CN1158096A - 内部增强的焊接管的制造 - Google Patents

内部增强的焊接管的制造 Download PDF

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CN1158096A
CN1158096A CN95194883A CN95194883A CN1158096A CN 1158096 A CN1158096 A CN 1158096A CN 95194883 A CN95194883 A CN 95194883A CN 95194883 A CN95194883 A CN 95194883A CN 1158096 A CN1158096 A CN 1158096A
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迈伦·兰德莱特
杰罗姆·M·杜皮
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Abstract

在使已增强的金属带(72，74，76)形成管状并焊接起之前，用一***件(80)对其两边缘整形。此金属带的两边缘整形成使得此带的未增强部(76)的这两个纵向边缘在焊接作业中能够触合，而得以减少焊接位置处金属体积波动导致的不稳定性。

Description

内部增强的焊接管的制造
本发明涉及用来制造内部增强的焊接的热交换管的方法。具体地说，本发明涉及对板的边缘整形来控制焊缝的流变。
在将金属带形成管时，是使其通过成型辊和翅件通过辊，将此带变形成开缝的管状而以两相对的纵边紧邻。然后使此带通过焊接站焊合这对纵边而形成管件。
焊接之后，通常使此管通过至少一组定径轧辊使其形成所需的直径。用来将管变换成焊接管的方法与设备已公开于下述美国专利中：Schatz等，3700158号；Yamamoto等，4697446号；Hellman，Sr.4905885号。
在许多热交换器的应用中，管壁是通过设置有结构的表面增强。已知有种种增强构型能改进热交换管的性能。这类构型包括Mclain于美国专利3861462号中公开的波纹状的脊以及Sukumonda等于美国专利5052476号中公开的梨形沟。
焊接管制造中的问题之一是挤突出的焊缝。从焊缝处流出有过剩的焊料，聚结于管的内、外壁上。除去这类焊珠一般要牵涉到除掉某些基料。虽然从未增强的(光滑的)管壁上除去某些基料是可以接收的，但是从已增强的表面作这样的除料时，就会在焊接区损伤增强结构而使管子的性能降低。
在钢管制造中用来除去焊珠的一种方法最初公开于美国专利2352306号中。这是在紧接焊接之后于焊珠还很热时将氧气喷嘴对向焊珠。此焊珠则烧热而形成光滑的焊缝。美国专利4905885号中公开了一种液压控制的焊珠减小辊和使焊珠变平的支承辊。另一种方法则是采用切削工具。
当管壁增强后，先有技术的除去焊珠的方法是不适当的。用机械平匀化的方法会损害增强的结果。增强的结构会使氧气流偏转而使焊珠不适当地烧燃。切削的结果将损坏部分增强构型。
为此，本发明的目的之一在于提供不需消除焊珠的焊接管的制造方法与制造设备。本发明的特点之一是将一种翅状***件按特定的角度，在焊珠对热交换器的效率影响最小处指向焊珠。
本发明的优点之一是形成了焊珠减小了的焊接管。本发明的另一优点是提高了焊接稳定性。
根据本发明，提供了用来从金属带来制造焊接管的翅状***件。这种翅状***件的第一部分具有相对于此***件轴线的第一角，而其第二部分则具有相对于此***件的第二角。此第二角小于第一角。
上述的目的、特点与优点可从下面的说明与附图中获得更清楚的理解。
图1是根据先有技术用来制造焊接管的金属带的等角图。
图2是根据先有技术在将金属带形成管子的初期阶段所用辊对的部分横剖图。
图3是根据先有技术的***件的横剖图。
图4是根据先有技术的高频焊接辊对的横剖图。
图5以横剖图表示翅状***件角为零度时的焊接管。
图6以横剖图表示翅状***件角为12°时的焊接管。
图7表明形成具有内部增强表面的焊接管所用金属带的等角图。
图8以横剖图表明依据本发明第一实施例的翅状***件。
图9以横剖图表明用图8的翅状***件所实现的焊接。
图10以横剖图表明依据本发明第二实施例的翅状***件。
图11以横剖图表明用图10的翅状***件所形成的焊珠。
图12以等角度表明两侧增强了的金属带。
