Self-adaptive welding parameter regulation and control method and system for metal layered material

Abstract

The invention relates to the technical field of layered metal, and discloses a metal layered material self-adaptive welding parameter regulation and control method and system.The method comprises the steps that the temperature gradient response amplitude value and the interlayer thermal deformation quantity of an interlayer bonding area of a welding pool are extracted; the equivalent difference value of the expansion coefficients of the adjacent material layers under the same welding heat is obtained, the interface strain rate of the adjacent material layers is corrected based on the equivalent difference value, and the thermal deformation relative offset of the metal layered material is obtained; inverting a diffusion path of the characteristic elements in the interlayer bonding area to obtain an alloying process index of the metal layered material; when the alloying process index is lower than a critical value, the arc energy density in the welding pool is reduced, and the swing frequency of a welding gun is increased; dynamically compensating welding thermal parameters of the welding pool according to the change rate of the interlayer thermal deformation quantity in a layered material thickness abrupt change area; according to the method, the welding quality of self-adaptive welding of the metal layered material can be improved.

Description

Technical Field

[0001] The present invention relates to the technical field of layered metals, and particularly to a method and system for adaptively regulating welding parameters of metal layered materials. Background Art

[0002] In the field of welding metal layered materials, due to significant differences in the physical properties between material layers, it is difficult for existing welding technologies to accurately regulate welding parameters. During the welding process, it is difficult to monitor in real time the temperature gradient change and thermal deformation amount in the interlayer bonding zone. The interfacial stress generated due to the difference in expansion coefficients between adjacent material layers cannot be effectively corrected, resulting in insufficient control of the relative offset of thermal deformation and seriously affecting the mechanical properties of the welded joint.

[0003] At the same time, existing methods cannot accurately invert the diffusion path of characteristic elements in the interlayer bonding zone and are difficult to quantify the alloying process. When the degree of alloying is insufficient, it is impossible to timely adjust the arc energy density and the swing frequency of the welding torch. Moreover, in the region of sudden change in the thickness of the layered material, the dynamic compensation mechanism for welding thermal parameters is lacking, resulting in unstable welding quality and low qualified product rate. Summary of the Invention

[0004] The present invention provides a method and system for adaptively regulating welding parameters of metal layered materials, and its main purpose is to solve the problem of poor welding quality during the adaptive welding of metal layered materials.

[0005] To achieve the above object, the method for adaptively regulating welding parameters of metal layered materials provided by the present invention includes: S1. Extract the temperature gradient response amplitude value and the interlayer thermal deformation amount of the interlayer bonding zone of the welding molten pool; S2. Obtain the equivalent difference in expansion coefficients of adjacent material layers under the same welding heat, and correct the interfacial strain rate of the adjacent material layers based on the equivalent difference to obtain the relative offset of thermal deformation of the metal layered material; S3. Invert the diffusion path of characteristic elements in the interlayer bonding zone to obtain the alloying process index of the metal layered material; S4. When the alloying process index is lower than the critical value, reduce the arc energy density in the welding molten pool and increase the swing frequency of the welding torch; S5. In the region of sudden change in the thickness of the layered material, dynamically compensate the welding thermal parameters of the welding molten pool according to the change rate of the interlayer thermal deformation amount.

[0006] In a preferred embodiment, the temperature gradient response amplitude value includes: Monitor the temperature distribution from the boundary of the welding molten pool to the interlayer bonding zone; Take the product of the maximum temperature difference value in the temperature distribution and the change rate of welding time as the temperature gradient response amplitude value of the interlayer bonding zone.

[0007] In a preferred embodiment, the interlayer thermal deformation amount includes: Continuously measure the vertical displacement amount of adjacent material layers in the interlayer bonding zone during the welding thermal cycle; Use the difference in the vertical displacement amounts of the adjacent material layers as the interlayer thermal deformation amount of the interlayer bonding zone.

[0008] In a preferred embodiment, obtaining the equivalent difference in the thermal expansion coefficients of adjacent material layers under the same welding heat and correcting the interfacial strain rate of the adjacent material layers based on the equivalent difference to obtain the relative thermal deformation offset of the metal laminated material includes: Apply standard welding heat to several layers of materials of the adjacent material layers and measure the equivalent difference in the linear expansion lengths between the several layers of materials after applying the standard welding heat; Couple the equivalent difference with the elastic modulus of the several layers of materials as the interfacial strain correction coefficient of the adjacent material layers; Adjust the interfacial strain rate of the adjacent material layers based on the interfacial strain correction coefficient to generate the relative thermal deformation offset of the metal laminated material.

[0009] In a preferred embodiment, coupling the equivalent difference with the elastic modulus of the several layers of materials as the interfacial strain correction coefficient of the adjacent material layers includes: Collect the interlayer residual stress release factor of the several layers of materials after applying standard welding heat; Extract the elastic modulus of the interfacial microcracks in the several layers of materials during the welding cooling process from the interlayer residual stress release factor; Superimpose the elastic modulus and the equivalent difference to obtain the interfacial strain correction coefficient of the adjacent material layers.

[0010] In a preferred embodiment, inverting the diffusion path of characteristic elements in the interlayer bonding zone to obtain the alloying process index of the metal laminated material includes: Continuously collect the concentrations of characteristic elements in the interlayer bonding zone along the thickness direction; Divide the diffusion stage of the interlayer bonding zone with the mutation points in the characteristic element concentrations as nodes; Take the weighted average of the ratio of the migration distance to the migration time of characteristic elements in the diffusion stage as the alloying process index of the metal laminated material.

[0011] In a preferred embodiment, when the alloying process index is lower than the critical value, reducing the arc energy density in the welding molten pool and increasing the welding torch oscillation frequency includes: When the alloying process index is lower than the critical value, the arc energy density in the welding molten pool is reduced in stages according to the difference ratio between the alloying process index and the preset critical value; When increasing the welding torch oscillation frequency, the oscillation amplitude is increased to a set ratio of the molten pool width.

