Multi-layer and multi-pass welding seam layer arrangement method and multi-layer and multi-pass welding device

Abstract

The invention relates to the field of welding, and provides a multi-layer and multi-pass welding seam layer way arrangement method and a multi-layer and multi-pass welding device. The multi-layer multi-welding-seam layer channel arrangement method comprises the following steps that the optimal orientation of a plate body is determined based on material rolling direction analysis, and a sample of the plate body is prepared; executing a flat surfacing test based on the thermal cycle analysis result of the sample so as to obtain layer channel distribution data capable of meeting the welding seam forming requirement; the welding deformation condition is analyzed through analogue simulation, so that the optimal layer channel welding sequence is obtained; and welding is executed based on the layer channel distribution data and the optimal layer channel welding sequence. The welding device can execute the method. According to the method and the welding device, the defects that in the prior art, various factors are not comprehensively considered in multilayer and multi-pass welding layer channel arrangement, and arrangement rules are missing can be overcome, subjective and criterion-free layer channel arrangement is converted into a method capable of being accurately and quantitatively designed through tests, the scientificity of layer channel arrangement is greatly improved, and the layer channel arrangement efficiency is improved. And the welding seam performance and the structural reliability are improved.

Description

Technical Field

[0001] The invention relates to the field of welding and provides a multi-layer multi-pass weld layer arrangement method and a multi-layer multi-pass welding device. Background Art

[0002] Arc welding is widely used in equipment manufacturing industries such as rail transit, energy and electricity, and the technology of aluminum alloy arc welding is currently widely used in the above industries. Among them, multi-layer and multi-pass welding is one of the important methods to achieve aluminum alloy plate welding. Affected by the physical properties of aluminum alloy materials themselves, the welding process is subject to heat cycles, which will cause joint softening and thermal crack defects in the weld area and heat-affected zone, resulting in a decrease in weld performance. Since multi-layer and multi-pass welding is used to perform plate welding, the heat effect of some weld areas is superimposed, and the weld performance will be further reduced. Therefore, the layout of the welding layers of aluminum alloy plates is crucial to ensure the final welding performance. However, the current research on the softening of the heat-affected zone cannot accurately complete sampling analysis and performance testing because the heat-affected zone is between the parent material and the weld zone. The use of thermal simulation experiments can accurately realize the application of different peak temperature thermal cycles and multiple thermal cycles, so that the microstructure and performance of the heat-affected zone can be analyzed, thereby providing technical support for the formulation of heat input and welding processes.

[0003] However, in the current multi-layer and multi-pass welding process of aluminum alloy plates, simple layer arrangement is only performed based on the weld size, without considering the influence of multiple factors such as material properties, joint structure, heat input effect and service conditions, resulting in failure to meet the service requirements of the welded structure, especially for welding components with harsh service conditions and high performance requirements, and even affecting service safety. In addition, layer arrangement is a key factor affecting the final welding quality, but there is no specific criterion for setting the number of layers for multi-layer and multi-pass welding in the prior art. Different process personnel may set completely different numbers of layers and welding sequences for the same joint, making it difficult to ensure the consistency of welding quality. Therefore, there are still major problems with the layer arrangement of aluminum alloy plate welding, and there is a lack of scientific and effective layer design methods. Summary of the invention

[0004] The present invention provides a multi-layer and multi-pass weld layer arrangement method to solve the defect that the layer arrangement in the related art is designed only based on the weld size and forming requirements, without comprehensively considering the influence of multiple factors such as material properties, joint structure, heat input influence and service conditions, thereby failing to obtain the optimal layer arrangement.

[0005] The invention also provides a welding device for multi-layer and multi-pass welding.

[0006] The present invention provides a multi-layer and multi-pass weld layer arrangement method, which comprises the following steps.

[0007] Based on the optimal orientation of the plate determined by the material rolling direction analysis, a sample of the plate is prepared.

[0008] A flat plate surfacing test is performed based on the thermal cycle analysis results of the sample to obtain layer distribution data that can meet the weld formation requirements.

[0009] The welding deformation is analyzed through simulation to obtain the optimal layer welding sequence.

[0010] Welding is performed based on the layer distribution data and the optimal layer welding sequence.

[0011] According to the multi-layer and multi-pass weld layer arrangement method proposed in the present invention, the step of preparing the sample of the plate body based on the optimal orientation of the plate body determined by analyzing the rolling direction of the material further includes the following steps.

[0012] Based on the various rolling directions of the plate body, samples are taken and tested respectively to obtain the sample properties of the plate body in various rolling directions.

[0013] The performance of the samples in various rolling directions of the plate is comprehensively evaluated, and the orientation with the best performance is selected as the optimal orientation of the plate based on the type of welded joint.

[0014] Sampling is performed based on the optimal orientation of the plate to prepare a test specimen of the plate.

[0015] According to the multi-layer and multi-pass weld layer arrangement method proposed in the present invention, the steps of sampling and testing respectively based on the various rolling directions of the plate body to obtain the sample performance in various rolling directions of the plate body, and the step of comprehensively evaluating the sample performance in various rolling directions of the plate body and selecting the orientation with the best performance as the optimal orientation of the plate body based on the type of welding joint further include the following steps.

[0016] A variety of rolling directions of the plate made of aluminum alloy are selected to prepare rolling texture samples.

[0017] The test data of the microstructure, tensile properties of the microstructure area and thermal crack sensitivity of each of the rolled texture samples are obtained respectively.

[0018] By comparing and analyzing the test data, the optimal rolled texture sample with the maximum tensile strength in the microstructure region under the same microstructure and thermal crack sensitivity conditions is obtained.

[0019] The material rolling direction corresponding to the optimal rolling texture sample is taken as the optimal orientation of the plate.

