During the welding process, the workpiece and the solder melt to form a molten region, and the molten pool is cooled and solidified to form a connection between the materials. In this process, it is usually necessary to apply pressure. There are many sources of energy for welding.
Overview During the welding process, the workpiece and the solder melt to form a molten zone, and the molten pool cools and solidifies to form a joint between the materials. In this process, it is usually necessary to apply pressure. There are many sources of energy for welding, including gas flames, arcs, lasers, electron beams, friction, and ultrasonics. Before the end of the 19th century, the only welding process was the use of metal forging by the blacksmith for hundreds of years. The earliest modern welding techniques appeared at the end of the 19th century, first with arc welding and oxygen gas welding, and later with resistance welding. In the early 20th century, with the first and second world wars, the demand for cheap and reliable connection methods for military equipment was extremely high, which promoted the development of welding technology. Today, with the wide application of welding robots in industrial applications, researchers are still studying the nature of welding and continuing to develop new welding methods to further improve the quality of welding.
Weld
1. The physical nature of the welding process Welding classification welding is a process in which two or more of the same or different materials are joined together by atomic or molecular bonding and diffusion. Promoting the bonding and diffusion between atoms and molecules. The method is heating or pressurizing, or heating and pressurizing at the same time.
2. Welding of classified metal welding, according to the characteristics of its process, there are three categories of welding, pressure welding and brazing. Welding is to heat the workpiece interface to the molten state during the welding process, and complete the welding without pressure. method. During fusion welding, the heat source rapidly heats and melts the joints of the two workpieces to be welded to form a molten pool. The molten pool moves forward with the heat source, and after cooling, forms a continuous weld to join the two workpieces into one body. During the fusion welding process, if the atmosphere is in direct contact with the high temperature molten pool, oxygen in the atmosphere oxidizes the metal and various alloying elements. Nitrogen, water vapor, etc. in the atmosphere enter the molten pool, and defects such as pores, slag inclusions, cracks, etc. are formed in the weld during the subsequent cooling process, which deteriorates the quality and performance of the weld.
In order to improve the quality of welding, various protection methods have been developed. For example, gas-shielded arc welding is to insulate the atmosphere with a gas such as argon or carbon dioxide to protect the arc and the molten pool rate during welding. For example, when the steel is welded, the ferrotitanium powder with a large affinity for oxygen is added to the electrode coating for deoxidation. It can protect the beneficial elements of the electrode, such as manganese and silicon, from oxidation and enter the molten pool, and obtain high-quality welds after cooling.
Pressure welding is to achieve atomic bonding in the solid state under pressure conditions, also known as solid state welding. The commonly used pressure welding process is resistance butt welding. When the current passes through the connection end of the two workpieces, the temperature rises due to the large resistance, and when heated to the plastic state, the connection is integrated under the axial pressure. A common feature of various pressure welding methods for benchtop cold welders is the application of pressure during the welding process without the addition of filler material. Most pressure welding methods, such as diffusion welding, high-frequency welding, cold-welding, etc., do not have a melting process, so there is no problem of burning of beneficial alloying elements like welding and intrusion of harmful elements into the weld, thereby simplifying the welding process. Improved safety and hygiene conditions for welding. At the same time, since the heating temperature is lower than the fusion welding and the heating time is short, the heat affected zone is small. Many materials that are difficult to weld by fusion welding can often be welded to a high quality joint of the same strength as the base material.
Brazing is to use a metal material with a lower melting point than the workpiece as a brazing material to heat the workpiece and the brazing material to a temperature higher than the melting point of the brazing material and lower than the melting point of the workpiece. The workpiece is wetted by the liquid brazing material, filling the interface gap and realizing with the workpiece. The method of mutual diffusion between atoms to achieve welding.
The seam formed by welding when joining two connected bodies is called a weld bead. Both sides of the weld are subjected to welding heat during welding, and changes in structure and properties occur. This area is called the heat affected zone. Due to different welding materials and welding currents of the workpiece during welding, overheating, embrittlement, hardening or softening may occur in the weld and heat affected zone after welding, and the weldment performance may be degraded and the weldability may be deteriorated. This requires adjustment of the welding conditions, pre-heating of the weldment interface before welding, welding heat preservation and post-weld heat treatment can improve the welding quality of the weldment.
