Welding method based on induction diffusion welding

Abstract

The invention relates to the technical field of welding methods, in particular to a welding method based on induction diffusion welding. The method comprises the steps of 1, workpiece preparation, 2, automatic positioning and clamping, 3, heating treatment, 4, temperature control, 5, pressure exerting and maintaining, 6, heat preservation and diffusion, 7, cooling and curing and 8, quality treatment. In the whole welding process, from workpiece preparation to quality treatment, most of the steps are automatically operated, manual intervention is reduced, the production efficiency and consistency are improved, an inert gas protection cover is arranged in a welding area, metal oxidation in the welding process is prevented, meanwhile, emission of harmful gas is reduced, environmental protection is facilitated, and the production cost is reduced. The opportunity of manual contact with high temperature and harmful substances is reduced through automatic operation, the operation safety is improved, the method is suitable for welding of various materials such as metal and alloy, workpieces of complex structures can be treated, and the application range is widened.

Description

Technical Field

[0001] The invention relates to the technical field of welding methods, and in particular to a welding method based on induction diffusion welding. Background Art

[0002] Induction diffusion welding is a welding method that uses a high-frequency electric field to cause the molecules at the edge and some areas of the workpiece to vibrate and generate heat through friction. The heat is concentrated and transferred to the center and gradually rises to a plastic state. Then, under the action of temperature and pressure, the workpieces approach each other, local plastic deformation occurs, and mutual diffusion occurs between atoms, forming a new diffusion layer at the interface, thereby achieving a reliable connection.

[0003] The current traditional induction diffusion welding part still needs to rely on manual operation, such as workpiece positioning, clamping, heating temperature control and post-welding processing operations. During the welding process, there is a lack of high-precision temperature monitoring and control systems, which leads to large temperature fluctuations in the welding area and is difficult to automatically and accurately control within the predetermined range. At the same time, there is also a lack of effective residual stress elimination methods, which further affects the mechanical properties and service life of the welded joint.

[0004] Therefore, in view of the problem that the above-mentioned traditional induction diffusion welding lacks a high-precision temperature monitoring and control system during the welding process, making it difficult to automatically and accurately control within a predetermined range, and also lacks effective means of eliminating residual stress, a welding method based on induction diffusion welding can be designed, which can significantly improve the degree of automation, accuracy and efficiency of welding, while reducing costs and expanding the scope of application. Summary of the invention

[0005] In order to overcome the problem that traditional induction diffusion welding lacks high-precision temperature monitoring and control systems during the welding process, it is difficult to automatically and accurately control within a predetermined range, and there is also a lack of effective residual stress elimination methods.

[0006] The technical solution of the present invention is: a welding method based on induction diffusion welding, and the specific preparation steps are as follows;

[0007] Step 1: Workpiece preparation

[0008] First, clean the surface of the workpiece, use sandpaper, grinding wheel or chemical cleaning agent to remove impurities, including rust, dirt, oil stains, and ensure that the welding area is clean and pollution-free;

[0009] Step 2: Automated positioning and clamping

[0010] Use automated fixtures to automatically and accurately assemble the above workpieces to the welding processing position, and use displacement sensors to position the workpieces, monitor the position and offset of the workpieces in real time, and ensure the accuracy of the welding area;

[0011] Step 3: Heat treatment

[0012] Use a temperature homogenization device to preheat the workpiece, and its preheating temperature is between 50% and 80% of the welding temperature. Start the induction heating device, and generate a high-frequency magnetic field through high-frequency current, so that the metal in the welding area generates eddy current and heats up. At the same time, the induction heating device is connected to the welding controller through wires, and the power range of the high-frequency power supply is between 5kw and 20kw;

