A pressure vessel submerged arc welding method and system

Abstract

The invention discloses a submerged arc welding method and system for a pressure vessel, the method comprising: matching a corresponding maximum penetration value of a single weld pass and a minimum penetration value of a single weld pass from a database based on current parent material and welding wire material information; dividing a cross section of a to-be-welded area into a filling area and a covering area according to the groove size after the weld bottom, the maximum penetration value of the single weld pass and the minimum penetration value of the single weld pass, the covering area being composed of a single layer of multiple first weld passes and a layer height being equal to the minimum penetration value of the single weld pass, and the filling area being composed of multiple layers of multiple second weld passes in each layer and a layer height being less than the maximum penetration value of the single weld pass; matching corresponding welding parameters from a database based on the size information of the first weld pass and the size information of the second weld pass to obtain first welding parameters and second welding parameters; performing multi-layer and multi-pass welding operations on the filling area in sequence based on the second welding parameters, wherein slag cleaning is performed after each weld pass is completed; performing single-layer and multi-pass welding operations on the covering area in sequence based on the first welding parameters, wherein slag cleaning is performed after each weld pass is completed. By maximizing the height of each weld bead in the filling layer, the present invention significantly reduces the number of welding layers, reduces welding time and cost, and reduces the risk of residual stress accumulation caused by multi-layer welding, compared with the method of blindly increasing the number of welding layers to achieve the required filling height.

Description

Technical Field

[0001] The invention relates to the technical field of submerged arc welding, and in particular to a submerged arc welding method and system for a pressure vessel. Background Art

[0002] In the traditional field of pressure vessel, shipbuilding and heavy structural welding, multi-layer and multi-pass submerged arc welding technology is widely used to ensure the strength and integrity of welded structures, especially when processing thick materials. However, the commonly used strategy in the prior art is often based on relatively fixed weld specifications and layer heights for multi-layer stacking, that is, each layer of weld maintains the same size and parameters, which has several limitations in actual operation.

[0003] First, the use of uniform weld beads for multi-layer welding fails to fully utilize the material properties and adjustability of welding parameters, resulting in the inability to accurately adapt to the geometric changes and material requirements of the actual welding area. This means that in some cases, more weld layers or weld beads may be required to achieve the desired filling effect, thereby increasing welding time and cost. Secondly, the fixed weld bead size and layer height strategy ignores the control of the heat-affected zone during welding, which can easily cause excessive heat input, resulting in welding deformation, stress concentration and even cracks, affecting the overall quality and safety of the welded structure. Summary of the invention

[0004] In order to solve at least one of the technical problems raised above, the present invention provides a submerged arc welding method and system for a pressure vessel, which avoids excessive stacking caused by traditional single-specification welds by accurately calculating and dynamically adjusting the weld bead size of the weld layer in the filling area, reduces material and time costs, effectively reduces the number of required weld layers and welds, minimizes welding time, and improves production efficiency and cost-effectiveness.

[0005] In one aspect, a pressure vessel submerged arc welding method is provided, the method comprising:

[0006] Based on the current parent material and welding wire material information, the corresponding single-pass maximum penetration value and single-pass minimum penetration value are matched from the database;

[0007] According to the groove size behind the weld bottom, the maximum penetration value of the single weld pass and the minimum penetration value of the single weld pass, the cross section of the area to be welded is divided into a filling area and a covering area, wherein the covering area is composed of a single layer of multiple first weld passes and the layer height is equal to the minimum penetration value of the single weld pass, and the filling area is composed of multiple layers of multiple second weld passes in each layer and the layer height is less than the maximum penetration value of the single weld pass;

[0008] Based on the size information of the first weld bead and the size information of the second weld bead, matching corresponding welding parameters from a database to obtain a first welding parameter and a second welding parameter;

[0009] Based on the second welding parameters, the filling area is subjected to a multi-layer and multi-pass welding operation in sequence, wherein slag is cleaned after each welding pass is completed;

[0010] The coverage area is subjected to single-layer multi-pass welding operations in sequence based on the first welding parameters, wherein slag cleaning is performed after each welding pass is completed.