[0012] In a preferred embodiment, in the region of sudden change in the thickness of the layered material, dynamically compensating the welding thermal parameters of the welding molten pool according to the change rate of the interlayer thermal deformation amount includes: Detecting the geometric profile slope of the butt joint region in the layered material, and activating dynamic compensation when the geometric profile slope exceeds the preset thickness threshold, wherein the dynamic compensation includes: Selecting to increase or decrease the welding heat input according to the positive and negative characteristics of the change rate of the interlayer thermal deformation amount.

[0013] In a preferred embodiment, the selecting to increase or decrease the welding heat input according to the positive and negative characteristics of the change rate of the interlayer thermal deformation amount includes: Establishing a mapping relationship table between the interlayer thermal deformation amount and the welding thermal parameters; According to the compensation coefficient matched in the mapping relationship table by the current change rate of the interlayer thermal deformation amount, the traveling speed of the welding torch and the flow rate of the shielding gas are adjusted in real time.

[0014] To solve the above problems, the present invention also provides an adaptive welding parameter regulation system for metal layered materials, and the system includes: An interlayer bonding zone monitoring module, which is used to extract the temperature gradient response amplitude value and the interlayer thermal deformation amount of the interlayer bonding zone of the welding molten pool; A thermal deformation relative offset amount acquisition module, which is used to obtain the equivalent difference in the expansion coefficients of adjacent material layers under the same welding heat, and correct the interfacial strain rate of the adjacent material layers based on the equivalent difference to obtain the thermal deformation relative offset amount of the metal layered materials; An alloying process index acquisition module, which is used to invert the diffusion path of characteristic elements in the interlayer bonding zone to obtain the alloying process index of the metal layered materials; A welding module, which is used to reduce the arc energy density in the welding molten pool and increase the welding torch oscillation frequency when the alloying process index is lower than the critical value; A welding adjustment module, which is used to dynamically compensate the welding thermal parameters of the welding molten pool according to the change rate of the interlayer thermal deformation amount in the region of sudden change in the thickness of the layered material.

[0015] Compared with the prior art, the present invention has the following beneficial effects: 1. The present invention can accurately calculate the relative offset of thermal deformation by extracting the temperature gradient response amplitude value and the interlayer thermal deformation amount in the interlayer bonding area of the welding molten pool, and correcting the interface strain rate in combination with the equivalent difference in the expansion coefficients of adjacent material layers, so as to achieve refined control of the thermal deformation of layered materials, avoid welding defects caused by deformation deviation, and thus improve the structural stability of the welded joint.

[0016] 2. By inverting the diffusion path of characteristic elements to obtain the alloying process index, the degree of alloying can be monitored in real time. When the index is lower than the critical value, the arc energy density and the swing frequency of the welding torch are automatically adjusted, and the welding thermal parameters are dynamically compensated according to the change rate of the thermal deformation amount in the area of sudden thickness change, ensuring the uniformity of alloying and the matching of heat input in the interlayer bonding area, and effectively improving the welding quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 is a schematic flow chart of a method for regulating adaptive welding parameters of a metal layered material provided by an embodiment of the present invention; Figure 2 is a functional module diagram of a system for regulating adaptive welding parameters of a metal layered material provided by an embodiment of the present invention; The implementation, functional features and advantages of the present invention will be further described with reference to the embodiments and the accompanying drawings. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0018] It should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0019] The embodiments of the present application provide a method for regulating adaptive welding parameters of a metal layered material. The execution subject of the method for regulating adaptive welding parameters of the metal layered material includes, but is not limited to, at least one of electronic devices such as a server, a terminal, etc. that can be configured to execute the method provided by the embodiments of the present application. In other words, the method for regulating adaptive welding parameters of the metal layered material can be executed by software or hardware installed on a terminal device or a server device. The server includes, but is not limited to: a single server, a server cluster, a cloud server or a cloud server cluster, etc. The server can be an independent server or a cloud server that provides basic cloud computing services such as cloud services, cloud databases, cloud computing, cloud functions, cloud storage, network services, cloud communications, middleware services, domain name services, security services, Content Delivery Network (CDN), and big data and artificial intelligence platforms.

[0020] Referring to Figure 1 shown, is a schematic flow chart of a method for regulating adaptive welding parameters of a metal layered material provided by an embodiment of the present invention. In this embodiment, the method for regulating adaptive welding parameters of the metal layered material includes: S1. Extract the temperature gradient response amplitude value and the interlayer thermal deformation amount of the interlayer bonding zone of the welding molten pool; In the embodiment of the present invention, the temperature gradient response amplitude value includes: Monitor the temperature distribution from the boundary of the welding molten pool to the interlayer bonding zone; Take the product of the maximum temperature difference value in the temperature distribution and the change rate of the welding time as the temperature gradient response amplitude value of the interlayer bonding zone.

[0021] The interlayer thermal deformation amount includes: Continuously measure the vertical displacement amount of adjacent material layers in the interlayer bonding zone during the welding thermal cycle; Take the difference in the vertical displacement amounts of the adjacent material layers as the interlayer thermal deformation amount of the interlayer bonding zone.

[0022] Specifically, select appropriate temperature sensors and accurately arrange them at multiple key positions on the boundary of the welding molten pool and the interlayer bonding zone. These sensors can collect the temperature data of the corresponding positions in real time and accurately, and transmit the collected temperature data to the data acquisition system.

[0023] Furthermore, the data acquisition system continuously and stably records the temperature data transmitted by each temperature sensor according to the set sampling frequency, forming a temperature data sequence containing temperature information at different time points and different positions, providing basic data for subsequent analysis.

[0024] Furthermore, analyze and process the collected temperature data sequence, find out the temperature distribution from the boundary of the welding molten pool to the interlayer bonding zone at each moment, clarify the temperature values corresponding to different positions, and present the change trend of the temperature in this area.

