Welding method and welding device

Abstract

This disclosure relates to a welding method and a welding apparatus. The welding method includes the following steps: controlling the magnetic field strength and direction switching frequency of a magnetic field generated by an electromagnetic coil, so that the magnetic field acts on continuously falling molten droplets generated by the welding equipment, causing the falling path of the continuously falling molten droplets to be deflected by the magnetic force. By using the magnetic field generated by the electromagnetic coil to act on the continuously falling molten droplets, the falling path of the continuously falling molten droplets is deflected by the magnetic force. Different magnetic field directions result in different directions of the magnetic force on the molten droplets, and different magnetic field strengths result in different magnetic forces on the molten droplets, resulting in different degrees of deflection. During the welding process, the continuously falling molten droplets, under the action of the magnetic force, can fall onto the bevel walls of the welding groove, thereby achieving a good fusion effect on the bevel walls.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to the technical field of welding, and in particular to a welding method and a welding device. BACKGROUND

[0002] Large thick plate structures are widely used in the fields of shipbuilding and aerospace. The welding groove form of thick plate components is mainly Y-type groove, which has the characteristics of high processing efficiency and low processing cost. However, Y-type groove has the problems of large welding filling amount and low welding efficiency in thick plate component production, and the Y-type groove of thick plate component is a variable gap groove, which is easy to cause welding defects such as incomplete fusion, hump and welding bead. SUMMARY

[0003] Some embodiments of the present disclosure provide a welding method and a welding device to alleviate the problem of poor fusion effect.

[0004] In one aspect of the present disclosure, a welding method is provided, comprising the following steps:

[0005] The magnetic field strength and the magnetic field direction switching frequency of the magnetic field generated by the electromagnetic coil are controlled, so that the falling path of the continuously falling droplet is deflected by the magnetic field force.

[0006] In some embodiments, the welding device comprises an arc welding device for generating the continuously falling droplet;

[0007] The welding method further comprises: controlling the magnetic field generated by the electromagnetic coil to also act on the electric arc emitted by the arc welding device, so that the emission direction of the electric arc is deflected by the magnetic field force.

[0008] In some embodiments, the welding method further comprises the following steps: adjusting the magnetic field strength and the magnetic field direction switching frequency according to the groove gap of the welding groove.

[0009] In some embodiments, the adjusting the magnetic field strength and the magnetic field direction switching frequency according to the groove gap of the welding groove comprises:

[0010] According to the functional relationship between the groove gap and the magnetic field strength, the magnetic field strength is adjusted to satisfy that the larger the groove gap, the larger the magnetic field strength.

[0011] In some embodiments, the adjusting the magnetic field strength and the magnetic field direction switching frequency according to the groove gap of the welding groove comprises:

[0012] According to the functional relationship between the groove gap and the magnetic field direction switching frequency, the magnetic field direction switching frequency is adjusted to satisfy that the larger the groove gap, the larger the magnetic field direction switching frequency.

[0013] In some embodiments, adjusting the magnetic field strength and magnetic field direction switching frequency according to the bevel gap of the welding groove includes:

[0014] The welding bevel shall be completed in at least two welding operations;

[0015] For the first weld, the control sensor detects the deepest bevel gap in the weld groove, and adjusts the magnetic field strength and magnetic field direction switching frequency according to the deepest bevel gap.

[0016] For welding that is not the first time, the control sensor detects the bevel gap corresponding to the weld surface formed after the previous welding is completed, and adjusts the magnetic field strength and magnetic field direction switching frequency according to the bevel gap corresponding to the weld surface.

[0017] In some embodiments, the welding equipment further includes laser welding equipment;

[0018] The welding method further includes: controlling the laser welding equipment and the electric arc welding equipment to work simultaneously, and performing laser-arc hybrid welding on the welding bevel.

[0019] In some embodiments, the switching frequency of the magnetic field strength and direction of the magnetic field generated by the control electromagnetic coil is used to cause the magnetic field to act on the continuously falling molten droplets generated by the welding equipment, so that the falling path of the continuously falling molten droplets is deflected by the magnetic force, including:

[0020] The direction of the magnetic field of the electromagnetic coil is controlled to be the first direction, so that the continuously falling molten droplets are subjected to the magnetic force of the first wall surface of the welding groove.

[0021] The magnetic field direction of the electromagnetic coil is controlled to be the second direction, so that the continuously falling molten droplets are subjected to the magnetic force of the second wall surface that is biased towards the welding groove;

[0022] The first direction and the second direction are opposite directions, and the switching frequency between the first direction and the second direction is the magnetic field direction switching frequency.

[0023] In some embodiments, the switching frequency of the magnetic field strength and direction of the magnetic field generated by the control electromagnetic coil is used to cause the magnetic field to act on the continuously falling molten droplets generated by the welding equipment, so that the falling path of the continuously falling molten droplets is deflected by the magnetic force, including:

[0024] During the welding process, the continuously falling molten droplets repeatedly fall back and forth onto the two walls of the welding groove.

