Welding-casting-stirring integrated connection manufacturing method

Abstract

The invention relates to a welding-casting-stirring integrated connection manufacturing method, which mainly solves the technical problems of poor quality consistency, low efficiency and the like due to the fact that the existing welding seam connection is insufficient, and a manual multi-layer and multi-pass surfacing connection mode is mostly adopted for thick plate welding. According to the technical scheme, the method is characterized in that a high-power plasma arc is used for deeply melting a base body into base body molten liquid, a molten pool is formed, then liquid metal filling liquid is injected into the molten pool and mixed with the base body molten liquid, mixed metal liquid is formed, meanwhile, a stirrer and a free electric arc are used for stirring and heating the mixed metal liquid, and the mixed metal liquid is cooled to the room temperature. Mixing of the metal filling liquid and the matrix melt is promoted, after the mixed metal liquid is cooled and solidified, the two thick plates are directly and tightly connected, and efficient and high-quality integrated connection manufacturing is achieved.

Description

Technical Field

[0001] The invention specifically relates to a welding-casting-stirring integrated connection manufacturing method, which belongs to the field of thick plate welding. Background Art

[0002] With the development of modern industrial manufacturing technology, thick plate connection manufacturing is widely used in rail transportation, ships and warships, high-pressure vessels, housing construction and other fields. After a large amount of literature and enterprise factory production surveys, it was found that thick plate welding mostly uses manual multi-layer and multi-pass surfacing technology, which is heavily dependent on the welder's own welding technology, with low manufacturing efficiency and poor consistency in forming quality. Current research is mainly focused on achieving multi-layer and multi-pass automation to replace manual labor, mainly involving welding trajectory extraction optimization, welding process parameter influence, multi-wire and multi-heat source composite, etc., but these are only improvements and optimizations of surfacing methods, and there is no technical research from the fundamental purpose and needs of connection manufacturing.

[0003] Thick plate connection technology has similarities with several technologies such as fusion welding-matrix melting, casting-filling, surfacing-filling and fusion. These technologies can be used to connect and manufacture metal workpieces. The advantages of these technologies can be combined and applied to thick plate connection manufacturing to form a new welding-casting-stirring integrated forming and manufacturing process. Summary of the invention

[0004] The purpose of the present invention is to provide a method for efficient and high-quality integrated connection manufacturing between thick plates, which uses a high-power plasma arc to melt the matrix into a matrix molten liquid and form a matrix molten pool. On this basis, the metal filling liquid is injected into the matrix molten pool through the filling liquid conduit, and then a large-scale free arc heating and a stirrer are used to maintain the temperature of the mixed metal liquid, so that it keeps the liquid form of the metal and further promotes the fusion of the matrix solution and the metal filling liquid. After cooling, the mixed metal liquid solidifies into a whole with the two thick plates, realizing the welding-casting-stirring integrated connection manufacturing.

[0005] The purpose of the present invention is achieved through the following technical scheme: the method is achieved through a welding-casting-stirring integrated mechanical structure device, using a high-power plasma arc to melt the matrix to form a matrix molten pool, on this basis, the liquid metal filling liquid is injected into the matrix molten pool through a conduit, and then a large-scale free arc heating and a stirrer are used to maintain the temperature of the mixing area, so that it maintains the liquid form of the metal, further promotes the fusion of the matrix solution and the metal filling liquid, and the mixed metal liquid is cooled and the two substrates are solidified into one. Its characteristics are: a high-power plasma arc melts the matrix metal and makes it liquid, and then the liquid metal is injected through the metal filling liquid conduit to contact and fuse with the matrix, the stirrer stirs at a high speed, and then cooperates with the argon arc welding gun to heat it in a large range to prevent it from solidifying rapidly, effectively increase the fusion degree of the metal liquid, reduce the pores in the filler, and cool after sufficient stirring and heating, so that the two thick plates are solidified into a whole, realizing efficient and high-quality integrated connection manufacturing.

[0006] The welding-casting-stirring integrated mechanical structure device is as follows: Figure 1 As shown: the device includes a plasma welding gun (1) that can provide a high-power plasma arc to melt the substrate, a guide tube (2) is used to inject metal filling liquid that has been melted in the molten pool in advance, a stirrer (3) fully stirs the filling liquid and the substrate molten liquid, and an argon arc welding gun (4) provides a large range of free arc heating to promote the fusion of the metal liquid, and then cools it to solidify. The power switch (5) provides power and controls the operation sequence of each device, and each device is fixed by a fixing fixture (6).