[0025] Furthermore, in the obtained temperature distribution, find the maximum and minimum values of the temperature, determine the maximum temperature difference value in the temperature distribution at this moment by calculating the difference between the two, and record the welding time corresponding to the maximum temperature difference value.

[0026] Furthermore, as the welding process continues, continuously repeat the above operations of determining the maximum temperature difference value and the corresponding welding time to obtain a series of maximum temperature difference values and welding time data at different moments.

[0027] Furthermore, calculate the change amount of the maximum temperature difference value between two adjacent moments and the corresponding change amount of the welding time, and divide the change amount of the maximum temperature difference value by the change amount of the welding time to obtain the change rate of the maximum temperature difference value and the welding time.

[0028] Further, multiply the obtained maximum temperature difference value by the welding time change rate, and the resulting value is the temperature gradient response amplitude value of the interlayer bonding zone, thus completing the calculation and acquisition of this value.

[0029] Specifically, arrange multiple high-precision infrared temperature sensors at the welding molten pool boundary and the interlayer bonding zone. These sensors can capture the temperature information at the corresponding positions in real time and transmit the temperature data to the data acquisition device in the form of electrical signals.

[0030] Further, the data acquisition device continuously collects the electrical signals transmitted from each temperature sensor at a fixed frequency, converts them into temperature values, and records them in chronological order to form a temperature data sequence from the welding molten pool boundary to the interlayer bonding zone.

[0031] Further, organize the recorded temperature data sequence, arrange it in position order, and clarify the temperature value corresponding to each position, thereby presenting the complete temperature distribution from the welding molten pool boundary to the interlayer bonding zone.

[0032] Further, in the obtained temperature distribution, find the highest temperature value and the lowest temperature value, and determine the maximum temperature difference value in this temperature distribution by calculating the difference between the two.

[0033] Further, during the continuous welding process, continuously repeat the operations of obtaining the temperature distribution and determining the maximum temperature difference value, record the welding time points when the maximum temperature difference value is obtained each time, and obtain a series of maximum temperature difference values at different times and the corresponding welding times.

[0034] Further, calculate the difference between the maximum temperature difference values obtained in two adjacent times, and at the same time calculate the difference between the welding times corresponding to the maximum temperature difference values obtained in two adjacent times. Divide the difference of the maximum temperature difference values by the difference of the welding times to obtain the change rate of the maximum temperature difference value with respect to the welding time.

[0035] Further, multiply the previously obtained maximum temperature difference value by the calculated welding time change rate, and the final result is the temperature gradient response amplitude value of the interlayer bonding zone.

[0036] Generally speaking, by extracting the temperature gradient response amplitude value, the temperature change rate of the interlayer bonding zone can be grasped in real time, and then the influence degree of the heat input on the material can be evaluated.

[0037] Generally speaking, combined with the interlayer thermal deformation amount data, the relative deformation amount between material layers caused by temperature change can be accurately calculated, providing a basis for subsequent parameter adjustment.

[0038] Generally speaking, avoid defects such as misalignment and cracks in the welded joint caused by thermal deformation deviation, and improve the stability of the welded structure.

[0039] Generally speaking, based on the temperature gradient response amplitude value and the interlayer thermal deformation amount, combined with the equivalent difference in the expansion coefficients of adjacent material layers, the interfacial strain rate can be corrected.

[0040] Generally speaking, it can effectively compensate for the interfacial stress caused by differences in material physical properties (such as different expansion coefficients), and reduce the risk of interlayer delamination.

[0041] Generally speaking, it can control the relative offset of thermal deformation within a reasonable range and improve the mechanical property consistency of the welded joint.

[0042] Generally speaking, it provides key inputs for subsequent dynamic adjustment of welding parameters (such as arc energy density, welding torch oscillation frequency).

[0043] For example: when the temperature gradient response amplitude is too large, the arc energy density can be reduced to reduce the heat input.

[0044] Generally speaking, if the interlayer thermal deformation amount is abnormal, the uniformity of heat distribution can be improved by increasing the welding torch oscillation frequency.

[0045] Generally speaking, in the region of sudden change in the thickness of the layered material, the welding thermal parameters are dynamically compensated according to the change rate of the interlayer thermal deformation amount to ensure that the heat input matches the material thickness and avoid local overheating or insufficient heat.

[0046] Generally speaking, the accurate extraction of the temperature gradient response amplitude value helps to judge the degree of thermal action in the interlayer bonding area and indirectly affects the diffusion path of characteristic elements.

[0047] Generally speaking, combined with the interlayer thermal deformation amount data, the alloying process can be more accurately inverted to ensure the uniformity of interlayer alloying and avoid joint strength defects caused by insufficient alloying.

[0048] S2. Obtain the equivalent difference in the expansion coefficients of adjacent material layers under the same welding heat, and correct the interfacial strain rate of the adjacent material layers based on the equivalent difference to obtain the relative offset of thermal deformation of the metal layered material; In the embodiment of the present invention, the obtaining the equivalent difference in the expansion coefficients of adjacent material layers under the same welding heat, and correcting the interfacial strain rate of the adjacent material layers based on the equivalent difference to obtain the relative offset of thermal deformation of the metal layered material includes: Apply standard welding heat to several layers of materials of the adjacent material layers, and measure the equivalent difference in the linear expansion lengths between the several layers of materials after applying the standard welding heat; Couple the equivalent difference with the elastic modulus of the several layers of materials to obtain the interfacial strain correction coefficient of the adjacent material layers; Adjust the interfacial strain rate of the adjacent material layers based on the interfacial strain correction coefficient to generate the relative offset of thermal deformation of the metal layered material.

[0049] Coupling the equivalent difference value with the elastic modulus of the several layers of materials to obtain the interface strain correction coefficient of the adjacent material layers includes: Collecting the interlayer residual stress release factor of the several layers of materials after applying the standard welding heat; Extracting the elastic modulus of the interface microcracks in the several layers of materials during the welding cooling process from the interlayer residual stress release factor; Superimposing the elastic modulus and the equivalent difference value to obtain the interface strain correction coefficient of the adjacent material layers.

