不锈钢真空保温器皿焊接工艺研究
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摘要
不锈钢真空保温器皿生产中普遍次品率过高。本文通过检测一批样品,并分析其生产过程,确定了焊接缺陷最易出现的部位,设计出一套焊接夹具,并优化了焊接工艺参数,提高了焊接质量。
采用压缩空气泄漏检测法测试一批保温杯样品,结果表明漏气部位主要分布在保温杯底部端焊焊缝位置和尾部铜管封口位置,底部端焊焊缝出现的焊接缺陷主要是焊瘤、烧穿和未熔合,原因是焊接时的对中偏差过大以及所使用的焊接工艺参数不够适合。
机械化焊接时的对中偏差主要是存在同轴度偏差、端跳偏差以及保温杯的圆度偏差。采用自动调整及柔性连接的方案设计出一套自动TIG焊焊接夹具,通过保温杯位置的自动调整,对中偏差控制在0.2mm之内。焊接夹具的适用性、稳定性较好,成本较低。
通过焊接工艺参数的优化试验,确定了使用焊接夹具时合适的焊接电流为20-22A,焊接速度为550-600mm/min。
在使用焊接夹具及合适的焊接工艺参数条件下,所得焊缝外观平整光滑,熔深均匀,没有明显的焊接缺陷,焊缝致密,组织为细小的奥氏体和少量铁素体,试验条件下焊缝合格率接近100%
Production of stainless steel vacuum vessels generally encountered high rate of product defects. This paper tested a number of samples, analyzed their production process, and determined the location of welding defects, a welding fixture was designed, welding parameters were adjusted, the quality of welding was improved
A number of insulation cup samples were tested by leak detection with compressed air, the results showed that the leak site mostly distributed in the edge weld seam position and sealing position of the tail brass at the bottom of the insulation cup, the main welding defects were weld beading, burning through and incomplete fusion, the main causes of welding defects are welding alignment deviation and the unsuitable welding parameters in welding process.
The main causes of weld misalignment for mechanized welding process, are coaxial deviation, end jump and roundness deviation of the cups; an automatic TIG welding fixture was designed fixed program of automatic adjustment and flexible connection, the position of the insulation cup can be automatically adjusted, welding alignment deviation can be controlled within0.2mm; the applicability, stability and manufacturing cost control of the fixture achieved the expected goals.
Welding parameters were optimized by experiment, the optimal welding current is20-22A, and the optimal welding speed is550-600mm/min for the welding with the welding fixture.
With the welding fixture and suitable welding parameters, high quality weld can be obtained, the appearance of the weld was smooth, the melting depth was uniform, there were no obvious welding defects, the weld is compact and the weld microstructure is small austenite and a small amount of ferrite, qualified rate of the weld ban be close to100%in experimental conditions
采用压缩空气泄漏检测法测试一批保温杯样品,结果表明漏气部位主要分布在保温杯底部端焊焊缝位置和尾部铜管封口位置,底部端焊焊缝出现的焊接缺陷主要是焊瘤、烧穿和未熔合,原因是焊接时的对中偏差过大以及所使用的焊接工艺参数不够适合。
机械化焊接时的对中偏差主要是存在同轴度偏差、端跳偏差以及保温杯的圆度偏差。采用自动调整及柔性连接的方案设计出一套自动TIG焊焊接夹具,通过保温杯位置的自动调整,对中偏差控制在0.2mm之内。焊接夹具的适用性、稳定性较好,成本较低。
通过焊接工艺参数的优化试验,确定了使用焊接夹具时合适的焊接电流为20-22A,焊接速度为550-600mm/min。
在使用焊接夹具及合适的焊接工艺参数条件下,所得焊缝外观平整光滑,熔深均匀,没有明显的焊接缺陷,焊缝致密,组织为细小的奥氏体和少量铁素体,试验条件下焊缝合格率接近100%
Production of stainless steel vacuum vessels generally encountered high rate of product defects. This paper tested a number of samples, analyzed their production process, and determined the location of welding defects, a welding fixture was designed, welding parameters were adjusted, the quality of welding was improved
A number of insulation cup samples were tested by leak detection with compressed air, the results showed that the leak site mostly distributed in the edge weld seam position and sealing position of the tail brass at the bottom of the insulation cup, the main welding defects were weld beading, burning through and incomplete fusion, the main causes of welding defects are welding alignment deviation and the unsuitable welding parameters in welding process.
The main causes of weld misalignment for mechanized welding process, are coaxial deviation, end jump and roundness deviation of the cups; an automatic TIG welding fixture was designed fixed program of automatic adjustment and flexible connection, the position of the insulation cup can be automatically adjusted, welding alignment deviation can be controlled within0.2mm; the applicability, stability and manufacturing cost control of the fixture achieved the expected goals.
