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WO2019000112A1 - 铝合金管氩弧焊接过程优化方法 - Google Patents

铝合金管氩弧焊接过程优化方法 Download PDF

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Publication number
WO2019000112A1
WO2019000112A1 PCT/CN2017/000402 CN2017000402W WO2019000112A1 WO 2019000112 A1 WO2019000112 A1 WO 2019000112A1 CN 2017000402 W CN2017000402 W CN 2017000402W WO 2019000112 A1 WO2019000112 A1 WO 2019000112A1
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WO
WIPO (PCT)
Prior art keywords
welding
aluminum alloy
welding process
weld
argon arc
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Ceased
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PCT/CN2017/000402
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English (en)
French (fr)
Inventor
张彬
庞继勇
陈雅斌
郭利伟
毛春生
陈丽刚
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SEPCO1 Electric Power Construction Co Ltd
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SEPCO1 Electric Power Construction Co Ltd
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Priority to PCT/CN2017/000402 priority Critical patent/WO2019000112A1/zh
Publication of WO2019000112A1 publication Critical patent/WO2019000112A1/zh
Anticipated expiration legal-status Critical
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/16—Arc welding or cutting making use of shielding gas
    • B23K9/173—Arc welding or cutting making use of shielding gas and of a consumable electrode
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/235—Preliminary treatment

Definitions

  • the invention relates to an optimization method for an argon arc welding process of an aluminum alloy tube.
  • the angle of the traditional specimen bevel processing is generally 30°, the welding angle is small under the butt joint, and the root is not welded and the defects are easily penetrated.
  • the bevel or the steel grinding head is used to polish the groove, so that the bevel edge exists.
  • the burr is easy to damage the edge of the inner slope, resulting in defects such as pores and burn through during welding.
  • the quality of the welded joints is slow to increase, the time and energy spent by the operators are long, the cost of materials and machinery is high, and the long-term training is due to the strong light and strong ultraviolet radiation during welding of the aluminum alloy.
  • the operator's physical and mental health causes damage.
  • the present invention proposes an optimization method for an argon arc welding process of an aluminum alloy tube, and the present invention provides a welding effect by setting a targeted welding method for several key technical points in the welding. Optimization, at the same time, can establish a unified evaluation criteria, a reasonable evaluation of the operator's level, can be applied to the welding skills competition project.
  • An optimization method for an argon arc welding process of an aluminum alloy tube comprising the following steps:
  • the test piece is polished by a super-hard tungsten steel circular saw blade for aluminum alloy, and the groove angle is 35° by the weld inspection rule inspection, and the inner groove edge is polished. Do not repair, keep it straight.
  • the surface of the test piece has a surface of 40-60 mm on both sides of the bevel, and the surface is polished with a steel grinding head to expose the metallic luster.
  • the prepared test piece must be welded within 1.5-2.5 hours, otherwise the grinding is repeated. preparation.
  • the purity of the argon gas is not less than 99.99%, the water content is not more than 50 mg/m 3 , the gas flow rate is 15-20 L/min, and the ambient temperature is not lower than 5 ° C, otherwise preheating to 100- After 200 ° C, apply welding.
  • the welding current is 150-160A
  • the cleaning ratio is [-20, -15]
  • the AC bias value is 120; when welding, the welding gun is at an angle of 90° with the test piece, and cannot be tilted back and forth.
  • the extension length of the tungsten electrode is [2, 4] mm, and the welding wire is at an angle of 50°-70° with the weld seam.
  • step (4) during the welding process, the solder joints to be solidified are to be ground, and the root of the groove is not worn.
  • step (4) if it is found that there is a pore, immediately stop the welding, perform the grinding treatment, and check whether the root of the weld is not fused.
  • the super-hard tungsten steel circular saw blade is used to grind the front arc-extinguishing point out of the slope, and when the arc starts, the arc is to be arced behind the slope to form a molten pool. Add the welding wire for welding. At the end of the arc collection, the first arcing point should be polished out of the slope and slowly arced.