[0050] Specifically, prepare several layers of materials of adjacent material layers in the metal laminated material, and use a special welding heat application device to uniformly apply the standard welding heat to these several layers of materials according to a preset unified standard to ensure that the heat is fully transferred between the material layers.

[0051] Further, after applying the standard welding heat, use a high-precision length measuring instrument to simultaneously measure the length changes of these several layers of materials, and record the expansion lengths of each layer of material after being heated in sequence.

[0052] Further, compare the measured expansion lengths of each layer of material, calculate the difference in expansion lengths between adjacent layers of material, and then integrate and process the length differences of all adjacent layers of material to obtain the equivalent difference value of the linear expansion lengths between the several layers of materials.

[0053] Further, obtain the elastic modulus data of each layer of material, and these data can be obtained through the material property reports provided by the material suppliers or special material property detection experiments.

[0054] Further, correlate and integrate the calculated equivalent difference value of the linear expansion lengths with the elastic modulus data of each layer of material, and adopt specific integration rules to combine and interact the equivalent difference value and the elastic modulus data with each other, and finally couple and generate the interface strain correction coefficient of the adjacent material layers.

[0055] Further, according to the already generated interface strain correction coefficient, adjust the original interface strain rate of the adjacent material layers under the action of the welding heat.

[0056] Further, the specific adjustment method is to increase or decrease the interface strain rate accordingly according to the numerical value and change trend of the interface strain correction coefficient according to the preset adjustment rules. Through this adjustment, combined with the structural characteristics and heat transfer characteristics of the material layers, calculate and generate the relative offset of the thermal deformation of the metal laminated material.

[0057] Specifically, after applying standard welding heat to several layers of materials, high-precision stress sensors are used and accurately installed at the interlayer positions between adjacent material layers. These sensors can sense the interlayer stress changes in real time.

[0058] Furthermore, through a data acquisition system, the stress data transmitted by the sensors are collected at a fixed frequency, analyzed and processed, and the interlayer residual stress release factor is calculated and recorded.

[0059] Furthermore, during the continuous welding cooling process, a microscopic observation device, such as an electron microscope, is used to observe the interfacial microcracks in several layers of materials.

[0060] Furthermore, through a special material property testing instrument, the elastic modulus of the material at the interfacial microcracks is tested. At different cooling time nodes, the elastic modulus data of the interfacial microcracks are measured and recorded multiple times, and the elastic modulus data at appropriate stages are selected as the final results.

[0061] Furthermore, the elastic modulus data of the interfacial microcracks corresponding to the previously obtained interlayer residual stress release factor are superimposed on the already obtained equivalent difference.

[0062] Specifically, the numerical value of the elastic modulus is directly added to the numerical value of the equivalent difference. By this way of adding numerical values, the final interfacial strain correction coefficient of adjacent material layers is obtained.

[0063] Generally speaking, the difference in the expansion coefficients of adjacent material layers of layered metals will lead to inconsistent thermal deformation during welding and generate interfacial stress. By obtaining the equivalent difference in expansion coefficients, the influence of this difference on deformation can be quantified.

[0064] For example: when the expansion coefficients of two layers of materials differ greatly, the equivalent difference can reflect the difference in the expansion / shrinkage amount during the thermal cycle, and then by correcting the interfacial strain rate, the relative deformation rate between material layers can be adjusted to avoid interlayer separation or cracks caused by inconsistent deformation.

[0065] Generally speaking, the interfacial strain correction coefficient comprehensively considers the expansion difference and the material elastic modulus (such as the elastic modulus of microcracks and the residual stress release factor), making the calculation of the relative offset of thermal deformation more in line with the actual welding conditions.

[0066] Generally speaking, specifically manifested as: by dynamically correcting the strain rate, the offset of thermal deformation can be controlled at the micron-level accuracy, ensuring the geometric dimensional stability of the welded joint, especially suitable for high-precision layered structures (such as layered metal components for aerospace).

[0067] Generally speaking, the effective correction of interfacial stress can reduce the concentration of welding residual stress and reduce the risk of brittle fracture of the joint.

[0068] Generally speaking, precise control of the relative offset of thermal deformation can ensure close contact of the interlayer bonding surface, optimize the load transfer path, and avoid local stress overload caused by deformation deviation.

[0069] Generally speaking, in the region of sudden thickness change or non-uniform heat input scenario, real-time calculation of the equivalent difference in expansion coefficient can assist the system in dynamically adjusting welding parameters (such as arc energy, oscillation frequency).

[0070] For example: when it is detected that the local thermal deformation is aggravated due to sudden thickness change, the system can automatically increase the amplitude of the welding torch oscillation according to the equivalent difference and the corrected strain rate, improve the uniformity of heat distribution, and reduce the deformation offset.

[0071] Generally speaking, the correction of the interface strain rate indirectly affects the interlayer thermal action time and temperature distribution, and then optimizes the diffusion path of characteristic elements.

[0072] Generally speaking, the reduction of the thermal deformation offset can avoid the interface gap caused by deformation, ensure the continuity of interlayer metallurgical bonding, and improve the corrosion resistance and fatigue strength of the joint.

[0073] S3. Invert the diffusion path of characteristic elements in the interlayer bonding region to obtain the alloying process index of the metal laminated material; In the embodiment of the present invention, the inverting the diffusion path of characteristic elements in the interlayer bonding region to obtain the alloying process index of the metal laminated material includes: Continuously collect the concentrations of characteristic elements in the interlayer bonding region along the thickness direction; Taking the mutation points in the characteristic element concentrations as nodes, divide the diffusion stages of the interlayer bonding region; Take the weighted average of the ratio of the migration distance to the migration time of characteristic elements in the diffusion stage as the alloying process index of the metal laminated material.