[0011] Preferably, the step of dividing the cross section of the area to be welded into a filling area and a covering area according to the groove size behind the weld bottom, the maximum penetration value of a single weld pass, and the minimum penetration value of a single weld pass includes a welding layer height planning step, specifically including:

[0012] Determine the single weld minimum penetration value as the depth of the coverage area, and determine the single weld minimum penetration value as the layer height of the first weld;

[0013] Subtract the minimum penetration value of a single weld bead from the thickness of the groove size to obtain a filling height of the filling area, divide the filling height by the maximum penetration value of a single weld bead and round up to obtain the number of filling layers of the filling area, and divide the filling height by the number of filling layers to obtain a layer height of the second weld bead;

[0014] Based on the layer height of the first weld bead and the layer height of the second weld bead, the weld bead size information of the maximum weld width value corresponding to the current layer height is matched from the database to obtain the size information of the first weld bead and the size information of the second weld bead.

[0015] Preferably, before matching the corresponding single-pass maximum penetration value and single-pass minimum penetration value from the database based on the current parent material and welding wire material information, the method further includes constructing the database, specifically including:

[0016] Creating the database based on different combinations of base materials and welding wires;

[0017] An intervalized welding parameter configuration library is used to select welding parameters in different intervals for each material combination, wherein the welding parameters include welding current, welding voltage, welding speed and wire feeding speed;

[0018] Based on the above-mentioned intervalized welding parameters, the weld bead sizes corresponding to different welding parameters are estimated through experiments and simulation analysis, and the weld bead sizes include weld bead penetration depth and weld bead width, and the intervalized welding parameters and the corresponding estimated results are saved in the database through a dictionary data structure.

[0019] Preferably, after estimating the weld bead sizes corresponding to different welding parameters, the method further includes estimating the inter-pass welding cooling time for the starting point temperature of the corresponding weld bead to drop to 150 degrees Celsius.

[0020] Preferably, the sequentially performing single-layer multi-pass welding operations on the coverage area based on the first welding parameters includes:

[0021] Acquire the interpass welding cooling time corresponding to the first welding parameter from the database;

[0022] The first welding parameter is used to perform section welding on all welds in the coverage area, specifically comprising:

[0023] The first welding parameter is used to weld the starting weld. When the welding time of the starting weld is equal to the inter-pass welding cooling time, the welding of this pass is suspended and the welding is transferred to its adjacent weld until the end point of each weld is gradually aligned with the weld end point of the starting weld, and all welds reach the same end position, that is, starting from the end point of the starting weld, and continuously completing the remaining welding parts until all weld operations are completed.

[0024] Preferably, the intra-layer weld bead welding of the multi-layer and multi-pass welding operation adopts the segmented welding process.

[0025] Preferably, after the welding of the welding bead of each welding layer is completed, the welding layer height planning step is re-executed on the area to be welded to update the size information of the second welding bead.

[0026] Preferably, before sequentially performing multi-layer and multi-pass welding on the filling area based on the second welding parameters, the method further includes:

[0027] Preheat the groove.

[0028] In a second aspect, a pressure vessel submerged arc welding system is provided, the system comprising:

[0029] A data acquisition module is used to match the corresponding single-pass maximum penetration value and single-pass minimum penetration value from a database based on the current parent material and welding wire material information;

[0030] An area division module is used to divide the cross section of the area to be welded into a filling area and a covering area according to the groove size after the weld bottom, the maximum penetration value of the single weld pass and the minimum penetration value of the single weld pass, wherein the covering area is composed of a single layer of multiple first weld passes and the layer height is equal to the minimum penetration value of the single weld pass, and the filling layer is composed of multiple layers of multiple second weld passes in each layer and the layer height is less than the maximum penetration value of the single weld pass;

[0031] A welding parameter module, used for matching corresponding welding parameters from a database based on the size information of the first welding bead and the size information of the second welding bead to obtain a first welding parameter and a second welding parameter;

[0032] A first welding module, used for sequentially performing multi-layer and multi-pass welding operations on the filling area based on the second welding parameters, wherein slag is cleaned after each welding pass is completed;

[0033] The second welding module is used to perform single-layer multi-pass welding operations on the coverage area in sequence based on the first welding parameters, wherein slag cleaning is performed after each welding pass is completed.

[0034] Preferably, the system further includes a database construction module, specifically including:

[0035] A database initialization unit, used for creating the database based on different material combinations of base materials and welding wires;

[0036] A welding parameter configuration unit, for selecting welding parameters in different intervals for each material combination, wherein the welding parameters include welding current, welding voltage, welding speed and wire feeding speed;

[0037] The welding parameter acquisition unit is used to estimate the weld bead dimensions corresponding to different welding parameters through experiments and simulation analysis based on the above-mentioned intervalized welding parameters, wherein the weld bead dimensions include weld bead penetration depth and weld bead width, and save the intervalized welding parameters and the corresponding estimation results into the database through a dictionary data structure.