In addition, the welding is a local rapid heating and cooling process. The welding zone cannot be freely expanded and contracted due to the restraint of the surrounding workpiece body, and the welding stress and deformation are generated in the weldment after cooling. Important products need to eliminate welding stress after welding and correct welding deformation.
Modern welding techniques have been able to weld welds with no internal or external defects and mechanical properties equal to or even higher than the welded joints. The mutual position of the welded body in space is called the welded joint, and the strength of the joint is affected by the quality of the weld, and also related to its geometry, size, stress and working conditions. The basic forms of the joints are butt joints, lap joints, T-joints (orthogonal joints) and corner joints.
The cross-sectional shape of the butt joint weld is determined by the thickness of the welded body before welding and the groove form of the two joints. When welding a thick steel plate, grooves of various shapes are opened at the joint edges for penetration to facilitate feeding of the welding rod or the welding wire. The groove form has a single-sided welded groove and a double-sided welded groove. When selecting the groove form, in addition to ensuring the penetration, the welding should be considered, the amount of filler metal is small, the welding deformation is small, and the processing cost of the groove is low.
When two steel plates with different thicknesses are butt jointed, in order to avoid severe stress concentration caused by sharp changes in the cross section, the thicker plate edges are often thinned to the same thickness at the two joint edges. The static strength and fatigue strength of the butt joint are higher than other joints. Welding of butt joints is often preferred over joints that operate under alternating, impact, or low temperature, high pressure vessels.
The pre-weld preparation of the lap joint is simple, the assembly is convenient, the welding deformation and the residual stress are small, so it is often used in the installation of joints on the construction site and unimportant structures. In general, lap joints are not suitable for operation under alternating loads, corrosive media, high temperatures or low temperatures.
The use of T-joints and corner joints is usually due to structural requirements. The work characteristics of the fillet welds that are not welded on the T-joint are similar to the fillet welds of the lap joint. When the weld is perpendicular to the direction of the external force, it becomes a front fillet weld. At this time, the shape of the weld surface will cause different degrees of stress concentration; the weld of the fillet weld is similar to that of the butt joint.
The angle joints have low load carrying capacity and are generally not used alone. They are only improved when they are welded through, or when there are fillet welds inside and outside. They are mostly used at the corners of closed structures.
Welded products are lighter in weight than rivets, castings and forgings, saving weight and saving energy for transportation. The welding has good sealing properties and is suitable for manufacturing various types of containers. The development of joint processing technology, combining welding with forging and casting, can be made into a large, economically reasonable cast-welded structure and forged welded structure with high economic benefits. The welding process can effectively utilize the materials, and the welded structure can adopt different performance materials in different parts, and fully exert the special features of various materials to achieve economic and high quality. Welding has become an indispensable and increasingly important processing method in modern industry.
In modern metal processing, welding is developing later than casting and forging, but the development speed is very fast. The weight of the welded structure accounts for about 45% of the steel output, and the proportion of welded structures of aluminum and aluminum alloys is also increasing.
In the future welding process, on the one hand, new welding methods, welding equipment and welding materials should be developed to further improve welding quality and safety and reliability, such as improving existing arc, plasma arc, electron beam, laser and other welding energy; using electronic technology And control technology to improve the process performance of the arc and develop a reliable and lightweight arc tracking method.
On the other hand, it is necessary to improve the mechanization and automation level of welding, such as the program control and digital control of the welding machine; the special welding machine for the automation of all processes from preparation process, welding to quality monitoring; in the automatic welding production line, the promotion and expansion of numerical control welding Robots and welding robots can improve the level of welding production and improve the sanitary and safety conditions of welding.