[0013] Step 4: Temperature Control

[0014] An inert gas protective cover is set in the welding area. At the same time, a temperature sensor is used to monitor the temperature of the welding area in real time, and the heating power and time are adjusted through the intelligent control system to ensure that the temperature is controlled within a predetermined range. The intelligent control system includes a displacement sensor, a welding controller, an intelligent host and an actuator. The welding controller analyzes and processes the received data according to preset algorithms and rules, makes decisions to adjust parameters, and the actuator performs corresponding operations according to the instructions of the welding controller, including adjusting the output power of the heating device, opening and closing the gas protective cover. The displacement sensor is usually connected to the welding controller through a signal line. The signal line adopts any one of the two-wire, three-wire and four-wire systems. The welding controller is connected to the heating device and the gas protective cover actuator through wires. The intelligent host is connected to the welding controller through Ethernet. The actuator is connected to the welding controller through wires or signal lines. The preset algorithms and rules specifically adopt one or more of the temperature control algorithm, pressure control algorithm, time control algorithm, fault diagnosis and alarm rules and remote monitoring and intervention rules. In the temperature control algorithm, the temperature data of the welding area monitored in real time by the temperature sensor is compared with the preset temperature range; in the pressure control algorithm, the applied pressure data monitored in real time by the pressure sensor is compared with the preset pressure range; in the time control algorithm, a time controller is used to accurately control the duration of each operation according to the different stages and time requirements in the welding process; in the fault diagnosis and alarm rules, if the sensor data is abnormal or the parameters in the welding process exceed the preset range, the fault diagnosis program is triggered and an alarm signal is issued; in the remote monitoring and intervention rules, the operator uses a smart phone or tablet computer as a remote monitoring terminal to view the image and data information of the welding process in real time, and conduct remote intervention and adjustment;

[0015] Step 5: Apply pressure and hold

[0016] Start the pressure control system and apply a certain pressure to the welding area to promote close contact between the workpieces and diffusion between atoms. At the same time, use a pressure sensor to monitor the applied pressure value in real time. After the welding area reaches a certain temperature and pressure is applied, this state is maintained for 8 minutes to 2 hours to ensure the welding quality. The pressure range of the pressure control system is between 8MPa-22MPa;

[0017] Step 6: Heat preservation and diffusion

[0018] While heating and applying pressure, a time controller is used to precisely control the time to ensure that the atoms can fully diffuse and form a metallurgical connection;

[0019] Step 7: Cooling and solidification

[0020] Turn off the heating device, gradually reduce the temperature of the welding area, use the cooling device to quickly cool the welding area to solidify the weld, and then use the automated fixture to take out the welded workpiece for automatic unloading;

[0021] Step 8: Quality Processing

[0022] 1) Inspection: Use testing equipment to conduct a comprehensive inspection of the weld quality of the workpiece to ensure that the integrity and strength of the welded joint meet the requirements;

[0023] 2) Residual stress elimination: Start the vibration aging device to perform vibration aging treatment on the welded joint to eliminate the residual stress generated during the welding process. The vibration frequency is between 30Hz and 150Hz, and the amplitude is between 3 microns and 5 mm;

[0024] 3) Post-processing: After the residual stress is eliminated, the weld joint is subjected to necessary post-processing, including burr removal, grinding and cleaning, to ensure that the weld surface is smooth and neat.

[0025] Preferably, an automated positioning clamping system and real-time monitoring of a displacement sensor are used to ensure the accuracy of the welding area and improve welding accuracy. A high-precision temperature and pressure control system, combined with precise control of a time controller, ensures the stability of various parameters during the welding process, thereby obtaining high-quality welded joints. The temperature homogenization device and intelligent control system can accurately control the heating power and time, reduce unnecessary energy consumption, and achieve energy-saving effects. While heating and applying pressure, a time controller is used to accurately control the time to ensure that atoms can fully diffuse and form a metallurgical connection, thereby improving the strength and toughness of the welded joint. The vibration aging device can effectively eliminate the residual stress generated during the welding process and improve the stability and service life of the welded joint.

[0026] Preferably, the preheating time in step three is between five minutes and one hour, and the preheating is ended after ensuring that the temperature in the welding area is evenly distributed.

[0027] Preferably, in step three, the induction coil is controlled by parameters preset by the welding controller to generate an alternating magnetic field, thereby generating eddy currents in the workpiece, and the eddy currents heat the workpiece.

[0028] Preferably, in step 4, a gas flow controller and a humidity sensor are used to monitor and adjust the microenvironment of the welding area in real time. The inert gas can be argon or nitrogen, and the gas flow rate is 5-20L / min to ensure that the welding area is free from contamination by oxygen and other harmful gases.

[0029] Preferably, the pressure control system in step five includes a pressure sensor, a hydraulic press or a pneumatic press.

[0030] Preferably, the cooling device in step seven may adopt a water cooling system or an air cooling system.

[0031] Preferably, high-definition cameras and infrared thermal imagers are installed in the welding area to capture the welding process in real time and display it on a large screen. At the same time, an intelligent control system is used in combination with welding data for analysis and early warning, as well as timely dynamic adjustments, to ensure a stable welding process.

[0032] Preferably, the residual stress elimination in step eight can also be processed in a heat treatment furnace, where the workpiece is placed in the heat treatment furnace and heat treated at a set temperature and time, wherein the temperature is between 50% and 70% of the welding temperature and the time is between 3 hours and 15 hours.