[0038] The beneficial effects of the present invention are:

[0039] (1) By re-executing the weld height planning step after each weld pass, the second weld pass size information is dynamically updated, ensuring the number of welding layers and passes is streamlined, minimizing material usage and welding time, and improving production efficiency and cost-effectiveness;

[0040] (2) The split-section welding technology is used to flexibly switch between welds according to the inter-pass cooling time corresponding to the welding parameters, which effectively controls the heat input and cooling process, greatly reduces welding deformation, and improves the dimensional accuracy and surface smoothness of the welded structure;

[0041] (3) A database of materials and welding parameters is constructed and utilized, as well as a real-time matching mechanism for weld bead size, so that the welding strategy can be adjusted instantly according to the base material, welding wire material and actual welding effect, thereby enhancing the adaptability to different working conditions and the flexibility of the welding process.

[0042] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0043] In order to more clearly illustrate the technical solutions in the embodiments of the present invention or the background technology, the drawings required for use in the embodiments of the present invention or the background technology will be described below.

[0044] The drawings herein are incorporated into the specification and constitute a part of the specification. These drawings illustrate embodiments consistent with the present disclosure and, together with the specification, are used to illustrate the technical solutions disclosed in the present invention.

[0045] Figure 1 A schematic flow chart of a submerged arc welding method for a pressure vessel provided by an embodiment of the present invention;

[0046] Figure 2 A schematic diagram of a flow chart of fill area coverage area weld planning provided by an embodiment of the present invention;

[0047] Figure 3 A schematic structural diagram of a submerged arc welding system for a pressure vessel provided in an embodiment of the present invention. DETAILED DESCRIPTION

[0048] In order to enable those skilled in the art to better understand the scheme of the present invention, the technical scheme in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0049] The terms "first", "second", etc. in the specification and claims of the present invention and the above-mentioned drawings are used to distinguish different objects, rather than to describe a specific order. In addition, the terms "including" and "having" and any variations thereof are intended to cover non-exclusive inclusions. For example, a process, method, system, product or device that includes a series of steps or units is not limited to the listed steps or units, but may optionally include steps or units that are not listed, or may optionally include other steps or units that are inherent to these processes, methods, products or devices.

[0050] The term "and / or" herein is only a description of the association relationship of the associated objects, indicating that there may be three relationships. For example, A and / or B can represent: A exists alone, A and B exist at the same time, and B exists alone. In addition, the term "at least one" herein represents any combination of at least two of any one or more of a plurality of. For example, including at least one of A, B, and C can represent including any one or more elements selected from the set consisting of A, B, and C.

[0051] Reference to "embodiments" herein means that a particular feature, structure, or characteristic described in conjunction with the embodiments may be included in at least one embodiment of the present invention. The appearance of the phrase in various places in the specification does not necessarily refer to the same embodiment, nor is it an independent or alternative embodiment that is mutually exclusive with other embodiments. It is explicitly and implicitly understood by those skilled in the art that the embodiments described herein may be combined with other embodiments.

[0052] In addition, in order to better illustrate the present invention, numerous specific details are provided in the following specific embodiments. It should be understood by those skilled in the art that the present invention can be implemented without certain specific details. In some examples, methods, means, components and circuits well known to those skilled in the art are not described in detail in order to highlight the subject matter of the present invention.

[0053] At present, due to the use of fixed specifications of weld bead sizes and the lack of a dynamic adjustment mechanism in the existing technology, there are problems such as excessive number of welding layers and weld passes, low efficiency and increased costs.

[0054] Example 1

[0055] Embodiment 1 of the present invention provides a submerged arc welding method for a pressure vessel, referring to Figure 1 , the method comprising:

[0056] S100, matching a corresponding single-pass maximum penetration value and a single-pass minimum penetration value from a database based on current parent material and welding wire material information;

[0057] S200, dividing the cross section of the area to be welded into a filling area and a covering area according to the groove size behind the weld bottom, the maximum penetration value of a single weld pass, and the minimum penetration value of a single weld pass, wherein the covering area is composed of a single layer of multiple first weld passes and the layer height is equal to the minimum penetration value of the single weld pass, and the filling area is composed of multiple layers of multiple second weld passes in each layer and the layer height is less than the maximum penetration value of the single weld pass;

[0058] S300, matching corresponding welding parameters from a database based on the size information of the first weld bead and the size information of the second weld bead to obtain a first welding parameter and a second welding parameter;

[0059] S400, performing multi-layer and multi-pass welding operations on the filling area in sequence based on the second welding parameters, wherein slag is cleaned after each welding pass is completed;

[0060] S500, performing single-layer multi-pass welding operations on the coverage area in sequence based on the first welding parameters, wherein slag cleaning is performed after each welding pass is completed.