  • the welding current is set to 140-150 A, the cleaning ratio is [-20, -5], and the AC bias value is 120.
  • the welding wire is applied at an angle of a shear line with the weld circle, and the welding gun is oscillated by a circular swing method, and the joint of the weld is made of tungsten.
  • the steel circular saw blade is ground to ensure the height difference of the joint.
  • the original weld seam should not be damaged when grinding.
  • the first arcing point should be polished out of the slope and slowly arced.
  • the invention adopts a super-hard tungsten steel circular saw blade for aluminum alloy to grind the groove, and has no burrs and notches on the edge of the groove to avoid defects such as pores and burn through when welding; the groove angle is 35°, and the test piece is solved.
  • the angle of the groove is too small, which may cause defects such as insufficient penetration of the root.
  • the invention guides the operator's operation method throughout the welding process, so that each operator is easy to palm
  • the welding skill of holding a uniform aluminum alloy tube ensures the appearance quality and internal quality of the welded joint.
  • the present application proposes an optimization method for an argon arc welding process of an aluminum alloy tube, comprising the following steps:
  • the test piece is polished by a super-hard tungsten steel circular saw blade for aluminum alloy, and the groove angle is 35° by the weld inspection rule inspection, and the inner groove edge is polished. Do not repair, keep it straight.
  • the surface of the test piece has a surface of 40-60 mm on both sides of the bevel, and the surface is polished with a steel grinding head to expose the metallic luster.
  • the prepared test piece must be welded within 1.5-2.5 hours, otherwise the grinding is repeated. preparation.
  • the purity of the argon gas is not less than 99.99%, the water content is not more than 50 mg/m 3 , the gas flow rate is 15-20 L/min, and the ambient temperature is not lower than 5 ° C, otherwise preheating to 100- After 200 ° C, apply welding.
  • the welding current is 150-160A
  • the cleaning ratio is [-20, -15]
  • the AC bias value is 120; when welding, the welding gun is at an angle of 90° with the test piece, and cannot be tilted back and forth.
  • the extension length of the tungsten electrode is [2, 4] mm, and the welding wire is at an angle of 50°-70° with the weld seam.
  • step (4) during the welding process, the solder joints to be solidified are to be ground, and the root of the groove is not worn.
  • step (4) if it is found that there is a pore, the welding is immediately stopped, the grinding treatment is performed, and the inspection is performed. Check if the root of the weld is not fused.
  • the super-hard tungsten steel circular saw blade is used to grind the front arc-extinguishing point out of the slope, and when the arc starts, the arc is to be arced behind the slope to form a molten pool. Add the welding wire for welding. At the end of the arc collection, the first arcing point should be polished out of the slope and slowly arced.
  • the welding current is set to 140-150 A, the cleaning ratio is [-20, -5], and the AC bias value is 120.
  • the welding wire is applied at an angle of a shear line with the weld circle, and the welding gun is oscillated by a circular swing method, and the joint of the weld is made of tungsten.
  • the steel circular saw blade is ground to ensure the height difference of the joint.
  • the original weld seam should not be damaged when grinding.
  • the first arcing point should be polished out of the slope and slowly arced.
  • the invention is used in competitions, the main equipment and materials required, and the welding method:
  • Welding equipment AC/DC square wave aluminum welding machine
  • Aluminum alloy tube specifications ⁇ 80 ⁇ 5mm, material: 5A06 aluminum-magnesium alloy;
  • Aluminum welding wire specification 2.4mm, 3.2mm, model: SAl5356;
  • Welding method AC tungsten argon arc welding
  • Welding position vertical fixed group pair welding
  • the test piece processed by the lathe is made of aluminum alloy special super-hard tungsten steel circular saw blade, and the groove is polished.
  • the angle of the groove is 35°, and the inner edge of the groove is observed during the grinding. Do not repair and keep it straight.
  • This processing method does not generate burrs at the groove, which can reduce the generation of air holes during welding.
  • the surface of the 50mm side of the bevel of the test piece is polished with a steel grinding head to expose the metallic luster.
