Multi-wire control and intelligent powder feeding welding device and composite steel plate welding method

Abstract

The application discloses a multi-wire control and intelligent powder feeding welding device, characterized in that the device comprises a multi-wire composite welding gun, a plurality of wire feeding devices, a back-pulling device, a cutting device and a control system; the multi-wire composite welding gun comprises a gun body, a conductive nozzle and a powder feeding head, a plurality of welding wire feeding channels and powder feeding channels are arranged in the gun body, a wire discharging channel is arranged in the conductive nozzle, and the powder feeding channels extend to the powder feeding head; the wire feeding devices are connected with the welding wire feeding channels one by one; the cutting device is arranged at the conductive nozzle; the control system is used for selecting the communication between the feeding channels and the wire discharging channel, controlling the cutting device to cut the end of the welding wire, controlling the back-pulling device to pull back the welding wire from the wire discharging channel and controlling the powder flow rate in each powder feeding channel. The application further discloses a clad steel plate welding method based on the welding device. The application can realize the optimization of a clad steel plate groove, the elimination of welding defects and the improvement of welding efficiency.

Description

TECHNICAL FIELD

[0001] The present application relates to composite steel plate welding, in particular to a multi-wire control and intelligent powder feeding welding device and a composite steel plate welding method. BACKGROUND

[0002] At present, after welding, the composite steel plate is prone to stress corrosion cracking and back bending cracking and other defects. In view of this problem, the prior art usually adopts a multi-wire alternating mode for welding, and a welding wire composition different from the base plate and the cladding layer is selected at the joint of the base plate and the cladding layer. However, the current welding method needs to frequently manually replace the welding wire, which is low in work efficiency.

[0003] In addition, since a welding wire composition different from the base plate and the cladding layer is selected at the joint of the base plate and the cladding layer, there are problems such as element mutation and large performance difference at the joint of the base plate and the cladding layer. SUMMARY

[0004] The purpose of the present application is to provide a multi-wire control and intelligent powder feeding welding device for improving welding efficiency and a welding method for improving the performance of a composite steel plate.

[0005] Technical scheme: The present application provides a multi-wire control and intelligent powder feeding welding device, characterized in that it comprises a multi-wire composite welding gun, a plurality of wire feeding devices, a back-pulling device, a cutting device and a control system; the multi-wire composite welding gun comprises a gun body and a conductive nozzle, a powder feeding head, the gun body is internally provided with a plurality of welding wire feeding channels and powder feeding channels, the conductive nozzle is internally provided with a wire feeding channel, and the powder feeding channel extends to the powder feeding head; the wire feeding device is connected to the welding wire feeding channel one by one; the cutting device is arranged at the conductive nozzle; the control system is used to select the communication between the feeding channel and the wire feeding channel, control the cutting device to cut the end of the welding wire, control the back-pulling device to pull the welding wire back from the wire feeding channel, and control the powder flow rate in each powder feeding channel.

[0006] Preferably, the wire feeding device is independently controlled to open and close by a power supply, and each wire feeding device is independently set with current, voltage and wire feeding speed by the control device.

[0007] Preferably, it further comprises a welding wire dry elongation sensing device arranged at the conductive nozzle for sensing the extension length range of the welding wire; the control system sets the rated extension length value of the welding wire, and controls the welding wire feeding to keep the extension length fixed by comparing the sensing data with the rated extension length value.

[0008] Preferably, the back-pulling device comprises a sensing component arranged at the welding wire feeding channel; the sensing component is connected to the control system.

[0009] Preferably, the control system controls the welding wire feeding speed and the powder flow rate at the same time, and is used to control the ratio of the welding wire and the powder.

[0010] Preferably, the number of the wire feeding channels is three.