[0025] In some embodiments, the welding method further includes the following steps:

[0026] Adjust the extension line of the welding wire in the arc welding equipment to intersect with the reference line; adjust the extension line of the central axis of the electromagnetic coil to intersect with the reference line; adjust the laser action point generated by the laser welding equipment to fall on the reference line; wherein, the reference line is the center line of the welding groove extending along the welding direction.

[0027] In some embodiments, the welding method further includes the following steps: controlling the laser power of the laser welding equipment to be 4kW to 10kW, the laser defocusing amount to be -5mm to +5mm; the welding speed to be 2m / min to 4m / min; and the distance between the laser action point of the laser welding equipment and the arc action point of the arc welding equipment on the reference line to be 1mm to 3mm.

[0028] In another aspect of this disclosure, a welding apparatus is provided, including a welding device, an electromagnetic coil, and a controller, the welding device being configured to generate continuously falling molten droplets, the controller being electrically connected to the electromagnetic coil, and the controller being configured to implement the welding method described above.

[0029] In another aspect of this disclosure, a welding apparatus is provided, comprising:

[0030] Welding equipment is configured to generate a continuous stream of falling molten droplets; and

[0031] An electromagnetic coil, whose magnetic field strength and magnetic field direction switching frequency are adjustable, is configured to generate a magnetic field that acts on a continuously falling molten droplet, so that the falling path of the continuously falling molten droplet is deflected by the magnetic field force.

[0032] In some embodiments, the welding apparatus further includes a sensor configured to detect the bevel gap of the weld groove for adjusting the magnetic field strength and magnetic field direction switching frequency based on the bevel gap.

[0033] In some embodiments, the welding apparatus further includes a controller electrically connected to the electromagnetic coil, the controller being configured to control the magnetic field strength and magnetic field direction switching frequency of the magnetic field generated by the electromagnetic coil, so that the magnetic field acts on the continuously falling molten droplets generated by the welding equipment, so that the falling path of the continuously falling molten droplets is deflected by the magnetic field force.

[0034] In some embodiments, the welding apparatus includes an arc welding apparatus configured to generate a continuous stream of falling molten droplets.

[0035] In some embodiments, the welding equipment further includes a laser welding device configured to operate simultaneously with the arc welding device to perform laser-arc hybrid welding on the weld bevel.

[0036] Based on the above technical solution, this disclosure has at least the following beneficial effects:

[0037] In some embodiments, a magnetic field generated by an electromagnetic coil acts on the continuously falling molten droplets, causing the droplets' path to be deflected by the magnetic force. Different magnetic field directions result in different directions of the magnetic force on the droplets, different deflection directions of the droplets' path, and different magnetic field strengths result in different magnetic forces on the droplets, and different degrees of deflection of the droplets' path. During the welding process, the continuously falling molten droplets, under the action of the magnetic force, can fall onto the bevel walls of the welding groove, thereby achieving a good fusion effect on the bevel walls. Attached Figure Description

[0038] The accompanying drawings, which are included to provide a further understanding of this disclosure and form part of this application, illustrate exemplary embodiments of this disclosure and are used to explain this disclosure, but do not constitute an undue limitation of this disclosure. In the drawings:

[0039] Figure 1 This is a schematic diagram of a welding bevel provided according to some embodiments of the present disclosure;

[0040] Figure 2 This is a schematic diagram illustrating the working principle of an alternating magnetic field according to some embodiments of this disclosure;

[0041] Figure 3 This is a schematic diagram illustrating the process by which the falling path of a continuously falling droplet changes under the influence of a magnetic field force, according to some embodiments of this disclosure.

[0042] Figure 4 This is a schematic diagram showing the working positions of the arc welding equipment and the laser welding equipment during a welding operation according to some embodiments of this disclosure;

[0043] Figure 5 This is a schematic diagram of a welding apparatus provided according to some embodiments of the present disclosure;

[0044] Figure 6 A flowchart illustrating the process of adjusting the magnetic field strength and magnetic field direction switching frequency based on the bevel gap of the welding groove according to some embodiments of this disclosure;

[0045] Figure 7 Metallographic images of welded joints without magnetic field and with applied alternating magnetic field according to some embodiments of this disclosure.

[0046] The labels in the attached diagram are explained as follows:

[0047] 1-Electromagnetic coil;

[0048] 2-Arc welding equipment; 21-Welding wire; 22-Welding torch; 23-Power supply;

[0049] 3-Sensors;

[0050] 4-Laser welding equipment; 41-Laser head; 42-Laser;

[0051] 5-Controller;

[0052] 100 - Welding bevel; 200 - Welding equipment; L - Reference line; M - Vertical line.

[0053] It should be understood that the dimensions of the various parts shown in the accompanying drawings are not drawn to actual scale. Furthermore, the same or similar reference numerals denote the same or similar components. Detailed Implementation

[0054] Various exemplary embodiments of the present disclosure will now be described in detail with reference to the accompanying drawings. The descriptions of the exemplary embodiments are merely illustrative and are in no way intended to limit the present disclosure or its application or use. The present disclosure may be implemented in many different forms and is not limited to the embodiments described herein. These embodiments are provided so that the present disclosure will be thorough and complete, and will fully express the scope of the disclosure to those skilled in the art. It should be noted that, unless specifically stated otherwise, the relative arrangement of components and steps, the composition of materials, numerical expressions, and values ​​set forth in these embodiments should be interpreted as exemplary only and not as limiting.

