A combined welding method for transverse position butt automatic welding

Abstract

The application discloses a combined welding method for transverse position butt full-automatic welding, comprising the following steps: step 1, groove preparation; step 2, adjusting a gas-electric transverse welding device; step 3, gas-electric transverse welding; step 4, adjusting a submerged arc transverse welding device; and step 5, submerged arc transverse welding. The application adopts a combined welding process of gas-electric transverse welding and submerged arc transverse welding, respectively utilizes the high deposition efficiency of gas-electric welding and the high quality process characteristics of submerged arc welding, realizes efficient automatic welding of the transverse position butt weld in the dock loading stage, effectively improves the product welding efficiency under the premise of ensuring the weld quality, and greatly reduces the welding construction cost compared with the prior art. The application is favorable for improving the welding efficiency and welding quality of the transverse position butt weld in the dock loading stage, effectively reducing the processing production cost in the process of groove machining, and improving the utilization rate of steel plates.

Description

Technical Field

[0001] This invention belongs to the field of shipbuilding, and specifically relates to a combined welding method for fully automatic welding of transverse butt joints. Background Technology

[0002] In modern shipbuilding welding processes, there is a high degree of reliance on efficient automated welding techniques. This is especially true during the dock assembly phase, where factors such as the ship's heavy loads, high torque forces, operational risks, hull stability, and safety must be considered. Therefore, there is an urgent need to select an automated welding method for transverse butt welds during the dock assembly phase. Summary of the Invention

[0003] To solve the above-mentioned technical problems, the present invention provides a combined welding method for fully automatic horizontal butt welding, which adopts a combination of gas-electric horizontal welding and submerged arc horizontal welding processes. It utilizes the high deposition efficiency of gas-electric welding and the high quality process characteristics of submerged arc welding to achieve efficient and automatic welding of horizontal butt welds during the dock assembly stage.

[0004] The objective of this invention is achieved through the following technical solution: a combined welding method for fully automated horizontal butt welding, comprising the following steps: Step 1: Beveling preparation; Step 2: Adjust the gas-electric horizontal welding device; Step 3: Gas-electric horizontal welding; Step 4: Adjust the submerged arc welding device; Step 5: Submerged arc horizontal welding.

[0005] Preferably, in step 1, the bevel type is a single-sided V-shaped butt bevel, the bevel gap is 5mm-8mm, the blunt edge is 0mm-2mm, the bevel angle is 35°-40°, and the bottom edge of the bevel remains horizontal.

[0006] Preferably, in step 2, the adjustment of the gas-electric horizontal welding device includes selecting the width of the slider forming groove and adjusting the position of the welding torch.

[0007] Preferably, in step 2, the width of the slider forming groove is selected according to the bevel width. When the bevel width is ≤17mm, the width of the slider forming groove is 20mm. When the bevel width is 18mm-21mm, the width of the forming groove is 24mm, and the slider and the bevel are kept in close contact.

[0008] Preferably, in step 2, the welding torch position adjustment includes: first, adjusting the angle between the welding torch and the horizontal plane to 5°-15°, and simultaneously adjusting the height of the welding torch so that the vertical distance between the top of the welding torch and the lower edge of the protective gas outlet of the slider is controlled at 20mm-30mm; finally, adjusting the welding torch oscillation parameters so that its oscillation amplitude is maintained at 8mm-10mm, the dwell time at the root of the bevel is 1.0s-1.5s, and the dwell time on the surface of the bevel is 1.0s-1.5s.

[0009] Preferably, in step 3, the diameter of the welding wire used for gas-electric horizontal welding is 1.4 mm.

[0010] Preferably, in step 3, the gas-electric horizontal welding adopts single-pass transverse position welding, the welding current is 300A-330A, the arc voltage is 37V-40V, the welding speed is 10.5cm / min-12.2cm / min, and the welding of the root and part of the filling and cover areas is completed. The weld accounts for 70%-80% of the total weld area.

[0011] Preferably, in step 4, the adjustment of the submerged arc horizontal welding device includes the installation of the operating platform and the walking mechanism within the construction area.

[0012] Preferably, in step 4, the diameter of the welding wire used for submerged arc horizontal welding is 1.6 mm.

