Aluminum alloy welding wire production process with excellent wire feeding performance

Abstract

The application provides an aluminum alloy welding wire production process with excellent wire feeding performance, which comprises the following steps: sequentially subjecting an aluminum alloy rod blank to multi-pass drawing and chemical polishing, cleaning, drying and winding to obtain the aluminum alloy welding wire with excellent wire feeding performance, wherein the drawing process is carried out in a complex water-based drawing liquid, and two chemical polishing tanks are arranged in the chemical polishing, wherein the tank liquid in the first chemical polishing tank is a complex alkaline cleaning liquid, and the tank liquid in the second chemical polishing tank is a complex chemical plating film liquid. The process optimizes the drawing, introduces the chemical polishing, strengthens the cleaning and the precise layer winding, and solves the wire feeding problem systematically through the synergistic effect of the multiple links.

Description

Technical Field

[0001] This invention belongs to the field of welding wire production, and in particular relates to a production process for aluminum alloy welding wire with excellent wire feeding performance. Background Technology

[0002] With the popularization of automated and robotic welding technologies, the requirements for the comprehensive performance of welding wire are becoming increasingly stringent. Wire feeding performance is a key factor determining the efficiency and quality of automated welding. Currently, the production of aluminum alloy welding wire both domestically and internationally generally adopts the process route of "melting → ingot casting → extrusion / rolling → drawing → surface treatment → layer winding".

[0003] The existing technology mainly has the following problems: (1) High surface friction: The surface of welding wire produced by traditional drawing process has micro-scratches, burrs and oxide film, and the surface roughness is high. When passing through the wire feeding hose that is several meters long, a large friction will be generated, resulting in high wire feeding resistance, unstable speed, and even wire jamming and wire skipping, which seriously affects the stability of the arc; (2) Uneven stiffness of welding wire: Inaccurate control of the compression ratio and lubrication and cooling conditions during the drawing process leads to different degrees of work hardening, large fluctuations in hardness, and residual stress in the wire. This results in poor wire stiffness, which makes it prone to plastic bending deformation in the wire feeding tube, forming a "bird's nest" blockage and causing the welding process to be interrupted; (3) Defects in layer winding quality: The tension control of traditional layer winding machines is not precise, which leads to uneven arrangement of welding wires on the I-beams, resulting in crossover and overlapping (wire pressing) phenomena. During wire feeding, the welding wires interfere with each other, requiring additional release force, causing fluctuations in the load of the wire feeding motor and affecting the uniformity of the wire feeding speed.

[0004] To address these issues, the industry has attempted various methods, including improving drawing dies, using different lubricants, or performing simple mechanical polishing. However, these efforts have yielded unsatisfactory results and have failed to systematically and fundamentally resolve the problem. Therefore, developing a new production process that can comprehensively improve the wire feeding performance of aluminum alloy welding wire has significant industrial application value. Summary of the Invention In view of this, the present invention aims to overcome the deficiencies in the prior art and propose a production process for aluminum alloy welding wire with excellent wire feeding performance. This production process systematically solves the wire feeding problem through the synergistic effect of multiple steps, including optimized drawing, introduction of chemical polishing, enhanced cleaning, and precision layer winding.

[0005] To achieve the above objectives, the technical solution of the present invention is implemented as follows: A manufacturing process for aluminum alloy welding wire with excellent wire feeding performance includes the following steps: After the aluminum alloy rod blank is subjected to multiple drawing and chemical polishing processes, it is cleaned, dried, and wound to obtain an aluminum alloy welding wire with excellent wire feeding performance. The drawing process is carried out in a compound water-based drawing fluid, which is composed of the following components in weight percentage: 20%-25% lubricant, 5%-8% extreme pressure agent, 3%-5% first surfactant, 2%-4% antioxidant, 0.2%-0.5% defoamer, and the balance being deionized water; The chemical polishing process includes two chemical polishing tanks. The first chemical polishing tank contains a compound alkaline cleaning solution, and the second chemical polishing tank contains a compound chemical plating solution. The compound alkaline cleaning solution is composed of the following components by weight percentage: 3%-8% inorganic alkali, 2%-5% organic alkali, 1%-3% chelating agent, 2%-6% second surfactant, and the balance being deionized water. The compound chemical plating solution is composed of the following components by weight percentage: 10%-20% film-forming agent, 0.5%-2% corrosion inhibitor, 0.1%-1% pH adjuster, and the balance being deionized water.

