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

Abstract

The present application relates to the field of welding, and provides a multi-layer multi-pass weld layer pass arrangement method and a multi-layer multi-pass welding device.The multi-layer multi-pass weld layer pass arrangement method comprises the following steps: preparing a sample of a plate body based on an optimal orientation of the plate body determined based on material rolling direction analysis; performing a flat plate surfacing test based on a heat cycle analysis result of the sample to obtain layer pass distribution data capable of meeting weld forming requirements; obtaining an optimal layer pass welding sequence by simulating and analyzing welding deformation; and performing welding based on the layer pass distribution data and the optimal layer pass welding sequence.The welding device is capable of performing the above method.The method and the welding device can solve the defects of the prior art, i.e., that the arrangement of the welding layer passes of the multi-layer multi-pass welding does not comprehensively consider various factors and lacks arrangement rules, and convert the subjective and rule-free arrangement of the layer passes into a method that can be accurately and quantitatively designed through tests, greatly improving the scientificity of the arrangement of the layer passes and further improving the weld performance and structural reliability.

Description

Technical Field

[0001] This invention relates to the field of welding, and provides a method for arranging multiple layers of weld seams and a welding apparatus for multiple layers of weld seams. Background Technology

[0002] Arc welding is widely used in equipment manufacturing industries such as rail transportation and energy power, and aluminum alloy arc welding technology is now widely applied in these industries. Multi-layer, multi-pass welding is one of the important methods for welding aluminum alloy plates. Due to the inherent physical properties of aluminum alloys, the welding process involves thermal cycling, which can cause joint softening and hot cracking defects in the weld zone and heat-affected zone, leading to a decline in weld performance. Because multi-layer, multi-pass welding is used for plate welding, the thermal effects in some weld areas are superimposed, further reducing weld performance. Therefore, the arrangement of welding layers in aluminum alloy plates is crucial to ensuring the final weld performance. However, current research on heat-affected zone softening cannot accurately perform sampling analysis and performance testing because the heat-affected zone is located between the base material and the weld zone. Thermal simulation experiments can accurately achieve thermal cycling at different peak temperatures and multiple thermal cycles, allowing for the analysis of the microstructure and properties of the heat-affected zone, thus providing technical support for the formulation of heat input and welding processes.

[0003] However, current multi-layer, multi-pass welding processes for aluminum alloy plates only consider the weld size for simple layer arrangement, neglecting the influence of multiple factors such as material properties, joint structure, heat input, and service conditions. This results in failure to meet the service requirements of the welded structure, especially for welded components with harsh service conditions and high performance requirements, which may even affect service safety. Furthermore, layer arrangement is a key factor affecting the final weld quality, but existing technologies lack specific guidelines for setting the number of layers in multi-layer, multi-pass welding. For the same joint, different process engineers may set completely different numbers of layers and welding sequences, making it difficult to ensure consistent weld quality. Therefore, significant problems remain regarding the layer arrangement for aluminum alloy plate welding, and a scientifically effective layer design method is lacking. Summary of the Invention

[0004] This invention provides a method for arranging multi-layer, multi-pass weld layers to address the shortcomings of related technologies where the layer arrangement is designed solely based on weld size and forming requirements, without comprehensively considering the influence of multiple factors such as material properties, joint structure, heat input, and service conditions, thus failing to achieve the optimal layer arrangement.

[0005] The present invention also provides a welding apparatus for multi-layer, multi-pass welding.

[0006] The present invention provides a method for arranging multi-layer, multi-pass weld seams, comprising 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] Based on the thermal cycling analysis results of the specimen, a flat plate welding test was performed to obtain layer distribution data that meets the weld formation requirements.

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

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

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

[0012] Samples were taken and tested in various rolling directions of the plate to obtain the sample performance of the plate in various rolling directions.

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

[0014] Samples of the plate are prepared by taking samples based on the optimal orientation of the plate.

[0015] The multi-layer, multi-pass weld arrangement method proposed in this invention includes the following steps: the step of sampling and testing samples based on various rolling directions of the plate to obtain the sample performance of the plate in various rolling directions; and the step of comprehensively evaluating the sample performance of the plate in various rolling directions and selecting the orientation with the best performance as the optimal orientation of the plate based on the weld joint type.

[0016] Rolled texture samples were prepared by selecting various rolling directions of the aluminum alloy plate.

[0017] The microstructure, tensile properties of the microstructure region, and hot crack sensitivity of each of the rolled textured specimens were obtained.

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

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

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

[0021] Thermal cycling analysis was performed on the plate sample to obtain the optimal thermal input parameters that meet the performance requirements.

[0022] A plate surfacing test was performed based on the actual welding location, welding joint type, and the optimal heat input parameters to obtain layer distribution data that meets the weld formation requirements.