[0061] In this embodiment, a typical pressure vessel manufacturing is taken as an example. The base material is Q345R low alloy high strength steel, and the welding wire is H08Mn2SiA. The maximum penetration value of a single weld matched in the database is 10mm, and the minimum penetration value of a single weld is 6mm. Assume that the fill height caused by the groove size after the bottom weld is 54mm. First, the welding area is divided:

[0062] The coverage layer height directly adopts the single weld pass minimum penetration value of 6mm. Since only a single layer is required, the coverage area is designed to be 6mm high and consists of multiple first weld passes to ensure a smooth surface.

[0063] The filling height is 48mm (54mm-6mm), and the maximum penetration depth of a single weld pass is 12mm. It is calculated that the filling area requires 4 layers (48mm / 10mm = 5 layers, rounded up to ensure complete filling). Each layer consists of multiple second weld passes. The layer height of each layer is controlled to be less than 12mm and is set to 10mm (48mm / 5) to leave a margin to ensure better control and quality.

[0064] Based on the size information of the first weld bead (6mm layer height) and the second weld bead (10mm layer height), the first welding parameters and the second welding parameters are matched from the database. For example, the first welding parameters may include welding current 220A, voltage 26V, welding speed 20cm / min, and wire feeding speed 12m / h; the second welding parameters are welding current 200A, voltage 25V, welding speed 22cm / min, and wire feeding speed 10m / h. These parameters are intended to ensure that the depth and width of penetration meet the design requirements, while reducing the heat-affected zone and improving welding efficiency and quality.

[0065] In actual operation, the second welding parameters are first used for multi-layer and multi-pass welding in the filling area. After all the welds of each layer are completed, the slag is cleaned to ensure the quality of the next layer of welding. By optimizing the second welding parameters, the number of required layers is minimized (4 layers in this case) to improve overall efficiency and reduce potential welding defects. The first welding parameters are used for single-layer and multi-pass welding in the covering area. Also, attention is paid to cleaning the slag after each weld to ensure surface finish. Through this strategy, not only the strength and sealing of the welded structure are guaranteed, but also because the priority is given to reducing the number of layers, the welding efficiency and consistency of the finished product are significantly improved, and the production cost is reduced.

[0066] In this embodiment, by maximizing the height of each weld bead of the filling layer, compared with the practice of blindly increasing the number of weld layers to achieve the required filling height, the number of welding layers is significantly reduced, the welding time and cost are reduced, and the risk of residual stress accumulation caused by multi-layer welding is reduced. Furthermore, by using precise welding parameters matched by the database, each weld can obtain the optimal penetration depth and width, reducing the phenomenon of excessive or insufficient welding, improving the one-time success rate of welding, and ensuring the mechanical properties and corrosion resistance of the welded joint. Furthermore, single-layer multi-pass welding is adopted in the covering area, which ensures the smoothness and beauty of the weld surface, reduces the subsequent grinding workload, and improves the overall manufacturing efficiency and finished product quality.

[0067] Preferably, reference Figure 2 , according to the groove size behind the weld bottom, the maximum penetration value of a single weld pass and the minimum penetration value of a single weld pass, the cross section of the area to be welded is divided into a filling area and a covering area, including the steps of planning the height of the weld layer, specifically including:

[0068] S210, determining the minimum penetration value of a single weld pass as the depth of the coverage area, and determining the minimum penetration value of a single weld pass as the layer height of the first weld pass;

[0069] S220, subtracting the minimum penetration value of a single weld pass from the thickness of the groove size to obtain a filling height of the filling area, dividing the filling height by the maximum penetration value of a single weld pass and rounding up to obtain the number of filling layers in the filling area, and dividing the filling height by the number of filling layers to obtain a layer height of the second weld pass;

[0070] S230, based on the layer height of the first weld bead and the layer height of the second weld bead, respectively match the weld bead size information of the maximum weld width value corresponding to the current layer height from the database to obtain the size information of the first weld bead and the size information of the second weld bead.

[0071] In this embodiment, a typical pressure vessel manufacturing is taken as an example, the base material is SA516 Gr.70, the welding wire is ER70S-6, and by querying the database, it is known that for this material combination, the maximum penetration value of a single weld is 14 mm, and the minimum penetration value of a single weld is 8 mm. It is assumed that the groove size thickness after the weld bottom is 30 mm.

