A parameter debugging method and system of a laser composite welding process

Abstract

The application provides a parameter debugging method and system of a laser composite welding process, comprising the following steps: constructing a welding process parameterization model platform; obtaining workpiece information and setting initial welding process parameters according to the workpiece information; setting laser power as an initial debugging variable, performing a first welding section test, and controlling other process parameters to be constant; if the test is unqualified, other welding process parameters are sequentially selected until the first welding section test is qualified in terms of weld forming and nondestructive testing; and if the best process cannot be obtained during the debugging process, the first welding section test step is repeated by sequentially reducing the difference value of the selected welding process parameters until the best process parameters are determined. The application solves the problem of how to quickly debug and determine the welding process parameter interval of high-strength steel of any thickness, and provides reliable welding process parameter selection suggestions for users.

Description

Technical Field

[0001] This application belongs to the field of shipbuilding technology, and in particular relates to a parameter debugging method and system for laser composite welding process. Background Technology

[0002] Laser hybrid welding can control the width, energy, peak power, and repetition frequency of laser pulses to melt the workpiece and form a specific molten pool. It boasts advantages such as high welding speed and minimal deformation, significantly improving the absorption and utilization of laser energy by the workpiece. In China's shipbuilding industry, laser hybrid welding, as an advanced welding process, has already seen engineering applications in civilian shipbuilding steel. The widespread adoption of laser hybrid welding in the future shipbuilding field is inevitable. However, due to the special properties of high-strength marine steel, its welding process differs significantly from that of ordinary steel, such as crack sensitivity during welding and the mechanical properties of the heat-affected zone. During the debugging of laser hybrid welding processes for low-alloy high-strength steel, various welding technical problems arise, such as weld beads, undercut, uneven weld formation, or internal porosity. Because laser hybrid welding involves numerous welding parameters, and the influence of these parameters on weld formation is non-linear, finding and determining the optimal welding process parameters for different steel plates remains a major challenge for technicians.

[0003] Therefore, there is a need to provide an improved technical solution that addresses the shortcomings of the existing technology. Summary of the Invention

[0004] In view of the shortcomings of the prior art described above, the purpose of this application is to provide a parameter debugging method and system for laser hybrid welding process, which can solve problems such as how to quickly debug and determine the welding process parameter range of high-strength steel of arbitrary thickness.

[0005] To achieve the above and other related objectives, this application provides a parameter adjustment method for a laser hybrid welding process, the parameter adjustment method comprising the following steps:

[0006] S1: Construct a parametric model platform for welding processes;

[0007] S2: Obtain workpiece information and set initial welding process parameters;

[0008] S3: Set the laser power as the initial debugging variable;

[0009] S4: Select one welding process parameter to conduct the first weld segment test, and keep other process parameters constant; if the test fails, select other welding process parameters in turn until the first weld segment test passes.

[0010] S5: Perform the second weld section test using the welding process parameters determined in S4; if the test fails, reduce the difference in the selected welding process parameters and repeat step S4 until the second weld section test passes.

[0011] S6: Use the welding process parameters determined in S5 to conduct the third weld section test. If the test fails, reduce the difference in the selected welding process parameters and repeat step S4 until the third weld section test passes.

[0012] The lengths of the first weld segment, the second weld segment, and the third weld segment increase sequentially.

[0013] In one embodiment, in step S2, the initial welding process parameters include welding speed Vh and wire feed speed Vs, wherein the wire feed speed Vs is calculated as follows:

[0014] V = T × L × W × 1.2

[0015] Vs=π×(d / 2)2×L / (Vh×V)

[0016] Where V is the filler volume of the welding wire, T is the workpiece thickness, L is the weld length, W is the weld width, Vs is the wire feed speed, Vh is the welding speed, and d is the welding wire diameter.

[0017] In one embodiment, in step S3, the initial laser power P is the minimum power value required for complete laser penetration of the workpiece under the initial welding speed Vh conditions.

[0018] In one embodiment, step S3 further includes setting the defocusing amount F, the wire extension H, the wire spacing D, the arc length correction α, and the focus offset A.