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

[0024] Thermal simulation tests were used to analyze the microstructure properties of the plate sample under different peak temperature conditions in a single thermal cycle, so as 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 aforementioned welding heat input range, the values ​​are analyzed and selected to analyze the microstructure properties under multiple thermal cycles using the analyzed welding heat input parameters, thereby obtaining the optimal heat input parameters that meet the performance requirements.

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

[0028] The heat input difference is calculated based on the welding heat input range.

[0029] Divide the heat input difference equally and calculate the unit heat input value.

[0030] Based on the welding heat input range and the unit heat input value, the input value for a single heat cycle is calculated.

[0031] By combining and analyzing multiple sets of single-cycle input values ​​of the aforementioned thermal cycle, the optimal thermal input parameters that meet the performance requirements are obtained through comparison.

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

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

[0034] Among them, Q i Let Q be the single input analysis value of the thermal cycle, where i is the number of inputs for the i-th thermal cycle. min This is the minimum value within the welding heat input range. The unit heat input value is [value].

[0035] The method for arranging multi-layer, multi-pass weld layers proposed in this invention further includes the following steps: 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 meets the weld formation requirements.

[0036] Based on the actual welding position, welding joint type, and optimal thermal input parameters, a plate surfacing test was performed to obtain the welding parameters corresponding to each single thermal cycle input value.

[0037] Based on the welding parameters, welding groove parameters, and layer overlap rate, layer distribution data that meets the weld formation requirements is obtained.

[0038] The multi-layer, multi-pass weld layer arrangement method proposed in this invention, after the step of performing a flat plate welding test based on the thermal cycling analysis results of the sample to obtain layer distribution data that can meet the weld formation requirements, further includes the following steps.

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

[0040] Based on the sample of the plate, a simulated sample with the same bevel structure is prepared, and the simulated sample is welded based on the layer distribution data to obtain the actual weld formation data of the simulated sample.

[0041] Based on the actual weld formation data, the analysis data of each single thermal cycle are adjusted within the maximum number of thermal cycles until the layer distribution data can meet the weld formation requirements.

[0042] The multi-layer, multi-pass weld arrangement method proposed in this invention further includes the following steps: the step of analyzing welding deformation through simulation to obtain the optimal welding sequence of the layers.

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

[0044] The multi-layer, multi-pass weld arrangement method proposed in this invention, after the step of performing welding based on the pass distribution data and the optimal pass welding sequence, further includes the following steps.

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

[0046] This invention also proposes a welding apparatus for multi-layer, multi-pass welding, capable of performing the aforementioned multi-layer, multi-pass weld layer arrangement method. The multi-layer, multi-pass welding apparatus 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 the plate based on the optimal orientation of the plate determined by material rolling direction analysis. The layer distribution data analysis module can perform a plate surfacing test based on the thermal cycling analysis results of the sample to obtain layer distribution data that meets the weld formation requirements. The simulation module can obtain the optimal layer welding sequence by analyzing welding deformation through simulation. The welding execution module can perform welding based on the layer distribution data and the optimal layer welding sequence.

[0047] The present invention provides a method for arranging multi-layer, multi-pass weld layers, comprising the following steps: preparing a plate sample based on the optimal orientation of the plate determined by material rolling direction analysis; performing a plate surfacing test based on the thermal cycling analysis results of the sample to obtain layer distribution data that meets weld formation requirements; analyzing welding deformation through simulation to obtain the optimal layer welding sequence; and performing welding based on the layer distribution data and the optimal layer welding sequence. The welding apparatus is capable of performing the above method. This method and welding apparatus can overcome the shortcomings of existing multi-layer, multi-pass weld layer arrangement methods, which do not comprehensively consider various factors and lack arrangement rules. It transforms the subjective, undefined layer arrangement into a method that can be accurately and quantitatively designed through experimentation, greatly improving the scientific nature of the layer arrangement and thus enhancing weld performance and structural reliability.

[0048] This method is applicable to the layer arrangement of multi-layer, multi-pass welds on plates for all fusion welding methods and joint types, especially for welding plates such as aluminum alloy plates where heat input has a significant impact. By extracting the key steps and elements of the layer arrangement design method—namely, plate orientation design, heat input design, number of layers design, and layer sequence design—and through targeted experiments to quantitatively evaluate each element, this method provides clear, scientific, and concise guidance for the layer arrangement of multi-layer, multi-pass welds, ensuring welding quality and structural reliability.

[0049] The welding apparatus for multi-layer, multi-pass welding provided by this invention includes a connected sample preparation module, a pass distribution data analysis module, a simulation module, and a welding execution module. Since each module of this welding apparatus can respectively execute the aforementioned multi-layer, multi-pass weld pass arrangement method, this multi-layer, multi-pass welding apparatus possesses all the advantages of the aforementioned multi-layer, multi-pass weld pass arrangement method, which will not be elaborated further here. Attached Figure Description

[0050] To more clearly illustrate the technical solutions in this invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0051] Figure 1 This is a flowchart illustrating the multi-layer, multi-pass weld arrangement method provided by the present invention.