[0072] For the covering layer, the minimum penetration value of a single weld bead of 8mm is determined as the depth of the covering area, which is also the layer height of the first weld bead, which means that the covering area will be composed of a single layer of welds, and the height of each weld bead is 8mm; for the filling layer, the filling height of the filling area is calculated, that is, the groove size thickness minus the depth of the covering area, that is, 30mm - 8mm = 22mm. Next, the number of layers in the filling area is determined, and the filling height is divided by the maximum penetration value of a single weld bead of 14mm and rounded up to obtain (22mm ÷ 14mm) ≈ 1.57, which is rounded up to 2 layers. Therefore, the filling area needs to be completed by two layers of welding. Next, the layer height of the second weld bead is calculated, and the filling height of 22mm is divided by the number of filling layers 2, and the layer height of each layer is about 11mm. Based on the first weld bead layer height of 8mm and the second weld bead layer height of 11mm, the weld bead size information of the corresponding maximum weld width value is searched from the database, and the size information of the first weld bead includes a weld width of about 10mm, and the size information of the second weld bead includes a weld width of about 12mm. These dimensional information will directly guide the parameter setting in the actual welding process and ensure the quality of the weld.

[0073] In this embodiment, through strict mathematical calculation and planning, the optimal distribution of welding layers is ensured, which not only meets the structural strength requirements but also avoids unnecessary multi-layer welding, thereby saving materials and working hours. Furthermore, through precise layer height planning and weld size matching, efficient execution of the welding process is achieved, subsequent correction work is reduced, and the overall welding efficiency and finished product quality are improved. At the same time, it also helps to extend the service life of the pressure vessel and reduce maintenance costs.

[0074] Preferably, based on the current parent material and welding wire material information, before matching the corresponding single-pass maximum penetration value and single-pass minimum penetration value from the database, it also includes building a database, specifically including:

[0075] Create a database based on different combinations of base materials and welding wires;

[0076] Intervalized welding parameter configuration library, for each material combination, select welding parameters in different intervals, welding parameters include welding current, welding voltage, welding speed and wire feeding speed;

[0077] Based on the above intervalized welding parameters, the weld bead dimensions corresponding to different welding parameters are estimated through experiments and simulation analysis. The weld bead dimensions include weld bead penetration depth and weld bead width. The intervalized welding parameters and the corresponding estimated results are saved in the database through a dictionary data structure.

[0078] Preferably, after estimating the weld bead sizes corresponding to different welding parameters, it also includes estimating the inter-pass welding cooling time for the starting point temperature of the corresponding weld bead to drop to 150 degrees Celsius.

[0079] In this embodiment, a database structure is designed to accommodate all relevant information of different combinations of base materials and welding wire materials. The database fields include but are not limited to material code, base material type, welding wire model, single-pass maximum penetration value, single-pass minimum penetration value, welding parameter range, etc. For the specific combination of stainless steel 304L and ER308L, the welding current range is 150A to 300A, with 25A as a step; the welding voltage range is 22V to 28V, with 1V as a step; the welding speed range is 10cm / min to 30cm / min, with 2cm / min as a step; the wire feeding speed range is 100cm / min to 200cm / min, with 20cm / min as a step. These parameters are intervalized to form a comprehensive parameter matrix. For each of the above parameter combinations, actual laboratory welding tests and computer simulations are carried out. For example, a set of parameters including welding current 200A, voltage 25V, welding speed 15cm / min, and wire feeding speed 150cm / min were selected for testing. The actual penetration depth and width of the weld were recorded by X-ray detection, metallographic analysis, etc. It was assumed that the measured penetration depth was 10mm and the weld width was 12mm. At the same time, simulation software was used to predict the penetration depth and weld width under different parameters to verify and supplement the experimental data, and further, the interpass welding cooling time was estimated when the starting point temperature of the corresponding weld was reduced to 150 degrees Celsius. All experimental and simulation data, including welding parameters (such as 200A, 25V, 15cm / min, 150cm / min), corresponding weld bead size information (such as 10mm penetration, 12mm weld width) and inter-pass welding cooling time (30s), are stored in the database in the form of key-value pairs (for example, {"current": 200, "voltage": 25, "speed": 15, "wire feeding": 150, "penetration": 10, "weld width": 12, "cooling time": 30}), forming a dictionary data structure that is easy to query and match.

[0080] In this embodiment, through the pre-constructed database, the optimal welding parameters can be matched quickly and accurately for different material combinations, reducing the on-site trial and error time, and improving the efficiency and accuracy of the welding process. Furthermore, with the application of new materials, the database can be continuously updated and expanded to support the welding of more material combinations, thereby enhancing the adaptability and flexibility of the welding process and meeting the needs of complex projects.

