CN114952050A - Composite welding method suitable for large-diameter thick-wall cylinder body with diameter of more than 8mm - Google Patents
Composite welding method suitable for large-diameter thick-wall cylinder body with diameter of more than 8mm Download PDFInfo
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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
- B23K28/00—Welding or cutting not covered by any of the preceding groups, e.g. electrolytic welding
- B23K28/02—Combined welding or cutting procedures or apparatus
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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
- B23K2101/00—Articles made by soldering, welding or cutting
- B23K2101/04—Tubular or hollow articles
- B23K2101/12—Vessels
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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
- B23K2103/05—Stainless steel
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Abstract
The invention discloses a composite welding method suitable for a large-diameter thick-wall cylinder body with the diameter of more than 8mm, which comprises the following steps of: aiming at a large-diameter thick-wall cylinder with the diameter of more than 8mm, the joint is a butt joint, a reverse Y-shaped groove is formed, the angle of the groove is 60-70 degrees, and the truncated edge is 5 mm; selecting a welding wire according to the thickness and the material of the weldment; the inner wall is additionally provided with a positioning support, the distance between the two cylinders is adjusted according to the assembly gap between the two cylinders read by the supporting sliding mechanism, and the misalignment amount between the two cylinders is adjusted by adjusting the cylinder support, so that the welding seam gap and the misalignment amount of the workpiece to be welded meet the welding requirement; manual TIG spot welding positioning is carried out on the outer side; the plasma + TIG electric arc + SAW composite welding is completed by adopting a welding combination mode that plasma outside the cylinder is not added with wire in the front for single-pass backing welding, TIG is added with cold wire after filling the cover surface, grinding wheel back chipping is carried out inside the cylinder, and SAW multi-pass multi-layer welding is carried out for filling the cover surface, wherein the performance of the steel welding joint meets the requirements of the welding process evaluation of pressure-bearing equipment for NB/T47014 plus 2011 and stainless steel and heat-resistant steel plates for pressure-bearing equipment and steel belts GB/T24511-2017.
Description
Technical Field
The invention relates to the field of cylinder welding, in particular to a composite welding method for a large-diameter thick-wall cylinder.
Background
Due to the particularity of the use environment and the use working conditions of the pressure vessel, the metal and welding line requirements of the pressure vessel are high in the high-temperature high-pressure corrosive liquid and gas environment, the welding process plays an important role in the manufacturing process of the pressure vessel, and the welding performance of the pressure vessel directly determines the quality and the safety performance of the pressure vessel to a great extent. With the development of petrochemical industry and steel manufacturing technology in China, the use of large-diameter thick-wall pressure containers with the diameter of more than 8mm is increasing day by day. As the diameter of the cylinder body of the pressure container is increased and the wall thickness is thickened, higher requirements are put forward on the assembly and girth welding process of the cylinder body.
The plasma and TIG welding method is a composite welding method widely used for chemical containers at present, has the advantages of good welding seam quality and high welding efficiency, saves welding materials by 10 times compared with SAW welding every 1000mm of welding seams, saves a great part of welding material cost, and has good economic benefit. The existing plasma and TIG welding mode generally adopts a method that plasma is not added with wires for bottoming in front and TIG electric arc is added with cold wires for filling the cover surface in back, and single-side welding and double-side forming are realized through the characteristics of plasma arc energy concentration, high productivity, high welding speed and high quality of TIG electric arc welding seams. However, for the large-diameter thick-wall cylinder with the diameter of more than 8mm, the welding process is used for welding outside the cylinder, the defects of incomplete penetration, incomplete fusion and the like can occur in a welding seam, and most plasma and TIG double-gun welding equipment is not suitable for welding the cylinder on the inner wall, so that the application is not flexible, the welding efficiency is low, and the production cost of enterprises is increased. In addition, the assembly requirement of the plasma welding on the cylinder before welding is high, the assembly gap of the large-diameter thick-wall cylinder is not easy to control, and if large assembly gaps and misalignment amount exist during welding, the quality problem that a welding seam is not completely welded or is missed easily occurs.
Disclosure of Invention
The invention aims to provide a composite welding method suitable for a large-diameter thick-wall cylinder with the diameter of more than 8mm, which aims to solve the problems that when the large-diameter thick-wall cylinder with the diameter of more than 8mm is welded in stainless steel, a plasma and TIG (tungsten inert gas) welding mode is adopted, the welding seam permeability is poor, the welding efficiency is low, and the assembly requirement before welding is high, the assembly gap and the misalignment amount between two cylinders are controlled by adjusting the inner wall positioning support, so that the problem that the assembly requirement before plasma welding on the cylinder is high is met, automatic plasma and TIG arc and automatic SAW (surface acoustic wave) welding are adopted, the welding quality and efficiency of the large-diameter thick-wall cylinder are improved, and the composite welding method suitable for the large-diameter thick-wall cylinder with the diameter of more than 8mm is provided. According to the invention, the plasma arc, TIG electric arc and SAW combined welding method is adopted for welding, the welding efficiency is improved compared with the plasma and TIG, the welding thickness range is enlarged, the penetration stability of the back weld is increased, and the efficient and stable welding of the large-diameter thick-wall cylinder with the thickness of 8mm-25mm is realized. The plasma arc, TIG arc and SAW combined welding method of the invention is composed of plasma arc, TIG arc and SAW, when welding, the outside of the cylinder body adopts a welding combination mode of filling the cover surface of the unwelded part by plasma single-pass backing welding without wire addition, TIG cold wire addition, back chipping of an internal grinding wheel, SAW multilayer multi-pass welding, the performance of the steel welding joint meets the requirements of the pressure-bearing equipment welding process evaluation NB/T47014-plus 2011 and the stainless steel and heat-resistant steel plate for pressure-bearing equipment and steel strip GB/T24511-2017, and the problems of low welding efficiency, unsuitability for welding the inner wall and limited welding thickness of a large-diameter thick-wall cylinder with the welding diameter of more than 8mm by using the plasma and TIG welding method are solved by utilizing the advantages of good welding line quality, welding material cost saving, attractive welding line forming, high welding efficiency, SAW convenience for internal welding and high welding bead quality of the plasma and TIG welding method.
