焊接电弧引燃过程的机理分析
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摘要
焊接在机械制造中是一种十分重要的加工工艺。它是两种或两种以上的同类或非同类材料通过原子(或分子)间的扩散与结合从而连接在一起的工艺过程。弧焊则是当前应用最为广泛的一类金属焊接方法,无论是在手工焊还是自动化、机器人等焊接生产中都得到广泛应用。
所谓电弧是指两个电极间由气体介质产生的持久而强烈的放电现象,具有低电压、高电流的特点。电弧现象是焊接物理的重要组成部分,一直备受焊接工作者的关注。引弧过程作为电弧放电过程的起始阶段,直接影响后续焊接过程的开展。由于引弧过程十分复杂,目前在国内外对其机理的研究还比较缺乏。
本文针对弧焊中几种常用焊接模式(包括TIG焊、MIG焊与激光辅助TIG焊)的引弧过程进行了详细地试验研究与理论分析。发现这些模式下的引弧过程虽然体现了不尽相同的特点,但都有着类似的气体导电特征,使得焊接引弧过程的这一物理特征具有认识的普遍性。在深入分析各个引弧过程的基础上,提出了TIG焊接触引弧过程中三个连续特征阶段的概念,并对TIG焊引弧、MIG焊引弧及激光辅助引弧过程进行了初步的定量研究。论文主要内容及创新点如下:
(1)通过焊接电源、透镜光学装置、光谱仪、高速摄像机、数据处理与分析系统等构建了光谱诊断试验系统平台,实现了对引弧过程准确可靠的实时观测。通过对电子数密度测试原理的说明,比较了两种基于Hα谱线Stark展宽的不同的计算模型。从接触引弧和非接触引弧两种条件下的引弧过程入手,对主要研究对象——焊接电弧引燃过程的时间进行了不同角度的界定,为后续试验的开展奠定了基础。
(2)从不同角度对铝板和低碳钢板TIG焊接触引弧过程进行了观测与研究。对该过程电子密度随时间的变化作出了定量计算分析,得到了引弧过程的基本特征,即过程存在着主体电离元素的变换现象。借助先进的高速摄像与电信号采集设备,对不同焊接条件(包括焊接电流、保护气体、焊接弧长、阳极材料、钨极直径与空载电压)下的TIG焊接触引弧过程进行了时间描述,得到了不同焊接输入量对输出量——引弧时间的变化趋势,并对影响机理进行了阐述。
(3)对铝合金MIG焊引弧及激光辅助引弧过程进行了详细地观测与研究。通过对MIG焊引弧过程电信号与光谱图像的采集与分析,得到了该过程存在着类似TIG焊的气体导电特征。研究还表明,在MIG焊引弧过程中当两电极同时被激发时,后续的导电速率将显著提高,并且具有在低温条件下,易电离元素优先激发提供电子的物理特征。将连续激光作为热源进行非接触引弧,尝试探索外部能量参与并建立电弧可能。研究发现,激光辅助引弧亦存在着贡献电子主体电离元素的变换现象。同时,该过程也支持了钨极电弧焊引弧的主要特点:即对金属工件的局部加热是产生电子碰撞进而进行电弧空间能量传递的初始条件。
(4)通过对焊接引弧弛豫现象的时序统计分析,概括了TIG焊接触引弧过程的三个连续特征阶段,即工件预热阶段、场致发射阶段及电弧放电阶段。分别对每个阶段的物理现象与特点进行了说明,并给出了可以定量描述该阶段的一般理论公式。采用Thomas-Fermi模型与Saha方程联立的方法,计算了引弧过程不同时刻的平均电离度,总结归纳了电离度的变化规律。借助试验数据的提炼与概括,对不同焊接条件对焊接引弧时间的影响规律进行了研究,给出了描述引弧过程时间的经验公式。
(5)以焦耳加热与金属熔化理论为基础,推导了MIG焊引弧过程时间的预测公式。结果表明,当焊丝熔化部分质量越小,焊丝直径越小,焊丝密度越大,焊接电流越大,局部接触电压越大时,引弧过程时间越短。以激光脉冲作用导致气体击穿形成等离子体理论为基础,在同时考虑多光子电离与碰撞电离的情况下,推导了用于描述激光辅助引弧中电弧空间自由电子密度发展过程的理论公式。公式中综合考虑了空载电压的持续作用,使得其更加符合实际的引弧过程。同时,也指出由于激光辅助引弧过程采用连续激光,使得空间击穿更容易发生。
论文的研究实现了对接触引弧过程(TIG焊与MIG焊)与非接触引弧过程(激光辅助TIG焊)的定性观测与定量分析,分别从宏观和微观角度对引弧过程的物理特征进行了阐述。研究有助于进一步深入理解焊接电弧产生的机理,对丰富焊接物理理论基础与提升自动化弧焊过程的精量监控都具有一定的学术和现实意义。
Welding is a very important processing technology in mechanical manufacturing. It is such a process that two or more similar or different materials are connected through the diffusion and the combination of atoms or molecules. Nowadays, arc welding is one of the most widely used metal welding methods, it has gotten extensive application in whether manual welding or automated welding and robotic welding.