[0033] Beneficial effects of the present invention:

[0034] 1. The present invention ensures the accuracy of the welding area and improves the welding accuracy through real-time monitoring of the automated positioning clamping system and the displacement sensor. The high-precision temperature and pressure control system, combined with the precise control of the time controller, ensures the stability of various parameters in the welding process, thereby obtaining high-quality welded joints. The temperature homogenization device and the intelligent control system can accurately control the heating power and time, reduce unnecessary energy consumption, and achieve energy-saving effects. While heating and applying pressure, the time controller is used to accurately control the time to ensure that atoms can fully diffuse and form metallurgical connections, thereby improving the strength and toughness of the welded joint. The vibration aging device can effectively eliminate the residual stress generated during the welding process and improve the stability and service life of the welded joint. The entire welding process, from workpiece preparation to quality processing, most steps are automated, reducing manual intervention and improving production efficiency and consistency. An inert gas protective cover is set in the welding area to prevent metal oxidation during welding and reduce the emission of harmful gases, which is beneficial to environmental protection. The automated operation reduces the chance of manual contact with high temperature and harmful substances and improves operational safety. The method is suitable for welding of a variety of materials, including metals and alloys, and can handle workpieces with complex structures, thus expanding the scope of application. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] Figure 1 The flowchart of the welding method based on induction diffusion welding of the present invention is presented;

[0036] Figure 2 Shown is a flow chart of quality processing in the welding method based on induction diffusion welding of the present invention. DETAILED DESCRIPTION

[0037] The present invention will be further described below in conjunction with the accompanying drawings and embodiments.

[0038] See also Figure 1 , the present invention provides an embodiment: a welding method based on induction diffusion welding, the specific preparation steps are as follows;

[0039] Step 1: Workpiece preparation

[0040] First, clean the surface of the workpiece, use sandpaper, grinding wheel or chemical cleaning agent to remove impurities, including rust, dirt, oil stains, and ensure that the welding area is clean and pollution-free;

[0041] Step 2: Automated positioning and clamping

[0042] Use automated fixtures to automatically and accurately assemble the above workpieces to the welding processing position, and use displacement sensors to position the workpieces, monitor the position and offset of the workpieces in real time, and ensure the accuracy of the welding area;

[0043] Step 3: Heat treatment

[0044] Use a temperature homogenization device to preheat the workpiece, and its preheating temperature is between 50% and 80% of the welding temperature. Start the induction heating device, and generate a high-frequency magnetic field through high-frequency current, so that the metal in the welding area generates eddy current and heats up. At the same time, the induction heating device is connected to the welding controller through wires, and the power range of the high-frequency power supply is between 5kw and 20kw;

[0045] Step 4: Temperature Control

[0046] An inert gas protective cover is set in the welding area. At the same time, a temperature sensor is used to monitor the temperature of the welding area in real time, and the heating power and time are adjusted through an intelligent control system to ensure that the temperature is controlled within a predetermined range. The intelligent control system includes a displacement sensor, a welding controller, an intelligent host and an actuator. The welding controller analyzes and processes the received data according to preset algorithms and rules, makes decisions to adjust parameters, and the actuator performs corresponding operations according to the instructions of the welding controller, including adjusting the output power of the heating device and opening and closing the gas protective cover. At the same time, the operator can use a smartphone or tablet computer as a remote monitoring terminal to view the image and data information of the welding process in real time, and perform remote intervention and adjustment when necessary;

[0047] Step 5: Apply pressure and hold

[0048] Start the pressure control system and apply a certain pressure to the welding area to promote close contact between the workpieces and diffusion between atoms. At the same time, use a pressure sensor to monitor the applied pressure value in real time. After the welding area reaches a certain temperature and pressure is applied, this state is maintained for 8 minutes to 2 hours to ensure the welding quality. The pressure range of the pressure control system is between 8MPa-22MPa;

[0049] Step 6: Heat preservation and diffusion

[0050] While heating and applying pressure, a time controller is used to precisely control the time to ensure that the atoms can fully diffuse and form a metallurgical connection;

[0051] Step 7: Cooling and solidification

[0052] Turn off the heating device, gradually reduce the temperature of the welding area, use the cooling device to quickly cool the welding area to solidify the weld, and then use the automated fixture to take out the welded workpiece for automatic unloading;

[0053] Step 8: Quality Processing

[0054] 1) Inspection: Use testing equipment to conduct a comprehensive inspection of the weld quality of the workpiece to ensure that the integrity and strength of the welded joint meet the requirements;

[0055] 2) Residual stress elimination: Start the vibration aging device to perform vibration aging treatment on the welded joint to eliminate the residual stress generated during the welding process. The vibration frequency is between 30Hz and 150Hz, and the amplitude is between 3 microns and 5 mm;

[0056] 3) Post-processing: After the residual stress is eliminated, the weld joint is subjected to necessary post-processing, including burr removal, grinding and cleaning, to ensure that the weld surface is smooth and neat.