[0006] Furthermore, the lubricant in the compound water-based drawing fluid is a long-chain fatty acid alcohol amide lubricant, the extreme pressure agent is selected from one or more of borate esters, phosphorus-containing extreme pressure agents, and polyester extreme pressure agents, the first surfactant is selected from one or more of fatty alcohol polyoxyethylene ethers, isomeric alcohol polyoxyethylene ethers, and alkylphenol polyoxyethylene ethers, the antioxidant is selected from one or more of benzotriazole derivatives, thiadiazole derivatives, and phenolic antioxidants, and the defoamer can be selected from one or more of silicone emulsions, polyether defoamers, and mineral oil defoamers.

[0007] Preferably, the long-chain fatty acid alcohol amide lubricant is selected from one or more of tall oleic acid diethanolamide, coconut oil diethanolamide, and oleic acid diethanolamide; the borate ester is one or two of nitrogen-containing borate ester and sulfur borate ester; the fatty alcohol polyoxyethylene ether is one or two of AEO-3 and AEO-9; the benzotriazole derivative is one or two of methylbenzotriazole and benzotriazole; and the silicone emulsion is one or two of polydimethylsiloxane emulsion and polyether-modified siloxane emulsion.

[0008] This compound system ensures a smooth drawing process through the synergistic effect of its components: the lubricant provides a basic lubricating film, the extreme pressure agent reacts with the metal surface under high temperature and pressure to form a chemically adsorbed film, and the two work together to form a high-strength boundary lubrication layer, significantly reducing the coefficient of friction; the surfactant reduces interfacial tension, allowing the drawing fluid to spread quickly and evenly, and assists in cooling; the antioxidant protects the surface of the welding wire and prevents oxidation and discoloration after processing; the defoamer effectively suppresses foam generated during high-speed drawing, ensuring stable coolant circulation. The coolant in this formulation must have good lubricity, cooling properties, anti-fouling properties, and easy cleaning properties to ensure a smooth drawing process, timely heat dissipation, and easy cleaning of surface residues after drawing, thereby obtaining a clean surface and uniform diameter intermediate welding wire.

[0009] Furthermore, in the compound alkaline cleaning solution, the inorganic base is selected from one or more of sodium carbonate, sodium bicarbonate, sodium silicate, and sodium metasilicate; the organic base is selected from one or more of triethanolamine, diethanolamine, monoethanolamine, and alkanolamine derivatives; the chelating agent is selected from one or more of sodium gluconate, sodium citrate, disodium EDTA, tetrasodium EDTA, and aminotrimethylenephosphonic acid; and the second surfactant is selected from one or more of alkyl glycosides, fatty alcohol polyoxyethylene ether carboxylates, and cocamidopropyl betaine.

[0010] Preferably, the alkyl glycoside is one or both of APG0810 and APG1214.

[0011] Preferably, the pH value of the compound alkaline cleaning solution is controlled at 7.5-8.5, the temperature is maintained at 60-80℃, preferably 65-75℃, and the contact time (reaction time) of the aluminum alloy billet in the compound alkaline cleaning solution is 15-60 seconds, preferably 25-40 seconds.

[0012] The synergistic effect of this compound system is as follows: the inorganic base and the organic base work together to effectively saponify and remove surface grease, and their buffering capacity can maintain pH stability and avoid excessive corrosion of the aluminum substrate; the chelating agent can complex and dissolve metal ions in the surface oxides, promoting efficient peeling of the oxide film; the second surfactant reduces the surface tension of the solution, enhances wetting and emulsifying ability, and evenly disperses the peeled dirt in the solution to prevent it from being re-adsorbed.

