等离子弧−MIG焊丝振荡式复合焊接工艺

张鸿昌; 李一楠; 于江; 张靖祎; 张洪涛; 高建国

doi:10.12073/j.hjxb.20220327002

等离子弧−MIG焊丝振荡式复合焊接工艺

张鸿昌^{1, 2,},
李一楠^1, ,,
于江³,
张靖祎³,
张洪涛³,
高建国⁴

1.
青岛理工大学, 青岛, 266000
2.
哈尔滨理工大学, 哈尔滨, 150001
3.
哈尔滨工业大学, 先进焊接与连接国家重点实验室, 哈尔滨, 150001
4.
山东经典重工集团股份有限公司, 济宁, 272000

基金项目: 国家自然科学基金面上资助项目(52175305)；国家自然科学基金企业联合基金资助项目(U22B20127)；2022年度山东省新旧动能转换重大产业攻关项目

详细信息

作者简介:
张鸿昌，博士研究生，讲师；主要研究方向为先进高效复合焊接装备及方法；Email: hongchangzhang123@163.com

通讯作者:
李一楠，博士，教授；Email: liyinan2004@163.com.

中图分类号: TG 444
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出版历程
- 收稿日期: 2022-03-26
- 网络出版日期: 2023-02-15
- 刊出日期: 2023-02-24

PAW−MIG wire oscillating hybrid welding technology

1.
Qingdao University of Technology, Qingdao, 266000, China
2.
Harbin University of Science and Technology, Harbin, 150001, China
3.
State Key Laboratory of Advanced Welding and Joining, Harbin Institute of Technology, Harbin, 150001, China
4.
Shandong Classic Group Co., Ltd., Jining, 272000, China

摘要

摘要: 针对现有的等离子弧-MIG复合焊接过程中的双弧排斥问题，基于MIG焊丝位移规律性改变提出了一种新型的MIG焊丝振荡与等离子弧共熔池的复合焊接工艺. 通过调节MIG焊丝电机转速(振荡频率)和振荡振幅进行了焊接工艺试验. 结果表明，随着电机转速(振荡频率0 ~ 41 Hz)的增加，等离子弧与MIG电弧排斥减弱，耦合趋势增大. 尤其是电机转速为2 000 r/min(振荡频率33 Hz)时，共熔池复合焊接效果较好；MIG焊炬振荡振幅为1 mm时，电弧形状最为稳定，但振荡频率和振荡振幅过大均不利于焊接过程稳定性；MIG焊炬振荡提高了熔滴过渡频率，使焊丝尖部呈现小熔滴过渡，减小了焊接飞溅. 对接试验力学性能测试表明，抗拉强度、抗弯强度均随振荡频率的提高呈现先增大后减小趋势，分析认为MIG焊炬振荡具有一定搅拌熔池的作用，有效提高了焊接接头的力学性能.
- 等离子弧−MIG复合焊接 /
- 振荡频率 /
- 电弧形态 /
- 力学性能
Abstract: In order to solve the problem of double arc repulsion in the existing PAW−MIG hybrid welding process, a new welding process based on the regular change of MIG wire displacement was proposed, which combined MIG wire oscillation with plasma arc in common weld pool. The welding process test was carried out by adjusting the rotation (oscillation frequency) and amplitude of MIG welding wire motor. The results show that with the increase of rotational speed (oscillation frequency), the repulsion between plasma arc and MIG arc decreases and the coupling trend increases. Especially when the rotational speed is 2000 r/min(oscillation frequency 33 Hz), the common weld pool effect is obvious. When the amplitude of MIG torch is 1 mm, the arc shape is the most stable. When the oscillation frequency and amplitude are too large, it is not conducive to the stability of welding process. The oscillation speeds up the droplet transition frequency so that the tip of the welding wire presents a small droplet transition and reduces the welding splash. The mechanical properties of the butt test show that the tensile strength and bending strength increase first and then decrease with the increase of the oscillation frequency. The oscillation enhances the stirring ability of the molten pool metal and effectively improves the mechanical properties of the welded joint.
- PAW−MIG hybrid welding /
- oscillation frequency /
- arc morphology /
- mechanical properties

