件端面接触更加紧密；
    (3.3)动夹具停止t1时间；
    (3.4)动夹具以-v1的速度后退，直至i≤I；
    (3.5)动夹具停止t2时间；
    (3.6)n：＝n+1，若n＜N，返回(3.2)，反之预热阶段结束，其中N为额定预热次数。
  4. 根据权利要求1所述预热闪光对焊方法，其特征在于，所述连续闪光阶段包括如下步骤：
    (4.1)判断连续闪光起点：动夹具以v3的速度前进，直至i＞I时，动夹具停止，确定连续闪光起点，此时令连续闪光开始时动-静夹具距离l′1＝l；
    (4.2)当i＞I时，动夹具以的速度后退，直至i≤I；当i≤I时，动夹具以的速度前进连续闪光，直至i＞I；
    (4.3)判断连续闪光距离，若l＞l′1-Lb+L′b，则返回(4.2)；若l≤l′1-Lb+L′b，动夹具以v3的速度做匀速前进，直至l≤l′1-Lb，动夹具停止，连续闪光阶段结束；其中，Lb为烧化长度，L′b为最短连续闪光长度。
  5. 根据权利要求1所述预热闪光对焊方法，其特征在于，所述顶锻阶段包括如下步骤：
    (5.1)令t＝0，顶锻开始时动-静夹具初始的距离l′2＝l；
    (5.2)动夹具以v4的速度前进，进行带电顶锻，此时不断记录当前经历的时间t，直至t≥tu，其中tu为带电顶锻时间；
    (5.3)切断焊接电流；
    (5.4)动夹具以v4的速度继续前进至l′2-Lc处，其中Lc为顶锻长度；
    (5.5)动夹具维持在l′2-Lc处不动，保持tm时间，其中tm为顶锻保持时间。
  6. 根据权利要求1所述预热闪光对焊方法，其特征在于，所述复位阶段包括如下步骤：
    (6.1)动夹具、静夹具松开；
    (6.2)动夹具退回至初始位置，焊接过程结束。
PCT/CN2023/082656 2023-01-31 2023-03-21 一种预热闪光对焊方法 Ceased WO2024159592A1 (zh)

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