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超高频可编辑脉冲电流作用下电弧特性与焊缝成形

Arc characteristics and weld formation under ultra-high-frequency editable pulsed current

  • 摘要: 为提高超高频焊接电流波形的调控能力,对多支路超高频脉冲焊接电源拓扑及控制时序进行优化.增加独立恒流支路和调整支路组合方式,可在单个周期内形成幅值、排列顺序和持续时间可调的多平台电流波形;同时在高速开关支路中设置吸收回路,改善复杂电流波形的输出精度与稳定性.搭建电弧观测与焊接试验平台,采用高速摄像、696.5 nm窄带滤光成像和Abel逆变换获得不同波形条件下的电弧形态及温度场,并开展IN718薄板焊接试验.结果表明,在平均电流均为90 A的条件下,电弧宽度和轮廓面积随脉冲频率提高整体减小,高温区域逐渐向弧柱中心集中.100 kHz时,Wave4的电弧宽度和轮廓面积较直流工况分别减小15.67%和20.28%,14 000 K以上高温区面积占比达到21.34%;焊缝熔深达到2.17 mm,较直流工况提高50.28%,焊缝中心平均晶粒尺寸降低39.5%.优化后的多支路电源可实现复杂超高频电流波形输出,并可通过调节单周期内电流平台的幅值组合与时间分布,实现对电弧形态、温度场分布、焊缝成形及晶粒组织的调控.

     

    Abstract: To improve the controllability of ultra-high-frequency welding current waveforms, the topology and control sequence of a multi-branch ultra-high-frequency pulsed welding power supply were optimized. By adding an independent constant-current branch and adjusting the branch combinations, multi-level current waveforms with adjustable amplitudes, sequences, and durations can be generated within a single cycle. In addition, a snubber circuit was incorporated into the high-speed switching branches to improve the output accuracy and stability of complex current waveforms. An experimental platform for arc observation and welding tests was established. High-speed imaging, narrow-band filter imaging at 696.5 nm, and Abel inversion were employed to obtain the arc morphology and temperature field under different current waveforms, and welding tests on IN718 sheets were conducted. The results indicate that, at an average current of 90 A, the arc width and contour area generally decrease with an increase in pulse frequency, and the high-temperature region gradually concentrates toward the arc column center. At 100 kHz, the arc width and contour area of Wave4 decrease by 15.67% and 20.28%, respectively, compared with the direct current condition; the area fraction above 14 000 K reaches 21.34%. The weld penetration reaches 2.17 mm, representing an increase of 50.28% over the direct current condition, and the average grain size in the weld center decreases by 39.5%. The optimized multi-branch power supply can output complex ultra-high-frequency current waveforms, and the regulation of arc morphology, temperature field distribution, weld formation, and grain structure can be achieved by adjusting the amplitude combinations and temporal distribution of current levels within a single cycle.

     

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