CN101870032A - Molten drop timed and forced short-circuiting transfer control method in large-current CO2 welding process - Google Patents
Molten drop timed and forced short-circuiting transfer control method in large-current CO2 welding process Download PDFInfo
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Abstract
The invention provides a molten drop timed and forced short-circuiting transfer control method in a large-current CO2 welding process. In the traditional CO2 welding process, by controlling the moving direction of the welding wire, the mechanical force on the molten drop, generated by the forward and reverse movement of the welding wire, is actively added on the basis of various traditional action forces which affect the molten drop transfer, and the molten drop transfer without short circuiting in the traditional large-current CO2 welding process is forced to realize drop short-circuiting transfer. In the process of the welding wire doing forward and reverse movement, the welding wire generates a certain acceleration on the molten drop, namely that the additional mechanical force is generated in the molten drop transfer process, and the welding wire forces the molten drop to generate short circuiting with the melting pool in the forward movement; after the short circuiting is generated, the moving direction of the welding wire is changed, the welding wire does reciprocating movement, and the molten drop is pulled off by the mechanical force generated by the reverse movement of the welding wire. By controlling the stable forward and reverse movement of the welding wire, the molten drop short-circuiting transfer frequency is stable and controllable, and the size of molten drop particles is uniform.
Description
Technical field
The invention belongs to consumable electrode gas protection welding method, relate in particular to a kind of big electric current CO
2Molten drop timed and forced short-circuiting transfer control method in the welding process.
Background technology
No matter connect in (GMAW) at gas metal-arc welding, be CO
2Arc-welding, or MAG welds, the MIG welding, and the droplet transfer is the key factor that influences welding stability.Patent 87103550.2 provides the method and apparatus of control short-circuit welding system, welding current makes welding wire in short-circuit condition and conditions at the arc intermediate change, metal transfer takes place during short-circuit condition, spills the distance that particle splashes thereby correspondingly reduce to splash and reduce.Patent 200410034849.7 provides and has been used to reduce the method and system that short circuit transfer gas shieled welding splashes, and makes short circuit liquid bridge submissive transition under the condition of little electric current, reduces spatter.The patent 200810063890.5 same output control methods that relate to the welding supply of use in the short circuiting arc welding that propose.But studies show that in the past reduces the method for spatter under the short circuiting transfer condition, also inapplicable under the condition of non-short circuiting transfer.For example: φ 1.2 welding wires, welding current are more than 200A, and gas metal-arc welding meets particularly CO
2Welding, molten drop is rejection-like, has not been the state of short circuiting transfer, owing to can't accurately switch welding current, control molten drop transition frequency by detecting short circuiting transfer electric arc, thereby bring problems such as welding stability is poor, spatter is big.
Traditional gas shield welding system is made of the source of welding current, wire feeder, gas protective welding gun etc.In the low welding current zone less than the extreme value electric current, welding process is under the short circuiting transfer state, and molten drop contacts with the molten bath and forms the short circuit fluid column, makes short circuit liquid bridge disrumpent feelings under less force of explosion by the control short circuit current, and what simultaneous was less splashes.But at extreme value electric current near zone, promptly welding current big, when arc voltage is higher, welding process is under the repulsion particle transition state that contains the instantaneous short-circuit transition, spatter amount maximum.Usually weld in the gas shield of extreme value electric current near zone, especially the CO of φ 1.2 welding wires, 200A～280A
2Welding, this is the most general welding conditions of industrial application, exactly has spatter maximum, the most unmanageable problem of welding quality.
Trace it to its cause, this mainly is because when the non-short circuiting transfer of extreme value electric current near zone, welding current is big, arc voltage is higher, molten drop no longer clocklike is short-circuited, electric arc produces repulsive interaction to molten drop, molten drop is under the effect of the surface tension of gravity and change at random, electromagnetic force, anode spot pressure, with the electric arc Dutch roll, freely to fly the form transition.The molten drop that the end of welding head length is big is sharply lifted under the effect of repulsive force, its center of gravity is higher than the position of short circuit liquid bridge, because welding current produces than great explosion power by this short circuit liquid bridge, this drop rotates along non-axis direction and flies out, and can cause that bulky grain splashes simultaneously.Under the repulsion particle transition state of this randomness, the motion of molten drop loses rule, it is stable to lose, and is to be difficult to control.
