磁控焊接电弧特性和熔滴过渡机理研究
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摘要
电磁作用焊接技术是近年来完善起来的一种新的焊接技术,应用也日趋广泛。电弧弧柱区是由自由电子和带正、负电荷的离子组成的等离子体,具有导电性、电准中性和与磁场的可作用性,因此通过外加磁场可以控制电弧的形态;同时也对处在电弧当中的熔滴过渡过程产生巨大影响。加入适当磁场可以改善焊接的质量。
论文将电磁控制电弧焊接机理研究和MIG/TIG焊接技术结合起来,在焊枪上外加间歇交变纵向磁场,使焊接电弧、熔滴过渡过程以及熔池表面都在外加磁场的包围之中,采用先进的高速摄影技术拍摄了纵向磁场作用下的MIG/TIG焊电弧和MIG焊熔滴过渡过程,利用带电粒子在磁场中运动的理论,分析了磁场作用下电弧行为和运动机制,对磁场作用下电弧的运动过程进行了描述,并且得到了外加纵向磁场作用下电弧形态和电弧运动行为的变化规律;同时研究了纵向磁场参数对熔滴形态、熔滴过渡轨迹和熔滴过渡频率的影响规律,为研究纵向磁场作用下电弧特性和熔滴过渡机理提供了坚实的理论基础。
在上述理论分析基础上,论文采用外加纵向磁场焊接技术对低碳钢和5A05铝合金进行MIG焊接,研究了外加纵向磁场对低碳钢及铝合金焊缝金属组织及性能的影响。试验结果表明:外加合适纵向磁场作用下,焊缝表面成形良好、焊缝组织得到明显细化,同时发现低碳钢及铝合金焊缝各项力学性能在适当匹配参数的纵向磁场作用下得到不同程度的提高。
Welding with magnetic field is more perfect in recent years as a new welding technology,its application is becoming increasingly widespread.Arc-zone is plasma body composed of the free electron and the ion with positive and negative charge,and it has electrical conductivity,electrical quasi-neutral and can act with the magnetic field.So the shape and running of arc can be controlled by external magnetic field.At the same time, metal transfer in the arc is also impacted by external magnetic to improve the welding technology.
In this paper,the electromagnetic control mechanism of arc welding and MIG/TIG welding technology were combined.Longitudinal intermittent alternative magnetic field was added in MIG/TIG arc welding in order to make the welding arc,metal transfer process and the pool surface be surrounded in longitudinal magnetic field.At the same time,the motion of arc and metal transfer were screened using the advanced high-speed video camera.In this paper,the motion and its mechanism of the magnetic control arc were analysed,and the change regularity of the arc in longitudinal magnetic field was got.Also, the shape,path,and frequency of metal transfer were studied and their regularities in longitudinal magnetic field were summing-up.They lay a solid foundation to research the characteristic of arc and mechanism of metal transfer under longitudinal magnetic.
On the base of the theoretic analysis above,longitudinal magnetic field acting on mild steel and 5A05 aluminum alloy MIG arc welding was used in this paper.How longitudinal magnetic field effecting the weld of the mild steel and aluminum alloy were studied through the microstructure and property tests.The results show that:the weld surface of the mild steel and aluminum alloy is slicked and the weld microstructure is refined obviously.At the same time,the weld properties of mild steel and aluminum alloy are enhanced with matched longitudinal magnetic field parameters.