  • the prepared test piece must be welded within 2 hours, otherwise it will be re-grinded, because aluminum It is easy to oxidize in the air to produce a dense oxide film. If it is not treated, it will cause pore defects during welding.
  • test piece is vertically aligned on the station frame to see if there is a gap. If there is a gap that will cause burn-through defects, use a trowel to level the force slightly through the edge of the inner groove. The burrs that appear after grinding should be cleaned up, and as far as possible, no blunt edges will occur. Otherwise, the thick blunt edges will affect the bottom welding. Causes no penetration.
  • the wire used is polished with a steel ball to ensure that the surface of the wire is polished.
  • the cleaned wire is placed in a special wire barrel and must be used within 8 hours. Otherwise, it will be easily oxidized and need to be reprocessed.
  • the tungsten rod of the welding torch is made of tantalum tungsten rod, and the tungsten pole is ground into a round pile type, which is not too sharp but smooth and has no edges and corners.
  • the purity of argon should not be lower than 99.99%, and the water content should not exceed 50 mg/m 3 , and the gas flow rate should be 15-20 L/min.
  • the ambient temperature should not be lower than 5 °C, otherwise it should be preheated to 100-200 °C before welding.
  • the prepared test pieces are paired, no gap is left in the pair, and there is no angular deformation.
  • the welder current Before the bottom welding, set the welder current to 150-160A, the cleaning ratio is -20--15, and the AC bias value is 120.
  • the welding arc is at point A.
  • the welding torch is at an angle of 90° to the test piece. It cannot be tilted back and forth, and the tungsten extension length is about 3 mm.
  • the welding wire and the weld bead are at an angle of 50°-70°.
  • When adding the wire use a wire to gently melt the molten pool. Add wire to the back of the molten pool, do not add wire to the inside of the molten pool, and add wire to the inside of the molten pool. It is easy to cause the roots to be wireged.
  • the welding torch can be slightly oscillated up and down. Then the welding gun does not need to swing, and the welding speed should not be too slow. If the front molten pool is too thick and too wide after welding, it indicates that the root is not After penetration, the added wire melts into the molten pool on the surface.
  • the solder joints to be grounded should be ground, but the roots of the groove should not be worn through. If defects such as pores are found, stop the welding immediately, perform the grinding process, and check if the root of the weld is not fused.
  • the front arc-extinguishing point is polished out of the slope with a super-hard tungsten steel circular saw blade, so that the joint is relatively easy.
  • the arc should be started behind the slope.
  • the welding wire is added for welding.
  • the first arcing point A is polished out of the slope, and the arc is slowly set, leaving a "small tail".
  • the welder current Before welding the cover, set the welder current to 140-150A, the cleaning ratio is -20--5, and the AC bias value is 120.
  • the joints and high points of the bottom weld are slightly polished with a super-hard tungsten steel circular saw blade to smooth the underlying weld.
  • the welding gun is at an angle of 90° with the weld.
  • the welding wire can be wired at an angle to the shear line of the weld circle, and the welding gun is oscillated by a circular swing method.
  • the joints of the welds are also ground with a super-hard tungsten steel circular saw blade to ensure the height difference of the joints, and the original welds that are not damaged when grinding.
  • the first arcing point should be polished out of the slope, and the arc should be slowly closed to close a small tail.
  • the internal quality of the appearance scoring and the radiographic inspection are carried out according to the criteria of the competition specification document.
  • the database of the training process of the player is established, and the scores and problems of the welded specimens are entered into the database, and the training effect of the players is analyzed by big data. Constantly adjust and optimize the welding process parameters to achieve the best welding results and the best results.
  • the super-hard tungsten steel circular saw blade for aluminum alloy is used to grind the groove, and the groove angle is 35°.
  • the test piece solves the defect that the root of the test piece is not penetrated due to the small angle of the groove of the test piece, if you want to let The root penetration will increase the current, which will cause the outer edge to be melted, the edge of the groove to be narrow and narrow, and the subsequent welding The seam cover has a great influence. At the same time, the current is too large to greatly increase the probability of generating pores inside the weld. If a boring tool or a steel grinding head is used to polish the groove, the burr is present on the edge of the groove and the inner edge of the groove is easily damaged, resulting in defects such as pores and burn through during welding.