In order to solve the technical problem of the invention, the technical scheme is as follows:
the hybrid welding method comprises plasma arc, TIG electric arc and SAW, and adopts a hybrid welding mode to butt joint bevels of the large-diameter thick-wall cylinder body with the diameter of more than 8mm in the stainless steel;
a plasma and TIG welding device adopts a circumferential seam P and T welding system; the SAW welding device adopts a special submerged arc automatic welding machine with a cross arm, and the machine head is deeply inserted into the cylinder body for welding.
The method comprises the following specific steps:
1) designing a groove for the composite welding of the large-diameter thick-wall cylinder according to the material and the wall thickness of a workpiece to be welded: opening a reverse Y-shaped groove on the stainless steel piece to be welded;
2) the thickness and the material of the welding cylinder body are selected: the diameter of the stainless steel cylinder is 1000-3000 mm, and the thickness is 8-25 mm.
3) Selecting the type and the diameter of the welding wire: during TIG welding, ER308L welding wire with the diameter phi of 1.2mm is adopted; during SAW welding, when the thickness of the cylinder is less than 12mm, welding wires with the diameter phi of 3.2mm are adopted; when the thickness of the cylinder body exceeds 12mm, welding wires with the diameter phi of 4.0mm are adopted.
4) Before welding, machining grooves on two sides of a welding seam of the cylinder body, cleaning impurities such as oil stains, burrs and the like in the two sides of the welding seam, and exposing the natural color of metal on the surface;
5) the method comprises the steps of hoisting a to-be-welded workpiece which is cleaned to a roller frame, additionally arranging positioning supports on the inner walls of the two cylinders, adjusting the distance between the two cylinders according to the group gap between the two cylinders read by a supporting sliding mechanism, adjusting the misalignment between the two cylinders by adjusting the cylinder supports, enabling the welding seam gap and the misalignment of the to-be-welded workpiece to meet the automatic welding requirement, rounding the inner wall, and enabling the positioning supports to comprise two parts, namely a cylinder support (1) and a supporting sliding mechanism (2).
The cylinder support is composed of a support plate (3), a support plate (4a), an adjusting ring (5), an upper sliding block (6), a lower sliding block (7), a nut (8), a threaded rod (9), a support rod (4b), a guide plate (10), a guide rod (11), a limiting block (12), a fixed block (13), an arc-shaped plate (14) and a rotating handle (15). Supporting disk (3) are circular, and supporting disk (3) edge evenly sets up 4 pairs of backup pad (4a), and backup pad (4a) welded connection adjusts ring (5) and supporting disk (3), and backup pad (4a) are the cuboid. The upper sliding block and the lower sliding block are respectively arranged at two ends of the adjusting ring (5), and each lower sliding block (7) is provided with a thread matched with the upper sliding block (6) and used for penetrating through the adjusting ring (5) to be in threaded connection with the upper sliding block (6). The number of the upper sliding blocks and the lower sliding blocks is 4 pairs, and the upper sliding blocks and the lower sliding blocks are rectangular blocks which are in contact with the bottom surface of the adjusting circular ring (5) in an arc shape and are horizontally provided with holes and far away from the bottom surface of the adjusting circular ring (5). The supporting rods (4b) are fixedly connected with the upper sliding blocks (6) and the limiting blocks (12), and each upper sliding block (6) is connected with the limiting block (12) through the two supporting rods (4 b). The threaded rods (9) penetrate through the sliding blocks and the guide plates (10) to be rotatably connected with the limiting blocks (12) and are fixed through the nuts (8), the number of the threaded rods (9) is 8, the angles of the 4 threaded rods (9) are adjustable, and the rest of the threaded rods are fixed. The number of the nuts (8) is the same as that of the threaded rods (9). Two guide rods (11) are connected in the limiting block (12) in a sliding mode, the fixing block (13) is fixedly connected with the guide rods (11) and the arc-shaped plate (14), and external threads matched with the fixing block (13) are machined at one end of the arc-shaped plate (14).
The supporting sliding mechanism (2) is composed of a fixed block (16), a lead screw (17), a guide rod (18), a rocker arm (18), a bolt (20) and a fixed disc (21). The lead screw (17) respectively passes through the central holes of two discoid cylinder supports, and the left end of lead screw (17) rotates and connects fixed block (16), and the right-hand member passes fixed disk (21) fixed connection rocking arm (18). The two cylinder supports are internally and slidably connected with four guide rods (18), and the guide rods (18) are fixedly connected with a fixed block (16) and a supporting plate (3) of the right cylinder support (1 a). The lower end of the rocker arm (18) is connected with the fixed disc (21) through a bolt (20) for rotation stopping, and bolt holes matched with each other are formed in the positions of the rocker arm (18) and the fixed disc (21) where the bolt (20) is installed.
Furthermore, the upper sliding block (6), the lower sliding block (7) and the threaded rod (9) are in threaded connection with the adjusting ring (5), and the barrel body support (1) selects a proper supporting point to support the barrel body by changing the positions of the upper sliding block and the lower sliding block on the adjusting ring (5).
6) Installing a back protection tool or a dragging cover: the width is generally 60-80 mm and the length is generally 100-120 mm according to the diameter and the wall thickness of the cylinder body; connecting a protective cover to the welding joint, wherein the gas flow is 10-15L/min;
7) the cylinder is directly spot-welded on the outer side through manual TIG: the general penetration is about 2mm, the welding current is 100A, the length of a welding spot is about 5mm, the width of the welding spot is 3mm, the welding discontinuity is 100mm, and the head-tail transition part is polished into a smooth and gentle slope shape. If there are cracks and other defects, the re-spot should be worn away completely.