The so-called arc is a lasting and strong discharging phenomenon generated by the gas medium between the two electrodes. It has the features as low voltage and high current. As an important part of the welding physics, arc phenomenon receives much concern in welding workers. Arc starting process that is the initial stage of the discharging process directly affects the subsequent development of the welding process. Because of the complexity of the process, the research on its mechanism is quite lack at home and abroad.
In this dissertation, the arc starting processes of several welding modes including TIG, MIG and laser-assisted TIG welding are discussed in detail through the experimental study and the theoretical analysis. The similar conductive characteristics in arc starting processes of these modes are found although the concrete forms are different in different modes. The universal understanding in physical characteristics in arc starting process is showed through this discovery. On the basis of in-depth analysis of these processes, the concept of three consecutive stages in TIG touch arc starting process is proposed. The quantitative studies on arc starting processes in TIG,MIG and laser-assisted TIG welding are primarily investigated. The main contents and innovations of this dissertation are as follows:
(1)The spectral diagnostic system is established through welding power source, optical device, spectroscopy, high-speed cameras, data processing and analysis system. The real-time observation for arc starting process is realized accurately and reliably by this system. Two different calculation models based on the Stark-broadened line of Hαare compared through the explanation of the testing principle for electron density. Under the two conditions including touch arc starting process and non-touch arc starting process, the time of welding arc starting process is defined from different angles and it laid the basis for the following experiments.
(2)The TIG touch arc starting process for aluminum plate and low-carbon steel plate in different angles are observed and studied. The changes of electron density in TIG touch arc starting process are quantitatively calculated and the changing phenomenon of the main ionized element in arc starting is found. The time descriptions on the arc starting processes under different welding parameters (including welding current, shielding gas, welding arc length, anode material, tungsten diameter and no-load voltage) are carried out with advanced high-speed camera and the acquisition equipment for electrical signal. The trends of different input-output (the arc starting time) are obtained and the mechanisms are also discussed.
(3)The MIG and the laser-assisted arc starting processes are observed and studied in detail. The similar conductive characteristics as above are observed via the acquisition and analysis on the MIG arc starting process. The results show that the rate of the subsequent energy transfer will be significantly increased when the metallic atoms from the two electrodes are excited at the same time. The characteristic that the easily ionized element has a priority of providing electrons under the low temperature condition in the initial time of the arc starting process is also verified. In order to investigate the possibility of using the external energy to establish an arc, the CW laser is used as heat source in non-touch arc starting process. It shows that the changing phenomenon of main ionized element providing the electrons can be also found in the laser-assisted arc starting process. Meanwhile, the features of the tungsten arc welding are also supported by the process, that is, the local heating of workpiece is the initial condition of the electron impact produced by the heating process and the energy transfer in the arc space.
(4)The three consecutive stages in TIG touch arc starting process are proposed through the timing sequential statistical analyses of welding arc starting relaxation phenomenon. That is, the workpiece preheating stage, the field emission stage and the arc discharging stage. The physical phenomena and characteristics of each stage are described separately and the general theoretical formulae in these stages are quantitatively described. The average ionization degree of arc plasma in arc starting process is calculated by the Thomas-Fermi model and the Saha equation. The change law of ionization degree is also summarized. With the refinement and generalization of test data, the rules that the different welding conditions have influences on the arc starting time are studied. The empirical formula is also given for describing the arc starting time.
(5)On the basis of Joule heating and melting theories, the prediction formula of MIG arc starting time is derived. The results show that the smaller the weight of the welding wire melting part, the smaller the welding wire diameter, the bigger the welding density, the bigger the welding current and the bigger the local touch voltage, the arc starting time will be shorter. The formula of development of free electron density in laser-assisted arc starting process is derived based on the theory of gaseous breakdown initiated by the laser pulse. The multiphoton ionization and collision ionization are also considered. Because of the consideration of continuing effect of no-load voltage, the formula is good agreement with that of the actual arc starting process. It also pointed out that due to using the CW laser in laser-assisted arc starting process, the space is more prone to breakdown.
In this dissertation, the touch arc starting process (including TIG and MIG welding)and the non-touch arc starting process (including laser-assisted welding) are realized in qualitative observations and quantitative analyses. The physical characteristics of arc starting processes are respectively described in macroscopic and microcosmic points of view. It is helpful to further understanding on the generation mechanism of welding arc starting and it also has a certain academic and practical significance on enriching the welding physical theoretical foundation and improving the precise monitoring on automatic arc welding process.