[0055] The terms "first," "second," and similar words used in this disclosure do not indicate any order, quantity, or importance, but are merely used to distinguish different parts. Words such as "including" or "contains" mean that the element preceding the word encompasses the element listed after it, and do not exclude the possibility of encompassing other elements as well. Terms such as "above," "below," "left," and "right" are used only to indicate relative positional relationships; when the absolute position of the described object changes, this relative positional relationship may also change accordingly.

[0056] In this disclosure, when a specific device is described as being located between a first device and a second device, an intermediary device may or may not be present between the specific device and the first or second device. When a specific device is described as being connected to other devices, the specific device may be directly connected to the other devices without an intermediary device, or it may be not directly connected to the other devices but have an intermediary device.

[0057] All terms used in this disclosure (including technical or scientific terms) have the same meaning as understood by one of ordinary skill in the art to which this disclosure pertains, unless otherwise specifically defined. It should also be understood that terms defined in a general dictionary, such as a dictionary, should be interpreted as having a meaning consistent with their meaning in the context of the relevant art, and not as having an idealized or highly formalized meaning, unless expressly defined herein.

[0058] Techniques, methods, and equipment known to those skilled in the art may not be discussed in detail, but where appropriate, such techniques, methods, and equipment should be considered part of the specification.

[0059] refer to Figure 1 The welding bevel 100 provided in some embodiments of this disclosure Figure 1 The welding bevel 100 is a Y-type bevel. Of course, the form of the welding bevel 100 is not limited to the Y-type bevel. It can also be a U-type bevel, a V-type bevel, or an I-type bevel, etc.

[0060] exist Figure 1 In the illustrated embodiment, the thickness H1 of the plate containing the Y-shaped bevel ranges from 12mm to 24mm. The height H2 of the vertical section of the Y-shaped bevel ranges from 4mm to 8mm. The bevel gap x at the deepest point of the Y-shaped bevel ranges from 0mm to 1.5mm. The single-sided bevel opening is 12° to 20°.

[0061] Y-groove joints have problems such as large welding filler and low welding efficiency in the production of thick plate components. Furthermore, the Y-groove joints of thick plate components are variable gap grooves, which are prone to welding defects such as incomplete fusion, humps, and weld beads.

[0062] Based on this, some embodiments of this disclosure provide welding methods and welding apparatus to alleviate the problem of poor fusion effect.

[0063] In some embodiments, the welding method includes the following steps:

[0064] The magnetic field strength and direction switching frequency of the magnetic field generated by the electromagnetic coil 1 are controlled so that the magnetic field acts on the continuously falling molten droplets generated by the welding equipment 200, so that the falling path of the continuously falling molten droplets is deflected by the magnetic field force.

[0065] refer to Figure 2 This is a comparison diagram showing the magnetic forces experienced by molten droplets generated by welding equipment 200 under opposite magnetic field directions.

[0066] In the above embodiment, the magnetic field generated by the electromagnetic coil 1 acts on the continuously falling molten droplets, causing the falling path of the continuously falling molten droplets to be deflected by the magnetic force. Different magnetic field directions result in different directions of magnetic force on the molten droplets, different deflection directions of the falling path of the molten droplets, and different magnetic field strengths result in different magnetic force on the molten droplets, resulting in different degrees of deflection of the falling path of the molten droplets. During the welding process, the continuously falling molten droplets can fall onto each bevel wall of the welding groove 100 under the action of the magnetic force, thereby achieving a good fusion effect of the bevel wall.

[0067] Furthermore, even with variable bevel gaps, good fusion of the bevel wall can still be achieved by adjusting the magnetic field strength and the frequency of magnetic field direction switching, thereby improving the bevel machining accuracy of large and complex structural parts and alleviating welding defects such as incomplete fusion, humps, and weld beads in variable bevel gap welding.

[0068] Furthermore, by setting the frequency of magnetic field direction switching, the magnetic field direction can be switched back and forth, which can periodically change the force direction of the continuously falling molten droplets. The continuously falling molten droplets will oscillate periodically, which can periodically adhere to the walls of each bevel of the welding groove, thereby achieving a good bevel wall fusion effect.

[0069] The welding method provided in this disclosure is applicable not only to thick plate welding but also to thin plate welding.

[0070] The welding method provided in this disclosure is not only applicable to Y-groove, but also to U-groove, V-groove, or I-groove, etc.

[0071] In some embodiments, the welding equipment 200 includes an arc welding device 2, which is used to generate continuously falling molten droplets.

[0072] The welding method also includes: controlling the magnetic field generated by the electromagnetic coil 1 to act on the electric arc emitted by the electric arc welding equipment 2, so that the direction of the electric arc is deflected by the magnetic force.