[0020] According to the multi-layer and multi-pass weld layer arrangement method proposed in the present invention, the step of performing a flat plate surfacing test based on the thermal cycle analysis results of the sample to obtain layer distribution data that can meet the weld formation requirements further includes the following steps.

[0021] A thermal cycle analysis is performed on the sample of the plate body to obtain the optimal heat input parameters that meet the performance requirements.

[0022] A flat plate surfacing test is performed based on the actual welding position, welding joint type and the optimal heat input parameters to obtain layer distribution data that can meet the weld formation requirements.

[0023] According to the multi-layer and multi-pass weld layer arrangement method proposed in the present invention, the step of performing thermal cycle analysis on the sample of the plate body to obtain the optimal heat input parameters further includes the following steps.

[0024] A thermal simulation test is used to perform thermal cycle analysis on the microstructure performance of the sample of the plate under a single thermal cycle under different peak temperature conditions to obtain single thermal cycle analysis data.

[0025] Based on the single thermal cycle analysis data and combined with the joint strength comparison data, the welding heat input range is obtained.

[0026] Based on the welding heat input range, analysis and value selection are performed to analyze the microstructure performance under multiple thermal cycles using the welding heat input parameters after analysis and value selection, so as to obtain the optimal heat input parameters that meet the performance requirements.

[0027] According to the multi-layer and multi-pass weld layer arrangement method proposed in the present invention, the step of analyzing and taking values ​​based on the welding heat input range, and using the welding heat input parameters after analysis and taking values ​​to analyze the microstructure performance under multiple thermal cycles, and obtaining the optimal heat input parameters that meet the performance requirements further includes the following steps.

[0028] Based on the welding heat input range, a heat input difference is calculated.

[0029] The heat input difference is evenly divided to calculate the unit heat input value.

[0030] Based on the welding heat input range and the unit heat input value, thermal cycle single input values ​​are calculated respectively.

[0031] A plurality of groups of thermal cycle single input values ​​are combined and analyzed, and the optimal thermal input parameters that meet the performance requirements are obtained through comparison.

[0032] According to the multi-layer and multi-pass weld layer arrangement method proposed in the present invention, the step of analyzing and selecting values ​​based on the welding heat input range, analyzing the microstructure performance under multiple thermal cycles using the welding heat input parameters after analysis and selection, and obtaining the optimal heat input parameters that meet the performance requirements further includes.

[0033] The thermal cycle single input analysis value is .

[0034] Among them, Q i is the single input analysis value of the thermal cycle, i is the number of thermal cycle inputs, Q min is the minimum value of the welding heat input range, is the unit heat input value.

[0035] According to the multi-layer and multi-pass weld layer arrangement method proposed in the present invention, the step of performing a flat plate surfacing test based on the actual welding position, welding joint type and the optimal heat input parameters to obtain layer distribution data that can meet the weld formation requirements further includes the following steps.

[0036] A flat plate surfacing test is performed based on the actual welding position, welding joint type and optimal heat input parameters to obtain welding parameters corresponding to each single input value of the thermal cycle.

[0037] According to the welding parameters, welding groove parameters and layer overlap rate, layer distribution data that can meet the weld forming requirements are obtained.

[0038] According to the multi-layer and multi-pass weld layer arrangement method proposed in the present invention, after the step of performing a flat plate surfacing test based on the thermal cycle analysis results of the sample to obtain layer distribution data that can meet the weld formation requirements, the following steps are also included.

[0039] Based on the optimal heat input parameters and the joint strength comparison data, the maximum number of thermal cycles corresponding to the current heat input value is obtained.

[0040] A simulation sample with the same groove structure is prepared based on the sample of the plate body, and the simulation sample is welded based on the layer distribution data to obtain actual weld formation data of the simulation sample.

[0041] According to the actual weld formation data, each of the single thermal cycle analysis data is adjusted within the maximum thermal cycle number range until the layer distribution data can meet the weld formation requirements.

[0042] According to the multi-layer and multi-pass weld layer arrangement method proposed by the present invention, the step of analyzing the welding deformation through simulation to obtain the optimal layer welding sequence further includes the following steps.

[0043] Based on the welding constraint conditions, the welding deformation conditions under various layer welding sequences are simulated through simulation, and the layer welding sequence with the smallest welding deformation is selected as the optimal layer welding sequence.

[0044] According to the multi-layer and multi-pass weld layer arrangement method proposed by the present invention, after the step of performing welding based on the layer distribution data and the optimal layer welding sequence, the following steps are also included.

[0045] During the welding process, the layer distribution data and the optimal layer welding sequence are respectively corrected based on the actual welding deformation.

[0046] The present invention also proposes a multi-layer multi-pass welding device, which can execute the above-mentioned multi-layer multi-pass weld layer arrangement method. The multi-layer multi-pass welding device includes a connected sample preparation module, a layer distribution data analysis module, a simulation module and a welding execution module; the sample preparation module can prepare the sample of the plate body based on the optimal orientation of the plate body determined by the material rolling direction analysis; the layer distribution data analysis module can perform a flat plate surfacing test based on the thermal cycle analysis results of the sample to obtain layer distribution data that can meet the weld forming requirements; the simulation module can obtain the optimal layer welding sequence through simulation analysis of welding deformation conditions; the welding execution module can perform welding based on the layer distribution data and the optimal layer welding sequence.