所谓电弧是指两个电极间由气体介质产生的持久而强烈的放电现象,具有低电压、高电流的特点。电弧现象是焊接物理的重要组成部分,一直备受焊接工作者的关注。引弧过程作为电弧放电过程的起始阶段,直接影响后续焊接过程的开展。由于引弧过程十分复杂,目前在国内外对其机理的研究还比较缺乏。
本文针对弧焊中几种常用焊接模式(包括TIG焊、MIG焊与激光辅助TIG焊)的引弧过程进行了详细地试验研究与理论分析。发现这些模式下的引弧过程虽然体现了不尽相同的特点,但都有着类似的气体导电特征,使得焊接引弧过程的这一物理特征具有认识的普遍性。在深入分析各个引弧过程的基础上,提出了TIG焊接触引弧过程中三个连续特征阶段的概念,并对TIG焊引弧、MIG焊引弧及激光辅助引弧过程进行了初步的定量研究。论文主要内容及创新点如下:
(1)通过焊接电源、透镜光学装置、光谱仪、高速摄像机、数据处理与分析系统等构建了光谱诊断试验系统平台,实现了对引弧过程准确可靠的实时观测。通过对电子数密度测试原理的说明,比较了两种基于Hα谱线Stark展宽的不同的计算模型。从接触引弧和非接触引弧两种条件下的引弧过程入手,对主要研究对象——焊接电弧引燃过程的时间进行了不同角度的界定,为后续试验的开展奠定了基础。
(2)从不同角度对铝板和低碳钢板TIG焊接触引弧过程进行了观测与研究。对该过程电子密度随时间的变化作出了定量计算分析,得到了引弧过程的基本特征,即过程存在着主体电离元素的变换现象。借助先进的高速摄像与电信号采集设备,对不同焊接条件(包括焊接电流、保护气体、焊接弧长、阳极材料、钨极直径与空载电压)下的TIG焊接触引弧过程进行了时间描述,得到了不同焊接输入量对输出量——引弧时间的变化趋势,并对影响机理进行了阐述。
(3)对铝合金MIG焊引弧及激光辅助引弧过程进行了详细地观测与研究。通过对MIG焊引弧过程电信号与光谱图像的采集与分析,得到了该过程存在着类似TIG焊的气体导电特征。研究还表明,在MIG焊引弧过程中当两电极同时被激发时,后续的导电速率将显著提高,并且具有在低温条件下,易电离元素优先激发提供电子的物理特征。将连续激光作为热源进行非接触引弧,尝试探索外部能量参与并建立电弧可能。研究发现,激光辅助引弧亦存在着贡献电子主体电离元素的变换现象。同时,该过程也支持了钨极电弧焊引弧的主要特点:即对金属工件的局部加热是产生电子碰撞进而进行电弧空间能量传递的初始条件。
(4)通过对焊接引弧弛豫现象的时序统计分析,概括了TIG焊接触引弧过程的三个连续特征阶段,即工件预热阶段、场致发射阶段及电弧放电阶段。分别对每个阶段的物理现象与特点进行了说明,并给出了可以定量描述该阶段的一般理论公式。采用Thomas-Fermi模型与Saha方程联立的方法,计算了引弧过程不同时刻的平均电离度,总结归纳了电离度的变化规律。借助试验数据的提炼与概括,对不同焊接条件对焊接引弧时间的影响规律进行了研究,给出了描述引弧过程时间的经验公式。
(5)以焦耳加热与金属熔化理论为基础,推导了MIG焊引弧过程时间的预测公式。结果表明,当焊丝熔化部分质量越小,焊丝直径越小,焊丝密度越大,焊接电流越大,局部接触电压越大时,引弧过程时间越短。以激光脉冲作用导致气体击穿形成等离子体理论为基础,在同时考虑多光子电离与碰撞电离的情况下,推导了用于描述激光辅助引弧中电弧空间自由电子密度发展过程的理论公式。公式中综合考虑了空载电压的持续作用,使得其更加符合实际的引弧过程。同时,也指出由于激光辅助引弧过程采用连续激光,使得空间击穿更容易发生。
论文的研究实现了对接触引弧过程(TIG焊与MIG焊)与非接触引弧过程(激光辅助TIG焊)的定性观测与定量分析,分别从宏观和微观角度对引弧过程的物理特征进行了阐述。研究有助于进一步深入理解焊接电弧产生的机理,对丰富焊接物理理论基础与提升自动化弧焊过程的精量监控都具有一定的学术和现实意义。
Welding is a very important processing technology in mechanical manufacturing. It is such a process that two or more similar or different materials are connected through the diffusion and the combination of atoms or molecules. Nowadays, arc welding is one of the most widely used metal welding methods, it has gotten extensive application in whether manual welding or automated welding and robotic welding.