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  • Physics & Mathematics (AREA)
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Abstract

一种铝合金管氩弧焊接过程优化方法，包括以下步骤：对试件进行坡口打磨处理，使坡口角度为35°，露出金属光泽后在设定时间内进行焊接；将试件在工位架上进行垂直组对检查，看是否存在间隙，如果存在缝隙则将坡口边缘锉平；打磨焊丝，将焊枪的钨棒钨极打磨成圆锥型，在保持设定的氩气纯度、含水量和气体流量下进行焊接；将制备好的试件组对，组对时不留间隙，不存在角变形，依次进行打底焊接、焊缝接头和盖面焊接；检测焊缝的外观和射线检测内部质量，将不同的焊接成品数据传输到数据库，进行大数据分析，根据数据分析，不断调整优化焊接工艺参数。

Description

铝合金管氩弧焊接过程优化方法 技术领域
本发明涉及一种铝合金管氩弧焊接过程优化方法。
背景技术
目前，在国家级的焊接技能竞赛项目中，铝合金管的焊接已成为常规比赛项目，由于铝及铝合金具有导热性强而热容量大，线胀系数大，熔点低和高温强度小等特点，铝管的焊接特性，在焊接时易产生氧化、气孔和未熔合等缺陷。在参赛选手培训过程，传统方法是按照竞赛技术文件要求，通过教练经验传授和选手的进行试件的焊接练习和个人摸索，才能长时间的总结适合于自己的一套焊接技艺，由于选手的水平差异导致培训所用时间长，材料和机械使用成本高，现场发挥时焊接质量不稳定。对于铝合金管氩弧焊接过程以及焊接的效果都无法公平、客观的进行评价或评估。
同时，传统的试件坡口加工时角度一般为30°，对接后焊接角度偏下偏小，易造成根部未焊透等缺陷，同时采用锉刀或钢磨头打磨坡口，致使坡口边存在毛刺且容易损伤内坡口边，导致焊接时产生气孔、烧穿等缺陷。
焊接接头成型质量提升慢，操作者所花费的时间、精力较长，所消耗的材料、机械等成本较高，同时由于铝合金焊接时的强光、强紫外线辐射等，较长时间的训练对操作者的身心健康造成伤害。
发明内容
本发明为了解决上述问题，提出了一种铝合金管氩弧焊接过程优化方法，本发明通过对焊接中几个关键技术点进行设置有针对性的焊接方法，使焊接效 果优化，同时，能够建立统一的评估准则，合理评价操作者的水平，能够适用于焊接技能竞赛项目。
为了实现上述目的，本发明采用如下技术方案：
一种铝合金管氩弧焊接过程优化方法，包括以下步骤：
(1)对试件进行坡口打磨处理，使坡口角度为35°，露出金属光泽后在设定时间内进行焊接；
(2)将试件在工位架上进行垂直组对检查，看是否存在间隙，如果存在缝隙则将坡口边缘锉平；
(3)打磨焊丝，将焊枪的钨棒钨极打磨成圆堆型，在保持设定的氩气纯度、含水量和气体流量下进行焊接；
(4)将制备好的试件组对，组对时不留间隙，不存在角变形，依次进行打底焊接、焊缝接头和盖面焊接；
(5)检测焊缝的外观和射线检测内部质量，将不同的焊接成品数据传输到数据库，进行大数据分析，根据数据分析，不断调整优化焊接工艺参数。
所述步骤(1)中，试件采用铝合金专用的超硬钨钢圆锯片对坡口打磨处理，通过焊缝检测尺检查确认使坡口角度为35°，在打磨时内坡口边不修理，保持平直。
所述步骤(1)中，试件坡口两侧40-60mm范围内表面用钢磨头打磨干净，露出金属光泽，制备好的试件必须在1.5-2.5小时内进行焊接，否则重新进行打磨制备.
