A double-wire composite welding device and method of welding with light beam swing coupling TIG arc

Abstract

The application belongs to the technical field of high-strength aluminum alloy welding, and discloses a double-wire composite welding device and a welding method of a light beam swing coupled TIG arc, which comprises a swing laser head, a TIG welding gun, a welding gun locking device, a wire feeding three-dimensional adjusting mechanism, a double-wire sliding groove adjusting mechanism, a clamping adjusting mechanism and a wire feeder fixing module. The TIG arc welding, double-wire filling technology and swing light beam control technology are combined to realize accurate optimization of the metallurgical structure of the high-strength aluminum alloy welding process and fundamentally inhibit solidification cracks. The application can realize stable forming, structure refinement and performance improvement of the high-strength aluminum alloy in a single process, and meets the demand of high-quality and high-efficiency manufacturing of high-performance aluminum alloy components in the fields of aviation and aerospace.

Description

Technical Field

[0001] This invention belongs to, but is not limited to, the field of high-strength aluminum alloy welding technology, and particularly relates to a dual-wire composite welding device and welding method for beam oscillation coupled with TIG arc. Background Technology

[0002] High-strength aluminum alloys (such as 2-series and 7-series aluminum alloys) have advantages such as low density, high strength, and good machinability, and are widely used in the aerospace field. Welding is a crucial basic process for manufacturing high-strength aluminum alloy components. However, during the fusion welding of high-strength aluminum alloys, the solidification of the molten pool usually produces coarse dendritic structures and severe solute segregation. Under the action of welding stress, the weld will crack along the grain boundaries, forming solidification cracks, which seriously impairs the mechanical properties of the welded joint.

[0003] Choosing the right filler material is crucial for welding high-strength aluminum alloys. In actual production, 4-series Al-Si welding wire is commonly used for welding high-strength aluminum alloys, mainly utilizing the "healing effect" of silicon to reduce the tendency for solidification cracking. Therefore, it is widely used in actual production. However, its strength is not high enough to meet the requirements of high-performance aerospace components. Patent CN202211105367.0 developed a stranded welding wire that can suppress solidification cracking in high-strength aluminum alloys. By selecting several heterogeneous welding wires and introducing microalloyed zirconium, the microstructure of the weld is refined to control the grain size, thereby suppressing solidification cracking. However, this composite welding wire is usually composed of several heterogeneous welding wires with large differences in melting point. When used with existing commercial welding machines in welding experiments, arc instability easily occurs, affecting welding quality. At the same time, the addition of flux increases the complexity of the welding wire preparation process, thus increasing cost and hindering the widespread use of the welding wire, affecting the high-quality and efficient welding of high-strength aluminum alloys.

[0004] Based on the above analysis, the urgent technical problems that need to be solved in the existing technology are:

[0005] Existing composite welding wires are usually composed of several heterogeneous welding wires with large differences in melting point. When used with existing commercial welding machines for welding experiments, arc instability is likely to occur, which affects the welding quality. At the same time, the addition of flux powder increases the complexity of the welding wire preparation process, thereby increasing the cost and hindering the promotion and use of welding wires, thus affecting the high-quality and high-efficiency welding of high-strength aluminum alloys. Summary of the Invention

[0006] To address the problems existing in the prior art, this invention provides a dual-wire composite welding device and welding method for beam oscillation coupled with TIG arc.

[0007] This invention is implemented as follows: a dual-wire composite welding device and method for TIG arc welding with oscillating laser beam coupling. The experimental device for oscillating laser beam-assisted TIG arc dual-wire welding mainly includes an oscillating laser head, a TIG welding torch, a welding torch locking device, a three-dimensional wire feeding adjustment mechanism, a dual-wire chute adjustment mechanism, a welding test plate, a clamping adjustment mechanism, a device back plate, a wire feeder mounting connection plate, a wire feeder fixing module, a wire feeder, welding wire, a transverse fixing plate, fixing screws, a TIG welding torch angle adjustment plate, a reinforcing beam, a welding torch locking mechanism, an adjustment connection module, a first adjusting screw, a first TIG welding torch locking plate, a second TIG welding torch locking plate, a second adjusting screw, a wire feed nozzle clamping block, a wire feed nozzle locking block, a wire feed nozzle angle adjustment plate, a chute limiting component, a wire feed nozzle, a connecting tongue plate, an adjusting copper shaft, an adjusting screw, a wire feed nozzle angle adjustment plate, an XZ axis connecting plate, a Z-axis slide, an X-axis adjusting screw, an X-axis slide, and a Z-axis adjusting screw.