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

[0053] Figure 3 This is a schematic diagram of the structure of the V-groove structure with a backing in the multi-layer, multi-pass weld layer arrangement method provided by the present invention.

[0054] Figure 4 This is a diagram of the weld pool structure corresponding to the V-groove structure with a backing in the multi-layer, multi-pass weld layer arrangement method provided by the present invention.

[0055] Figure 5 This is a schematic diagram of the layer arrangement for a V-groove structure with a backing in the multi-layer, multi-pass weld layer arrangement method provided by the present invention.

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

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

[0058] Figure label:

[0059] 1. Rolled 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 bevel; 6. Backing plate; 7. Molten pool; 8. Substrate. Detailed Implementation

[0060] The embodiments of the present invention will be described in further detail below with reference to the accompanying drawings and examples. The following examples are for illustrative purposes only and should not be construed as limiting the scope of the invention.

[0061] The following is combined with Figures 1 to 7 This invention describes in detail a method for arranging multiple layers of weld seams in a multi-layer, multi-pass weld (hereinafter referred to as the "layer arrangement method" or "method"), and a welding apparatus for performing this method (hereinafter referred to as the "welding apparatus" or "apparatus"). This method and welding apparatus address the shortcomings of existing multi-layer, multi-pass weld seam arrangements, which lack comprehensive consideration of various factors and lack clear arrangement rules. They transform the subjective, undefined layer arrangement into a method that can be accurately and quantitatively designed through experimentation, greatly improving the scientific rigor of the layer arrangement and consequently enhancing weld performance and structural reliability.

[0062] In embodiments of the present invention, such as Figure 1 As shown, the layer arrangement method includes the following steps: Step S1, plate orientation design; Step S2, heat input design; Step S3, number of layers design; Step S5, layer sequence design; and welding execution. Details are as follows.

[0063] Plate orientation design steps: Based on the optimal orientation of the plate determined by the material rolling direction analysis, a sample of the plate is prepared.

[0064] Heat input design steps and layer number design steps: Based on the thermal cycle analysis results of the sample, perform plate surfacing tests to obtain layer distribution data that can meet the weld formation requirements.

[0065] Layer sequence design steps: Analyze welding deformation through simulation to obtain the optimal layer welding sequence.

[0066] Welding execution steps: Welding is performed based on layer distribution data and the optimal layer welding sequence.

[0067] This method is applicable to the layer arrangement of multi-layer, multi-pass welds on plates for all fusion welding methods and joint types, especially for welding plates such as aluminum alloy plates where heat input has a significant impact. By extracting the key steps and elements of the layer arrangement design method—namely, plate orientation design, heat input design, number of layers design, confirmation of the number of layers and optimization of heat input, layer sequence design, and welding deformation optimization—and through targeted experiments, quantitatively evaluating each element, this method provides clear, scientific, and explicit guidance for the layer arrangement of multi-layer, multi-pass welds, ensuring welding quality and structural reliability.

[0068] It should be noted that the method described in the embodiments of the present invention is preferably applied to the welding process of multi-layer, multi-pass welding of aluminum alloy plates.

[0069] It should be noted that the method described in the embodiments of the present invention is applicable to various fusion welding methods such as arc welding, laser welding, and laser-arc hybrid welding of aluminum alloy plates.

[0070] It should be noted that the method described in the embodiments of the present invention is applicable to all types of welded joint structures, such as butt joints, corner joints, and lap joints.

[0071] In some embodiments, step S1 described above further includes the following steps.

[0072] Step S11: Samples are taken and tested according to the various rolling directions of the plate to obtain the sample performance of the plate in various rolling directions.

[0073] 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.

[0074] Step S13: Sample the plate based on its optimal orientation to prepare a plate specimen.

[0075] In some specific embodiments, such as Figure 2 As shown, steps S11 and S12 further include the following steps.

[0076] Rolled texture samples were prepared by selecting various rolling directions of aluminum alloy plates.

[0077] Data on the microstructure, tensile properties of the microstructure region, and hot crack sensitivity of each rolled textured specimen were obtained.

[0078] By comparing and analyzing the test data, the optimal rolled texture sample with the highest tensile strength in the microstructure region under the same microstructure and thermal crack sensitivity conditions was obtained.

[0079] The optimal orientation of the plate is determined by the rolling direction of the material corresponding to the optimal rolled texture sample.

[0080] In this embodiment, the method first quantitatively analyzes the anisotropy of the aluminum alloy plate material based on specific requirements such as the mechanical properties of the welded structure, weld formation, and welding deformation requirements, to determine the orientation of the plate in the joint. Specifically, samples are taken from different rolling directions of the aluminum alloy plate, and their microstructure, micro-area tensile properties, and hot cracking sensitivity are tested to evaluate the performance of the plate in different rolling directions. The test results are then synthesized, and the orientation with the best performance is selected as the plate orientation in the joint based on the joint type.

