Influence factors and control methods of droplet transfer in narrow gap P-GMAW overhead welding position
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摘要:
管道窄间隙全位置焊接过程中，在接近仰焊位置容易出现焊接缺陷，制约了管道施工的质量和效率.文中针对管道自动焊仰焊位置成形差、可靠性低的问题，分析P-GMAW过程送丝速度、弧长修正、导电嘴到熔池距离等因素对熔滴过渡的影响规律.结果表明，增加弧长修正系数可以增大电弧对侧壁的热输入，能够缓解侧壁熔合不良的问题，但会使熔滴过渡路径难以控制.因此当焊枪运动到仰焊位置时，提高送丝速度有利于获得更小的熔滴、更高的过渡频率；降低导电嘴到熔池距离，可以增加电磁力、减小熔滴尺寸，从而更有利于仰焊位置熔滴向熔池的过渡，研究结果对于管道窄间隙焊接的工艺设计具有一定的指导意义.
Abstract:When conducting narrow gap all position welding of pipelines, welding defects are easy to occur near the overhead welding position, which restricts the quality and efficiency of pipeline construction. Aiming at the problem of poor formation and low reliability of overhead welding position in automatic pipe welding, this paper studies the influence of wire feeding speed, arc length correction, contact nozzle distance to molten pool and other factors on droplet transfer in P-GMAW process. It is found that increasing the arc length correction coefficient can increase the heat input of the arc to the side wall, which can alleviate the problem of poor side wall fusion, but will make the droplet transfer path difficult to control, Therefore, when the welding gun moves to the overhead welding position, short arc welding shall be adopted and the heat input to the side wall shall be supplemented by increasing the side stop time and swing; Increasing the wire feeding speed is conducive to obtaining smaller droplets, higher transfer frequency, reducing the distance between the contact tip and the molten pool, increasing the electromagnetic force and reducing the droplet size, which is more conducive to the transfer of droplets to the molten pool in overhead welding position. The research results have certain guiding significance for the process design of pipe narrow gap welding.
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Keywords:
- droplet transfer /
- Swing arc /
- MIG welding /
- Narrow gap welding
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图 3 焊枪摆动到侧壁时弧长修正系数对电弧燃烧位置和熔滴过渡路径的影响
Figure 3. Influence of arc length correction coefficient on arc combustion position and droplet transition path when welding torch swings to side wall. (a) influence on the arc combustion; (b) influence on the droplet transition
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图 5 焊枪在侧壁时不同弧长修正系数下熔滴的过渡位置
Figure 5. Transfer position of droplet under different arc length correction factors when the welding gun is on the side wall
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图 6 熔滴受力示意图
Figure 6. Diagram of droplet stress.(a) stress in the initial forming stage of droplets；(b) stress in the middle and late stage of droplet formation
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图 8 送丝速度对过渡频率和熔滴直径的影响
Figure 8. Influence of wire feeding speed on the transition frequenay and droplet diameter. (a) transition frequency; (b) droplet diameter
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图 9 送丝速度对脉冲频率和熔滴获得的能量的影响
Figure 9. Influence of wire feeding speed on the pulse frequeney and energy acquisition of moltem droplets. (a) pulse frequency; (b) energy gained by the droplet
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图 10 CTWD变化前后电压电流
Figure 10. Voltage and current change diagram before and after CTWD change
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