[0047] The multi-layer multi-pass weld layer arrangement method provided by the present invention includes the following steps: preparing a sample of the plate body based on the optimal orientation of the plate body determined by the material rolling direction analysis; performing a flat plate surfacing test based on the thermal cycle analysis results of the sample to obtain layer distribution data that can meet the weld forming requirements; analyzing the welding deformation through simulation to obtain the optimal layer welding sequence; performing welding based on the layer distribution data and the optimal layer welding sequence. The welding device can execute the above method. The method and the welding device can solve the defects of the welding layer arrangement of multi-layer multi-pass welding in the prior art that various factors are not comprehensively considered and the arrangement rules are missing, and transform the subjective and non-criteria layer arrangement into a method that can be accurately and quantitatively designed through experiments, which greatly improves the scientific nature of the layer arrangement, thereby improving the weld performance and structural reliability.

[0048] This method is applicable to the layout of multi-layer and multi-pass welds of plates of all fusion welding methods and joint types, especially for the welding of plates with large heat input influence such as aluminum alloy plates. By refining the key steps and elements of the layer layout design method, namely the plate orientation design step, heat input design step, layer number design step and layer sequence design step, and quantitatively evaluating each element through targeted experiments, it provides clear, scientific and clean guidance for the layout of multi-layer and multi-pass welding welds, and ensures the welding quality and structural reliability of multi-layer and multi-pass welding.

[0049] The multi-layer multi-pass welding device provided by the present invention comprises a connected sample preparation module, a layer distribution data analysis module, a simulation module and a welding execution module. Since each module of the welding device can respectively execute the above-mentioned multi-layer multi-pass weld layer arrangement method, the multi-layer multi-pass welding device has all the advantages of the above-mentioned multi-layer multi-pass weld layer arrangement method, and the details are not repeated here. BRIEF DESCRIPTION OF THE DRAWINGS

[0050] In order to more clearly illustrate the technical solutions in the present invention or the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0051] Figure 1 It is a specific flow chart of the multi-layer and multi-pass weld layer arrangement method provided by the present invention.

[0052] Figure 2 It is a schematic diagram of the optimal orientation of the plate in the multi-layer and multi-pass weld layer arrangement method provided by the present invention.

[0053] Figure 3 It is a structural schematic diagram of a V-shaped groove structure with a gasket in the multi-layer and multi-pass weld layer arrangement method provided by the present invention.

[0054] Figure 4 It is a molten pool structure diagram corresponding to a V-shaped groove structure with a gasket in the multi-layer and multi-pass weld layer arrangement method provided by the present invention.

[0055] Figure 5 It is a schematic diagram of the layer arrangement corresponding to the V-groove structure with a gasket in the multi-layer and multi-pass weld layer arrangement method provided by the present invention.

[0056] Figure 6 It is a structural schematic diagram of a T-type HV groove structure in the multi-layer and multi-pass weld layer arrangement method provided by the present invention.

[0057] Figure 7 It is a schematic diagram of the layer arrangement corresponding to the T-type HV groove structure in the multi-layer and multi-pass weld layer arrangement method provided by the present invention.

[0058] Reference numerals: 1. Rolling texture structure; 2. Sampling position; X, plate length direction; Y, plate width direction; Z, plate thickness direction; A, rolling direction; 3. First plate body; 4. Second plate body; 5. Welding groove; 6. Backing plate; 7. Molten pool; 8. Base plate. DETAILED DESCRIPTION

[0059] The following embodiments of the present invention are described in further detail in conjunction with the accompanying drawings and examples. The following examples are used to illustrate the present invention, but are not intended to limit the scope of the present invention.

[0060] Combine the following Figures 1 to 7 The present invention describes in detail a multi-layer multi-pass weld layer arrangement method (the present invention is referred to as "layer arrangement method" or "method") and a multi-layer multi-pass welding device capable of executing the method (the present invention is referred to as "welding device" or "device"). The method and welding device can solve the defects of the prior art that the layer arrangement of multi-layer multi-pass welding does not comprehensively consider various factors and lacks arrangement rules, and transforms the subjective and non-criteria layer arrangement into a method that can be accurately and quantitatively designed through experiments, which greatly improves the scientific nature of the layer arrangement, thereby improving the weld performance and structural reliability.

[0061] In the embodiment of the present invention, Figure 1 As shown, the layer arrangement method includes the following steps: step S1 plate orientation design step, step S2 heat input design step, step S3 layer number design step, step S5 layer sequence design step and welding execution step. The details are as follows.

[0062] Plate orientation design steps: The plate body is subjected to the optimal orientation determined by the analysis of the material rolling direction, and the plate body specimen is prepared.

[0063] Heat input design steps and layer number design steps: Based on the thermal cycle analysis results of the specimen, a flat plate cladding test is performed to obtain layer distribution data that can meet the weld formation requirements.

[0064] Layer sequence design steps: Analyze welding deformation through simulation to obtain the optimal layer welding sequence.

[0065] Welding execution steps: Welding is performed based on the layer distribution data and the optimal layer welding sequence.

[0066] This method is applicable to the layout of multi-layer and multi-pass welds of plates of all fusion welding methods and joint types, especially for the welding of plates with large heat input influence such as aluminum alloy plates. By refining the key steps and elements of the layer layout design method, namely the plate orientation design step, heat input design step, layer number design step, layer number confirmation and heat input optimization step, layer sequence design step and welding deformation optimization step, and quantitatively evaluating each element through targeted experiments, it provides clear, scientific and clear guidance for the layout of welds of multi-layer and multi-pass welding, and ensures the welding quality and structural reliability of multi-layer and multi-pass welding.

[0067] It should be noted that the method described in the embodiment of the present invention is preferably applied to the welding process of multi-layer and multi-pass welding of plates made of aluminum alloy.

[0068] It should be noted that the method described in the embodiment of the present invention is applicable to various fusion welding methods such as aluminum alloy plate arc welding, laser welding and laser-arc hybrid welding.