8) Carrying out plasma + TIG + SAW hybrid welding treatment on the stainless steel cylinder, and setting hybrid welding parameters before welding and arc striking:
the welding voltage for plasma welding is 29-31V, the welding current is 240-260A, the welding speed range is 150-200 mm/min, and the polarity of a welding power supply is direct current positive connection; the central shaft of the plasma welding gun is vertical to the tangent line of the circular seam and does not swing, the distance between a welding gun conductive nozzle and a workpiece ranges from 10 mm to 15mm, and the tungsten electrode shrinks inwards by 2.8 mm;
the TIG welding voltage is 17-19V, the welding current is 230-250A, the wire feeding speed is 1200-1500 mm/min, the welding speed range is 160-200 mm/min, and the polarity of the welding power supply is direct current positive connection; the TIG welding gun is normal and vertical and has swinging, the transverse swinging speed is 1500mm/min, the left swinging distance is 2.3mm, the right swinging distance is 2.3mm, the left stopping time is 0.2s, the right stopping time is 0.2s, the distance range from the conductive nozzle of the welding gun to a workpiece is 20-30 mm, and the distance range between a tungsten electrode and the workpiece is 10-15 mm;
when the diameter of the welding wire is phi 3.2mm, the welding current used by SAW is 380-420A, the welding voltage is 28-32V, and the linear energy is 12.77-20.16 KJ/cm; when the diameter of the welding wire is phi 4.0mm, the welding current used by SAW is 500-550A, the welding voltage is 30-36V, the linear energy is 18.0-29.7 KJ/cm, the polarity of a welding power supply is direct current reverse connection, and the welding speed range is 400-500 mm/min; the distance between a conductive nozzle of the welding gun and the workpiece ranges from 32 mm to 40 mm;
planning a welding path: firstly welding a front blunt edge of a welding seam by plasma arc without adding wires and backing-up one time, then welding an unfilled part by filling and covering one time by TIG (tungsten inert gas) arc cold wire, polishing the back of the welding seam by using a stainless steel special grinding wheel to obtain metallic luster, and finally performing SAW (surface acoustic wave) multilayer multi-pass welding on a back groove of the welding seam; during welding, the plasma arc is started firstly, after about 10s, the TIG electric arc is started for welding, when the plasma welding gun exceeds an arc striking point by 15-20 mm, a progressive arc quenching program is started, the plasma arc is turned off firstly, and after 10s, the TIG welding is progressively quenched.
9) And cleaning the welded seam until the surface has metallic luster.
In order to ensure a better welding effect, in the step 8), the arc striking needs to avoid spot welding seams as much as possible, shielding gas is filled in the welding process, the flow of the plasma welding gun is controlled to be 5-6L/min, the flow of the shielding gas is 20-25L/min, the gas is fed for 3s in advance, and argon continues to flow for 15s after the arc is broken.
In order to ensure the welding effect, when the automatic SAW multilayer multi-pass welding is carried out in the step 8), the interlayer temperature is controlled to be not more than 150 ℃, the slag crust is considered to be easy to fall off, the stainless steel wire brush is not needed to polish the welding seam and impurities on two sides of the welding seam after each layer is welded, and whether polishing is carried out can be determined according to the welding seam fusion and forming conditions.
In order to ensure the welding effect, along with the increase of the thickness of a welding seam, an operator observes the forming condition of the welding seam in a molten pool at any time through an electric arc monitoring system, particularly when the misalignment amount and the gap are large, the operator needs to timely pass through a control panel, adjust the distance between a nozzle of a welding gun and the welding seam, adjust the welding current, the welding speed and the wire feeding speed, always keep the distance between the tip of a tungsten electrode and a workpiece unchanged, and walk the tip of a welding wire on an automatic wire feeder along the central line of a reverse Y-shaped groove so as to ensure that the welding gun stretches into the position, avoid the drift of TIG electric arc and improve the forming condition of the welding seam.
The material of the workpiece to be welded in the step 1) is stainless steel.
The inverted Y-shaped groove in the step 1) has a truncated edge thickness of 5mm and a groove angle controlled at 60-70 degrees.
The protective gas in the step 6) and the step 9) is argon with the purity of 99.99 percent or argon with the purity of 95 percent and hydrogen with the purity of 5 percent; and 8) performing automatic start-stop control on the plasma arc and the TIG arc, wherein the start and stop of the TIG arc are lagged by the plasma arc for 10 s.
The welding seam gap and the misalignment of the workpieces to be welded in the step 5) are not more than 0.5 mm.
And (5) arranging bolt holes matched with each other at the positions of the rocker arm (18) and the mounting bolt (20) of the fixed disc (21).
Has the advantages that:
(1) the invention adopts the plasma arc, TIG arc and SAW combined welding method to weld, the welding efficiency is improved compared with the plasma and TIG, the welding thickness range is enlarged, the penetration stability of the back weld is increased, and the high-efficiency stable welding of the large-diameter thick-wall cylinder with the thickness of 8mm-25mm is realized.
The plasma arc, TIG arc and SAW combined welding method of the invention is composed of plasma arc, TIG arc and SAW, when welding, adopts a welding combination mode of external plasma single-pass backing welding without wire addition, TIG cold wire addition to fill the capping surface of the unwelded part, internal grinding wheel polishing and back chipping, SAW multilayer multi-pass welding to fill the capping surface, the performance of the steel welding joint meets the requirements of the pressure-bearing equipment welding process evaluation NB/T47014-plus 2011 and the stainless steel and heat-resistant steel plate for pressure-bearing equipment and steel strip GB/T24511-2017, and the problems of low welding efficiency, inconvenience in welding the inner wall and limitation of welding thickness of a large-diameter thick-wall cylinder body with the diameter of more than 8mm by using a plasma and TIG welding method are solved by utilizing the advantages of good welding line quality, welding material cost saving, attractive welding line forming, high welding efficiency, convenience in internal welding of SAW and high welding bead quality of the plasma and TIG welding method.
