中国近十年绿色焊接技术研究进展
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摘要
"绿色制造"是中国制造2025的重要前提,绿色焊接是"绿色制造"的重要组成部分,是针对焊接行业中普遍存在的能源消耗大、资源有效利用率低等问题而提出的发展概念,其主要理念是研发并采用低排放、低污染的焊接材料、焊接工艺及新型高效、绿色的焊接方法。黑色金属主要指钢及不锈钢,其构件主要用于造船、汽车制造、电站设备、石油化工设备以及桥梁建设等大型构件。随着我国制造行业轻量化进程的不断加快,铝合金、镁合金以及钛合金等轻量化产品在各行各业的应用也越来越广泛。焊接技术作为装备制造领域的共性技术,已经成为影响黑色、有色金属在装备制造领域应用的关键技术之一。围绕黑色金属绿色焊接,船舶制造领域CO_2气体保护焊用药芯焊丝逐渐取代实心焊丝;汽车制造领域为减轻车身质量,大幅采用热成形钢、镀锌钢以及铝/钢异种结构,主流的绿色焊接技术包括动态电阻中频自适应焊接技术、激光焊、搅拌摩擦焊等;火、水、核电站等大型构件主要采用的绿色焊接方法为热丝TIG焊、窄间隙热丝TIG焊、窄间隙埋弧焊以及多头熔化极气体保护焊等;石油化工设备制造多为现场焊接,对于球罐结构多采用焊接机器人进行焊接,对于海洋管道的维修和抢修,水下干式高压焊是比较成熟的高质量焊接方法,未来发展的重点是无潜式全自动海洋管道焊接维修系统;我国当前桥用结构钢已经发展到第六代桥梁钢Q500q钢,Q500q钢的发展带动了新型绿色药芯气体保护焊丝等焊接材料的成功研发。针对高铁、汽车、五金家电、电子行业等制造领域有色金属构件的焊接,可采用激光焊、高效电弧焊及激光-电弧复合焊、搅拌摩擦焊、新型绿色钎焊技术等诸多方法。本文综合评述了黑色、有色金属构件与熔化焊、压力焊、钎焊相关的新型高效绿色焊接方法及绿色焊接材料的研究进展。首先介绍了造船、汽车、电力、石油化工、桥梁建设等领域黑色金属大型构件的绿色焊接技术,以及每种焊接技术各自的特点和应用范围;然后综述了与有色金属构件相关的高铁、汽车制造、五金家电和电子行业等领域连接所涉及的绿色焊接技术,并对机器人自动化焊接、典型绿色焊接技术如激光-电弧复合能场焊、搅拌摩擦焊等以及绿色焊接材料如高铁制造用铝合金焊丝以及无镉低银、无铅钎料进行了简单举证与分析;最后整理了目前绿色焊接技术所存在的问题,并展望了未来的发展趋势,以期为我国绿色焊接技术在各行各业的进一步推广应用提供有益的参考。
Green manufacturing is animportant prerequisite of achieving the goal of "Made in China in 2025". Green welding is an important part ofgreen manufacturing. Green welding is a development concept aiming at the common issues of high energy consumption and low effective utilization of resources in welding industries. Its main content is to develop and use green welding materials and technologies with low emission and low pollution,and new high-efficient green welding methods.Ferrous metal mainly refers to steel and stainless steel. Their structure parts are mainly used in shipbuilding,automobile manufacturing,power plant equipment,petrochemical equipment,bridge construction and fabricating other large components. With the acceleration of lightweight process in Chinese manufacturing industry,the applications of lightweight non-ferrous metals such as aluminum alloy,magnesium alloy and titanium alloy are more and more widespread in all walks of life. As a generic technology,welding technology has become one of the key technologies affecting the application of ferrous and non-ferrous metals in the field of equipment manufacturing.For green welding of ferrous metals,the solid welding wire used for CO2 gas shielded welding is gradually replaced by the flux-cored wire in the field of shipbuilding. In order to reduce the weight of automobile body,hot-formed steel,galvanized steel and aluminum/steel dissimilar structures are widely used in the field of automobile manufacturing. The mainstream green welding technologies in automobile manufacturing include dynamic electric resistance controlled medium frequency resistance spot welding,laser welding,friction stir welding and so on. The main green welding methods used in power plant construction( include thermal power,hydro power and nuclear power) are all-position TIG hot wire welding,narrow gap TIG hot wire welding,narrow gap submerged arc welding and multi-head gas shielded arc welding,etc. Field welding is widely used in the manufacture of petrochemical equipment. Arc welding robots are often used for spherical tank structures. For the maintenance and emergent repair of marine pipelines,underwater dry high-pressure welding is a relatively mature high-quality welding method and the future focus is on developing submersible full-automatic marine pipeline welding maintenance system. At present,bridge structural steel in China has already developed to the sixth generation of bridge steel-Q500 q,which promotes the successful development of new green flux-cored gas shielded welding wire and other welding materials. For the welding of non-ferrous metal components in the fields of high-speed rail,automobile,hardware and household appliances,many green welding methods such as laser welding,laser-arc hybrid welding,friction stir welding,new green brazing technology can be used to realize the green connection of non-ferrous metals.In this paper,the research progress of new efficient green welding technologies and green welding materials related to melt welding,pressure welding and brazing for both ferrous and non-ferrous metal components were reviewed systematically. Firstly,the green welding technologies of large ferrous metal components in shipbuilding,automobile,electric power,petrochemical industry,bridge construction and other fields,as well as their respective characteristics and application scope were introduced. Then,green welding technologies of non-ferrous metal components related to high-speed train,automobile manufacturing,household appliances,electronics industry were summarized. Moreover,robot automaticwelding,typical green welding technologies such as laser-arc hybrid welding,friction stir welding and green welding materials such as shaved aluminum alloy wire for high-speed train and low-silver,cadmium-free brazing filler metals and lead-free solders were simply exampled and analyzed.Finally,the existing problems and the future development trends of green welding technologies were summarized and proposed,respectively,which can provide a valuable reference for further popularization and application of green welding technologies in all walks of life in China.