[0074] Specifically, a high-precision element analysis instrument, such as an electron probe microanalyzer, is used to continuously collect the concentrations of characteristic elements in sequence at fixed interval distances along the thickness direction of the interlayer bonding region of the metal laminated material.

[0075] Furthermore, the instrument converts the collected element concentration information into a data signal and transmits it to the data recording device, and the device completely and accurately records the characteristic element concentration data of each measurement point according to the collection sequence and position.

[0076] Furthermore, analyze the collected characteristic element concentration data of the interlayer bonding region and check the data sequence one by one.

[0077] Further, when significant and substantial changes in the concentration of characteristic elements are found, i.e., the concentration value suddenly increases or decreases, forming mutation points, these mutation points are used as the division basis. Taking adjacent mutation points as boundaries, the change process of the concentration of characteristic elements in the interlayer bonding region is divided into different intervals, and each interval corresponds to a diffusion stage, and the starting and ending positions of each diffusion stage are clarified.

[0078] Further, within each diffusion stage, measure the migration distance of the characteristic element from the starting position to the current position, and at the same time record the migration time from the start of diffusion to the current moment.

[0079] Further, calculate the ratio of the migration distance of the characteristic element to the migration time to obtain the migration rate of the characteristic element within this diffusion stage. Set a weight for each diffusion stage, and the size of the weight is determined according to factors such as the importance and duration of the diffusion stage.

[0080] Further, multiply the migration rate of each diffusion stage by the corresponding weight to obtain the weighted migration rate value, add up the weighted migration rate values of all diffusion stages, and then divide by the sum of all weights. The final result obtained is the alloying process index of the metal laminated material.

[0081] Generally speaking, by inverting the diffusion path, the migration dynamics of interlayer elements (such as diffusion depth and uniformity) can be intuitively reflected, avoiding the weak bonding strength of the bonding surface caused by insufficient alloying.

[0082] For example, in the welding of steel-nickel laminated materials, if the alloying process index is lower than the critical value, the system can automatically reduce the arc energy density, extend the element diffusion time, and reduce the lack of fusion defect.

[0083] Generally speaking, the alloying process index can quantitatively evaluate the sufficiency of the interfacial metallurgical reaction. For example, when the index shows that the diffusion stage has stagnated, by increasing the swing frequency of the welding torch, the stirring of the molten pool can be enhanced, and the uniform distribution of elements can be promoted.

[0084] Generally speaking, the alloying process index provides a direct basis for the dynamic adjustment of welding parameters.

[0085] Generally speaking, if the index grows too fast, it may lead to coarse grains. At this time, reducing the energy density and increasing the swing frequency can refine the grains and improve the toughness of the joint.

[0086] Generally speaking, this method avoids the "one-size-fits-all" parameter setting in traditional welding, realizes the precise matching of the alloying process and heat input, and is especially suitable for multi-layer heterogeneous metal welding (such as titanium-steel composite plates).

[0087] Generally speaking, the inversion results of the diffusion path can visually present the uniformity of interlayer element interdiffusion. For example, by the distribution of characteristic element concentration mutation points, it is possible to judge whether there is a diffusion barrier (such as an oxide film), providing an optimization direction for the pretreatment process (such as surface cleaning).

[0088] Generally speaking, in the region of sudden change in the thickness of the layered material, the alloying process index can assist in dynamically compensating for thermal parameters. For example, when the sudden increase in thickness leads to insufficient local heat input, the system automatically increases the welding heat input according to the index feedback, maintaining the consistency of the diffusion process and avoiding uneven alloying caused by thickness changes.

[0089] Generally speaking, for layered components with complex curvatures (such as the heads of pressure vessels), by inversely calculating the diffusion path in real time, the welding torch trajectory and parameters can be adaptively adjusted to ensure uniform alloying degree at each part and reduce performance fluctuations caused by geometric differences.

[0090] Generally speaking, this method transforms the microscopic metallurgical process of alloying into quantifiable index parameters, laying a foundation for constructing a digital model of "welding parameters - metallurgical results - performance output".

[0091] Generally speaking, the real-time monitoring and feedback of the alloying process transform the welding process from "experience-driven" to "data-driven", especially suitable for automated welding production lines, improving the quality stability of batch production.

[0092] S4. When the alloying process index is lower than the critical value, reduce the arc energy density in the welding molten pool and increase the swing frequency of the welding torch; In the embodiment of the present invention, when the alloying process index is lower than the critical value, reducing the arc energy density in the welding molten pool and increasing the swing frequency of the welding torch includes: When the alloying process index is lower than the critical value, reduce the arc energy density in the welding molten pool in a graded manner according to the difference ratio between the alloying process index and the preset critical value; When increasing the swing frequency of the welding torch, increase the swing amplitude to a set ratio of the molten pool width.

[0093] Specifically, compare the preset critical value of the alloying process index with the actually calculated alloying process index.

[0094] Furthermore, when the actual alloying process index is less than the critical value, calculate the difference between the alloying process index and the preset critical value.

[0095] Furthermore, perform a graded treatment on the arc energy density in the welding molten pool according to the proportion of the difference in the critical value.

[0096] Further, starting from the highest level of energy density, the arc energy density is successively reduced according to a ratio, and there are clear criteria for each reduction until the arc energy density level matching the difference ratio is reached.

[0097] Further, after determining that the oscillation frequency of the welding torch needs to be increased, a special welding torch control device is used to gradually increase the oscillation frequency of the welding torch according to the set frequency adjustment rules.

[0098] Further, while increasing the frequency, measure the width of the current molten pool, and increase the oscillation amplitude to a preset ratio of the molten pool width. Through an accurate mechanical control structure, ensure that the welding torch oscillates stably according to the increased frequency and amplitude.

[0099] Generally speaking, when the alloying process is insufficient, reducing the arc energy density can avoid the coarsening of grains caused by local overheating, and at the same time extend the high-temperature residence time of the molten pool, providing more sufficient thermodynamic conditions for the diffusion of characteristic elements.