(2) In the cylinder butt joint process, the inner wall positioning support of the cylinder is designed and used, the two cylinder supports connected with the center are used, the distance between the two cylinders is adjusted according to the assembly gap between the two cylinders read by the support sliding mechanism, the misalignment between the two cylinders is adjusted by adjusting the elongation of the arc-shaped plate, and the assembly gap and the misalignment of the cylinders before welding meet the automatic welding requirement, so that the plasma welding quality of the large-diameter thick-wall cylinder is ensured; the angle of the threaded rod is adjusted by moving the upper and lower sliding blocks along the adjusting ring, and a proper supporting point is selected for supporting the barrel body, so that the positioning support of the inner wall is ensured to be attached to the barrel body; the structure that the threaded rod, the guide rod and the limiting block are arranged on the cylinder body support is matched with the guide plate, and the guide rod is adjusted through the threaded rod, so that the guide rod is lengthened or shortened, the cylinders with different diameters are supported, and the manufacturing cost is saved; the left cylinder support can be moved to a proper position only by rotating the rocker arm according to the scales on the guide rod of the support sliding mechanism, so that the left cylinder support can be conveniently installed; the rotary handle and the nut are used for fixing the barrel support, the rocker arm is stopped to rotate through the bolt, the adjusted barrel support position is fixed, and therefore welding efficiency is improved.
(3) The automatic plasma + TIG arc and the automatic SAW are used for replacing manual electric arc welding, so that the welding efficiency and the welding seam stability are greatly improved, the groove is designed to be a reverse Y-shaped groove, the groove angle is controlled to be 60-70 degrees, a blunt edge with the thickness of 5mm is reserved at the bottom of the groove surface, the welding of a large-diameter thick-wall steel cylinder with the diameter of phi 1000-3000 mm and the thickness of 8-25 mm is realized, and the problems of low labor intensity, welding operation environment, low welding material utilization rate and the like are solved.
(4) The P + T + SAW welding method can solve the problems of incomplete penetration and fusion and difficult assembly of the large-diameter thick-wall cylinder by welding the large-diameter thick-wall cylinder with the diameter of more than 8mm by using plasma and TIG, and can meet the problem of high assembly requirement of the cylinder before plasma welding and welding by adjusting the inner wall positioning support to control the assembly gap and the misalignment amount between the two cylinders.
(5) The invention discloses a composite welding method suitable for a large-diameter thick-wall cylinder body with the diameter of more than 8mm, relates to the field of cylinder body welding, and particularly relates to a composite welding method for a large-diameter thick-wall cylinder body, which comprises the following steps: aiming at a large-diameter thick-wall cylinder with the diameter of more than 8mm, the joint is a butt joint, a reverse Y-shaped groove is formed, the angle of the groove is 60-70 degrees, and the truncated edge is 5 mm; selecting a welding wire according to the thickness and the material of the weldment; the inner wall is additionally provided with a positioning support, the distance between the two cylinders is adjusted according to the assembly gap between the two cylinders read by the supporting sliding mechanism, and the misalignment amount between the two cylinders is adjusted by the cylinder support, so that the welding seam gap and the misalignment amount of the cylinder to be welded meet the automatic welding requirement; manual TIG spot welding positioning is carried out on the outer side; the plasma + TIG electric arc + SAW composite welding is completed by adopting a welding combination mode that plasma outside the cylinder is not added with wire in the front for single-pass backing welding, TIG is added with cold wire after filling the cover surface, grinding wheel back chipping is carried out inside the cylinder, and SAW multi-pass multi-layer welding is carried out for filling the cover surface, wherein the performance of the steel welding joint meets the requirements of the welding process evaluation of pressure-bearing equipment for NB/T47014 plus 2011 and stainless steel and heat-resistant steel plates for pressure-bearing equipment and steel belts GB/T24511-2017. The invention is suitable for the large-diameter thick-wall cylinder with the diameter of more than 8mm, has good welding seam quality, saves welding material cost, has beautiful welding seam forming and high welding efficiency, can improve the assembly quality of the large-diameter thick-wall cylinder, and solves the problems of low welding efficiency, inconvenience for welding the inner wall and limitation of welding thickness of the large-diameter thick-wall cylinder with the diameter of more than 8mm by plasma and TIG welding.
Description of the drawings:
FIG. 1 is a schematic view of a welding groove
FIG. 2 is a schematic view of the overall structure of the inner wall positioning support in the working state
FIG. 3 is a schematic view of a cartridge support structure
FIG. 4 is a schematic view of the structure of the supporting and sliding mechanism
FIG. 5 is a schematic view of the structure of the upper and lower sliders
In the figure: the device comprises a barrel support 1, a barrel support 1a right side, a barrel support 1b left side, a sliding mechanism 2, a support plate 3, a support rod 4a, an adjusting ring 5, an upper sliding block 6, a lower sliding block 7, a nut 8, a threaded rod 9, a support rod 4b, a guide plate 10, a guide rod 11, a limiting block 12, a fixing block 13, an arc plate 14, a rotating handle 15, a fixing block 16, a lead screw 17, a guide rod 18, a rocker arm 19, a bolt 20 and a fixing plate 21.
The specific implementation mode is as follows:
the present application will be described in detail with reference to fig. 1 to 5, and in conjunction with the following embodiments, the present invention provides a technical solution:
example 1:
a composite welding method suitable for a large-diameter thick-wall cylinder body with the diameter of more than 8 mm.
The embodiment provides a hybrid welding method, which comprises a plasma + TIG welding method and an SAW welding method, wherein for an S30403 cylinder with a large diameter and a thick wall of more than 8mm, the size of the cylinder is phi 2000mm (diameter) multiplied by 20mm (thickness), and an adopted hybrid welding system comprises a HCJ4030B circular seam P + T welding system and a special cross arm submerged arc automatic welding machine, which are jointly researched and developed by manufacturers.