[0008] Furthermore, the oscillating laser head is connected to the back plate of the device by screws, the wire feeder fixing module is also fixed to the back plate of the device by screws, the clamping and adjusting mechanism is connected to the side hole of the oscillating laser head by screws, the welding torch locking device is connected to the clamping and adjusting mechanism by screws, and the welding torch locking device is fixed to the TIG welding torch by internal locking and set screws. The wire feeding three-dimensional adjustment mechanism locks the TIG welding torch by the first adjusting screw and the second adjusting screw. The TIG welding torch with a diameter of 16~40mm can be locked by adjusting the screws.

[0009] Furthermore, the wire feeder fixing module includes a wire feeder mounting connection plate, a wire feeder, and welding wire. The welding wire is fed to the front end of the wire feeding nozzle by the wire feeder. The wire feeder is fixed to the wire feeder mounting connection plate by screws and nuts through its own holes.

[0010] Furthermore, the clamping and adjustment mechanism includes a horizontal fixing plate, fixing screws, a TIG welding torch angle adjustment plate, and a reinforcing beam. The horizontal fixing plate has a 0-10mm groove on its upper part and is fixed to the side of the swing laser head with screws. The two horizontal fixing plates are connected by two reinforcing beams in the middle. The TIG welding torch angle adjustment plate has four 0-20mm grooves. Screws pass through the grooves to fix the TIG welding torch angle adjustment to the horizontal fixing plate. At the same time, the TIG welding torch angle plate is provided with an angle adjustment groove of 15°-45°. The TIG welding torch angle plate is fixed together with the welding torch locking device by screws.

[0011] Furthermore, the welding torch locking device includes a welding torch locking mechanism and an adjustment connection module. The adjustment connection module has two threaded holes on each of its left and right sides, which are fixed to the TIG welding torch angle adjustment plate by screws. The welding torch locking mechanism has three 5mm sliding grooves, which are fixed to the adjustment connection module by screws. The TIG welding torch is fixed by tightening the screws on the side.

[0012] Furthermore, the three-dimensional wire feeding adjustment mechanism includes a first adjusting screw, a first TIG welding torch locking plate, a second TIG welding torch locking plate, a second adjusting screw, a connecting tongue plate, an adjusting copper shaft, an adjusting lead screw, a wire feeding nozzle angle adjusting plate, an XZ axis connecting plate, a Z-axis slide, an X-axis adjusting lead screw, an X-axis slide, and a Z-axis adjusting lead screw. The first adjusting screw is connected to the second TIG welding torch locking plate and the first TIG welding torch locking plate, and the second adjusting screw is connected to the first TIG welding torch locking plate and the second TIG welding torch locking plate. The first TIG welding torch locking plate is connected by screws. On the X-axis slide, the X-axis slide is connected to the XZ-axis connecting plate. The X-axis adjusting screw can adjust the relative position of the X-axis slide and the XZ-axis connecting plate. The Z-axis slide is connected to the XZ-axis connecting plate. The Z-axis adjusting screw can adjust the relative position of the Z-axis slide and the XZ-axis connecting plate. The Z-axis slide is connected to the wire feed nozzle angle adjusting plate by two screws. The adjusting copper shaft is fixed in the symmetrical hole position of the wire feed nozzle angle adjusting plate. The adjusting screw passes through the adjusting copper shaft and is connected to the connecting tongue plate by a thread. By rotating the adjusting screw, the angle between the connecting tongue plate and the TIG welding gun can be adjusted.

[0013] Furthermore, the dual-wire groove adjustment mechanism includes a wire feeding nozzle clamping block, a wire feeding nozzle locking block, a wire feeding nozzle angle adjusting plate, a groove limiting component, and a wire feeding nozzle. The groove limiting component has a threaded hole on its side, which is locked to the connecting tongue plate by a set screw. At the same time, the hole contained in the groove limiting component can also serve as a fixing hole for the wire feeding nozzle. The wire feeding nozzle angle adjusting plate is nested inside the groove limiting component and connected to the connecting tongue plate. The set screw can fix the wire feeding nozzle angle adjusting plate, the groove limiting component, and the connecting tongue plate together. The wire feeding nozzle angle adjusting plate has a groove with an angle of -45° to 45°. The wire feeding nozzle passes through the inside of the wire feeding nozzle clamping block and is locked by a set screw. The wire feeding nozzle clamping block passes through the groove of the wire feeding nozzle angle adjusting plate and is connected to the wire feeding nozzle locking block by a nut. Tightening the nut achieves fixation on the groove.

[0014] Furthermore, a welding test plate is provided below the oscillating laser head and the TIG welding torch.

[0015] Furthermore, the welding torch locking device is adjustable in relative position to the TIG welding torch in the Z-axis direction.

[0016] Furthermore, the relative position of the wire feeding three-dimensional adjustment mechanism and the TIG welding torch in the Z-axis direction is adjustable, while the adjustable range in the X-axis direction is 0~20mm, and the angle between the dual-wire groove adjustment mechanism and the TIG welding torch is adjustable in the range of 15°~60°.