[0013] Preferably, the film-forming agent in the compound chemical plating solution is selected from one or more of ammonium fluorozirconate, potassium fluorozirconate, ammonium fluorotitanate, and potassium fluorotitanate; the corrosion inhibitor is selected from one or more of sodium molybdate, sodium tungstate, vanadate, and organophosphonic acid corrosion inhibitors; and the pH adjuster is selected from one or more of triethanolamine, sodium hydroxide, potassium hydroxide, and ammonia. Preferably, the pH value of the compound chemical plating solution is controlled at 7.5-8.5, and the temperature is maintained at 20-45℃, preferably 25-40℃; the contact time of the aluminum alloy billet in the compound chemical plating solution is 15-60 seconds, preferably 25-40 seconds.

[0014] The synergistic effect of this compound system is as follows: the film-forming agent, through a chemical conversion reaction on the aluminum surface, grows a dense and uniform nanoscale conversion film (such as a zirconium or titanium oxide film) in situ. This film has strong adhesion to the aluminum substrate, significantly reduces surface energy, and achieves a smoothing effect similar to "sealing holes." The corrosion inhibitor K fills microscopic defects in the film, further enhancing the film's density and corrosion resistance, while avoiding excessive reaction that could cause surface roughness. The pH adjuster ensures that the bath is maintained in the optimal weakly alkaline environment for aluminum welding wire production, achieving an optimal balance between film formation rate and film quality. This process, through controlled chemical corrosion and film formation reactions, effectively removes surface oxides, micro-burrs, and scratches, making the surface smooth and flat. Simultaneously, by forming a strong protective film on the welding wire surface, it further increases the uniformity of the welding wire surface and improves the wire feeding performance.

[0015] Synergistic effect of compound alkaline cleaning solution and compound chemical plating solution: The alkaline cleaning solution, through the synergistic effect of inorganic alkali, organic alkali, chelating agent and second surfactant, gently removes residual drawing oil, natural oxide film and impurities on the surface of aluminum welding wire, while achieving uniform weak etching of the aluminum substrate. It not only effectively removes micro burrs and fine scratches on the surface, but also forms a large number of uniformly distributed active reaction sites on the welding wire surface, providing stable "growth anchors" for the subsequent film formation reaction of the plating solution, avoiding problems such as local thinning of the film layer, insufficient adhesion or even peeling due to uneven surface conditions. After entering the coating process, the film-forming agent (such as ammonium fluorozirconate) in the compound chemical plating solution undergoes a controllable chemical transformation reaction at the active sites on the aluminum surface, growing a dense and uniform nanoscale zirconium or titanium conversion film in situ. This film layer has strong adhesion to the aluminum substrate, can significantly reduce surface energy, and achieve a smoothing effect similar to "sealing holes", while the corrosion inhibitor (such as sodium molybdate) preferentially fills the microscopic gaps in the film layer. The defects are further enhanced to improve the density and corrosion resistance of the film layer, while inhibiting the excessive reaction of the film-forming agent and avoiding surface roughness and uneven film layer caused by violent reaction. With the help of pH adjusters (such as triethanolamine), the bath is maintained in the optimal weakly alkaline environment for aluminum welding wire production, so that the film formation rate and film quality reach a dynamic optimal balance. The "activation pretreatment" of the cleaning solution and the "film formation protection" of the coating solution form a closed loop synergy. The cleaning solution removes surface impurities and uniformly activates the substrate, solving the problem of insufficient film adhesion caused by surface state differences in traditional processes. The dense protective film of the coating solution provides long-term protection for the active aluminum substrate exposed after cleaning, avoiding secondary oxidation. The combination of the two achieves the complete removal of surface oxides and micro-defects through controlled chemical corrosion and film formation reaction, making the welding wire surface smooth and flat. At the same time, the uniform and firm protective film improves the consistency and stability of the welding wire surface, fundamentally improving the wire feeding performance and ensuring the stability of the subsequent welding process.

[0016] Preferably, the compression rate of each drawing pass in the multi-pass drawing is controlled between 12% and 18%, and more preferably between 14% and 16%.

