脉冲MIG焊接外加磁场控制研究
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摘要
21世纪是海洋的世纪,水下焊接是海洋工程建设、维护重要的支持技术之一,水下焊接面临深水油气田开发带来的巨大挑战。TIG焊接能够适应的最大水深大约是500m,MIG焊接能够用于水深超过1000m的场合。国外研究虽然实现了250bar压力即相当于2500m水深条件之下的MIG焊接的重大突破,但是没有彻底解决高压之下MIG焊接熔滴过渡受阻问题,而只是被动地将弧长控制在非常之短,不可避免的短路过渡导致焊接过程不够稳定和接头质量欠佳。因为外加磁场能够显著增加弧柱电场强度、能量密度和电弧挺度,所以有望从根本上解决制约高压MIG焊接研究的首要问题,即高压之下反向等离子流阻碍等离子流、导致熔滴过渡困难的问题,并借助于外加纵向磁场的电磁搅拌作用改善接头焊接质量。
本论文的依托项目是国家自然科学基金课题“海洋结构修复用空气加压高压MIG焊接的外加磁场控制”(40776054)。本论文主要研究常压环境下,磁场对MIG焊接电弧特性、熔滴过渡行为等的影响,其成果将为依托项目拟定的高压环境之下磁场控制MIG焊接研究打下坚实基础。
本论文以高速摄像和数据采集系统等为手段,研究了常压环境下脉冲MIG焊接外加磁场控制的影响因素。本文采用纵向磁场,在相同的保护气体下,以焊接电流、励磁电流为控制参数进行MIG焊接,全面、深入地分析了纵向磁场对脉冲MIG焊电弧形态、熔滴过渡行为、焊丝熔化特性的影响特点,提出了磁场控制脉冲MIG焊接工艺。
在综合考虑工程实用性和磁控稳定性等因素的基础上,本文设计了纵向磁场装置,将外加磁场技术用于脉冲MIG焊接,期望通过磁场能量平衡高压环境介质压力的影响,从根本上突破熔滴过渡问题,改善接头质量。本论文利用有限元方法对影响焊接区域外加磁场分布的相关因素进行仿真研究,分析了励磁线圈的形状、位置、励磁电流的大小、焊接材料的变化等诸多因素对磁场分布的影响,为在不同形式下焊接时选择科学、合理的外加磁场控制提供了理论上的支持。研究结果表明,合理设置纵向磁场的参数可以有效地控制焊接质量,适应不同场合的焊接要求,从而为进一步实现高压环境焊接奠定了基础。
本论文提出,采用外加纵向磁场控制电弧形态,进而控制熔滴过渡过程,以纯氩气保护气体获得稳定的射滴过渡形式。为此,本论文建立了一套磁场控制的脉冲MIG焊接系统,主要包括性能优良的焊接电源、稳定可靠的送丝系统、简单实用的励磁装置和操作简单的焊接平台,以及数据采集系统。该数据采集系统对焊接过程中的焊接电压、焊接电流、电弧图像等重要参数进行同步采集,实际工作过程为:高速摄像机实时拍摄磁控焊电弧及熔滴过渡过程,同时数据采集卡采集焊接电弧电压、电流信号以及高速摄像机Strobe输出信号,从而准确确定每一帧高速图像的拍摄时刻,并与电压、电流信号相对应,实现焊接过程的多信息同步采集。
本论文利用磁场控制脉冲MIG焊接系统进行了焊接实验,证实了外加纵向磁场对射滴过渡过程的控制作用。实验验证,采用外加磁场控制脉冲MIG焊接电弧,以纯氩气气体保护,获得了稳定的射滴过渡形式,解决了熔滴过渡稳定性问题,为以后高压环境MIG焊接提供了良好的实验依据。
The 21st century is the century of marine.As one of the important supporting technologies,underwater welding is used in ocean engineering construction,which faces up to the great challenge of development of oil & gas fields in deep water.TIG welding can adapt to the greatest depth of 500m, and MIG welding can be used in the situation at depth greater than about 1000m.Although study abroad has made important breakthrough in the MIG welding under the conditions of 250bar pressure,which is equal to the condition of the water depth of 2500m,it hasn't resolved MIG welding drip melting translation bottlenecks under high-pressure conditions completely. Study abroad only controls the arc length very short passively.Unavoidable dip transfer results in the unsteadiness during the welding process and quality defect of welded splice.Because the external magnetic field can significantly increase the arc column electric field strength,energy density and arc stiffness, the primary problem of restricting MIG welding of high pressure,namely, reverse flow of plasma impedes the flow of plasma and leads to the difficulties of drip melting translation,is expected to be solved fundamentally.Meantime, the quality of junction seal can be improved by the aid of the role of electromagnetic stirring of additional longitudinal magnetic field.