[0069] It should be noted that the method described in the embodiment of the present invention is applicable to all types of welded joint structures such as butt joints, corner joints and lap joints.

[0070] In some embodiments, the above step S1 further includes the following steps.

[0071] Step S11: sampling and testing are performed based on various rolling directions of the plate body to obtain the sample properties of the plate body in various rolling directions.

[0072] Step S12: Comprehensively evaluate the performance of the samples in various rolling directions of the plate, and select the orientation with the best performance as the optimal orientation of the plate based on the type of welded joint.

[0073] Step S13: Sampling is performed based on the optimal orientation of the plate to prepare a sample of the plate.

[0074] In some specific embodiments, Figure 2 As shown, step S11 and step S12 further include the following steps.

[0075] Various rolling directions of aluminum alloy plates were selected to prepare rolling texture samples.

[0076] The test data of the microstructure, tensile properties of the microstructure area and thermal crack sensitivity of each rolled texture sample were obtained respectively.

[0077] By comparing and analyzing the test data, the optimal rolled texture specimen with the maximum tensile strength in the microstructure zone under the same microstructure and thermal crack sensitivity conditions was obtained.

[0078] The rolling direction of the material corresponding to the optimal rolling texture sample is taken as the optimal orientation of the plate.

[0079] Corresponding to this embodiment, the method can first quantitatively analyze the anisotropy of the aluminum alloy plate material and determine the orientation of the plate in the joint based on the specific requirements of the mechanical properties of the welded structure, the weld formation, and the welding deformation requirements. That is, the aluminum alloy plate is sampled in different rolling directions, and its microstructure, micro-area tensile properties and thermal crack sensitivity are respectively detected to evaluate the performance of the plate in different rolling directions; the test results are integrated, and the orientation with the best performance is selected as the plate orientation in the joint according to the joint type.

[0080] This setting can ensure that the sampling of this method fully considers the comprehensive performance of the rolling texture structure 1 in the plate length direction X, plate width direction Y and plate thickness direction Z, and also considers the specific rolling direction A of the rolling texture structure 1, and comprehensively considers the influence of the sampling position 2 on the strength of the selected sample, so as to more accurately and efficiently select the most reasonable sampling position 2, and then select the one with the best comprehensive performance as the joint orientation. For example, Figure 2 As shown, the anisotropy of the plate is analyzed according to the load conditions in the plate length direction X, plate width direction Y and plate thickness direction Z, and multiple sampling positions are selected on the plate. The microstructure, micro-area tensile properties and thermal crack sensitivity of the samples at each position are quantitatively analyzed. The performance of the samples at each sampling position is comprehensively analyzed. Several performance indicators with the same or basically the same values ​​can be used as the benchmark, and the performance indicators with large numerical differences can be used as the basis for judgment. For example, when comparing the samples at each sampling position, the microstructure and thermal crack sensitivity are equivalent, and the direction or sampling position with larger tensile strength is selected as the orientation with the best comprehensive performance.

[0081] In some embodiments, step S2 and step S3 further include the following steps.

[0082] Step S2: heat input design step: perform thermal cycle analysis on the plate sample to obtain the optimal heat input parameters that meet the performance requirements.

[0083] Step S3: Designing the number of layers: Based on the actual welding position, welding joint type and optimal heat input parameters, a flat plate surfacing test is performed to obtain layer distribution data that can meet the weld formation requirements.

[0084] In some specific embodiments, the above step S2 can analyze the weld microstructure and properties and determine the optimal heat input for each weld by performing thermal simulation experiments under single thermal cycles and multiple thermal cycles at different peak temperatures. Specifically, step S2 further includes the following steps.

[0085] Step S21: thermal simulation test is used to perform thermal cycle analysis on the microstructure performance of the plate sample under a single thermal cycle under different peak temperature conditions to obtain single thermal cycle analysis data.

[0086] Step S22: Based on the single thermal cycle analysis data and combined with the joint strength comparison data, the welding heat input range is obtained.

[0087] Step S23: Analyze and determine values ​​based on the welding heat input range, and use the welding heat input parameters after analysis to analyze the microstructure performance under multiple thermal cycles to obtain the optimal heat input parameters that meet the performance requirements.

[0088] In some specific embodiments, the above-mentioned step S23 further includes: calculating the heat input difference based on the welding heat input range; dividing the heat input difference equally to calculate the unit heat input value; calculating the single input value of the thermal cycle based on the welding heat input range and the unit heat input value respectively; combining and analyzing multiple groups of single input values ​​of the thermal cycle, and obtaining the optimal heat input parameters that meet the performance requirements through comparison.

[0089] In this embodiment, the above steps are to calculate the optimal heat input parameters through the welding heat input range. The corresponding formula is: The single input analysis value of the thermal cycle is ; Among them, Q i is the single input analysis value of the thermal cycle, i is the number of thermal cycle inputs, Q min is the minimum value of the welding heat input range, is the unit heat input value.

[0090] In other words, the thermal simulation experimental method is used to analyze the microstructural properties under a single thermal cycle at different peak temperature conditions, and the welding heat input range is obtained by comparing it with the joint design strength, where the minimum welding heat input is Q min , the maximum welding heat input is Q max The absolute value of the heat input difference |Q max -Q min ∣Equally divided into N parts, each part is recorded as , that is, the unit heat input value Then, the analysis values ​​were inputted in a single thermal cycle. As heat input, the microstructure performance under multiple thermal cycles is analyzed to obtain the optimal heat input parameters. Where i is an integer between (1, N).

[0091] In some specific embodiments, the above step S3 can adopt an experimental method of equal plate surfacing to obtain the weld penetration and weld width data under the corresponding heat input, so as to complete the layer number design step according to the groove shape and size and layer overlap rate. Specifically, step S3 further includes the following steps.

