CN112475571A - Method for efficiently welding straight seam of air condition compressor shell - Google Patents
Method for efficiently welding straight seam of air condition compressor shell Download PDFInfo
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- CN112475571A CN112475571A CN201910856563.3A CN201910856563A CN112475571A CN 112475571 A CN112475571 A CN 112475571A CN 201910856563 A CN201910856563 A CN 201910856563A CN 112475571 A CN112475571 A CN 112475571A
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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
- B23K10/00—Welding or cutting by means of a plasma
- B23K10/02—Plasma welding
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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
- B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
- B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
- B23K35/38—Selection of media, e.g. special atmospheres for surrounding the working area
- B23K35/383—Selection of media, e.g. special atmospheres for surrounding the working area mainly containing noble gases or nitrogen
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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
- B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
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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
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/02—Iron or ferrous alloys
- B23K2103/04—Steel or steel alloys
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- Engineering & Computer Science (AREA)
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Abstract
The invention discloses a method for efficiently welding a straight seam of an air condition compressor shell, which mainly solves the technical problems of poor welding quality and low welding efficiency in the straight seam welding of a shell blank of the existing air condition compressor. The invention provides a method for efficiently welding straight seams of a shell of an air condition compressor, which comprises the following steps: 1) cleaning the surface to be welded of the steel plate; 2) preparing a shell blank of the air conditioner compressor; 3) welding a shell blank of the air conditioner compressor, welding a butted straight seam of the rolled steel plate by adopting a small-hole type plasma welding process, controlling the shell blank to perform movable welding along the center of the welding seam in the welding process by adopting the plasma welding process, wherein the welding current is 200-240A, the arc voltage is 25-31V, and the welding speed is 750-850 mm/min. The method has the advantages of high welding efficiency, good welding quality, simple and convenient operation and low welding cost.
Description
Technical Field
The invention relates to a welding processing method of a compressor shell, in particular to a method for efficiently welding a straight seam of an air conditioner compressor shell, and belongs to the technical field of steel material welding processing.
Background
The shell of the air conditioner compressor usually adopts a hot-rolled pickled steel plate as a substrate, the thickness of the steel plate is 3.0-4.0 mm, and a certain compressor shell manufacturer mainly adopts a pickled steel plate with the Bao steel brand of SPHC for processing a compressor shell blank. The content of C in SPHC is 0.04-0.058%, the yield strength is 232-336 MPa, a steel plate is processed into small plates according to a set size, the small plates are rolled into a compressor shell blank by using a rolling device, then plasma straight seam butt welding is carried out, and then the subsequent assembly process of the air conditioner compressor is continuously completed.
The welded joint is a weak link of the shell of the air-conditioning compressor, and the air leakage failure of most of the shells of the air-conditioning compressors occurs at the welded joint, and the main reason is that the welded joint has defects of undercut, penetration welding, incomplete penetration welding and the like locally, so that the welded joint of the shell of the air-conditioning compressor cracks and leaks air in the using process. According to the high-speed plasma welding processing technology adopted by the shell of the air conditioner compressor at present, undercut can occur on the front side of a welding line, the back side of the welding line is not uniformly formed, and even the phenomena of welding beading and incomplete penetration can occur. The compressor shell with a part of qualified water pressure tests and poor quality of the welding joint is easy to crack under the impact of alternate pressure in the long-term use process, the service life is shortened, and more complaints are made by users, so that the improvement of the quality of the welding joint is very necessary.
Because the improvement of the degree of automation of the existing user side greatly accelerates the production rhythm, the requirement on the welding speed is further improved, when the welding speed is too high, the temperature of a molten pool is insufficient, the defects of incomplete penetration, incomplete fusion, poor weld forming and the like are easily caused, under the same welding current and welding voltage, the weld can be narrowed due to the improvement of the welding speed, the quality of the whole welding joint can be influenced, the compressor shell can be cracked and leaked gas when the welding joint is serious, and the product fails. Therefore, to ensure the quality of the weld, it is necessary to increase the heat input during high-speed welding.
Along with the further improvement of the automation degree of a production plant, the welding speed needs to be improved, the welding quality control requirement needs to be more refined during high-speed welding, and an effective method for ensuring the high-speed welding quality of the edge rolling type straight seam of the shell of the air conditioner compressor is lacked in the prior art.
