Aluminum alloy semi-automatic and automatic vertical position butt welding method

Abstract

The application provides an aluminum alloy semi-automatic and automatic vertical plus horizontal butt welding method, which comprises the following steps: determining welding equipment and welding materials; opening a welding groove at the butt joint of the aluminum alloy and assembling the aluminum alloy to be welded, and installing the welding equipment at a preset position; performing positioning welding to fix the assembly of the aluminum alloy to be welded; and performing formal welding, which comprises the following steps: firstly, adopting semi-automatic vertical welding to weld 2-3 welds on the front surface, and adopting a milling cutter to clean the root of the weld by 1-2 mm; secondly, adopting automatic horizontal welding to weld one weld on the back surface; the welding parameter of semi-automatic welding is 120-180 A, 17-22 V and the welding speed is 15-25 cm / min; the welding parameter of automatic welding is 120-180 A, 17-22 V and the welding speed is 40-50 cm / min; the swing range of the welding gun of automatic welding is 1.0-1.5 mm, the swing frequency is 30-40 times / min, and the included angle between the welding gun and the welding piece is kept between 60°-70°. The method adopts semi-automatic and automatic vertical plus horizontal welding process, and the welding process has no burning-through problem, the weld surface is well formed, there are no defects such as edge biting and cracks, the welding deformation is small, and the efficiency is high.

Description

TECHNICAL FIELD

[0001] The application relates to the technical field of aluminum alloy welding, in particular to a semi-automatic and automatic overhead horizontal-vertical butt welding method for aluminum alloy. BACKGROUND

[0002] The 5083 aluminum alloy is a typical aluminum-magnesium aluminum alloy, has excellent seawater corrosion resistance, good weldability and mechanical properties, and is widely used in high-speed ships. At present, the deck and outer plate structure of the ship main hull mainly adopts 4-8mm thick 5083 aluminum alloy plates. The above-mentioned aluminum alloy plates are relatively thin and are prone to deformation during welding operation. However, due to the non-magnetic characteristics of aluminum alloy materials, the semi-automatic gas shielded welding process is still commonly used for welding during the total assembly welding of ship sections. The semi-automatic gas shielded welding process has the problems of large workload and low efficiency. Moreover, the unstable welding process of semi-automatic welding easily causes welding deformation and weld quality problems. SUMMARY

[0003] The purpose of the embodiment of the application is to provide a semi-automatic and automatic overhead horizontal-vertical butt welding method for aluminum alloy, which has the characteristics of high welding efficiency, stable welding process and small welding deformation.

[0004] The application provides a semi-automatic and automatic overhead horizontal-vertical butt welding method for aluminum alloy, which comprises the following steps:

[0005] Firstly, welding equipment and welding materials are determined;

[0006] Secondly, a welding groove is formed at the butt joint of the aluminum alloy, and the aluminum alloy to be welded is assembled, and the welding equipment is installed at a preset position;

[0007] Thirdly, positioning welding is performed to fix the assembly of the aluminum alloy to be welded;

[0008] Fourthly, formal welding is performed, including adopting semi-automatic overhead welding for 2-3 welding passes on the front surface, and adopting a milling cutter to clean the root of 1-2mm after welding; and adopting automatic horizontal welding for 1 welding pass on the back surface to seal the bottom; the semi-automatic welding parameters are 120-180A, 17-22V and a welding speed of 15-25cm / min; the automatic welding parameters are 120-180A, 17-22V and a welding speed of 40-50cm / min; the welding gun of the automatic welding device is swung at an amplitude of 1.0-1.5mm, a frequency of 30-40 times / min, and an angle between the welding gun and the welding piece is kept at 60°-70°.

[0009] In an embodiment, the welding equipment comprises an automatic welding equipment, the automatic welding equipment comprises a walking track, a suction cup, a trolley and a welding torch; the welding equipment installation at a preset position comprises installing the walking track parallel to the welding seam of the aluminum alloy to be welded, adsorbing the walking track on the surface of the aluminum alloy through the suction cup, installing the trolley on the walking track, clamping the welding torch on the clamping end of the trolley, and adjusting the welding torch to a preset clamping angle.

[0010] In an embodiment, in the second step, the welding groove adopts a Y type, a single side is inclined by 25°, a root gap of 0-1 mm is left, and a backing pad is arranged at the bottom of the welding groove.