[0019] In one embodiment, step S4, the test of the first weld segment, is as follows:

[0020] S41: Select laser power P as the debugging object, and set welding power P to P-2dp, P-dp, P, P+dp, P+2dp in sequence, where dp is the welding power difference;

[0021] S42: Select wire feeding speed Vs as the debugging object. The wire feeding speed Vs is set to Vs-2dv, Vs-dv, Vs, Vs+dv, Vs+2dv in sequence, where dv is the difference in wire feeding speed.

[0022] S43: Select arc length correction α as the debugging object. The arc length correction α is set to α-2δ, α-δ, α, α+δ, α+2δ in sequence, where δ is the arc length correction difference.

[0023] If any step of the test in the first welding segment passes, the test for the second welding segment can proceed.

[0024] In one implementation method

[0025] The test qualification method for the second welding section is: the workpiece surface forming is qualified and the porosity defect rate meets the standard;

[0026] The test qualification method for the third welding section is: the workpiece surface forming is qualified and the porosity defect rate meets the standard.

[0027] In one embodiment, in step S5, if the test result of the second weld segment is that the porosity exceeds the standard, then the decoking amount F is increased and step S4 is repeated.

[0028] In one embodiment, in step S6, if the test result of the third weld segment is that the porosity exceeds the standard, then the decoking amount F is increased and step S4 is repeated.

[0029] In one embodiment, the lengths of the first weld segment, the second weld segment, and the third weld segment are 100mm, 500mm, and 1500mm, respectively.

[0030] This application also provides a parameter adjustment system for laser hybrid welding process, including:

[0031] The acquisition module is used to acquire workpiece information;

[0032] The input module is used to set the initial welding process parameters;

[0033] The first calculation module is used to generate suggested welding process parameters and conduct a test on the first weld segment based on the acquired workpiece information and the set initial welding process parameters. The suggested welding process parameters include laser power P, wire feed speed Vs and arc length correction α.

[0034] The second calculation module is used to generate suggestions for adjusting the difference in welding process parameters based on the welding process parameters determined by the first calculation module and to conduct a second weld segment test.

[0035] The third calculation module is used to generate suggestions for adjusting the difference in welding process parameters based on the welding process parameters determined by the second calculation module and to conduct a third weld segment test.

[0036] The output module is used to output the welding process parameters determined by the third calculation module.

[0037] Compared with the prior art, the technical solution provided in this application has the following beneficial effects:

[0038] 1. The parameter adjustment method for laser hybrid welding process of this application can quickly and efficiently determine the optimal welding parameters for workpiece welding, and is especially suitable for selecting welding process parameters for low alloy high strength steel workpieces of arbitrary thickness. By sequentially selecting different welding process parameters for testing, and dividing the weld segment into the first weld segment, the second weld segment, and the third weld segment according to the weld segment length, the selection range of process parameters is narrowed down step by step to determine the optimal welding process parameters more quickly.

[0039] 2. In this application, the initial laser power is determined by laser penetration test, and the laser power is adjusted first to lock the selectable range of welding process parameters. Then, other welding process parameters, such as wire feed speed and arc length correction, are adjusted to obtain accurate optimal process parameters.

[0040] 3. The parameter adjustment system for laser hybrid welding process of this application provides users with reliable welding process parameter suggestions, improves the matching degree between welding parameters and workpiece, thereby quickly finding the optimal welding process parameter range. In addition, the parameter adjustment system of this application can store and call its generated data model to further optimize the selection suggestions for process adjustment parameters. Attached Figure Description

[0041] Figure 1 This is a flowchart of the parameter adjustment method for the welding process in this application;

[0042] Figure 2 This is a logic block diagram for adjusting the welding process parameters in this application;

[0043] Figure 3 This is a block diagram of the parameter adjustment system for the welding process in this application.

[0044] Explanation of reference numerals in the attached figures:

[0045] 1. Acquisition module; 2. Input module; 3. First calculation module; 4. Second calculation module; 5. Third calculation module; 6. Output module. Detailed Implementation

[0046] The following specific examples illustrate the implementation of this application. Those skilled in the art can easily understand other advantages and principles of this application from the content disclosed in this specification. This application can also be implemented or applied through other different specific embodiments, and various details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of this application.