[0013] Preferably, in step 4, the submerged arc horizontal welding adopts multi-pass transverse position weld welding, wherein the welding current of the filling area is 255A-340A, the arc voltage is 39V-42V, and the welding speed is 30cm / min-65cm / min; the welding current of the cover area is 312A-365A, the arc voltage is 39V-42V, and the welding speed is 30cm / min-50cm / min, completing the welding of the remaining filling and cover areas of the bevel, and the interpass temperature of the submerged arc horizontal welding is less than or equal to 250℃.

[0014] Compared with the prior art, the present invention has the following advantages: This invention provides a combined welding method for fully automated butt welding in a transverse position. In this method, a single-sided V-groove is used for groove preparation, which not only facilitates control of the molten pool flow direction during welding but also reduces the need for beveling on one side, thus lowering groove processing costs. Furthermore, this invention employs gas-electric welding principles for root pass and partial filling / covering welding within the groove, achieving a single weld pass accounting for 70%-80% of the total weld, significantly improving welding efficiency compared to existing welding processes.

[0015] This invention fundamentally solves the technical challenge of transverse welding in submerged arc welding by adding a flux recovery device, thus promoting the development and application of submerged arc transverse welding technology. Compared with existing technologies, this invention improves the welding efficiency and quality of transverse butt welds during the dock assembly stage, while effectively reducing processing costs and increasing steel plate utilization during beveling. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the bevel form in an embodiment of the present invention; Figure 2 This is a schematic diagram of the weld bead arrangement in an embodiment of the present invention; Figure 3 This is a schematic diagram of the macroscopic inspection of the weld in Embodiment 1 of the present invention; Figure 4 This is a schematic diagram of the macroscopic inspection of the weld in Embodiment 2 of the present invention; Figure 5 This is a schematic diagram of the macroscopic inspection of the weld in Embodiment 3 of the present invention. Detailed Implementation

[0017] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and not intended to limit it. Furthermore, it should be noted that, for ease of description, the accompanying drawings show only the parts relevant to the present invention, and not all of the structures.

[0018] The following example, using the welding of a 20mm thick DH36 steel horizontal welding position single-sided welding double-sided forming butt test plate, further illustrates the combined welding method of fully automatic horizontal butt welding provided in the technical solution of this invention.

[0019] Example 1 Step 1: Bevel preparation. Process the upper bevel base material and complete the bevel assembly. The bevel type is a single-sided V-shaped butt bevel with a bevel gap of 6mm-7mm, a blunt edge of 0mm, a bevel angle of 35°, and the bottom edge of the bevel is kept horizontal.

[0020] Step 2: Preparation of the gas-electric horizontal welding device. In this embodiment, the bevel width is between 18mm and 21mm. First, select a 24mm gas-electric horizontal welding slider and install it at the center of the weld. The slider should fit tightly against the bevel, and the air vent of the slider should be clean and unobstructed. At the same time, adjust the welding torch angle, welding height, and welding torch swing parameters. That is, the angle between the welding torch and the horizontal plane should be 10°, the vertical distance between the top of the welding torch and the lower edge of the shielding gas outlet of the slider should be controlled at 25mm, the swing amplitude should be 8mm-10mm, the dwell time at the root of the bevel should be 1.1s-1.3s, and the dwell time on the surface of the bevel should be 1.1s-1.3s.

[0021] Step 3: Gas-electric horizontal welding. Use gas-electric horizontal welding material with a welding wire diameter of 1.4mm. Utilize the principle of gas-electric welding to perform single-pass horizontal position welding, completing the root pass and part of the fill and cover areas. According to volume measurement, the weld area should account for 75% of the total weld area. Welding current: 300A-330A, arc voltage: 37V-40V, welding speed: 10.5cm / min-12.2cm / min.

[0022] Step 4: Prepare the submerged arc horizontal welding device. Complete the installation of the operating platform, walking mechanism, and flux recovery device in the construction area.