[0073] In the above embodiments, by setting a magnetic field direction switching frequency, the magnetic field direction is switched back and forth, which periodically changes the force direction of the continuously falling molten droplets and the electric arc. Under the influence of the magnetic field, the continuously falling molten droplets and the electric arc can oscillate periodically. After oscillation, the molten droplets can periodically adhere to the bevel walls of the welding groove 100, thereby achieving a good bevel wall fusion effect. Furthermore, the periodic oscillation of the electric arc and the continuously falling molten droplets improves the adaptability of the welding method provided in this embodiment to variable bevel gaps. Moreover, the periodic oscillation of the electric arc can also reduce the size of the molten droplets, making it easier for smaller droplets to oscillate periodically with the electric arc. This droplet behavior allows them to better adhere to the bevel wall transition, thereby alleviating the problem of incomplete bevel wall fusion.

[0074] Furthermore, the magnetically controlled oscillating electric arc can also stir the molten pool, which can break up dendrites and refine the microstructure. At the same time, the stirring effect of the oscillating arc on the molten pool is conducive to the escape of pores, which helps to reduce porosity, improve welding quality, and alleviate the problem of excessive porosity in thick plate welding.

[0075] In some embodiments, the welding method further includes the step of adjusting the magnetic field strength and magnetic field direction switching frequency according to the bevel gap of the welding groove 100.

[0076] In the above embodiments, the magnetic field strength and direction are adjusted according to the groove gap of the welding groove 100, which is applicable to welding grooves 100 with variable groove gaps. This meets welding quality requirements such as groove gap adaptability, reduces welding defects such as incomplete fusion, humps and weld beads, improves welding efficiency, has higher adaptability to narrow groove gaps, greatly reduces material consumption, and saves time and energy costs.

[0077] In some embodiments, adjusting the magnetic field strength and magnetic field direction switching frequency according to the bevel gap of the welding groove 100 includes:

[0078] Based on the functional relationship between the bevel gap and the magnetic field strength, the magnetic field strength is adjusted to ensure that the larger the bevel gap, the greater the magnetic field strength.

[0079] In the above embodiments, the larger the bevel gap of the welding groove 100, the greater the oscillation amplitude of the continuously falling molten droplet needs to be. Therefore, a greater magnetic field strength is required. A greater magnetic field strength generates a greater magnetic force on the molten droplet, enabling a significant deflection of the continuously falling droplet, which is suitable for larger bevel gaps. Similarly, the smaller the bevel gap of the welding groove 100, the smaller the oscillation amplitude of the continuously falling molten droplet needs to be. Therefore, a smaller magnetic field strength is required. A smaller magnetic field strength generates a smaller magnetic force on the molten droplet, enabling a smaller deflection of the continuously falling droplet, which is suitable for smaller bevel gaps.

[0080] In some embodiments, the functional relationship between the bevel gap and the magnetic field strength can be a linear function or a nonlinear function.

[0081] In some embodiments, the functional relationship between bevel gap and magnetic field strength can be fitted using multiple sets of experimental data on bevel gap and magnetic field strength. For example, parabolic fitting or least squares fitting methods can be used to obtain the functional relationship between bevel gap and magnetic field strength.

[0082] In some embodiments, using experimental data on multiple sets of bevel gaps and magnetic field strength, a parabolic fitting method is employed to fit the functional relationship between bevel gaps and magnetic field strength, as follows:

[0083] H = F(x) = Ax n +Bx+C, where...

[0084] x represents the bevel gap of a 100mm welding bevel;

[0085] H is the magnetic field strength;

[0086] A, B, and C are constant terms.

[0087] In this context, A and B both range from 8 to 12, and n is an integer greater than 1. The value of C is unlimited and is determined based on the plate thickness.

[0088] Optionally, A is 10, B is 10, and n is 2. The functional relationship between the bevel gap and the magnetic field strength is: H = F(x) = 10x 2 +10x+C.

[0089] As the bevel gap increases, a greater magnetic field strength is required to control the continuously falling molten droplets and the amplitude of the arc. However, the relationship between the increase in amplitude and the magnetic field strength is non-linear. This is suitable for welding bevels with variable bevel gaps, such as bevel gap adaptability, and meets welding quality requirements.

[0090] In some embodiments, adjusting the magnetic field strength and magnetic field direction switching frequency according to the bevel gap of the welding groove 100 includes:

[0091] Based on the functional relationship between the bevel gap and the magnetic field direction switching frequency, the magnetic field direction switching frequency is adjusted to ensure that the larger the bevel gap, the larger the magnetic field direction switching frequency.

[0092] In the above embodiments, the larger the bevel gap of the welding groove 100, the more times the molten droplet needs to oscillate back and forth before falling. Therefore, a higher magnetic field direction switching frequency is required. A higher magnetic field direction switching frequency allows the molten droplet to oscillate back and forth more times per unit time, which is suitable for larger bevel gaps. Similarly, the smaller the bevel gap of the welding groove 100, the fewer times the molten droplet needs to oscillate back and forth before falling. Therefore, a lower magnetic field direction switching frequency is required. A lower magnetic field direction switching frequency allows the molten droplet to oscillate back and forth less times per unit time, which is suitable for smaller bevel gaps.

[0093] In some embodiments, the functional relationship between the bevel gap and the magnetic field direction switching frequency can be a linear functional relationship or a nonlinear functional relationship.

