Welding method and welded prefabricated part

Abstract

The invention discloses a method, a process and a medium for welding by using a prefabricated welding wire, a workpiece to be welded and the prefabricated welding wire are supplied, and the prefabricated welding wire is pre-processed into a shape which is basically consistent with the geometrical shape of a welding bead on the workpiece; the prefabricated welding wire is placed on a welding bead, and the prefabricated welding wire and the workpiece are temporarily fixed in at least one position in at least one mode of single-point welding or multi-point welding or resistance projection welding or micro arc nail welding or argon arc welding or laser welding or plasma welding spot welding so as to restrain displacement and deformation of the prefabricated welding wire and the workpiece in the melting process; and finally, at least one energy beam of a laser beam, an electron beam, a plasma arc or a high-energy-density electric arc is used for fusion welding. The invention further provides a corresponding welding prefabricated part and a prefabricated welding wire assembly. The prefabricated welding wire is temporarily fixed, so that the welding wire is effectively prevented from shifting and excessively deforming in the welding process, the forming precision and the welding quality of a welding bead are ensured, the welding process is simplified, and the requirement for operating skills is lowered.

Description

[0001] The present application relates to the technical field of welding, in particular to a welding method and a welding preform. BACKGROUND

[0002] In the current field of welding technology, whether it is manual argon arc welding, laser welding or electron beam welding, the real-time wire feeding method is generally used. This method requires that the wire feeding process must be accurately synchronized with the movement of the welding heat source, and the control precision of the operation personnel or the automatic wire feeding equipment is extremely high. It takes a long time and costs a lot to train skilled welders, and high-precision automatic wire feeding equipment is also expensive, increasing the production cost of enterprises.

[0003] In addition, when welding complex curved surfaces or fine structures, real-time wire feeding is prone to problems such as deviation of wire feeding angle, uneven wire feeding speed, and oxidation of wire end, resulting in poor weld formation, porosity or incomplete fusion and other defects. Especially for high-energy density fusion welding (such as laser welding), if the welding wire is not effectively positioned, it is easy to drift or collapse under the action of the heat source, which seriously affects the welding quality and consistency.

[0004] It is worth noting that in the field of electronic processing, there is a technology of pre-preparing solder into sheet, ring or gasket shape (i.e. "pre-solder" or Preform) for brazing or reflow soldering. However, this technology is mainly applied to low-temperature, non-melting parent material connection process, and its purpose is to fill small gaps, not to form deep fusion welds.

[0005] The present application is fundamentally different from the above-mentioned technology: the present application is aimed at high-energy density fusion welding of steel, aluminum and other metal structural parts, and in this process, the parent material and the preformed welding wire must be completely melted and metallurgically bonded. If the preformed welding wire is not effectively fixed before melting, it is easy to deform, shift or even splash under high heat input, resulting in weld collapse and uncontrolled formation. Therefore, the present application proposes a new welding scheme: the preformed welding wire is temporarily fixed to the workpiece by single-point welding or multi-point welding, which not only solves the problem of real-time wire feeding, but also effectively restricts the deformation of the welding wire in a high-heat environment, ensuring the accurate formation of deep fusion welds, and has outstanding substantial features and significant progress. Therefore, the present application is proposed.

[0006] Therefore, a welding method and a welding preform are proposed. SUMMARY

[0007] The present application aims to provide a welding method and a welding preform to solve the problems raised in the background art.

[0008] To achieve the above-mentioned purpose, the present application provides the following technical solutions:

[0009] A welding method, characterized in that it comprises the following steps:

[0010] (a) Provide a workpiece to be welded, the workpiece having a preset weld bead;

[0011] (b) Provide a pre-made welding wire, which is pre-processed into a shape substantially consistent with the geometry of the weld bead;

[0012] (c) The pre-made welding wire is placed on the weld bead of the workpiece, and the pre-made welding wire and the workpiece are temporarily fixed at at least one position by at least one resistance heat welding method selected from single-point welding or multi-point welding, resistance projection welding and micro arc stud welding or argon arc welding or laser welding or plasma welding, so as to constrain the spatial displacement and / or deformation of the pre-made welding wire during the subsequent melting process;

[0013] (d) Using at least one energy beam selected from laser beam, electron beam, plasma arc and high energy density electric arc, the workpiece and prefabricated welding wire processed in step (c) are melted and welded to melt the prefabricated welding wire and fill the weld bead to form a weld.

[0014] In step (c), the temporary fixing connection method is single-point welding or multi-point welding.

[0015] The temporary fixing is performed at multiple locations, and the multiple locations are spaced apart along the length direction of the prefabricated welding wire.