Disclosure of Invention
The invention aims to provide a method for efficiently welding a straight seam of a shell of an air condition compressor, which mainly solves the technical problems of poor welding quality and low welding efficiency in the straight seam welding of a blank of the shell of the existing air condition compressor; the method has high welding quality and the welding speed meets the requirement of high-rhythm production.
The invention adopts the technical scheme that a method for efficiently welding straight seams of a shell of an air conditioner compressor comprises the following steps:
1) cleaning the surface to be welded of the steel plate, removing burrs at a notch of the steel plate for the acid pickling air conditioner compressor with the thickness of 3.0-4.0 mm, and cleaning the surface to be welded of the steel plate by using acetone;
2) preparing a shell blank of the air condition compressor, rolling the steel plate and then butting the steel plate, wherein the butting gap is 0, and the misalignment in the thickness direction of the steel plate at the butting position is less than or equal to 0.25 mm;
3) welding a shell blank of an air conditioner compressor, welding a butted straight seam of a rolled steel plate by adopting a small-hole plasma welding process, controlling the arc center to be over against the center of the butted straight seam in the welding process, keeping the position of a welding gun unchanged, controlling the shell blank to move along the center of a welding seam for welding, controlling the inclination angle of the welding gun and the horizontal direction of welding advance to be 80-83 degrees during welding, controlling the welding current to be 200-240A, controlling the arc voltage to be 25-31V, controlling the welding speed to be 750-850 mm/min, and protecting the front side of the welding seam by adopting gas in the welding process.
Further, in the welding process in the step 3), the ion gas is a mixed gas of argon and hydrogen, the volume percentage of the hydrogen in the mixed gas is 3%, and the ion gas flow is 3.0-3.5L/min; the hydrogen is added into the argon, the plasma flow force and the penetrating power are increased, the arc temperature is increased, the heat input of the base metal can be increased, and the arc temperature is higher than that of the arc which only uses Ar as the ion gas, so that the requirement of rapid welding is met.
Further, in the welding process in the step 3), the front protective gas is a mixed gas of argon and hydrogen, the volume percentage of the hydrogen in the mixed gas is 3%, the flow of the protective gas is 18-20L/min, and the pressure of the protective gas is 0.25-0.45 MPa; the pressure is too small or too large, the protection effect is influenced, the welding quality is poor, the flexible design is carried out on the pressure of the protective gas, under the condition of rapid high-current welding, the penetration of the welding is ensured, and the impact effect of the protective gas on a molten pool is reduced, so that the generation of welding defects such as undercut, incomplete penetration of the welding, penetration of the welding and the like is reduced, and the welding process can be stable because the ion gas and the protective gas adopt the same components.
Further, in the step 3), the current at the initial welding stage is 10-20A, the current at the later welding stage is 10-70A, the ascending time is 0-1 s, and the descending time is 0-1 s; by adopting the arc starting control with the welding current increasing progressively and the arc ending control with the welding current decreasing progressively, the arc starting point can be ensured to fully penetrate, the arc ending point is prevented from being welded through, and air holes can be effectively prevented from occurring.
Furthermore, the inclination angle of the welding gun and the horizontal direction of welding advance is 80-83 degrees, the welding gun has a certain inclination angle to push a molten pool during welding, welding seam forming is facilitated, a welding bead with deep penetration and narrow welding width is easy to form, and welding can be completed only by small heat input.
The welding seam is completely welded, the surface and the back of the welding seam are formed uniformly, and welding defects such as undercut and welding flash are avoided.
The invention is a small hole type plasma welding process, which ensures the stability of the small hole in the welding process, and is the key for obtaining a high-quality welding seam.
The welding process is characterized in that the electric arc is mechanically compressed by a water-cooled central nozzle, so that a heat affected zone is narrower, energy is more concentrated, and the utilization rate is higher.
Compared with the prior art, the invention has the following positive effects:
1. the invention is suitable for large-specification welding, namely high-current rapid welding, the welding current is 200-240A, and the welding speed is 750-850 mm/min. Through the improvement, the requirement of a production factory on the production rhythm can be met.