[0092] Step S31: performing a flat plate surfacing test based on the actual welding position, welding joint type and optimal heat input parameters, and obtaining welding parameters corresponding to single input values ​​of each thermal cycle.

[0093] Step S32: According to welding parameters, welding groove parameters and layer overlap ratio, layer distribution data that can meet the weld formation requirements is obtained.

[0094] In this embodiment, the above steps specifically use the actual welding position to perform the plate-plate surfacing test to obtain the thermal cycle single input analysis value Q i The weld penetration depth Di and weld width Wi under Figure 4 Then, according to the design size requirements of the groove, the overlap ratio between the layers is considered and the required number of layers is determined as the layer distribution data.

[0095] In some embodiments, the method further comprises step S4 of layer number confirmation and heat input optimization. Step S4 further comprises step S24, step S25 and step 26 after the above step S23. Specifically, step S4 comprises the following steps.

[0096] Step S24: Based on the optimal heat input parameters and joint strength comparison data, the maximum number of thermal cycles corresponding to the current heat input value is obtained.

[0097] Step S25: preparing a simulation sample with the same groove structure based on the plate sample, and welding the simulation sample based on the layer distribution data to obtain actual weld formation data of the simulation sample.

[0098] Step S26: According to the actual weld formation data, the single thermal cycle analysis data are adjusted within the maximum thermal cycle number range until the layer distribution data can meet the weld formation requirements.

[0099] In the above step S4, the plate joint simulation is welded and the number of layers is confirmed. If it does not meet the requirements, the heat input of each weld and the corresponding number of thermal cycles are adjusted until the number of layers meets the weld formation requirements. Specifically, the maximum number of thermal cycles ni under the heat input is obtained by comparing with the design strength of the joint. Then a plate joint simulation with the same groove form is made, and welding is performed using the designed number of layers. The number of layers is confirmed by actual weld formation. If the groove is not filled and the forming requirements are not met, the single input analysis values ​​Q of different thermal cycles obtained in steps S2 and S3 are used. i The heat input of each weld is adjusted according to the depth of penetration Di, the width of penetration Wi and the maximum number of thermal cycles ni under the condition of the weld depth Di, the width of penetration Wi and the maximum number of thermal cycles ni, until the number of layers meets the weld formation requirements. The correction process can continuously optimize the heat input, thereby improving the accuracy of the layer distribution data.

[0100] In some embodiments, Figure 1 As shown, the above step S5 further includes the following steps.

[0101] Step S51: Based on the welding constraint conditions, the welding deformation conditions under various layer welding sequences are simulated, and the layer welding sequence with the smallest welding deformation is selected as the optimal layer welding sequence.

[0102] In this embodiment, step S51 considers the actual constraint conditions of the welding structure, and preferably uses Simufact welding to simulate welding deformation and residual stress distribution to obtain the optimal layer welding sequence. That is, considering the constraint conditions during the actual production of the welding structure, the Simufact welding simulation software is used to simulate the welding deformation under different welding sequences, and the sequence with the smallest welding deformation is used as the optimal layer welding sequence. Adding the simulation process can ensure that the method is closer to actual production, improve the accuracy and scientificity of the layer layout, and has more practical significance.

[0103] In some embodiments, after the above step S5, the overall order optimization step of the layer arrangement is also included in step S5. Figure 1 The step S6 shown is a design scheme confirmation and optimization sequence step. Specifically, the above step S5 and subsequent steps further include the following steps.

[0104] Step S6: During the welding process, the layer distribution data and the optimal layer welding sequence are respectively corrected based on the actual welding deformation.

[0105] In this embodiment, step S6 can use the actual number of layers and welding sequence to complete the welding of the actual plate structure and confirm the layer design scheme. That is, after the actual plate structure is welded using the obtained number of layers and sequence, the layer design scheme is confirmed by the actual welding deformation. In addition, if the welding deformation does not meet the design requirements, the constraint conditions in the actual welding production process are checked, and the welding deformation under different welds is continuously simulated until the welding deformation meets the welding structure deformation requirements.

[0106] This step S6 can fully consider the deformation and residual stress analysis of the welding structure under actual constraint conditions, so as to reasonably optimize the layer distribution data and the optimal layer welding sequence, thereby improving the accuracy and reliability of the method.

[0107] The following references Figures 3 to 6 , through two specific test examples, the implementation method and corresponding effects of this method are explained in detail.

[0108] refer to Figures 3 to 5 The test example 1 shown is a V-groove butt joint structure welding of a 12 mm thick 7N01 aluminum alloy plate with a backing plate 6. The angle of the welding groove 5 of the joint structure is 60°, and the blunt edge of the groove is 1 mm.

[0109] The various steps in the method described in this embodiment are described as follows.

[0110] Step S1: Since the butt joint does not bear external load in the thickness direction Z, only the anisotropy in the length direction X and the width direction Y of the plate is analyzed. Figure 2 As shown in the figure, samples were taken along the length direction X and the width direction Y of the 7N01 aluminum alloy plate, and then the microstructure, micro-area tensile properties and thermal crack sensitivity were quantitatively analyzed. The comprehensive comparison test results show that the micro-area tensile strength along the length direction X is 385.4MPa, while the micro-area tensile strength along the width direction Y is 368.9MPa, and the thermal crack sensitivity obtained by sampling and testing of the two is equivalent. Therefore, the performance of the sample in the length direction X is the best. The plate body is cut along the length direction X and the groove is processed to obtain the following Figure 3 The first plate body 3 and the second plate body 4 are shown, and the first plate body 3 and the second plate body 4 are butt-jointed to form a V-shaped welding groove 5, and a backing plate 6 is arranged on the back side of the welding groove 5.

