Large diameter hollow stud welding process based on longitudinal magnetic field control
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摘要: 采用电弧螺柱焊方法对外径20 mm、内径10 mm的空心螺柱与45钢板材进行焊接，研究了旋弧磁场对接头显微组织特征及力学性能的影响. 结果表明，在纵向旋弧磁场作用下，电弧中电荷受洛伦兹力作用呈螺旋运动，接头外观成形得到改善. 受磁场控制的电弧持续搅拌熔池，改善了焊接热循环条件，影响了熔池凝固结晶过程. 接头中先共析铁素体呈有规律的网状分布，珠光体也变得细化. 接头温度梯度减小使得固态相变时间增长，母材侧热影响区马氏体数量显著下降，热影响区宽度变小. 但旋弧磁场电流过大时焊接过程飞溅倾向明显增大，焊缝中气孔增多. 在焊接时间1 400 ms、焊接电流800 A、旋弧磁场电流0.43 A时，电弧在空心螺柱端面充分燃烧，接头抗剪强度可达到325 MPa.Abstract: The arc stud welding method was used to weld 45 steel plate and hollow stud with outer diameter of 20 mm and inner diameter of 10 mm. Effects of the rotating arc magnetic field on microstructure and mechanical properties were studied. The results show that with the longitudinal rotating arc magnetic field, the charge in the arc moved spirally under the action of Lorentz force, which extended outward to some extent and the appearance of the joint was improved. The thermal cycle condition of joint was improved thanks to the continuous stirring of molten pool by controlled arc, and the solidification and crystallization of molten pool was affected. The proeutectoid ferrite showed a regular network distribution and the pearlite became fine. For the decrease of joint temperature gradient, the solid-state phase transition time increased, the martensite content in the heat affected zone of the parent metal of 45 steel side decreased significantly and the width of HAZ became smaller. When the rotating arc magnetic field current was too large, the spatter tendency increased obviously as well as the porosity in the weld increased. When the welding time of 1 400 ms, the welding current of 800 A and the rotating arc current of 0.43 A, the arc was fully burned at the full end face of the hollow stud, the shear strength of joints can reach 325 MPa.
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Keywords:
- arc stud welding /
- hollow stud /
- magnetic field /
- arc
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图 2 旋转电弧模型
Figure 2. Rotating arc model. (a) schematic diagram of hollow stud welding rotating arc; (b) arc force model
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图 3 不同旋弧电流条件下接头的外观成形
Figure 3. Appearance form of joints at different rotating arc current. (a) 0 A; (b) 0.25 A; (c) 0.43 A; (d) 0.61 A
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图 4 不同旋弧电流条件下接头宏观照片
Figure 4. Macrograph of joints with different rotating arc current. (a) 0.25 A; (b) 0.43 A
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图 5 旋弧磁场对空心螺柱焊接头组织的影响
Figure 5. Effects of rotating arc magnetic field on the microstructure of hollow stud welded joints. (a) non-magnetic field stud welding seam; (b) weld microstructure of rotating arc stud welding; (c) non-magnetic field stud welding fusion line; (d) rotating arc stud welding fusion line
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图 6 不同旋弧电流下接头中树枝晶SEM照片
Figure 6. SEM micrographs of joint dendrites at different rotating arc current. (a) 0. 25 A; (b) 0. 43 A
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图 7 不同旋弧电流下接头过渡区域SEM照片
Figure 7. SEM micrographs of transition region of joint at different rotating arc currents. (a) 0.43 A; (b) 0.61 A
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图 8 接头线扫描区的元素分布
Figure 8. Element distribution at the line scanning area of joint. (a) line scanning area; (b) element distribution
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图 9 空心螺柱焊接头的剪切试验结果
Figure 9. Shear strength test of hollow stud welded joints. (a) shear strength curve of welded joint; (b) SEM of fracture surface
表 1 45钢的化学成分(质量分数，%)
Table 1 Chemical compositions of 45 steel
C Si Mn Cr+Ni+Cu P S Fe 0.42~0.50 0.17~0.37 0.5~0.8 0.7 0.035 0.035 余量 
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表 2 焊接工艺参数及接头抗剪强度
Table 2 Welding process parameters and shear strength of joints
编号 焊接电流
I/A焊接时间
t/ms旋弧电流
I/A抗剪强度
Rτ/MPa1 800 1 400 0 278 2 800 1 400 0.25 302 3 800 1 400 0.43 325 4 800 1 400 0.61 310
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