论文将电磁控制电弧焊接机理研究和MIG/TIG焊接技术结合起来,在焊枪上外加间歇交变纵向磁场,使焊接电弧、熔滴过渡过程以及熔池表面都在外加磁场的包围之中,采用先进的高速摄影技术拍摄了纵向磁场作用下的MIG/TIG焊电弧和MIG焊熔滴过渡过程,利用带电粒子在磁场中运动的理论,分析了磁场作用下电弧行为和运动机制,对磁场作用下电弧的运动过程进行了描述,并且得到了外加纵向磁场作用下电弧形态和电弧运动行为的变化规律;同时研究了纵向磁场参数对熔滴形态、熔滴过渡轨迹和熔滴过渡频率的影响规律,为研究纵向磁场作用下电弧特性和熔滴过渡机理提供了坚实的理论基础。
在上述理论分析基础上,论文采用外加纵向磁场焊接技术对低碳钢和5A05铝合金进行MIG焊接,研究了外加纵向磁场对低碳钢及铝合金焊缝金属组织及性能的影响。试验结果表明:外加合适纵向磁场作用下,焊缝表面成形良好、焊缝组织得到明显细化,同时发现低碳钢及铝合金焊缝各项力学性能在适当匹配参数的纵向磁场作用下得到不同程度的提高。
Welding with magnetic field is more perfect in recent years as a new welding technology,its application is becoming increasingly widespread.Arc-zone is plasma body composed of the free electron and the ion with positive and negative charge,and it has electrical conductivity,electrical quasi-neutral and can act with the magnetic field.So the shape and running of arc can be controlled by external magnetic field.At the same time, metal transfer in the arc is also impacted by external magnetic to improve the welding technology.
In this paper,the electromagnetic control mechanism of arc welding and MIG/TIG welding technology were combined.Longitudinal intermittent alternative magnetic field was added in MIG/TIG arc welding in order to make the welding arc,metal transfer process and the pool surface be surrounded in longitudinal magnetic field.At the same time,the motion of arc and metal transfer were screened using the advanced high-speed video camera.In this paper,the motion and its mechanism of the magnetic control arc were analysed,and the change regularity of the arc in longitudinal magnetic field was got.Also, the shape,path,and frequency of metal transfer were studied and their regularities in longitudinal magnetic field were summing-up.They lay a solid foundation to research the characteristic of arc and mechanism of metal transfer under longitudinal magnetic.
On the base of the theoretic analysis above,longitudinal magnetic field acting on mild steel and 5A05 aluminum alloy MIG arc welding was used in this paper.How longitudinal magnetic field effecting the weld of the mild steel and aluminum alloy were studied through the microstructure and property tests.The results show that:the weld surface of the mild steel and aluminum alloy is slicked and the weld microstructure is refined obviously.At the same time,the weld properties of mild steel and aluminum alloy are enhanced with matched longitudinal magnetic field parameters.
引文
[1]常云龙.新型焊接电源实用技术北京:中国教育文化出版社,2003.
[2]贾昌申,殷咸青,贾涛.纵向磁场中的焊接电弧行为.西安交通大学学报,1994,28(4):7-13.
[3]殷咸青,罗键,李海刚,等.纵向磁场参数对LD10CS铝合金TIG焊焊缝组织的影响.西安交通大学学报.1999,33(7):71-74.
[4]Selyanenkov V N.Formation of the weld in a longitudinal magnetic field in argon-arc welding.Welding Production,1975,22(11):50-53.
[5]常云龙,宋文清,张建民.逆变方波焊接电磁搅拌电源研究及应用,焊接技术,2005,34(1):36-40.
[6]Brown D C et al.The effect of electromagnetic stirring and mechanical vibration on arc welding Welding,Journal.1962.41(2):241-250.
[7]王军,陈树君,卢振洋,等.磁场控制横向MAG焊接焊缝成型工艺的研究.北京工业大学学报,2003,29(2):147-150.
[8]罗键,贾涛,殷咸青.GTAW外加间歇交变纵向磁场的数值计算及其对焊接行为的影响.金属学报,1999,35(3):330-334.
[9]常云龙,陈德善,肖纪云.磁控等离子弧的基本特性.焊接技术,2001,30(4):29-30.
[10]罗键,贾昌申,王雅生,等.外加纵向磁场GTAW焊接机理.金属学报,2001,37(2):212-216.
[11]江淑园,陈焕明,刘志凌.磁控技术在焊接中的应用及进展.中国机械工程,2002,13(21):1876-1879.
[12]张忠典,李冬青,赵洪运,等.外加磁场对焊接过程的影响.焊接,2002(3):10-14.
