高频耦合电弧热源特性及工艺性研究
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摘要
脉冲焊工艺因能实现对热输入量、焊缝成形的精确控制而得到了广泛的应用。本文以航天高强铝合金材料在焊接制造过程中的实际工程需求为背景，以耦合型脉冲焊接电源及工艺实现为基础，通过对高频电弧形貌特性、电热物理特性及焊接工艺特性的研究，力图通过改善电弧热源特性实现提高铝合金焊接质量的目的。
针对现有焊接电源动特性无法实现高频脉冲电流输出的限制，在不改变已有商品化电源输出方式和控制模式的基础上，搭建了数字化耦合型高频脉冲TIG电源系统，选用适合的外特性输出模式配合新型拓扑电路，摆脱了逆变电源自身工作频率对脉冲电流频率的限制，实现高于电源逆变频率的高频脉冲电流输出。并利用数字化控制系统易于实现柔性化控制的特点，完善了上述电源系统的时序控制程序及闭环控制算法，保证焊接电源输出稳定可靠。建立了高频脉冲电源的等效理论模型，在分析电容容值、电容电压、回路电感及回路等效电阻对脉冲电流的波形影响的基础上，确定了欠阻尼电路结构作为系统有效工作的状态。
对高频脉冲电弧的形貌及电参数进行了观测，通过对不同频率下的电弧测试结果进行分析，发现随着脉冲频率的升高，电弧形貌峰基值间的差距逐渐减小并伴随沿电弧轴向的球状收缩，结合电弧自磁压缩理论配合多周期宏观高速摄像分析了脉冲参数对电弧能量的影响；随频率的提高，电信号主要表现为基值电压保持在较低值，而峰值电压则升高；高频电弧的伏安特性表明本系统产生的高频脉冲电弧阻抗特性存在从感性向阻性转变的过程。
根据高频脉冲电弧特点，采用错时采集并配合软件同步的方法，能够准确有效地反映高频电弧瞬态变化过程；光谱诊断结果发现20kHz附近的耦合型电弧能获得较为显著的高频效应；通过对不同脉冲参数条件下的电弧进行光谱诊断，得到与电弧形貌相符的结论，验证了脉冲参数对电弧能量变化规律的机理；针对20kHz附近区间的电弧能量进行光谱分析，发现随着脉冲幅值的增加和占空比的减小，电子密度均呈现出增加的趋势，表征为峰值电流时段电弧能量密度增大的效应，是脉冲电弧不同于直流电弧在热力学状态上的一个重要区别。
针对航天高强铝合金的材料特性和焊接性，选择直流、交流混合输出的特殊波形进行高频能量的耦合。力学性能测试结果表明高频脉冲能量提高了焊接接头的拉伸强度和延伸率，显著减少了微气孔的数量。焊接接头的断口形貌也验证了耦合高频能量后，焊接接头断口有向韧性断裂转变的趋势；此外，根据高频脉冲频率渐变试验的结果提出了以实际过冷度（枝状晶生长率）和新晶体形核条件（等轴晶生长率）竞争作用为机理的工艺优化思路，为耦合型高频脉冲焊接电弧的参数调控及其工程应用提供的重要基础。
Pulse arc welding process has been widely used in manufacturing industrybecause the heat input and weld shape can be controlled precisely. In accordance withthe welding requirement of Aerospace high strength aluminum-alloy materials, theTIG welding system with high frequency pulse coupling has been proposed to adjustthe welding heat source performance in order to improve welding quality of highstrength aluminum-alloy based research of arc-physics and process characteristic.
The high frequency current pulse output is difficult to achieve because ofdynamic characteristic limit. The digital control TIG welding system with highfrequency pulse coupling has been established. This system can realize highfrequency pulse current output without limitation because the novel power circuit andspecial external characteristic are adopted. According to strength the flowmanagement and PI arithmetic support by flexible digitalized control system, thewhole system can achieve stable welding process. The circuit parameters, includingcap value, charge voltage and equivalent inductor, have been studied. The result showthe circuit is suitable for working in underdamping pattern.
Appearance and electrical parameters of high-frequency pulse arc observed indifferent frequency. The result shows, with the frequency increasing, the differencebetween peak period and base period decreases. In the meanwhile, ball-like shrinkphenomenon arises. Pulse parameters on the effect of arc energy are analyzed basedself-magnetic compress theory and macro high-speed camera photos with multi-cycleexposure. The peak period voltage presents a ascend tendency with the increase ofpulse frequency. The base period voltage shows reverse trends, but when the pulsefrequency surpasses20kHz, base period voltage no longer change significantly. Atransition process from inductor to resistor has been found base the U-I chart analyze.
The transient variation process of high-frequency arc can be effectively andaccurately sampled because the dislocation photo take method and softwaresynchronization adopted according to high-frequency arc characteristics. The pulsearc in20kHz presents obviously high-frequency effect on the basis of spectroscopicdiagnosis data. The result of spectroscopic diagnosis in different pulse parameters isbasic same to the arc appearance consequence. This conclusion, as effectivelyevidence, can prove the arc energy variation rules and high-speed camera test result. The results of spectroscopic diagnosis around20k Hz show that the electron densitycan be increased with the pulse amplitude increasing and the duty ratio decreasing. Itindicates arc energy density enhancing during the peak current period and also themain difference between pulse arc and DC arc.
The high-frequency pulse energy coupling on DC and AC mixture arc acts thepart in high strength aluminum-alloy welding. The mechanical properties, strengthand ductility of welded joints are all enhanced. The micro-porosity quantity at theboth sides of the fusion line can be significantly decreased. Welding joint fracturemorphology shows that the connections between the cleavage surfaces may bechanged from the secondary cleavage fracture to the shearing fracture. Furthermore, aproposal based on grain-grow mechanism may be put forward to reducecolumnar-dendritic region and increase equiaxed region by experiment of HFcoupling effectivity. It may provide a way to optimize the welding process parameteras well as its quality in industrial application.