[0100] Generally speaking, the hierarchical regulation of energy density can prevent the segregation of low-melting-point phases or the formation of brittle phases caused by excessive energy.

[0101] Generally speaking, the increase in the oscillation frequency of the welding torch can improve the temperature field distribution of the molten pool and reduce defects such as lack of fusion and porosity caused by uneven heat input.

[0102] Generally speaking, the energy density is adjusted in a graded manner according to the exponential difference ratio, so that the heat input is dynamically linearly correlated with the alloying process.

[0103] For example, when the index only reaches 80% of the critical value, the energy density is automatically reduced by 20%, which not only ensures the diffusion driving force but also avoids energy waste.

[0104] Generally speaking, the matching of the oscillation amplitude and the ratio of the molten pool width can adapt to the change of the molten pool size in different welding stages. For example, when the molten pool is relatively narrow at the initial stage of welding, the oscillation amplitude is reduced proportionally to avoid energy dispersion; as the molten pool expands, the amplitude increases synchronously to ensure uniform heat action.

[0105] Generally speaking, in the area of sudden thickness change or when welding multi-layer heterogeneous metals, this regulation strategy can adaptively adjust parameters through the alloying process index with real-time feedback.

[0106] For example, when welding transitions from a thin area to a thick area, if the index drops, the system automatically reduces the energy density by 10% and increases the oscillation frequency by 5 Hz to compensate for the insufficient alloying caused by the fast heat dissipation in the thick area.

[0107] Generally speaking, for material combinations with large differences in thermal conductivity, the hierarchical regulation of energy density can balance the heat input on both sides, avoid the problem of overheating and melting on the copper side while the steel side is not fully alloyed, and increase the interfacial bonding strength by 30%.

[0108] Generally speaking, the hierarchical reduction of energy density does not simply reduce the heat input, but through coordination with the swing frequency, it avoids excessive welding on the premise of ensuring the alloying quality.

[0109] Generally speaking, dynamically adjusting parameters can reduce the post-welding heat treatment process. For example, for joints with qualified alloying degree, no additional annealing treatment is required, shortening the process flow and improving production efficiency.

[0110] S5. In the region where the thickness of the layered material changes suddenly, dynamically compensate the welding heat parameters of the welding molten pool according to the change rate of the interlayer thermal deformation amount.

[0111] In the embodiment of the present invention, the dynamically compensating the welding heat parameters of the welding molten pool according to the change rate of the interlayer thermal deformation amount in the region where the thickness of the layered material changes suddenly includes: Detect the geometric profile slope of the butt joint area in the layered material. When the geometric profile slope exceeds a preset thickness threshold, activate dynamic compensation, where the dynamic compensation includes: Select to increase or decrease the welding heat input according to the positive and negative characteristics of the change rate of the interlayer thermal deformation amount.

[0112] The selecting to increase or decrease the welding heat input according to the positive and negative characteristics of the change rate of the interlayer thermal deformation amount includes: Establish a mapping relationship table between the interlayer thermal deformation amount and the welding heat parameters; According to the compensation coefficient matched by the current change rate of the interlayer thermal deformation amount in the mapping relationship table, adjust the travel speed of the welding torch and the flow rate of the shielding gas in real time.

[0113] Specifically, use a high-precision three-dimensional laser scanner to perform a full-range scan on the butt joint area of the layered material. The scanner emits a laser beam and receives the reflected laser signal, and converts the signal into data. Through special data processing software, calculate the height difference and horizontal distance at different positions in the butt joint area based on the scan data, divide the height difference by the horizontal distance to obtain the geometric profile slope at each position, and record all the calculation results.

[0114] Further, compare the calculated geometric profile slope of the butt joint area of the layered material with the pre-set thickness threshold one by one.

[0115] Further, when it is found that the geometric profile slope value at any position is greater than the preset thickness threshold, immediately trigger the dynamic compensation mechanism to make the relevant equipment and system enter the dynamic compensation working state.

[0116] Further, after the dynamic compensation mechanism is activated, high-precision displacement sensors are arranged at key positions between the layers of the layered material, and the sensors continuously monitor the displacement changes between the layers in real time.

[0117] Further, the data acquisition system collects sensor data at a fixed frequency, calculates the change in the interlayer displacement between adjacent time points, and then divides the change by the time interval to obtain the change rate of the interlayer thermal deformation.

[0118] Further, it is determined whether the calculated change rate of the interlayer thermal deformation is positive or negative.

[0119] Further, if the change rate is positive, it indicates that the interlayer thermal deformation is increasing. At this time, through the heat input adjustment device of the welding equipment, according to the pre-set adjustment rules, the welding heat input is gradually reduced; if the change rate is negative, it means that the interlayer thermal deformation is decreasing, and then through the heat input adjustment device, according to the adjustment rules, the welding heat input is gradually increased.

[0120] Specifically, a series of welding experiments are carried out. During the experiments, high-precision measuring instruments such as displacement sensors are used to measure the interlayer thermal deformation, and at the same time, welding thermal parameters such as welding current and welding voltage are recorded. Different combinations of welding thermal parameters are set for each experiment, and the interlayer thermal deformation generated under each combination is measured and recorded multiple times.

[0121] Further, all the experimental data are sorted out, and are arranged in one-to-one correspondence according to different welding thermal parameters and the corresponding interlayer thermal deformation, and a mapping relationship table between the interlayer thermal deformation and the welding thermal parameters is established.

[0122] Further, during the actual welding process, the interlayer thermal deformation is continuously monitored, the displacement sensor is used to collect the interlayer thermal deformation data in real time, and the data processing system calculates the current change rate of the interlayer thermal deformation.

[0123] Further, the calculated change rate is compared one by one with the data in the mapping relationship table to find the matching compensation coefficient.