[0017] Furthermore, the two wire feeding nozzles are adjustable within a plane range of -45° to 45°, which enables stable dual-wire feeding.

[0018] Based on the above technical solutions and the technical problems solved, the advantages and positive effects of the technical solution to be protected by this invention are as follows:

[0019] (1) To fundamentally solve the problem of arc instability caused by composite welding wire and achieve high-quality and high-efficiency welding.

[0020] Stable arc and controllable process: This invention abandons the complex form of mechanically combining multiple heterogeneous wires and uses two independent solid welding wires for feeding. Two independent TIG arcs melt the two types of welding wires separately, fundamentally avoiding the problems of single-arc disturbance, drift, and instability caused by differences in melting point, resistivity, and melting characteristics of heterogeneous materials. The independent and adjustable energy input of the dual arcs ensures good stability and repeatability of the welding process, laying the foundation for obtaining high-quality, defect-free welds.

[0021] Simplified welding wire preparation and significantly reduced costs: This invention directly uses mature commercial solid welding wire, eliminating the need for complex secondary processing such as stranding and coating with flux. This greatly simplifies the welding wire preparation process, reduces raw material and manufacturing costs, and solves the core defects of composite welding wire described in patent CN202211105367.0, which are "complex to prepare, costly, and not conducive to promotion," making this technology have the potential for large-scale industrial application.

[0022] (2) Achieve flexible and precise in-situ synthesis of alloy composition, breaking through the limitations of single welding wire performance.

[0023] Flexible and adjustable composition, customizable performance: The dual-wire system allows for the combination of welding wires with varying compositions. The two metals mix and react thoroughly within the molten pool, achieving "in-situ synthesis" of the alloy composition. By precisely controlling the feed rate ratio of the two welding wires, the final chemical composition of the deposited metal can be infinitely adjusted, enabling precise customization of performance targets from "high crack resistance" to "high strength and high toughness," overcoming the limitations of insufficient strength in traditional 4-series Al-Si welding wires.

[0024] Synergistic effect and performance optimization: The stirring effect of the oscillating beam ensures the uniform distribution of heterogeneous elements in the molten pool and avoids compositional segregation. This allows the "healing effect" of Si and the "grain refinement / precipitation strengthening effect" of elements such as Zr to work synergistically, ultimately achieving comprehensive mechanical properties with both excellent crack resistance and high strength and high toughness.

[0025] (3) The device has obvious structural advantages, high integration and wide applicability.

[0026] Modular design, easy to integrate and promote: This device integrates the TIG arc system, beam oscillation system, and dual-wire feed system into one compact structure with clearly defined functions. Each module (such as the oscillating laser head and TIG welding torch) is a mature commercial product, which is easy to obtain and integrate into existing automated welding equipment, and the technology transfer threshold is low.

[0027] Highly adaptable welding capabilities: This device is suitable for welding traditional high-strength aluminum alloys. Its stable dual arc and adjustable oscillating thermal field enable high-efficiency, low-defect manufacturing of large-size, complex structural components, providing a brand-new solution for the short-cycle, low-cost development and production of high-performance aluminum alloy components in the aerospace field.

[0028] (4) The expected benefits and commercial value of the technical solution of this invention after transformation are as follows:

[0029] Driving the Upgrading of Aerospace Manufacturing Technology: This invention directly addresses the technical bottlenecks in high-strength aluminum alloy welding in the aerospace field—solidification cracking and insufficient strength and toughness. Its successful application will achieve a qualitative leap in the performance of high-strength aluminum alloy welded joints, meeting the stringent requirements of next-generation aircraft and launch vehicles for lightweight structures, high reliability, and long service life, and providing core process support for the independent manufacturing of high-end equipment in my country.

[0030] Driving the development of the welding materials and equipment industry chain: Activating the high-end welding wire market will significantly increase the demand for high-performance single-component micro-alloyed welding wires (such as Al-Zr and Al-Sc welding wires), promoting the upgrading and development of the upstream welding wire materials industry. Fostering new welding equipment: This invention will promote the research and development and production of multifunctional and intelligent integrated welding equipment, opening up new high-end markets for domestic welding equipment manufacturers and enhancing their international competitiveness.

[0031] Significant economic benefits: Reduced costs – the use of low-cost solid welding wire instead of expensive customized composite welding wire directly lowers raw material costs. Improved process stability reduces scrap and rework rates, increasing production efficiency and product qualification rates. Value creation – by enabling rapid, low-cost welding of high-performance components, product development cycles can be shortened, enabling small-batch, personalized customized production and creating high added value.