所述步骤(3)中，氩气纯度不低于99.99％，且含水量不大于50mg/m3，气体流量为15-20L/min，环境温度不低于5℃，否则预热至100-200℃后再施焊。
所述步骤(4)中，打底焊接电流为150-160A，清理比例为[-20，-15]，交流偏值为120；焊接时焊枪与试件成90°夹角，不可前后倾斜，钨极伸出长度为[2，4]mm，焊丝与焊缝成50°-70°夹角，加丝时利用焊丝顶融化的熔池，向熔池后面加丝。
所述步骤(4)中，焊接过程中，点固的焊点要打磨掉，且不要把坡口根部磨穿。
所述步骤(4)中，若发现存在气孔，立即停止施焊，进行修磨处理，并检查焊缝根部是否未熔合。
所述步骤(4)中，在打底焊缝接头前，适用超硬钨钢圆锯片将前面的熄弧点打磨出斜坡，起弧时要在斜坡的后面起弧，形成熔池后在加入焊丝进行焊接，最后收弧时要将第一个起弧点打磨出斜坡，慢慢息弧。
所述步骤(4)中，盖面焊接前，设置焊机电流为140-150A，清理比例为[-20，-5]，交流偏值为120。
所述步骤(4)中，盖面时焊枪与焊缝成90°夹角，焊丝采用与焊缝圆的剪切线的角度加丝，焊枪采用圆圈型摆动法摆动，焊缝的接头利用钨钢圆锯片打磨，以保证接头的高低差，打磨时不要损伤的原始焊缝，最后的收弧时要把第一个起弧点打磨出斜坡，慢慢息弧。
与现有技术相比，本发明的有益效果为：
本发明采用铝合金专用的超硬钨钢圆锯片对坡口打磨处理，坡口边无毛刺和缺口避免焊接时产生气孔、烧穿等缺陷；坡口角度为35°，解决了由于试件坡口角度偏小，易造成根部未焊透等缺陷的问题。
本发明在整个焊接过程对操作者操作手法进行指导，使每个操作者易于掌 握统一的铝合金管的焊接技能，保证焊接接头的外观质量和内部质量。
对操作者的焊接效果进行大数据分析，根据数据分析不断调整优化焊接工艺参数，达到最佳焊接效果，有助于在更优化焊接过程。
具体实施方式：
下面结合实施例对本发明作进一步说明。
应该指出，以下详细说明都是例示性的，旨在对本申请提供进一步的说明。除非另有指明，本文使用的所有技术和科学术语具有与本申请所属技术领域的普通技术人员通常理解的相同含义。
需要注意的是，这里所使用的术语仅是为了描述具体实施方式，而非意图限制根据本申请的示例性实施方式。如在这里所使用的，除非上下文另外明确指出，否则单数形式也意图包括复数形式，此外，还应当理解的是，当在本说明书中使用术语“包含”和/或“包括”时，其指明存在特征、步骤、操作、器件、组件和/或它们的组合。
正如背景技术所介绍的，现有技术中存在对于铝合金管氩弧焊接过程以及焊接的效果都无法公平、客观的进行评价或评估且焊接接头成型质量提升慢，操作者所花费的时间、精力较长，所消耗的材料、机械等成本较高，同时由于铝合金焊接时的强光、强紫外线辐射等，较长时间的训练对操作者的身心健康造成伤害的不足，为了解决如上的技术问题，本申请提出了一种铝合金管氩弧焊接过程优化方法，包括以下步骤：
(1)对试件进行坡口打磨处理，使坡口角度为35°，露出金属光泽后在设定时间内进行焊接；
(2)将试件在工位架上进行垂直组对检查，看是否存在间隙，如果存在缝 隙则将坡口边缘锉平；
(3)打磨焊丝，将焊枪的钨棒钨极打磨成圆堆型，在保持设定的氩气纯度、含水量和气体流量下进行焊接；
(4)将制备好的试件组对，组对时不留间隙，不存在角变形，依次进行打底焊接、焊缝接头和盖面焊接；
(5)检测焊缝的外观和射线检测内部质量，将不同的焊接成品数据传输到数据库，进行大数据分析，根据数据分析，不断调整优化焊接工艺参数。
所述步骤(1)中，试件采用铝合金专用的超硬钨钢圆锯片对坡口打磨处理，通过焊缝检测尺检查确认使坡口角度为35°，在打磨时内坡口边不修理，保持平直。
所述步骤(1)中，试件坡口两侧40-60mm范围内表面用钢磨头打磨干净，露出金属光泽，制备好的试件必须在1.5-2.5小时内进行焊接，否则重新进行打磨制备.