[0047] It should be noted that the illustrations provided in this embodiment are only schematic representations of the basic concept of this application. The drawings only show the steps related to this application and are not drawn according to the actual number of steps in the implementation. The actual implementation steps may be arbitrarily changed or may be more complex.

[0048] Example 1

[0049] This embodiment discloses a parameter adjustment method for a laser hybrid welding process. See [link to relevant documentation]. Figures 1-2 The parameter debugging method includes the following steps:

[0050] S1: Construct a parametric model platform for welding processes;

[0051] S2: Obtain workpiece information, including the workpiece's physical and chemical properties, such as workpiece size, material and model, yield strength and hardness, and then set the initial welding process parameters;

[0052] Specifically, the initial welding process parameters include welding speed V. h Wire feeding speed V s The weld width W, the filler volume V, and the weld length L, where the welding speed V h Based on the user's production efficiency, other parameters are adjusted to achieve the best process requirements while ensuring production efficiency.

[0053] Wire feeding speed V s It is calculated using the following formula:

[0054] V = T × L × W × 1.2

[0055] V s =π×(d / 2) 2 ×L / (V h ×V)

[0056] Where V is the filler volume of the welding wire, T is the workpiece thickness, L is the weld length, and W is the weld width. s V is the wire feeding speed. h d represents the welding speed, and d represents the diameter of the welding wire.

[0057] S3: Set the laser power as the initial debugging variable;

[0058] Specifically, the initial laser power P is determined through a laser penetration test, and is set at the initial welding speed V. h The minimum power value required for complete laser penetration during pure laser welding under certain conditions is recorded as the initial laser power P.

[0059] As an example: for 6mm thick steel plate workpieces, a 6000W laser power is preferred for testing; for 8mm thick steel plate workpieces, an 8000W laser power is preferred, and so on. At the preset welding speed V... h Under the specified conditions, pure laser welding is performed to observe whether the laser can completely penetrate both sides of the steel plate workpiece. If it fails to penetrate, the laser power P is appropriately increased, and the penetration test is repeated until both sides of the steel plate workpiece can be completely penetrated. This laser power P is used as the basis for subsequent parameter adjustments. If it has penetrated, the laser power P can be appropriately reduced, and the minimum power required to completely penetrate both sides of the steel plate is observed. This laser power P is used as the basis for subsequent parameter adjustments.

[0060] After determining the initial laser power P, other parameters need to be set, such as: defocusing amount F, wire feed speed Vs, wire extension H, wire spacing D, arc length correction α, and focus offset A.

[0061] As an example: For thin plate workpieces with a thickness of less than 10mm, since the focal plane of the thin plate is located above the surface of the steel plate workpiece, the energy requirement is relatively small. In order to avoid workpiece deformation caused by concentrated welding energy, positive defocusing can be selected. The defocusing amount F is usually set in the range of 0mm to +5mm. For example, the middle value of +3mm can be used as the initial welding parameter for adjustment. For workpieces with a thickness of more than 10mm, since the focal plane position is lower and the welding energy that it can withstand is larger, the defocusing amount F is usually set in the range of -5mm to +3mm. For example, the middle value of 0mm can be used as the initial welding parameter for adjustment.

[0062] As an example: the wire extension H refers to the distance from the end of the welding wire to the end of the contact tip. The wire extension H is generally controlled between 5 and 25 mm. It should not be too short or too long, otherwise defects such as pits, air grooves, and unstable arcs are likely to occur. Typically, the wire extension H for 0.9 mm diameter welding wire is controlled at around 15 mm, and for welding wire with a diameter of 1.2–1.6 mm, it is controlled at around 20 mm. A fixed initial value should be set according to the welding wire parameters to facilitate subsequent adjustment of process parameters.

