A method for manufacturing a welded-cast-stirred integrated connection

Abstract

The application relates to a method for manufacturing a welding-casting-stirring integrated connection, which mainly solves the technical problems of insufficient welding connection, poor quality consistency, low efficiency and the like of a manual multi-layer multi-pass surfacing connection mode for thick plate welding. The technical scheme is as follows: a high-power plasma arc is used to melt a base into a base melt and form a molten pool, liquid metal filling liquid is injected into the molten pool to mix with the base melt to form mixed metal liquid, a stirrer and a free arc are used to stir and heat the mixed metal liquid to promote the mixing of the metal filling liquid and the base melt, and after the mixed metal liquid is cooled and solidified, two thick plates are directly connected closely to realize high-efficiency and high-quality integrated connection manufacturing.

Description

TECHNICAL FIELD

[0001] The present application relates to a method for manufacturing a welding-casting-stirring integrated connection, and belongs to the field of thick plate welding. BACKGROUND

[0002] With the development of modern industrial manufacturing technology, thick plate connection manufacturing is widely used in the fields of rail transportation, warships, high-pressure containers, and house building. Through a large number of literature and enterprise factory production research, it is found that thick plate welding mostly uses manual multi-layer multi-pass surfacing technology, which seriously depends on the welding technology of the welder, and the manufacturing efficiency is low and the forming quality consistency is poor. Current research mainly focuses on realizing multi-layer multi-pass automation instead of manual work, mainly involving welding trajectory extraction optimization, welding process parameter influence, multi-wire multi-heat source complex, etc., but these are only improvements and optimizations of the surfacing method, and do not conduct technical research from the fundamental purpose and demand of connection manufacturing.

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

[0004] The purpose of the present application is to provide a method for efficiently and integrally connecting and manufacturing thick plates, using a high-power plasma arc to melt the base into a base melt and form a base molten pool, on the basis of which metal filler liquid is injected into the base molten pool through a filler liquid conduit, and a large-scale free electric arc heating and a stirrer are used to maintain the temperature of the mixed metal liquid to keep it in a liquid state, and further promote the fusion of the base solution and the metal filler liquid. After the mixed metal liquid is cooled, it solidifies with the two thick plates to form a whole, realizing welding-casting-stirring integrated connection manufacturing.

[0005] The object of the present application is achieved by the following technical solution: the method is realized by a welding-casting-stirring integrated mechanical structure device, a high-power plasma arc is used to melt the base to form a base molten pool, on the basis of which a liquid metal filling liquid is injected into the base molten pool through a pipe, and a large-range free electric arc heating and a stirrer are used to maintain the temperature of the mixing area to keep the metal in a liquid state, further promote the fusion of the base solution and the metal filling liquid, and make the mixed metal liquid solidify into one body after cooling. The characteristics are that the high-power plasma arc melts the base metal to make it into a liquid state, then the liquid metal is injected into contact with the base through the metal filling liquid pipe, the high-speed stirring of the stirrer, and the large-scale heating of the argon arc welding gun to prevent rapid solidification, effectively increase the fusion degree of the metal liquid, reduce the pores in the filler, and after sufficient stirring and heating, the two thick plates are cooled to solidify into one whole, realizing efficient and high-quality integrated connection manufacturing.

[0006] The welding-casting-stirring integrated mechanical structure device is as shown in Figure 1 The device includes a plasma welding gun (1) that can provide a high-power plasma arc to melt the base, a pipe (2) for injecting the metal filling liquid that is melted in the molten pool in advance, a stirrer (3) for fully stirring the filling liquid and the base molten liquid, an argon arc welding gun (4) for providing large-range free electric arc heating to promote the fusion of the metal liquid, and then cooling to solidify. A power switch (5) provides power supply and controls the operation sequence of each device, and each device is fixed by a fixed clamp (6).

[0007] The switch power supply, the plasma welding gun, the filling pipe, the stirrer, and the argon arc welding gun are started in sequence by the switch on the power supply to provide reliable power output.

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

[0009] The metal filling liquid is fused with the base solution, first, the oxide layer and impurities on the surface of the thick plate are removed, then the high-power plasma arc generated by the plasma welding gun (1) has super-high temperature, can melt the solid base into a metal liquid, and forms a base molten pool on the surface of the component. The base moves forward at a suitable speed on the workbench, the metal liquid pipe (2) injects the metal liquid that is melted in the molten pool outside the device into the weld joint in advance, and the metal filling liquid quickly fuses with the base molten liquid.

[0010] The principle of the stirrer is that the fusion between the molten base solution and the injected metal filling liquid is relatively uneven due to the influence of external air or the shape of the base, and through the rotating movement of the stirrer, the metal liquid is rapidly stirred and shear force and disturbance force are generated, so as to promote the mutual mixing of the base solution and the metal filling liquid. The rotating movement of the stirrer can break the surface tension and adhesion, accelerate the mass transfer and reaction rate, make the liquid more easily mixed with each other, and improve the efficiency of liquid mixing.

[0011] The liquid metal is heated in a large range by using a free electric arc under the high-speed stirring of the stirrer, which functions to slowly reduce the temperature of the metal liquid while stirring, and affects the fusion of the metal liquid. The use of the free electric arc heating in a large range can ensure that the metal liquid does not prematurely solidify due to too long process time during the mixing process, provides a relatively stable fusion environment, and promotes better fusion of the two metal liquids.

[0012] The main features of the present application are as follows: instead of directly adding material to the base, the base is melted by using a high-temperature electric arc, and then the metal liquid is injected and fused with it, so that it can become a whole and reduce the generation of delamination; then the mixed metal solution is rotated and stirred by using a stirrer, and heated by using a free electric arc in a large range, so as to promote the full fusion of the metal liquid, and finally cooled and solidified.