This essay relies on the project of National Natural Science Foundation: Using MIG welding of high pressure air pressure coupled with magnetic field control in the repair of marine structures 40776054).This paper is concerned with the impacts of magnetic field on the arc characteristics of MIG welding, metal transfer behavior etc.in atmospheric environment.The achievement will lay a solid foundation for the research of magnetic field control MIG welding under the hyperbaric environment drafted by the project.
This essay studies the influencing factors of the external magnetic field pulse MIG welding control in atmospheric environment by means of high-speed camera and data acquisition system.Adopting longitudinal magnetic field and making the welding current and field current as controls parameter under the same protection gas during MIG welding,this essay makes an assay of the impact characteristics of longitudinal magnetic field on pulsed MIG welding arc shape,drop transfer activity and wire melting.Pulse MIG welding process controlled by magnetic field is raised in this paper.
On the basis of considering the project practicability and magnetic control stability,a new type of longitudinal magnetic field generating device is designed,and the technique of additional magnetic field is used in pulsed MIG welding.This paper is expected to balance the impact of high-pressure environment medium pressure by magnetic field energy.The problem of drip melting translation can be solved and the quality of junction seal can be improved fundamentally.This paper makes a simulation study on the correlative factors of influencing the welding regional distribution of the additional magnetic field using finite element method,and makes an assay of the impacts of the shape and position of magnet exciting coil,the magnitude of field current and changes in welding materials,etc.,on the magnetic field distribution.This paper provides a theoretical foundation for choosing scientific and reasonable additional magnetic field control in different welding forms.The results show that the setting the parameters of longitudinal magnetic field reasonably can control welding quality effectively and adapt welding requirements in different occasions,which lay a good foundation for further achievement of high pressure welding.
On the basis of simplifying the structure of magnetic head and reinforcing the stability of magnetic strength,a new type of longitudinal magnetic field generating device id designed,and the techniques of external magnetic field in the pulsed MIG welding.
Base on the finite element software of ANSYS,the distribution of the magnetic field is simulated.The factors which affect the distribution of the magnetic field are discussed,such as the shape of the excitation coil,the location of the excitation coil,the location of the excitation coil,the materials to be welded,and the shape of the groove,etc.Based on the simulation,we can select the scientific and suitable additional magnetic field.
Based on the theoretic analyses and simulation,the high performance MIG welding system is established,including the good performance power source, the stable and reliable wire feed system,the less cost common shielding gas and the simply.Based on the high performance welding system,the interaction of the projected transfer and additional longitudinal magnetic field is testified by the experimental results.
By the experimental verification,the stable projected transfer mode by using additional magnetic field control instead of the pure Ar in shielding-gas, and solving the problem of projected transfer.At the same time,the result will provide a good experiment basis.
本论文的依托项目是国家自然科学基金课题“海洋结构修复用空气加压高压MIG焊接的外加磁场控制”(40776054)。本论文主要研究常压环境下,磁场对MIG焊接电弧特性、熔滴过渡行为等的影响,其成果将为依托项目拟定的高压环境之下磁场控制MIG焊接研究打下坚实基础。
本论文以高速摄像和数据采集系统等为手段,研究了常压环境下脉冲MIG焊接外加磁场控制的影响因素。本文采用纵向磁场,在相同的保护气体下,以焊接电流、励磁电流为控制参数进行MIG焊接,全面、深入地分析了纵向磁场对脉冲MIG焊电弧形态、熔滴过渡行为、焊丝熔化特性的影响特点,提出了磁场控制脉冲MIG焊接工艺。
在综合考虑工程实用性和磁控稳定性等因素的基础上,本文设计了纵向磁场装置,将外加磁场技术用于脉冲MIG焊接,期望通过磁场能量平衡高压环境介质压力的影响,从根本上突破熔滴过渡问题,改善接头质量。本论文利用有限元方法对影响焊接区域外加磁场分布的相关因素进行仿真研究,分析了励磁线圈的形状、位置、励磁电流的大小、焊接材料的变化等诸多因素对磁场分布的影响,为在不同形式下焊接时选择科学、合理的外加磁场控制提供了理论上的支持。研究结果表明,合理设置纵向磁场的参数可以有效地控制焊接质量,适应不同场合的焊接要求,从而为进一步实现高压环境焊接奠定了基础。
本论文提出,采用外加纵向磁场控制电弧形态,进而控制熔滴过渡过程,以纯氩气保护气体获得稳定的射滴过渡形式。为此,本论文建立了一套磁场控制的脉冲MIG焊接系统,主要包括性能优良的焊接电源、稳定可靠的送丝系统、简单实用的励磁装置和操作简单的焊接平台,以及数据采集系统。该数据采集系统对焊接过程中的焊接电压、焊接电流、电弧图像等重要参数进行同步采集,实际工作过程为:高速摄像机实时拍摄磁控焊电弧及熔滴过渡过程,同时数据采集卡采集焊接电弧电压、电流信号以及高速摄像机Strobe输出信号,从而准确确定每一帧高速图像的拍摄时刻,并与电压、电流信号相对应,实现焊接过程的多信息同步采集。
本论文利用磁场控制脉冲MIG焊接系统进行了焊接实验,证实了外加纵向磁场对射滴过渡过程的控制作用。实验验证,采用外加磁场控制脉冲MIG焊接电弧,以纯氩气气体保护,获得了稳定的射滴过渡形式,解决了熔滴过渡稳定性问题,为以后高压环境MIG焊接提供了良好的实验依据。