[0063] As an example: the filament spacing D refers to the distance from the center of the laser spot to the point of contact between the welding wire tip and the workpiece surface. When the filament spacing D is negative (e.g., -2mm), arc interruption occurs severely during welding, the workpiece's laser absorption rate decreases, the welding process becomes unstable, and the weld is discontinuous. When the filament spacing D approaches 0mm, the laser spot's position is closer to the lower part of the molten droplet, causing the droplet to continuously increase in size at the tip of the welding wire, preventing it from smoothly transitioning into the molten pool. When the large droplet contacts the molten pool, it will cause a strong burst and a large amount of spatter. As the filament spacing D continues to increase, the two heat sources become relatively independent, the photo-induced plasma cannot attract the arc, and the welding stability decreases. For welding processes of high-strength steel workpieces, the filament spacing D can be appropriately increased, for example, the initial filament spacing D can be set to 2mm to facilitate subsequent adjustment of process parameters.

[0064] As an example: taking the location of the focus at the origin as the initial value setting principle, the focus offset A can be set to 0mm.

[0065] S4: After the initial values ​​of the above welding process parameters are set, select one of the welding process parameters to conduct the first weld section test, and control the other process parameters to be constant; if the test fails, select other welding process parameters in turn until the first weld section test is qualified; if any step of the first weld section test is qualified, proceed to the second weld section test.

[0066] Specifically, the steps for the first weld section test are as follows:

[0067] S41: Select laser power P as the debugging object, and set welding power P to P-2dp, P-dp, P, P+dp, P+2dp in sequence, where dp is the welding power difference;

[0068] As an example: The first welding segment consists of five short welding segments. The dp value is selected as 500w, so the welding power is P-1000, P-500, P, P+500, P+1000 in sequence. After welding, observe the weld formation state. Select the laser power parameter that is basically melted and uniformly formed on both sides of the weld as the adjustment object of S42. If the surface formation is good, such as no undercut occurs in the weld, the second welding segment can be tested. If there are surface formation defects, select the next welding process parameter such as wire feed speed Vs or arc length correction α for adjustment.

[0069] S42: Select wire feeding speed Vs as the debugging object. The wire feeding speed Vs is set to Vs-2dv, Vs-dv, Vs, Vs+dv, Vs+2dv in sequence, where dv is the difference in wire feeding speed.

[0070] As an example: With the laser power parameters and other welding process parameters fixed as determined in S41, only the wire feed speed Vs is adjusted. The dv value is selected as 0.5 m / min. The wire feed speeds are then Vs-1, Vs-0.5, Vs, Vs+0.5, and Vs+1. Observe whether the workpiece surface forming condition is optimized, such as whether the undercut phenomenon is reduced or eliminated. If there is no undercut, the second welding section test can proceed. If the undercut phenomenon is reduced but not eliminated, the next welding process parameter, arc length correction α, is selected for adjustment.

[0071] S43: Select arc length correction α as the debugging object. The arc length correction α is set to α-2δ, α-δ, α, α+δ, α+2δ in sequence, where δ is the arc length correction difference.

[0072] As an example: Fix the laser power parameters, wire feed speed, and other welding process parameters determined in S41 and S42, and only adjust the arc length correction α. ​​The δ value is selected as 3%. If the initial arc length correction α is defined as 0, the adjusted arc length correction α is -6%, -3%, 0, +3%, and +6% in sequence. Observe whether the surface forming state of the workpiece is optimized. If the undercut is eliminated, the second welding section test can be carried out.

[0073] S5: Perform the second weld section test using the welding process parameters determined in S4; if the test fails, reduce the difference in the selected welding process parameters and repeat step S4 until the second weld section test passes.

[0074] Specifically, the length of the second weld segment is greater than that of the first weld segment, and the test qualification method for the second weld segment is: the surface forming of the workpiece is qualified and the porosity defect rate meets the standard.

[0075] As an example: If the workpiece surface has defects, repeat steps S41 to S43. During the repeated tests, reduce the selected difference for each welding process parameter and make fine adjustments. For example, reduce the welding power difference dp from 500 to 400, 300, 200, etc.; reduce the wire feed speed difference dv from 0.5 to 0.4, 0.3, 0.2, etc.; reduce the arc length correction difference δ from 3% to 2%, 1.5%, 1%, etc. If the test result of the second weld segment is that the workpiece surface is qualified but the porosity exceeds the standard, increase the decoking amount F and then repeat steps S41 to S43.