[0081] This setup ensures that the sampling method fully considers the comprehensive performance of the rolled texture structure 1 in the length direction (X), width direction (Y), and thickness direction (Z), as well as the specific rolling direction (A) of the rolled texture structure 1. Furthermore, it comprehensively considers the influence of sampling position 2 on the strength of the selected sample, thereby more accurately and efficiently selecting the most reasonable sampling position 2, and ultimately choosing the one with the best comprehensive performance as the joint orientation. For example, as... Figure 2 As shown, the anisotropy of the plate is analyzed based on its load-bearing capacity in the X-direction (length), Y-direction (width), and Z-direction (thickness). Multiple sampling locations are selected on the plate, and the microstructure, micro-area tensile properties, and hot crack susceptibility of the samples at each location are quantitatively analyzed. A comprehensive analysis of the sample performance at each sampling location is conducted. Several performance indicators with similar or nearly identical values ​​can be used as benchmarks, with those showing significant differences serving as the basis for judgment. For example, comparing samples from different sampling locations, if the microstructure and hot crack susceptibility are comparable, the direction or sampling location with higher tensile strength is selected as the orientation with the best overall performance.

[0082] In some embodiments, steps S2 and S3 further include the following steps.

[0083] Step S2: Thermal input design step: Perform thermal cycling analysis on the plate sample to obtain the optimal thermal input parameters that meet the performance requirements.

[0084] Step S3 Layer Number Design Step: Based on the actual welding position, welding joint type and optimal heat input parameters, perform a plate surfacing test to obtain layer distribution data that meets the weld formation requirements.

[0085] In some specific embodiments, step S2 described above can analyze the weld microstructure and properties by conducting thermal simulation experiments under different peak temperatures in single and multiple thermal cycles, and determine the optimal heat input for each weld. Specifically, step S2 further includes the following steps.

[0086] Step S21: The microstructure properties of the plate sample under different peak temperature conditions in a single thermal cycle are analyzed by thermal simulation test to obtain single thermal cycle analysis data.

[0087] Step S22: Based on the single thermal cycle analysis data and combined with the joint strength comparison data, obtain the welding heat input range.

[0088] Step S23: Analyze and select values ​​based on the welding heat input range, and use the analyzed welding heat input parameters to analyze the microstructure properties under multiple thermal cycles, so as to obtain the optimal heat input parameters that meet the performance requirements.

[0089] In some specific embodiments, step S23 above 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 heat cycle input value based on the welding heat input range and the unit heat input value; combining and analyzing multiple sets of single heat cycle input values, and obtaining the optimal heat input parameters that meet the performance requirements by comparison.

[0090] In this embodiment, the above steps involve calculating the optimal heat input parameters based on the welding heat input range. The corresponding formula is: the single-cycle input analysis value is... ; where Q i Q represents the single-cycle input analysis value, where i is the number of input cycles for the i-th cycle. min This represents the minimum value within the welding heat input range. The unit is the heat input value.

[0091] In other words, the microstructure properties under a single thermal cycle at different peak temperatures were analyzed using thermal simulation experiments. By comparing these microstructure properties with the designed joint strength, the welding heat input range was obtained, where the minimum welding heat input value was Q. min The maximum welding heat input is Q. max The absolute value of the heat input difference |Q max -Q min | Divide into N equal parts, each denoted as . That is, unit heat input value Then, the analysis values ​​were input for each single thermal cycle. As a heat input, the microstructure properties under multiple thermal cycles are analyzed to obtain the optimal heat input parameters. Here, i is an integer between (1, N).

[0092] In some specific embodiments, step S3 above can use an experimental method of equal plate surfacing to obtain weld penetration and width data under corresponding heat input, thereby completing the layer design step based on the bevel shape and overlap rate. Specifically, step S3 further includes the following steps.

[0093] Step S31: Perform a plate surfacing test based on the actual welding position, welding joint type and optimal thermal input parameters to obtain the welding parameters corresponding to the single input value of each thermal cycle.

[0094] Step S32: Based on the welding parameters, welding groove parameters, and layer overlap rate, obtain layer distribution data that meets the weld formation requirements.

[0095] In this embodiment, the above steps specifically involve conducting a plate-to-plate welding test at the actual welding location to obtain the single-cycle thermal cycle input analysis value Q. i The weld penetration depth Di and weld width Wi are as follows: Figure 4 As shown. Then, based on the bevel design dimensions and considering the overlap rate between layers, the required number of layers is determined as the layer distribution data.

[0096] In some embodiments, the method further includes step S4, which involves confirming the number of channels and optimizing thermal input. Step S4 further includes steps S24, S25, and S26 following step S23 described above. Specifically, step S4 includes the following steps.

[0097] Step S24: Based on the optimal thermal input parameters and joint strength comparison data, obtain the maximum number of thermal cycles corresponding to the current thermal input value.