[0111] Step S2: A thermal simulation experiment is performed on the 7N01 plate sample cut in the plate length direction X to analyze the microstructure properties under a single thermal cycle at different peak temperatures (e.g., 150 degrees Celsius, 200 degrees Celsius, 300 degrees Celsius, 400 degrees Celsius, 500 degrees Celsius, etc.). By comparing with the joint design strength, the maximum peak temperature that can meet the design strength requirements and the minimum peak temperature that ensures melting are obtained, and the welding heat input Q is calculated. max and Q min ; The absolute value of the heat input difference Divide into 3 parts, each part is recorded as , respectively (i=1,2,3) is used as heat input to analyze the microstructure performance under multiple thermal cycles, and the maximum number of thermal cycles ni under this heat input is obtained by comparing it with the joint design strength. For example, under Q3 heat input, the performance can no longer meet the design strength requirements after 5 thermal cycles, so the maximum number of thermal cycles under this heat input is 4.

[0112] Step S3: Since the actual welding position of the welding structure is PA, the flat plate surfacing test of the 12mm thick 7N01 substrate 8 is still carried out at the PA position, and the weld penetration depth D3=5.0mm and the weld width W3=6.5mm corresponding to the molten pool 7 under the heat input of Q3 are obtained respectively. Figure 4 As shown. Figure 3 and Figure 4 As shown in FIG. 1 , the groove depth D of the V-groove is 11 mm, the opening width W of the welding groove 5 is 12.7 mm, and the overlap rate between the layers is set to 0.1. Then, the required number of layers is determined to be three layers and six passes to meet the weld formation requirements. That is, one pass for the first layer, two passes for the second layer, and three passes for the third layer. Figure 5 As shown. The welding heat input of each weld in each layer must be the same, and the heat input between different layers can be different, that is, the heat input of the first layer can be Q2, and the heat input of the second and third layers can be Q3.

[0113] Step S4: Make a 12mm plate V-groove joint simulation, use the PA position, and complete three-layer six-pass welding with corresponding welding parameters. Cut the cross-section sample and observe the weld formation. If the formation is good, it proves that the three-layer six-pass design under this heat input is reasonable. If the groove is not filled in the third layer and does not meet the forming requirements, the single heat input value Q of the third layer can be adjusted. i and the maximum allowable number of thermal cycles ni, and adjust the number of passes at the same time until the weld formation requirements are met.

[0114] Step S5: Considering the constraint conditions of the V-groove butt joint in the actual production of the welded structure, specifically in this test example, it is preferred to use Simufact welding simulation software to simulate the weld sequence, and determine the welding deformation under different weld sequences such as 1→2→3→4→5→6, 1→2→3→6→5→4, 1→3→2→4→5→6, 1→3→2→6→5→4, etc. The welding sequence with the smallest welding deformation is determined as the optimal welding sequence, such as Figure 5 shown.

[0115] Step S6: Use three layers and six passes and their optimal sequence to complete the welding of the actual plate structure. After welding, detect the actual welding deformation of the structure and compare it with the design requirements. If the design requirements are met, the layer design scheme is proven to be reasonable. If the welding deformation does not meet the design requirements, check the constraint conditions in the actual welding production process, and continue to simulate the welding deformation under different weld passes until the welding deformation meets the welding structure deformation requirements.

[0116] refer to Figure 6 and Figure 7 The second test example shown is a 12 mm thick 7N01 aluminum alloy plate structure T-type HV groove joint structure welding as an example. Among them, the groove angle of the welding groove 5 of the joint structure is 55°, the groove blunt edge is 2 mm, and the melting depth of the molten pool is 11 mm.

[0117] The various steps in the method described in this embodiment are described as follows.

[0118] Step S1: The sampling position 2 of the first plate 3 of the T-type HV groove joint is sampling along the plate thickness direction Z. Therefore, the anisotropy in the plate length direction X, plate width direction Y and plate thickness direction Z is analyzed. Samples are cut along the three directions of the 7N01 aluminum alloy plate, and then the microstructure, micro-area tensile properties and thermal crack sensitivity are quantitatively analyzed, such as Figure 2As shown. Comprehensive comparison of test results shows that the micro-area tensile strength in the plate length direction X is 396.2MPa, the micro-area tensile strength in the plate width direction Y is 367.7MPa, and the micro-area tensile strength in the plate thickness direction Z is 347.5MPa. Therefore, it is determined that the tensile performance in the plate length direction X is the best. After testing, it was determined that the thermal crack sensitivity in the plate length direction X is equivalent to that in the plate width direction Y, and the thermal crack sensitivity in the plate thickness direction Z is higher. Therefore, the heat input of the weld in the plate thickness direction Z of the first plate body 3 needs to be strictly controlled to reduce the tendency of thermal cracking. The second plate body 4 adopts the plate length direction X and cuts the plate body along this direction and processes the welding groove 5, and then the second plate body 4 is docked on the surface of the first plate body 3 to form a T-joint groove structure, as shown Figure 6 shown.

[0119] Step S2: Samples are cut from the first plate body 3 along the plate thickness direction Z and the second plate body 4 along the plate length direction X, and the microstructure properties under a single thermal cycle at different peak temperatures (e.g., 150°C, 200°C, 300°C, 400°C, 500°C, etc.) are analyzed by thermal simulation experiments. By comparing with the design strength of the joint, the maximum peak temperature that can meet the design strength requirements and the minimum peak temperature that ensures melting are obtained, and the welding heat input Q is calculated. max and Q min Then, the absolute value of the heat input difference Divide into 5 equal parts, each part is recorded as In this test example, according to the above content, (i=1,2,3,4,5) is used as heat input to analyze the microstructure performance under multiple thermal cycles, and the maximum number of thermal cycles ni under this heat input is obtained by comparing it with the joint design strength. For example, under Q4 heat input, the performance can no longer meet the design strength requirements after 4 thermal cycles, so the maximum number of thermal cycles under this heat input is 3.