In order to overcome the above problems, pulse MIC welding and the pulse MAG welding welding system used in gas shield welding field in recent years, the control of the droplet transfer by many in one in an arteries and veins or an arteries and veins has been stablized and has been penetrated a transient process.But the adjustable welding parameter of this welding method zone is very narrow; the control system complexity; only be only applicable to MIG welding (consumable electrode noble gas protective arc welding) or MAG welding (active gases protection arc welding; 85% argon gas and 15% carbon dioxide mixed gas protected), can not be applicable to most widely used CO
2The gas shield welding.So, at the CO of MIG welding, MAG welding and control difficulty maximum
2In the gas shield welding, how to control the active force of molten drop, the size and the transit time of control molten drop directly and accurately, be a difficult problem of being concerned about in the gas shield welding field always.
In general, connect for non-short circuit transfer gas shieled welding, the active force that metal drop is subjected to size time and frequency consistent more, the droplet transfer regular more, that form molten drop is constant more, helps obtaining stable appearance of weld more and reduces spatter.So; consequent problem is: in non-short circuit transfer gas shieled welding termination process, how to overcome the repulsive force at random that metal drop is subjected to, improve the uniformity of droplet size; improve the time of droplet transfer and the uniformity of frequency, to obtain good welding effect.
Summary of the invention
CO at big welding current
2In the welding process, molten drop is rejection-like, the randomness of droplet transfer and dispersiveness, the transient process of each molten drop is all inequality, the preset current waveform is difficult to the synchronous and adaptation with each droplet transfer process, lack the accurate detection of short circuit liquid bridge contraction state in Waveform Control, Current Control lacks foundation, thereby brings problems such as welding stability is poor, spatter is big.The present invention is directed to this problem, a kind of big electric current CO is provided
2Molten drop timed and forced short-circuiting transfer control method in the welding process is for realizing that further better Waveform Control strategy provides necessary condition.
In traditional gas metal-arc welding, molten drop is that the gas at gravity, surface tension, arc force (mainly comprising electromagnetic contractile force, plasma jet power, spot power etc.), molten drop force of explosion and electric arc blows and carries out transition under the power acting in conjunction.Big electric current CO of the present invention
2Molten drop timed and forced short-circuiting transfer control method in the welding process is based on the thought that the motive power that influences the droplet transfer is controlled, to initiatively adding the mechanical force that the positive and negative motion of welding wire produces molten drop on the above-mentioned active force basis that influences the droplet transfer, force molten drop to carry out short circuiting transfer, and then realize welding process is carried out precision control.
Method provided by the invention is a kind of big electric current CO
2Molten drop timed and forced short-circuiting transfer control method in the welding process.At existing CO
2In the welding process,, make at the big electric current CO of tradition by control to the welding wire direction of motion
2The non-short circuiting transfer of molten drop in the welding process forces to realize short circuiting transfer, and every drip melt drips quality and equates, each molten drop realizes that equate to the transit time of short circuit; The welding wire forward is forward in the motion process, welding wire produces certain acceleration to molten drop, promptly the transient process to molten drop produces an additional mechanical force, make and force molten drop and molten bath to be short-circuited forward when the welding wire forward moves, after being short-circuited, change the direction of motion of welding wire, realize that welding wire oppositely toward swivel motion, leans on welding wire oppositely to break molten drop toward the mechanical force of swivel motion; Short circuiting transfer of the positive and negative motion of welding wire once, molten drop is realized a step one smooth transition, its transition frequency depends on the frequency of the positive and negative motion of welding wire, can judge that by the positive and negative motion state of welding wire the molten drop short circuit begins and molten drop short circuit finish time, rely on the stable forward of control welding wire to move forward and oppositely past swivel motion, guarantee that the distance that the each forward of welding wire moves equates forward, each oppositely distance toward swivel motion is equal, the distance that forward moves forward is greater than the distance of oppositely past swivel motion, molten drop is totally sent to, thereby can guarantee that molten drop transition frequency is stable and controlled, the molten drop even particle size; The speed of the positive and negative motion of welding wire near sinusoidal ripple in one-period changes or is similar to square-wave variations; The distance of welding wire positive movement is 1.5～6mm, and heterodromous distance is 0.25～3mm; The frequency of the positive and negative motion of welding wire is 25～100HZ, and promptly the transition frequency of molten drop is 25～100HZ.