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图 1 等离子弧−MIG焊丝振荡式复合焊接系统

Figure 1. PAW-MIG wire oscillation hybrid welding system

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图 2 振荡式复合焊接平台装配实物图

Figure 2. Oscillating hybrid welding platform

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图 3 复合焊焊缝形貌

Figure 3. Weld morphology of hybrid welding

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图 4 不同转速(振荡频率)下复合焊接电弧形态

Figure 4. Arc morphology of hybrid welding at different rotational speed (oscillation frequency). (a) rotational speed 0 r/min (0 Hz); (b) rotational speed 1 000 r/min (16 Hz); (c) rotational speed 1 500 r/min (25 Hz); (d) rotational speed 2 000 r/min (33 Hz); (e) rotational speed 2 500 r/min (41 Hz)

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图 5 不同转速下复合焊接熔滴过渡及电信号采集

Figure 5. Droplet transfer and electrical signal of hybrid welding at different rotational speed. (a) rotational speed 0 r/min (0 Hz); (b) rotational speed 1 000 r/min (16 Hz); (c) rotational speed 1500 r/min (25 Hz); (d) rotational speed 2 000 r/min (33 Hz)

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图 6 不同振荡振幅下复合焊接电弧形态

Figure 6. Hybrid welding arc morphology with different oscillation amplitude. (a) oscillation amplitude 1 mm ; (b) oscillation amplitude 2 mm; (c) oscillation amplitude 3 mm; (d) oscillation amplitude 4 mm; (e) oscillation amplitude 5 mm ; (f) oscillation amplitude 6 mm

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图 7 不同转速和振荡振幅复合焊接熔滴过渡及电信号采集

Figure 7. Droplet transfer and electrical signal of hybrid welding at different rotational speed and oscillation amplitude. (a) rotational speed 1 000 r/min (16 Hz), oscillation amplitude 1 mm; (b) rotational speed 1 500 r/min (25 Hz), oscillation amplitude 3 mm

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图 8 不同转速(振荡频率)的焊缝成形

Figure 8. Weld formation at different rotational speed (oscillation frequency). (a) rotational speed 0 r/min (0 Hz); (b) rotational speed 1 000 r/min (16 Hz); (c) rotational speed 1 500 r/min (25 Hz); (d) rotational speed 2 000 r/min (33 Hz)

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表 1 Q235钢和ER50-6焊丝的化学成分(质量分数，%)

Table 1 Chemical compositions of Q235 steel and ER50-6 welding wire

材料	C	Mn	Si	P	S	Ni	Fe
Q235	≤0.18	0.35 ~ 0.80	≤0.30	≤0.040	—	—	余量
ER50-6	0.06 ~ 0.15	1.40 ~ 1.85	0.80 ~ 1.15	0.025	0.025	0.15	余量

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表 2 焊接工艺参数

Table 2 Welding process parameters

组别	等离子弧电流I_P/A	MIG电流I_M/A	焊接速度v/(mm·s⁻¹)	电机转速n/(r·min⁻¹)	振荡振幅A/mm
1	40	120	4	0	0
2	40	120	4	1 000,1 500,2 000,2500	3
3	40	120	4	1 000	1，2，3，4，5，6
4	100	100	4	0	3
5	100	100	4	1 000,1 500,2 000	3
6	100	100	4	1 000	4
7	100	100	4	1 500	3

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表 3 拉伸和弯曲试验的测试结果

Table 3 Results of tensile and bending tests

电机转速n/( r·min⁻¹)	抗拉强度R_m /MPa		抗弯强度R_τ /MPa
电机转速n/( r·min⁻¹)	实测值	平均值	实测值	平均值
0	167，178，155	167	200,175,179	185
1 000	220，240，285	248	280,235,300	272
1 500	325，275，235	278	260,220,265	248
2 000	260，225，174	220	305,200,205	237

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