[0016] The distance between two adjacent temporary fixed positions is between 3mm and 60mm or between 60.00001mm and 120mm.

[0017] A welded preform, characterized in that it comprises:

[0018] The workpiece to be welded has a pre-set weld bead.

[0019] Pre-fabricated welding wire, which is pre-processed into a shape that is substantially consistent with the geometry of the weld bead and placed on the weld bead;

[0020] The pre-made welding wire is connected to the workpiece by at least one resistance heat welding method selected from single-point welding or multi-point welding, resistance projection welding and micro arc stud welding or argon arc welding or laser welding or plasma welding. The connection is used to fix the position of the pre-made welding wire before molten welding, so as to suppress its unexpected displacement and / or deformation during the molten process.

[0021] The prefabricated welding wire is connected to the workpiece through multiple discrete connection points, and the multiple discrete connection points are arranged in an array along the length direction of the prefabricated welding wire.

[0022] A prefabricated welding wire assembly for welding, characterized in that it comprises:

[0023] The prefabricated welding wire body is pre-processed into a shape that is substantially consistent with the geometry of the target weld bead; multiple fixing structures are disposed on the prefabricated welding wire body for temporarily fixing the prefabricated welding wire body to the weld bead of the workpiece to be welded during use by at least one of the following methods: single-point welding or multi-point welding, resistance projection welding and micro-arc stud welding or argon arc welding or laser welding or plasma spot welding, so as to maintain the spatial configuration stability of the prefabricated welding wire body during subsequent fusion welding process; wherein, the fixing structure is selected from at least one of metal bosses, conductive coatings and pre-placed micro-resistive elements.

[0024] The material of the pre-made welding wire is selected from at least one of the following: metals that are the same as the base material of the workpiece, alloys that are compatible with the base material of the workpiece, and composite welding wires with specific metallurgical functions.

[0025] The cross-sectional shape of the prefabricated welding wire is selected from at least one of circular, flat, rectangular, triangular, and irregular shapes that match the weld bead design.

[0026] The application path of the energy beam is substantially coincident with the centerline of the prefabricated welding wire. Attached Figure Description

[0027] Figure 1 This is a schematic flowchart of a welding method according to the present invention; Detailed Implementation

[0028] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0029] It is worth noting that:

[0030] The word "or" is mainly used in the text to indicate that in addition to these two, there is also a combination of one of them, and the corresponding items in the context are one-to-one.

[0031] Similar reference numerals and letters in the accompanying drawings denote similar items; therefore, once an item is defined in one drawing, it need not be further discussed in subsequent drawings. In the specification and claims of this invention, the term "single-point welding" refers to the operation or process of forming a single, discrete welded connection at a specific location on a workpiece by applying a heat source and / or pressure. This connection takes the form of a single weld point or a small molten pool, not constituting a continuous weld seam. In this invention, single-point welding specifically refers to the process used to temporarily fix prefabricated welding wire, the resulting connection being completely melted and integrated into the final weld seam during the subsequent main welding process. Techniques for achieving single-point welding include, but are not limited to: resistance spot welding, single-point laser welding, single-point micro-arc welding, etc.

[0032] Multi-point welding

[0033] Multi-point welding refers to the process of performing single-point welding operations continuously or intermittently at multiple different locations on a workpiece to form multiple discrete welded joints. In this invention, multi-point welding is used to set multiple temporary fixing points along the length of the prefabricated welding wire to more effectively constrain the overall shape of the welding wire and prevent it from bending, twisting, or shifting as a whole during handling or in the main welding heat field.

[0034] Spot welding / resistance spot welding (RSW)

[0035] A typical method of single-point welding belongs to pressure resistance welding. The workpiece (or the workpiece and welding wire) is pressed together at a local contact point using electrodes, and a large instantaneous current is applied. The Joule heat generated by the contact resistance melts the metal at that point, which then solidifies under pressure to form a weld nugget. In this invention, spot welding is a preferred technique for achieving "single-point welding" for temporary fixation.

[0036] Temporary Fixing

[0037] Pre-formed welding wire is a process used before the final main fusion welding process to temporarily and detachably position and connect a pre-formed welding wire to the workpiece weld bead using single-point welding, multi-point welding, or other mechanical methods. Its core purpose is to maintain the spatial position and pre-set shape of the pre-formed welding wire stable before the main welding begins. The temporary connection strength only needs to resist disturbances during handling and the heat start-up phase; it is not itself part of the final structural weld and will be completely melted, diluted, and integrated into the final continuous weld under the heat of the main welding.

