金属粉芯型药芯焊丝熔滴过渡及飞溅的试验研究
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摘要
金属粉芯型药芯焊丝已经广泛应用于桥梁、船舶、航空航天、管道等领域。但是目前有关金属粉芯型药芯焊丝的研究报道主要在其工艺性方面,对其电弧物理特性的研究却少见报道。电弧物理特性是指焊接过程中所表现出来的多种物理特性的过程,包括熔滴过渡模式、熔滴过渡机理、电弧行为及电弧参数特征等,是指导焊接材料工艺性能和提高焊接材料质量的最重要的理论之一,也是实现科学和定量评价焊接材料工艺性的必要理论基础。目前对电弧物理特性的研究主要集中在熔滴过渡、焊接飞溅以及焊接电参数特征的研究,并结合电参数特征利用数学方法建立模型来表征焊接过程稳定性、熔滴过渡的稳定性以及飞溅的严重性。
本文以市售的两种不同金属粉芯型药芯焊丝为研究对象,借助高速摄影技术、汉诺威弧焊分析仪、焊接飞溅试验、数值计算等方法,对不同电压下的金属粉芯型药芯焊丝的电弧物理特性进行分析研究。
研究结果表明：金属粉芯型药芯焊丝在预设电参数下的熔滴过渡形式为：短路过渡、排斥过渡、细颗粒过渡、射滴过渡、爆炸过渡。短路过渡时,电流电压较小,熔滴尚未长大脱落就与熔池接触,形成液桥,液桥处电流增大,电磁收缩力随之增大,在电磁收缩力和熔池表面张力的共同作用下向熔池过渡。
排斥过渡时作用于熔滴底部的斑点压力阻碍熔滴的过渡,使得熔滴长时间在焊丝端部长大,导致排斥过度时熔滴较大,且偏离焊丝轴线、过渡频率较低、飞溅较大、电弧稳定性差,整个过程熔滴不停地在焊丝端部摆动同时熔池也是在不停地翻滚。
细颗粒过渡、射滴过渡时电压的增大使促进熔滴过渡的等离子流力和电磁收缩力增大并成为主导力,阻碍熔滴过渡的表面张力减小,这些变化促使熔滴还未长大就已经过渡到熔池中。细颗粒过渡、射滴过渡时熔滴过渡频率较快、熔滴细小、焊缝成形良好、焊丝熔化效率高,且射滴过渡时整个过程中电弧呈钟罩状一直罩住整个熔滴直到过渡到熔池。
爆炸过渡是因为熔滴内部气体急剧膨胀导致熔滴爆炸而发发生的过渡形式。
金属粉芯型药芯焊丝的飞溅形式主要为：气泡放出型飞溅、电弧力引起的飞溅、熔滴爆炸引起的飞溅、缩颈飞溅、电爆炸飞溅。
通过对电弧电压近似熵值以及近似熵标准偏差值的计算来表征熔滴过渡的稳定性,结果表明：电弧电压瞬时值平均近似熵越大,近似熵标准差越小,熔滴过渡过程越稳定。
以平均电压、大电流概率密度和、大电压概率密度和、电压变异系数为指标,利用单因变量偏最小二乘回归法建立数学模型表征飞溅的严重性,结果表明：平均电压值越小、大电压概率密度和越大、大电流概率密度和越大、电压变异系数越大则飞溅越严重。其中大电压概率密度和对飞溅率的影响最大,大电流概率密度和的影响次之；而平均电压和电压变异系数对飞溅率的影响相对来说较小。
Metal powder flux-cored wire is widely used in bridge engineering, ship, aerospace, pipeline engineering. However, the current report about the metal powder flux-cored wire was concertrated on its process, the welding arc physical characteristic of research was rarely reported. Arc physics theories of welding material, including the metal transfer mode, the physical mechanism of metal transfer, arc behavior and characteristics of electric arc parameters etc. is one of the most important theory for guiding to enhance the level of operational behavior and improve the quality of welding materials as well as for scientific and quantitative evaluation of its operational behavior.