[0098] Step S25: Prepare a simulated specimen with the same bevel structure based on the plate specimen, and weld the simulated specimen based on the layer distribution data to obtain the actual weld formation data of the simulated specimen.

[0099] Step S26: Based on the actual weld formation data, adjust the analysis data of each single thermal cycle within the maximum number of thermal cycles until the layer distribution data can meet the weld formation requirements.

[0100] In step S4 above, the plate joint simulation component is welded, and the number of passes is confirmed. If the requirements are not met, the heat input and corresponding number of thermal cycles for each weld pass are adjusted until the number of passes meets the weld formation requirements. Specifically, the maximum number of thermal cycles ni under this heat input is first obtained by comparing it with the joint design strength. Then, a plate joint simulation component with the same bevel shape is fabricated, and welding is performed using the designed number of passes. The number of passes is confirmed through actual weld formation. If situations such as incomplete bevel filling occur and the formation requirements are not met, the single-cycle input analysis value Q obtained in steps S2 and S3 is used. i The heat input for each weld pass is adjusted by setting the penetration depth Di, weld width Wi, and maximum number of thermal cycles ni, until the number of passes meets the weld formation requirements. This correction process continuously optimizes the heat input, thereby improving the accuracy of the pass distribution data.

[0101] In some embodiments, such as Figure 1 As shown, step S5 above further includes the following steps.

[0102] Step S51: Based on the welding constraint conditions, simulate the welding deformation under various layer welding sequences, and select the layer welding sequence with the smallest welding deformation as the optimal layer welding sequence.

[0103] In this embodiment, step S51 considers the actual constraint conditions of the welded 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 actual production of the welded structure, Simufact welding simulation software is used to simulate welding deformation under different weld sequence sequences, and the sequence with the smallest welding deformation is taken as the optimal layer welding sequence. Incorporating the simulation process ensures that the method is closer to actual production, improves the accuracy and scientific nature of the layer arrangement, and has greater practical significance.

[0104] In some embodiments, after step S5 described above, a step of optimizing the overall sequence of the floor layout (step S5) is further included. That is, as... Figure 1 The steps shown in S6 are the design scheme confirmation and optimization sequence steps. Specifically, after step S5, the following steps are also included.

[0105] Step S6: During the welding process, the layer distribution data and the optimal layer welding sequence are corrected based on the actual welding deformation.

[0106] In this embodiment, step S6 can complete the welding of the actual plate structure using the actual number of layers and welding sequence, and confirm the layer design scheme. That is, after completing the welding of the actual plate structure using the obtained number of layers and sequence, the layer design scheme is confirmed by the actual welding deformation. Furthermore, 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 weld passes is simulated again until the welding deformation meets the welding structure deformation requirements.

[0107] Step S6 can fully consider the deformation and residual stress analysis of the welded structure under actual restraint conditions, thereby reasonably optimizing the layer distribution data and the optimal layer welding sequence, and improving the accuracy and reliability of the method.

[0108] The following is for reference Figures 3 to 6 The implementation method and its corresponding effects are explained in detail through two specific experimental examples.

[0109] refer to Figures 3 to 5 The first experimental example shown uses the welding of a V-groove butt joint structure of a 12mm thick 7N01 aluminum alloy plate with a backing plate 6 as an example. In this example, the angle of the welding groove 5 of the joint structure is 60°, and the blunt edge of the groove is 1mm.

[0110] The steps in the method described in this embodiment are as follows.

[0111] Step S1: Since the thickness direction Z of the butt joint plate does not bear external loads, only the anisotropy in the length direction X and width direction Y of the plate is analyzed. For example... Figure 2 As shown, samples were taken along the length (X) and width (Y) directions of the 7N01 aluminum alloy plate, and then quantitative analyses of microstructure, micro-area tensile properties, and hot crack susceptibility were performed. A comprehensive comparison of the test results revealed that the micro-area tensile strength along the length (X) direction was 385.4 MPa, while the micro-area tensile strength along the width (Y) direction was 368.9 MPa. Furthermore, the hot crack susceptibility of both samples was comparable. Therefore, the sample taken along the length (X) direction exhibited the best performance. Thus, the plate was cut along the length (X) direction and beveled to obtain the sample shown below. Figure 3 The first plate 3 and the second plate 4 shown are joined together to form a V-shaped weld groove 5, and a backing plate 6 is provided on the back of the weld groove 5.

[0112] Step S2: A thermal simulation experiment is conducted on a 7N01 plate sample taken along the X-axis of the plate length to analyze 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.). By comparing this with the joint design strength, the maximum peak temperature that meets the design strength requirements and the minimum peak temperature that ensures melting are obtained. The welding heat input Q is then calculated. max and Q min The absolute value of the heat input difference Divide into 3 equal parts, each denoted as _____. , respectively (i=1,2,3) is used as the heat input to analyze the microstructure properties under multiple thermal cycles. By comparing with the joint design strength, the maximum number of thermal cycles ni under this heat input is obtained. For example, under a heat input of Q3, 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.