The 21st century is the century of marine.As one of the important supporting technologies,underwater welding is used in ocean engineering construction,which faces up to the great challenge of development of oil & gas fields in deep water.TIG welding can adapt to the greatest depth of 500m, and MIG welding can be used in the situation at depth greater than about 1000m.Although study abroad has made important breakthrough in the MIG welding under the conditions of 250bar pressure,which is equal to the condition of the water depth of 2500m,it hasn't resolved MIG welding drip melting translation bottlenecks under high-pressure conditions completely. Study abroad only controls the arc length very short passively.Unavoidable dip transfer results in the unsteadiness during the welding process and quality defect of welded splice.Because the external magnetic field can significantly increase the arc column electric field strength,energy density and arc stiffness, the primary problem of restricting MIG welding of high pressure,namely, reverse flow of plasma impedes the flow of plasma and leads to the difficulties of drip melting translation,is expected to be solved fundamentally.Meantime, the quality of junction seal can be improved by the aid of the role of electromagnetic stirring of additional longitudinal magnetic field.
This essay relies on the project of National Natural Science Foundation: Using MIG welding of high pressure air pressure coupled with magnetic field control in the repair of marine structures 40776054).This paper is concerned with the impacts of magnetic field on the arc characteristics of MIG welding, metal transfer behavior etc.in atmospheric environment.The achievement will lay a solid foundation for the research of magnetic field control MIG welding under the hyperbaric environment drafted by the project.
This essay studies the influencing factors of the external magnetic field pulse MIG welding control in atmospheric environment by means of high-speed camera and data acquisition system.Adopting longitudinal magnetic field and making the welding current and field current as controls parameter under the same protection gas during MIG welding,this essay makes an assay of the impact characteristics of longitudinal magnetic field on pulsed MIG welding arc shape,drop transfer activity and wire melting.Pulse MIG welding process controlled by magnetic field is raised in this paper.
On the basis of considering the project practicability and magnetic control stability,a new type of longitudinal magnetic field generating device is designed,and the technique of additional magnetic field is used in pulsed MIG welding.This paper is expected to balance the impact of high-pressure environment medium pressure by magnetic field energy.The problem of drip melting translation can be solved and the quality of junction seal can be improved fundamentally.This paper makes a simulation study on the correlative factors of influencing the welding regional distribution of the additional magnetic field using finite element method,and makes an assay of the impacts of the shape and position of magnet exciting coil,the magnitude of field current and changes in welding materials,etc.,on the magnetic field distribution.This paper provides a theoretical foundation for choosing scientific and reasonable additional magnetic field control in different welding forms.The results show that the setting the parameters of longitudinal magnetic field reasonably can control welding quality effectively and adapt welding requirements in different occasions,which lay a good foundation for further achievement of high pressure welding.
On the basis of simplifying the structure of magnetic head and reinforcing the stability of magnetic strength,a new type of longitudinal magnetic field generating device id designed,and the techniques of external magnetic field in the pulsed MIG welding.
Base on the finite element software of ANSYS,the distribution of the magnetic field is simulated.The factors which affect the distribution of the magnetic field are discussed,such as the shape of the excitation coil,the location of the excitation coil,the location of the excitation coil,the materials to be welded,and the shape of the groove,etc.Based on the simulation,we can select the scientific and suitable additional magnetic field.
Based on the theoretic analyses and simulation,the high performance MIG welding system is established,including the good performance power source, the stable and reliable wire feed system,the less cost common shielding gas and the simply.Based on the high performance welding system,the interaction of the projected transfer and additional longitudinal magnetic field is testified by the experimental results.
By the experimental verification,the stable projected transfer mode by using additional magnetic field control instead of the pure Ar in shielding-gas, and solving the problem of projected transfer.At the same time,the result will provide a good experiment basis.
引文
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