2. According to the method, the ion gas is the mixed gas of argon and hydrogen, and compared with the method of adopting pure Ar as the ion gas, the plasma flow force and the penetration capacity are increased, the electric arc temperature is increased, and the heat input of the base metal can be increased, so that the requirement of rapid welding is met; the volume fraction of hydrogen is small and is only 3%, so that hydrogen holes can be effectively prevented, double arcs can be avoided, and the welding stability is improved;
3. the pressure of the protective gas on the front surface of the welding area is 0.25-0.45 MPa, the pressure is too low, the welding quality is affected, and when the pressure is more than 0.45MPa, a complete welding seam can be formed, but the probability of undercut defects during welding is increased. According to the invention, the flexible design is carried out on the pressure of the protective gas, so that the good forming of the welding seam is ensured. Through measurement, the width of a front welding seam is 5.0-6.2 mm, the surplus height is 1.0-1.5 mm, and the back welding seam is 1.8-2.2 mm without surplus height. And nondestructive flaw detection is carried out on the welding seam, the qualification rate reaches more than 98%, and no bubble is generated in the hydrostatic test.
4. The method has the advantages that when heavy current welding is carried out, the ion gas and the protective gas adopt the same components, so that the welding process can be stable.
5. The method of the invention adopts the unchanged position of the welding gun, realizes the arc striking, welding and arc closing by pushing the shell blank to move through the push rod, and forms a welding seam.
6. The invention adopts the arc starting control with the welding current increasing gradually and the arc closing control with the welding current decreasing gradually, can ensure that an arc starting point fully penetrates and the arc closing point is prevented from being welded through, and can effectively prevent air holes from appearing, wherein the current at the initial welding stage is 10-20A, the current at the later welding stage is 10-70A, the ascending time is 0-1 s, and the descending time is 0-1 s.
7. The method has the advantages of simple operation method and low implementation cost, the welding speed is increased from 420mm/min to more than 750mm/min, the welding speed is increased by one time, the welding rhythm of a production factory can be met, the welding seam is completely welded through, the surface is uniformly formed, and the welded joint without undercut defects is obtained.
Detailed Description
The invention is further described below with reference to examples 1-3, in which the welding process control parameters are shown in table 1.
In the embodiment of the invention, the hot-rolled pickled steel plate has the mark of SPHC, the thickness of 3.2mm, the content of C of 0.056 percent, the content of Mn of 0.203 percent and the yield strength of 270 MPa.
Embodiment 1, a method for improving plasma welding joint quality and welding efficiency, comprising the steps of:
1) cleaning the surface to be welded of the steel plate, processing the hot-rolled pickling air conditioner compressor steel SPHC steel plate with the thickness of 3.2mm into small plates according to the size of the shell, and removing burrs and oil stains at the cut;
2) preparing a shell blank of the air conditioner compressor, rolling the small plate by using a rolling device to form the shell blank of the compressor, wherein the opening degree of the shell blank is 5-7 mm, the shell blank enters a welding station for butt joint, two butted edges of the shell blank of the air conditioner compressor are respectively fixed by using a clamp, so that a steel plate does not slide in the welding process, the butt joint gap is 0, and the misalignment of the steel plate at two sides of the butt joint in the thickness direction is less than or equal to 0.25 mm;
3) welding the blank of the shell of the air compressor, adopting a small-hole plasma welding process to weld the blank of the shell of the air compressor, keeping the position of a welding gun unchanged, aligning plasma arcs to the center of a straight seam, pushing the blank of the shell to move through a push rod, realizing arc starting, welding and arc ending, and forming a welding seam. During welding, the inclination angle of the welding gun is 10 degrees, the inclination direction is forward inclination, namely the welding gun is inclined towards the welding advancing direction, and the inclination angle of the welding gun and the welding advancing horizontal direction is 80 degrees. Controlling the welding current to be 230A, the arc voltage to be 28V, the welding speed to be 850mm/min, the initial current to be 15A, the later current to be 50A, the ascending time to be 0.8s and the descending time to be 0.8 s. Ar + H is adopted in the welding process2As an ionic gas, wherein H2The volume fraction of (A) was 3%, and the ionic gas flow rate was 3.1L/min. The welding area adopts gas protection, and the protection gas is Ar + H2The proportion is the same as that of the ion gas, the flow of the protective gas is 18L/min, and the protection is realizedThe pressure of the gas is 0.25MPa, and the plasma welding gun is cooled by adopting internal circulating cooling water, wherein the temperature of the cooling water is 15 ℃.