[0113] Step S3: Since the actual welding position of this welded structure is PA, a plate surfacing test on a 12mm thick 7N01 substrate 8 is still conducted at the PA position. The weld penetration depth D3 = 5.0mm and weld width W3 = 6.5mm are obtained for the molten pool 7 under heat input Q3. Figure 4 As shown. Figure 3 and Figure 4 As shown, the bevel depth D of the V-groove is 11mm, the opening width W of the welding groove 5 is 12.7mm, and the overlap rate between layers is set to 0.1. Therefore, three layers and six passes are required to meet the weld formation requirements. That is, the first layer has one pass, the second layer has two passes, and the third layer has three passes. Figure 5 As shown. The welding heat input for each weld in each layer must be the same, but the heat input between different layers can be different. That is, the heat input for the first layer can be Q2, and the heat input for the second and third layers can be Q3.

[0114] Step S4: Fabricate a 12mm plate V-groove joint simulation piece, using position PA, and complete a three-layer, six-pass weld with the corresponding welding parameters. Cut a cross-sectional sample and observe the weld formation. If the formation is good, it proves that the designed three-layer, six-pass design is reasonable under this heat input. If the bevel is not fully filled in the third layer, or if the formation requirements are not met, the single-pass heat input value Q of the third layer can be adjusted. i The maximum number of permissible thermal cycles (ni) is determined, and the number of passes is adjusted until the weld formation requirements are met.

[0115] Step S5: Considering the constraint conditions of the V-groove butt joint in actual production, specifically in this experimental example, Simufact welding simulation software is preferred to simulate the weld sequence, determining 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, and 1→3→2→6→5→4. The welding sequence with the least welding deformation is determined as the optimal welding sequence. Figure 5 As shown.

[0116] Step S6: Weld the actual plate structure using a three-layer, six-pass welding process and its optimal sequence. After welding, inspect 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 considered 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 requirements of the welded structure.

[0117] refer to Figure 6 and Figure 7 The second experimental example shown uses the welding of a T-type HV groove joint structure constructed from a 12mm thick 7N01 aluminum alloy plate as an example. In this example, the groove angle of the welding groove 5 of the joint structure is 55°, the blunt edge of the groove is 2mm, and the depth of the weld pool is 11mm.

[0118] The steps in the method described in this embodiment are as follows.

[0119] Step S1: Sampling position 2 of the first plate 3 of the T-type HV bevel joint is taken along the thickness direction Z of the plate. Therefore, the anisotropy of the plate length direction X, width direction Y, and thickness direction Z is analyzed. Samples are taken from the 7N01 aluminum alloy plate along the three directions, and then quantitative analysis of microstructure, micro-area tensile properties, and hot crack susceptibility is performed, such as... Figure 2As shown. Based on comprehensive comparative test results, the micro-area tensile strength in the length direction X is 396.2 MPa, the micro-area tensile strength in the width direction Y is 367.7 MPa, and the micro-area tensile strength in the thickness direction Z is 347.5 MPa. Therefore, the tensile performance in the length direction X is determined to be the best. Testing confirmed that the hot cracking susceptibility in the length direction X and width direction Y is comparable, while the hot cracking susceptibility in the thickness direction Z is higher. Therefore, the heat input of the weld bead in the thickness direction Z of the first plate 3 needs to be strictly controlled to reduce the tendency for hot cracking. The second plate 4 is cut along the length direction X and a welding bevel 5 is machined. Then, the second plate 4 is butt-jointed to the surface of the first plate 3 to form a T-joint bevel structure, as shown. Figure 6 As shown.

[0120] Step S2: Samples are taken from the first plate 3 along the thickness direction Z and the second plate 4 along the length direction X. Thermal simulation experiments are used to analyze the microstructure properties under a single thermal cycle at different peak temperatures (e.g., 150℃, 200℃, 300℃, 400℃, 500℃, etc.). By comparing these values ​​with the joint design strength, the maximum peak temperature that meets the design strength requirements and the minimum peak temperature that ensures melting are obtained. The welding heat input Q is then calculated. max and Q min Then, the absolute value of the thermal input difference is... Divide into 5 equal parts, each denoted as _____. In this experimental example, based on the above content, respectively using... The microstructure properties under multiple thermal cycles are analyzed using (i=1,2,3,4,5) as heat inputs. By comparing these values ​​with the joint design strength, the maximum number of thermal cycles ni under this heat input is obtained. For example, under a heat input of Q4, the performance no longer meets the design strength requirements after 4 thermal cycles, so the maximum number of thermal cycles under this heat input is 3.