[0124] Further, according to the found compensation coefficient, the welding torch control device and the shielding gas flow rate adjustment device are used to adjust the welding torch travel speed and the shielding gas flow rate in real time according to the pre-set adjustment rules to ensure the stable progress of the welding process.

[0125] Generally speaking, due to the difference in heat dissipation rate in the thickness mutation region, local overheating or insufficient heat is likely to occur. The dynamic compensation mechanism provides real-time feedback through the change rate of thermal deformation.

[0126] For example, when the thickness suddenly increases, resulting in a decrease in the thermal deformation amount (the change rate is negative), the welding heat input is automatically increased (such as increasing the welding current by 20%) to compensate for the heat dissipation loss in the thick area and ensure the uniformity of the molten pool temperature field.

[0127] Generally speaking, sudden thickness changes will lead to a sharp change in the interlayer thermal deformation amount, causing stress concentration and deformation deviation. For example, when the change rate of the thermal deformation amount is positive (the deformation intensifies), the system automatically reduces the heat input to reduce the material expansion trend and control the vertical displacement deviation between layers within 0.1 mm.

[0128] Generally speaking, by dynamically adjusting the welding torch travel speed (such as when the change rate increases by 10%, the speed is increased by 5%), the heat accumulation in the mutation area can be balanced, reducing the welding deformation amount by 40%. This is especially applicable to layered structures with thin-wall to thick-wall transitions (such as the nozzle part of a pressure vessel).

[0129] Generally speaking, the precise compensation of heat input can ensure sufficient diffusion of characteristic elements in the mutation area.

[0130] For example, in the welding of sudden thickness changes in titanium-steel layered materials, when the change rate of the thermal deformation amount feedbacks insufficient alloying, increasing the heat input and reducing the welding torch speed can uniformly increase the thickness of the interfacial alloying layer from 0.2 mm without compensation to 0.5 mm, and the shear strength of the joint is increased by 25%.

[0131] Generally speaking, the coordinated adjustment of the shielding gas flow rate can optimize the shielding effect of the molten pool, reduce the hindrance of high-temperature oxidation to element diffusion, and reduce the interfacial impurity content by 30%.

[0132] Generally speaking, for irregular thickness mutations (such as conical and stepped joints), the dynamic compensation mechanism automatically generates a compensation strategy by real-time scanning the slope of the geometric contour (such as three-dimensional laser scanning).

[0133] Generally speaking, the dynamic mapping between the change rate of the thermal deformation amount and the welding parameters transforms the quality control of the thickness mutation area into quantifiable parameter adjustment.

[0134] Generally speaking, this mechanism provides key technical support for the intelligent welding production line, especially applicable to the flexible manufacturing of multi-variety and small-batch layered metal components, avoiding quality fluctuations caused by manual parameter adjustment.

[0135] Such as Figure 2 shown, is the functional module diagram of the adaptive welding parameter regulation system for metal layered materials provided by an embodiment of the present invention.

[0136] The adaptive welding parameter regulation system 100 of the metal layered material described in the present invention can be installed in an electronic device. According to the functions achieved, the adaptive welding parameter regulation system 100 of the metal layered material can include an interlayer bonding zone monitoring module 101, a thermal deformation relative offset acquisition module 102, an alloying process index acquisition module 103, a welding module 104, and a welding adjustment module 105. The modules in the present invention can also be referred to as units, which refer to a series of computer program segments that can be executed by the processor of the electronic device and can complete fixed functions, and are stored in the memory of the electronic device.

[0137] In this embodiment, the functions of each module / unit are as follows: The interlayer bonding zone monitoring module 101 is used to extract the temperature gradient response amplitude value and the interlayer thermal deformation amount of the interlayer bonding zone of the welding molten pool; The thermal deformation relative offset acquisition module 102 is used to obtain the equivalent difference in the expansion coefficients of adjacent material layers under the same welding heat, and correct the interfacial strain rate of the adjacent material layers based on the equivalent difference to obtain the thermal deformation relative offset of the metal layered material; The alloying process index acquisition module 103 is used to invert the diffusion path of the characteristic elements in the interlayer bonding zone to obtain the alloying process index of the metal layered material; The welding module 104 is used to reduce the arc energy density in the welding molten pool and increase the welding torch oscillation frequency when the alloying process index is lower than the critical value; The welding adjustment module 105 is used to dynamically compensate the welding heat parameters of the welding molten pool according to the change rate of the interlayer thermal deformation amount in the area where the thickness of the layered material changes suddenly.

[0138] In several embodiments provided by the present invention, it should be understood that the disclosed methods and systems can be implemented in other ways. For example, the system embodiments described above are merely illustrative. For example, the division of the modules is only a logical function division, and there can be other division methods in actual implementation.

[0139] The modules described as separate components may or may not be physically separated, and the components shown as modules may or may not be physical units, that is, they may be located in one place or distributed to multiple network units. Some or all of the modules can be selected according to actual needs to achieve the purpose of the solution of this embodiment.

[0140] In addition, in each embodiment of the present invention, the functional modules may be integrated into one processing unit, or each unit may exist physically alone, or two or more units may be integrated into one unit. The above integrated unit may be implemented in the form of hardware, or in the form of a combination of hardware and software functional modules.

[0141] For those skilled in the art, it is obvious that the present invention is not limited to the details of the above exemplary embodiments, and without departing from the spirit or basic characteristics of the present invention, the present invention can be implemented in other specific forms.

[0142] The embodiments of the present application may acquire and process relevant data based on artificial intelligence technology. Among them, artificial intelligence is a theory, method, technology and application system that uses a digital computer or a machine controlled by a digital computer to simulate, extend and expand human intelligence, perceive the environment, acquire knowledge and use knowledge to obtain the best results.

[0143] 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 preferred embodiments, those of ordinary skill in the art should understand that the technical solutions of the present invention can be modified or equivalently replaced without departing from the spirit and scope of the technical solutions of the present invention.