[0023] Step 5: Submerged arc horizontal welding. Use specialized submerged arc horizontal welding materials with a welding wire diameter of 1.6mm and a matching flux. Utilize the principle of automatic submerged arc welding to perform multi-pass horizontal welds, completing the welding of the remaining filler and cover areas of the bevel. The interpass temperature for submerged arc horizontal welding should be less than or equal to 250℃. Filler area: welding current 255A-340A, arc voltage 39V-42V, welding speed 30cm / min-65cm / min; Cover area: welding current 312A-365A, arc voltage 39V-42V, welding speed 30cm / min-50cm / min.

[0024] Example 2 Step 1: Bevel preparation. Process the upper bevel base material and complete the bevel assembly. The bevel type is a single-sided V-shaped butt bevel with a bevel gap of 5mm, a blunt edge of 0mm, a bevel angle of 37°, and the bottom edge of the bevel is kept horizontal.

[0025] Step 2: Preparation of the gas-electric horizontal welding device. In this embodiment, the bevel width is less than or equal to 17 mm. First, select a gas-electric horizontal welding slider with a size of 20 mm, install the slider at the center of the weld, ensure that the slider fits tightly with the bevel, and ensure that the air vent of the slider is clean and unobstructed. At the same time, adjust the welding torch angle, welding height, and welding torch swing parameters, that is, the angle between the welding torch and the horizontal plane is 5°, the vertical distance between the top of the welding torch and the lower edge of the shielding gas outlet of the slider is controlled at 20 mm, the swing amplitude is 8 mm-10 mm, the dwell time at the root of the bevel is 1.0 s-1.1 s, and the dwell time at the surface of the bevel is 1.0 s-1.1 s.

[0026] Step 3: Gas-electric horizontal welding. Use gas-electric horizontal welding material with a welding wire diameter of 1.4mm. Utilize the principle of gas-electric welding to perform single-pass horizontal position welding, completing the root pass and part of the fill and cover areas. According to volume measurement, the weld area should account for 70% of the total weld area. Welding current: 300A-330A, arc voltage: 37V-40V, welding speed: 10.5cm / min-12.2cm / min.

[0027] Step 4: Prepare the submerged arc horizontal welding device. Complete the installation of the operating platform, walking mechanism, and flux recovery device in the construction area.

[0028] Step 5: Submerged arc horizontal welding. Use specialized submerged arc horizontal welding materials with a welding wire diameter of 1.6mm and a matching flux. Utilize the principle of automatic submerged arc welding to perform multi-pass horizontal welds, completing the welding of the remaining filler and cover areas of the bevel. The interpass temperature for submerged arc horizontal welding should be less than or equal to 250℃. Filler area: welding current 255A-340A, arc voltage 39V-42V, welding speed 30cm / min-65cm / min; Cover area: welding current 312A-365A, arc voltage 39V-42V, welding speed 30cm / min-50cm / min.

[0029] Example 3 Step 1: Bevel preparation. Process the upper bevel base material and complete the bevel assembly. The bevel type is a single-sided V-shaped butt bevel with a bevel gap of 8mm, a blunt edge of 0mm, a bevel angle of 40°, and the bottom edge of the bevel is kept horizontal.

[0030] Step 2: Preparation of the gas-electric horizontal welding device. In this embodiment, the bevel width is between 18mm and 21mm. First, select a 24mm gas-electric horizontal welding slider and install it at the center of the weld. The slider should fit tightly against the bevel, and ensure that the air vent of the slider is clean and unobstructed. At the same time, adjust the welding torch angle, welding height, and welding torch oscillation parameters. That is, the angle between the welding torch and the horizontal plane should be 15°, the vertical distance between the top of the welding torch and the lower edge of the shielding gas outlet of the slider should be controlled at 30mm, the oscillation amplitude should be 8mm-10mm, the dwell time at the root of the bevel should be 1.3s-1.5s, and the dwell time on the surface of the bevel should be 1.3s-1.5s.

[0031] Step 3: Gas-electric horizontal welding. Use gas-electric horizontal welding material with a welding wire diameter of 1.4mm. Utilize the principle of gas-electric welding to perform single-pass horizontal position welding, completing the root pass and part of the fill and cover areas. According to volume measurement, the weld area should account for 80% of the total weld area. Welding current: 300A-330A, arc voltage: 37V-40V, welding speed: 10.5cm / min-12.2cm / min.

[0032] Step 4: Prepare the submerged arc horizontal welding device. Complete the installation of the operating platform, walking mechanism, and flux recovery device in the construction area.