[0057] Example 1

[0058] The present invention provides an embodiment: a welding method based on induction diffusion welding, and the specific preparation steps are as follows;

[0059] Step 1: Workpiece preparation

[0060] First, clean the surface of the workpiece, use sandpaper, grinding wheel or chemical cleaning agent to remove impurities, including rust, dirt, oil stains, and ensure that the welding area is clean and pollution-free;

[0061] Step 2: Automated positioning and clamping

[0062] Use automated fixtures to automatically and accurately assemble the above workpieces to the welding processing position. Use displacement sensors to position the workpieces, monitor the position and offset of the workpieces in real time to ensure the accuracy of the welding area. Install high-definition cameras and infrared thermal imagers in the welding area to capture the welding process in real time and display it on a large screen. Use intelligent control systems to analyze and warn combined with welding data, as well as timely dynamic adjustments, to ensure the stability of the welding process.

[0063] Step 3: Heat treatment

[0064] Use a temperature homogenization device to preheat the workpiece, and its preheating temperature is 50% of the welding temperature. Start the induction heating device, and generate a high-frequency magnetic field through a high-frequency current, so that the metal in the welding area generates eddy currents and generates heat. At the same time, the induction heating device is controlled and connected to the welding controller through wires. The power of the high-frequency power supply is 5kw, and the preheating time is between five minutes and one hour. After ensuring that the temperature in the welding area is evenly distributed, the preheating is terminated, and the induction coil is controlled by the preset parameters of the welding controller to generate an alternating magnetic field, thereby generating eddy currents in the workpiece, and the eddy currents heat the workpiece;

[0065] Step 4: Temperature Control

[0066] An inert gas protective cover is set in the welding area. At the same time, a temperature sensor is used to monitor the temperature of the welding area in real time, and the heating power and time are adjusted through the intelligent control system to ensure that the temperature is controlled within the predetermined range. A gas flow controller and a humidity sensor are used to monitor and adjust the microenvironment of the welding area in real time. Argon gas can be used as inert gas, and the gas flow rate is 5L / min to ensure that the welding area is free from pollution by oxygen and other harmful gases. The intelligent control system includes a displacement sensor, a welding controller, an intelligent host and an actuator. The welding controller analyzes and processes the received data according to preset algorithms and rules, makes decisions to adjust parameters, and the actuator performs corresponding operations according to the instructions of the welding controller, including adjusting the output power of the heating device and opening and closing the gas protective cover. The displacement sensor is usually connected to the welding controller through a signal line. The signal line adopts any one of the two-wire, three-wire and four-wire systems. The welding controller is connected to the heating device and the gas protective cover actuator through wires, and the intelligent host is connected to the welding controller through Ethernet. The network is connected to the welding controller, and the actuator is connected to the welding controller through wires or signal lines. The preset algorithms and rules in the welding controller specifically adopt one or more of the temperature control algorithm, pressure control algorithm, time control algorithm, fault diagnosis and alarm rules and remote monitoring and intervention rules. In the temperature control algorithm, the temperature data of the welding area monitored in real time by the temperature sensor is compared with the preset temperature range; in the pressure control algorithm, the applied pressure data monitored in real time by the pressure sensor is compared with the preset pressure range; in the time control algorithm, according to the different stages and time requirements of the welding process, the time controller is used to accurately control the duration of each operation; in the fault diagnosis and alarm rules, if the sensor data is abnormal or the parameters in the welding process exceed the preset range, the fault diagnosis program is triggered and an alarm signal is issued; in the remote monitoring and intervention rules, the operator uses a smart phone or tablet computer as a remote monitoring terminal to view the image and data information of the welding process in real time, and conduct remote intervention and adjustment;

[0067] Step 5: Apply pressure and hold

[0068] Start the pressure control system and apply a certain pressure to the welding area to promote close contact between the workpieces and diffusion between atoms. At the same time, use a pressure sensor to monitor the applied pressure value in real time. After the welding area reaches a certain temperature and pressure is applied, this state is maintained for 8 minutes to 2 hours to ensure the welding quality. The pressure range of the pressure control system is between 8MPa-22MPa. The pressure control system includes a pressure sensor, a hydraulic press or a pneumatic press.