图13是用来形成具有增强表面的焊接管的金属带的顶视平面图。
图14以横剖图表明依据本发明第三实施例的翅状***件。
图15以横剖图表明用图14的翅状***件所形成的焊珠。
图1以等角图表明了根据先有技术用来制造焊接管的金属带10。金属带10的宽度略大于所需管的周长。金属带10可用任何适于焊接的金属或合金制成。在用于热交换目的时，这种管通常用铜基合金、铝基合金、不锈钢或钛。
金属带10通过图2所示和根据先有技术已知的成形辊形成弧形。此种成形辊一般包括：第一成形辊12，它呈凹形，用来逐渐地确定金属带10应取的外径；第二成形辊14，它呈凸形，用来逐渐地限定金属带10应取的内径。
用一列成形辊将金属带10转变成图3所示的，先有技术中已知的开缝管。金属带10的两个纵边18由翅件通过辊16带到互相对准和紧密邻接。这种上部翅件通过辊16连带着翅状***件20。此翅状***件给纵边18整形，给这对边形成了供焊接用的一致外观。翅状***件30使金属带10的两纵边10形成所需的角“θ”。θ在传统上是从0°至约15°，而典型的情形是约12°。这一角度取决于管径与翅件(边缘)宽度两者。
在使金属带10的纵边18整形之后，由图4所示先有技术的焊接辊22将此两纵边带到一起。用高频感应或电阻型加热方式将两纵边18加热到其熔化温度。焊接辊22促致这对纵边18相互触合。熔融的纵边熔合成焊缝24。过剩的熔融金属从焊缝挤出，并在管的内、外壁上堆积成焊珠32、34，如图6所示。
有一或多组定径轧辊(未示明)可随焊接辊运动，以确保这样焊接成的管能变成所需直径的最终圆管。
翅状***件的角θ影响着焊缝24。图5表明由具有0°角的翅状***件所形成的焊缝。与管子的外壁26邻接的焊缝24很结实，形成了良好的结合。与内壁28邻接的焊缝由于带的纵边在焊接辊作用下不具有恰当的外形是不完全的。无焊缝区30在焊接管的内壁上形成了凹坑。这种凹坑减弱了焊缝强度，会在通过管的液体中形成流体扰动。过剩的金属只有从形成管子外壁26上的焊珠21的焊缝处向外挤出。
当翅状***件的角度约为12°时，可以得到如图6所示的焊缝24。此焊缝24从管的外壁26到内壁28都是一致的。从管的内、外壁都延伸出有焊珠31、32。焊珠31用传统的方法例如烧剥方法清除。焊珠32必须清除以免液体通过热交换管时发生紊流。当焊接管的内表面28光滑且管子的内径大例如大于约8.25mm(0.325英寸)时，清除焊珠32并不困难。可用芯轴或其它机械装置通过管的内孔以剔平此焊珠或通过烧剥方法将其除去。
虽然用传统的方法能从具有光滑内孔的大直径焊接管中除去焊珠32，但当内壁28业已经过增强处理，若不除去增强内壁的一部分就难以除去此焊珠。这最好是在使管子的金属保持完整焊接的同时，将过多的金属引到焊管的外壁26之上，以使焊珠32的形成减至最小。
图7以等角图表明用来形成内部增强的焊接管的金属带34。增强部36可以用铣削、烧剥、其它的精减处理或通过滚轧成形而形成。在滚轧成形中，使金属带通过一对辊，其中的至少一个辊构型成能将所需的结构压印到此带的表面上。图7所示的金属带34具有增强表面38和光滑表面39。在形成管件时，金属带34变形成管状形式而以增强表面38形成内壁。
图8以横剖图表明了依据本发明第一实施例的翅状***件40。翅状***件40使波纹状金属带34的两个边缘42上形成分开的角。此翅状***件的第一部分相对于此***件的中央轴线45构成第一角44。
在此整个说明书中，所有的角都是按顺时针走向从中央轴线部分到相邻的管的外壁计算的。
第一角44可取大于零的任意值。最好，第一角44是从约6°至约8°，而更好是从约10°至约15°。当管径约16mm(0.625英寸)时，第一角44的上述最佳值是极为有效的。此种最佳值对于其它管径可有稍许不同。此第一角实质上确定了带的未增强的部分46的形状。
翅状***件40的第二部分49形成了由此***件40的第二部分49与中央轴线45所确定的角48。此第二角48确定了带的增强部50的边缘形状。(由180°减去此第二角的)这一值小于第一角但等于或大于零。此第二角最好是从约175°至约180°。
第一角44确定了已增强的带34的底部46的边缘形状，第二角48确定了此带的增强部50的边缘形状。转折点52并不一定要是上述增强部与底部的交点。第一角44最好确定带的底部的从约20％至约100％的形状。而更好是，此第一角44确定了上述底部的从约60％至约100％的形状。类似地，第二角48最好应确定带的增强部从约20％至约100％的，而更好是此增强部的从约75％至约100％的形状。