The welding joint is a butt joint, a reverse Y-shaped groove is formed, the angle of the groove is 70 degrees, and the truncated edge is 5 mm; the filler material for TIG welding is ER308L welding wire with diameter phi of 1.2mm, the filler material for SAW welding is ER308L welding wire with diameter phi of 3.2mm or phi of 4.0mm, and the flux is SJ 601.
And (4) cleaning impurities such as oil stains, burrs and the like in the range of 20mm on two sides of the welding line. And hoisting the two to-be-welded workpieces after polishing or cleaning to a precise adjustable roller frame, and enabling the workpieces to lean against the anti-channeling wheel. And (3) additionally arranging positioning supports on the inner walls of the cylinders at two sides, adjusting the welding seam clearance and the misalignment of the workpieces to be welded to be less than 0.5mm by adjusting the positioning supports, and rounding the inner walls. The positioning support comprises a cylinder support (1) and a support sliding mechanism (2).
As shown in fig. 3, the cylinder support (1) is composed of a support plate (3), a support plate (4a), an adjusting ring (5), an upper slide block (6), a lower slide block (7), a nut (8), a threaded rod (9), a support rod (4b), a guide plate (10a), a guide rod (11), a limit block (12), a fixed block (13), an arc-shaped plate (14) and a rotating handle (15). Supporting disk (3) are circular, and supporting disk (3) edge evenly sets up 4 pairs of backup pad (4a), and backup pad (4a) welded connection adjusts ring (5) and supporting disk (3), and backup pad (4a) are the cuboid. The upper sliding block and the lower sliding block are respectively arranged at two ends of the circular ring (5), and each lower sliding block (7) is provided with a thread matched with the upper sliding block (6) and used for penetrating through the adjusting circular ring (5) to be in threaded connection with the upper sliding block (6). The number of the upper sliding blocks and the lower sliding blocks is 4 pairs, the upper sliding blocks and the lower sliding blocks are rectangular blocks which are in contact with the bottom surface arc of the adjusting ring (5) and are far away from the bottom surface level of the adjusting ring (5) and are provided with holes, the curvature of the upper sliding blocks and the lower sliding blocks is equal to that of the adjusting ring (5), and the positions of the upper sliding blocks and the lower sliding blocks can be adjusted along the adjusting ring (5). The supporting rods (4b) are fixedly connected with the upper sliding blocks (6) and the limiting blocks (12), each upper sliding block (6) is connected with the limiting block (12) through the two supporting rods (4b), and the supporting rods (4b) are solid cylinders. The inner sides of the upper sliding block and the lower sliding block are connected with threaded rods (9) in a threaded mode, the threaded rods (9) penetrate through the upper sliding block and the lower sliding block to be connected with limiting blocks (12) in a rotating mode, the threaded rods (9) are fixed through nuts (8), the number of the threaded rods (9) is 8, 4 angles of the threaded rods are adjustable, the rest of the threaded rods are fixed, and the number of the nuts (8) is consistent with that of the threaded rods (9). Stopper (12) sliding connection has two guide bar (11), fixed block (13) fixed connection guide bar (11) and arc (14), and this arc (14) one end processing has the external screw thread with fixed block (13) complex, adopts arc (14) to be in order to adapt to the support requirement of different internal diameter barrels.
As shown in fig. 4, the supporting and sliding mechanism (2) is composed of a fixed block (16), a lead screw (17), a guide rod (18), a rocker arm (19), a bolt (20), and a fixed disk (21). The lead screw (17) passes the centre bore that is discoid two barrel supports respectively, and lead screw (17) and left side barrel support (1a) threaded connection rotate with right side barrel support (1b) and be connected, and left side barrel support (1a) center is equipped with lead screw (17) complex screw hole, and lead screw (17) left end rotates and connects fixed block (16), and the right-hand member passes fixed disk (21) and rocking arm (19) fixed connection. The two cylinder supports are internally and slidably connected with four guide rods (18), and the guide rods (18) are fixedly connected with the fixed block (16) and the supporting plate (3) of the right cylinder support (1 a). The lower end of the rocker arm (19) is connected with the fixed disc (21) through a bolt (20) for rotation stopping, and bolt holes matched with the bolt (20) are formed in the positions where the rocker arm (19) and the fixed disc (21) are installed.
As shown in fig. 2, when in use, firstly, two contracted cylinder supports (1) and a support sliding mechanism (2) are moved into a cylinder which is preliminarily assembled, 4 pairs of upper and lower sliding blocks are moved along an adjusting ring (5) of the right cylinder support (1b) according to the roundness of the cylinder, the angles of threaded rods (9) at different positions are adjusted, a proper position is selected to support the cylinder, an upper sliding block (6) is screwed, the position of the threaded rod is fixed (9), a rotating handle (15) is operated to drive the threaded rod (9) to rotate according to the inner diameter of a welded cylinder, a guide plate (10) is moved outwards, the extending length of the guide rod (11) is adjusted by utilizing the screw action of the guide plate (10) and the threaded rod (9), an arc plate (14) is pressed against the inner wall of the cylinder, and the threaded rod (9) of the right cylinder support (1b) is fixed through a nut (8). The rocker arm (19) is rotated to enable the screw rod (17) to rotate, the left barrel support (1a) moves along the guide rod (18), the arc plate (14) of the left barrel support (1a) can be pushed against the left side of the butt joint gap by adjusting the rocker arm (19), the scale on the guide rod (18) is read to obtain the pairing gap between the two barrels, the distance between the two barrels is adjusted, and the pairing gap between the barrels meets the welding requirement. According to the scales on the guide rod (18), the left barrel support (1a) is moved to the installation position by rotating the rocker arm (19), the screwing bolt (20) is used for stopping the rotation of the rocker arm (19), the upper sliding block and the lower sliding block are moved to adjust the angle of the threaded rod (9), the extension amount of the arc plate (14) is adjusted by adjusting the rotating handle (15), the misalignment amount between the two barrels is adjusted, and the left barrel support (1a) is fixed by screwing the nut (8).