Welding parameters were optimized by experiment, the optimal welding current is20-22A, and the optimal welding speed is550-600mm/min for the welding with the welding fixture.
With the welding fixture and suitable welding parameters, high quality weld can be obtained, the appearance of the weld was smooth, the melting depth was uniform, there were no obvious welding defects, the weld is compact and the weld microstructure is small austenite and a small amount of ferrite, qualified rate of the weld ban be close to100%in experimental conditions
引文
[1]王宗杰主编.熔焊方法及设备[M].北京：机械工业出版社,2006：1,133-165
[2]李亚江主编.焊接冶金学-材料焊接性[M].北京：机械工业出版社,2006：119-135
[3]田书华.世界不锈钢行业状况与中国研究报告[R].北京大军智库经济咨询有限公司.2004
[4]张青辉.中国不锈钢工业现状及未来趋势[N].中国金属通报,2011,(1)：28-29
[5]王政编著.焊接工装夹具及变位机械-性能、设计、选用[M].北京：机械工业出版社,2006：11-59
[6]徐志明.钨极氩弧焊在不锈钢薄板焊接中的应用[J].电焊机,2005,35(6)：65-72
[7]徐志明.钨极氩弧焊在不锈钢薄板焊接中的应用及技术要领[J].机械工人热加工2006,(4)：58-60
[8]张惠凤.钨极氩弧焊在不锈钢焊接中的试验研究[J].山西冶金,2009,120(4)：13-14
[9]丁正东.奥氏体不锈钢薄壁管纵缝焊接工艺[J].压力容器,1997,14(2)：44--45,66
[10]Pierre-Jean Cunat. The Welding of Stainless Steels. [J].Materials and Applications Series, 2007, Volume 3
[11]齐晓娟,谢文军,曲广善.奥氏体不锈钢的焊接特点及焊接程序认可试验[J].航海工程,2008,37(2)：24-26
[12]徐文晓,徐文慧.奥氏体不锈钢容器的焊接[J].焊接技术,2006,35(5)：26-27
[13]陈连山,陈兵辉,安金平.304L不锈钢氩弧焊接工艺特点及常见缺陷的防治措施[J].石油工程建设,2008,34(3)：49-50
[14]马海强,李炜.304L薄壁不锈钢管的焊接[J].大型锻件,2010,3(1)：41-42
[15]杨宝雷.薄板不锈钢焊接成本的分析与对比[J].现代制造工程,2005(08)
[16]魏晓彤.不锈钢薄板焊接方法的探讨[J].广州化工,2010,38(5)：234-235
[17]吴金艳,王晓香.不锈钢薄板容器的焊接方法.中国新技术新产品,2009,(17)：138
[18]李小建.浅谈不锈钢薄板容器的焊接[J].化工装备技术,2009,30(2)：69-70
[19]关长江,李伟,罗淑芬,张文良.不锈钢薄板(δ<0.3mm)的焊接工艺[J].生产应用焊接,2008,(4)：59—62
[20]徐锴斯,顾春玲.薄壁不锈钢管道焊接技术研究.广西工学院学报,2001,12(4)：81-84
[21]姜劲松.超薄奥氏体不锈钢TIG焊[J].焊接技术,1997,(1)
[22]许旭东,李光俊.控制不锈钢筒体焊接变形工艺[C].中国航空学会青年科技论坛,2004,601-608
[23]张丽萍.不锈钢薄板的应用及焊接[J].甘肃冶金,2006,28(4)：62-64
[24]张飞.不锈钢薄板容器焊接变形的控制方法[J].金属加工,2009,6：41-42
[25]孙守礼,吴风顺,孙智富.不锈钢薄板的焊接质量及其控制[J].武汉汽车工业大学学报.,1996,18(1)：62-65
[26]李文利,张汉仁,刘志勇等.不锈钢薄板自TiG焊工艺试验及生产应用[J].纺织机械,2003,(05)：39-40
[27]郭云曾.超薄不锈钢板钨极氩弧焊工艺探讨[J].电焊机,1900,2.29-32
[28]孙仲吕.焊接0.3mmm厚不锈钢带的夹具与工艺[J].焊接,1990,19-21
[29]佳木斯电机厂.0.5毫米厚不锈钢圆筒的氩弧焊[J].焊接,1977：31-33
[30]聂骊涛,宋炎,吴葵芬.薄壁不锈钢管接头自动氩弧焊接的研究[J].沈阳化工,1999,28(2)：25-27
[31]李明利,蒋应田.不锈钢薄壁容器-咖啡壶的焊接[J].电焊机,1994,(5)：32-34
[32]刘宇霞.BHF-250不锈钢环焊缝焊接机床的研制[J].广东有色金属学报,2001,11(2)：151-153
[33]熊腊森主编.焊接工程基础[M].北京：机械工业出版社,2002,176～182.