[13]朱志明.熔化极气体保护焊熔滴控制的发展现状及关键技术.2004全国焊接学术交流会,69-77.
[14]Haidar J,Lowke J.Predictions of Metal Droplet Formation in Arc Welding.J of phys.D:Applied hys,1996(29):2951-2960.
[15]Choi S K,Yoo C D,Kim Y S.Dynamic Simulation of Metal Transfer in GMAW.Part 1:Globular and Spray Transfer Models.Welding J,1998(1):38-44.
[16]王学东,张伟强,时海芳.电磁搅拌技术的国内外发展现状.辽宁工程技术大学学报,2001(2):82-87.
[17]Manabe.Investigation on TIG welding using 2 filler wires with Electromagnetically Controlled Molten Poolprocess in horizontal position.Quarterly Journal of the Japan Welding Society,2000(1):40-50.
[18]杨成刚,国旭明,洪张飞,等.电磁搅拌对2219A1-Cu合金焊缝组织及力学性能的影响.金属学报,2005,41(10):1071-1081.
[19]过增元,赵文华.电弧和热等离子体.科学出版社,1986:37-42.
[20]Bols.Shielding gases-product & produc- tivity.Welding Review International,1997,16(1) 157-159
[21]陈强,孙振国.旋转射流过渡.清华大学机械工程系,2003.
[22]Jayarajan,Jackson.Magnetic Control of Gas Tungsten-Arc Weldmg Process.Welding Journal,1972:377s-385s.
[23]Hicken,Jackson.The Effects of Applied Magnetic Fields on Welding Arcs.Welding Journal,1966(11):515s-525s.
[24]Ando,Nishikawa and Yamanouchi.Effects of Magnetic Field on Bead Formation in TIG Arc Welding.Journal of Japan Welding Society,1968.(3):43-48.
[25]安藤弘平,长谷川光雄,施雨湘译.焊接电弧现象.机械工业出版社,1985.
[26]林杰才,赵国华,宋奇岭.交角磁场对细丝CO_2焊接电弧及熔滴过渡的研究.焊接,1987(3):8-10.
[27]Dilthey,Uirich.High-production MAGM Welding Solid and Flux-cored Wires.Welding and Cutting,2001(3):E47-E49.
[28]Boldyrev A.M.Special features of Melting the Electrode Metal when Welding in an externalMagnetic Field.Welding Production,2002(5):28-30
[29]Iofinaov P.A.Effect of an external Electromagnetic Field on the Melting Rate of ElectrodeWire in automatic Submerged-Arc Surfacing.Welding Production,1991(1):34-35.
[30]Ito,Nakura.Mitsibishi.Heavy Industries Engineering Reports,1982(4):404-409.
[31]Yukio.Basic Concept and Viability of Electromagnetically Controlled Molten Pool Welding Process.ⅡW Doc.Ⅻ-1668-0,2003:63-77.
[32]江淑园.外加磁场对CO2焊飞溅的控制机理.焊接学报,2004(2):50-53.
[33]徐鲁宁.磁控高熔敷率MAG焊的研究.北京工业大学博士毕业论文,2002:20-25.
[34]宫野,张林.旋转磁场作用下电弧螺旋不稳定性的数值研究.大连理工大学学报,2004(1):30-32.
[35]贾均,张宝书.旋转磁场作用下合金结晶过程的研究.特种铸造及有色合金,1981(1):32-37.
[36]包晔峰,周昀,吴毅雄,等.熔化极气体保护焊熔滴过渡研究.电焊机36(3):55-58.
[37]吴丰顺.纵向磁场作用下电弧的运动机制.武汉汽车工业大学学报.1997,9(1):43-46.
[38]罗键.外加纵向磁场GTAW焊接熔池流体流动与传热行为的研究.西安交通大学博士学位论文.1999.
[39]殷树言,张九海.气体保护焊工艺.哈尔滨工业大学出版社,1989.