[0011] The application also provides a composite steel plate welding method using the multi-wire control and intelligent powder feeding welding device, comprising the following steps:

[0012] S1: processing a welding groove on the composite steel plate;

[0013] S2: assembling the composite steel plate and installing a ceramic gasket on the back surface;

[0014] S3: welding:

[0015] A first kind of welding wire with a material similar to that of the base plate is selected, the corresponding wire feeding channel is connected to the wire outlet channel by operating the control system, and the first part of welding is performed by using the galvanometer laser-arc hybrid welding method, the welding is performed to a position 1-2 mm below the junction line between the base plate and the cladding layer, the control system of the welding device is operated to cut off the end of the welding wire and make the welding wire retract;

[0016] A second kind of welding wire different from the material of the base plate and the cladding layer is selected, the corresponding wire feeding channel is connected to the wire outlet channel by operating the control system, the second part of welding is performed by using the galvanometer laser-arc hybrid welding method, the powder flow rate of the powder feeding channel is controlled in the process of composite welding, the welding powder is filled in the welding bead to form a stepped transition welding layer, the welding is performed to a position 1-2 mm above the junction line between the base plate and the cladding layer, the control system is operated to cut off the end of the welding wire and make the welding wire retract, and the powder feeding is stopped at the same time;

[0017] A third kind of welding wire with a material similar to that of the cladding layer is selected, the corresponding wire feeding channel is connected to the wire outlet channel by operating the control system, and the third part of welding is performed by using the galvanometer laser-arc hybrid welding method.

[0018] S4: testing the performance of the composite steel plate.

[0019] Preferably, the welding method of the galvanometer laser-arc hybrid welding is laser-GTAW wire feeding or laser-GMAW.

[0020] Preferably, the galvanometer laser moves along the direction perpendicular to the welding direction, the laser scanning amplitude is 0-5 mm, the scanning frequency is 10-200 Hz, and the horizontal distance between the light and the wire is 1-4 mm.

[0021] Preferably, the fusion width and the penetration depth of the welding process of the composite steel plate galvanometer laser-arc hybrid welding are achieved by adjusting the laser scanning amplitude, within a certain range, when the laser scanning amplitude increases, the width of the molten pool increases and the penetration depth decreases.

[0022] Beneficial effects: compared with the prior art, the present application has the following remarkable advantages: 1, the joint of the coating and the substrate selects the composition of the welding wire which is different from the substrate and the coating, adopts the method of galvanometer laser-arc composite welding, realizes the regulation of the molten pool and the penetration by changing the scanning amplitude of the galvanometer laser, and can realize the optimization of the composite steel plate groove, the elimination of welding defects and the improvement of welding efficiency; 2, the welding device of the present application can intelligently select the required welding wire type according to the welding wire use sequence, reduce the labor cost and time cost increased by alternating use of multiple brands of welding wires in the composite steel plate welding process, and improve the welding production efficiency; 3, the welding process combines the welding wire and the welding powder, and the superposition can change the composition of the joint, obtain a composition-controllable step transition layer, avoid the problems of element mutation and large performance difference at the joint of the substrate and the coating, can meet the use requirements in different places, and expand the application range of the composite plate welding. BRIEF DESCRIPTION OF DRAWINGS

[0023] Figure 1 A "V-shaped" groove schematic diagram of the composite steel plate of example 1;

[0024] Figure 2 A "V-shaped" welding bead layout diagram of the composite steel plate of example 1;

[0025] Figure 3 A "Y-shaped" groove layout diagram of the composite steel plate of example 2;

[0026] Figure 4 A "Y-shaped" welding bead layout diagram of the composite steel plate of example 2;

[0027] Figure 5 A "X-shaped" groove layout diagram of the composite steel plate of example 3;

[0028] Figure 6 A "X-shaped" welding bead layout diagram of the composite steel plate of example 3. DETAILED DESCRIPTION

[0029] The technical solutions of the present application will be further described below in combination with the drawings.

[0030] A multi-wire control and intelligent powder feeding welding device, comprising a multi-wire composite welding gun, a plurality of wire feeding devices, a back-pulling device, a cutting device, a welding wire dry elongation sensing device and a control system.

[0031] The multi-wire composite welding gun comprises a gun body and a conductive nozzle, a powder feeding head, the gun body is internally provided with a powder feeding channel and three welding wire feeding channels, the conductive nozzle is internally provided with a wire feeding channel, and the powder feeding channel extends to the powder feeding head.

[0032] The wire feeding devices are connected to the welding wire feeding channels one by one. Each wire feeding device is independently controlled to open and close by a power supply, and each wire feeding device is independently set with current, voltage and wire feeding speed by the control device.

