大电流GMAW的熔滴过渡行为及控制
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摘要
具有稳定熔滴过渡过程的单丝大电流GMAW(熔化极气体保护焊)焊接方法拥有其他高效GMAW焊接方法不可取代的优势.通过采集大电流GMAW的熔滴过渡高速摄像和焊接电流电压信号,对比分析了大电流MIG(熔化极惰性气体保护焊)和MAG(熔化极活性气体保护焊)焊接过程中不同的熔滴过渡行为,分析了焊接电流和保护气体成分对熔滴过渡频率的影响.结果表明:大电流MIG焊接熔滴过渡形式为单一的旋转射流过渡,且旋转频率随着焊接电流的增大先减小后增大;大电流MAG焊接熔滴过渡形式为摆动和旋转射流混合过渡,且摆动过渡频率会因为液流束与熔池接触短路而增大;外加磁场能够改变大电流GMAW液流束和电弧的旋转方向,减小旋转角度,这一发现为400 A以上稳定单丝高效GMAW焊接工艺的研发提供了新思路.
Single wire high-current GMAW welding methods with steady metal transfer processes has irreplaceable advantages over other high-efficiency GMAW welding methods.Based on the high-speed photography and electric signals selecting technology in metal transfer process of GMAW,the differences between MIG and MAG welding were discussed,and the impacts of current or shielding gas constitution on transfer frequency were highlighted.The results indicate that metal transfer style of high-current MIG welding is rotating spray transfer,and the rotating frequency of MIG welding decrease at first and then increase with the increase of welding current;while in the MAG welding,it becomes a mixing rotating and swing transfer style,and the rotating frequency or swing frequency increases when the flow beam contacts with the weld pool in high current condition.In addition,the external magnetic field can change the rotation direction of large current GMAW flow beam and arc,and reduce the rotation angle.This discovery provides a new idea for the research and development of high efficiency GMAW welding process with single wire over 400 A.
Single wire high-current GMAW welding methods with steady metal transfer processes has irreplaceable advantages over other high-efficiency GMAW welding methods.Based on the high-speed photography and electric signals selecting technology in metal transfer process of GMAW,the differences between MIG and MAG welding were discussed,and the impacts of current or shielding gas constitution on transfer frequency were highlighted.The results indicate that metal transfer style of high-current MIG welding is rotating spray transfer,and the rotating frequency of MIG welding decrease at first and then increase with the increase of welding current;while in the MAG welding,it becomes a mixing rotating and swing transfer style,and the rotating frequency or swing frequency increases when the flow beam contacts with the weld pool in high current condition.In addition,the external magnetic field can change the rotation direction of large current GMAW flow beam and arc,and reduce the rotation angle.This discovery provides a new idea for the research and development of high efficiency GMAW welding process with single wire over 400 A.
引文
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[2] 黄健康,何笑英,石玗,等.脉冲频数对pulsed DE-GMAW焊缝成形的分析 [J].焊接学报,2017,38(6):51- 55.HUANG Jian-kang,HE Xiao-ying,SHI Yu,et al.Study for pulse frequency and number influence on welding joint of pulsed DE-GMAW [J].Transactions of the China Welding Institution,2017,38(6):51- 55.
[3] WU K,HE Z,LIANG Z,et al.The dynamic behavior of double arc interference in high-power double wire pulsed GMAW [J].The International Journal of Advanced Ma-nufacturing Technology,2017,88(9/10/11/12):2795- 2802.
[4] UEYAMA T,UEZONO T,ERA T,et al.Solution to problems of arc interruption and arc length control in tandem pulsed gas metal arc welding [J].Science and Technology of Welding and Joining,2009,14(4):305- 314.
[5] ARITA M H,MORIMOTO M T,SHIGEO N,et al.Development of advanced 3-electrode MAG high-speed horizontal fillet welding process [J].Welding in the World,2009,53(5/6):35- 43.
[6] YOKOTA M Y,SHIMIZU M H,SHIGEO N,et al.Development and application of the 3-electrode MAG high-speed horizontal fillet welding process [J].Welding in the World,2012,56(1/2):43- 47.
[7] TANG G,CHEN H,YANG X,et al.Effects of different welding process on the electronic temperature of plasma and weld shape during laser-MIG hybrid welding of A7N01P-T4 aluminum alloy [J].Journal of Laser Applications,2018,30(2):022002- 1- 022002- 18.
[8] 殷树言,陈树君,华爱兵.单丝高熔敷率MAG焊接工艺的研究 [J].电焊机,2009,39(1):73- 76.YIN Shu-yan,CHEN Shu-jun,HUA Ai-bing.Research on high penetration MAG welding process with single wire [J].Electric Welding Machine,2009,39(1):73- 76.
[9] 华爱兵,殷树言,陈树君,等.细丝大电流MAG焊的熔滴过渡机制 [J].焊接学报,2009,30(8):93- 96.HUA Ai-bing,YIN Shu-yan,CHEN Shu-jun,et al.Mechanics of drop transfer for high-current density MAG welding process [J].Transactions of the China Welding Institution,2009,30(8):93- 96.
[10] 华爱兵,殷树言,陈树君,等.细丝大电流MAG焊接机理 [J].机械工程学报,2010,46(16):142- 147.HUA Ai-bing,YIN Shu-yan,CHEN Shu-jun,et al.Mechanism of thin wire high current MAG welding [J].Journal of Mechanical Engineering,2010,46(16):142- 147.
[11] BABA H,ERA T,UEYAMA T,et al.Single pass full penetration joining for heavy plate steel using high cu-rrent GMA process [J].Welding in the World,2017,61(1):1- 7.
[12] 过增元,赵文华.电弧和热等离子体 [M].北京:科学出版社,1986.
[13] 陈树君,王军,王会霞,等.纵向磁场作用下的旋转射流过渡的机理 [J].焊接学报,2005,26(3):45- 49,54.CHEN Shu-jun,WANG Jun,WANG Hui-xia,et al.Principle of rotating transfer undergoing longitudinal magnetic field control [J].Transactions of the China Welding Institution,2005,26(3):45- 49,54.
[14] 王军.磁场控制高效MAG焊接旋转射流过渡稳定性的研究 [D].北京:北京工业大学,2003.
[15] 华爱兵,殷树言,陈树君,等.纵向磁场对MAG焊电弧及熔滴过渡的控制作用 [J].机械工程学报,2010,46(14):95- 100.HUA Ai-bing,YIN Shu-yan,CHEN Shu-jun,et al.Behavior of arc and drop transfer of MAG welding controlled by longitudinal magnetic field [J].Journal of Mechanical Engineering,2010,46(14):95- 100.
[16] 黄炜,艾盛,王震.MAG焊脉冲电流控制旋转喷射过渡 [J].焊接学报,1996,17(3):145- 149.HUANG Wei,AI Sheng,WANG Zhen.Pulsed rotating-spray transfer during MAG welding [J].Transactions of the China Welding Institution,1996,17(3):145- 149.
[17] 黄炜.脉冲旋转喷射过渡的电弧行为及熔滴过渡特性的研究 [D].西安:西北工业大学,1995.
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