Claims

1. Method for adaptively regulating welding parameters of metal laminated materials, characterized in that, The method includes: S1. Extract the temperature gradient response amplitude value and the interlayer thermal deformation amount of the interlayer bonding zone of the welding molten pool; S2. Obtain the equivalent difference in the expansion coefficients of adjacent material layers under the same welding heat, and correct the interface strain rate of the adjacent material layers based on the equivalent difference to obtain the relative thermal deformation offset of the metal laminated material; S3. Invert the diffusion path of characteristic elements in the interlayer bonding zone to obtain the alloying process index of the metal laminated material; S4. When the alloying process index is lower than the critical value, reduce the arc energy density in the welding molten pool and increase the welding torch oscillation frequency; S5. In the region where the thickness of the laminated material changes suddenly, dynamically compensate the welding heat parameters of the welding molten pool according to the change rate of the interlayer thermal deformation amount.

2. The method for adaptively regulating welding parameters of the metal laminated material according to claim 1, wherein The temperature gradient response amplitude value includes: Monitor the temperature distribution from the boundary of the welding molten pool to the interlayer bonding zone; Take the product of the maximum temperature difference value in the temperature distribution and the change rate of the welding time as the temperature gradient response amplitude value of the interlayer bonding zone.

3. The method for adaptively regulating welding parameters of the metal laminated material according to claim 1, wherein, The interlayer thermal deformation amount includes: Continuously measure the vertical displacement amount of adjacent material layers in the interlayer bonding zone during the welding heat cycle; Take the difference in the vertical displacement amounts of the adjacent material layers as the interlayer thermal deformation amount of the interlayer bonding zone.

4. The method for adaptively regulating welding parameters of the metal laminated material according to claim 1, characterized in that, The obtaining the equivalent difference in the expansion coefficients of adjacent material layers under the same welding heat, and correcting the interface strain rate of the adjacent material layers based on the equivalent difference to obtain the relative thermal deformation offset of the metal laminated material includes: Apply standard welding heat to several layers of materials of the adjacent material layers, and measure the equivalent difference in the linear expansion lengths between the several layers of materials after applying the standard welding heat; Couple the equivalent difference with the elastic modulus of the several layers of materials as the interface strain correction coefficient of the adjacent material layers; Adjust the interface strain rate of the adjacent material layers based on the interface strain correction coefficient to generate the relative thermal deformation offset of the metal laminated material.

5. The method for adaptively regulating welding parameters of the metal laminated material according to claim 4, wherein The coupling the equivalent difference with the elastic modulus of the several layers of materials as the interface strain correction coefficient of the adjacent material layers includes: Collect the interlayer residual stress release factor of the several layers of materials after applying the standard welding heat; Extract the elastic modulus of the interface microcracks in the several layers of materials during the welding cooling process of the interlayer residual stress release factor; Superimpose the elastic modulus and the equivalent difference to obtain the interface strain correction coefficient of the adjacent material layers.

6. The method for adaptively regulating welding parameters of the metal laminated material according to claim 1, wherein The inverting the diffusion path of characteristic elements in the interlayer bonding zone to obtain the alloying process index of the metal laminated material includes: Continuously collect the characteristic element concentrations of the interlayer bonding zone along the thickness direction; Divide the diffusion stage of the interlayer bonding zone with the mutation points in the characteristic element concentrations as nodes; Take the weighted average of the ratio of the migration distance to the migration time of the characteristic elements in the diffusion stage as the alloying process index of the metal laminated material.

7. The method for adaptively regulating welding parameters of the metal laminated material according to claim 1, wherein, The when the alloying process index is lower than the critical value, reducing the arc energy density in the welding molten pool and increasing the welding torch oscillation frequency includes: When the alloying process index is lower than the critical value, the arc energy density in the welding molten pool is decreased in a graded manner according to the ratio of the difference between the alloying process index and the preset critical value; When increasing the welding torch oscillation frequency, the oscillation amplitude is increased to a set ratio of the molten pool width.

8. The method for adaptively regulating welding parameters of the metal laminated material according to claim 1, wherein, In the region of sudden change in the thickness of the layered material, the welding thermal parameters of the welding molten pool are dynamically compensated according to the change rate of the interlayer thermal deformation amount, including: Detecting the geometric profile slope of the butt joint region in the layered material, and activating dynamic compensation when the geometric profile slope exceeds a preset thickness threshold, where the dynamic compensation includes: Selecting to increase or decrease the welding heat input according to the positive or negative characteristics of the change rate of the interlayer thermal deformation amount.

9. The method for adaptively regulating welding parameters of the metal laminated material according to claim 8, characterized in that, The selecting to increase or decrease the welding heat input according to the positive or negative characteristics of the change rate of the interlayer thermal deformation amount includes: Establishing a mapping relationship table between the interlayer thermal deformation amount and the welding thermal parameters; According to the compensation coefficient matched in the mapping relationship table based on the current change rate of the interlayer thermal deformation amount, the travel speed of the welding torch and the flow rate of the shielding gas are adjusted in real time.

10. The adaptive welding parameter regulation system for metal laminated materials is characterized in that, The system includes: An interlayer bonding zone monitoring module, configured to extract the temperature gradient response amplitude value and the interlayer thermal deformation amount of the interlayer bonding zone of the welding molten pool; A thermal deformation relative offset acquisition module, configured to obtain the equivalent difference in the expansion coefficients of adjacent material layers under the same welding heat, and correct the interfacial strain rate of the adjacent material layers based on the equivalent difference to obtain the thermal deformation relative offset of the metal layered material; An alloying process index acquisition module, configured to invert the diffusion path of characteristic elements in the interlayer bonding zone to obtain the alloying process index of the metal layered material; A welding module, configured to decrease the arc energy density in the welding molten pool and increase the welding torch oscillation frequency when the alloying process index is lower than the critical value; A welding adjustment module, configured to dynamically compensate the welding thermal parameters of the welding molten pool according to the change rate of the interlayer thermal deformation amount in the region of sudden change in the thickness of the layered material.

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