所述步骤(3)中，氩气纯度不低于99.99％，且含水量不大于50mg/m3，气体流量为15-20L/min，环境温度不低于5℃，否则预热至100-200℃后再施焊。
所述步骤(4)中，打底焊接电流为150-160A，清理比例为[-20，-15]，交流偏值为120；焊接时焊枪与试件成90°夹角，不可前后倾斜，钨极伸出长度为[2，4]mm，焊丝与焊缝成50°-70°夹角，加丝时利用焊丝顶融化的熔池，向熔池后面加丝。
所述步骤(4)中，焊接过程中，点固的焊点要打磨掉，且不要把坡口根部磨穿。
所述步骤(4)中，若发现存在气孔，立即停止施焊，进行修磨处理，并检 查焊缝根部是否未熔合。
所述步骤(4)中，在打底焊缝接头前，适用超硬钨钢圆锯片将前面的熄弧点打磨出斜坡，起弧时要在斜坡的后面起弧，形成熔池后在加入焊丝进行焊接，最后收弧时要将第一个起弧点打磨出斜坡，慢慢息弧。
所述步骤(4)中，盖面焊接前，设置焊机电流为140-150A，清理比例为[-20，-5]，交流偏值为120。
所述步骤(4)中，盖面时焊枪与焊缝成90°夹角，焊丝采用与焊缝圆的剪切线的角度加丝，焊枪采用圆圈型摆动法摆动，焊缝的接头利用钨钢圆锯片打磨，以保证接头的高低差，打磨时不要损伤的原始焊缝，最后的收弧时要把第一个起弧点打磨出斜坡，慢慢息弧。
作为一种典型实施例，本发明用于竞赛，所需主要设备和材料及焊接方法：
焊接设备：交直流方波铝焊机；
铝合金管规格：Φ80×5mm，材质：5A06铝镁合金；
铝焊丝规格：2.4mm，3.2mm，型号：SAl5356；
焊接方法：交流钨极氩弧焊；
焊接位置：垂直固定组对焊接；
参训选手：具有一定的GTAW操作技能基础。
首先对经过车床加工好的试件采用铝合金专用的超硬钨钢圆锯片对坡口打磨处理，通过焊缝检测尺检查确认使坡口角度为35°，在打磨时注意内坡口边不得修理，保持平直。该加工方式坡口处不会产生毛刺，可以减小焊接时气孔的产生。试件坡口两侧50mm范围内表面用钢磨头打磨干净，露出金属光泽，制备好的试件必须在2小时内进行焊接，否则重新进行打磨制备，这是因为铝 易在空气中氧化产生致密的氧化膜，如不进行处理在焊接时会出现气孔缺陷。
将试件在工位架上进行垂直组对检查，看是否存在间隙。如果存在间隙会造成烧穿缺陷，可用锉刀经内坡口边缘轻微用力锉平，打磨后出现的毛刺要清理干净，尽量不出现钝边，否则钝边过厚会对打底焊接时造成影响，导致未焊透。
所用焊丝用钢丝球打磨一遍，确保焊丝表面打磨干净，清理好的焊丝放入专用焊丝筒内，必须在8小时内用完，否则容易氧化需要重新处理。
焊枪的钨棒选用铈钨棒，钨极打磨成圆堆型，不可太尖但要圆滑没有棱角。
氩气纯度不得低于99.99％，且含水量不应大于50mg/m3，气体流量为15-20L/min。
环境温度不低于5℃，否则应预热至100-200℃方可施焊。
将制备好的试件组对，组对时不留间隙，不得存在角变形。
点固前预留好起弧点A，以A点为等边三角形顶点，确定另外两个顶点B、C，也就是需要点固的两点，点固电流不宜过大，不可焊透，点固牢靠，以防焊接时受力变形或拉开。
打底焊接前，设置焊机电流为150-160A，清理比例为-20--15，交流偏值为120。
焊接起弧处在A点，焊枪与试件成90°夹角，不可前后倾斜，钨极伸出长度约为3mm。焊丝与焊缝成50°-70°夹角，加丝时要用焊丝轻轻去顶融化的熔池，要向熔池后面加丝，不要向熔池里面加丝，向熔池里面加丝容易造成根部夹丝。在起弧时可以上下轻微摆动焊枪，随后焊枪无需摆动，焊接时焊接速度不宜过慢。焊接时若发现加入焊丝后正面熔池过厚、过宽，这表明根部没有 焊透，加入的焊丝都融化在了表面的熔池里。