[0032] Promoting Green Manufacturing and Sustainable Development: This invention reduces energy and material consumption caused by rework due to defects by improving the first-pass yield of welding quality. Furthermore, the high-quality and efficient welding technology itself is a near-net-shape forming technology, with material utilization far exceeding that of traditional "subtractive manufacturing," aligning with the national strategy of green and sustainable development. Attached Figure Description

[0033] Figure 1This is an overall structural diagram of a dual-wire composite welding device and welding method for beam oscillation coupling TIG arc provided in an embodiment of the present invention;

[0034] Figure 2 This is a structural diagram of the welding torch locking device, the wire feeding three-dimensional adjustment mechanism, and the double-wire chute adjustment mechanism of a double-wire composite welding device and welding method for beam oscillation coupling TIG arc provided in an embodiment of the present invention.

[0035] Figure 3 This is a structural diagram of the clamping and adjustment mechanism of a double-wire composite welding device and welding method for beam oscillation coupling TIG arc provided in an embodiment of the present invention;

[0036] Figure 4 These are surface and cross-sectional morphology diagrams of an actual welded component of a dual-wire composite welding device and welding method for beam oscillation coupled with TIG arc provided in this embodiment of the invention.

[0037] Figure 5 These are the test results of the mechanical properties of the joint provided in the embodiments of the present invention;

[0038] In the diagram: 1. Oscillating laser head; 2. TIG welding torch; 3. Welding torch locking device; 4. Wire feeding three-dimensional adjustment mechanism; 5. Double wire chute adjustment mechanism; 6. Welding test plate; 7. Clamping adjustment mechanism; 8. Device back plate; 9. Wire feeder mounting connection plate; 10. Wire feeder fixing module; 11. Wire feeder; 12. Welding wire; 13. Horizontal fixing plate; 14. Fixing screw; 15. TIG welding torch angle adjustment plate; 16. Reinforcing crossbeam; 17. Welding torch locking mechanism; 18. Adjustment connection module; 19. First adjustment... 20. First TIG welding torch locking plate; 21. Second TIG welding torch locking plate; 22. Second adjusting screw; 23. Wire feed nozzle clamping block; 24. Wire feed nozzle locking block; 25. Wire feed nozzle angle adjusting plate; 26. Slide limiter; 27. Wire feed nozzle; 28. Connecting tongue plate; 29. ​​Adjusting copper shaft; 30. Adjusting screw; 31. Wire feed nozzle angle adjusting plate; 32. XZ axis connecting plate; 33. Z axis slide; 34. X axis adjusting screw; 35. X axis slide; 36. Z axis adjusting screw. Detailed Implementation

[0039] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0040] like Figure 1 , Figure 2 and Figure 3As shown, the present invention provides a dual-wire composite welding device and welding method for beam oscillation coupled with TIG arc, including an oscillating laser head 1, a TIG welding torch 2, a welding torch locking device 3, a wire feeding three-dimensional adjustment mechanism 4, a dual-wire chute adjustment mechanism 5, a clamping adjustment mechanism 7, and a wire feeder fixing module 10.

[0041] The oscillating laser head 1 is connected to the device back plate 8 by screws, and the wire feeder fixing module 10 is also fixed to the device back plate 8 by screws. The two wire feeders 11 can feed welding wire 12 in the same direction or in different directions. The wire feeding mounting connecting plate 9 is connected to the four threaded holes of the device back plate 8 by screws. There are two threaded holes on each side of the oscillating laser head 1, and the clamping adjustment mechanism is connected through the threaded holes. The welding gun locking device 3 adjusts the tightness of the clamping by adjusting screws. At the same time, there are threaded holes on the side, and the TIG welding gun 2 is locked by set screws. The wire feeding three-dimensional adjustment mechanism locks the TIG welding gun 2 by simultaneously adjusting the first adjusting screw 19 and the second adjusting screw 22. The TIG welding gun 2 with a diameter of 37.5mm is locked by adjusting the screws.

[0042] The wire feeder fixing module 10 includes a wire feeder mounting connection plate 9, a wire feeder 11, and a welding wire 12. The welding wire 12 is fed to the front end of the wire feeding nozzle 27 by the wire feeder 11. The wire feeder 11 is fixed to the wire feeder mounting connection plate 9 by screws and nuts through its own holes.

[0043] The clamping and adjusting mechanism 7 includes a transverse fixing plate 13, fixing screws 14, a TIG welding torch angle adjusting plate 15, and a reinforcing beam 16. The transverse fixing plate 13 has a 0-10mm groove on its upper surface and is fixed to the side of the oscillating laser head 1 with screws. This transverse groove allows for changes in the relative position of the TIG welding torch 2 and the oscillating laser head 1, and also prevents positional interference when the protective shield of the welding head is removed. The two transverse fixing plates 13 are connected by two reinforcing beams 16. The TIG welding torch angle adjusting plate 15... There are four 0~20mm grooves on it. The purpose of the grooves is to compensate for the displacement difference between the laser oscillating welding head 1 and the TIG welding torch 2 due to the angle change, and further improve the adaptability of the device. The screw passes through the groove to fix the TIG welding torch angle adjustment 15 to the horizontal fixing plate 13. At the same time, the TIG welding torch angle plate 15 is provided with an angle adjustment groove of 15°~45°. In this embodiment, the included angle between the laser oscillating welding head and the TIG welding torch is 20°. The TIG welding torch angle plate 15 and the welding torch locking device 3 are fixed together by screws.