[0069] Step 6: Heat preservation and diffusion

[0070] While heating and applying pressure, a time controller is used to precisely control the time to ensure that the atoms can fully diffuse and form a metallurgical connection;

[0071] Step 7: Cooling and solidification

[0072] Turn off the heating device, gradually reduce the temperature of the welding area, use the cooling device to quickly cool the welding area to solidify the weld, and then use the automated fixture to take out the welded workpiece for automatic unloading. The cooling device can use a water cooling system or an air cooling system;

[0073] Step 8: Quality Processing

[0074] 1) Inspection: Use testing equipment to conduct a comprehensive inspection of the weld quality of the workpiece to ensure that the integrity and strength of the welded joint meet the requirements;

[0075] 2) Residual stress elimination: Start the vibration aging device to perform vibration aging treatment on the welded joint to eliminate the residual stress generated during the welding process. The vibration frequency is between 30Hz and 150Hz, and the amplitude is between 3 microns and 5 mm;

[0076] 3) Post-processing: After the residual stress is eliminated, the weld joint is subjected to necessary post-processing, including burr removal, grinding and cleaning, to ensure that the weld surface is smooth and neat.

[0077] Example 2

[0078] The present invention provides an embodiment: a welding method based on induction diffusion welding, and the specific preparation steps are as follows;

[0079] Step 1: Workpiece preparation

[0080] First, clean the surface of the workpiece, use sandpaper, grinding wheel or chemical cleaning agent to remove impurities, including rust, dirt, oil stains, and ensure that the welding area is clean and pollution-free;

[0081] Step 2: Automated positioning and clamping

[0082] Use automated fixtures to automatically and accurately assemble the above workpieces to the welding processing position. Use displacement sensors to position the workpieces, monitor the position and offset of the workpieces in real time to ensure the accuracy of the welding area. Install high-definition cameras and infrared thermal imagers in the welding area to capture the welding process in real time and display it on a large screen. Use intelligent control systems to analyze and warn combined with welding data, as well as timely dynamic adjustments, to ensure the stability of the welding process.

[0083] Step 3: Heat treatment

[0084] Use a temperature homogenization device to preheat the workpiece, and its preheating temperature is 65% of the welding temperature. Start the induction heating device, and generate a high-frequency magnetic field through a high-frequency current, so that the metal in the welding area generates eddy currents and generates heat. At the same time, the induction heating device and the welding controller are controlled and connected through wires. The power of the high-frequency power supply is 12kw, and the preheating time is between five minutes and one hour. After ensuring that the temperature in the welding area is evenly distributed, the preheating is terminated, and the induction coil is controlled by the preset parameters of the welding controller to generate an alternating magnetic field, thereby generating eddy currents in the workpiece, and the eddy currents heat the workpiece;

[0085] Step 4: Temperature Control

[0086] An inert gas protective cover is set in the welding area. At the same time, a temperature sensor is used to monitor the temperature of the welding area in real time, and the heating power and time are adjusted through the intelligent control system to ensure that the temperature is controlled within the predetermined range. A gas flow controller and a humidity sensor are used to monitor and adjust the microenvironment of the welding area in real time. Nitrogen can be used as an inert gas, and the gas flow rate is 14L / min to ensure that the welding area is free from oxygen and other harmful gases. The intelligent control system includes a displacement sensor, a welding controller, an intelligent host and an actuator. The welding controller analyzes and processes the received data according to preset algorithms and rules, makes decisions to adjust parameters, and the actuator performs corresponding operations according to the instructions of the welding controller, including adjusting the output power of the heating device and opening and closing the gas protective cover. The displacement sensor is usually connected to the welding controller through a signal line. The signal line adopts any one of the two-wire, three-wire and four-wire systems. The welding controller is connected to the heating device and the gas protective cover actuator through wires, and the intelligent host is connected through Ethernet. The network is connected to the welding controller, and the actuator is connected to the welding controller through wires or signal lines. The preset algorithms and rules in the welding controller specifically adopt one or more of the temperature control algorithm, pressure control algorithm, time control algorithm, fault diagnosis and alarm rules and remote monitoring and intervention rules. In the temperature control algorithm, the temperature data of the welding area monitored in real time by the temperature sensor is compared with the preset temperature range; in the pressure control algorithm, the applied pressure data monitored in real time by the pressure sensor is compared with the preset pressure range; in the time control algorithm, according to the different stages and time requirements of the welding process, the time controller is used to accurately control the duration of each operation; in the fault diagnosis and alarm rules, if the sensor data is abnormal or the parameters in the welding process exceed the preset range, the fault diagnosis program is triggered and an alarm signal is issued; in the remote monitoring and intervention rules, the operator uses a smart phone or tablet computer as a remote monitoring terminal to view the image and data information of the welding process in real time, and conduct remote intervention and adjustment;