[0033] The wire dry extension sensing device is arranged at the conductive nozzle for sensing the wire extension length range; the control system sets the rated wire extension length value, and controls the wire feeding to keep the wire extension length fixed by comparing the sensing data with the rated extension length value.

[0034] The cutting device is arranged at the conductive nozzle for cutting the wire end to prevent the wire end from having a large diameter mutation due to the welding process and being unable to complete the wire retraction due to the small size of the channel. Cutting the wire end can ensure smooth wire retraction.

[0035] The retraction device includes a sensing component arranged at the wire feeding channel, and the sensing component is connected with the control system.

[0036] The control system is used to select the communication between the feeding channel and the wire discharge channel, control the cutting device to cut the wire end, control the retraction device to retract the wire from the wire discharge channel, and control the powder flow rate in each powder feeding channel. The control system controls the wire feeding speed and the powder flow rate at the same time, and is used to control the ratio of the wire and the powder.

[0037] Example 1: welding of Q420qE steel + S31603 stainless steel composite plate by GMAW welding method

[0038] Q420qE bridge steel and S31603 stainless steel with good corrosion resistance are selected to form a composite plate, Q420qE steel is used as substrate A, and S31603 stainless steel is used as cladding B. The thickness of the composite plate is 19 mm, the thickness of the substrate A is 16 mm, and the thickness of the cladding B is 3 mm.

[0039] The steps are as follows:

[0040] S1: processing “V-shaped” groove

[0041] First, the composite plate is processed with a “V-shaped” groove, and the groove size is as shown in the figure. The upper surface and the lower surface of the composite plate are polished to remove the oxide skin, then the workpiece side surface, the upper and lower surfaces are cleaned with oil cleaner, and finally alcohol is used for wiping to ensure that the welding area of the composite plate is clean and tidy. Figure 1

[0042] S2: composite plate assembly

[0043] According to the groove size diagram, the composite plate is assembled, and the gap between the two abutted composite plates is 6 mm. In order to control the back forming during welding, a ceramic pad C is added to the back to forcibly form the backing welding.

[0044] S3: GMAW welding of composite plate using the above welding device

[0045] ​The assembled composite steel plate is fixed on the base, and the composite steel plate welding bead arrangement is as shown in Table 1. Figure 2

[0046] Table 1 GMAW welding process parameters of composite steel plate

[0047]

[0048] The first part of the welding uses ER55-G welding wire, and the specific process parameters are as follows:

[0049] The first pass of the welding 1 uses ER55-G welding wire with a diameter of 1.2 mm, a welding speed of 180 mm / min, and a current of 200 A. Considering the use of ceramic liner, the current should not be too large, otherwise it is easy to cause poor forming quality of the back of the weld. Therefore, the current should be controlled below 250 A.

[0050] The second and third passes of the welding 2, 3 use ER55-G welding wire, which has higher welding efficiency than the first pass of the welding 1. The third pass of the weld should not exceed the junction line of the substrate and the cladding layer, and the height should be controlled below 1-2 mm below the junction line.

[0051] After the third pass of the welding is completed, the operation control system cuts off the end of the welding wire and withdraws the welding wire.

[0052] The second part of the welding uses 309 stainless steel welding wire, and the specific process parameters are as follows:

[0053] The welding device automatically switches to 309 stainless steel welding wire.

[0054] The fourth pass of the welding 4 is the main position where the performance of the composite steel plate does not meet the standard and defects occur, which is mainly related to the selection of welding wire composition and the arrangement of welding beads. In this embodiment, the fourth pass of the welding 4 uses 309 stainless steel welding wire, and the welding powder is mainly composed of Cr and Ni powder, and the composition can be controlled. The weld covers the entire junction line area of the substrate and the cladding layer, and the weld height is 1-2 mm above the junction line.

[0055] After the fourth pass of the welding 4 is completed, the operation control system cuts off the end of the welding wire, withdraws the welding wire, and stops powder feeding.

[0056] The third part of the welding uses 316 stainless steel welding wire, and the specific process parameters are as follows:

[0057] The fifth and sixth passes of the welding 5, 6 are in the area corresponding to the cladding layer B, and the welding device operation control system automatically switches to 316 stainless steel welding wire during welding.