[0044] The welding torch locking device 3 includes a welding torch locking mechanism 17 and an adjustment connection module 18. The adjustment connection module 18 has two threaded holes on each of its left and right sides, which are fixed to the TIG welding torch angle adjustment plate 15 by screws. Since the laser is reflected and emitted from the front end of the laser oscillating welding head 1, the laser may not be at the center of the structure. Therefore, the welding torch locking mechanism 17 is provided with three 5mm sliding grooves. In order to ensure the stability of the combined action of laser and electric arc, the welding torch locking mechanism 17 is fixed to the adjustment connection module 18 by three screws. A part of the welding torch locking mechanism 17 is cut off, and a threaded hole is provided at the cross-section. A through hole is provided on the other side. The screw passes through the through hole and connects to the threaded hole. The clamping force is adjusted by adjusting the depth of the screw entering the threaded hole, thereby achieving fixation with the TIG welding torch 2.

[0045] The three-dimensional wire feeding adjustment mechanism 4 includes a first adjusting screw 19, a first TIG welding torch locking plate 20, a second TIG welding torch locking plate 21, a second adjusting screw 22, a connecting tongue plate 28, an adjusting copper shaft 29, an adjusting lead screw 30, a wire feeding nozzle angle adjusting plate 31, an XZ axis connecting plate 32, a Z-axis slide 33, an X-axis adjusting lead screw 34, an X-axis slide 35, and a Z-axis adjusting lead screw 36. The first adjusting screw 19 and the second adjusting screw can adjust the second TIG welding torch locking plate 21 and the first TIG welding torch locking plate 20 by adjusting the depth of the screw entering the threaded hole. The relative position of the IG welding torch locking plate 20 enables the fixing of TIG welding torches 2 with diameters ranging from 16 to 40 mm. This fixing method allows the TIG welding torch 2 and the wire feeding three-dimensional adjustment mechanism 4 to be adjusted arbitrarily in the Z-axis direction, ensuring that the lower welding wire 12 can interact well with the TIG welding torch 2. The first TIG welding torch locking plate 20 is connected to the X-axis slide 35 by screws. The X-axis slide 35 is connected to the XZ-axis connecting plate 32. The X-axis adjusting screw 34 can adjust the relative position of the X-axis slide 35 and the XZ-axis connecting plate 32. In this embodiment, the first TIG welding torch locking plate 20 is connected to the X-axis slide 35. Therefore, when the size of the TIG welding torch 2 changes, the lower mechanism is on the same plane as the TIG welding torch 2, requiring adjustment of the X-axis displacement to ensure that the lower mechanism and the TIG welding torch 2 are on the same plane as the welding direction. The Z-axis slide 33 is connected to the XZ-axis connecting plate 32. The Z-axis adjusting screw 36 can adjust the relative position of the Z-axis slide 33 and the XZ-axis connecting plate 32, avoiding insufficient Z-axis adjustment space due to interference from the upper mechanical structure. The Z-axis slide 33 can be adjusted within the range of 0~20mm. The Z-axis slide 33 is connected to the wire feed nozzle angle adjustment plate 31 by two screws. The adjusting copper shaft 29 is fixed in the symmetrical hole position of the wire feed nozzle angle adjustment plate 31. The adjusting screw 30 passes through the adjusting copper shaft 29 and is connected to the connecting tongue plate 28 by a thread. By rotating the adjusting screw 30, the connecting tongue plate 28 can be rotated along the lower fixed axis, which can achieve an adjustment of 15~60°. The angle used in this embodiment is 20°, that is, the angle between the wire feed nozzle 27 and the TIG welding gun is 70°.