[0011] In an embodiment, before the third step, the method further comprises cleaning the oxides and oil stains within a range of 20-30 mm on both sides of the welding groove to expose the metal of the aluminum alloy butt joint, and drying the water vapor at the welding groove.

[0012] In an embodiment, the positioning welding adopts gas shielded spot welding, the positioning welding adopts the same welding process as the formal welding, the spot welding interval is 150 mm, and the welding length of each welding spot is 20-30 mm.

[0013] In an embodiment, the welding material comprises an aluminum alloy, a welding wire and a shielding gas, the aluminum alloy is 5083 aluminum alloy with a tensile strength ≥ 305 MPa, and the plate thickness ranges from 4 mm to 8 mm; the welding wire adopts Φ1.2 mm ER5183 welding wire with the same strength as the aluminum alloy, and the shielding gas adopts 75% He+Ar gas, and the gas flow is 15-25 L / min.

[0014] In an embodiment, the welding equipment further comprises a semi-automatic welding machine, the semi-automatic welding machine can control the welding current, the arc voltage, the welding speed and the wire feeding speed.

[0015] In an embodiment, the assembly gap of the aluminum alloy to be welded is 0-2 mm.

[0016] In an embodiment, the semi-automatic welding machine adopts Fronius TPS500i welding machine.

[0017] The aluminum alloy semi-automatic and automatic vertical welding method has the following beneficial effects:

[0018] 1. The application proposes a semi-automatic and automatic vertical and horizontal welding process method for 4-8mm aluminum alloy ship structure material section assembly, which overturns the traditional semi-automatic welding process and innovatively adopts semi-automatic-vertical and horizontal butt welding process to accurately control key technologies such as weld back cleaning and bottom welding. This process solves the problems of difficult control of 4-8mm 5083 aluminum alloy section assembly welding deformation and low production efficiency.

[0019] 2. The automatic welding process can greatly improve the welding efficiency, improve the labor conditions of shipbuilding, reduce the cost, and improve the weld quality and stability, and reduce the welding deformation.

[0020] 3. The application is suitable for 4-8mm thick 5083 aluminum alloy sheet section assembly welding, and the construction process is simple, easy to popularize and apply, and can be used as a guiding process for 4-8mm 5083 aluminum alloy section assembly welding. BRIEF DESCRIPTION OF DRAWINGS

[0021] In order to more clearly illustrate the technical solutions of the embodiments of the application, the following will briefly introduce the drawings needed to be used in the embodiments. It should be understood that the following drawings only show some embodiments of the application, and therefore should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can also be obtained without creative labor.

[0022] Figure 1 A flowchart of an aluminum alloy semi-automatic and automatic vertical and horizontal butt welding method according to an embodiment of the application is shown.

[0023] Figure 2 A structural diagram of an aluminum alloy welding groove according to an embodiment of the application is shown.

[0024] Figure 3 A flowchart of a formal welding according to an embodiment of the application is shown.

[0025] Figure 4 A layout diagram of a weld according to an embodiment of the application is shown.

[0026] 100, aluminum alloy to be welded; 110, welding groove; 120, gasket; 200, semi-automatic welding machine; 300, automatic welding equipment; 400, weld; 410, first weld; 420, second weld; 430, third weld. DETAILED DESCRIPTION

[0027] To make the objectives, technical solutions and advantages of the embodiments of the present application clearer, the following will be combined with the accompanying drawings in the embodiments of the present application to make a clear and complete description of the technical solutions in the embodiments of the present application. Obviously, the described embodiments are only some of the embodiments of the present application, rather than all the embodiments. The components of the embodiments of the present application described and shown in the accompanying drawings can be arranged and designed in various different configurations.

[0028] Therefore, the following detailed description of the embodiments of the present application provided in the accompanying drawings is not intended to limit the scope of the claimed present application, but only represents selected embodiments of the present application. All other embodiments obtained by those of ordinary skill in the art based on the embodiments in the present application without creative labor are within the scope of protection of the present application.