The development history of the welding process The hammer anchor drawing welding technology in "Tiangong Kaiwu" appears with the smelting production of copper and iron metals and the application of various heat sources. The ancient welding methods were mainly cast, brazed, forged and riveted. The iron-bladed copper gongs manufactured by the Shang Dynasty in China are the welded parts of iron and copper. The fusion line of copper and iron on the surface is meandering and well-joined. During the Spring and Autumn Period and the Warring States period, there were many dragons on the bronze drums in the tomb of Zeng Houyi, which were formed by segmental brazing. After analysis, the composition used is similar to that of modern solder. The swords made during the Warring States Period were made of steel with a blade and wrought iron on the back. They were generally heated and forged. According to the book "Tiangong Kaiwu" written by Song Yingxing of the Ming Dynasty, in ancient China, copper and iron were heated together in a furnace, and a knife and an axe were made by forging. The yellow clay or sieved Chen Jiuqiang soil was sprinkled on the interface. Segmented brazing large anchors. In the Middle Ages, weapons were also produced by forging welding in Damascus, Syria. Ancient welding technology has long stayed at the level of casting, forging, brazing and rivet welding. The heat source used is fire, low temperature, inconsistent energy, and can not be used for welding large-section, long-weld workpieces. Can be used to make decorations, simple tools, living utensils and weapons. At the beginning of the 19th century, Davis of the United Kingdom discovered two high-temperature heat sources that could locally melt metals, such as arc and oxyacetylene flames. In 1885–1887, Benaldos of Russia invented carbon-polar arc welding tongs; in 1900, aluminum appeared again. Heat welding. Electrode arc welding At the beginning of the 20th century, carbon arc welding and gas welding were applied. At the same time, thin arc welding electrode arc welding occurred. The arc was relatively stable, the welding pool was protected by slag, the welding quality was improved, and the manual arc welding was put into practical use. At the stage, arc welding has become an important welding method since the 1920s. It has also become the beginning of the development of modern welding processes. During this period, Noble of the United States used the arc voltage to control the welding rod to feed the speed to make an automatic arc welder, which became the beginning of welding mechanization and automation. In 1930, Robinov of the United States invented submerged arc welding using welding wire and flux, and the mechanization of welding was further developed. In the 1940s, tungsten and molten inert gas shielded welding were introduced to meet the needs of welding aluminum, magnesium alloys and alloy steels. In 1951, the Barton Institute of Electric Welding in the Soviet Union created electroslag welding, which became an efficient welding method for large-thickness workpieces. In 1953, the Soviet Union's Liubovsky and others invented carbon dioxide gas shielded welding, which promoted the application and development of gas shielded arc welding, such as the emergence of mixed gas shielded welding, flux-cored wire and slag joint protective welding and self-protective arc welding. Wait. In 1957, Gage in the United States invented plasma arc welding; in the 1940s, electron beam welding invented in Germany and France was also practical and further developed in the 1950s; in the 1960s, the emergence of laser welding plasma, electron beam and laser welding methods appeared. The new development of high energy density welding has greatly improved the weldability of materials and has enabled many materials and structures that are difficult to weld by other methods. Other welding techniques are also available in 1887. Thompson in the United States invented resistance welding and used for spot welding and seam welding of thin plates. Seam welding is the earliest semi-mechanized welding method in pressure welding. With the seam welding process, the workpiece is two The rollers were pushed forward; in the 1920s, the use of flash butt welding to weld bars and chains began. At this point, resistance welding has entered a practical stage. In 1956, Jones of the United States invented ultrasonic welding; Chutkov of the Soviet Union invented friction welding; in 1959, the Stanford Institute of the United States successfully studied explosive welding; in the late 1950s, the Soviet Union made vacuum diffusion welding equipment.
The emergence of welding-industrial art welding caters to the need for new technological means in the development of metal art. On the other hand, the unique and wonderful changes produced by the metal under the influence of welding heat also satisfy the metal art's demand for a new artistic expression language. In today's metal art creations, welding can and is being expressed as a unique artistic expression language. This paper analyzes the emergence and application of this technology.