[0046] The dual-wire groove adjustment mechanism 5 includes a wire feeding nozzle clamping block 23, a wire feeding nozzle locking block 24, a wire feeding nozzle angle adjusting plate 25, a groove limiting member 26, and a wire feeding nozzle 27. The groove limiting member 26 has a threaded hole on its side, which is locked to the connecting tongue plate 28 by a set screw. The hole in the groove limiting member 26 can also serve as a fixing hole for the wire feeding nozzle 27. Therefore, theoretically, this embodiment can fix three wire feeding nozzles. The wire feeding nozzle angle adjusting plate 25 is nested inside the groove limiting member 26 and connected to the connecting tongue plate 28. The set screw can fix the wire feeding nozzle angle adjusting plate 25, the groove limiting member 26, and the connecting tongue plate 28 together. One end of the groove limiting member 26 is a curved surface with the same curvature as the wire feeding nozzle angle adjusting plate 25, and the other end is a flat surface. Thus, the wire feeding nozzle angle... The adjusting plate 25 fits well with the slide groove limiting member 26. To prevent the wire feeding nozzle angle adjusting plate 25 from sliding within the slide groove limiting member 26, it has a threaded hole in the center to ensure good symmetry of the installation position. The wire feeding nozzle angle adjusting plate 25 is provided with a slide groove of -45° to 45°. In this embodiment, a fixed position of 30° on each side is used. The wire feeding nozzle 27 passes through the inside of the wire feeding nozzle clamping block 23 and is locked by a set screw. The wire feeding nozzle clamping block 23 passes through the slide groove of the wire feeding nozzle angle adjusting plate 25 and is connected to the wire feeding nozzle locking block 24 by a nut. The wire feeding nozzle clamping block 23 protrudes 0.5mm after passing through the slide groove, while the wire feeding nozzle locking block 24 has a 1mm groove in the middle. Therefore, by tightening the nut, the two fixing members can be tightly connected and fixed on the wire feeding nozzle angle adjusting plate 25.

[0047] The core working principle of the oscillating beam-assisted TIG arc double-wire welding device of the present invention is to integrate TIG arc welding, double-wire filling technology and oscillating beam control technology to achieve precise optimization of the metallurgical structure of high-strength aluminum alloy welding process and fundamentally suppress solidification cracks.

[0048] First, the TIG arc-dual-wire feed system serves as the core of metal melting and filling. The centrally located TIG welding torch generates a stable burning arc, acting as the primary heat source for melting the welding wire and the substrate. Two welding wires with different compositions—one Al-Si wire and the other a special wire containing microalloying elements such as Zr—are precisely fed into the arc and molten pool area at a specific angle through symmetrically arranged wire feed guides. The wire feed system is equipped with a precise straightening and clamping mechanism to ensure that both welding wires remain straight before entering the arc zone, resulting in a smooth and interference-free wire feed process, laying the foundation for the uniformity of the deposited metal composition.

[0049] Secondly, the oscillating beam system acts as a dynamic controller for the weld pool. A high-energy-density beam (such as a laser) is guided to the weld pool through an oscillating module integrated with the TIG welding torch. This module drives the beam to scan at high speed along a preset path, frequency, and amplitude. The oscillation of the beam has a crucial dual effect on the weld pool: firstly, it acts as an auxiliary heat source, broadening and homogenizing the thermal field distribution and delaying the cooling and solidification of the weld pool; secondly, the strong electromagnetic hydrodynamic effect it generates violently stirs the weld pool, effectively breaking up growing coarse dendrites and creating favorable conditions for heterogeneous nucleation, thereby significantly refining the grains.

[0050] The synergistic effect of the TIG arc and the oscillating beam is key to the high-performance manufacturing achieved by this device. The TIG arc, with its gentle and stable heat input, simultaneously melts two dissimilar welding wires, allowing elements such as silicon (Si) and zirconium (Zr) to undergo sufficient in-situ metallurgical reactions within the molten pool, achieving flexible alloy composition adjustment. Simultaneously, the intervention of the oscillating beam not only eliminates the nucleation sites of solidification cracks by refining the grains but also relaxes welding stress by optimizing the temperature gradient. This synergistic mode of "arc-powered cladding - beam-controlled microstructure" jointly creates a weld layer with uniform composition, fine microstructure, and optimized stress state.

[0051] Finally, the integrated and protective design of the entire system ensures the stability and reliability of the process. The device adopts a modular design, compactly integrating the TIG main gun, beam oscillator, and dual wire feed mechanism. To ensure the long-term stable operation of optical components in the harsh welding environment, the system is equipped with positive pressure air curtain protection and forced water cooling channels. The air curtain forms a clean barrier, effectively isolating metal vapor and splashes; the water cooling system ensures that the optical lenses and welding gun body are not damaged by overheating.

[0052] Through this complete "arc-beam-dual-wire" composite welding system, the present invention can simultaneously achieve stable forming, microstructure refinement and performance improvement of high-strength aluminum alloys in a single process, meeting the needs of aerospace and other fields for high-quality and efficient manufacturing of high-performance aluminum alloy components.

[0053] The experimental device for oscillating beam-assisted TIG arc double-wire welding provided in this embodiment of the invention connects oscillating laser welding, TIG welding torch, and double filler wire welding. It achieves a good combined effect of efficient heat source by using lightweight design components. Furthermore, the design of various adjustment components significantly improves the adaptability of the equipment and ensures the stability and efficiency of the welding process.

[0054] I. Specific application areas or related products of this invention.