[0038] This refers to welding wire that has been pre-processed (e.g., bent, stamped, 3D printed) before welding to achieve a shape that is essentially identical to the geometry (including length, curvature, and spatial orientation) of the target weld bead. Its shape matches the contour to be welded, aiming to achieve precise pre-positioning and targeting of the welding material.

[0039] Welding Seam Path

[0040] It refers to the planned path or area on the workpiece to be welded that needs to be fused together, defining the trajectory of the final continuous weld, which can be a straight line, a planar curve, or a three-dimensional spatial curve.

[0041] Energy Beam

[0042] This refers to a high-energy-density heat source used to perform the final fusion welding. In this invention, this includes, but is not limited to: laser beams, electron beams, plasma arcs, and high-energy-density electric arcs (such as TIG and PAW arcs). These heat sources are used to melt the pre-made welding wire and the base material together to form a continuous weld with a metallurgical bond.

[0043] Fixed Feature

[0044] This refers to specific physical or chemical features designed onto prefabricated welding wires to optimize the temporary fixing effect of "single-point welding" or "multi-point welding". Examples include: metal bosses (providing localized high contact pressure points), conductive coatings (such as copper plating to improve electrical contact), or pre-placed miniature resistive elements (as localized heat sources). These structures are designed to improve the efficiency and reliability of temporary fixing processes.

[0045] The terms "welding" should be interpreted broadly, and their specific meanings should follow the literal interpretations and specific implementation methods of mainstream drawing software such as UG, CAD, and SolidWorks. These terms are well known to those skilled in the art and do not require excessive interpretation. Therefore, they should not be construed as limitations on the present invention. They are merely for the purpose of simplifying the description of the present invention and do not indicate or imply that the device or component referred to must have a specific structure or specific orientation and operation.

[0046] It is also important to note that when using descriptive words such as "or" and " / ", it not only represents their individual applications, but also the applications of using them in combination.

[0047] The following specific embodiments describe specific embodiments of the present invention. Techniques, methods, and devices known to those skilled in the art may not be discussed in detail, but where appropriate, the described technical inventions, methods, and apparatus should be considered part of the specification. In all examples implemented and discussed herein, any specific values ​​should be interpreted as merely exemplary and not as limitations. Therefore, other exemplary embodiments may have different values.

[0048] See appendix Figure 1 Therefore, we can provide an example of a welding method and a specific embodiment of the welding preform:

[0049] A welding method, characterized by comprising the following steps:

[0050] (a) Provide a workpiece to be welded, the workpiece having a preset weld bead;

[0051] (b) Provide a pre-made welding wire, which is pre-processed into a shape substantially consistent with the geometry of the weld bead;

[0052] (c) The pre-made welding wire is placed on the weld bead of the workpiece, and the pre-made welding wire and the workpiece are temporarily fixed at at least one position by at least one resistance heat welding method selected from single-point welding or multi-point welding, resistance projection welding and micro arc stud welding or argon arc welding or laser welding or plasma welding, so as to constrain the spatial displacement and / or deformation of the pre-made welding wire during the subsequent melting process;

[0053] (d) Using at least one energy beam selected from laser beam, electron beam, plasma arc and high energy density electric arc, the workpiece and prefabricated welding wire processed in step (c) are melted and welded to melt the prefabricated welding wire and fill the weld bead to form a weld.

[0054] Furthermore, in step (c), the temporary fixing connection method is single-point welding or multi-point welding.

[0055] Furthermore, the temporary fixing is performed at multiple locations, and the multiple locations are spaced apart along the length direction of the prefabricated welding wire.

[0056] Furthermore, the distance between two adjacent temporary fixed positions is between 3mm and 60mm or between 60.00001mm and 120mm.

[0057] A welded preform, characterized in that it comprises:

[0058] The workpiece to be welded has a pre-set weld bead.

[0059] Pre-fabricated welding wire, which is pre-processed into a shape that is substantially consistent with the geometry of the weld bead and placed on the weld bead;

[0060] Furthermore, the prefabricated welding wire is connected to the workpiece by at least one resistance heat welding method selected from single-point welding or multi-point welding, resistance projection welding and micro arc stud welding or argon arc welding or laser welding or plasma spot welding. The connection is used to fix the position of the prefabricated welding wire before molten welding to suppress its unintended displacement and / or deformation during the molten process.

[0061] Furthermore, the prefabricated welding wire is connected to the workpiece through multiple discrete connection points, and the multiple discrete connection points are arranged in an array along the length direction of the prefabricated welding wire.