Artistic creation and craftsmanship are always inseparable. As an industrial technology, the emergence of welding caters to the needs of the development of metal art for new processes. On the other hand, the unique and wonderful changes produced by the metal under the influence of welding heat also satisfy the metal art's demand for a new artistic expression language. In today's metal art creations, welding can and is being expressed as a unique artistic expression language. The art of metal welding can be separated from traditional metal art as a relatively independent art form in a branched way, because welding is artistic. Welded welding can produce a rich expression language of artistic creation. Welding is usually done at high temperatures, and metals produce many wonderful changes at high temperatures. The metal base material will undergo color change and thermal deformation (ie, weld heat affected zone); the wire will form some beautiful texture after melting; and welding defects are often used in the art of welding. Welding defects refer to defects in the welded joint that do not meet the design or process requirements during the welding process. Its manifestations mainly include welding cracks, pores, undercuts, incomplete penetration, unfusion, slag inclusion, welding, collapse, pits, burn through, inclusions, etc. This is a very interesting phenomenon: the artistic nature of welding is usually reflected in the failure of some industrial welding operations, or in some welding defects that industrial welding is extremely difficult to avoid. Second, the welding art language is unique. Using different metal materials and using different welding techniques, the art of welding can be fully realized in different metal art forms.
In welding sculptures, welds and cuts are not passively present as a trace of technical processing, but are expressed in a wonderful and indispensable expression language. A welding sculpture, the thick weld is exposed on the surface of the sculpture, and various irregular cutting marks have become the artist's beautiful artistic language. In many cases, due to the rough and rustic style pursued by the welding sculpture, the metal is rusted, Most of them are reserved according to the needs of the work. Therefore, a non-carved, original beauty can often be felt in the welding sculpture.
The weld seam of the steel plate joint in the lower part of the sculpture is very large. From the point of view of the firmness of the welding process, it is obviously not only for the consideration of the degree of solidity of the sculpture. In this sculpture, the lower twisted welds have been used as An important factor in the overall aesthetic of sculpture is an indispensable part of it. From the overall perspective of the sculpture, whether it is the upper part of the text, or the lower part of the texture treatment, there are twisted weld marks everywhere, the whole work has reached the unity of the overall visual language. The manual plasma cutting method uses the heat of the current during cutting to create a heat-affected zone at the cutting edge, thus giving the bright white stainless steel "target=_blank> stainless steel "dye" a circle of slightly gradual color. For the adjustment of the welding specification, the strong airflow from the torch will “blow†a randomly formed texture at the cutting edge at the moment of melting of the cutting steel plate, and solidify into a beautiful cut after the metal is cooled by the cutting. The flat, bright stainless steel "target=_blank> stainless steel sheet forms a texture contrast. The formation process of this random effect has certain contingency, but it is a phenomenon that must be produced under certain welding specifications. From the perspective of size, the larger size of the welded art wall decoration can be semi-automatic CO2 gas shielded welding, and the smaller one can be manually tungsten argon arc welding.
If a wall painting is regarded as a painting, the processing of dots, lines, faces, black, white, gray and even colors in the picture can be achieved by welding. Various types of wire, various materials, different welding processes will appear in different forms on the screen. Different metals have different colors, stainless steel "target=_blank> stainless steel bright silver, aluminum sub-silver, carbon steel black bright, titanium steel, bronze, copper, brass and steel, different steels are heated at high temperatures Different color changes occur, that is, the welding heat affected zone is different. In addition, cutting is also one of the methods of welding art wall decoration, which can be used in combination with welding or alone, depending on the creative intention of the creator. And the mastery of the process and effect. The above-mentioned methods are combined, and the richness of change can be imagined.
Welding type 1, welding rod arc welding: principle - arc welding method for welding by hand operation of welding rod. A stable burning arc is established between the welding rod and the weldment to melt the welding rod and the weldment, thereby obtaining a firm welded joint. It is a gas-slag joint protection. Main features - flexible operation; low requirements for assembly of welded joints; wide range of weldable metal materials; low welding productivity; strong weld quality dependence (depending on welder's operational skills and on-site performance). Applications - Widely used in the manufacturing and maintenance industries of shipbuilding, boilers and pressure vessels, machinery manufacturing, building structures, chemical equipment, etc. Suitable for welding of various metal materials, various thicknesses, and various structural shapes (in the above-mentioned industries).
2. Submerged arc welding (automatic welding): Principle - The arc burns under the flux layer. The weld is formed by the heat generated by the arc burned between the wire and the weldment, melting the wire, the flux and the base metal (weld). It is slag protection. Main features - high welding productivity; good weld quality; low welding cost; good working conditions; difficult to weld in space; high quality requirements for welding parts; not suitable for welding thin plates (arable stability when welding current is less than 100A) Not good) and short welds. Applications - Widely used in shipbuilding, boilers, bridges, lifting machinery and metallurgical machinery manufacturing. Submerged arc welding is available for weldments where the weld can be kept in a horizontal position or with a small angle of inclination. The thickness of the plate needs to be greater than 5 mm (anti-burn through). Welded carbon structural steel, low alloy structural steel, stainless steel "target=_blank> stainless steel, heat-resistant steel, composite steel, etc.