[40]王军.磁场控制高效MAG焊接旋转射流过渡稳定性的研究.北京工业大学工学博士学位论文,2003:32-40.
[41]祁贵云.旋转磁场作用下电弧特性和电弧行为的研究.北京工业大学工学硕士学位论文,2004:8-10.
[42]林尚扬,关桥.我国制造业焊接生产现状与发展战略研究.中国工程院咨询项目总结报告.2003,8.
[43]林尚扬.中国从焊接大国向世界焊接强国迈进.航空制造技术.2002(11):7-9.
[44]阿勃拉洛夫MA,阿勃杜拉赫曼诺夫P.Y.电磁作用焊接技术.韦福水,路登平译:北京:机械工业出版社,1988.
[45]Kuznetsov V D.Behaviour of the arc and transfer of electrode metal during welding in a longitudenal magnetic field.Welding Production,1972,19(4):1-4
[46]殷咸青.用电磁搅拌抑制L D 10 C S铝合金焊缝热裂纹的研究.西安交通大学学报,1998,32(5):91-95.
[47]李桓,李国华,李俊岳,等.熔化极电弧焊熔滴过渡过程的高速摄影.中国机械工程,2002,13(9):796-798.
[2]贾昌申,殷咸青,贾涛.纵向磁场中的焊接电弧行为.西安交通大学学报,1994,28(4):7-13.
[3]殷咸青,罗键,李海刚,等.纵向磁场参数对LD10CS铝合金TIG焊焊缝组织的影响.西安交通大学学报.1999,33(7):71-74.
[4]Selyanenkov V N.Formation of the weld in a longitudinal magnetic field in argon-arc welding.Welding Production,1975,22(11):50-53.
[5]常云龙,宋文清,张建民.逆变方波焊接电磁搅拌电源研究及应用,焊接技术,2005,34(1):36-40.
[6]Brown D C et al.The effect of electromagnetic stirring and mechanical vibration on arc welding Welding,Journal.1962.41(2):241-250.
[7]王军,陈树君,卢振洋,等.磁场控制横向MAG焊接焊缝成型工艺的研究.北京工业大学学报,2003,29(2):147-150.
[8]罗键,贾涛,殷咸青.GTAW外加间歇交变纵向磁场的数值计算及其对焊接行为的影响.金属学报,1999,35(3):330-334.
[9]常云龙,陈德善,肖纪云.磁控等离子弧的基本特性.焊接技术,2001,30(4):29-30.
[10]罗键,贾昌申,王雅生,等.外加纵向磁场GTAW焊接机理.金属学报,2001,37(2):212-216.
[11]江淑园,陈焕明,刘志凌.磁控技术在焊接中的应用及进展.中国机械工程,2002,13(21):1876-1879.
[12]张忠典,李冬青,赵洪运,等.外加磁场对焊接过程的影响.焊接,2002(3):10-14.
[13]朱志明.熔化极气体保护焊熔滴控制的发展现状及关键技术.2004全国焊接学术交流会,69-77.
[14]Haidar J,Lowke J.Predictions of Metal Droplet Formation in Arc Welding.J of phys.D:Applied hys,1996(29):2951-2960.
[15]Choi S K,Yoo C D,Kim Y S.Dynamic Simulation of Metal Transfer in GMAW.Part 1:Globular and Spray Transfer Models.Welding J,1998(1):38-44.
[16]王学东,张伟强,时海芳.电磁搅拌技术的国内外发展现状.辽宁工程技术大学学报,2001(2):82-87.
[17]Manabe.Investigation on TIG welding using 2 filler wires with Electromagnetically Controlled Molten Poolprocess in horizontal position.Quarterly Journal of the Japan Welding Society,2000(1):40-50.
[18]杨成刚,国旭明,洪张飞,等.电磁搅拌对2219A1-Cu合金焊缝组织及力学性能的影响.金属学报,2005,41(10):1071-1081.
[19]过增元,赵文华.电弧和热等离子体.科学出版社,1986:37-42.