[0087] Step 5: Apply pressure and hold

[0088] Start the pressure control system and apply a certain pressure to the welding area to promote close contact between the workpieces and diffusion between atoms. At the same time, use a pressure sensor to monitor the applied pressure value in real time. After the welding area reaches a certain temperature and pressure is applied, this state is maintained for 8 minutes to 2 hours to ensure the welding quality. The pressure range of the pressure control system is between 8MPa-22MPa. The pressure control system includes a pressure sensor, a hydraulic press or a pneumatic press.

[0089] Step 6: Heat preservation and diffusion

[0090] While heating and applying pressure, a time controller is used to precisely control the time to ensure that the atoms can fully diffuse and form a metallurgical connection;

[0091] Step 7: Cooling and solidification

[0092] Turn off the heating device, gradually reduce the temperature of the welding area, use the cooling device to quickly cool the welding area to solidify the weld, and then use the automated fixture to take out the welded workpiece for automatic unloading. The cooling device can use a water cooling system or an air cooling system;

[0093] Step 8: Quality Processing

[0094] 1) Inspection: Use testing equipment to conduct a comprehensive inspection of the weld quality of the workpiece to ensure that the integrity and strength of the welded joint meet the requirements;

[0095] 2) Residual stress elimination: Use a heat treatment furnace for processing, place the workpiece in the heat treatment furnace, and perform heat treatment according to the set temperature and time. The temperature is 60% of the welding temperature and the time is between 3 hours and 15 hours;

[0096] 3) Post-processing: After the residual stress is eliminated, the weld joint is subjected to necessary post-processing, including burr removal, grinding and cleaning, to ensure that the weld surface is smooth and neat.

[0097] Example 3

[0098] The present invention provides an embodiment: a welding method based on induction diffusion welding, and the specific preparation steps are as follows;

[0099] Step 1: Workpiece preparation

[0100] First, clean the surface of the workpiece, use sandpaper, grinding wheel or chemical cleaning agent to remove impurities, including rust, dirt, oil stains, and ensure that the welding area is clean and pollution-free;

[0101] Step 2: Automated positioning and clamping

[0102] Use automated fixtures to automatically and accurately assemble the above workpieces to the welding processing position. Use displacement sensors to position the workpieces, monitor the position and offset of the workpieces in real time to ensure the accuracy of the welding area. Install high-definition cameras and infrared thermal imagers in the welding area to capture the welding process in real time and display it on a large screen. Use intelligent control systems to analyze and warn combined with welding data, as well as timely dynamic adjustments, to ensure the stability of the welding process.

[0103] Step 3: Heat treatment

[0104] Use a temperature homogenization device to preheat the workpiece, and its preheating temperature is 80% of the welding temperature. Start the induction heating device, and generate a high-frequency magnetic field through a high-frequency current, so that the metal in the welding area generates eddy currents and generates heat. At the same time, the induction heating device is controlled and connected to the welding controller through wires. The power of the high-frequency power supply is 20kw, and the preheating time is between five minutes and one hour. After ensuring that the temperature in the welding area is evenly distributed, the preheating is terminated, and the induction coil is controlled by the preset parameters of the welding controller to generate an alternating magnetic field, thereby generating eddy currents in the workpiece, and the eddy currents heat the workpiece;