[0081] Preferably, performing a single-layer multi-pass welding operation on the coverage area in sequence based on the first welding parameter comprises:

[0082] Obtaining an interpass welding cooling time corresponding to a first welding parameter from a database;

[0083] The first welding parameter is used to perform section welding on all welds in the coverage area, specifically including:

[0084] The first welding parameter is used to weld the starting weld. When the welding time of the starting weld is equal to the inter-pass welding cooling time, the welding of this weld is suspended and the welding is transferred to the adjacent weld until the end point of each weld is gradually aligned with the end point of the starting weld, and all welds reach the same end position, that is, starting from the end point of the starting weld, and continuously completing the remaining welding parts until all weld operations are completed.

[0085] In this embodiment, a database containing multiple welding parameters (such as current, voltage, welding speed, etc.) and corresponding interpass welding cooling time is constructed. These data are obtained based on previous experimental research and simulation analysis to ensure the accuracy and practicality of the data. The first welding parameter set suitable for the current welding material and thickness is selected, for example: current 280A, voltage 30V, welding speed 8cm / min, and by querying the database, the corresponding interpass welding cooling time is 2 minutes. The first weld pass in the coverage area is welded using the above first welding parameters. The operator or the automated welding robot monitors the welding time to ensure that it stops automatically when the welding time reaches 2 minutes. After the first weld pass reaches the preset cooling time point, it is immediately and seamlessly transferred to the second weld pass adjacent to it to start welding without waiting for the weld pass to completely cool to room temperature, and so on, until all the predetermined weld passes in the coverage area are started one by one. As each weld seam is gradually advanced, the alignment of the starting point of the weld seam with the end point of the previous weld seam is precisely controlled to ensure that all weld passes can converge at the same position in the final welding stage. Once all weld passes have reached a common start / end point, continue to complete the remaining welds using the first welding parameters until all weld passes have been completed.

[0086] In this embodiment, by precisely controlling the welding cooling time and welding sequence, the welding heat affected zone is effectively dispersed, local overheating during welding is reduced, and the risk of welding deformation and thermal cracking is reduced. Furthermore, the segmented welding strategy allows flexible switching between different welds, and the adjacent welds are welded using the inter-pass cooling time, avoiding the inefficient waiting period in the traditional welding method where each weld must wait for complete cooling after completion, significantly improving the overall efficiency of the welding operation. Furthermore, the optimized heat management and continuous operation mode reduce energy consumption, reduce production costs, and reduce the impact on the environment, which is in line with the sustainable development principles of modern manufacturing.

[0087] Preferably, the welding of the intra-layer weld passes in the multi-layer and multi-pass welding operation is performed by segmented welding.

[0088] In this embodiment, the segmented welding processing method can effectively manage the heat-affected zone by controlling the welding and cooling cycle of each weld, thereby ensuring welding quality, reducing thermal deformation and improving operating efficiency while achieving the goals of fine control of material thermal stress and energy conservation and emission reduction. It is particularly suitable for high-quality manufacturing of large structures such as oil storage tanks.

[0089] Preferably, after the welding of each weld bead of each weld layer is completed, the weld layer height planning step is re-executed on the area to be welded, and the size information of the second weld bead is updated.

[0090] In this embodiment, according to the characteristics of the parent material and the material of the welding wire, the appropriate welding parameters are matched from the database, and the initial single weld penetration range is set, and the layer height of the first layer of welds is planned based on this. Welding operations are performed on all welds of the first layer, and the slag is cleaned in time after each weld is completed. After each layer of welding is completed, the thickness of the welding area is measured in real time by ultrasonic detection or laser scanning technology to evaluate the deviation between the actual welding effect and the expected target, including factors such as material shrinkage and deformation caused by welding heat. Based on the real-time detection data, the actual required filling height of the area to be welded is recalculated, and the layer height planning of the next layer of welds is adjusted accordingly. This means that the size information of the second weld may need to be updated, such as adjusting the width of the weld, the preset value of the penetration, etc., to ensure the accuracy and efficiency of subsequent welding operations. After each layer is completed, the above-mentioned detection, evaluation and planning adjustment process is repeated until the predetermined total welding thickness is reached, ensuring that the welding of each layer can accurately meet the actual needs, reduce material waste, and improve the overall welding quality and structural stability.