[0029] The present application is directed to the current low quality, low efficiency and large deformation of 4-8mm 5083 aluminum alloy gas shielded butt welding, and proposes a semi-automatic and automatic overhead plus flat welding process method for 4-8mm aluminum alloy section assembly of ship structural material. This method overturns the traditional semi-automatic overhead-flat welding process, innovatively adopts semi-automatic-automatic overhead plus flat butt welding process, precisely controls the key technologies such as weld back welding and backing welding, and solves the problems of 4-8mm 5083 aluminum alloy section assembly welding, deformation control and low production efficiency. It can be used as a guiding process for 4-8mm 5083 aluminum alloy section assembly welding. Next, the aluminum alloy semi-automatic and automatic overhead plus flat butt welding method will be described in detail.

[0030] Figure 1 To show a flow chart of an aluminum alloy semi-automatic and automatic overhead plus flat butt welding method according to the embodiments of the present application. Referring to Figure 1 The welding method proposed in the present application includes:

[0031] First, determine the welding equipment and welding materials.

[0032] Among them, the semi-automatic welding machine 200 in the welding equipment adopts Fronius TPS500i welding machine, which can control welding current, arc voltage, welding speed and wire feeding speed. The fully automatic welding equipment 300 adopts automatic welding equipment specially for gas shielded welding, which can flexibly adjust the welding gun swing amplitude and walking speed. The welding materials include the aluminum alloy 100 to be welded, welding wire and shielding gas. The aluminum alloy in the welding material is 5083 aluminum alloy with tensile strength ≥305MPa, and the applicable plate thickness range is 4-8mm. The present application takes 6mm thick 5083 plate as an example. The welding wire adopts Φ1.2mm ER5183 welding wire with equal strength matching, and the shielding gas adopts 75% He+Ar gas with a gas flow of 15-25L / min.

[0033] Secondly, a welding groove 110 is opened at the butt joint of the aluminum alloy, and the aluminum alloy 100 to be welded is assembled, and a welding device is installed at a preset position.

[0034] Figure 2 For the structural diagram of the welding groove of the aluminum alloy according to the embodiment of the present application, see Figure 2 The Y-shaped (single side 25°, root 0-1mm) welding groove 110 is used for the butt joint of the 4-8mm thick 5083 aluminum alloy sheet, which can reduce the welding amount at the flat position, improve the welding efficiency at the flat position, and prevent burn-through, thereby effectively ensuring the weld quality. A gasket 120 is arranged for assembly. The assembly precision is that the gap is between 0-2mm.

[0035] Thirdly, the positioning welding is performed to fix the assembly of the aluminum alloy to be welded. The positioning welding is fixed by using the gas shielded spot welding, the same welding process as the formal welding is used for the positioning welding, the spot welding interval is about 150mm, and the length of each point positioning welding is 20-30mm, so as to ensure sufficient firmness.

[0036] Fourthly, the formal welding is performed, including that the front surface is welded by using the semi-automatic overhead welding with 2-3 welding passes, see the first welding pass 410 and the second welding pass 420 in Figure 3 and Figure 4 . The root of the weld is cleaned by using a milling cutter by 1-2mm. The back surface is welded by using the automatic flat welding with one welding pass. See the third welding pass 430 in Figure 3 and Figure 4 . The welding parameters of the semi-automatic welding are 120-180A, 17-22V, and the welding speed is 15-25cm / min. The welding parameters of the automatic welding are 120-180A, 17-22V, and the welding speed is 40-50cm / min. The welding gun swing range of the automatic welding is 1.0-1.5mm, and the swing frequency is 30-40 times / min, which is 36 times / min in the present application. The inclination angle between the welding gun and the welding piece should not be too large, and the included angle between the welding gun and the welding piece is kept between 60°-70°, so as to ensure the full protection of the molten pool by the gas. The automatic MIG welding is used for the flat welding, and the semi-automatic MIG welding is used for the overhead welding position.

[0037] In the above implementation process, the automatic welding device is arranged, the semi-automatic and automatic overhead and flat welding processes are used for efficient welding, and the welding process is free of operation problems such as burn-through and welding deviation. The weld surface is well formed, the weld has no defects such as undercut and crack, the welding deformation is small, and the efficiency is high. The high-efficiency and high-precision construction requirements of the sheet can be met.