[0062] A prefabricated welding wire assembly for welding, characterized in that it comprises:

[0063] The prefabricated welding wire body is pre-processed into a shape that is substantially consistent with the geometry of the target weld bead; multiple fixing structures are disposed on the prefabricated welding wire body for temporarily fixing the prefabricated welding wire body to the weld bead of the workpiece to be welded during use by at least one of the following methods: single-point welding or multi-point welding, resistance projection welding and micro-arc stud welding or argon arc welding or laser welding or plasma spot welding, so as to maintain the spatial configuration stability of the prefabricated welding wire body during subsequent fusion welding process; wherein, the fixing structure is selected from at least one of metal bosses, conductive coatings and pre-placed micro-resistive elements.

[0064] Furthermore, the material of the pre-made welding wire is selected from at least one of the following: metals that are the same as the base material of the workpiece, alloys that are compatible with the base material of the workpiece, and composite welding wires with specific metallurgical functions.

[0065] Furthermore, the cross-sectional shape of the prefabricated welding wire is selected from at least one of circular, flat, rectangular, triangular, and irregular shapes that match the weld bead design.

[0066] Furthermore, the application path of the energy beam substantially coincides with the centerline of the preformed welding wire.

Claims

1. A welding method, characterized in that, Includes the following steps: (a) Provide a workpiece to be welded, the workpiece having a preset weld bead; (b) Provide a pre-made welding wire, which is pre-processed into a shape substantially consistent with the geometry of the weld bead; (c) The pre-made welding wire is placed on the weld bead of the workpiece, and the pre-made welding wire and the workpiece are temporarily fixed at at least one position by at least one resistance heat welding method selected from single-point welding or multi-point welding, resistance projection welding and micro arc stud welding or argon arc welding or laser welding or plasma welding, so as to constrain the spatial displacement and / or deformation of the pre-made welding wire during the subsequent melting process; (d) Using at least one energy beam selected from laser beam, electron beam, plasma arc and high energy density electric arc, the workpiece and prefabricated welding wire processed in step (c) are melted and welded to melt the prefabricated welding wire and fill the weld bead to form a weld.

2. The welding method according to claim 1, characterized in that, In step (c), the temporary fixing connection method is single-point welding or multi-point welding.

3. The welding method according to claim 1, characterized in that, The temporary fixing is performed at multiple locations, and the multiple locations are spaced apart along the length direction of the prefabricated welding wire.

4. The welding method according to claim 3, characterized in that, The distance between two adjacent temporary fixed positions is between 3mm and 60mm or between 60.00001mm and 120mm.

5. A welded precast component, characterized in that, include: The workpiece to be welded has a pre-set weld bead. Pre-fabricated welding wire, which is pre-processed into a shape that is substantially consistent with the geometry of the weld bead and placed on the weld bead; The pre-made welding wire is connected to the workpiece by at least one resistance heat welding method selected from single-point welding or multi-point welding, resistance projection welding and micro arc stud welding or argon arc welding or laser welding or plasma welding. The connection is used to fix the position of the pre-made welding wire before molten welding, so as to suppress its unexpected displacement and / or deformation during the molten process.

6. The welded preform according to claim 5, characterized in that, The prefabricated welding wire is connected to the workpiece through multiple discrete connection points, and the multiple discrete connection points are arranged in an array along the length direction of the prefabricated welding wire.

7. A prefabricated welding wire assembly for welding, characterized in that, include: The prefabricated welding wire body is pre-processed into a shape that is substantially consistent with the geometry of the target weld bead. Multiple fixing structures are disposed on the prefabricated welding wire body for temporarily fixing the prefabricated welding wire body to the weld bead of the workpiece to be welded during use by at least one of the following methods: single-point welding or multi-point welding, resistance projection welding and micro arc stud welding or argon arc welding or laser welding or plasma welding, so as to maintain the spatial configuration stability of the prefabricated welding wire body during subsequent fusion welding process; wherein, the fixing structure is selected from at least one of metal bosses, conductive coatings and pre-placed micro resistance sheets.

8. The welding method according to any one of claims 1-4, characterized in that, The material of the prefabricated welding wire is selected from at least one of the following: metals that are the same as the base material of the workpiece, alloys that are compatible with the base material of the workpiece, and composite welding wires with specific metallurgical functions.

9. The welded preform according to claim 5 or 6, characterized in that, The cross-sectional shape of the prefabricated welding wire is selected from at least one of circular, flat, rectangular, triangular, and irregular shapes that match the weld bead design.

10. The welding method according to any one of claims 1-4, characterized in that, The path of the energy beam is substantially coincident with the centerline of the prefabricated welding wire.

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