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焊接参数对摆动电弧窄间隙GMAW立向上焊过程稳定性的影响

Effect of welding parameters on process stability of oscillating arc narrow-gap GMAW vertical-up welding

  • 摘要: 为了解决窄间隙熔化极气体保护电弧焊(gas metal arc welding,GMAW)立向上焊因电弧热量分配不均易产生未熔合、熔池下淌导致成形困难,且摆动电弧下焊接参数与电弧侧壁爬升及未熔合机制尚不明确的问题,采用690 MPa级低合金高强钢配套焊丝MG-80进行摆动电弧窄间隙GMAW立向上焊接试验,研究了峰值电压、摆动幅度、侧壁停留时间对电弧稳定性以及熔化尺寸的影响.采用焊丝端部坐标的空间分布以及焊丝端部距坡口底面距离的数值分布表征电弧稳定性,采用近坡口圆角处最小侧壁熔深、坡口内部底面最小熔深以及焊缝宏观形貌评价侧壁未熔合和层间未熔合的产生倾向.结果表明,若参数变化加剧电弧侧壁爬升行为,会导致焊接最小熔深降低,峰值电压、摆动幅度、侧壁停留时间的增大均会使摆动阶段焊丝端部距坡口底面的距离增大,导致电弧在摆动阶段与坡口底面导通概率降低,电弧跳过由坡口底面到坡口圆角再到侧壁的过渡过程并提前与侧壁燃弧,进而使坡口底面及侧壁的最小熔深降低,侧壁未熔合与层间未熔合产生的倾向增大.

     

    Abstract: To address the problems of lack of fusion caused by uneven arc heat distribution and poor weld formation induced by molten pool sagging in narrow-gap GMAW vertical-up welding, as well as the unclear mechanism relating welding parameters to arc sidewall climbing and lack of fusion under oscillating arc conditions, oscillating arc narrow-gap GMAW vertical-up welding experiments were conducted using the matching welding wire MG-80 for 690 MPa-grade low-alloy high-strength steel. The effects of peak voltage, oscillation amplitude, and sidewall residence time on arc stability and melting dimensions were investigated. The spatial distribution of wire tip coordinates and the numerical distribution of the distance from the wire tip to the groove bottom were adopted to characterize arc stability. The minimum sidewall penetration near the groove fillet, the minimum penetration at the inner groove bottom, and the macro morphology of weld seams were used to evaluate the tendency to generate sidewall and interlayer lack of fusion. The results indicate that if parameter variations intensify the arc sidewall climbing behavior, the minimum welding penetration decreases. The increases in peak voltage, oscillation amplitude, and sidewall residence time all increase the distance from the wire tip to the groove bottom during the oscillation stage, lowering the probability of arc conduction with the groove bottom. The arc skips the transition process from the groove bottom to the groove fillet and then to the sidewall and ignites on the sidewall in advance. Consequently, the minimum penetration at both the groove bottom and the sidewall decreases, and the tendency to generate sidewall and interlayer lack of fusion increases.

     

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