[0094] In some embodiments, the functional relationship between the bevel gap and the magnetic field direction switching frequency can be fitted using multiple sets of experimental data on the bevel gap and magnetic field direction switching frequency. For example, parabolic fitting or least squares fitting methods can be used to obtain the functional relationship between the bevel gap and the magnetic field direction switching frequency.

[0095] In some embodiments, using experimental data on multiple sets of bevel gap and magnetic field direction switching frequencies, a parabolic fitting method is employed to fit the functional relationship between bevel gap and magnetic field direction switching frequency, as follows:

[0096] f = F(x) = Dx n +Ex; where,

[0097] x represents the bevel gap of a 100mm welding bevel;

[0098] f is the frequency at which the magnetic field direction switches;

[0099] D and E are constant terms.

[0100] Where D ranges from 3 to 6, E ranges from 3 to 6, and n is an integer greater than 1.

[0101] Optionally, D is 5, E is 5, and n is 2. The functional relationship between the bevel gap and the switching frequency of the magnetic field direction is: f = F(x) = 5x 2 +5x.

[0102] As the bevel gap increases, a higher magnetic field direction switching frequency is needed to adapt to the bevel gap; otherwise, poor fusion will occur under a large bevel gap.

[0103] In some embodiments, adjusting the magnetic field strength and magnetic field direction switching frequency according to the bevel gap of the welding groove 100 includes:

[0104] The welding bevel must be completed in at least two welding operations;

[0105] For the first welding, the control sensor 3 detects the deepest bevel gap of the welding groove 100, and adjusts the magnetic field direction switching frequency and magnetic field strength according to the deepest bevel gap.

[0106] For welding that is not the first time, the control sensor 3 detects the bevel gap corresponding to the weld surface formed after the previous welding is completed, and adjusts the magnetic field strength and magnetic field direction switching frequency according to the bevel gap corresponding to the weld surface.

[0107] The groove gap corresponding to the weld surface formed after the previous welding is the deepest groove gap of the groove that needs to be welded this time.

[0108] For welding bevels on thick plate components, due to the large bevel depth, welding can be performed in at least two stages. After each welding operation, the bevel gap at the deepest point of the unfinished bevel is checked to re-determine the magnetic field strength and magnetic field direction switching frequency. As the bevel depth decreases towards the shallower end, the bevel gap of the Y-shaped bevel increases, requiring a higher magnetic field strength to cause the continuously falling molten droplets to oscillate more significantly, and a higher magnetic field direction switching frequency to cause the droplets to oscillate and fall more frequently.

[0109] In some embodiments, the welding equipment 200 further includes a laser welding device 4.

[0110] The welding method also includes controlling the laser welding equipment 4 and the electric arc welding equipment 2 to work simultaneously to perform laser-electric arc hybrid welding on the welding groove 100.

[0111] Laser welding, as a high-energy beam welding method, has the characteristics of high energy density and low heat input, and has significant advantages in the field of thick plate welding.

[0112] The laser-arc hybrid welding method combines two heat sources, laser and electric arc, to achieve greater weld penetration and enable efficient and high-quality welding.

[0113] In some embodiments, controlling the switching frequency of the magnetic field strength and direction of the magnetic field generated by the electromagnetic coil 1, so that the magnetic field acts on the continuously falling molten droplets generated by the welding equipment 200, so that the falling path of the continuously falling molten droplets is deflected by the magnetic force, including:

[0114] The magnetic field direction of the electromagnetic coil 1 is controlled to be the first direction, so that the continuously falling molten droplets are subjected to the magnetic force biased towards the first wall surface of the welding groove 100.

[0115] The magnetic field direction of the electromagnetic coil 1 is controlled to be the second direction, so that the continuously falling molten droplets are subjected to the magnetic force of the second wall surface of the welding groove 100.

[0116] The first direction and the second direction are opposite directions, and the switching frequency between the first direction and the second direction is the magnetic field direction switching frequency.

[0117] refer to Figure 3 At time t0, the arc and molten droplet are in the first magnetic field direction, experiencing a force deflected towards the first wall. This is the final moment of this deflection. At this moment, the molten droplet falling onto the first wall experiences the magnetic force deflected towards the first wall throughout its entire descent, resulting in the maximum amplitude of its oscillation. At the extreme point of this deflection, the maximum amplitude of the sidewall transition is achieved, and the direction of the magnetic field begins to reverse. The molten droplet and arc then begin to experience a magnetic force deflected towards the second wall. The molten droplet that has not yet reached the bevel wall begins to deflect towards the second wall. At that moment, some molten droplets had not yet deflected to the second wall surface but had already dripped onto the first wall surface. At that moment, the molten droplets had all been deflected to the second wall. At that moment, the deflection positions of the arc and the molten droplet reach their extreme values ​​on the second wall, and the molten droplet achieves its maximum sidewall transition on the second wall. Simultaneously, the magnetic field direction reverses again, and the molten droplet and the arc begin to experience a force deflecting towards the first wall. At that moment, some molten droplets had not yet deflected to the first wall surface, but had already dripped onto the second wall surface. At time t0+T, the molten droplet has been completely deflected to the first wall surface. At this time, the deflection position of the arc and the molten droplet reaches its extreme value on the first wall surface, and at the same time, the direction of the magnetic field changes in the opposite direction again. This cycle repeats to achieve high-frequency oscillating welding and a good bevel wall transition.