[0076] S6: Use the welding process parameters determined in S5 to conduct the third weld section test. If the test fails, reduce the difference in the selected welding process parameters and repeat step S4 until the third weld section test passes.

[0077] Specifically, the length of the third weld segment is greater than that of the second weld segment, and the test qualification method for the third weld segment is: the surface forming of the workpiece is qualified and the porosity defect rate meets the standard.

[0078] As an example: If the workpiece surface has defects, repeat steps S41 to S43. During the repeated tests, continue to narrow down the selected differences for each welding process parameter and make fine adjustments. For example, based on the adjustment range of the process parameter differences in step S5, further narrow down the range of the welding power difference dp, the wire feed speed difference dv, and the arc length correction difference δ. If the test result of the third weld segment is that the workpiece surface is qualified but the porosity exceeds the standard, increase the decoking amount F and then repeat steps S41 to S43.

[0079] The lengths of the first, second, and third welding segments increase sequentially. The lengths of the first, second, and third welding segments can be set to 100mm, 500mm, and 1500mm respectively. That is, the total length of the five short welding segments included in the first welding segment is the same as that of the second welding segment. This ensures a certain continuity in the three selections of welding process parameters, progressively optimizing and narrowing the range of process parameters to more quickly determine the optimal welding process parameters.

[0080] Example 2

[0081] This embodiment discloses a parameter adjustment system for laser hybrid welding process, see [link to documentation]. Figure 3 ,include:

[0082] Module 1 is used to acquire workpiece information input by the user;

[0083] Input module 2 is used to set the initial welding process parameters;

[0084] The first calculation module 3 is used to generate suggested welding process parameters and conduct a test on the first weld segment based on the acquired workpiece information and the set initial welding process parameters. The suggested welding process parameters include laser power P, wire feed speed Vs, and arc length correction α. ​​The test process on the first weld segment includes:

[0085] S41: Select laser power P as the debugging object, and set welding power P to P-2dp, P-dp, P, P+dp, P+2dp in sequence, where dp is the welding power difference;

[0086] S42: Select wire feeding speed Vs as the debugging object. The wire feeding speed Vs is set to Vs-2dv, Vs-dv, Vs, Vs+dv, Vs+2dv in sequence, where dv is the difference in wire feeding speed.

[0087] S43: Select arc length correction α as the debugging object. The arc length correction α is set to α-2δ, α-δ, α, α+δ, α+2δ in sequence, where δ is the arc length correction difference.

[0088] If any step of the first welding segment passes the test and the welding process parameters are confirmed, they are imported into the second calculation module 4 to conduct the second welding segment test.

[0089] The second calculation module 4 is used to generate suggestions for adjusting the difference in welding process parameters based on the welding process parameters determined by the first calculation module 3 and to conduct a second welding segment test. If there are defects in the surface forming of the workpiece, the test steps for the second welding segment are the same as those for the first welding segment. If the test result of the second welding segment is that the surface forming of the workpiece is qualified but the porosity exceeds the standard, the decoking amount F is increased and the test steps for the first welding segment are repeated.

[0090] The third calculation module 5 is used to generate suggestions for adjusting the difference in welding process parameters based on the welding process parameters determined by the second calculation module 4 and to conduct a third welding segment test. The adjustment range of the welding process parameters of the third calculation module 5 is set to be smaller than the adjustment range of the welding process parameters of the second calculation module 4. If there are defects in the surface forming of the workpiece, the test steps of the third welding segment are the same as those of the first welding segment. If the test result of the third welding segment is that the surface forming of the workpiece is qualified but the porosity exceeds the standard, the decoking amount F is increased and the test steps of the first welding segment are repeated.

[0091] Output module 6 is used to output the welding process parameters determined by the third calculation module 5.

[0092] In summary, this application provides a parameter debugging method and system for laser hybrid welding process. By sequentially selecting different welding process parameters for testing, and dividing the weld segment into a first weld segment, a second weld segment, and a third weld segment according to the weld segment length, the selection range of process parameters is gradually optimized and narrowed. This solves the problem of how to quickly debug and determine the welding process parameter range for laser hybrid welding of high-strength steel of arbitrary thickness, and provides users with reliable welding process parameter suggestions. Therefore, this application effectively overcomes the various shortcomings of the prior art and has high industrial application value.