[0013] The method has the beneficial effects of providing a welding-casting-stirring integrated thick plate connection manufacturing method, abandoning the traditional multi-layer multi-pass surfacing connection mode of thick plates, combining the phase change theory, fluid mechanics theory and mixing liquid stirring effect, and inventing a new method for efficient and high-quality integrated direct manufacturing of thick plate connection; the metal liquid mixing and stirring principle is used to replace the layer-by-layer welding in the traditional multi-layer multi-pass surfacing, so that the welding operation is simpler and more efficient; the advantages of fusion welding, casting and surfacing are comprehensively utilized, which is beneficial to reduce the stress and deformation generated in the welding process, and also weakens the influence of air on the thick plate welding process; the stirrer stirring and electric arc heating effectively avoid the rapid cooling and solidification of the mixed liquid, can improve the weld forming, increase the fusion time, and fully fuse. BRIEF DESCRIPTION OF DRAWINGS

[0014] Figure 1 is a device structure schematic diagram

[0015] Figure 2 is a working flowchart DETAILED DESCRIPTION

[0016] The present application will be further described in detail below in combination with the drawings and examples.

[0017] Reference Figure 1 , Figure 2The application combines welding, casting, stirring to realize connection manufacturing, and the device comprises 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 fixing support (6). The plasma welding gun is used first to output a high-power plasma arc to form a molten pool on the surface of a welding part, and a molten metal in the molten pool is prepared beside the device to form a metal filling liquid, which is then injected into the molten pool on the surface of the welding part to be fused with the solution after the base body of the welding part is melted. Then, the stirrer is used to stir the mixed liquid after preliminary fusion to discharge a small amount of gas existing in the mixed liquid to prevent the gas from mixing into the metal liquid, which may cause many pores and cracks in the finally formed welding seam, reduce the quality of the welding seam, and affect the strength and corrosion resistance of the welding seam. The argon arc welding gun is used to generate a large range of free arcs to heat the mixed liquid in the molten pool to maintain the high-temperature flow state of the mixed metal liquid, so that the welding seam can reach sufficient depth and uniformity to ensure that the base body molten liquid and the metal filling liquid can be completely fused. Finally, the mixed metal liquid is cooled and solidified to realize integrated connection manufacturing.

[0018] In the embodiment 1, the part is repaired. The part repair refers to a series of means and processes taken to repair the damaged, worn-out parts of mechanical equipment or workpieces to prolong the service life of the parts. The commonly used methods are direct welding repair, direct additive manufacturing, or mechanical finishing such as turning, grinding, and other subtractive methods. The device uses the method of welding and then casting to repair the damaged, broken parts of workpieces, and the specific implementation is as follows: first, the damaged part is evaluated to fully understand the type, location, and severity of the damage, and the oxides in the damaged area are cleared to ensure that the welding surface is clean, then a liquid filling material compatible with the part material is prepared, the parameters of the plasma welding gun are controlled, a high-power, high-temperature plasma arc is provided to form a uniform molten pool in the damaged area, then the prepared metal filling liquid is injected into the molten pool, the stirrer is used to stir during the liquid filling process, the large range of free arcs is used to heat the mixed metal liquid area to prevent it from cooling rapidly and affecting the surface quality, and finally it is gradually cooled and solidified to ensure that the filling material is well combined with the surrounding metal and the residual stress is reduced to realize the repair of the part. Since this method uses arc welding and metal liquid filling, the damaged part of the part can be highly fused with the filling liquid to ensure the durability and stability of the repaired part, reduce the cost, improve the repair speed, and be more economical, efficient, and reliable in quality.

[0019] Case 2, to achieve thick plate connection. Two thick plate opening groove formed V-shaped weld, usually using multi-layer multi-pass welding technology, slow welding speed, relatively low efficiency. Thick plate welding usually includes three parts, one is to open the V-shaped space dense filling, two thick substrate and filler closely fused, three surface repair. The device combines the technical advantages of fusion welding, surfacing together, for thick plate efficient, high-quality connection, the specific implementation as follows: first, the V-shaped groove between the two thick plate surface clean, then using the plasma torch to melt the groove surface, the groove surface to form a molten pool, using a metal filler liquid catheter will be prepared to fill the liquid into the molten pool, after the liquid filling, using the stirrer by controlling the appropriate stirrer speed, in the metal filler liquid friction, generate heat, and stirring uniform, improve efficiency, using a wide range of free arc to heat the mixed metal liquid, prevent the metal liquid solidification, auxiliary metal liquid fusion. Therefore, using this method can make thick plate connection faster, and more efficient, stable, to achieve thick plate integration connection manufacturing.

Claims

1. A method for integrated welding-casting-stirring connection manufacturing, characterized by: This method is achieved through a welding-casting-stirring integrated mechanical device, which uses a high-power plasma arc to melt the substrate into a substrate melt and form a substrate molten pool. On this basis, the metal filling liquid is injected into the substrate 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 maintains 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. The method for integrated welding-casting-stirring connection and manufacturing according to claim 1, characterized in that: The 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 switching power supply (5) and a fixing fixture (6), which are arranged in sequence. 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, and the argon arc welding gun (4) generates a large-scale free arc. The working sequence of each device is controlled by the switching power supply (5).

3. The method for integrated welding-casting-stirring connection and manufacturing according to claim 1, wherein: The plasma welding gun (1) is controlled by a switching power supply (5) to melt the edge substrate at the connection between the two substrates and make it liquid. Then, the filling liquid conduit (2) starts to inject liquid metal filling liquid into the melted 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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