[0121] Step S3: Since the actual welding location of this welded structure is PE, a plate surfacing test on a 12mm thick 7N01 plate is still conducted at the PE location. The weld penetration depth D5 = 5.5mm and weld width W5 = 7.0mm are obtained under a heat input of Q5. In this test example, the groove depth D corresponding to the T-type HV-type groove 5 is 10mm, the opening width W of the groove 5 is 14.3mm, and the overlap rate between layers is set to 0.1. Therefore, the required number of layers is three layers and six passes to meet the weld formation requirements, i.e., one pass for the first layer, two passes for the second layer, and three passes for the third layer. Figure 7As shown. However, since the first plate 3 bears the load in the thickness direction Z, to reduce the tendency of the first plate 3 to hot crack, before the formal welding, half of the heat input of other weld passes in the same layer is used as the heat input to melt the bevel area of ​​the first plate 3, so that the heat-affected zone of other weld passes can be far away from the first plate 3, thereby reducing the tendency of hot crack. Therefore, the layer arrangement is three layers and eight passes, that is, the first layer has one pass, the second layer has three passes, and the third layer has four passes. Among them, the heat input of the first layer can be Q3; the heat input of the weld pass near plate 1 in the second layer can be half Q4, and the heat input of the remaining weld passes is Q4; the heat input of the weld pass near plate 1 in the third layer can be half Q5, and the heat input of the remaining weld passes is Q5. Specifically, as shown... Figure 7 As shown.

[0122] Step S4: Fabricate a 12mm plate T-type HV groove joint simulation part, using the PE position, and complete a three-layer eight-pass weld with the corresponding welding parameters. Cut a cross-sectional sample and observe the weld formation. If the formation is good, it proves that the designed three-layer eight-pass weld is reasonable under this heat input. If the groove is not fully filled in the third layer, or if the formation requirements are not met, the heat input value of the third layer and the maximum allowable number of thermal cycles can be adjusted, and the number of passes can be adjusted until the weld formation requirements are met.

[0123] Step S5: Considering the constraint conditions of the T-type HV joint in the actual production of the welded structure, the Simufactwelding simulation software is used to simulate the welding deformation under different weld sequence 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, and 1→2→5→3→4→6→8→7. The welding sequence with the smallest welding deformation is determined as the optimal welding sequence. Figure 7 As shown.

[0124] Step S6: Weld the actual plate structure using three layers and eight passes in the optimal sequence. After welding, inspect 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 considered reasonable. If the welding deformation does not meet the design requirements, the constraint conditions in the actual welding production process need to be checked, and the welding deformation under different weld passes needs to be simulated until the welding deformation meets the requirements of the welded structure.

[0125] The welding apparatus for multi-layer multi-pass welding provided by the present invention will be described below. The welding apparatus for multi-layer multi-pass welding described below can be referred to in correspondence with the method described above.

[0126] The multi-layer, multi-pass welding apparatus provided by this invention includes a connected sample preparation module, a pass distribution data analysis module, a simulation module, and a welding execution module. The sample preparation module prepares a sample of the plate based on the optimal orientation of the plate determined by material rolling direction analysis. The pass distribution data analysis module performs a plate surfacing test based on the thermal cycling analysis results of the sample to obtain pass distribution data that meets the weld formation requirements. The simulation module analyzes welding deformation through simulation to obtain the optimal pass welding sequence. The welding execution module performs welding based on the pass distribution data and the optimal pass welding sequence. Since each module of this welding apparatus can correspondingly execute the aforementioned multi-layer, multi-pass weld pass arrangement method, this multi-layer, multi-pass welding apparatus possesses all the advantages of the aforementioned multi-layer, multi-pass weld pass arrangement method, which will not be elaborated further here.