[0093] The above embodiments are merely illustrative of the principles and effects of this application and are not intended to limit this application. Any person skilled in the art can modify or alter the above embodiments without departing from the spirit and scope of this application. Therefore, all equivalent modifications or alterations made by those skilled in the art without departing from the spirit and technical concept disclosed in this application should still be covered by the claims of this application.

Claims

1. A parameter adjustment method for a laser hybrid welding process, characterized in that, The parameter debugging method includes the following steps: S1: Construct a parametric model platform for welding processes; S2: Obtain workpiece information and set initial welding process parameters based on the workpiece information; S3: Set the laser power as the initial debugging variable; S4: Select one welding process parameter to conduct the first weld segment test, and keep other process parameters constant; if the test fails, select other welding process parameters in turn until the first weld segment test passes. S5: Perform the second weld section test using the welding process parameters determined in S4; if the test fails, reduce the difference in the selected welding process parameters and repeat step S4 until the second weld section test passes. S6: Use the welding process parameters determined in S5 to conduct the third weld section test. If the test fails, reduce the difference in the selected welding process parameters and repeat step S4 until the third weld section test passes. The lengths of the first weld segment, the second weld segment, and the third weld segment increase sequentially.

2. The parameter adjustment method for the laser hybrid welding process according to claim 1, characterized in that, In step S2, the initial welding process parameters include welding speed V. h and wire feeding speed V s Wherein, the wire feeding speed V s The calculation method is as follows: V = T × L × W × 1.2 V s =π×(d / 2) 2 ×L / (V h ×V) Where V is the filler volume of the welding wire, T is the workpiece thickness, L is the weld length, and W is the weld width. s V is the wire feeding speed. h d represents the welding speed, and d represents the diameter of the welding wire.

3. The parameter adjustment method for the laser hybrid welding process according to claim 1, characterized in that, In step S3, the initial laser power P is the initial welding speed V. h The minimum power value required for complete laser penetration of a workpiece under pure laser welding conditions.

4. The parameter adjustment method for the laser hybrid welding process according to claim 1, characterized in that, Step S3 also includes setting the defocusing amount F, the wire extension H, the wire spacing D, the arc length correction α, and the focus offset A.

5. The parameter adjustment method for the laser composite welding process according to claim 1, characterized in that, In step S4, the steps for testing the first weld segment are as follows: S41: Select laser power P as the debugging object, and set welding power P to P-2dp, P-dp, P, P+dp, P+2dp in sequence, where dp is the welding power difference; S42: Select wire feeding speed V s For the debugging object, the wire feeding speed V s Set them sequentially to V s -2dv、V s -dv、V s V s +dv、V s +2dv, where dv is the difference in wire feeding speed; S43: Select arc length correction α as the debugging object. The arc length correction α is set to α-2δ, α-δ, α, α+δ, α+2δ in sequence, where δ is the arc length correction difference. If any step of the test in the first welding segment passes, the test for the second welding segment can proceed.

6. The parameter adjustment method for the laser hybrid welding process according to claim 1, characterized in that, The test qualification method for the second welding section is: the workpiece surface forming is qualified and the porosity defect rate meets the standard; The test qualification method for the third welding section is: the workpiece surface forming is qualified and the porosity defect rate meets the standard.

7. The parameter adjustment method for the laser hybrid welding process according to claim 6, characterized in that, In step S5, if the test result of the second weld segment is that the porosity exceeds the standard, then increase the decoking amount F and repeat step S4.

8. The parameter adjustment method for the laser hybrid welding process according to claim 6, characterized in that, In step S6, if the test result of the third weld segment is that the porosity exceeds the standard, then increase the decoking amount F and repeat step S4.

9. The parameter adjustment method for the laser hybrid welding process according to any one of claims 1 to 8, characterized in that, The lengths of the first weld segment, the second weld segment, and the third weld segment are 100mm, 500mm, and 1500mm, respectively.

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