After welding, appearance inspection is carried out on the welded joint, the welding seam is completely welded, the surface of the welding seam is formed uniformly, no undercut defect exists, the width of the welding seam on the front side is 5.0-6.2 mm, the residual height is 1.0-1.5 mm, the welding seam on the back side is 1.8-2.2 mm, and no residual height exists; carrying out radiographic inspection on the welded joint, and finding no dense air holes; and carrying out a hydrostatic test on the finished product of the air conditioner compressor shell, and finding no bubbles at the welding joint.
Embodiment 2, a method for improving plasma welding joint quality and welding efficiency, comprising the steps of:
1) cleaning the surface to be welded of the steel plate, processing the hot-rolled pickling air conditioner compressor steel SPHC steel plate with the thickness of 3.2mm into small plates according to the size of the shell, and removing burrs and oil stains at the cut;
2) preparing a shell blank of the air conditioner compressor, rolling the small plate by using a rolling device to form the shell blank of the compressor, wherein the opening degree of the shell blank is 5-7 mm, the shell blank enters a welding station for butt joint, two butted edges of the shell blank of the air conditioner compressor are respectively fixed by using a clamp, so that a steel plate does not slide in the welding process, the butt joint gap is 0, and the misalignment of the steel plate at two sides of the butt joint in the thickness direction is less than or equal to 0.25 mm;
3) welding the blank of the shell of the air compressor, adopting a small-hole plasma welding process to weld the blank of the shell of the air compressor, keeping the position of a welding gun unchanged, aligning plasma arcs to the center of a straight seam, pushing the blank of the shell to move through a push rod, realizing arc starting, welding and arc ending, and forming a welding seam. During welding, the inclination angle of the welding gun is 10 degrees, the inclination direction is forward inclination, namely the welding gun is inclined towards the welding advancing direction, and the inclination angle of the welding gun and the welding advancing horizontal direction is 80 degrees. Controlling the welding current to be 230A, the arc voltage to be 28V, the welding speed to be 850mm/min, the initial current to be 15A, the later current to be 50A, the ascending time to be 0.8s and the descending time to be 0.8 s. Ar + H is adopted in the welding process2As an ionic gas, wherein H2Has a volume fraction of 3% and an ionic gas flow rate of 31L/min. The welding area adopts gas protection, and the protection gas is Ar + H2The proportion is the same as that of the ion gas, the flow rate of the protective gas is 18L/min, the pressure of the protective gas is 0.35MPa, and the plasma welding gun is cooled by adopting internal circulating cooling water, wherein the temperature of the cooling water is 15 ℃. .
After welding, appearance inspection is carried out on the welded joint, the welding seam is completely welded, the surface of the welding seam is formed uniformly, no undercut defect exists, the width of the welding seam on the front side is 5.0-6.2 mm, the residual height is 1.0-1.5 mm, the welding seam on the back side is 1.8-2.2 mm, and no residual height exists; carrying out radiographic inspection on the welded joint, and finding no dense air holes; and carrying out a hydrostatic test on the finished product of the air conditioner compressor shell, and finding no bubbles at the welding joint.