[20]Bols.Shielding gases-product & produc- tivity.Welding Review International,1997,16(1) 157-159
[21]陈强,孙振国.旋转射流过渡.清华大学机械工程系,2003.
[22]Jayarajan,Jackson.Magnetic Control of Gas Tungsten-Arc Weldmg Process.Welding Journal,1972:377s-385s.
[23]Hicken,Jackson.The Effects of Applied Magnetic Fields on Welding Arcs.Welding Journal,1966(11):515s-525s.
[24]Ando,Nishikawa and Yamanouchi.Effects of Magnetic Field on Bead Formation in TIG Arc Welding.Journal of Japan Welding Society,1968.(3):43-48.
[25]安藤弘平,长谷川光雄,施雨湘译.焊接电弧现象.机械工业出版社,1985.
[26]林杰才,赵国华,宋奇岭.交角磁场对细丝CO_2焊接电弧及熔滴过渡的研究.焊接,1987(3):8-10.
[27]Dilthey,Uirich.High-production MAGM Welding Solid and Flux-cored Wires.Welding and Cutting,2001(3):E47-E49.
[28]Boldyrev A.M.Special features of Melting the Electrode Metal when Welding in an externalMagnetic Field.Welding Production,2002(5):28-30
[29]Iofinaov P.A.Effect of an external Electromagnetic Field on the Melting Rate of ElectrodeWire in automatic Submerged-Arc Surfacing.Welding Production,1991(1):34-35.
[30]Ito,Nakura.Mitsibishi.Heavy Industries Engineering Reports,1982(4):404-409.
[31]Yukio.Basic Concept and Viability of Electromagnetically Controlled Molten Pool Welding Process.ⅡW Doc.Ⅻ-1668-0,2003:63-77.
[32]江淑园.外加磁场对CO2焊飞溅的控制机理.焊接学报,2004(2):50-53.
[33]徐鲁宁.磁控高熔敷率MAG焊的研究.北京工业大学博士毕业论文,2002:20-25.
[34]宫野,张林.旋转磁场作用下电弧螺旋不稳定性的数值研究.大连理工大学学报,2004(1):30-32.
[35]贾均,张宝书.旋转磁场作用下合金结晶过程的研究.特种铸造及有色合金,1981(1):32-37.
[36]包晔峰,周昀,吴毅雄,等.熔化极气体保护焊熔滴过渡研究.电焊机36(3):55-58.
[37]吴丰顺.纵向磁场作用下电弧的运动机制.武汉汽车工业大学学报.1997,9(1):43-46.
[38]罗键.外加纵向磁场GTAW焊接熔池流体流动与传热行为的研究.西安交通大学博士学位论文.1999.
[39]殷树言,张九海.气体保护焊工艺.哈尔滨工业大学出版社,1989.
[40]王军.磁场控制高效MAG焊接旋转射流过渡稳定性的研究.北京工业大学工学博士学位论文,2003:32-40.
[41]祁贵云.旋转磁场作用下电弧特性和电弧行为的研究.北京工业大学工学硕士学位论文,2004:8-10.
[42]林尚扬,关桥.我国制造业焊接生产现状与发展战略研究.中国工程院咨询项目总结报告.2003,8.
[43]林尚扬.中国从焊接大国向世界焊接强国迈进.航空制造技术.2002(11):7-9.
[44]阿勃拉洛夫MA,阿勃杜拉赫曼诺夫P.Y.电磁作用焊接技术.韦福水,路登平译:北京:机械工业出版社,1988.
[45]Kuznetsov V D.Behaviour of the arc and transfer of electrode metal during welding in a longitudenal magnetic field.Welding Production,1972,19(4):1-4
[46]殷咸青.用电磁搅拌抑制L D 10 C S铝合金焊缝热裂纹的研究.西安交通大学学报,1998,32(5):91-95.
[47]李桓,李国华,李俊岳,等.熔化极电弧焊熔滴过渡过程的高速摄影.中国机械工程,2002,13(9):796-798.