[0127] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for arranging multiple layers and multiple passes of weld seams, characterized in that, Includes the following steps: Based on the optimal orientation of the plate determined by material rolling direction analysis, a sample of the plate is prepared. Based on the thermal cycling analysis results of the sample, a flat plate welding test was performed to obtain layer distribution data that meets the weld formation requirements; Welding deformation is analyzed through simulation to determine the optimal welding sequence for each layer. Welding is performed based on the layer distribution data and the optimal layer welding sequence; The step of performing a flat plate welding test based on the thermal cycling analysis results of the sample to obtain layer distribution data that meets the weld formation requirements further includes the following steps: Thermal cycling analysis was performed on the plate sample to obtain the optimal thermal input parameters that meet the performance requirements; A plate surfacing test was performed based on the actual welding position, welding joint type, and the optimal heat input parameters to obtain layer distribution data that meets the weld formation requirements. The step of performing thermal cycling analysis on the plate sample to obtain the optimal thermal input parameters further includes the following steps: Thermal simulation tests were used to analyze the microstructure properties of the plate sample under different peak temperature conditions in a single thermal cycle, so as 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 aforementioned welding heat input range, the values ​​are analyzed and selected to analyze the microstructure properties under multiple thermal cycles using the analyzed welding heat input parameters, thereby obtaining the optimal heat input parameters that meet the performance requirements. The step of analyzing and selecting values ​​based on the welding heat input range, and then using the analyzed welding heat input parameters to analyze the microstructure properties under multiple thermal cycles to obtain the optimal heat input parameters that meet the performance requirements, further includes the following steps: Calculate the heat input difference based on the welding heat input range; Divide the heat input difference equally and calculate the unit heat input value; Based on the welding heat input range and the unit heat input value, calculate the input value for a single heat cycle; By combining and analyzing multiple sets of single-cycle input values ​​of the aforementioned thermal cycle, the optimal thermal input parameters that meet the performance requirements are obtained through comparison. 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 meets the weld formation requirements further includes the following steps: Based on the actual welding position, welding joint type and optimal thermal input parameters, a plate surfacing test was performed to obtain the welding parameters corresponding to the single input value of each thermal cycle. Based on the welding parameters, welding groove parameters, and layer overlap rate, obtain layer distribution data that meets the weld formation requirements; The step of performing a flat plate welding test based on the thermal cycling analysis results of the sample to obtain layer distribution data that meets the weld formation requirements also includes the following steps: Based on the optimal thermal input parameters and the joint strength comparison data, the maximum number of thermal cycles corresponding to the current thermal input value is obtained; Based on the sample of the plate, a simulated sample with the same bevel structure is prepared, and the simulated sample is welded based on the layer distribution data to obtain the actual weld formation data of the simulated sample. Based on the actual weld formation data, the analysis data of each single thermal cycle are adjusted within the maximum number of thermal cycles until the layer distribution data can meet the weld formation requirements.

2. The method for arranging multiple layers and multiple passes of weld seams according to claim 1, characterized in that, The step of preparing a sample of the plate based on the optimal orientation of the plate determined by material rolling direction analysis further includes the following steps: Samples were taken and tested in various rolling directions of the plate to obtain the sample performance of the plate in various rolling directions; The performance of the specimens in various rolling directions of the plate was comprehensively evaluated, and the orientation with the best performance was selected as the optimal orientation of the plate based on the type of welded joint. Samples of the plate are prepared by taking samples based on the optimal orientation of the plate.

3. The method for arranging multiple layers and multiple passes of weld seams according to claim 2, characterized in that, The steps of sampling and testing samples in various rolling directions of the plate to obtain the performance of the samples in various rolling directions, and the steps of comprehensively evaluating the performance of the samples in various rolling directions of the plate and selecting the orientation with the best performance as the optimal orientation of the plate based on the weld joint type, further include the following steps: Rolled texture samples were prepared by selecting various rolling directions of the aluminum alloy plate. The microstructure, tensile properties of the microstructure region, and hot crack sensitivity of each of the rolled textured specimens were obtained. By comparing and analyzing the test data, the optimal rolled texture sample with the highest tensile strength in the microstructure region under the same microstructure and thermal crack sensitivity conditions was obtained. The optimal orientation of the plate is defined as the rolling direction of the material corresponding to the optimal rolled texture sample.

4. The method for arranging multiple layers and multiple passes of weld seams according to claim 1, characterized in that, The step of analyzing and selecting values ​​based on the welding heat input range, and using the analyzed welding heat input parameters to analyze the microstructure properties under multiple thermal cycles, to obtain the optimal heat input parameters that meet the performance requirements, further includes: The single input analysis value of the thermal cycle is Q. i =Q min +ΔQ×i; Among them, Q i Let Q be the single input analysis value of the thermal cycle, i be the number of inputs for the i-th thermal cycle, and Q be the input value for the ith thermal cycle. min ΔQ is the minimum value of the welding heat input range, and ΔQ is the unit heat input value.

5. The method for arranging multiple layers and multiple passes of weld seams according to any one of claims 1-4, characterized in that, The step of analyzing welding deformation through simulation to obtain the optimal layer welding sequence further includes the following steps: Based on welding constraint conditions, the welding deformation under various layer welding sequences is simulated, and the layer welding sequence with the smallest welding deformation is selected as the optimal layer welding sequence.

6. The method for arranging multiple layers and multiple passes of weld seams according to any one of claims 1-4, characterized in that, After the step of performing welding based on the layer distribution data and the optimal layer welding sequence, the method further includes the following steps: During the welding process, the layer distribution data and the optimal layer welding sequence are corrected based on the actual welding deformation.

7. A welding apparatus for multi-layer, multi-pass welding, characterized in that, It is capable of performing the multi-layer, multi-pass weld arrangement method as described in any one of claims 1-6; The welding apparatus for multi-layer multi-pass welding 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 the plate based on the optimal orientation of the plate determined by material rolling direction analysis. The layer distribution data analysis module can perform a flat plate welding test based on the thermal cycling analysis results of the sample to obtain layer distribution data that meets the weld formation requirements. The simulation module can analyze welding deformation through simulation to obtain the optimal welding sequence for each layer. The welding execution module can perform welding based on the layer distribution data and the optimal layer welding sequence.

Images