Embodiment 3, a method for improving plasma welding joint quality and welding efficiency, comprising the steps of:
1) cleaning the surface to be welded of the steel plate, processing the hot-rolled pickling air conditioner compressor steel SPHC steel plate with the thickness of 3.2mm into small plates according to the size of the shell, and removing burrs and oil stains at the cut;
2) preparing a shell blank of the air conditioner compressor, rolling the small plate by using a rolling device to form the shell blank of the compressor, wherein the opening degree of the shell blank is 5-7 mm, the shell blank enters a welding station for butt joint, two butted edges of the shell blank of the air conditioner compressor are respectively fixed by using a clamp, so that a steel plate does not slide in the welding process, the butt joint gap is 0, and the misalignment of the steel plate at two sides of the butt joint in the thickness direction is less than or equal to 0.25 mm;
3) welding the blank of the shell of the air compressor, adopting a small-hole plasma welding process to weld the blank of the shell of the air compressor, keeping the position of a welding gun unchanged, aligning plasma arcs to the center of a straight seam, pushing the blank of the shell to move through a push rod, realizing arc starting, welding and arc ending, and forming a welding seam. During welding, the inclination angle of the welding gun is 10 degrees, the inclination direction is forward inclination, namely the welding gun is inclined towards the welding advancing direction, and the inclination angle of the welding gun and the welding advancing horizontal direction is 80 degrees. Controlling the welding current to 230A, the arc voltage to 28V, the welding speed to 850mm/min, the initial current to 15A, the later current to 50A, and the uphill timeIt is 0.8s and the downhill time is 0.8 s. Ar + H is adopted in the welding process2As an ionic gas, wherein H2The volume fraction of (A) was 3%, and the ionic gas flow rate was 3.1L/min. The front surface of the welding area is protected by gas, and the protective gas is Ar + H2The proportion is the same as that of the ion gas, the flow rate of the protective gas is 18L/min, the pressure of the protective gas is 0.45MPa, and the plasma welding gun is cooled by adopting internal circulating cooling water, wherein the temperature of the cooling water is 15 ℃.
After welding, appearance inspection is carried out on the welded joint, the welding seam is completely welded, the surface of the welding seam is formed uniformly, no undercut defect exists, the width of the welding seam on the front side is 5.0-6.2 mm, the residual height is 1.0-1.5 mm, the welding seam on the back side is 1.8-2.2 mm, and no residual height exists; carrying out radiographic inspection on the welded joint, and finding no dense air holes; and carrying out a hydrostatic test on the finished product of the air conditioner compressor shell, and finding no bubbles at the welding joint.
Table 1 welding process control parameters of embodiments of the invention
It should be noted that the above-mentioned embodiments are only preferred embodiments of the present invention, and are not intended to limit the scope of the present invention, and all equivalent substitutions or substitutions made on the basis of the above-mentioned technical solutions belong to the scope of the present invention.
Claims (4)
1. A method for efficiently welding straight seams of air condition compressor shells is characterized by comprising the following steps:
1) cleaning the surface to be welded of the steel plate, removing burrs at a notch of the steel plate for the acid pickling air conditioner compressor with the thickness of 3.0-4.0 mm, and cleaning the surface to be welded of the steel plate by using acetone;
2) preparing a shell blank of the air condition compressor, rolling the steel plate and then butting the steel plate, wherein the butting gap is 0, and the misalignment in the thickness direction of the steel plate at the butting position is less than or equal to 0.25 mm;
3) welding a shell blank of an air conditioner compressor, welding a butted straight seam of a rolled steel plate by adopting a small-hole plasma welding process, controlling the arc center to be over against the center of the butted straight seam in the welding process, keeping the position of a welding gun unchanged, controlling the shell blank to move along the center of a welding seam for welding, controlling the inclination angle of the welding gun and the horizontal direction of welding advance to be 80-83 degrees during welding, controlling the welding current to be 200-240A, controlling the arc voltage to be 25-31V, controlling the welding speed to be 750-850 mm/min, and protecting the front side of the welding seam by adopting gas in the welding process.
2. The method for efficiently welding the straight seam of the shell of the air conditioner compressor as claimed in claim 1, wherein the ionic gas in the welding process in the step 3) is a mixed gas of argon and hydrogen, the volume percentage of the hydrogen in the mixed gas is 3%, and the ionic gas flow is 3.0-3.5L/min.
3. The method for efficiently welding the straight seam of the shell of the air conditioner compressor as claimed in claim 1, wherein the front shielding gas in the welding process in the step 3) is a mixed gas of argon and hydrogen, the volume percentage of the hydrogen in the mixed gas is 3%, the flow rate of the shielding gas is 18-20L/min, and the pressure of the shielding gas is 0.25-0.45 MPa.
4. The method for efficiently welding the straight seam of the shell of the air conditioner compressor as claimed in claim 1, wherein the current in the initial welding stage in the step 3) is 10-20A, the current in the later welding stage is 10-70A, the ascending time is 0-1 s, and the descending time is 0-1 s.
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Cited By (1)
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