[0058] During the welding of the first to sixth passes of the welding, the workpiece temperature should not exceed 100℃.

[0059] S4: Performance test of composite steel plate ​

[0060] Tests showed that the tensile strength of the Q420qE steel + S31603 stainless steel composite plate joint was 576 MPa, and the fracture occurred in the weld, which meets the technical requirements of GB / T 2651-2008. No visible cracks were found in the bending test of the joint, which meets the technical requirements of GB / T2653-2008. The average impact absorption energy at the weld center was 61 J, which meets the technical requirements of GB / T 2650-2008. The average impact absorption energy in the heat-affected zone was 228 J, which meets the technical requirements of GB / T 2650-2008.

[0061] Case 2:

[0062] Similar to Example 1, a composite steel plate was constructed using Q420qE steel and S31603 stainless steel. Q420qE steel served as the substrate A, and S31603 stainless steel as the cladding layer B. The composite steel plate was 19 mm thick, with substrate A being 16 mm thick and cladding layer B being 3 mm thick. Welding was performed using a galvanometer laser-arc hybrid welding method. The specific difference lies in:

[0063] In this embodiment S1, the bevel of the composite steel plate is "Y-shaped", and its bevel dimensions are as follows: Figure 3 As shown in Figure S2, the composite steel plates are assembled according to the bevel size diagram. The gap between the two butt-jointed composite steel plates is 0mm, and no ceramic gasket is required.

[0064] In S3, the assembled composite steel plate is fixed to the base. The weld layout diagram of the composite steel plate is as follows. Figure 4 As shown in Table 2, the specific process parameters are as follows.

[0065] Table 2. Process parameters for laser-arc welding of composite steel plates using galvanometers.

[0066]

[0067] The first root pass welding 1 uses ER55-G welding wire with a diameter of 1.2mm, welding speed of 800mm / min, and current of 180A. Considering that no ceramic backing is added to the back of the first pass welding, and it is necessary to melt through the 5mm blunt edge, a larger penetration depth is required through the action of the laser. Therefore, the laser scanning amplitude is 0mm during the first pass welding to increase the welding penetration depth.

[0068] The second filler weld 2 uses ER55-G welding wire. Compared with Example 1, the galvanometer laser-arc hybrid welding is more efficient. At the same time, the second pass requires a larger weld width than the first pass. Therefore, the laser scanning amplitude is set to 2mm during the second pass to increase the weld width. The second weld should not exceed the boundary line between the substrate and the cladding. The height of the second weld is controlled to be 1-2mm below the boundary line.

[0069] After the second pass welding, the operation control system cuts off the end of the welding wire, retracts the welding wire, and automatically switches to the 309 stainless steel welding wire.

[0070] The weld of the third pass 3 is the main position where the performance of the clad steel plate does not meet the standard and defects are generated, which is mainly related to the selection of the welding wire composition and the arrangement of the welding pass. For this embodiment, the 309 stainless steel welding wire is selected for the third pass 3, supplemented by a mixed powder of Cr and Ni. The weld needs to cover the entire joint line area between the substrate and the cladding layer, and the weld height is 1-2 mm above the joint line;

[0071] After the third pass welding, the operation control system cuts off the end of the welding wire, retracts, and stops powder feeding, and automatically switches to the 316 stainless steel welding wire.

[0072] The fourth pass 4 weld is in the area corresponding to the cladding layer B. Unlike the GMAW covering, the galvanometer laser-arc hybrid welding covering only needs one pass. When welding, the laser scanning amplitude is set to 5 mm, which increases the laser fusion width and improves the ability of complete fusion at the edge.

[0073] When welding the first to fourth pass welds, the workpiece temperature should not exceed 100℃.

[0074] S4: Performance test of the clad steel plate

[0075] It is tested that the tensile strength of the Q420qE steel+S31603 stainless steel clad steel plate joint is 581 MPa, and the fracture occurs in the weld, which meets the technical requirements of GB / T 2651-2008; no visible cracks are found in the joint bend test, which meets the technical requirements of GB / T2653-2008; the average impact energy of the weld center is 63 J, which meets the technical requirements of GB / T 2650-2008; the average impact energy of the heat-affected zone is 235 J, which meets the technical requirements of GB / T 2650-2008.