3, carbon dioxide gas shielded welding (automatic or semi-automatic welding): principle: the use of carbon dioxide as a protective gas melting arc welding method. It is a gas protection. Main features - high welding productivity; low welding cost; small welding deformation (concentrated arc heating); high welding quality; simple operation; large spatter rate; difficult to weld with AC power; poor wind resistance; Gold. Application - mainly welding low carbon steel and low alloy steel. Suitable for all thicknesses. Widely used in automobile manufacturing, locomotive and vehicle manufacturing, chemical machinery, agricultural machinery, mining machinery and other departments.
4, MIG / MAG welding (melting inert gas shielded welding): principle - the use of inert gas as a shielding gas, the use of welding wire as a melting electrode of an arc welding method. The shielding gas is usually argon or helium or a mixture thereof. MIG uses an inert gas, and MAG adds a small amount of active gas such as oxygen, carbon dioxide gas or the like to an inert gas. Main features - good welding quality; high welding productivity; no deoxidation and dehydrogenation reaction (easy to form welding defects, special requirements for surface cleaning of welding materials); poor wind resistance; complex welding equipment. Application - can weld almost all metal materials, mainly used for welding non-ferrous metals and their alloys, stainless steel "target=_blank> stainless steel and some alloy steels (too expensive). The thinnest thickness is about 1 mm, the thickness is basically Unlimited.
5, TIG welding (tungsten inert gas shielded welding) principle - under the protection of inert gas, the use of arc heat generated between the tungsten electrode and the weldment to melt the base metal and filler wire (with or without filler wire), forming a weld Welding method. Main features - strong adaptability (arable arc, no spatter); low welding productivity (tungary current carrying capacity is poor (anti-tungsten melting and evaporation, anti-weld tungsten); high production costs. Applications - almost all metal materials can be welded, often used in stainless steel "target=_blank> stainless steel, high temperature alloys, aluminum, magnesium, titanium and their alloys, refractory active metals (zirconium, hafnium, molybdenum, niobium, etc.) and heterogeneous metals Welding. Welds with a thickness of generally less than 6 mm, or bases with thick parts.
6. Principle of plasma arc welding - By means of the restraining effect of water-cooled nozzles on the arc, a plasma arc with high energy density is obtained for welding. Main features (compared with argon arc welding) - (1) Energy concentration and high temperature, the small hole effect can be obtained for most metals within a certain thickness range, and a weld seam with sufficient penetration and uniform surface formation can be obtained. (2) The arc stiffness is good, the plasma arc is basically cylindrical, and the change of the arc length has little influence on the heating area and current density on the weldment. Therefore, the effect of arc length variation of plasma arc welding on weld formation is not obvious. (3) The welding speed is faster than the argon arc welding. (4) It is possible to weld thinner and thinner workpieces. (4) The equipment is complicated and the cost is high.
Application - (1) Penetrating (small hole type) plasma arc welding: using the characteristics of small plasma arc diameter, high temperature, high energy density and strong penetrating power, under proper process parameters (larger welding) Current 100A ~ 500A), the weldment is completely penetrated, and under the action of plasma flow, a small hole that penetrates the weldment is formed, and a plasma arc welding method of partially plasma arc is sprayed from the back surface of the weldment. Single-sided welding can be formed on both sides. It is most suitable for welding 3~8mm stainless steel "target=_blank> stainless steel, titanium alloy below 12mm, 2~6mm low carbon steel or low alloy structural steel and copper, brass, nickel and Butt welding of nickel alloy. (The plate is too thick, it is difficult to form small holes due to the energy density of plasma arc; the plate is too thin, the hole cannot be completely closed by liquid metal, and the small hole welding method cannot be realized.) (2) Melting Transmissive (dissolved) plasma arc welding: using a small welding current (30A ~ 100A) and a low plasma gas flow, using a hybrid plasma arc welding method, does not form a small hole effect. Mainly used for thin plates ( Welding of 0.5 to 2.5 mm or less) Welding of the layers and welding of the fillet welds after the multi-layer welding of the bottom bead. (3) Micro-plasma arc: Plasma arc welding with a welding current of 30 A or less. The nozzle diameter is small ( Φ0.5～Φ1.5mm), which is a needle-shaped small plasma arc. It is mainly used for welding ultra-thin, ultra-small and precise weldments below 1mm. Note: 1. The above are commonly used welding methods. , each has its own advantages and disadvantages, choose welding When connecting the method, there are many factors to consider, such as the type of weldment material, the thickness of the weld, the position of the weld in space, etc. The principle of the welding method is: under the premise of ensuring the quality of the welded joint, the total cost is low. Welding method.