[0055] 1. Example 1: Welding of high-strength aluminum alloy load-bearing components for aerospace applications

[0056] In the aerospace field, the pursuit of ultimate lightweight and performance integration has led to the development of numerous aluminum alloy components with complex internal cavities, thin walls, or lattice structures. These components are traditionally manufactured using a "split casting + machining + welding assembly" process, which is cumbersome, time-consuming, and results in low material utilization. Furthermore, the joints are prone to becoming weak points in performance. This is especially true for high-strength aluminum alloys such as 2-series and 7-series alloys, where solidification cracks are highly likely to occur during welding, leading to overall component failure. The oscillating beam-assisted TIG arc dual-wire welding device of this invention simultaneously melts ER2319 aluminum alloy welding wire and a specially designed zirconium (Zr) grain-refining welding wire using a TIG arc, combined with active oscillating stirring of the high-energy laser beam in the molten pool region, achieving excellent metallurgical control during the layer-by-layer deposition process. The ER2319 welding wire provides an aluminum-copper alloy system that matches the matrix, ensuring fundamental mechanical properties. The introduction of Zr acts as a highly efficient nucleating agent, synergistically enhancing the effect with the stirring action of the oscillating beam. This transforms the solidification structure of the weld metal from coarse columnar crystals to uniform, fine equiaxed crystals, fundamentally eliminating the conditions for solidification crack formation. This device successfully solves the problem of hot cracking sensitivity in welding high-strength aluminum alloys. The manufactured complex components have dense internal quality and are free of cracks. Their strength, toughness, and fatigue performance all meet the stringent requirements of aerospace, providing reliable technical support for the rapid development and high-performance overall manufacturing of key components.

[0057] 2. Example 2: Repair and remanufacturing of high-performance racing car aluminum alloy chassis structure

[0058] In the field of high-end racing car manufacturing and maintenance, high-quality repair of key structural components such as aluminum alloy chassis after impact or wear is a major challenge. The repaired area must restore or even exceed its original mechanical properties, and the repair process must have good accessibility to adapt to complex structures. The oscillating beam-assisted TIG arc dual-wire welding device of this invention, with its compact integrated design, can flexibly and precisely repair cracks or wear areas on the chassis. By selecting a welding wire that matches the base material and a second welding wire containing a special grain refiner, under the synergistic effect of the TIG arc and the oscillating beam, deposited metal with ultra-fine grains can be synthesized in situ in the repair area. This method not only significantly reduces the tendency for hot cracking in the repair area, but also greatly improves the strength and fatigue performance of the repaired part, ensuring the structural integrity and safety of the racing car chassis under extreme conditions, and realizing high-performance, long-life remanufacturing of high-value components.

[0059] II. Evidence related to the technical effects obtained by the embodiments of the present invention.

[0060] Figure 4This invention relates to the application of a dual-wire composite welding device and method for beam oscillation coupled with TIG arc in aluminum alloy welding. In the welding of 10mm aluminum alloy, the process parameters are: laser power 10000W, welding speed 10mm / s, oscillation amplitude 1.5mm, frequency 300Hz, and wire feed speed 0.5m / min. This method can produce aluminum alloy welds with good surface formation, significantly reduced internal porosity, and an average tensile strength of 276MPa, reaching 64% of the tensile strength of the base material.

[0061] It should be noted that embodiments of the present invention can be implemented in hardware, software, or a combination of both. The hardware portion can be implemented using dedicated logic; the software portion can be stored in memory and executed by a suitable instruction execution system, such as a microprocessor or dedicated-design hardware. Those skilled in the art will understand that the above-described devices and methods can be implemented using computer-executable instructions and / or included in processor control code, for example, such code provided on a carrier medium such as a disk, CD, or DVD-ROM, a programmable memory such as read-only memory (firmware), or a data carrier such as an optical or electronic signal carrier. The devices and modules of the present invention can be implemented by hardware circuitry such as very large-scale integrated circuits or gate arrays, semiconductors such as logic chips, transistors, or programmable hardware devices such as field-programmable gate arrays, programmable logic devices, etc., or by software executed by various types of processors, or by a combination of the above-described hardware circuitry and software, such as firmware.

[0062] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any modifications, equivalent substitutions, and improvements made by those skilled in the art within the scope of the technology disclosed in the present invention, and within the spirit and principles of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A dual-wire composite welding device and welding method for beam oscillation coupled with TIG arc, characterized in that, Includes a oscillating laser head, a TIG welding torch, a welding torch locking device, a three-dimensional wire feeding adjustment mechanism, a dual-wire chute adjustment mechanism, and a welding test plate; The oscillating laser head is arranged coaxially with the TIG welding torch. The oscillating laser head is used to form a controllable oscillating auxiliary beam in the TIG arc action zone. The welding torch locking device is fixedly connected to the clamping and adjusting mechanism to lock the angle and position of the TIG welding torch. The three-dimensional wire feeding adjustment mechanism is mounted on the back plate of the device and is used to precisely adjust the relative position between the wire feeding nozzle and the TIG welding torch in the X and Z axis directions. The dual-wire groove adjustment mechanism is connected to the three-dimensional wire feeding adjustment mechanism, and is used to realize the synchronous adjustment of the angle of the two wire feeding nozzles in the same plane, so as to maintain the stability of the dual wires entering the arc. The welding test plate is placed in the welding area below the oscillating laser head and the TIG welding torch.