[0118] In some embodiments, controlling the switching frequency of the magnetic field strength and direction of the magnetic field generated by the electromagnetic coil 1, so that the magnetic field acts on the continuously falling molten droplets generated by the welding equipment 200, so that the falling path of the continuously falling molten droplets is deflected by the magnetic force, including:

[0119] During the welding process, the continuously falling molten droplets are repeatedly dropped onto the two walls of the welding groove 100.

[0120] In the above embodiments, the force direction of the continuously falling molten droplets and electric arc changes periodically. The continuously falling molten droplets and electric arc can oscillate periodically under the influence of the magnetic field. After oscillation, the molten droplets can periodically adhere to the bevel walls of the welding groove 100, thereby achieving a good bevel wall fusion effect.

[0121] refer to Figure 4 In some embodiments, the welding method further includes the following steps:

[0122] Adjust the extension line of the welding wire in the arc welding equipment 2 to intersect with the reference line L;

[0123] Adjust the extension line of the central axis of electromagnetic coil 1 to intersect the reference line L;

[0124] Adjust the laser action point generated by laser welding equipment 4 to fall on reference line L;

[0125] Among them, reference line L is the center line of the welding groove 100 extending along the welding direction.

[0126] In the above embodiments, by adjusting the position of the welding wire in the arc welding equipment 2, the position of the electromagnetic coil 1, and the position of the laser action point generated by the laser welding equipment 4, a better welding effect can be achieved.

[0127] In some embodiments, the angle α1 between the extension of the welding wire in the arc welding equipment 2 and the perpendicular M is 35°, but it is not limited thereto.

[0128] In some embodiments, the laser generated by the laser welding device 4 forms an angle α2 of 5° with the vertical line M, but is not limited thereto.

[0129] The perpendicular line M is perpendicular to the reference line L.

[0130] In some embodiments, the welding method further includes the following steps: controlling the laser power of the laser welding equipment 4 to be 4kW to 10kW, the laser defocusing amount to be -5mm to +5mm; the welding speed to be 2m / min to 4m / min; and the distance between the laser action point of the laser welding equipment 4 and the arc action point of the arc welding equipment 2 on the reference line L to be 1mm to 3mm.

[0131] The laser application point of the laser welding equipment 4, the arc application point of the electric arc welding equipment 2, and the moving speed of the electromagnetic coil 1 along the welding direction are consistent with the welding speed.

[0132] refer to Figure 6 In some embodiments, the welding method includes the following steps:

[0133] Clean and grind the welding bevel of the plates to be welded;

[0134] The plates to be welded are clamped and fixed using a fixture;

[0135] Welding process parameter settings;

[0136] The switching frequency of the magnetic field strength and direction of the electromagnetic coil is set to control the oscillation amplitude and oscillation period of the electric arc and molten droplet;

[0137] Perform laser-arc hybrid welding operations;

[0138] The welding bevel is welded in at least two stages. Before the next welding is performed after the previous welding is completed, the bevel gap in front of the laser spot is detected by a sensor, and the detected bevel gap data is sent back to the controller (computer).

[0139] The controller (computer) sends instructions based on the received bevel gap data to reset the magnetic field strength and magnetic field direction switching frequency of the electromagnetic coil, so as to adjust the oscillation amplitude and oscillation period of the electric arc and molten droplet, and achieve a good match between the oscillation amplitude and the bevel gap.

[0140] The electric arc and molten droplets can oscillate periodically under the influence of the magnetic field. After oscillation, the molten droplets can periodically adhere to the groove walls on both sides of the welding groove, thereby achieving a good sidewall fusion effect.

[0141] In some specific embodiments, the welding method includes the following steps:

[0142] 1) After cleaning and grinding the welding bevel of the plate to be welded, clamp and fix the plate to be welded with a fixture and place it on the welding workbench.

[0143] Install the corresponding welding device, adjust the extension line of the welding wire in the arc welding equipment 2 to intersect with the reference line L; adjust the extension line of the central axis of the electromagnetic coil 1 to intersect with the reference line L; adjust the laser action point generated by the laser welding equipment 4 to fall on the reference line L.

[0144] 2) Set the welding process parameters. Set the laser power of the laser welding equipment 4 to 4kW~10kW, the laser defocusing amount to -5mm~+5mm, the welding speed to 2m / min~4m / min, and the distance between the laser action point of the laser welding equipment 4 and the arc action point of the arc welding equipment 2 on the reference line L to 1mm~3mm.

[0145] The initial magnetic field strength and magnetic field direction switching frequency are set based on the deepest bevel gap of the initial weld groove 100. See [link / reference] Figure 2 This illustrates the effect of an alternating magnetic field on the electric arc and molten droplets during welding. The dashed arrows indicate the direction of the current, while the solid arrows indicate the direction of the force on the electric arc and molten droplets. Within one cycle, the direction of the magnetic field lines changes.