For little electric current CO
2Welding, control method provided by the invention can make existing short circuiting transfer have more regularity, and transition frequency is stable and controlled more, and this method is equally applicable to little electric current CO
2Welding.
Big electric current CO of the present invention
2Molten drop timed and forced short-circuiting transfer control method in the welding process is initiatively realized forced short-circuiting transfer by the direction of motion of control welding wire at the big electric current molten drop that welding current surpasses more than the 200A, and the frequency of short circuiting transfer is constant.Waveform Control can be finished in a very wide scope, for realizing that the Waveform Control strategy provides necessary condition preferably.
Description of drawings
Fig. 1 is the disrumpent feelings process schematic diagram of liquid bridge unstability
Fig. 2 is big electric current CO of the present invention
2The schematic diagram of the molten drop timed and forced short-circuiting transfer control method in the welding process
Specific implementation method
In conjunction with the accompanying drawings, will be further described below specific implementation method of the present invention.
In traditional gas metal-arc welding, molten drop is that the gas at gravity, surface tension, arc force (mainly comprising electromagnetic contractile force, plasma jet power, spot power etc.), molten drop force of explosion and electric arc blows and carries out transition under the power acting in conjunction.Big electric current CO of the present invention
2Molten drop timed and forced short-circuiting transfer control method in the welding process is based on the thought that motive power in the droplet transfer is controlled, to initiatively adding the mechanical force that the positive and negative motion of welding wire produces molten drop on the above-mentioned active force basis that influences the droplet transfer, force molten drop to carry out short circuiting transfer, and then realize welding process is carried out precision control.Welding wire can produce certain acceleration to molten drop in the motion process forward at forward, promptly the transient process to molten drop produces an additional mechanical external force, welding wire forces molten drop and molten bath to be short-circuited in the motion process forward, welding wire is broken the liquid bridge again during oppositely toward swivel motion by force, thereby makes molten drop can successfully finish the transition of a step molten drop under very little short circuit current.
Fig. 1 is the disrumpent feelings process schematic diagram of liquid bridge unstability.As shown in Figure 1, any liquid all is with cylinder form (the liquid bridge that is equivalent to molten drop) stable existence under certain condition.When conditions such as material category, temperature, surrounding medium, liquid quality and solid body contact area one regularly, then the stable condition of major decision liquid bridge is the R/L ratio of liquid bridge length L (the liquid bridge diameter R with).Can influence the stable factor of liquid bridge from the external world and have only liquid bridge length L and liquid bridge minimum diameter R.Generally quick-fried disconnected in order to prevent that the liquid bridge from taking place, the moment current value disrumpent feelings in the nearly unstability of liquid bridge joint should be as far as possible little, and whether the disrumpent feelings external condition of unstability only is liquid bridge length L so influence the liquid bridge.Therefore under certain condition, all there is a limiting length Lmax that liquid bridge unstability is disrumpent feelings.When the liquid bridge will lose stablely and disrumpent feelings automatically, do not need the help of other any power, but molten drop just smooth transition to the molten bath.Welding wire oppositely impels the faster and more easily realization of L＞=Lmax condition toward the molten drop control method of swivel motion, thereby makes the more steady reliable transition of molten drop.
Fig. 2 is big electric current CO of the present invention
2The schematic diagram of the molten drop timed and forced short-circuiting transfer control method in the welding process.As shown in Figure 2, A～C, E～G are arc stage, and C～E is a short-circuit stage.