图9以横剖图表明由此种翅状***件所形成的焊缝54。焊缝54在整个的底部上形成了一致的牢靠的焊接，而在增强部中形成了小的无焊缝区。焊缝54形成了干扰通过此管内液体流的最小的内部焊珠。无焊接区30小于已增强表面上的沟槽，使得对液体流动的影响最小。外部焊珠31易于除去而不会损伤增强构型或结构。
图10表明依据本发明第二实施例的翅状***件60。翅状***件60与上一实施例中的类似具有取正值的第一角44。第二角48’可取小于180°的任何角度。此第二角最好是从约170°至约180°而更好是从约175°至约179°。在增强部50终止的区域中的转折段52’使此翅状***件从正值的第一角44转变到具有小的零度区的第二角48’。此零度区的长度最好相当于底部金属的未增强部的从约10％至约30％的厚度。
如图11的横剖图所示，第一角在金属带34的底部46中形成了结实的焊珠62。第二角使增强区中的材料挤出，使得焊缝在转折段52”中的这一头逐渐变细，而在增强部50的第二角度段48”中无焊缝。应用这种翅状***件形成了对增强结构影响极小的焊缝62。流过此第二实施例有关焊接管的流体是与一致的表面相接触，所受焊珠或未焊接段的干扰最小。不需为除去内部焊珠作任何加工。
上面虽然是就具有内部增强表面的焊接管来描述本发明，但本发明同样适用于内、外表面都增强了的焊接管。此外，本发明的上述翅状***件构型特别适用于难从其中除去焊珠的小孔焊接管。
图12以部分横剖图示明了一种金属带70，在其第一侧上形成有第一增强部72。上述金属带的第一侧确定为形成管子外壁的这一侧。在金属带70的第二侧上形成了第二增强部74。在第一增强部72与第二增强部74之间设有未增强的底部金属段76。此第一与第二增强部未必相同。在一个增强部中可以包括有在表面之下的终结于小表面孔隙的通道，以促进泡核沸腾。另一增强部则可取截锥形以增强紊流。
第一增强部72、底段76、第二增强部74的横剖面厚度分别以“a”、“b”、“c”标明，如图12所示。
当增强的金属带形成为弧形时，如果此两个增强部沿着两纵边对准，从各边缘的有一致体积的金属便形成了焊缝。但要是金属的体积沿着纵边改变而形成一种螺旋式增强部时，沿着纵边的变动着的厚度就会使可用作电接触的金属表面量发生波动。这种变动的荷载便构成了不稳定的焊接条件。图13以顶视平面图表明了这种增强了的金属带77。此金属带的厚度在高区域81与下凹区域(带点的区域)83中是交替变化的。没有本发明的翅状***件时，将带77的两个纵边焊接就会引起电性质的波动和焊接的不稳定。
如图14所示，通过对金属带的两纵边作合适的整形，底段76就会在焊缝中占主要地位，而焊接增强部时对焊接稳定性的影响可减至最小。为了保证底段76能完全焊接，使增强段的一小部分78整形成具有与底段76相同的角度。这一小部78是取自任一已增强区域，而最好是使取自第一增强区域72和取自第二增强区域74的基本上等同。结果，金属带的整形成具有与底段76相同角度这部分的长度b’便从约(b＋0.05a＋0.05c)到约(b＋0.2a＋0.2c)。b’的长度增加了从a的长度的5％加c的长度的50％到a的长度的20％加c的长度的20％。而最好是，b’从约(b＋0.08a＋0.08c)到约(b＋0.12a＋0.12c)。
翅状***件80使底段76整形成一角α，角α相对于中央轴线82依顺时针走向测量由管子的外壁起计算是从约5°至约30°，而更好是从约10°至约20°。
翅状***件80与第一增强部72之间的角β的度数是从约(α＋1°)至约(α＋15°)，而更好是从约(α＋2°)至约(α＋10°)。第二增强部74最好整形成基本上与中央轴线82平行。
当如图15所示，金属带70的两边缘在焊接辊操作下带到一起时，b’表面便完全接触在加热时进行焊接。焊珠84流入外部间隙86与内部间隙88之中，至少是部分地充填这两个间隙但不延伸到超过焊接管的内径或外径。最好是翅状***件能将两纵边整形为，使得内部间隙88的容积略大于排入相应间隙内的焊珠的体积。
显然，依据本发明业已提供了能完全实现前述目的一装置与优点的形成内部增强的焊接管的方法。尽管本发明是结合它的特定实施例作了说明，但显然，内行的人借鉴以上所述是可以了解到有关的种种其它形式、改型与变体的。因此，应该把所有这种其它形式、改型与变体视作为包括在后附权利要求书的精神与其宽广范围内。