[0038] In an embodiment, the welding equipment comprises an automatic welding equipment 300, which comprises a walking track, a suction cup, a trolley and a welding torch. The installation of the welding equipment at a preset position comprises installing the walking track parallel to the welding seam 400 of the aluminum alloy to be welded, adsorbing the walking track on the surface of the aluminum alloy through the suction cup, installing the trolley on the walking track, clamping the welding torch on the clamping end of the trolley, and adjusting the welding torch to a preset clamping angle. The automatic welding equipment 300 adopts a special automatic welding equipment for gas shielded welding, and can flexibly adjust the swing range of the welding torch and the walking speed.

[0039] In an embodiment, before the third step, the process further comprises cleaning the oxides and oil stains within a range of 20-30 mm on both sides of the welding groove 110 to expose the metal at the butt joint of the aluminum alloy, and drying the water vapor at the welding groove. The entire process does not require preheating before welding, only the water vapor at the welding groove needs to be dried.

[0040] In an embodiment, the welding equipment comprises a semi-automatic welding machine 200, which can control the welding current, arc voltage, welding speed and wire feeding speed.

[0041] The above only describes the preferred embodiments of the present application and is not intended to limit the present application. Those skilled in the art can make various modifications and changes to the present application. Any modification, equivalent replacement, improvement, etc. within the spirit and principles of the present application shall be included in the protection scope of the present application.

Claims

1. A semi-automatic and automatic overhead-plus-flat butt welding method for aluminum alloys, characterized in that, include: The first step is to determine the welding equipment and welding materials; The second step is to open a welding bevel at the aluminum alloy joint and assemble the aluminum alloy to be welded, and install the welding equipment at the preset position. The third step is to perform tack welding to fix the aluminum alloy to be welded into the assembly. The fourth step is formal welding, which includes first performing 2-3 semi-automatic overhead welding passes on the front side, followed by milling the root 1-2mm with a milling cutter; then performing one automatic flat welding pass on the back side for sealing the bottom. The semi-automatic welding parameters are 120-180A, 17-22V, and a welding speed of 15-25cm / min; the automatic welding parameters are 120-180A, 17-22V, and a welding speed of 40-50cm / min; the automatic welding torch oscillation amplitude is 1.0-1.5mm, the oscillation frequency is 30-40 times / min, and the angle between the welding torch and the workpiece is maintained between 60° and 70°. In the second step, the welding bevel adopts a Y-shape, with one side inclined at 25°, leaving a 0-1mm bevel, and a liner is placed at the bottom of the welding bevel; The tack welding is fixed by gas shielded spot welding. The tack welding and the formal welding adopt the same welding process. The spot welding spot spacing is 150mm, and the welding length of each spot welding spot is 20-30mm. The welding materials include aluminum alloy, welding wire, and shielding gas. The aluminum alloy is 5083 aluminum alloy with a tensile strength ≥305MPa and a plate thickness range of 4-8mm. The welding wire is ER5183 welding wire with a diameter of 1.2mm and a strength matching that of the aluminum alloy. The shielding gas is 75%He+Ar gas with a gas flow rate of 15-25L / min.

2. The semi-automatic and automatic overhead and flat butt welding method for aluminum alloys according to claim 1, characterized in that, The welding equipment includes an automatic welding device, which includes a traveling track, a suction cup, a trolley, and a welding torch. The installation of the welding device at the preset position includes installing the traveling track parallel to the weld seam of the aluminum alloy to be welded, adsorbing the traveling track onto the surface of the aluminum alloy using the suction cup, installing the trolley on the traveling track, clamping the welding torch at the clamping end of the trolley, and adjusting the welding torch to a preset angle.

3. The semi-automatic and automatic overhead and flat butt welding method for aluminum alloys according to claim 1, characterized in that, Before the third step, the process also includes cleaning oxides and oil stains within a 20-30mm range on both sides of the weld bevel to expose the metal at the aluminum alloy joint and drying the moisture at the weld bevel.

4. The semi-automatic and automatic overhead and flat butt welding method for aluminum alloys according to claim 1, characterized in that, The welding equipment also includes a semi-automatic welding machine, which can control the welding current, arc voltage, welding speed and wire feeding speed.

5. The semi-automatic and automatic overhead and flat butt welding method for aluminum alloys according to claim 1, characterized in that, The assembly gap of the aluminum alloy to be welded is 0-2mm.

6. The semi-automatic and automatic overhead and flat butt welding method for aluminum alloys according to claim 4, characterized in that, The semi-automatic welding machine used is the Fronius TPS500i welding machine.

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