The threaded rod (9) is provided with eight groups, wherein the angle of adjustment of the adjusting ring (5) can be set by four groups through the upper and lower sliding blocks, and the other four groups are fixedly arranged at equal included angles of the circle center of the adjusting ring (5) through the upper sliding block (6).
Installing a back protection tool or a dragging cover, filling argon with the purity of 99.99% into the welding pool on the front side of a welding seam and the inner surface and the outer surface of a welding joint in the welding process by adopting the dragging cover as protective gas, wherein the flow of the argon is 10-15L/min, the air feeding time is 3s in advance, the argon continues to circulate for 15s after arc breaking, the argon dragging cover is close to a welding gun nozzle, high-temperature-resistant cloth is attached to the periphery of the dragging cover, a closed protection cavity is formed between the dragging cover and a barrel, and the position of the groove is isolated from the outside air. A dragging cover with the width of 60mm and the length of 120mm is adopted;
the cylinder is directly positioned at the outer side through manual TIG spot welding, the melting depth is about 2mm generally, the discontinuous spot welding current is 100A, the length of a welding spot is about 5mm, the width of the welding spot is 3mm, the welding discontinuity is 100mm, and the head and tail transition part is polished to be in a gentle slope shape and polished smoothly. The tack welding should not have cracks and other defects, and the defects should be thoroughly ground and tack welding should be carried out again.
And performing wire-free backing welding and cold wire filling cover welding on the front welding line respectively in a mode that plasma arcs are in front and TIG electric arcs are in back. During welding, the plasma arc is started firstly, after about 10s, the TIG electric arc is started for welding, when the plasma welding gun exceeds an arc striking point by 15-20 mm, a progressive arc quenching program is started, the plasma arc is turned off firstly, and after 10s, the TIG welding is progressively quenched.
Adjusting the angles of the plasma welding torch and the TIG welding torch by a Huaheng intelligent welding control system to enable the two welding torches to be aligned to the center of a welding seam, wherein the central shaft of the plasma welding torch is perpendicular to the tangent line of the circumferential seam, and the TIG welding torch is normal and perpendicular; adjusting the distance between a plasma welding gun and the surface of a workpiece to be 10-15 mm, and the internal shrinkage of a tungsten electrode to be 2.8 mm; and adjusting the distance between the TIG welding gun and the surface of the workpiece to be 20-30 mm, and the distance between the tip of the TIG tungsten electrode and the surface of the workpiece to be 10-15 mm.
The process parameters of plasma welding are set as follows: the welding voltage is 30V, the welding current is 210A, the welding speed is 185mm/min, the welding ion gas flow is 5.5L/min, the protective gas flow is 20-25L/min, and the polarity is direct current positive connection;
the TIG welding process parameters are set as follows: the welding voltage is 14V, the welding current is 230A, the welding speed is 160mm/min, and the wire feeding speed is 1200 mm/min; the TIG welding gun has swinging, the horizontal swinging speed is 1500mm/min, the left swinging distance is 2.3mm, the right swinging distance is 2.3mm, the left stopping time is 0.2s, the right stopping time is 0.2s, and the polarity of the welding power supply is direct current positive connection;
after the back of the welding seam is ground and back-gouged by a stainless steel special grinding wheel, a special cross arm submerged arc automatic welding machine is adopted to enable the machine head to penetrate into the barrel body for multi-layer and multi-pass welding, and the distance between a welding gun conductive nozzle and a workpiece ranges from 32 mm to 40 mm. The technical parameters of the automatic submerged arc welding are set as follows: when the diameter of the welding wire is phi 3.2mm, the welding current is 380-420A, the welding voltage is 28-32V, and the linear energy is 12.77-20.16 KJ/cm; when the diameter of the welding wire is phi 4.0mm, the welding current is 500-550A, the welding voltage is 30-36V, the linear energy is 18.0-29.7 KJ/cm, the polarity of a welding power supply is direct current reverse connection, and the welding speed is 400-500 mm/min. And then finishing the plasma + TIG electric arc + SAW composite welding according to the set parameters.
In the welding process, an operator observes the welding seam forming condition in the molten pool at any time through an electric arc monitoring system, particularly when the misalignment amount and the gap are large, the operator needs to timely pass through a control panel, adjust the distance between a nozzle of a welding gun and the welding seam, adjust the welding current, the welding speed, the wire feeding speed and the like, and ensure that the tip end of a welding wire on an automatic wire feeder travels along the central line of a reverse Y-shaped groove so as to avoid TIG electric arc drift and improve the welding seam forming condition.
After welding is finished, the thick-wall cylinder is taken out of the welding machine, mechanical property tests are carried out on the NB/T47016 and 2011 cutting sample according to mechanical property tests of a welding test piece of a product of the pressure-bearing equipment, and the welding seam completely meets the requirements of assessment of NB/T47014-2011 of the welding process of the pressure-bearing equipment, stainless steel and heat-resistant steel plates for the pressure-bearing equipment and steel belts GB/T24511 and 2017.
Example 2:
a composite welding method suitable for a large-diameter thick-wall cylinder body with the diameter of more than 8 mm. The procedure was substantially the same as in example 1, except that stainless steel S31603 was welded to a thickness of 14 mm.
Comparative example:
and welding the stainless steel No. S31603 with the thickness of 12mm by a manual operation welding rod in a common SMAW welding mode to finish the operation.
