Sensitivity analysis of process parameters of self-shielded flux cored wire
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摘要: 自保护药芯焊丝是一种适合于野外作业的焊接材料，广泛应用于船舶、钻井平台、石油管道、集装箱等结构件焊接及修复. 采用自保护药芯焊丝在Q235钢板表面进行单层单道平板堆焊试验，运用二次回归通用旋转组合设计方法建立了电弧电压、送丝速度、焊接速度与熔宽、余高、熔高的二次回归数学模型，分析了工艺参数与熔敷几何尺寸的关系. 结果表明，该模型能够预测稳定工艺区间内工艺参数变化对熔敷层几何尺寸的影响规律；当电压较低时，送丝速度是影响熔宽和余高的主要因素，电压较高时，焊接速度是影响熔宽和余高的主要因素.Abstract: Self-shielded flux cored wire is a kind of welding material suitable for field project, which is widely used in welding and repair of field project such as ships, drilling platforms, oil pipelines and containers. Single-layer single-bead welding was carried out on the surface of Q235 steel by self-shielded flux cored wire, and quadratic regression mathematical model between arc voltage, wire feeding speed, welding speed and melting width, reinforcement, melting height was established by quadratic regression universal rotating combination design method. The relationship between process parameters and deposited geometries is analyzed, the results show that the model can predict the influence of process parameter variation on the geometry of the deposited layer in the stable process interval. The wire feeding speed is the main factor affecting the melting width and reinforcement at low voltage, while the welding speed is the main factor affecting the melting width and reinforcement at high voltage.
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图 3 熔宽对电弧电压、送丝速度、焊接速度的敏感性
Figure 3. Sensitivity of melting width to arc voltage, wire feeding speed and welding speed
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图 4 余高对电弧电压、送丝速度、焊接速度的敏感性
Figure 4. Sensitivity of reinforcement to arc voltage, wire feeding speed and welding speed
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图 5 熔高对电弧电压、送丝速度、焊接速度的敏感性
Figure 5. Sensitivity of melting height to arc voltage, wire feeding speed and welding speed
表 1 自保护药芯焊丝熔敷金属化学成分(质量分数，%)
Table 1 Deposited metal chemical composition of self-shielded flux cored wire
C W Mn Si Fe 1.5 ~ 3.0 40.0 ~ 50.0 ≤ 2.0 ≤ 4.0 余量 
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表 2 因素水平编码表
Table 2 Factor levels coding table
水平 电弧电压U/V 送丝速度vf/(mm·s–1) 焊接速度v/(mm·s–1) –1.682 23.64 13.83 2.76 –1 25.00 16.67 3.33 0 27.00 20.83 4.17 1 29.00 25.00 5.00 1.682 30.36 27.84 5.57
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表 3 回归方程拟合度和回归方差分析
Table 3 Analysis of regression equation fitting degree and regression variance
熔宽W/mm 余高H/mm 熔高P/mm FLf F FLf F FLf F 10.12 12.36 3.45 7.78 9.36 5.02 其中FLf为拟合度，F为回归方差.
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表 4 试验结果
Table 4 Experimental results
序号 电弧电压z1 送丝速度z2 焊接速度z3 熔宽W/mm 余高H/mm 熔高P/mm 1 1 1 1 9.02 1.26 3.68 2 1 1 –1 11.59 2.01 3.68 3 1 –1 –1 9.41 1.73 3.10 4 1 –1 1 7.41 1.10 2.40 5 –1 –1 1 7.53 1.26 2.56 6 –1 –1 –1 8.95 1.45 2.64 7 –1 1 –1 10.76 2.07 4.84 8 –1 1 1 9.20 1.95 3.64 9 –1.682 0 0 8.90 1.67 3.16 10 1.682 0 0 9.37 1.28 2.56 11 0 –1.682 0 10.50 2.09 3.84 12 0 1.682 0 7.44 1.02 2.54 13 0 0 –1.682 7.97 1.37 2.84 14 0 0 1.682 10.36 1.78 3.26 15 0 0 0 9.32 1.60 3.20 16 0 0 0 9.11 1.57 2.80 17 0 0 0 8.95 1.65 3.10 18 0 0 0 8.80 1.69 3.10 19 0 0 0 8.90 1.63 3.00 20 0 0 0 9.06 1.70 3.20
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