1, in A～C stage (arc stage), welding wire 1 forward moves forward, electric arc 3 smooth combustions, and arc heat filler wire metal gathers a certain amount of liquid metal, forms molten drop 2.Simultaneously also heat molten pool metal, make it the temperature and the metal flow that keep certain, for molten drop 2 contacts with molten bath 4, transition, the wetting condition that is ready to.At the A point, welding wire 1 is at the highest notch, and this moment, the motion of welding wire 1 transferred positive movement to by counter motion, and the welding wire movement velocity is zero; At the B point, welding wire 1 continues forward and moves forward, and electric arc 3 length shorten than the A point; Near the C point, though being in, welding wire 1 motion sends late period to, but 1 pair of molten drop of welding wire 2 produces certain acceleration, promptly the transient process to molten drop 2 produces an additional mechanical force, since welding wire send to and molten metal increases gradually, the end less area of molten drop 2 at first contacts with 4 surfaces, molten bath and makes, and forces molten drop 2 and molten bath 4 to be short-circuited forward when welding wire moves.The back arc extinction is short-circuited.
2, in C～E stage (short-circuit stage), molten drop 2 short circuit, electric arc 3 extinguishes.In C～D stage, welding wire 1 continues down motion.After the C point, molten drop 2 because capillary effect and welding wire continue the effect of motion forward, is expanded to bigger contact-making surface with 4 contact positions, molten bath rapidly by less contact-making surface; At the D point, welding wire 1 is in minimum point, and this moment, the motion of welding wire transferred counter motion to by positive movement, and the welding wire movement velocity is zero; In D～E stage, welding wire 1 prepares to rely on welding wire oppositely toward swivel motion molten drop 2 additional mechanical forces to be forced to break the liquid bridge oppositely toward swivel motion.At the E point, welding wire continues oppositely past swivel motion, and liquid bridge length L is near the disrumpent feelings limiting length Lmax of liquid bridge unstability at this moment, and the liquid bridge is about to lose stable and disrumpent feelings, and short circuit closes to an end.
3, in E～G stage (arc stage), electric arc 3 ignites automatically once again.After the E point, welding wire 1 continues reverse toward swivel motion, relies on the welding wire counter motion that the additional mechanical force of molten drop is forced to break the liquid bridge, and the welding wire counter motion impels the faster and more easily realization of L＞=Lmax condition, sets up the electric arc that extinguishes rapidly.After the E point, electric arc rekindles, and the both end voltage that the liquid bridge disconnects raises automatically.At the F point, this moment, electric arc began refuse metal welding wire again, forms new molten drop 2 because electric arc 3 rekindles.After welding wire arrived the G point, this moment, welding wire 1 was at the highest notch again, and the direction of motion of welding wire will transfer positive movement to from counter motion, and this moment, the movement velocity of welding wire was zero.Thereby repeat above-mentioned A～C droplet transfer process.
In the one-period of the positive and negative motion of welding wire, short circuiting transfer of the positive and negative motion of welding wire once, realize a step one smooth transition, its transition frequency depends on the frequency of the positive and negative motion of welding wire, rely on stable positive movement and the counter motion of control welding wire, guarantee distance and each reverse stable distance that the each forward of welding wire moves forward toward swivel motion, the distance that forward moves forward is greater than the distance of oppositely past swivel motion, molten drop is totally sent to, thereby can guarantee that molten drop transition frequency is constant, the molten drop even particle size.The speed of the positive and negative motion of welding wire near sinusoidal ripple in one-period changes; The distance that the welding wire forward moves forward is 1.5～6mm, and oppositely the distance toward swivel motion is 0.25～3mm; The frequency of the positive and negative motion of welding wire is 25～100HZ, and promptly the transition frequency of molten drop is 25～100HZ.