2. The apparatus as claimed in claim 1, characterized in that, The three-dimensional adjustment mechanism for wire feeding includes a wire feeder, a wire feeder mounting plate, and a wire feeder fixing module. The welding wire is fed to the front end of the wire feeding nozzle via the wire feeder. The wire feeder is fixed to the wire feeder mounting plate by screws and nuts to achieve continuous and stable output of the welding wire.

3. The apparatus as described in claim 1, characterized in that, The clamping and adjusting mechanism includes a horizontal fixing plate, fixing screws, a welding torch angle adjusting plate, and a reinforcing beam. The horizontal fixing plate is provided with a 10 mm long sliding groove, and the welding torch angle adjusting plate is provided with an angle adjusting sliding groove in the range of 15° to 45°. The TIG welding torch angle is adjustable by connecting screws.

4. The apparatus as claimed in claim 1, characterized in that, The welding torch locking device includes a welding torch locking mechanism and an adjustment connection module. The adjustment connection module has threaded holes on its left and right sides to be fixed with the welding torch angle adjustment plate. The welding torch locking mechanism has three 5 mm sliding grooves, and reliable locking with the TIG welding torch is achieved by tightening the screws.

5. A three-dimensional wire feeding adjustment mechanism, characterized in that, It includes a first adjusting screw, a second adjusting screw, a first welding gun locking plate, a second welding gun locking plate, an X-axis slide, a Z-axis slide, an adjusting screw, and an XZ-axis connecting plate; The first and second welding torch locking plates are respectively connected to the welding torch via the first adjusting screw and the second adjusting screw; The X-axis slide and the Z-axis slide are connected by an XZ-axis connecting plate. By rotating the X-axis adjusting screw and the Z-axis adjusting screw, the relative position between the welding torch and the wire feed nozzle in the X-axis and Z-axis directions can be adjusted respectively, achieving fine adjustment within the range of 0 to 20 mm.

6. The three-dimensional wire feeding adjustment mechanism as described in claim 5, characterized in that, The Z-axis slide is connected to a wire feed nozzle angle adjustment plate. The adjustment screw passes through the adjustment copper shaft and is threadedly connected to the connecting tongue plate. By rotating the adjustment screw, the included angle between the wire feed nozzle and the TIG welding gun can be precisely adjusted.

7. A double-wire sliding groove adjustment mechanism, characterized in that, Includes wire feed nozzle clamping block, wire feed nozzle locking block, wire feed nozzle angle adjusting plate, slide groove limiter and wire feed nozzle; The slide rail limiting component is fixed to the connecting tongue plate by a set screw and is provided with a thread feed nozzle fixing hole; The wire feeding nozzle angle adjustment plate is embedded in the slide groove limiter, and the wire feeding nozzle clamping block passes through the slide groove of the adjustment plate and is connected to the wire feeding nozzle locking block by a nut. The angle of the wire feed nozzle can be changed within the range of -45° to 45° by adjusting the nut, so as to achieve matching of the wire feeding directions of the two wires.

8. The double-wire slide adjustment mechanism as described in claim 7, characterized in that, The two wire feed nozzles are located in the same plane and their angle can be adjusted within the range of -45° to 45°. When the two wires enter the arc, they form a symmetrical and stable metal droplet transition.

9. A system for coordinated adjustment of a oscillating beam and a TIG welding torch, characterized in that, Includes a wobbling laser head, a TIG welding torch, and an angle adjustment assembly; The oscillating laser head and the optical axis of the TIG welding torch are arranged parallel to each other in the Z-axis direction. The angle adjustment component is used to adjust the angle between the TIG welding torch and the laser optical axis, with an adjustment range of 15° to 60°. The beam output by the oscillating laser head acts on the TIG arc zone at a set oscillation frequency, achieving dual-energy field coupling welding formation.

10. The collaborative system as described in claim 9, characterized in that, The beam output by the oscillating laser head intersects with the TIG arc to form a stable molten pool. Combined with the three-dimensional adjustment mechanism described in claim 5 and the chute adjustment mechanism described in claim 7, real-time coordinated control of the wire feeding angle, arc entry distance, and molten pool temperature field can be achieved, thereby improving the interlayer bonding strength and surface quality of the metal forming.

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