低电流TIG电弧辅助MIG高速焊咬边缺陷抑制机理及措施的研究
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摘要
基于温度场、流场、熔滴过渡以及电弧形态检测,开展低电流钨极氩弧焊(Tungsten inert gas welding,TIG)辅助熔化极惰性气体保护(Metal inert gas welding,MIG)高速焊工艺试验。从传热、传质以及受力等角度分析低电流TIG辅助电弧对高速MIG咬边缺陷的抑制机理,并分析各工艺参数对最终焊缝成形的影响。相比常规MIG高速焊,低电流TIG辅助电弧能有效降低MIG高速焊前部熔池边缘的温度梯度,延长熔池存在时间,促进液态金属向焊缝边缘填充。电弧力和熔滴冲击力是影响高速焊咬边缺陷的主要作用力,低电流TIG辅助电弧对MIG熔滴冲击力改变较小,但两电弧耦合后,电弧静、动压力明显降低,可有效地抑制MIG高速焊中咬边缺陷的产生。此外,正交工艺试验显示,丝-极间距和焊枪倾角是影响复合焊工艺的重要参数,而钨极距工件距离和TIG焊接电流则对咬边缺陷的影响较小,通过对丝-极间距和焊枪倾角的调节能快速实现该复合焊工艺参数的优化,抑制咬边缺陷。
The low current auxiliary TIG arc assisted high speed MIG process is carried out to analyze the suppression mechanism of undercut defect from the aspects of heat transfer,mass transfer and force field.The influence of the welding parameters on undercut defect is also analyzed.The low current auxiliary TIG arc can effectively reduce the temperature gradient around the edge of the weld pool during high speed MIG,which prolongs the existence time of the molten pool and promotes the filler metal to the edge of the weld to prevent undercut defect.The arc force and the droplet impact play major roles in the formation of the undercut defect.The auxiliary of low current TIG presents slight influence on MIG droplet,however,it can reduce the arc static and dynamic pressure obviously to mitigate or even inhibit undercut defect during the high-speed welding process.The orthogonal test shows that the inclination angle of welding torch,and the spacing of wire-pole are the important parameters affecting the formation of undercut defect compared with TIG current and tungsten distance workpiece distance.Optimizing torch angle and wire-pole spacing is a fast and economical way to improve low current auxiliary TIG-MIG hybrid welding to suppress undercut defect.
The low current auxiliary TIG arc assisted high speed MIG process is carried out to analyze the suppression mechanism of undercut defect from the aspects of heat transfer,mass transfer and force field.The influence of the welding parameters on undercut defect is also analyzed.The low current auxiliary TIG arc can effectively reduce the temperature gradient around the edge of the weld pool during high speed MIG,which prolongs the existence time of the molten pool and promotes the filler metal to the edge of the weld to prevent undercut defect.The arc force and the droplet impact play major roles in the formation of the undercut defect.The auxiliary of low current TIG presents slight influence on MIG droplet,however,it can reduce the arc static and dynamic pressure obviously to mitigate or even inhibit undercut defect during the high-speed welding process.The orthogonal test shows that the inclination angle of welding torch,and the spacing of wire-pole are the important parameters affecting the formation of undercut defect compared with TIG current and tungsten distance workpiece distance.Optimizing torch angle and wire-pole spacing is a fast and economical way to improve low current auxiliary TIG-MIG hybrid welding to suppress undercut defect.
引文
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[2]NGUYEN T C,WECKMAN D C,JOHNSON D A,et al.The humping phenomenon during high speed gas metal arc welding[J].Science and Technology of Welding and Joining,2005,10(4):447-459.
[3]MENG X,QIN G,ZHANG Y,et al.High speed TIG-MAG hybrid arc welding of mild steel plate[J].Journal of Materials Processing Technology,2014,214(11):2417-2424.
[4]娄小飞,陈茂爱,武传松,等.高速TIG-MIG复合焊焊缝驼峰及咬边消除机理[J].焊接学报,2014,35(8):87-90.LOU Xiaofei,CHEN Maoai,WU Chuansong,et al.Suppression mechanism of humps and undercuts of high-speed TIG-MIG welding[J].Transactions of the China Welding Institution,2014,35(8):87-90.
[5]杨涛,张生虎,高洪明,等.TIG-MIG复合焊电弧特性机理分析[J].焊接学报,2012,33(7):25-28.YANG Tao,ZHANG Shenghu,GAO Hongming,et al.Analysis of arc mechanism of TIG-MIG composite welding[J].Transactions of the China Welding Institution,2012,33(7):25-28.
[6]KANEMARU S,SASAKI T,SATO T,et al.Study for the mechanism of TIG-MIG hybrid welding process[J].Welding in the World,2015,59(2):261-268.
[7]陈姬,宗然,武传松,等.TIG-MIG复合焊电弧间相互作用对焊接过程的影响[J].机械工程学报,2016,52(6):59-64.CHEN Ji,ZONG Ran,WU Chuansong,et al.Influence of arcs interaction on TIG-MIG hybrid welding process[J].Journal of Mechanical Engineering,2016,52(6):59-64.
[8]ZONG R,CHEN J,WU C S,et al.Influence of molten metal flow on undercutting formation in GMAW[J].Science and Technology of Welding and Joining,2017,22(3):198-207.
[9]徐向方,苗玉刚,韩端锋,等.旁路分流双面电弧焊耦合电弧形态及电弧压力测量[J].焊接学报,2014,35(7):101-104.XU Xiangfang,MIAO Yugang,HAN Duanfeng,et al.Coupled arc shape and arc pressure measurement of bypass shunt double-sided arc welding[J].Transactions of the China Welding Institution,2014,35(7):101-104.
[10]WANG Y,TSAI H L.Impingement of filler droplets and weld pool dynamics during gas metal arc welding process[J].International Journal of Heat and Mass Transfer,2001,44(11):2067-2080.
[11]黄健康,韩日宏,石玗,等.双旁路耦合电弧MIG焊熔滴过渡受力分析[J].机械工程学报,2012,48(8):44-48.HUANG Jiankang,HAN Rihong,SHI Yu,et al.Force analysis of metal transfer in dual bypass MIG welding[J].Journal of Mechanical Engineering,2012,48(8):44-48.
[12]LU S,FUJII H,NOGI K.Marangoni convection and weld shape variations in Ar-O2 and Ar-CO2 shielded GTA welding[J].Materials Science and Engineering A,2004,380(1-2):290-297.
[13]岳建锋,李亮玉,刘文吉,等.基于外加高频交变磁场下向MAG焊熔池成形控制[J].机械工程学报,2013,49(8):65-70.YUE Jianfeng,LI Liangyu,LIU Wenji,et al.Welding pool shape control based on exterior high frequency alternative magnetic field[J].Journal of Mechanical Engineering,2013,49(8):65-70.