Green manufacturing is animportant prerequisite of achieving the goal of "Made in China in 2025". Green welding is an important part ofgreen manufacturing. Green welding is a development concept aiming at the common issues of high energy consumption and low effective utilization of resources in welding industries. Its main content is to develop and use green welding materials and technologies with low emission and low pollution,and new high-efficient green welding methods.Ferrous metal mainly refers to steel and stainless steel. Their structure parts are mainly used in shipbuilding,automobile manufacturing,power plant equipment,petrochemical equipment,bridge construction and fabricating other large components. With the acceleration of lightweight process in Chinese manufacturing industry,the applications of lightweight non-ferrous metals such as aluminum alloy,magnesium alloy and titanium alloy are more and more widespread in all walks of life. As a generic technology,welding technology has become one of the key technologies affecting the application of ferrous and non-ferrous metals in the field of equipment manufacturing.For green welding of ferrous metals,the solid welding wire used for CO2 gas shielded welding is gradually replaced by the flux-cored wire in the field of shipbuilding. In order to reduce the weight of automobile body,hot-formed steel,galvanized steel and aluminum/steel dissimilar structures are widely used in the field of automobile manufacturing. The mainstream green welding technologies in automobile manufacturing include dynamic electric resistance controlled medium frequency resistance spot welding,laser welding,friction stir welding and so on. The main green welding methods used in power plant construction( include thermal power,hydro power and nuclear power) are all-position TIG hot wire welding,narrow gap TIG hot wire welding,narrow gap submerged arc welding and multi-head gas shielded arc welding,etc. Field welding is widely used in the manufacture of petrochemical equipment. Arc welding robots are often used for spherical tank structures. For the maintenance and emergent repair of marine pipelines,underwater dry high-pressure welding is a relatively mature high-quality welding method and the future focus is on developing submersible full-automatic marine pipeline welding maintenance system. At present,bridge structural steel in China has already developed to the sixth generation of bridge steel-Q500 q,which promotes the successful development of new green flux-cored gas shielded welding wire and other welding materials. For the welding of non-ferrous metal components in the fields of high-speed rail,automobile,hardware and household appliances,many green welding methods such as laser welding,laser-arc hybrid welding,friction stir welding,new green brazing technology can be used to realize the green connection of non-ferrous metals.In this paper,the research progress of new efficient green welding technologies and green welding materials related to melt welding,pressure welding and brazing for both ferrous and non-ferrous metal components were reviewed systematically. Firstly,the green welding technologies of large ferrous metal components in shipbuilding,automobile,electric power,petrochemical industry,bridge construction and other fields,as well as their respective characteristics and application scope were introduced. Then,green welding technologies of non-ferrous metal components related to high-speed train,automobile manufacturing,household appliances,electronics industry were summarized. Moreover,robot automaticwelding,typical green welding technologies such as laser-arc hybrid welding,friction stir welding and green welding materials such as shaved aluminum alloy wire for high-speed train and low-silver,cadmium-free brazing filler metals and lead-free solders were simply exampled and analyzed.Finally,the existing problems and the future development trends of green welding technologies were summarized and proposed,respectively,which can provide a valuable reference for further popularization and application of green welding technologies in all walks of life in China.
引文
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