[0120] Step S3: Since the actual welding position of the welding structure is PE, the flat plate surfacing test of the 12mm thick 7N01 plate is still carried out at the PE position, and the weld penetration D5=5.5mm and the weld width W5=7.0mm are obtained under the heat input of Q5. The groove depth D corresponding to the welding groove 5 of the T-type HV groove described in this test example is 10mm, the opening width W of the welding groove 5 is 14.3mm, and the overlap rate between the layers is set to 0.1. It is determined that the required number of layers is three layers and six passes to meet the weld formation requirements, that is, one pass for the first layer, two passes for the second layer, and three passes for the third layer, such as Figure 7As shown. However, since the first plate body 3 bears the load in the plate thickness direction Z, in order to reduce the tendency of thermal cracks in the first plate body 3, before formal welding, 1 / 2 of the heat input of other welds in the same layer is used as heat input to complete the melting of the groove area of ​​the first plate body 3, so that the heat affected zones of other welds can be away from the first plate body 3, thereby reducing the tendency of thermal cracks. Therefore, the layers are arranged as three layers and eight passes, that is, one weld in the first layer, three welds in the second layer, and four welds in the third layer. Among them, the heat input of the first layer can be Q3; the heat input of the weld close to the plate 1 in the second layer can be 1 / 2 Q4, and the heat input of the remaining welds is Q4; the heat input of the weld close to the plate 1 in the third layer can be 1 / 2 Q5, and the heat input of the remaining welds is Q5. Specifically as Figure 7 shown.

[0121] Step S4: Make a 12mm plate T-type HV groove joint simulation, use the PE position, and complete three-layer eight-pass welding with corresponding welding parameters. Cut the cross-section sample and observe the weld formation. If the formation is good, it proves that the three-layer eight-pass design under the heat input is reasonable; if the groove is not filled in the third layer and the forming requirements are not met, the heat input value of the third layer and the maximum number of thermal cycles allowed can be adjusted, and the number of passes can be adjusted at the same time until the weld formation requirements are met.

[0122] Step S5: Considering the constraint conditions of the T-type HV joint in the actual production of the welding structure, the Simufact welding simulation software is used to simulate the welding deformation under different welding pass sequences such as 1→2→3→4→5→6→7→8, 1→2→3→4→5→6→8→7, 1→2→5→3→4→6→7→8, 1→2→5→3→4→6→8→7, and the welding sequence with the smallest welding deformation is determined as the optimal welding sequence, such as Figure 7 shown.

[0123] Step S6: Use three layers and eight passes and their optimal sequence to complete the welding of the actual plate structure. After welding, detect the actual welding deformation of the structure and compare it with the design requirements. If the design requirements are met, it proves that the layer design is reasonable. If the welding deformation does not meet the design requirements, it is necessary to check the constraint conditions in the actual welding production process, and continue to simulate the welding deformation under different weld passes until the welding deformation meets the welding structure deformation requirements.

[0124] The multi-layer multi-pass welding device provided by the present invention is described below. The multi-layer multi-pass welding device described below and the method described above can be referred to each other.

[0125] The multi-layer multi-pass welding device provided by the present invention includes a connected sample preparation module, a layer distribution data analysis module, a simulation module and a welding execution module. The sample preparation module can prepare a sample of a plate body based on the optimal orientation of the plate body determined by the material rolling direction analysis. The layer distribution data analysis module can perform a flat plate surfacing test based on the thermal cycle analysis results of the sample to obtain layer distribution data that can meet the weld forming requirements. The simulation module can obtain the optimal layer welding sequence by analyzing the welding deformation through simulation. The welding execution module can perform welding based on the layer distribution data and the optimal layer welding sequence. Since each module of the welding device can respectively execute the above-mentioned multi-layer multi-pass weld layer arrangement method, the multi-layer multi-pass welding device has all the advantages of the above-mentioned multi-layer multi-pass weld layer arrangement method, and the details are not repeated here.

[0126] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A multi-layer and multi-pass weld layer arrangement method, characterized in that: The following steps are involved: Preparing a sample of the plate based on the optimal orientation of the plate determined by the material rolling direction analysis; Performing a flat plate surfacing test based on the thermal cycle analysis results of the sample to obtain layer distribution data that can meet the weld formation requirements; Analyze welding deformation through simulation to obtain the optimal layer welding sequence; Welding is performed based on the layer distribution data and the optimal layer welding sequence.

2. The multi-layer and multi-pass weld layer arrangement method according to claim 1, characterized in that: The step of preparing the sample of the plate body based on the optimal orientation of the plate body determined by analyzing the rolling direction of the material further comprises the following steps: Based on the various rolling directions of the plate body, samples are taken and tested respectively to obtain the sample properties of the plate body in various rolling directions; Comprehensively evaluate the performance of the samples in various rolling directions of the plate, and select the orientation with the best performance as the optimal orientation of the plate based on the type of welded joint; Sampling is performed based on the optimal orientation of the plate to prepare a test specimen of the plate.