[0017] The present invention also provides an aluminum alloy welding wire with excellent wire feeding performance produced by the above-mentioned production process.

[0018] Compared with the prior art, the present invention has the following advantages: (1) The smooth surface obtained by chemical polishing in this invention greatly reduces the friction with the wire feeding hose, resulting in very low wire feeding resistance and significantly improved wire feeding smoothness; (2) The optimized drawing process of this invention ensures the uniformity of the welding wire hardness and low residual stress. The welding wire has good stiffness and is not prone to plastic bending in the hose, thus fundamentally avoiding the occurrence of blockage. (3) The process of the present invention improves the welding quality. Stable wire feeding means stable arc and droplet transfer, thereby reducing welding spatter, improving weld formation consistency, and comprehensively improving the production efficiency and product quality of automated welding. (4) The aluminum alloy welding wire prepared by this invention has excellent wire feeding performance and its core application is positioned in high-end fields with high requirements for welding process consistency and welding stability. It can be applied to the manufacturing of key structures such as high-speed rail vehicle bodies, integrated die-cast rear bodies of new energy vehicles, and battery trays. This technology is particularly suitable for intelligent production lines based on robotics and arc additive manufacturing, providing the underlying material foundation for the lightweighting, long life and high reliability of major equipment. Attached Figure Description

[0019] Figure 1 Photographs showing the surface quality of the aluminum alloy welding wire prepared in Example 1; Figure 2 Photographs showing the surface quality of the aluminum alloy welding wire obtained in Example 2; Figure 3 Photographs showing the surface quality of the aluminum alloy welding wire obtained in Example 3; Figure 4 Photographs showing the surface quality of the aluminum alloy welding wire prepared in Comparative Example 1. Figure 5 Photographs showing the surface quality of the aluminum alloy welding wire prepared in Comparative Example 2; Figure 6 Photographs showing the surface quality of the aluminum alloy welding wire prepared in Comparative Example 3; Figure 7 Photographs showing the surface quality of the aluminum alloy welding wire prepared in Comparative Example 4. Figure 8 Photographs showing the surface quality of the aluminum alloy welding wire prepared in Comparative Example 5. Figure 9 Photographs showing the surface quality of the aluminum alloy welding wire prepared in Comparative Example 6. Detailed Implementation

[0020] The embodiments of the present invention are described in detail below. The embodiments described below are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0021] In this document, unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains.

[0022] In this document, when values ​​are described as ranges, it should be understood that such disclosure includes disclosure of all possible subranges within that range, as well as the specific numerical values ​​falling within that range, regardless of whether the specific numerical value or specific subrange is explicitly specified.

[0023] In this article, the terms "multiple" or "more than" are used unless otherwise specified, referring to a quantity greater than or equal to 2. For example, "one or more" means one or more types.

[0024] In this document, the terms "preferred" and "more preferred" are used only to describe implementation methods or embodiments with better effects, and should be understood as not constituting a limitation on the scope of protection of this invention.

[0025] In this document, terms such as "further" are used for descriptive purposes to indicate differences in content, but should not be construed as limiting the scope of protection of this invention.

[0026] In this article, the term "and / or" describes an association between objects, indicating that three relationships can exist. For example, A and / or B means: A or B, or A and B.

[0027] In this document, the term "about" means a specified value of + / - 10%, preferably + / - 5%, and more preferably + / - 1%.

[0028] In this article, the terms “include,” “including,” “have,” “contain,” etc., are all open-ended terms, meaning that they include but are not limited to.

[0029] Unless otherwise stated, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art. While only preferred methods and materials have been described herein, any methods and materials similar to or equivalent to those described herein may be used in the implementation or testing of this invention.

[0030] A manufacturing process for aluminum alloy welding wire with excellent wire feeding performance includes the following steps: S1. Multi-pass optimized pull: The purpose of this step is to ensure dimensional accuracy and control work hardening and residual stress.

