CN1152766C - Casting hole welding-on method and special welding-on machine - Google Patents
Casting hole welding-on method and special welding-on machine Download PDFInfo
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- CN1152766C CN1152766C CNB021324999A CN02132499A CN1152766C CN 1152766 C CN1152766 C CN 1152766C CN B021324999 A CNB021324999 A CN B021324999A CN 02132499 A CN02132499 A CN 02132499A CN 1152766 C CN1152766 C CN 1152766C
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Abstract
The present invention discloses a welding repair method for casting holes and a special welding repair machine. The method is finished by the automatic welding repair machine with high current and low voltage; the method comprises the following operation steps: filling rods are clamped on a welding gun, and the materials of the filling rods are the same as that of castings; then, the welding gun aims at casting holes to carry out welding repair; a contact surface is instantly melted under the condition of gas protection; the upset forging is carried out, and the melted metal is pushed in the holes; and the superfluous liquid metal is pushed out. The method has the advantages of no difference of materials, high intensity, small heat affected zone and no deformation or cracks. The welding repair machine used by the present invention is characterized in that the welding repair machine is provided with a biasing preventing circuit of an inversion high-frequency transformer to prevent the damage of the welding repair machine in work with high current. In addition, arcing time controlling signals from an arcing time relay are added to the pin 1 of an SG3525 chip of a pulse width modulating circuit so that the strong welding current is easily controlled to be switched on or off. The welding gun is provided with a gas protection device so that protective gases are transported to the welding repair zone during welding repair.
Description
Technical field
The present invention relates to a kind of repair method of casting hole, also relate to a kind of special-purpose welding repair machine of realizing that this method is used.
Background technology
The eyelet that foundry goods after the eyelet of cast(ing) surface and the processing is come out, generally be by pore that produces in the casting process or sand hole, belong to casting flaw, the necessity that repairing is arranged that has, generally adopt methods such as manual electric arc welding, argon tungsten-arc welding to carry out soldering at present both at home and abroad, it is big that but said method exists the material difference of soldering position and matrix, the soldering position easily produces the metallographic structure of dendrite, and make it be difficult for processing, often before machining, to anneal, improve processing cost virtually; And the heat affected area of said method is excessive, and postwelding is yielding, often causes being become waste product by the foundry goods of soldering.
Summary of the invention
The objective of the invention is to provide a kind of repair method of casting hole, this method can realize casting hole soldering intensity height, indeformable, the effect that do not ftracture, do not have material difference, the no white structure of ironcasting is produced.
A further object of the present invention provides a kind of special-purpose welding repair machine of realizing that said method is used; this welding repair machine has the output of low-voltage and high-current high power; and tool inversion high frequency transformer magnetic bias prevents circuit, reaches the safeguard protection to the output of welding repair machine low-voltage and high-current high power.
The repair method of the present invention's casting hole is operated according to the following steps:
1, to be processed into drift angle with electric drill be 120 ° conical groove to the casting hole that will treat soldering, gets and the identical blank of part material of feeding a casting to be welded, is processed into that the end is identical with the groove shape, length is that charge bar is filled in soldering about 3cm;
2, will fill the charge bar clamping on the welding gun of special-purpose welding repair machine;
3, special-purpose welding repair machine is connected on the power supply of three-phase 380V, 50kw capacity, the soldering parameter of adjusting welding repair machine then is as follows: welding current 1000～1500A; Weldingvoltage 18～22V; Arc time 20～40ms; Shield gas flow rate 8～12L/min;
4, then welding gun is picked up, will be clamped in the eyelet of the filling charge bar aligning foundry goods on this welding gun, pull the start button of welding gun, welding repair machine is finished ventilation, arcing, arcing, blow-out, pressurization upset, homing action automatically.
5, after the casting hole soldering finishes, will fill the charge bar the raised area and knock out, be polished into identical then with sanding machine with the peripheral region complexion.
The intact foundry goods of this method soldering can directly carry out machining, without any need for heat treatment.
The operation principle of this method is as follows:
This method is passed through in low-voltage, big electric current, under the short period condition, packing material and (be generally 10 microsecond levels) at short notice by the electric arc between the welding repair material and produce huge heat, make packing material (adopt with by the identical material of welding repair material) and melted by the corresponding surface of salvaging casting, in the process that packing material after this presses down, the liquid metal of fusing is extruded, local plastic deformation and chemical analysis diffusion take place in the soldering position, reach the atom combination, this method firing rate is fast, cooling velocity is fast, make the crystal grain refinement greatly of the heat affected area of soldering district and soldering, particularly can not form white structure to ironcasting, whole welding repair process is finished under the automatic control of special-purpose welding repair machine.This method has been avoided the shortcoming of aforementioned existing casting hole restorative procedure, has that no material difference, intensity height, heat affected area are little, the advantage of no strain cracking.