Test example 1:
the thick-walled stainless steel No. S31603 welded in the example 2 and the comparative example are respectively taken for tensile test detection: respectively cutting a test piece from the middle position of a stainless steel test plate No. S31603 welded in the embodiment 2 and the comparative example by using a sawing machine, and performing a tensile test on the test piece by using a microcomputer-controlled electro-hydraulic servo universal testing machine to obtain that the tensile strength of the welding joint in the embodiment 2 is 616.5 MPa; the tensile strength of the welded joint in the comparative example was 609.5 MPa.
Test example 2:
the thick-walled stainless steel No. S31603 welded in the example 2 and the comparative example is respectively taken for impact test detection: cutting a test sample from the middle position of a stainless steel test plate of No. S31603 welded in the embodiment 2 and the comparative example by using a sawing machine, grinding the cut surface by using a planer and a grinder, respectively processing a V-shaped notch on a welding line and a heat affected zone by using an impact test sample notch hydraulic broaching machine, and performing a Charpy impact test on the test sample by using a pendulum impact testing machine, wherein the impact absorption power of the Charpy V-shaped notch at the welding line in the embodiment 2 is 82.33MPa, and the impact absorption power of the Charpy V-shaped notch at the heat affected zone is 281.33 MPa; in the comparative example, the impact absorption work at the weld at the position of the Charpy V-notch was 34.33MPa, and the impact absorption work at the heat-affected zone at the position of the Charpy V-notch was 70.67 MPa.
From the test data of example 2 and comparative example, it can be seen that: the welding method provided by the invention can enable the strength and the notch resistance sensitivity of the welding joint to be higher than those of the existing SMAW method, and improve the welding quality.
In conclusion, the welding method combining the three methods of plasma, TIG and SAW solves the problems of assembly of the large-diameter thick-wall cylinder body with the diameter of more than 8mm and quality control of plasma and TIG welding.
Claims (6)
1. The utility model provides a hybrid welding method suitable for major diameter thick wall barrel more than 8mm which characterized in that: the hybrid welding method comprises plasma arc, TIG arc and SAW welding, and adopts a hybrid welding mode to butt joint grooves of a large-diameter thick-wall cylinder body with the diameter phi of 1000-3000 mm and the thickness of 8-25 mm; the method comprises the following steps:
a plasma and TIG welding device adopts a circumferential seam P and T welding system; the SAW welding device adopts a special cross arm submerged arc automatic welding machine, and the machine head is deeply inserted into the cylinder body for welding;
a) designing a composite welding groove of the large-diameter thick-wall cylinder according to the material and the wall thickness of a workpiece to be welded, and processing the groove into a reverse Y shape;
b) selecting the type of the welding wire, wherein the type of the welding wire is selected according to the thickness and the material of the barrel;
c) before welding, machining grooves on two sides of a welding seam of the cylinder body, cleaning impurities such as oil stains, burrs and the like in the two sides of the welding seam, and exposing the natural color of metal on the surface;
d) hoisting the cleaned workpiece to be welded to a roller frame, installing positioning supports on the inner walls of the cylinders at two sides, adjusting the distance between the two cylinders according to the assembly gap between the two cylinders read by the supporting sliding mechanism, adjusting the misalignment amount between the two cylinders by adjusting the cylinder supports to ensure that the welding seam gap and the misalignment amount of the workpiece to be welded meet the automatic welding requirement, fixing the positioning supports, and rounding the inner walls;
the positioning support consists of a cylinder support (1) and a support sliding mechanism (2):
the cylinder support comprises a support disc (3), a support plate (4a), an adjusting ring (5), an upper sliding block (6), a lower sliding block (7), a nut (8), a threaded rod (9), a support rod (4b), a guide plate (10), a guide rod (11), a limiting block (12), a fixing block (13), an arc plate (14) and a rotating handle (15), wherein the support disc (3) is circular, the adjusting ring (5) is arranged outside the support disc (3), the adjusting ring (5) is fixedly connected with the support disc (3) through the support plate (4a) in a welding way, 4 arc grooves are symmetrically formed in the periphery of the adjusting ring (5), an upper sliding block and a lower sliding block are arranged on two sides of the adjusting ring (5), the upper sliding block and the lower sliding block are rectangular blocks which are in contact with the arc shape of the bottom surface of the adjusting ring (5) and are far away from the horizontal hole of the bottom surface of the adjusting ring (5), and the lower sliding block (7) penetrates through the arc grooves to be in threaded connection with one end of the upper sliding block (6), the other end of the upper sliding block (6) is fixedly connected with a supporting rod (4b), the outside of the supporting rod (4b) is fixedly connected with a limiting block (12), a threaded rod (9) passes through the upper sliding block, the lower sliding block and the guide plate (10) to be rotatably connected with the limiting block (12), the lower end of the threaded rod is provided with a rotating handle (15), and is fixed by a nut (8), the threaded rod (9) can be provided with 8 groups, wherein 4 groups are connected with an adjusting ring (5) through an upper sliding block and a lower sliding block, the angle along the adjusting ring (5) is adjustable, the other 4 groups penetrate through the upper sliding block (6) and are arranged around the circle center of the adjusting circular ring (5) at equal included angles, the inner side of the limiting block (12) is connected with a guide rod (11) in a sliding mode, the tail end of the guide rod (11) is fixedly connected with a fixing block (13), and the upper end of the fixing block (13) is connected with an arc-shaped plate (14) in a threaded mode;
the supporting sliding mechanism (2) comprises a lead screw (17), the lead screw (17) penetrates through center holes of two cylinder supports arranged in a disc shape respectively, one end of the lead screw (17) is rotatably connected with a fixed block (16), the other end of the lead screw penetrates through a fixed disc (21) and is fixedly connected with a rocker arm (19), a bolt (20) is arranged at the lower end of the rocker arm (19) and used for stopping rotation, four guide rods (18) are connected in the two cylinder supports in a sliding mode, and the guide rods (18) are fixedly connected with the fixed block (16) and a supporting disc (3) of the right cylinder support (1 a); the uppermost guide rod (18) is provided with scale marks and scale numbers, and the minimum unit of the scale numbers is millimeter;