针对现有焊接电源动特性无法实现高频脉冲电流输出的限制，在不改变已有商品化电源输出方式和控制模式的基础上，搭建了数字化耦合型高频脉冲TIG电源系统，选用适合的外特性输出模式配合新型拓扑电路，摆脱了逆变电源自身工作频率对脉冲电流频率的限制，实现高于电源逆变频率的高频脉冲电流输出。并利用数字化控制系统易于实现柔性化控制的特点，完善了上述电源系统的时序控制程序及闭环控制算法，保证焊接电源输出稳定可靠。建立了高频脉冲电源的等效理论模型，在分析电容容值、电容电压、回路电感及回路等效电阻对脉冲电流的波形影响的基础上，确定了欠阻尼电路结构作为系统有效工作的状态。
对高频脉冲电弧的形貌及电参数进行了观测，通过对不同频率下的电弧测试结果进行分析，发现随着脉冲频率的升高，电弧形貌峰基值间的差距逐渐减小并伴随沿电弧轴向的球状收缩，结合电弧自磁压缩理论配合多周期宏观高速摄像分析了脉冲参数对电弧能量的影响；随频率的提高，电信号主要表现为基值电压保持在较低值，而峰值电压则升高；高频电弧的伏安特性表明本系统产生的高频脉冲电弧阻抗特性存在从感性向阻性转变的过程。
根据高频脉冲电弧特点，采用错时采集并配合软件同步的方法，能够准确有效地反映高频电弧瞬态变化过程；光谱诊断结果发现20kHz附近的耦合型电弧能获得较为显著的高频效应；通过对不同脉冲参数条件下的电弧进行光谱诊断，得到与电弧形貌相符的结论，验证了脉冲参数对电弧能量变化规律的机理；针对20kHz附近区间的电弧能量进行光谱分析，发现随着脉冲幅值的增加和占空比的减小，电子密度均呈现出增加的趋势，表征为峰值电流时段电弧能量密度增大的效应，是脉冲电弧不同于直流电弧在热力学状态上的一个重要区别。
针对航天高强铝合金的材料特性和焊接性，选择直流、交流混合输出的特殊波形进行高频能量的耦合。力学性能测试结果表明高频脉冲能量提高了焊接接头的拉伸强度和延伸率，显著减少了微气孔的数量。焊接接头的断口形貌也验证了耦合高频能量后，焊接接头断口有向韧性断裂转变的趋势；此外，根据高频脉冲频率渐变试验的结果提出了以实际过冷度（枝状晶生长率）和新晶体形核条件（等轴晶生长率）竞争作用为机理的工艺优化思路，为耦合型高频脉冲焊接电弧的参数调控及其工程应用提供的重要基础。
Pulse arc welding process has been widely used in manufacturing industrybecause the heat input and weld shape can be controlled precisely. In accordance withthe welding requirement of Aerospace high strength aluminum-alloy materials, theTIG welding system with high frequency pulse coupling has been proposed to adjustthe welding heat source performance in order to improve welding quality of highstrength aluminum-alloy based research of arc-physics and process characteristic.
The high frequency current pulse output is difficult to achieve because ofdynamic characteristic limit. The digital control TIG welding system with highfrequency pulse coupling has been established. This system can realize highfrequency pulse current output without limitation because the novel power circuit andspecial external characteristic are adopted. According to strength the flowmanagement and PI arithmetic support by flexible digitalized control system, thewhole system can achieve stable welding process. The circuit parameters, includingcap value, charge voltage and equivalent inductor, have been studied. The result showthe circuit is suitable for working in underdamping pattern.
Appearance and electrical parameters of high-frequency pulse arc observed indifferent frequency. The result shows, with the frequency increasing, the differencebetween peak period and base period decreases. In the meanwhile, ball-like shrinkphenomenon arises. Pulse parameters on the effect of arc energy are analyzed basedself-magnetic compress theory and macro high-speed camera photos with multi-cycleexposure. The peak period voltage presents a ascend tendency with the increase ofpulse frequency. The base period voltage shows reverse trends, but when the pulsefrequency surpasses20kHz, base period voltage no longer change significantly. Atransition process from inductor to resistor has been found base the U-I chart analyze.
The transient variation process of high-frequency arc can be effectively andaccurately sampled because the dislocation photo take method and softwaresynchronization adopted according to high-frequency arc characteristics. The pulsearc in20kHz presents obviously high-frequency effect on the basis of spectroscopicdiagnosis data. The result of spectroscopic diagnosis in different pulse parameters isbasic same to the arc appearance consequence. This conclusion, as effectivelyevidence, can prove the arc energy variation rules and high-speed camera test result. The results of spectroscopic diagnosis around20k Hz show that the electron densitycan be increased with the pulse amplitude increasing and the duty ratio decreasing. Itindicates arc energy density enhancing during the peak current period and also themain difference between pulse arc and DC arc.
The high-frequency pulse energy coupling on DC and AC mixture arc acts thepart in high strength aluminum-alloy welding. The mechanical properties, strengthand ductility of welded joints are all enhanced. The micro-porosity quantity at theboth sides of the fusion line can be significantly decreased. Welding joint fracturemorphology shows that the connections between the cleavage surfaces may bechanged from the secondary cleavage fracture to the shearing fracture. Furthermore, aproposal based on grain-grow mechanism may be put forward to reducecolumnar-dendritic region and increase equiaxed region by experiment of HFcoupling effectivity. It may provide a way to optimize the welding process parameteras well as its quality in industrial application.
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