The so-called arc is a lasting and strong discharging phenomenon generated by the gas medium between the two electrodes. It has the features as low voltage and high current. As an important part of the welding physics, arc phenomenon receives much concern in welding workers. Arc starting process that is the initial stage of the discharging process directly affects the subsequent development of the welding process. Because of the complexity of the process, the research on its mechanism is quite lack at home and abroad.
In this dissertation, the arc starting processes of several welding modes including TIG, MIG and laser-assisted TIG welding are discussed in detail through the experimental study and the theoretical analysis. The similar conductive characteristics in arc starting processes of these modes are found although the concrete forms are different in different modes. The universal understanding in physical characteristics in arc starting process is showed through this discovery. On the basis of in-depth analysis of these processes, the concept of three consecutive stages in TIG touch arc starting process is proposed. The quantitative studies on arc starting processes in TIG,MIG and laser-assisted TIG welding are primarily investigated. The main contents and innovations of this dissertation are as follows:
(1)The spectral diagnostic system is established through welding power source, optical device, spectroscopy, high-speed cameras, data processing and analysis system. The real-time observation for arc starting process is realized accurately and reliably by this system. Two different calculation models based on the Stark-broadened line of Hαare compared through the explanation of the testing principle for electron density. Under the two conditions including touch arc starting process and non-touch arc starting process, the time of welding arc starting process is defined from different angles and it laid the basis for the following experiments.
(2)The TIG touch arc starting process for aluminum plate and low-carbon steel plate in different angles are observed and studied. The changes of electron density in TIG touch arc starting process are quantitatively calculated and the changing phenomenon of the main ionized element in arc starting is found. The time descriptions on the arc starting processes under different welding parameters (including welding current, shielding gas, welding arc length, anode material, tungsten diameter and no-load voltage) are carried out with advanced high-speed camera and the acquisition equipment for electrical signal. The trends of different input-output (the arc starting time) are obtained and the mechanisms are also discussed.
(3)The MIG and the laser-assisted arc starting processes are observed and studied in detail. The similar conductive characteristics as above are observed via the acquisition and analysis on the MIG arc starting process. The results show that the rate of the subsequent energy transfer will be significantly increased when the metallic atoms from the two electrodes are excited at the same time. The characteristic that the easily ionized element has a priority of providing electrons under the low temperature condition in the initial time of the arc starting process is also verified. In order to investigate the possibility of using the external energy to establish an arc, the CW laser is used as heat source in non-touch arc starting process. It shows that the changing phenomenon of main ionized element providing the electrons can be also found in the laser-assisted arc starting process. Meanwhile, the features of the tungsten arc welding are also supported by the process, that is, the local heating of workpiece is the initial condition of the electron impact produced by the heating process and the energy transfer in the arc space.
(4)The three consecutive stages in TIG touch arc starting process are proposed through the timing sequential statistical analyses of welding arc starting relaxation phenomenon. That is, the workpiece preheating stage, the field emission stage and the arc discharging stage. The physical phenomena and characteristics of each stage are described separately and the general theoretical formulae in these stages are quantitatively described. The average ionization degree of arc plasma in arc starting process is calculated by the Thomas-Fermi model and the Saha equation. The change law of ionization degree is also summarized. With the refinement and generalization of test data, the rules that the different welding conditions have influences on the arc starting time are studied. The empirical formula is also given for describing the arc starting time.
(5)On the basis of Joule heating and melting theories, the prediction formula of MIG arc starting time is derived. The results show that the smaller the weight of the welding wire melting part, the smaller the welding wire diameter, the bigger the welding density, the bigger the welding current and the bigger the local touch voltage, the arc starting time will be shorter. The formula of development of free electron density in laser-assisted arc starting process is derived based on the theory of gaseous breakdown initiated by the laser pulse. The multiphoton ionization and collision ionization are also considered. Because of the consideration of continuing effect of no-load voltage, the formula is good agreement with that of the actual arc starting process. It also pointed out that due to using the CW laser in laser-assisted arc starting process, the space is more prone to breakdown.
In this dissertation, the touch arc starting process (including TIG and MIG welding)and the non-touch arc starting process (including laser-assisted welding) are realized in qualitative observations and quantitative analyses. The physical characteristics of arc starting processes are respectively described in macroscopic and microcosmic points of view. It is helpful to further understanding on the generation mechanism of welding arc starting and it also has a certain academic and practical significance on enriching the welding physical theoretical foundation and improving the precise monitoring on automatic arc welding process.
引文
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