[0105] Step 4: Temperature Control

[0106] An inert gas protective cover is set in the welding area. At the same time, a temperature sensor is used to monitor the temperature of the welding area in real time, and the heating power and time are adjusted through the intelligent control system to ensure that the temperature is controlled within the predetermined range. A gas flow controller and a humidity sensor are used to monitor and adjust the microenvironment of the welding area in real time. The inert gas can be argon or nitrogen, and the gas flow rate is 20L / min to ensure that the welding area is free from oxygen and other harmful gases. The intelligent control system includes a displacement sensor, a welding controller, an intelligent host and an actuator. The welding controller analyzes and processes the received data according to preset algorithms and rules, makes decisions to adjust parameters, and the actuator performs corresponding operations according to the instructions of the welding controller, including adjusting the output power of the heating device and opening and closing the gas protective cover. The displacement sensor is usually connected to the welding controller through a signal line. The signal line adopts any one of the two-wire, three-wire and four-wire systems. The welding controller is connected to the heating device and the gas protective cover actuator through wires. The intelligent host is connected to the welding controller through wires. The Ethernet is connected to the welding controller, and the actuator is connected to the welding controller through wires or signal lines. The preset algorithms and rules in the welding controller specifically adopt one or more of the temperature control algorithm, pressure control algorithm, time control algorithm, fault diagnosis and alarm rules, and remote monitoring and intervention rules. In the temperature control algorithm, the temperature data of the welding area monitored in real time by the temperature sensor is compared with the preset temperature range; in the pressure control algorithm, the applied pressure data monitored in real time by the pressure sensor is compared with the preset pressure range; in the time control algorithm, according to the different stages and time requirements in the welding process, the time controller is used to accurately control the duration of each operation; in the fault diagnosis and alarm rules, if the sensor data is abnormal or the parameters in the welding process exceed the preset range, the fault diagnosis program is triggered and an alarm signal is issued; in the remote monitoring and intervention rules, the operator uses a smart phone or tablet computer as a remote monitoring terminal to view the image and data information of the welding process in real time, and conduct remote intervention and adjustment;

[0107] Step 5: Apply pressure and hold

[0108] Start the pressure control system and apply a certain pressure to the welding area to promote close contact between the workpieces and diffusion between atoms. At the same time, use a pressure sensor to monitor the applied pressure value in real time. After the welding area reaches a certain temperature and pressure is applied, this state is maintained for 8 minutes to 2 hours to ensure the welding quality. The pressure range of the pressure control system is between 8MPa-22MPa. The pressure control system includes a pressure sensor, a hydraulic press or a pneumatic press.

[0109] Step 6: Heat preservation and diffusion

[0110] While heating and applying pressure, a time controller is used to precisely control the time to ensure that the atoms can fully diffuse and form a metallurgical connection;

[0111] Step 7: Cooling and solidification

[0112] Turn off the heating device, gradually reduce the temperature of the welding area, use the cooling device to quickly cool the welding area to solidify the weld, and then use the automated fixture to take out the welded workpiece for automatic unloading. The cooling device can use a water cooling system or an air cooling system;

[0113] Step 8: Quality Processing

[0114] 1) Inspection: Use testing equipment to conduct a comprehensive inspection of the weld quality of the workpiece to ensure that the integrity and strength of the welded joint meet the requirements;

[0115] 2) Residual stress elimination: Use a heat treatment furnace for processing, place the workpiece in the heat treatment furnace, and perform heat treatment according to the set temperature and time. The temperature is 70% of the welding temperature and the time is between 3 hours and 15 hours;

[0116] 3) Post-processing: After the residual stress is eliminated, the weld joint is subjected to necessary post-processing, including burr removal, grinding and cleaning, to ensure that the weld surface is smooth and neat.

[0117] The welding methods of Examples 1, 2, and 3 and the traditional induction diffusion welding method were used as a control group to process the same standard workpiece. The processing test results are shown in Table 1:

[0118]

[0119]

[0120] Table 1

[0121] It can be seen from Table 1 that the welding efficiency, welding quality, energy consumption, residual stress level and automation degree of the welding methods of Examples 1, 2 and 3 are all higher than those of the traditional induction diffusion welding method.