[0091] In this embodiment, by real-time detection and dynamic adjustment of the welding layer height, accurate control during the welding process is ensured, over-welding or under-welding caused by estimation errors is reduced, and the dimensional accuracy and consistency of the welded structure are improved. Furthermore, dynamic adjustment of the layer height can effectively cope with material deformation during welding, reduce the addition of additional materials, optimize material use, and reduce costs.

[0092] Preferably, before performing multi-layer and multi-pass welding on the filling area in sequence based on the second welding parameters, the method further includes:

[0093] Preheat the groove.

[0094] In this embodiment, the groove area is uniformly heated to eliminate moisture and control the cooling rate, thereby effectively suppressing the formation of welding cracks and optimizing the welding quality. This not only enhances the toughness and adaptability of the welded structure, but also prevents defects, improves operating efficiency, and extends the life of the structure, demonstrating its significant benefits in ensuring welding reliability under special materials and harsh environments.

[0095] Example 2

[0096] Embodiment 2 of the present invention provides a pressure vessel submerged arc welding system, referring to Figure 3 The system comprises:

[0097] A data acquisition module 100 is used to match the corresponding single-pass maximum penetration value and single-pass minimum penetration value from a database based on the current parent material and welding wire material information;

[0098] The area division module 200 is used to divide the cross section of the area to be welded into a filling area and a covering area according to the groove size after the weld bottom, the maximum penetration value of a single weld pass, and the minimum penetration value of a single weld pass, wherein the covering area is composed of a single layer of multiple first weld passes and the layer height is equal to the minimum penetration value of a single weld pass, and the filling layer is composed of multiple layers of multiple second weld passes in each layer and the layer height is less than the maximum penetration value of a single weld pass;

[0099] A welding parameter module 300, for matching corresponding welding parameters from a database based on the size information of the first welding bead and the size information of the second welding bead to obtain a first welding parameter and a second welding parameter;

[0100] The first welding module 400 is used to sequentially perform multi-layer and multi-pass welding operations on the filling area based on the second welding parameters, wherein slag cleaning is performed after each welding pass is completed;

[0101] The second welding module 500 is used to perform single-layer multi-pass welding operations on the coverage area in sequence based on the first welding parameters, wherein slag cleaning is performed after each welding pass is completed.

[0102] Preferably, the system also includes a database construction module, specifically including:

[0103] A database initialization unit is used to create a database based on different combinations of base materials and welding wires;

[0104] A welding parameter configuration unit is used to select welding parameters in different ranges for each material combination. The welding parameters include welding current, welding voltage, welding speed and wire feeding speed.

[0105] The welding parameter acquisition unit is used to estimate the weld bead size corresponding to different welding parameters through experiments and simulation analysis based on the above-mentioned intervalized welding parameters. The weld bead size includes weld bead penetration depth and weld bead width, and the intervalized welding parameters and the corresponding estimation results are saved in the database through a dictionary data structure.

[0106] The foregoing is merely a specific embodiment of the present invention, which enables those skilled in the art to understand or implement the present invention. Various modifications to these embodiments will be apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention will not be limited to the embodiments shown herein, but rather to the widest scope consistent with the principles and novel features claimed herein.

Claims

1. A submerged arc welding method for a pressure vessel, characterized in that: The method comprises: Based on the current parent material and welding wire material information, the corresponding single-pass maximum penetration value and single-pass minimum penetration value are matched from the database; According to the groove size behind the weld bottom, the maximum penetration value of the single weld pass and the minimum penetration value of the single weld pass, the cross section of the area to be welded is divided into a filling area and a covering area, wherein the covering area is composed of a single layer of multiple first weld passes and the layer height is equal to the minimum penetration value of the single weld pass, and the filling area is composed of multiple layers of multiple second weld passes in each layer and the layer height is less than the maximum penetration value of the single weld pass; Based on the size information of the first weld bead and the size information of the second weld bead, matching corresponding welding parameters from a database to obtain a first welding parameter and a second welding parameter; Based on the second welding parameters, the filling area is subjected to a multi-layer and multi-pass welding operation in sequence, wherein slag is cleaned after each welding pass is completed; Based on the first welding parameters, a single-layer multi-pass welding operation is sequentially performed on the coverage area, wherein slag is cleaned after each welding pass is completed; The step of dividing the cross section of the area to be welded into a filling area and a covering area according to the groove size behind the weld bottom, the maximum penetration value of a single weld pass, and the minimum penetration value of a single weld pass includes a welding layer height planning step, specifically including: Determine the single weld minimum penetration value as the depth of the coverage area, and determine the single weld minimum penetration value as the layer height of the first weld; Subtract the minimum penetration value of a single weld bead from the thickness of the groove size to obtain a filling height of the filling area, divide the filling height by the maximum penetration value of a single weld bead and round up to obtain the number of filling layers of the filling area, and divide the filling height by the number of filling layers to obtain a layer height of the second weld bead; Based on the layer height of the first weld bead and the layer height of the second weld bead, respectively matching the weld bead size information of the maximum weld width value corresponding to the current layer height from the database to obtain the size information of the first weld bead and the size information of the second weld bead; Before matching the corresponding single-pass maximum penetration value and single-pass minimum penetration value from the database based on the current parent material and welding wire material information, the database is constructed, specifically including: Creating the database based on different combinations of base materials and welding wires; An intervalized welding parameter configuration library is used to select welding parameters in different intervals for each material combination, wherein the welding parameters include welding current, welding voltage, welding speed and wire feeding speed; Based on the above-mentioned intervalized welding parameters, the weld bead sizes corresponding to different welding parameters are estimated through experiments and simulation analysis, and the weld bead sizes include weld bead penetration depth and weld bead width, and the intervalized welding parameters and the corresponding estimated results are saved in the database through a dictionary data structure.