[0007] The switching power supply described above can control the start-up sequence of the plasma welding gun, the filling conduit, the stirrer and the argon arc welding gun through the switch on the power supply, thereby providing reliable power output.

[0008] The plasma welding gun can generate high-temperature plasma, which can melt the substrate to form a substrate molten pool. The plasma arc column is strong and can produce a larger melting depth, which can better melt the bottoms of the two substrates, ensure that the contact area between the two substrates is melted into a molten pool, and promote the mixing of the melted substrate and the metal filling liquid.

[0009] The metal filling liquid is fused with the matrix solution, firstly, the oxide layer and impurities on the surface of the thick plate are removed, and then the high-power plasma arc generated by the plasma welding gun (1) has an ultra-high temperature, which can melt the solid matrix into metal liquid, forming a molten pool on the matrix on the surface of the component. The matrix moves forward on the workbench at a suitable speed, and the metal liquid conduit (2) injects the metal liquid melted in the molten pool outside the device into the weld, and the metal filling liquid and the matrix molten liquid quickly merge.

[0010] The principle of setting a stirrer to stir the filling liquid after it is fused with the matrix solution is that the fusion between the melted matrix solution and the injected metal filling liquid will be relatively uneven due to the influence of the external air or the matrix shape. Through the rotation of the stirrer, the metal liquid is quickly stirred and shear force and disturbance force are generated, thereby promoting the mixing of the matrix solution and the metal filling liquid. The rotation of the stirrer can break the surface tension and adhesion, accelerate the material transfer and reaction rate, make the liquids easier to mix with each other, and improve the efficiency of liquid mixing.

[0011] The liquid metal is heated over a large area using a free arc under high-speed stirring of the stirrer. The effect is that the temperature of the molten metal will slowly decrease while stirring, affecting the fusion of the molten metal. Using a large area of ​​free arc heating can ensure that the molten metal will not solidify prematurely during the mixing process due to the long process time, provide a relatively stable fusion environment, and promote better fusion of the two molten metals.

[0012] The main features of the present invention are: unlike directly adding materials to the substrate, the substrate is melted by a high-temperature electric arc, and then molten metal is injected to fuse with it, so that it can become a whole and reduce the occurrence of stratification; then the mixed metal solution is rotated and stirred by a stirrer, and heated by a large-scale free electric arc to promote the full fusion of the metal solution, and finally cooled and solidified.

[0013] The beneficial effect of the method is that it provides a method for manufacturing thick plate connections by integrating welding, casting and stirring, abandons the traditional multi-layer and multi-pass surfacing connection method of thick plates, combines phase change theory, fluid mechanics theory and mixed liquid stirring effect, and invents a new method for efficient and high-quality integrated direct manufacturing of thick plate connections; utilizes the principle of metal liquid mixing and stirring to replace the layer-by-layer welding in traditional multi-layer and multi-pass surfacing, making the welding operation simpler and more efficient; comprehensively utilizes the advantages of fusion welding, casting and surfacing, which is beneficial to reducing the stress and deformation generated during the welding process, and also weakens the influence of air on the thick plate welding process; utilizes a stirrer for stirring and arc heating to effectively avoid the rapid cooling and solidification of the mixed liquid, which can improve the weld formation, increase the fusion time, and fully fuse. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 Schematic diagram of the device structure

[0015] Figure 2 Workflow diagram DETAILED DESCRIPTION

[0016] The present invention is further described in detail below with reference to the accompanying drawings and embodiments.

[0017] See also Figure 1 , Figure 2The present invention combines welding, casting and stirring to achieve connection manufacturing. The device includes a plasma welding gun (1), a filling liquid conduit (2), a stirrer (3), an argon arc welding gun (4), a switching power supply (5) and a fixed bracket (6). The plasma welding gun works first, outputting a high-power plasma arc to form a molten pool on the surface of the weldment. At the same time, the molten metal in the molten pool is prepared beside the device to form a metal filling liquid. The metal filling liquid is then injected into the molten pool on the surface of the weldment through the filling liquid conduit to merge with the melted solution of the weldment matrix. Then, a stirrer is used to stir the preliminarily fused mixed liquid to discharge a small amount of gas in the mixed liquid to prevent the gas from mixing into the metal liquid, which will cause the weld to be finally formed to have many pores and cracks, reduce the quality of the weld, and affect the strength and corrosion resistance of the weld. While stirring, a argon arc welding gun is used to generate a large-scale free arc to heat the mixed liquid in the molten pool, maintain the high-temperature flow state of the mixed metal liquid, so that the weld can reach a sufficient depth and uniformity, and ensure that the matrix molten liquid and the metal filling liquid can be completely fused. Finally, the mixed metal liquid is cooled and solidified to achieve integrated connection manufacturing.