焊接过程中，点固的焊点要打磨掉，但不可要把坡口根部磨穿。若发现存在气孔等缺陷，立即停止施焊，进行修磨处理，并检查焊缝根部是否未熔合。
在打底焊缝接头前，要先用超硬钨钢圆锯片将前面的熄弧点打磨出斜坡，这样接头比较容易。起弧时要在斜坡的后面起弧，形成熔池后在加入焊丝进行焊接。最后收弧时要将第一个起弧点A打磨出斜坡，慢慢息弧，并留出一段“小尾巴”。
盖面焊接前，设置焊机电流为140-150A，清理比例为-20--5，交流偏值为120。
打底焊接完成后，经目视检查确认无误后，用超硬钨钢圆锯片将打底层焊缝的接头和高点轻微打磨一下，使打底层焊缝平滑。盖面时焊枪与焊缝成90°夹角，焊丝可采用与焊缝圆的剪切线的角度加丝，焊枪采用圆圈型摆动法摆动。焊缝的接头同样用超硬钨钢圆锯片打磨一下，以保证接头的高低差，打磨时不要损伤的原始焊缝。最后的收弧时要把第一个起弧点打磨出斜坡，慢慢息弧，收出一个“小尾巴”。
焊接完成后依据竞赛规程文件评判标准进行外观评分和射线检测内部质量，建立选手培训过程数据库，将所焊的试件得分和出现问题情况输入数据库，对选手培训效果进行大数据分析，根据数据分析，不断调整优化焊接工艺参数，达到最佳焊接效果和最优成绩。
采用铝合金专用的超硬钨钢圆锯片对坡口打磨处理，坡口角度为35°，试件解决了由于试件坡口角度偏小，易造成根部未焊透等缺陷，如果想让根部焊透就要加大电流，这样会造成外坡口边被融化，坡口边宽窄不齐，对后续的焊 缝盖面造成很大影响。同时电流过大会大大增加焊缝内部产生气孔的几率。若采用锉刀或钢磨头打磨坡口，致使坡口边存在毛刺且容易损伤内坡口边，导致焊接时产生气孔、烧穿等缺陷。
以上所述仅为本申请的优选实施例而已，并不用于限制本申请，对于本领域的技术人员来说，本申请可以有各种更改和变化。凡在本申请的精神和原则之内，所作的任何修改、等同替换、改进等，均应包含在本申请的保护范围之内。
上述虽然对本发明的具体实施方式进行了描述，但并非对本发明保护范围的限制，所属领域技术人员应该明白，在本发明的技术方案的基础上，本领域技术人员不需要付出创造性劳动即可做出的各种修改或变形仍在本发明的保护范围以内。

Claims (10)

  1. 一种铝合金管氩弧焊接过程优化方法，其特征是：包括以下步骤：
    (1)对试件进行坡口打磨处理，使坡口角度为35°，露出金属光泽后在设定时间内进行焊接；
    (2)将试件在工位架上进行垂直组对检查，看是否存在间隙，如果存在缝隙则将坡口边缘锉平；
    (3)打磨焊丝，将焊枪的钨棒钨极打磨成圆堆型，在保持设定的氩气纯度、含水量和气体流量下进行焊接；
    (4)将制备好的试件组对，组对时不留间隙，不存在角变形，依次进行打底焊接、焊缝接头和盖面焊接；
    (5)检测焊缝的外观和射线检测内部质量，将不同的焊接成品数据传输到数据库，进行大数据分析，根据数据分析，不断调整优化焊接工艺参数。
  2. 如权利要求1所述的一种铝合金管氩弧焊接过程优化方法，其特征是：所述步骤(1)中，试件采用铝合金专用的超硬钨钢圆锯片对坡口打磨处理，通过焊缝检测尺检查确认使坡口角度为35°，在打磨时内坡口边不修理，保持平直。
  3. 如权利要求1所述的一种铝合金管氩弧焊接过程优化方法，其特征是：所述步骤(1)中，试件坡口两侧40-60mm范围内表面用钢磨头打磨干净，露出金属光泽，制备好的试件必须在1.5-2.5小时内进行焊接，否则重新进行打磨制备.