[0076] Case 3:

[0077] The same as embodiment 1, Q420qE steel and S31603 stainless steel are selected to form a clad steel plate. Q420qE steel is used as the substrate A, and S31603 stainless steel is used as the cladding layer B. The thickness of the clad steel plate is 19 mm, of which the thickness of the substrate A is 13 mm, the thickness of the cladding layer B on the upper part of the substrate A is 3 mm, and the thickness of the cladding layer B on the lower part of the substrate A is 3 mm. The galvanometer laser-arc hybrid welding method is used for welding, and the specific difference is that:

[0078] The groove of the clad steel plate in S1 of this embodiment is "X type", and the groove size is as shown in Figure 5 The clad steel plates are assembled according to the groove size diagram in S2, and the gap between the two abutted clad steel plates is 0 mm without the need to install ceramic gaskets.

[0079] The assembled composite steel plate is fixed on the base in S3, and the composite steel plate welding bead arrangement is as shown in Figure 6 The specific process parameters are shown in Table 3.

[0080] Table 3. Process parameters of composite steel plate vibrating mirror laser-arc welding

[0081]

[0082] The first pass of the backing welding 1 uses ER55-G welding wire with a diameter of 1.2 mm, a welding speed of 800 mm / min, a current of 200 A, and a laser scanning amplitude of 0 mm to increase the welding depth, and the weld height is 1-2 mm below the junction line.

[0083] After the first pass of welding is completed, the operation control system cuts off the end of the welding wire, pulls back the welding wire, and automatically switches to 309 stainless steel welding wire.

[0084] The weld of the second pass 2 is the main position where the performance of the composite steel plate does not meet the standard and defects are generated, which is mainly related to the selection of welding wire composition and the arrangement of welding bead. For this embodiment, 309 stainless steel welding wire is selected for the second pass 2, supplemented with mixed powder of Cr and Ni, the weld covers the entire junction line area of the substrate and the cladding layer, and the weld height is 1-2 mm above the junction line.

[0085] After the second pass 2 of welding is completed, the operation control system cuts off the end of the welding wire, pulls back the welding wire, and stops powder feeding, and automatically switches to 316 stainless steel welding wire.

[0086] The weld of the third pass 3 is in the S31603 stainless steel area, which mainly uses 316 stainless steel welding wire, and the laser scanning amplitude is set to 5 mm during welding, which increases the laser width and improves the ability of complete fusion of the side part.

[0087] After the third pass 3 of welding is completed, the operation control system cuts off the end of the welding wire, pulls back the welding wire, and automatically switches to ER55-G stainless steel welding wire.

[0088] The fourth pass 4 uses ER55-G welding wire with a diameter of 1.2 mm to promote the fusion of the side wall, and the laser scanning amplitude is set to 2 mm, and the weld height is 1-2 mm below the junction line.

[0089] After the fourth pass 4 of welding is completed, the operation control system cuts off the end of the welding wire, pulls back the welding wire, and automatically switches to 309 stainless steel welding wire.

[0090] The weld of the fifth pass 5 covers the entire junction line area of the substrate and the cladding layer, and the welding powder is mainly mixed with Cr and Ni elements, and the weld height is 1-2 mm above the junction line.

[0091] After the fifth pass welding 5 is finished, the operation control system cuts off the welding wire end, withdraws the welding wire, stops the powder feeding, and automatically switches the 316 stainless steel welding wire.

[0092] The sixth pass welding 6 is at the S31603 stainless steel area, and the laser scanning amplitude is set to 5mm during welding, so as to increase the laser fusion width and improve the ability of complete fusion of the edge.

[0093] During the welding of the first to sixth pass welds, the workpiece temperature should not exceed 100℃.

[0094] S4: composite plate performance test

[0095] It is tested that the tensile strength of the Q420qE steel + S31603 stainless steel composite steel plate joint is 553MPa, the fracture occurs in the weld, which meets the technical requirements of GB / T 2651-2008; no visible cracks are found in the joint bend test, which meets the technical requirements of GB / T2653-2008; the average impact energy of the weld center is 59J, which meets the technical requirements of GB / T 2650-2008; the average impact energy of the heat affected zone is 223J, which meets the technical requirements of GB / T 2650-2008.