At present,the report on the arc physical characteristic research mainly concentrated on the droplet transfer characteristics&mechanism, welding spatter characteristics&mechanism and the change of welding electric parameters, at the same time according to the change of welding electric parameters,through the mathematical method to build a model to evaluation the stability of welding process, the stability of droplet transfer and the severity of spatter.
The paper on a base of analyzing two typical commercial metal powder flux-cored wire, use the high-speed photography and the ANALYSATOR HANNOVER as well as welding spatter test methods and the numerical experiment at different voltage, to research the characteristic of arc physical.
The matal transfer of metal powder flux-cored wire include:short circuiting transfer、globular repelled transfer、fine transfer、spray transfer、explosive transfer。When the short circuiting transfer take place,the metal is contact with the molten pool when it is not big enough,the liquid bridge is formed.The current in the liquid bridge increase rapidly as well as the electromagnetic retractile power increase rapidly. Through the interaction of the surface tension of the molten pool and the electromagnetic retractile power the metal transferred to the molten pool.
Because of the spot pressure resisit the transfer of matal at the globular repelled transfer,the charactersticsof gobular repelled transfer is the bigger drop size, the lower metal transfer frequency, the more spatter, the worse arc stability and the lower melting efficiency.
Because of the increase of the voltage,lead to the increase of plasma power and electromagnetic retractile power as well as the decrease surface tension,the metal transferred to the molten pool when the metal is not big enough.The the charactersticsof fine transfer、spray transfer are the smaller drop size, the size is almost equal to the wire diameter,the metal transfer frequency is higher, the welding process is stable, the spatter is less, the appearance of weld is better.
The explosive transfer is take placed when the gas inside the metal expansion rapidly lead to the explosive of metal.
The spatter of metal powder flux-cored wire include:electro-explosive spatter,spatter created by arc force,spatter created by metal burst, necking spatter, bubble release spatter.
Through the statistical analysis of instantaneous value of the arc voltage, it unfolds that the approximate entropy of arc voltage can be used to assess the stability of metal transfer. The higher the average approximate entropy of arc voltage is, the lower the approximate entropy standard deviation will be, and the more stability of metal transfer.
Through the PLSR establish mathematical model between the average voltage, E n(UB), E n(Is), the coefficient of variation of voltage and the severity of spatter. the result indicate:that the lower the average voltage is, the higher the Σn(UB) will be; the higher the Σn(Is), the more serious the spatter of metal powder flux-cored wire will be. Furthermore, the effects of the high voltage probability density are the biggest, the effects of high current probability density comes next, whereas the effects of average voltage and the coefficient of variation of voltage is relatively small.
本文以市售的两种不同金属粉芯型药芯焊丝为研究对象,借助高速摄影技术、汉诺威弧焊分析仪、焊接飞溅试验、数值计算等方法,对不同电压下的金属粉芯型药芯焊丝的电弧物理特性进行分析研究。
研究结果表明：金属粉芯型药芯焊丝在预设电参数下的熔滴过渡形式为：短路过渡、排斥过渡、细颗粒过渡、射滴过渡、爆炸过渡。短路过渡时,电流电压较小,熔滴尚未长大脱落就与熔池接触,形成液桥,液桥处电流增大,电磁收缩力随之增大,在电磁收缩力和熔池表面张力的共同作用下向熔池过渡。
排斥过渡时作用于熔滴底部的斑点压力阻碍熔滴的过渡,使得熔滴长时间在焊丝端部长大,导致排斥过度时熔滴较大,且偏离焊丝轴线、过渡频率较低、飞溅较大、电弧稳定性差,整个过程熔滴不停地在焊丝端部摆动同时熔池也是在不停地翻滚。
细颗粒过渡、射滴过渡时电压的增大使促进熔滴过渡的等离子流力和电磁收缩力增大并成为主导力,阻碍熔滴过渡的表面张力减小,这些变化促使熔滴还未长大就已经过渡到熔池中。细颗粒过渡、射滴过渡时熔滴过渡频率较快、熔滴细小、焊缝成形良好、焊丝熔化效率高,且射滴过渡时整个过程中电弧呈钟罩状一直罩住整个熔滴直到过渡到熔池。
爆炸过渡是因为熔滴内部气体急剧膨胀导致熔滴爆炸而发发生的过渡形式。
金属粉芯型药芯焊丝的飞溅形式主要为：气泡放出型飞溅、电弧力引起的飞溅、熔滴爆炸引起的飞溅、缩颈飞溅、电爆炸飞溅。
通过对电弧电压近似熵值以及近似熵标准偏差值的计算来表征熔滴过渡的稳定性,结果表明：电弧电压瞬时值平均近似熵越大,近似熵标准差越小,熔滴过渡过程越稳定。
以平均电压、大电流概率密度和、大电压概率密度和、电压变异系数为指标,利用单因变量偏最小二乘回归法建立数学模型表征飞溅的严重性,结果表明：平均电压值越小、大电压概率密度和越大、大电流概率密度和越大、电压变异系数越大则飞溅越严重。其中大电压概率密度和对飞溅率的影响最大,大电流概率密度和的影响次之；而平均电压和电压变异系数对飞溅率的影响相对来说较小。