Claims

1. A welding method based on induction diffusion welding, characterized in that: The specific preparation steps are as follows; Step 1: Workpiece preparation First, clean the surface of the workpiece, use sandpaper, grinding wheel or chemical cleaning agent to remove impurities, including rust, dirt, oil stains, and ensure that the welding area is clean and pollution-free; Step 2: Automated positioning and clamping Use automated fixtures to automatically and accurately assemble the above workpieces to the welding processing position, and use displacement sensors to position the workpieces, monitor the position and offset of the workpieces in real time, and ensure the accuracy of the welding area; Step 3: Heat treatment Use a temperature homogenization device to preheat the workpiece, and its preheating temperature is between 50% and 80% of the welding temperature. Start the induction heating device, and generate a high-frequency magnetic field through high-frequency current, so that the metal in the welding area generates eddy current and heats up. At the same time, the induction heating device is connected to the welding controller through wires, and the power range of the high-frequency power supply is between 5kw and 20kw; Step 4: Temperature Control An inert gas protective cover is set in the welding area. At the same time, a temperature sensor is used to monitor the temperature of the welding area in real time, and the heating power and time are adjusted through the intelligent control system to ensure that the temperature is controlled within a predetermined range. The intelligent control system includes a displacement sensor, a welding controller, an intelligent host and an actuator. The welding controller analyzes and processes the received data according to preset algorithms and rules, makes decisions to adjust parameters, and the actuator performs corresponding operations according to the instructions of the welding controller, including adjusting the output power of the heating device, opening and closing the gas protective cover. The displacement sensor is usually connected to the welding controller through a signal line. The signal line adopts any one of the two-wire, three-wire and four-wire systems. The welding controller is connected to the heating device and the gas protective cover actuator through wires. The intelligent host is connected to the welding controller through Ethernet. The actuator is connected to the welding controller through wires or signal lines. The preset algorithms and rules specifically adopt one or more of the temperature control algorithm, pressure control algorithm, time control algorithm, fault diagnosis and alarm rules and remote monitoring and intervention rules. In the temperature control algorithm, the temperature data of the welding area monitored in real time by the temperature sensor is compared with the preset temperature range; in the pressure control algorithm, the applied pressure data monitored in real time by the pressure sensor is compared with the preset pressure range; in the time control algorithm, a time controller is used to accurately control the duration of each operation according to the different stages and time requirements in the welding process; in the fault diagnosis and alarm rules, if the sensor data is abnormal or the parameters in the welding process exceed the preset range, the fault diagnosis program is triggered and an alarm signal is issued; in the remote monitoring and intervention rules, the operator uses a smart phone or tablet computer as a remote monitoring terminal to view the image and data information of the welding process in real time, and conduct remote intervention and adjustment; Step 5: Apply pressure and hold Start the pressure control system and apply a certain pressure to the welding area to promote close contact between the workpieces and diffusion between atoms. At the same time, use a pressure sensor to monitor the applied pressure value in real time. After the welding area reaches a certain temperature and pressure is applied, this state is maintained for 8 minutes to 2 hours to ensure the welding quality. The pressure range of the pressure control system is between 8MPa-22MPa; Step 6: Heat preservation and diffusion While heating and applying pressure, a time controller is used to precisely control the time to ensure that the atoms can fully diffuse and form a metallurgical connection; Step 7: Cooling and solidification Turn off the heating device, gradually reduce the temperature of the welding area, use the cooling device to quickly cool the welding area to solidify the weld, and then use the automated fixture to take out the welded workpiece for automatic unloading; Step 8: Quality Processing 1) Inspection: Use testing equipment to conduct a comprehensive inspection of the weld quality of the workpiece to ensure that the integrity and strength of the welded joint meet the requirements; 2) Residual stress elimination: Start the vibration aging device to perform vibration aging treatment on the welded joint to eliminate the residual stress generated during the welding process. The vibration frequency is between 30Hz and 150Hz, and the amplitude is between 3 microns and 5 mm; 3) Post-processing: After the residual stress is eliminated, the weld joint is subjected to necessary post-processing, including burr removal, grinding and cleaning, to ensure that the weld surface is smooth and neat.

2. The welding method based on induction diffusion welding according to claim 1, characterized in that: The preheating time in step 3 is between five minutes and one hour, and the preheating is completed after ensuring that the temperature in the welding area is evenly distributed.

3. The welding method based on induction diffusion welding according to claim 1, characterized in that: In step three, the induction coil is controlled by the preset parameters of the welding controller to generate an alternating magnetic field, thereby generating eddy currents in the workpiece, and the eddy currents heat the workpiece.

4. The welding method based on induction diffusion welding according to claim 1, characterized in that: In step 4, a gas flow controller and a humidity sensor are used to monitor and adjust the microenvironment of the welding area in real time. Argon or nitrogen can be used as inert gas with a gas flow rate of 5-20 L / min to ensure that the welding area is free from contamination by oxygen and other harmful gases.

5. The welding method based on induction diffusion welding according to claim 1, characterized in that: The pressure control system in step five includes a pressure sensor, a hydraulic press or a pneumatic press.

6. The welding method based on induction diffusion welding according to claim 1, characterized in that: The cooling device in step seven can adopt a water cooling system or an air cooling system.

7. The welding method based on induction diffusion welding according to claim 1, characterized in that: High-definition cameras and infrared thermal imagers are installed in the welding area to capture the welding process in real time and display it on a large screen. At the same time, an intelligent control system is used to analyze and warn the welding data, as well as make timely dynamic adjustments to ensure a stable welding process.

8. The welding method based on induction diffusion welding according to claim 1, characterized in that: The residual stress elimination in step eight can also be processed in a heat treatment furnace. The workpiece is placed in the heat treatment furnace and heat treated according to the set temperature and time. The temperature is between 50% and 70% of the welding temperature, and the time is between 3 hours and 15 hours.

Images