The structure that realizes the special-purpose welding repair machine of the inventive method is, this welding repair machine is by Arc Welding Power, logic control circuit and arc stud welding welding gun constitute, wherein, Arc Welding Power is made of IGBT (ambipolar insulation gate pole FET) full-bridge inverting main circuit, the electric arc that meets the demands power is provided, it is characterized in that, have inversion high frequency transformer magnetic bias and prevent circuit, this magnetic bias prevents that circuit from being to be made of two comparators in the CA124 chip that is installed on Hall current sensor on two brachium pontis of inverter main circuit and the output voltage signal that compares the two-way Hall current sensor, the output control signal that magnetic bias prevents circuit by the two of 7408 chips with respectively with PWM (pulsewidth modulation) circuit in two output pins 11 of SG3525 chip, 14 output signal is done and computing, by the HCC40106BF chip two-way pulsewidth modulation signal converting is become two-way positive pulse and two-way negative pulse afterwards, output to 4 IGBT driver element circuit respectively, the action of control inverter main circuit makes the high frequency transformer reliable operation; Open-loop control circuit such as logic control circuit comprises ventilation, arcing, arcing, blow-out, pressurization upset, reset, and guarantee holding circuit that welding machine runs well, keep welding current and the stable two close loop negative feedback circuit of weldingvoltage, the arc time control signal that is characterized in coming from the arc time relay is added to 1 pin of SG3525 chip in the pwm circuit, makes the break-make control of powerful welding current easier; Welding gun then is the executing agency of welding repair machine, and is basic identical with common arc stud welding welding gun, and different is to have gas shield device, and the upset force of upset spring is bigger.
Description of drawings
Fig. 1 is the pulse-width modulation circuit figure of the present invention's special-purpose welding repair machine.
Fig. 2 is the drive circuit figure of the present invention's special-purpose welding repair machine.
Fig. 3 is the circuit block diagram of the present invention's special-purpose welding repair machine.
Fig. 4 is the inverter main circuit figure of the present invention's special-purpose welding repair machine.
Fig. 5 is the operation chart of the present invention's method.
The specific embodiment
See also shown in Figure 5ly, the present invention's method is operated according to the following steps:
1, to be processed into drift angle be 120 ° conical groove to the eyelet 3 usefulness electric drills that will treat the foundry goods 1 of soldering, gets and the identical blank of part material of feeding a casting to be welded, is processed into that the end is identical with the groove shape, length is that charge bar 2 is filled in soldering about 3cm;
2, will fill charge bar 2 clampings on the welding gun of special-purpose welding repair machine;
3, special-purpose welding repair machine is connected on the power supply of three-phase 380V, 50kw capacity, the soldering parameter of adjusting welding repair machine then is as follows: welding current 1000～1500A; Weldingvoltage 18～22V; Arc time 20～40ms; Shield gas flow rate 8～12L/min;
4, then welding gun is picked up, the eyelet 3 of the filling charge bar 2 aligning foundry goods 1 on this welding gun will be clamped in, pull the start button of welding gun, welding repair machine is finished ventilation, arcing, arcing, blow-out, pressurization upset, homing action automatically, melt metal is extruded in the eyelet 3, unnecessary liquid metal is extruded, formed overlap 4;
5, after 3 soldering of foundry goods 1 eyelet finish, will fill charge bar 1 the raised area and knock out, be polished into identical then with sanding machine with the peripheral region complexion.
The intact foundry goods 1 of this method soldering can directly carry out machining, without any need for heat treatment.
This method firing rate is fast, and cooling velocity is fast, and weldering is distinguished and the crystal grain refinement greatly of the heat affected area 5 of soldering, can not form white structure for ironcasting especially, and whole welding repair process is finished under the automatic control of special-purpose welding repair machine; This method has been avoided the shortcoming of existing casting hole restorative procedure, has that no material difference, intensity height, heat affected area are little, the advantage of no strain cracking.