2. A pressure vessel submerged arc welding method according to claim 1, characterized in that: After estimating the weld bead sizes corresponding to different welding parameters, the method also includes estimating the inter-pass welding cooling time for the starting point temperature of the corresponding weld bead to drop to 150 degrees Celsius.

3. A submerged arc welding method for a pressure vessel according to claim 2, characterized in that: The sequentially performing a single-layer multi-pass welding operation on the coverage area based on the first welding parameter includes: Acquire the interpass welding cooling time corresponding to the first welding parameter from the database; The first welding parameter is used to perform section welding on all welds in the coverage area, specifically comprising: The first welding parameter is used to weld the starting weld. When the welding time of the starting weld is equal to the inter-pass welding cooling time, the welding of this pass is suspended and the welding is transferred to its adjacent weld until the end point of each weld is gradually aligned with the weld end point of the starting weld, and all welds reach the same end position, that is, starting from the end point of the starting weld, and continuously completing the remaining welding parts until all weld operations are completed.

4. A pressure vessel submerged arc welding method according to claim 3, characterized in that: The intra-layer weld bead welding of the multi-layer and multi-pass welding operation adopts the segmented welding process.

5. The submerged arc welding method for a pressure vessel according to claim 1, characterized in that: After the welding of each welding bead of each welding layer is completed, the welding layer height planning step is re-executed on the area to be welded to update the size information of the second welding bead.

6. A pressure vessel submerged arc welding method according to claim 1, characterized in that: Before sequentially performing multi-layer and multi-pass welding on the filling area based on the second welding parameters, the method further includes: Preheat the groove.

7. A pressure vessel submerged arc welding system, used to perform a pressure vessel submerged arc welding method according to any one of claims 1 to 6, characterized in that: The system comprises: A data acquisition module is used to match the corresponding single-pass maximum penetration value and single-pass minimum penetration value from a database based on the current parent material and welding wire material information; An area division module is used to divide the cross section of the area to be welded into a filling area and a covering area according to the groove size after the weld bottom, the maximum penetration value of the single weld pass and the minimum penetration value of the single weld pass, wherein the covering area is composed of a single layer of multiple first weld passes and the layer height is equal to the minimum penetration value of the single weld pass, and the filling layer is composed of multiple layers of multiple second weld passes in each layer and the layer height is less than the maximum penetration value of the single weld pass; A welding parameter module, used for matching corresponding welding parameters from a database based on the size information of the first welding bead and the size information of the second welding bead to obtain a first welding parameter and a second welding parameter; A first welding module, used for sequentially performing multi-layer and multi-pass welding operations on the filling area based on the second welding parameters, wherein slag is cleaned after each welding pass is completed; A second welding module is used to perform a single-layer multi-pass welding operation on the coverage area in sequence based on the first welding parameters, wherein slag cleaning is performed after each welding pass is completed; The system also includes a database construction module, specifically including: A database initialization unit, used for creating the database based on different material combinations of base materials and welding wires; A welding parameter configuration unit, for selecting welding parameters in different intervals for each material combination, wherein the welding parameters include welding current, welding voltage, welding speed and wire feeding speed; The welding parameter acquisition unit is used to estimate the weld bead dimensions corresponding to different welding parameters through experiments and simulation analysis based on the above-mentioned intervalized welding parameters, wherein the weld bead dimensions include weld bead penetration depth and weld bead width, and save the intervalized welding parameters and the corresponding estimation results into the database through a dictionary data structure.

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