The welding temperature controls the temperature of the molten pool, which directly affects the welding quality. The molten pool temperature is high, the molten pool is large, the molten iron has good fluidity, and it is easy to fuse. However, when the temperature is too high, the molten iron is easy to smash, and the single-sided welded double-sided formed back is easy to burn. Wearing, forming a weld, the formation is also difficult to control, and the joint plasticity is reduced, and the bending is easy to crack. When the temperature of the molten pool is low, the molten pool is small, the molten iron is dark, the fluidity is poor, and defects such as incomplete penetration, unfusion, and slag inclusion are easily generated. The temperature of the molten pool is closely related to the welding current, the diameter of the welding rod, the angle of the welding rod, the burning time of the arc, etc. The following measures are taken to control the temperature of the molten pool for relevant factors.
1. Welding current and electrode diameter: The welding current and the diameter of the welding rod are selected according to the spatial position of the weld and the welding level. When welding, the welding current and the diameter of the welding rod are larger, and the vertical and horizontal positions are smaller. For example, 12mm flat butt welding flat layer is made of φ3.2mm electrode, welding current: 80-85A, filling, cover layer is φ4.0mm electrode, welding current: 165-175A, reasonable selection of welding current and electrode diameter, Easy control of bath temperature is the basis for weld formation.
2. The method of transporting the strip, the temperature of the molten pool of the circle shaped strip is higher than the temperature of the crescent-shaped moving strip, and the temperature of the crescent-shaped moving strip is higher than the temperature of the molten pool of the zigzag moving strip, and the bottom of the 12 mm flat welding seal adopts a zigzag moving strip. And with the amplitude of the swing and the pause on both sides of the groove, the temperature of the molten pool is effectively controlled, the size of the molten holes is basically the same, the probability of no weld formation and burn through at the root of the groove is decreased, and there is no penetration. The improvement has made it difficult to make double-sided forming of single-sided welding of butt-welded flat welding.
3, the angle of the welding rod, the angle between the welding rod and the welding direction is 90 degrees, the arc is concentrated, the temperature of the molten pool is high, the angle is small, the arc is dispersed, the temperature of the molten pool is low, such as the bottom layer of 12mm flat welding, the angle of the welding rod: 50- 70 degrees, so that the temperature of the molten pool has decreased, avoiding the formation of a weld on the back or lifting up. For example, after adjusting the welding electrode at the bottom of the 12mm plate welding seal, the angle of the electrode is 90-95 degrees, the temperature of the molten pool is rapidly increased, the melt hole can be opened smoothly, and the back surface is formed flat, effectively controlling the joint point. Concave phenomenon.
4, arc burning time, φ57 × 3.5 pipe horizontal fixed and vertical fixed welding practice teaching, using arc breaking method welding, sealing the bottom layer welding, the frequency of arc breaking and arc burning time directly affect the molten pool temperature, due to The wall of the pipe is thin, and the heat resistance of the arc is limited. If the arc breaking frequency is slowed down to reduce the temperature of the molten pool, shrinkage holes are easily generated. Therefore, the arc burning time can only be used to control the temperature of the molten pool. If the temperature of the molten pool is too high, When the melting hole is large, the arc burning time can be reduced, and the temperature of the molten pool is lowered. At this time, the melting hole becomes small, and the internal forming height of the pipe is moderate, so that the weld seam inside the pipe is prevented from being too high or a weld bead is generated.
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