Big electric current CO of the present invention
2Molten drop timed and forced short-circuiting transfer control method in the welding process all is proved to be a kind of more rational short-circuiting transfer control method from theory and practice, a large amount of engineer testings prove, this method not only can significantly reduce spatter loss coefficient, and can be at interval short circuit transition stable, low spatter and the satisfied appearance of weld of obtaining of lower average current.Because the more reasonability on this control method principle, its superiority embodies more outstandingly when the welding of thick welding wire.
The tradition waveform controlling method is to be main with the little current domain control mode that just the short circuiting transfer field is relevant about the corresponded manner of low spatter, facing to surpassing big current conditions more than the 200A, the non-short circuiting transfer mode of molten drop makes that the waveform controlling method incapability is unable.Exactly for the welding current below being lower than 200A, the randomness of droplet transfer and dispersiveness, the transient process of each molten drop is all inequality, the preset current waveform is difficult to the synchronous and adaptation with each droplet transfer process, lack the accurate detection of short circuit liquid bridge contraction state in Waveform Control, Current Control lacks foundation.The tradition Waveform Control needs superfast digital control technology as support.Big electric current CO of the present invention
2Molten drop timed and forced short-circuiting transfer control method in the welding process is initiatively realized forced short-circuiting transfer by the method for the control welding wire direction of motion at the molten drop that welding current surpasses more than the 200A, and short circuiting transfer frequency is stable and controlled.Waveform Control can be finished in a very wide scope, provides necessary condition for realizing better Waveform Control strategy.
Claims (11)
1. one kind big electric current CO
2Molten drop timed and forced short-circuiting transfer control method in the welding process is characterized in that: at existing CO
2In the welding process,,, make at the big electric current CO of tradition to initiatively adding the positive and negative motion of welding wire on the existing motive power basis that influences the droplet transfer to the mechanical force that molten drop produces by control to the welding wire direction of motion
2The non-short circuiting transfer of molten drop in the welding process forces to realize short circuiting transfer.
2. big electric current CO according to claim 1
2Molten drop timed and forced short-circuiting transfer control method in the welding process, it is characterized in that: the welding wire forward is forward in the motion process, welding wire produces certain acceleration to molten drop, promptly the transient process to molten drop produces an additional mechanical force, make and force molten drop and molten bath to be short-circuited forward when the welding wire forward moves, after being short-circuited, change the direction of motion of welding wire, realize that welding wire oppositely toward swivel motion, relies on welding wire oppositely to break molten drop toward the mechanical force of swivel motion.
3. big electric current CO according to claim 1
2Molten drop timed and forced short-circuiting transfer control method in the welding process is characterized in that: short circuiting transfer of the positive and negative motion of welding wire once, molten drop is realized a step one smooth transition.
4. big electric current CO according to claim 1
2Molten drop timed and forced short-circuiting transfer control method in the welding process is characterized in that: can judge that by the positive and negative motion state of welding wire the molten drop short circuit begins and molten drop short circuit finish time.
5. big electric current CO according to claim 1
2Molten drop timed and forced short-circuiting transfer control method in the welding process is characterized in that: change the frequency of the positive and negative motion of welding wire, can change the short circuiting transfer frequency of molten drop.
6. big electric current CO according to claim 1
2Molten drop timed and forced short-circuiting transfer control method in the welding process, it is characterized in that: the distance that the each forward of welding wire moves forward is greater than the distance of each oppositely past swivel motion, molten drop is totally sent to, the distance that the each forward of welding wire moves forward equates, the each oppositely distance toward swivel motion of welding wire is equal, and each molten drop quality that forms equates.
7. big electric current CO according to claim 1
2Molten drop timed and forced short-circuiting transfer control method in the welding process is characterized in that: the frequency of the positive and negative motion of welding wire is constant, and each molten drop realizes that equate to the transit time of short circuit.
8. big electric current CO according to claim 1
2Molten drop timed and forced short-circuiting transfer control method in the welding process is characterized in that: the speed of the positive and negative motion of welding wire near sinusoidal ripple in one-period changes or is similar to square-wave variations.