See also Fig. 1, Fig. 2, Fig. 3, shown in Figure 4, the structure that realizes the special-purpose welding repair machine that the inventive method is used is, this welding repair machine is by Arc Welding Power, logic control circuit and arc stud welding welding gun constitute, wherein, Arc Welding Power is made of IGBT (ambipolar insulation gate pole FET) full-bridge inverting main circuit 8, the electric arc that meets the demands power is provided, it is characterized in that, have inversion high frequency transformer magnetic bias and prevent circuit 6, this magnetic bias prevents that circuit 6 from being to be made of two comparators 62 in the CA124 chip that is installed on Hall current sensor 61 on 8 two brachium pontis of inverter main circuit and the output voltage signal that compares two-way Hall current sensor 61, the output control signal that magnetic bias prevents circuit 6 by the two of 7408 chips with respectively with PWM (pulsewidth modulation) circuit in two output pins 11 of SG3525 chip, 14 output signal is done and computing, by the HCC40106BF chip two-way pulsewidth modulation signal converting is become two-way positive pulse and two-way negative pulse afterwards, output to 4 IGBT driver element circuit 7 respectively, the action of control inverter main circuit 8 makes the high frequency transformer reliable operation; Open-loop control circuit such as logic control circuit comprises ventilation, arcing, arcing, blow-out, pressurization upset, reset, and guarantee holding circuit that welding machine runs well, keep welding current and the stable two close loop negative feedback circuit of weldingvoltage, be characterized in, the arc time control signal that will come from the arc time relay is added to 1 pin of SG3525 chip in the pwm circuit, makes the break-make control of powerful welding current easier; Welding gun then is the executing agency of welding repair machine, and is basic identical with common arc stud welding welding gun, and different is, this welding gun has gas shield device, and the upset force of upset spring is bigger.
Claims (2)
1, the repair method of casting hole, this method is operated according to the following steps:
(1) to be processed into drift angle with electric drill be 120 ° conical groove to the casting hole that will treat soldering, gets and the identical blank of part material of feeding a casting to be welded, is processed into that the end is identical with the groove shape, length is that charge bar is filled in soldering about 3cm;
(2) will fill the charge bar clamping on the welding gun of special-purpose welding repair machine;
(3) special-purpose welding repair machine is connected on the power supply of three-phase 380V, 50kw capacity, the soldering parameter of adjusting welding repair machine then is as follows: welding current 1000～1500A; Weldingvoltage 18～22V; Arc time 20～40ms; Shield gas flow rate 8～12L/min;
(4) then welding gun is picked up, will be clamped in the eyelet of the filling charge bar aligning foundry goods on this welding gun, pull the start button of welding gun, welding repair machine is finished ventilation, arcing, arcing, blow-out, pressurization upset, homing action automatically.
(5) after the casting hole soldering finishes, will fill the charge bar the raised area and knock out, be polished into identical then with sanding machine with the peripheral region complexion.
2, realize the special-purpose welding repair machine of the described method of claim 1, it is characterized in that: this welding repair machine is by Arc Welding Power, logic control circuit and arc stud welding welding gun constitute, wherein, Arc Welding Power is made of IGBT full-bridge inverting main circuit, its magnetic bias that is provided with the inversion high frequency transformer prevents circuit (6), this magnetic bias prevent circuit (6) be by be installed on (8) two brachium pontis of inverter main circuit Hall current sensor (61) and relatively two comparators (62) in the CA124 chip of the output voltage signal of two-way Hall current sensor (61) constitute, the output control signal that magnetic bias prevents circuit (6) by the two of 7408 chips with respectively with pulse-width modulation circuit in two output pins 11 of SG3525 chip, 14 output signal is done and computing, by the HCC40106BF chip two-way pulsewidth modulation signal converting is become two-way positive pulse and two-way negative pulse afterwards, output to four driver element circuit (7) respectively; The arc time control signal that comes from the arc time relay is added to 1 pin of SG3525 chip in the pulse-width modulation circuit; Open-loop control circuit such as logic control circuit comprises ventilation, arcing, arcing, blow-out, pressurization upset, reset, and guarantee holding circuit that welding machine runs well, keep welding current and the stable two close loop negative feedback circuit of weldingvoltage, the arc time control signal that is characterized in coming from the arc time relay is added to 1 pin of SG3525 chip in the pwm circuit, makes the break-make control of powerful welding current easier; The welding gun of welding repair machine has gas shield device.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CNB021324999A CN1152766C (en) | 2002-06-27 | 2002-06-27 | Casting hole welding-on method and special welding-on machine |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CNB021324999A CN1152766C (en) | 2002-06-27 | 2002-06-27 | Casting hole welding-on method and special welding-on machine |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN1387973A CN1387973A (en) | 2003-01-01 |
| CN1152766C true CN1152766C (en) | 2004-06-09 |
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| Application Number | Title | Priority Date | Filing Date |
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| CNB021324999A Expired - Fee Related CN1152766C (en) | 2002-06-27 | 2002-06-27 | Casting hole welding-on method and special welding-on machine |
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Families Citing this family (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102266935B (en) * | 2011-06-29 | 2014-08-27 | 章祖文 | Casting device composed of alternated current/direct current gas shielded electric welder and mobile intermediate frequency mould |
| US9085042B2 (en) * | 2012-08-10 | 2015-07-21 | Siemens Energy, Inc. | Stud welding repair of superalloy components |
| CN104607863A (en) * | 2014-12-10 | 2015-05-13 | 湘潭锅炉有限责任公司 | Iron casting mold repair welding method |
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- 2002-06-27 CN CNB021324999A patent/CN1152766C/en not_active Expired - Fee Related
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