3. The multi-layer and multi-pass weld layer arrangement method according to claim 2, characterized in that: The steps of sampling and testing respectively based on the various rolling directions of the plate body to obtain the performance of the samples in various rolling directions of the plate body, and the step of comprehensively evaluating the performance of the samples in various rolling directions of the plate body and selecting the orientation with the best performance as the optimal orientation of the plate body based on the type of the welded joint, further include the following steps: Selecting various rolling directions of the plate made of aluminum alloy to prepare rolling texture samples; Respectively obtaining the test data of the microstructure, tensile properties of the microstructure area and thermal crack sensitivity of each of the rolled texture samples; Comparative analysis of the test data to obtain an optimal rolled texture sample with the maximum tensile strength in the microstructure region under the same microstructure and thermal crack sensitivity conditions; The material rolling direction corresponding to the optimal rolling texture sample is taken as the optimal orientation of the plate.

4. The multi-layer and multi-pass weld layer arrangement method according to claim 1, characterized in that: The step of performing a flat plate surfacing test based on the thermal cycle analysis result of the sample to obtain layer distribution data that can meet the weld formation requirements further includes the following steps: Performing thermal cycle analysis on the sample of the plate to obtain the optimal heat input parameters that meet the performance requirements; A flat plate surfacing test is performed based on the actual welding position, welding joint type and the optimal heat input parameters to obtain layer distribution data that can meet the weld formation requirements.

5. The multi-layer and multi-pass weld layer arrangement method according to claim 4, characterized in that: The step of performing thermal cycle analysis on the sample of the plate body to obtain the optimal heat input parameter further comprises the following steps: A thermal simulation test is used to perform thermal cycle analysis on the microstructure performance of the sample of the plate under a single thermal cycle under different peak temperature conditions to obtain single thermal cycle analysis data; Based on the single thermal cycle analysis data and combined with the joint strength comparison data, the welding heat input range is obtained; Based on the welding heat input range, analysis and value selection are performed to analyze the microstructure performance under multiple thermal cycles using the welding heat input parameters after analysis and value selection, so as to obtain the optimal heat input parameters that meet the performance requirements.

6. The multi-layer and multi-pass weld layer arrangement method according to claim 5, characterized in that: The step of analyzing and obtaining values ​​based on the welding heat input range, and using the welding heat input parameters after the analysis and obtaining values ​​to analyze the microstructure performance under multiple thermal cycles to obtain the optimal heat input parameters that meet the performance requirements, further includes the following steps: Calculating a heat input difference based on the welding heat input range; Divide the heat input difference evenly to calculate the unit heat input value; Based on the welding heat input range and the unit heat input value, respectively calculating a single input value of a thermal cycle; A plurality of groups of thermal cycle single input values ​​are combined and analyzed, and the optimal thermal input parameters that meet the performance requirements are obtained through comparison.

7. The multi-layer and multi-pass weld layer arrangement method according to claim 6, characterized in that: The step of analyzing and obtaining values ​​based on the welding heat input range, and using the welding heat input parameters after the analysis and obtaining values ​​to analyze the microstructure performance under multiple thermal cycles, and obtaining the optimal heat input parameters that meet the performance requirements, further includes: The thermal cycle single input analysis value is ; Among them, Q i is the single input analysis value of the thermal cycle, i is the number of thermal cycle inputs, Q min is the minimum value of the welding heat input range, is the unit heat input value.

8. The multi-layer and multi-pass weld layer arrangement method according to claim 6, characterized in that: The step of performing a plate surfacing test based on the actual welding position, the welding joint type and the optimal heat input parameters to obtain layer distribution data that can meet the weld formation requirements further includes the following steps: Perform a flat plate surfacing test based on the actual welding position, welding joint type and optimal heat input parameters to obtain welding parameters corresponding to each single input value of the thermal cycle; According to the welding parameters, welding groove parameters and layer overlap rate, layer distribution data that can meet the weld forming requirements are obtained.

9. The multi-layer and multi-pass weld layer arrangement method according to claim 5, characterized in that: After the step of performing a flat plate surfacing test based on the thermal cycle analysis result of the sample to obtain layer distribution data that can meet the weld formation requirements, the following steps are also included: Based on the optimal heat input parameter and the joint strength comparison data, obtaining the maximum number of heat cycles corresponding to the current heat input value; Preparing a simulation sample with the same groove structure based on the sample of the plate body, and welding the simulation sample based on the layer distribution data to obtain actual weld formation data of the simulation sample; According to the actual weld formation data, each of the single thermal cycle analysis data is adjusted within the maximum thermal cycle number range until the layer distribution data can meet the weld formation requirements.

10. The multi-layer and multi-pass weld layer arrangement method according to any one of claims 1 to 9, characterized in that: The step of analyzing the welding deformation through simulation to obtain the optimal layer welding sequence further includes the following steps: Based on the welding constraint conditions, the welding deformation conditions under various layer welding sequences are simulated through simulation, and the layer welding sequence with the smallest welding deformation is selected as the optimal layer welding sequence.

11. The multi-layer and multi-pass weld layer arrangement method according to any one of claims 1 to 9, characterized in that: After the step of performing welding based on the layer distribution data and the optimal layer welding sequence, the following steps are also included: During the welding process, the layer distribution data and the optimal layer welding sequence are respectively corrected based on the actual welding deformation.

12. A multi-layer multi-pass welding device, characterized in that: Able to execute the multi-layer and multi-pass weld layer arrangement method as described in any one of claims 1 to 11; The multi-layer and multi-pass welding device comprises a connected sample preparation module, a layer distribution data analysis module, a simulation module and a welding execution module; A sample preparation module, capable of preparing a sample of the plate body based on the optimal orientation of the plate body determined by the material rolling direction analysis; A layer distribution data analysis module, capable of performing a flat plate surfacing test based on the thermal cycle analysis results of the sample to obtain layer distribution data that can meet the weld formation requirements; The simulation module can analyze the welding deformation through simulation to obtain the optimal layer welding sequence; The welding execution module can execute welding based on the layer distribution data and the optimal layer welding sequence.

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