Claims

1. A method for welding composite steel plates using a multi-wire control and intelligent powder feeding welding device, characterized in that, Includes the following steps: S1: Processing and welding bevels on composite steel plates; S2: Assemble composite steel plates and add ceramic pads on the back; S3: Perform welding. Select the first type of welding wire that is similar to the substrate material. The operation and control system connects the corresponding welding wire feed channel with the wire feeding channel. The first part of the welding is performed using a galvanometer laser-arc hybrid welding method. Weld to a distance of 1-2 mm below the junction line between the substrate and the cladding. The operation and control system then cuts off the end of the welding wire and pulls the welding wire back. Select a second type of welding wire that is different from the substrate and cladding materials. The operation control system connects the corresponding welding wire feed channel with the wire feeding channel. The second part of the welding is performed using a galvanometer laser-arc hybrid welding method. At the same time, the powder flow rate of the powder feeding channel is controlled during the hybrid welding process. Welding powder is filled into the weld bead to form a stepped transition weld layer. Weld to 1-2 mm above the junction line between the substrate and the cladding. The operation control system cuts off the end of the welding wire and pulls the welding wire back, while stopping the powder feeding. Select a third type of welding wire that is similar to the coating material, and connect the corresponding welding wire feed channel with the wire feeding channel using the operation control system. Use a galvanometer laser-arc hybrid welding method to perform the third part of the welding. S4: Test the performance of the composite steel plate; The multi-wire control and intelligent powder feeding welding device includes a multi-wire composite welding torch, several wire feeding devices, a retraction device, a cutting device, and a control system. The multi-wire composite welding torch includes a torch body, a conductive nozzle, and a powder feeding head. The torch body has several wire feeding channels and powder feeding channels inside, and the conductive nozzle has a wire feeding channel. The powder feeding channel extends to the powder feeding head. The wire feeding devices are connected one-to-one with the wire feeding channels. The cutting device is located at the conductive nozzle. The control system is used to select the connection between the feeding channel and the wire feeding channel, to control the cutting device to cut off the end of the welding wire, to control the retraction device to pull the welding wire back from the wire feeding channel, and to control the powder flow rate in each powder feeding channel. The control system simultaneously controls the wire feeding speed and the powder feeding speed to control the ratio of welding wire to powder.

2. The composite steel plate welding method using a multi-wire control and intelligent powder feeding welding device according to claim 1, characterized in that, The wire feeding device is controlled by a single power supply, and each wire feeding device has its current, voltage, and wire feeding speed set independently by a control device.

3. The composite steel plate welding method using a multi-wire control and intelligent powder feeding welding device according to claim 1, characterized in that, It also includes a welding wire dry extension sensing device, which is located at the conductive tip and is used to sense the extension length range of the welding wire; the control system sets the rated extension length value of the welding wire and controls the welding wire feed to keep its extension length fixed by comparing the sensing data with the rated extension length value.

4. The composite steel plate welding method using a multi-wire control and intelligent powder feeding welding device according to claim 1, characterized in that, The retraction device includes a sensing component located at the wire feed channel; the sensing component is connected to the control system.

5. The composite steel plate welding method using a multi-wire control and intelligent powder feeding welding device according to claim 1, characterized in that, The number of welding wire feed channels is three.

6. The composite steel plate welding method using a multi-wire control and intelligent powder feeding welding device according to claim 1, characterized in that, The welding method of the galvanometer laser-arc hybrid welding is laser-GTAW wire feeding or laser-GMAW.

7. The composite steel plate welding method using a multi-wire control and intelligent powder feeding welding device according to claim 1, characterized in that, The galvanometer laser moves perpendicular to the welding direction, with a laser scanning amplitude of 0-5 mm, a scanning frequency of 10-200 Hz, and a horizontal filament spacing of 1-4 mm.

8. The composite steel plate welding method using a multi-wire control and intelligent powder feeding welding device according to claim 1, characterized in that, The weld width and depth of the composite steel plate galvanometer laser-arc hybrid welding process are achieved by adjusting the laser scanning amplitude. Within a certain range, when the laser scanning amplitude increases, the weld pool width increases and the weld depth decreases.

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