[0146] During the first half of the cycle, the magnetic field lines are opposite to the welding direction and point towards the back of the weld, while the current direction is from the substrate to the welding torch. According to the left-hand rule, the arc will be subjected to a force perpendicular to the current direction to the left, thereby deflecting the arc and the molten droplet and transitioning towards one side of the weld groove wall.

[0147] In the second half of the cycle, the magnetic field lines are in the same direction as the welding direction, pointing towards the welding direction, and the current direction is from the substrate to the welding torch. At this time, according to the left-hand rule, the arc will be subjected to a force to the right perpendicular to the current direction. The arc and the molten droplet will deflect in the opposite direction to the first half of the cycle, transitioning to the groove wall on the other side of the welding groove.

[0148] 3) Perform laser-arc hybrid welding. During the welding process, sensor 3 detects the groove gap of the welding groove 100 at the welding position in real time and sends the detected groove gap data back to the controller.

[0149] 4) The controller calls a function to adjust the magnetic field strength. The specific function call is H = F(x) = 10x. 2 +10x+C, where x is the bevel gap of the weld groove 100 detected by sensor 3, H is the magnetic field strength, and C is a constant. This parameter serves as a loading factor to optimize the welding quality of different materials. As the bevel gap increases, a larger magnetic field strength is required to control the arc amplitude. However, the relationship between the amplitude increment and the magnetic field strength is non-linear, and the above functional relationship is preferred.

[0150] At the same time, the function f = F(x) = 5x is called. 2+5x is used to adjust the magnetic field direction switching frequency. As the bevel gap increases, a higher oscillation frequency f is needed to adapt to the bevel gap; otherwise, poor fusion will occur under a large bevel gap.

[0151] 5) After receiving the bevel gap data of the welding groove 100, the controller sends a command to the magnetic control device to adjust the magnetic field strength to further control the magnetic force on the molten droplet and the electric arc, thereby controlling the oscillation amplitude of the electric arc and the molten droplet to further adapt to the welding work, and always achieving good matching between the oscillation amplitude and the bevel gap during the welding process.

[0152] The actual droplet oscillation during welding is as follows Figure 3 As shown, time t0 is the moment when the deflection positions of the arc and the molten droplet reach their extreme values. At this moment, the sidewall transition with maximum amplitude is achieved, and the direction of the magnetic field also begins to reverse from this moment. The arc and the molten droplet begin to be subjected to forces in opposite directions, and the molten droplet begins to deflect to the other side. At this moment, the deflection positions of the electric arc and the molten droplet reach their extreme values ​​on the other side, and the molten droplet achieves the maximum amplitude sidewall transition on the other side. At the same time, the direction of the magnetic field changes in the opposite direction again. This cycle repeats to achieve high-frequency oscillating welding and a good sidewall transition.

[0153] refer to Figure 7 The left image shows the metallographic image of the welded joint without an alternating magnetic field, while the right image shows the metallographic image of the welded joint with an alternating magnetic field. The welded joint in the left image exhibits porosity and lack of fusion defects, with the size of the lack of fusion reaching the millimeter level. This has an extremely serious and detrimental impact on the performance of the actual welded joint. In contrast, the metallographic image of the joint after applying the alternating magnetic field, as shown in the right image, shows a uniform and neat multi-pass weld with no porosity or lack of fusion defects. Furthermore, observing the cap weld in both images reveals slight undercut defects in the metallographic image of the welded joint without an alternating magnetic field, while the weld in the joint with an alternating magnetic field is smoother, with a smooth transition to the base metal, and no undercut defects. An alternating magnetic field facilitates the spread of the molten pool, thus achieving a smooth transition between the weld and the base metal.

[0154] refer to Figure 5 Some embodiments of this application also provide a welding apparatus including a welding device 200, an electromagnetic coil 1, and a controller 5. The welding device 200 is configured to generate continuously falling molten droplets, and the controller 5 is electrically connected to the electromagnetic coil 1 and configured to implement the welding method as described in any of the above embodiments.

[0155] refer to Figure 5 Some embodiments of this application also provide a welding apparatus, which includes:

[0156] Welding equipment 200 is configured to generate continuously falling molten droplets; and

[0157] Electromagnetic coil 1 has an adjustable frequency for switching magnetic field strength and direction. Electromagnetic coil 1 is configured to generate a magnetic field that acts on a continuously falling molten droplet, so that the falling path of the continuously falling molten droplet is deflected by the magnetic force.

[0158] In some embodiments, the welding apparatus further includes a sensor 3 configured to detect the bevel gap of the welding groove 100 for adjusting the magnetic field strength and magnetic field direction switching frequency according to the bevel gap.

[0159] In some embodiments, the welding apparatus further includes a controller 5, which is electrically connected to the electromagnetic coil 1. The controller 5 is configured to control the magnetic field strength and magnetic field direction switching frequency of the magnetic field generated by the electromagnetic coil 1, so that the magnetic field acts on the continuously falling molten droplets generated by the welding equipment 200, so that the falling path of the continuously falling molten droplets is deflected by the magnetic field force.

[0160] Controller 5 may be a computer-readable storage medium.