[34]刘家发,朱宪宝.储罐倒装埋弧横焊自动对中装置的研制[J].电焊机,2008,38(3)：23-26
[35]何成旦,李鹤岐,李春旭等.电子束焊缝自动跟踪系统设计[J].核技术,2004,27(7)：529-533
[36]沈鸿源.铝合金弧焊机器人视觉实时焊缝跟踪与成形控制方法研究[D].上海交通大学博士论文,2008,1-17
[37]孙治宇,徐圆,赵曙东.新兴消费品行业市场需求研究-以我国不锈钢真空保温器皿行业为例[J].产业经济研究,2010(1)：72-79
[38]郭进全.不锈钢真空保温器皿的焊接.[J].焊接,1997,(12)：16-19
[39]Howard B.Cary, Scott C.Helzer著.(陈茂爱,王新洪等译).现代焊接技术[M].北京：化学工业出版社.2010,491-514
[40]成大先主编.机械设计手册单行本弹簧·起重机·五金件[M].北京：化学工业出版社,2004,7-19-7-22.
[41]成大先主编.机械设计手册单行本轴承[M].北京：化学工业出版社,2004,7-274-7-276.
[42]成大先主编.机械设计手册单行本连接与紧固[M].北京：化学工业出版社,2009,5-23,5-114.
[43]汪信远主编.机械设计基础.第三版[M].北京：高等教育出版社,2001,146-147.
[44]成大先主编.机械设计手册单行本机械制图极限与配合[M].北京：化学工业出版社,2009,2-74-2-136.
[45]许菊若主编.机械设计[M].北京：化学工业出版社,2005,40-71
[46]桂志炼.全不锈钢保温瓶的焊接工艺及设备[J].工厂建设与设计.199012
[47]崔丽,朱学军,栗卓新.不锈钢薄板高速钨极氩弧焊的研究[J].热加工工艺.2005-4：22-24
[48]Heryueh HUANG, Shengwen SHYU, Kuanghung TSENG等.Effects of the Process Parameters on Austenitic Stainless Steel by TIG-Flux Welding [J] J. Mater. Sci. Technol. Vol.22 No.3,2006:367-374
[49]陈孙艺,柳曾典.0.5mm奥氏体不锈钢薄板对接焊的试验研究及应用[J].焊接技术,2002,31(6)：46-47.
[50]刘亦兵,赖康生,安永印等.真空保温杯与真空钎焊炉[J].真空,2006,43(2)54-55
[2]李亚江主编.焊接冶金学-材料焊接性[M].北京：机械工业出版社,2006：119-135
[3]田书华.世界不锈钢行业状况与中国研究报告[R].北京大军智库经济咨询有限公司.2004
[4]张青辉.中国不锈钢工业现状及未来趋势[N].中国金属通报,2011,(1)：28-29
[5]王政编著.焊接工装夹具及变位机械-性能、设计、选用[M].北京：机械工业出版社,2006：11-59
[6]徐志明.钨极氩弧焊在不锈钢薄板焊接中的应用[J].电焊机,2005,35(6)：65-72
[7]徐志明.钨极氩弧焊在不锈钢薄板焊接中的应用及技术要领[J].机械工人热加工2006,(4)：58-60
[8]张惠凤.钨极氩弧焊在不锈钢焊接中的试验研究[J].山西冶金,2009,120(4)：13-14
[9]丁正东.奥氏体不锈钢薄壁管纵缝焊接工艺[J].压力容器,1997,14(2)：44--45,66
[10]Pierre-Jean Cunat. The Welding of Stainless Steels. [J].Materials and Applications Series, 2007, Volume 3
[11]齐晓娟,谢文军,曲广善.奥氏体不锈钢的焊接特点及焊接程序认可试验[J].航海工程,2008,37(2)：24-26
[12]徐文晓,徐文慧.奥氏体不锈钢容器的焊接[J].焊接技术,2006,35(5)：26-27
[13]陈连山,陈兵辉,安金平.304L不锈钢氩弧焊接工艺特点及常见缺陷的防治措施[J].石油工程建设,2008,34(3)：49-50
[14]马海强,李炜.304L薄壁不锈钢管的焊接[J].大型锻件,2010,3(1)：41-42
[15]杨宝雷.薄板不锈钢焊接成本的分析与对比[J].现代制造工程,2005(08)
[16]魏晓彤.不锈钢薄板焊接方法的探讨[J].广州化工,2010,38(5)：234-235