Claims (9)

1.由具有相对的第一表面(38)与第二表面(39)的金属带(34)来制造内部增强的焊接管的方法，特征在于，此方法包括下述步骤：
a)在金属带(34)的至少是第一表面(38)上形成构型(36)；
b)将金属带(34)形成管状，以第一表面(38)形成内壁(50)；
c)使金属带(34)通过连带有翅状***件(60)的翅件通过辊，将金属带(34)的两个纵边整形成至少取两个不同角(44，48’)，其中所述纵边的与第二表面(39)邻接的第一部分相对于翅状***件(60)的中央轴线整形成第一角(44)，而此纵边的与第一表面(38)邻接的第二部分则整形成第二角(48’)，这里的第一角(44)大于(180°-第二角(48’))；
d)使金属带(34)的所述边缘触合；以及
e)使上述边缘焊接到一起(54)。
2.如权利要求1所述方法，特征在于：第一部分(38)整形成具有相对于所述中央轴线从约6°至约18°的角(44)，而第二部分(39)整形成具有相对于此中央轴线从约175°至约180°的角(48’)。
3.由金属带(70)制造内部增强焊接管的方法，特征在于，此方法包括下述步骤：
a)在金属带(70)的第一侧上形成第一增强部(72)，此第一增强部(72)  所具的横剖面厚度记为“a”；
b)在金属带(70)的相对的第二侧上形成第二增强部(74)，此第二增强部所具的横剖面厚度记为“c”，其中在第一增强部(72)与第二增强部(74)之间设有横剖面厚度记为“b”的未增强的底段(76)；
c)使金属带(70)形成管状，以第一侧壁(72)形成外壁；
d)使金属带(70)通过连带有翅状***件(80)的翅件通过辊，将金属带(70)的两个纵边整形成至少三个不同的角，其中的底段(76)整形成具有相对于翅状***件(80)的中央轴线(82)从约5°至约30°的角“α”，与第一增强部(72)相邻的部分相对于中央轴线(82)整形成具有从约(α＋1°)至约(α＋15°)的角“β”，而与第二增强部(74)相邻的部分则基本上与中央轴线(82)平行；
e)使金属带(70)的两个边缘相接触，以及
f)使上述两边缘焊接到一起(84)。
4.如权利要求3所述方法，特征在于：所述纵边的部分(76)整形成具有从约(b＋0.05a＋0.05c)至约(b＋0.20a＋0.20c)长度的角“α”。
5.如权利要求4所述方法，特征在于“α”是从约10°至约20°。
6.如权利要求4或5所述方法，特征在于：“β”是从约(α＋2°)至约(α＋10°)。
7.焊接的金属管，特征在于：此金属管有：
带有一批沟槽的内部增强的内壁(50)，和凹入这些沟槽内的焊缝(62)。
8.如权利要求7所述焊接管，特征在于：形成所述管的材料是选自铜、铝、铜合金、铝合金、不锈钢与钛中的一种。
9.如权利要求8所述焊接管，特征在于：所述的管基本上没有延伸超过此管内径或外径的焊珠。
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