e) mounting a back protection tool or a dragging cover, wherein the form of the back protection tool or the dragging cover is determined according to the diameter and the wall thickness of the cylinder body, the width of the back protection tool or the dragging cover is generally 60-80 mm, the length of the back protection tool or the dragging cover is 100-120 mm, high-temperature-resistant cloth is pasted on the periphery of the dragging cover, a sealed protection cavity is formed with the cylinder body, the position of the groove is isolated from the outside air, the gas flow of an external protection cover is 10-15L/min, the inside and outside surfaces of a welding joint are filled with protection gas, the gas supply time is 3s in advance, and the gas circulation is continued for 15s after the arc is broken;
f) the cylinder is directly positioned at the outer side by manual TIG spot welding, the general penetration is about 2mm, the welding current is 100A, the length of a welding spot is about 5mm, the width of the welding spot is 3mm, the welding discontinuity is 100mm, the transition part between the head and the tail is polished into a smooth and gentle slope shape, and if cracks and other defects exist, the cylinder is thoroughly ground to be re-spot-welded;
g) setting welding process parameters before welding arcing;
the parameters of the automatic plasma welding process are set as follows: the central axis of the plasma welding gun is perpendicular to the tangent line of the circular seam, the distance between a conductive nozzle of the welding gun and a workpiece ranges from 10 mm to 15mm, the tungsten electrode contracts inwards by 2.8mm, the plasma welding gun does not swing, the ionic gas flow is 5L/min to 6L/min, the protective gas flow is 20L/min to 25L/min, the welding voltage is 29V to 31V, the welding current is 240A to 260A, the polarity of a welding power supply is direct current direct connection, and the welding speed ranges from 150 mm/min to 200 mm/min;
the parameters of the automatic TIG welding process are set as follows: the TIG welding gun is normal and vertical, the distance between a conductive nozzle of the welding gun and a workpiece ranges from 20mm to 30mm, the distance between a tungsten electrode and the workpiece ranges from 10 mm to 15mm, the TIG welding gun has swing, the yaw speed is 1500mm/min, the left swing distance is 2.3mm, the right swing distance is 2.3mm, the left stop time is 0.2s, and the right stop time is 0.2 s; the welding voltage is 17-19V, the welding current is 230-250A, the wire feeding speed is 1200-1500 mm/min, the polarity of a welding power supply is direct current positive connection, and the welding speed range is 160-200 mm/min;
the automatic SAW welding process parameters are set as follows: the distance between a conductive nozzle of a welding gun and a workpiece ranges from 32 mm to 40mm, the diameter of the SAW welding wire is selected according to the thickness of a cylinder, when the thickness of the cylinder is less than 12mm, the diameter of the welding wire is phi 3.2mm, the welding current is 380-420A, the welding voltage is 28-32V, and the linear energy is 12.77-20.16 KJ/cm; when the thickness of the cylinder body exceeds 12mm, the diameter of a welding wire is phi 4.0mm, the welding current is 500-550A, the welding voltage is 30-36V, the linear energy is 18.0-29.7 KJ/cm, the polarity of a welding power supply is direct current reverse connection, and the welding speed range is 400-500 mm/min;
h) when welding, the protective gas is communicated 3s in advance, plasma arc is adopted to weld the blunt edge on the front side of the weld seam without adding wires to perform backing welding, and TIG electric arc is used to add cold wires to fill the cover surface on the incomplete welding part; the back groove of the welding seam is firstly polished to have metallic luster by using a stainless steel special grinding wheel, then SAW is used for multi-layer and multi-pass welding, the temperature between layers is controlled to be not more than 150 ℃, considering that a skull is easy to fall off, the welding seam and impurities on two sides of the welding seam are not required to be polished by using a stainless steel wire brush after each layer of welding is finished, and whether polishing is carried out can be determined according to the fusion and forming conditions of the welding seam; during welding, starting a plasma arc, starting a TIG electric arc for welding after about 10s, starting a progressive arc quenching program when a plasma welding gun is welded and exceeds an arc striking point by 15-20 mm, and stopping the plasma arc firstly and stopping the TIG welding progressively after 10 s;
i) and cleaning the welded seam until the surface has metallic luster.
2. The hybrid welding method suitable for the large-diameter thick-wall cylinder with the diameter of more than 8mm according to claim 1, characterized in that: the material of the workpiece to be welded in the step (a) is stainless steel.
3. The hybrid welding method suitable for the large-diameter thick-wall cylinder with the diameter of more than 8mm according to claim 1, characterized in that: the inverted Y-shaped groove in the step (a) has a truncated edge thickness of 5mm and a groove angle controlled at 60-70 degrees.
4. The hybrid welding method suitable for the large-diameter thick-wall cylinder with the diameter of more than 8mm in the claim 1, wherein the shielding gas in the steps (e), (h) and (g) is 99.99% argon or 95% argon + 5% hydrogen with purity; and (h) performing automatic start-stop control on the plasma arc and the TIG electric arc, wherein the start and stop of the TIG electric arc are lagged by the plasma arc for 10 s.
5. The hybrid welding method suitable for the large-diameter thick-wall cylinder with the diameter of more than 8mm according to claim 1, characterized in that: and (d) the welding seam gap and the misalignment of the workpieces to be welded in the step (d) are not more than 0.5 mm.
6. The hybrid welding method suitable for the large-diameter thick-wall cylinder with the diameter of more than 8mm according to claim 1, characterized in that: and (d) arranging bolt holes matched with the positions of the rocker arm (18) and the mounting bolt (20) of the fixed disc (21) in the step (d).
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| CN117840590A (en) * | 2024-03-07 | 2024-04-09 | 成都天成电科科技有限公司 | Method for protecting inner cavity chip during laser re-welding and laser re-welding system |
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