[0161] In some embodiments, the welding apparatus 200 includes an arc welding apparatus 2, which is configured to generate continuously falling molten droplets.

[0162] In some embodiments, the arc welding apparatus 2 includes a welding torch 22, a power supply 23, and a welding wire 21. The welding wire 21 is mounted on the welding torch 22, and the power supply 23 is used to supply power to the welding torch 22 so that the welding torch 22 emits an electric arc.

[0163] In some embodiments, the welding equipment 200 further includes a laser welding equipment 4, which is configured to work simultaneously with the arc welding equipment 2 to perform laser-arc hybrid welding on the welding groove 100.

[0164] In some embodiments, the laser welding equipment 4 includes a laser head 41 and a laser 42, wherein the laser 42 is used to generate laser light and the laser head 41 is used to emit the laser light generated by the laser 42.

[0165] The welding apparatus provided in this embodiment is used to implement the welding method provided in this embodiment, and therefore has the beneficial effects of the welding method.

[0166] Based on the embodiments disclosed above, in the absence of explicit denial or conflict, the technical features of one embodiment may be advantageously combined with one or more other embodiments.

[0167] While specific embodiments of this disclosure have been described in detail by way of examples, those skilled in the art should understand that the examples are for illustrative purposes only and not intended to limit the scope of this disclosure. Those skilled in the art should understand that modifications can be made to the above embodiments or equivalent substitutions can be made to some technical features without departing from the scope and spirit of this disclosure. The scope of this disclosure is defined by the appended claims.

Claims

1. A welding method, characterized in that, Includes the following steps: Controlling the magnetic field strength and magnetic field direction switching frequency of the magnetic field generated by the electromagnetic coil (1) so that the magnetic field acts on the continuously falling molten droplets generated by the welding equipment (200) so that the falling path of the continuously falling molten droplets is deflected by the magnetic field force, including: controlling the magnetic field direction of the electromagnetic coil (1) to be a first direction so that the continuously falling molten droplets are subjected to a magnetic field force deflected towards the first wall surface of the welding groove (100); controlling the magnetic field direction of the electromagnetic coil (1) to be a second direction so that the continuously falling molten droplets are subjected to a magnetic field force deflected towards the second wall surface of the welding groove (100); wherein, the first direction and the second direction are opposite directions, and the switching frequency between the first direction and the second direction is the magnetic field direction switching frequency; According to the bevel gap of the welding groove (100), the magnetic field strength and magnetic field direction switching frequency are adjusted, including: according to the functional relationship between the bevel gap and the magnetic field direction switching frequency, the magnetic field direction switching frequency is adjusted so that the larger the bevel gap, the larger the magnetic field direction switching frequency; according to the functional relationship between the bevel gap and the magnetic field strength, the magnetic field strength is adjusted so that the larger the bevel gap, the larger the magnetic field strength; and the welding groove (100) is completed in at least two welding operations; for the first welding, the control sensor (3) detects the deepest bevel gap of the welding groove (100), and the magnetic field strength and magnetic field direction switching frequency are adjusted according to the deepest bevel gap; for non-first welding, the control sensor (3) detects the bevel gap corresponding to the welding surface formed after the previous welding is completed, and the magnetic field strength and magnetic field direction switching frequency are adjusted according to the bevel gap corresponding to the welding surface.

2. The welding method according to claim 1, characterized in that, The welding equipment (200) includes an arc welding device (2) for generating continuously falling molten droplets; The welding method further includes: controlling the magnetic field generated by the electromagnetic coil (1) to also act on the electric arc emitted by the electric arc welding equipment (2), so that the ejection direction of the electric arc is deflected by the magnetic force.

3. The welding method according to claim 2, characterized in that, The welding equipment (200) further includes a laser welding device (4); The welding method further includes: controlling the laser welding equipment (4) and the electric arc welding equipment (2) to work simultaneously to perform laser-electric arc composite welding on the welding groove (100).

4. The welding method according to any one of claims 1 to 3, characterized in that, The switching frequency of the magnetic field strength and direction of the magnetic field generated by the control electromagnetic coil (1) causes the magnetic field to act on the continuously falling molten droplets generated by the welding equipment (200), so that the falling path of the continuously falling molten droplets is deflected by the magnetic force, including: During the welding process, the continuously falling molten droplets are repeatedly dropped onto the two walls of the welding groove (100).

5. The welding method according to claim 3, characterized in that, It also includes the following steps: Adjust the extension line of the welding wire in the arc welding equipment (2) to intersect with the reference line (L); adjust the extension line of the central axis of the electromagnetic coil (1) to intersect with the reference line (L); adjust the laser action point generated by the laser welding equipment (4) to fall on the reference line (L); wherein, the reference line (L) is the center line of the welding groove (100) extending along the welding direction.

6. The welding method according to claim 5, characterized in that, It also includes the following steps: The laser power of the laser welding equipment (4) is 4 kW to 10 kW, the laser defocusing amount is -5 mm to +5 mm, the welding speed is 2 m / min to 4 m / min, and the distance between the laser action point of the laser welding equipment (4) and the arc action point of the arc welding equipment (2) on the reference line (L) is 1 mm to 3 mm.

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