Metal powder flux-cored wire is widely used in bridge engineering, ship, aerospace, pipeline engineering. However, the current report about the metal powder flux-cored wire was concertrated on its process, the welding arc physical characteristic of research was rarely reported. Arc physics theories of welding material, including the metal transfer mode, the physical mechanism of metal transfer, arc behavior and characteristics of electric arc parameters etc. is one of the most important theory for guiding to enhance the level of operational behavior and improve the quality of welding materials as well as for scientific and quantitative evaluation of its operational behavior.
At present,the report on the arc physical characteristic research mainly concentrated on the droplet transfer characteristics&mechanism, welding spatter characteristics&mechanism and the change of welding electric parameters, at the same time according to the change of welding electric parameters,through the mathematical method to build a model to evaluation the stability of welding process, the stability of droplet transfer and the severity of spatter.
The paper on a base of analyzing two typical commercial metal powder flux-cored wire, use the high-speed photography and the ANALYSATOR HANNOVER as well as welding spatter test methods and the numerical experiment at different voltage, to research the characteristic of arc physical.
The matal transfer of metal powder flux-cored wire include:short circuiting transfer、globular repelled transfer、fine transfer、spray transfer、explosive transfer。When the short circuiting transfer take place,the metal is contact with the molten pool when it is not big enough,the liquid bridge is formed.The current in the liquid bridge increase rapidly as well as the electromagnetic retractile power increase rapidly. Through the interaction of the surface tension of the molten pool and the electromagnetic retractile power the metal transferred to the molten pool.
Because of the spot pressure resisit the transfer of matal at the globular repelled transfer,the charactersticsof gobular repelled transfer is the bigger drop size, the lower metal transfer frequency, the more spatter, the worse arc stability and the lower melting efficiency.
Because of the increase of the voltage,lead to the increase of plasma power and electromagnetic retractile power as well as the decrease surface tension,the metal transferred to the molten pool when the metal is not big enough.The the charactersticsof fine transfer、spray transfer are the smaller drop size, the size is almost equal to the wire diameter,the metal transfer frequency is higher, the welding process is stable, the spatter is less, the appearance of weld is better.
The explosive transfer is take placed when the gas inside the metal expansion rapidly lead to the explosive of metal.
The spatter of metal powder flux-cored wire include:electro-explosive spatter,spatter created by arc force,spatter created by metal burst, necking spatter, bubble release spatter.
Through the statistical analysis of instantaneous value of the arc voltage, it unfolds that the approximate entropy of arc voltage can be used to assess the stability of metal transfer. The higher the average approximate entropy of arc voltage is, the lower the approximate entropy standard deviation will be, and the more stability of metal transfer.
Through the PLSR establish mathematical model between the average voltage, E n(UB), E n(Is), the coefficient of variation of voltage and the severity of spatter. the result indicate:that the lower the average voltage is, the higher the Σn(UB) will be; the higher the Σn(Is), the more serious the spatter of metal powder flux-cored wire will be. Furthermore, the effects of the high voltage probability density are the biggest, the effects of high current probability density comes next, whereas the effects of average voltage and the coefficient of variation of voltage is relatively small.
引文
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