[17]吴金艳,王晓香.不锈钢薄板容器的焊接方法.中国新技术新产品,2009,(17)：138
[18]李小建.浅谈不锈钢薄板容器的焊接[J].化工装备技术,2009,30(2)：69-70
[19]关长江,李伟,罗淑芬,张文良.不锈钢薄板(δ<0.3mm)的焊接工艺[J].生产应用焊接,2008,(4)：59—62
[20]徐锴斯,顾春玲.薄壁不锈钢管道焊接技术研究.广西工学院学报,2001,12(4)：81-84
[21]姜劲松.超薄奥氏体不锈钢TIG焊[J].焊接技术,1997,(1)
[22]许旭东,李光俊.控制不锈钢筒体焊接变形工艺[C].中国航空学会青年科技论坛,2004,601-608
[23]张丽萍.不锈钢薄板的应用及焊接[J].甘肃冶金,2006,28(4)：62-64
[24]张飞.不锈钢薄板容器焊接变形的控制方法[J].金属加工,2009,6：41-42
[25]孙守礼,吴风顺,孙智富.不锈钢薄板的焊接质量及其控制[J].武汉汽车工业大学学报.,1996,18(1)：62-65
[26]李文利,张汉仁,刘志勇等.不锈钢薄板自TiG焊工艺试验及生产应用[J].纺织机械,2003,(05)：39-40
[27]郭云曾.超薄不锈钢板钨极氩弧焊工艺探讨[J].电焊机,1900,2.29-32
[28]孙仲吕.焊接0.3mmm厚不锈钢带的夹具与工艺[J].焊接,1990,19-21
[29]佳木斯电机厂.0.5毫米厚不锈钢圆筒的氩弧焊[J].焊接,1977：31-33
[30]聂骊涛,宋炎,吴葵芬.薄壁不锈钢管接头自动氩弧焊接的研究[J].沈阳化工,1999,28(2)：25-27
[31]李明利,蒋应田.不锈钢薄壁容器-咖啡壶的焊接[J].电焊机,1994,(5)：32-34
[32]刘宇霞.BHF-250不锈钢环焊缝焊接机床的研制[J].广东有色金属学报,2001,11(2)：151-153
[33]熊腊森主编.焊接工程基础[M].北京：机械工业出版社,2002,176～182.
[34]刘家发,朱宪宝.储罐倒装埋弧横焊自动对中装置的研制[J].电焊机,2008,38(3)：23-26
[35]何成旦,李鹤岐,李春旭等.电子束焊缝自动跟踪系统设计[J].核技术,2004,27(7)：529-533
[36]沈鸿源.铝合金弧焊机器人视觉实时焊缝跟踪与成形控制方法研究[D].上海交通大学博士论文,2008,1-17
[37]孙治宇,徐圆,赵曙东.新兴消费品行业市场需求研究-以我国不锈钢真空保温器皿行业为例[J].产业经济研究,2010(1)：72-79
[38]郭进全.不锈钢真空保温器皿的焊接.[J].焊接,1997,(12)：16-19
[39]Howard B.Cary, Scott C.Helzer著.(陈茂爱,王新洪等译).现代焊接技术[M].北京：化学工业出版社.2010,491-514
[40]成大先主编.机械设计手册单行本弹簧·起重机·五金件[M].北京：化学工业出版社,2004,7-19-7-22.
[41]成大先主编.机械设计手册单行本轴承[M].北京：化学工业出版社,2004,7-274-7-276.
[42]成大先主编.机械设计手册单行本连接与紧固[M].北京：化学工业出版社,2009,5-23,5-114.
[43]汪信远主编.机械设计基础.第三版[M].北京：高等教育出版社,2001,146-147.
[44]成大先主编.机械设计手册单行本机械制图极限与配合[M].北京：化学工业出版社,2009,2-74-2-136.
[45]许菊若主编.机械设计[M].北京：化学工业出版社,2005,40-71
[46]桂志炼.全不锈钢保温瓶的焊接工艺及设备[J].工厂建设与设计.199012
[47]崔丽,朱学军,栗卓新.不锈钢薄板高速钨极氩弧焊的研究[J].热加工工艺.2005-4：22-24
[48]Heryueh HUANG, Shengwen SHYU, Kuanghung TSENG等.Effects of the Process Parameters on Austenitic Stainless Steel by TIG-Flux Welding [J] J. Mater. Sci. Technol. Vol.22 No.3,2006:367-374
[49]陈孙艺,柳曾典.0.5mm奥氏体不锈钢薄板对接焊的试验研究及应用[J].焊接技术,2002,31(6)：46-47.
[50]刘亦兵,赖康生,安永印等.真空保温杯与真空钎焊炉[J].真空,2006,43(2)54-55