[0033] Step 5: Submerged arc horizontal welding. Use specialized submerged arc horizontal welding materials with a welding wire diameter of 1.6mm and a matching flux. Utilize the principle of automatic submerged arc welding to perform multi-pass horizontal welds, completing the welding of the remaining filler and cover areas of the bevel. The interpass temperature for submerged arc horizontal welding should be less than or equal to 250℃. Filler area: welding current 255A-340A, arc voltage 39V-42V, welding speed 30cm / min-65cm / min; Cover area: welding current 312A-365A, arc voltage 39V-42V, welding speed 30cm / min-50cm / min.

[0034] In the above embodiments, the gas-electric horizontal welding device and the submerged arc horizontal welding device are used to perform gas-electric horizontal welding and submerged arc horizontal welding on the test plate. The equipment used is conventional equipment, and its structure will not be described in detail here.

[0035] Non-destructive testing was performed on the test plate welded using the combined welding method of fully automatic butt welding in the horizontal position provided in the above embodiments. No welding defects were found in the weld. Mechanical property tests were performed on the test plate welded in the above embodiments, including impact performance, tensile strength, and bending performance. All of these met the standard requirements. The specific mechanical test results of the test plate in the above embodiments are shown in Table 1. Table 1 Results of mechanical property tests on the test plate

[0036] The above are preferred embodiments of the present invention. It should be noted that, for those skilled in the art, several improvements and modifications can be made without departing from the principle of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A combined welding method for fully automatic butt welding in a transverse position, characterized in that: The welding method includes the following steps: Step 1: Beveling preparation; The bevel type is a single-sided V-shaped butt bevel, the bevel gap is 5mm-8mm, the blunt edge is 0mm-2mm, the bevel angle is 35°-40°, and the bottom edge of the bevel remains horizontal. Step 2: Adjust the gas-electric horizontal welding device; The adjustment of the gas-electric horizontal welding device includes the selection of the slider forming groove width and the adjustment of the welding gun position. The slider forming groove width is selected according to the bevel width. When the bevel width is ≤17mm, the slider forming groove width is 20mm. When the bevel width is 18mm-21mm, the forming groove width is 24mm. The slider and the bevel are kept in close contact. The welding torch position adjustment includes: first, adjusting the angle between the welding torch and the horizontal plane to 5°-15°, and simultaneously adjusting the height of the welding torch so that the vertical distance between the top of the welding torch and the lower edge of the shielding gas outlet of the slider is controlled at 20mm-30mm; finally, adjusting the welding torch oscillation parameters so that the oscillation amplitude is maintained at 8mm-10mm, the dwell time at the root of the bevel is 1.0s-1.5s, and the dwell time on the surface of the bevel is 1.0s-1.5s. The gas-electric horizontal welding device is used to perform gas-electric horizontal welding on the test plate, and the equipment used is conventional equipment; Step 3: Gas-electric horizontal welding; The diameter of the welding wire used in gas-electric horizontal welding is 1.4 mm; Gas-electric horizontal welding adopts single-pass transverse position welding, with a welding current of 300A-330A, an arc voltage of 37V-40V, and a welding speed of 10.5cm / min-12.2cm / min. It completes the welding of the root pass and part of the fill and cover areas, with the weld accounting for 70%-80% of the total weld area. Step 4: Adjust the submerged arc welding device; The adjustment of the submerged arc horizontal welding device includes the installation of the operating platform and the walking mechanism within the construction area; The submerged arc horizontal welding device is used for submerged arc horizontal welding of test plates, and the equipment used is conventional equipment; Step 5: Submerged arc horizontal welding; The diameter of the welding wire used in submerged arc horizontal welding is 1.6mm; Submerged arc horizontal welding employs multi-pass transverse position welds. In the filling area, the welding current is 255A-340A, the arc voltage is 39V-42V, and the welding speed is 30cm / min-65cm / min. In the cover area, the welding current is 312A-365A, the arc voltage is 39V-42V, and the welding speed is 30cm / min-50cm / min. The remaining filling and cover areas of the bevel are then welded. The interpass temperature of submerged arc horizontal welding is less than or equal to 250℃.

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