9. big electric current CO according to claim 1
2Molten drop timed and forced short-circuiting transfer control method in the welding process is characterized in that: the distance that the welding wire forward moves forward is 1.5～6mm, and oppositely the distance toward swivel motion is 0.25～3mm.
10. big electric current CO according to claim 1
2Molten drop timed and forced short-circuiting transfer control method in the welding process is characterized in that: the frequency of the positive and negative motion of welding wire is 25～100HZ, and promptly the transition frequency of molten drop is 25～100HZ.
11. big electric current CO according to claim 1
2Molten drop timed and forced short-circuiting transfer control method in the welding process is characterized in that: for little electric current CO
2Welding can make existing short circuiting transfer have more regularity by claim 1 described method, and transition frequency is stable and controlled more, and this method is equally applicable to little electric current CO
2Welding.
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Cited By (11)
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| CN105026088A (en) * | 2013-02-28 | 2015-11-04 | 林肯环球股份有限公司 | Methods of promoting droplet transfer and corresponding welding system for co2 globular transfer |
| CN105829006A (en) * | 2014-03-17 | 2016-08-03 | 株式会社达谊恒 | Arc welding control method |
| CN105935828A (en) * | 2016-05-30 | 2016-09-14 | 重庆理工大学 | Electric arc three-dimensional rapid forming and manufacturing method based on pulse current forcible molten drop transition |
| CN107107241A (en) * | 2015-02-02 | 2017-08-29 | 株式会社达谊恒 | Arc welding control method |
| US10532418B2 (en) | 2017-08-08 | 2020-01-14 | Lincoln Global, Inc. | Dual wire welding or additive manufacturing contact tip and diffuser |
| US10773335B2 (en) | 2017-08-08 | 2020-09-15 | Lincoln Global, Inc. | Dual wire welding or additive manufacturing system and method |
| US10792752B2 (en) | 2017-08-08 | 2020-10-06 | Lincoln Global, Inc. | Dual wire welding or additive manufacturing system and method |
| CN112338324A (en) * | 2019-08-06 | 2021-02-09 | 株式会社达谊恒 | Arc welding method |
| US11440121B2 (en) | 2017-08-08 | 2022-09-13 | Lincoln Global, Inc. | Dual wire welding or additive manufacturing system and method |
| US11498146B2 (en) | 2019-09-27 | 2022-11-15 | Lincoln Global, Inc. | Dual wire welding or additive manufacturing system and method |
| US11504788B2 (en) | 2017-08-08 | 2022-11-22 | Lincoln Global, Inc. | Dual wire welding or additive manufacturing system and method |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN105026088A (en) * | 2013-02-28 | 2015-11-04 | 林肯环球股份有限公司 | Methods of promoting droplet transfer and corresponding welding system for co2 globular transfer |
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| US10532418B2 (en) | 2017-08-08 | 2020-01-14 | Lincoln Global, Inc. | Dual wire welding or additive manufacturing contact tip and diffuser |
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| US10792752B2 (en) | 2017-08-08 | 2020-10-06 | Lincoln Global, Inc. | Dual wire welding or additive manufacturing system and method |
| US11440121B2 (en) | 2017-08-08 | 2022-09-13 | Lincoln Global, Inc. | Dual wire welding or additive manufacturing system and method |
| US11484960B2 (en) | 2017-08-08 | 2022-11-01 | Lincoln Global, Inc. | Dual wire welding or additive manufacturing contact tip and diffuser |
| US11504788B2 (en) | 2017-08-08 | 2022-11-22 | Lincoln Global, Inc. | Dual wire welding or additive manufacturing system and method |
| US11964346B2 (en) | 2017-08-08 | 2024-04-23 | Lincoln Global, Inc. | Dual wire welding or additive manufacturing system and method |
| CN112338324A (en) * | 2019-08-06 | 2021-02-09 | 株式会社达谊恒 | Arc welding method |
| US11498146B2 (en) | 2019-09-27 | 2022-11-15 | Lincoln Global, Inc. | Dual wire welding or additive manufacturing system and method |
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Application publication date: 20101027 |