  4. 如权利要求1所述的一种铝合金管氩弧焊接过程优化方法，其特征是：所述步骤(3)中，氩气纯度不低于99.99％，且含水量不大于50mg/m3，气体流量为15-20L/min，环境温度不低于5℃，否则预热至100-200℃后再施焊。
  5. 如权利要求1所述的一种铝合金管氩弧焊接过程优化方法，其特征是：所述步骤(4)中，打底焊接电流为150-160A，清理比例为[-20，-15]，交流偏值为120；焊接时焊枪与试件成90°夹角，不可前后倾斜，钨极伸出长度为[2，4]mm，焊丝与焊缝成50°-70°夹角，加丝时利用焊丝顶融化的熔池，向熔池后面加丝。
  6. 如权利要求1所述的一种铝合金管氩弧焊接过程优化方法，其特征是：所述步骤(4)中，焊接过程中，点固的焊点要打磨掉，且不要把坡口根部磨穿。
  7. 如权利要求1所述的一种铝合金管氩弧焊接过程优化方法，其特征是：所述步骤(4)中，若发现存在气孔，立即停止施焊，进行修磨处理，并检查焊缝根部是否未熔合。
  8. 如权利要求1所述的一种铝合金管氩弧焊接过程优化方法，其特征是：所述步骤(4)中，在打底焊缝接头前，适用超硬钨钢圆锯片将前面的熄弧点打磨出斜坡，起弧时要在斜坡的后面起弧，形成熔池后在加入焊丝进行焊接，最后收弧时要将第一个起弧点打磨出斜坡，慢慢息弧。
  9. 如权利要求1所述的一种铝合金管氩弧焊接过程优化方法，其特征是：所述步骤(4)中，盖面焊接前，设置焊机电流为140-150A，清理比例为[-20，-5]，交流偏值为120。
  10. 如权利要求1所述的一种铝合金管氩弧焊接过程优化方法，其特征是：所述步骤(4)中，盖面时焊枪与焊缝成90°夹角，焊丝采用与焊缝圆的剪切线的角度加丝，焊枪采用圆圈型摆动法摆动，焊缝的接头利用钨钢圆锯片打磨，以保证接头的高低差，打磨时不要损伤的原始焊缝，最后的收弧时要把第一个起弧点打磨出斜坡，慢慢息弧。
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CN105499805A (zh) * 2016-02-24 2016-04-20 山东雅百特科技有限公司 一种智能激光焊接系统及其工作方法
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Publication number Priority date Publication date Assignee Title
JPH08238569A (ja) * 1995-03-02 1996-09-17 Matsushita Electric Ind Co Ltd 狭開先部のアーク溶接方法
US7304268B2 (en) * 2006-02-16 2007-12-04 Lincoln Global, Inc. Method for rating stick electrodes for pipe welding
CN102528238A (zh) * 2012-01-18 2012-07-04 江苏中核利柏特股份有限公司 手工钨极氩弧焊焊接工艺
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