[0018] Implementation case 1: Parts repair. Parts repair refers to the use of a series of methods and processes to repair mechanical equipment or workpieces that are damaged, worn or have other problems in order to extend the service life of the parts. Commonly used methods include direct welding repair, direct additive manufacturing, or mechanical finishing, such as turning, grinding and other subtractive methods. This device uses the method of welding first and then casting to repair damaged workpieces, broken parts, etc. The specific implementation is as follows: First, evaluate the damaged parts, fully understand the type, location, and severity of the damage, clear the oxides in the damaged area, and ensure that the welding surface is clean. Then prepare a liquid filling material compatible with the part material, control the parameters of the plasma welding gun, provide a high-power, high-temperature plasma arc, and form a uniform molten pool in the damaged area. Then inject the prepared metal filling liquid into the molten pool. During the liquid filling process, use a stirrer to stir, and use a large range of free arcs to heat the mixed metal liquid area to prevent it from cooling rapidly and affecting the surface quality. Finally, wait for it to gradually reduce the temperature, cool and solidify, ensure that the filling material is well combined with the surrounding metal, and reduce residual stress to achieve part repair. Since this method uses arc welding and metal liquid filling, the damaged part of the part can be highly integrated with the filling liquid, ensuring the durability and stability of the repaired part, and reducing costs, improving the repair speed, and being more economical, efficient, and reliable in quality.

[0019] Implementation case 2, achieving thick plate connection. The V-shaped weld formed by the grooves of two thick plates usually adopts multi-layer and multi-pass surfacing technology, which has slow welding speed and relatively low efficiency. Thick plate welding usually includes three parts: one is to densely fill the V-shaped space of the groove, the second is to tightly fuse the two thick substrates with the filler, and the third is surface repair. This device combines the technical advantages of fusion welding and surfacing to connect thick plates efficiently and with high quality. The specific implementation is as follows: first, the V-shaped groove surface between the two thick plates is cleaned, and then the groove surface is melted by a plasma welding gun to form a molten pool on the groove surface, and then the metal filling liquid conduit is used to inject the pre-prepared filling liquid into the molten pool. After the liquid is filled, the stirrer is used to control the appropriate stirrer speed to rub in the metal filling liquid to generate heat, and stir evenly to improve efficiency. A large range of free arcs is used to heat the mixed metal liquid to prevent the metal liquid from solidifying rapidly and assist the fusion of the metal liquid. Therefore, the use of this method can make the thick plates connected faster, more efficient and stable, and realize the integrated connection manufacturing of thick plates.

Claims

1. A method for welding-casting-stirring integrated connection manufacturing, characterized in that: The method is realized by a welding-casting-stirring integrated mechanical device, which uses a high-power plasma arc to melt the matrix into a matrix molten liquid and form a matrix molten pool. On this basis, the metal filling liquid is injected into the matrix molten pool through the filling liquid conduit, and then a large-scale free arc heating and a stirrer are used to maintain the temperature of the mixed metal liquid, so that it keeps the liquid form of the metal and further promotes the fusion of the matrix solution and the metal filling liquid. After cooling, the mixed metal liquid solidifies into a whole with the two thick plates, realizing welding-casting-stirring integrated connection manufacturing.

2. A method for manufacturing thick plate connections by welding-casting-stirring integration according to claim 1, characterized in that: A welding-casting-stirring integrated mechanical device comprises a plasma welding gun (1), a filling liquid conduit (2), a stirrer (3), an argon arc welding gun (4), a switch power supply (5) and a fixing fixture (6), which are arranged in sequence, wherein the plasma welding gun (1) generates a high-power plasma arc, the filling liquid conduit (2) can inject liquid metal, the outer contour of the stirrer (3) fits the weld space to be filled, the argon arc welding gun (4) generates a large-scale free arc, and the working sequence of each device is controlled by the switch power supply (5).

3. A method for manufacturing thick plate connection by welding-casting-stirring integration according to claim 1, characterized in that: The plasma welding gun (1) is controlled by a switch power supply (5) to melt the edge substrate at the connection between the two substrates and make it liquid. Then, the metal filling liquid conduit (2) starts to inject liquid metal filling liquid into the molten substrate molten pool. Then, the agitator (3) is used to fully stir the mixed liquid to reduce the gas in the mixed liquid and increase the density. While stirring, the argon arc welding gun (4) generates a large-scale free arc to heat the mixed metal liquid to ensure that the fusion time is longer and the fusion is more complete. Finally, the thick plates are cooled and solidified to achieve a tight connection.

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