[0031] Aluminum alloy blanks conforming to standards (e.g., 9.5mm in diameter) are drawn in multiple passes using a series drawing machine to gradually reduce the diameter to the target size (e.g., 1.2mm). The compression rate of each pass is strictly controlled between 12% and 18% (preferably 14% to 16%). Simultaneously, a compound water-based drawing fluid specifically designed for aluminum alloy drawing is used. This compound water-based drawing fluid is composed of the following components by weight percentage: lubricant: 20%-25%, extreme pressure agent: 5%-8%, surfactant: 3%-5%, antioxidant: 2%-4%, defoamer: 0.2%-0.5%, with the balance being deionized water.

[0032] S2. Precision chemical polishing: The purpose of this step is to improve the surface quality of the welding wire and reduce surface roughness.

[0033] The drawn intermediate welding wire is passed continuously and at a constant speed through two chemical polishing tanks.

[0034] The bath solution in the first chemical polishing tank is a compound alkaline cleaning solution, composed of the following components by weight percentage: inorganic alkali: 3%-8%, organic alkali: 2%-5%, chelating agent: 1%-3%, secondary surfactant: 2%-6%, and the balance being water. The pH value of this cleaning solution is controlled at 7.5-8.5, the temperature is maintained at 60-80℃ (preferably 65-75℃), and the contact time (reaction time) of the welding wire in the bath solution is 15-60 seconds (preferably 25-40 seconds).

[0035] The second chemical polishing tank contains a compound chemical plating solution, composed of the following components by weight percentage: film-forming agent: 10%-20%, corrosion inhibitor: 0.5%-2%, pH adjuster: 0.1%-1%, with the remainder being water. The pH of this plating solution is controlled at 7.5-8.5, the temperature is maintained at 20-45℃ (preferably 25-40℃), and the contact time (reaction time) of the welding wire in the solution is 15-60 seconds (preferably 25-40 seconds).

[0036] S3. Deep cleaning and drying: The purpose of this step is to remove residual chemical polishing solution from the surface of the welding wire, prevent future corrosion, and ensure that the surface is absolutely dry.

[0037] After polishing, the welding wire first enters a clean water rinsing tank for initial washing. Then, it must enter an ultrasonic cleaning tank to utilize cavitation to thoroughly remove stubborn residues adhering to the surface. Finally, the welding wire is thoroughly dried in a high-temperature drying device (hot air circulating oven) at 100-150℃, resulting in a clean and dry finished product surface.

[0038] S4. Constant tension precision layer winding: The purpose of this step is to neatly and evenly wind the welding wire onto the spool, ensuring smooth wire feeding.

[0039] Precision winding equipment with a closed-loop tension control system is employed. Stable tension control during take-up, combined with a precision wire guide, ensures the welding wire is neatly arranged on the spool, without crossing or wire compression. The winding speed is synchronized with the speeds of the preceding processes. Constant tension precision winding ensures a perfect wire coil shape, minimal and constant release force during unwinding, and a stable wire feed speed, thereby guaranteeing arc stability and the continuity of the welding process. The present invention will be described in detail below with reference to the embodiments.

[0040] Example 1 A manufacturing process for aluminum alloy welding wire with excellent wire feeding performance includes the following steps: S1. An aluminum alloy rod blank with a diameter of 9.5 mm is gradually reduced to an intermediate welding wire with a diameter of 1.2 mm through multiple drawing passes. The compression rate of each drawing pass is controlled at 15%. The drawing process is carried out in a compound water-based wire drawing solution. The compound water-based wire drawing solution is composed of the following components in weight percentage: tall oleic acid diethanolamide 22%, borate ester 6%, fatty alcohol polyoxyethylene ether 4%, benzotriazole derivative 3%, organosilicon emulsion 0.4%, and the balance is deionized water. S2. The drawn intermediate welding wire is continuously and uniformly passed through two chemical polishing tanks. The chemical polishing process includes two tanks. The first chemical polishing tank contains a compound alkaline cleaning solution, and the second chemical polishing tank contains a compound chemical plating solution. The compound alkaline cleaning solution is composed of the following components by weight percentage: sodium carbonate 5%, triethanolamine 3%, sodium gluconate 2%, alkyl glycoside 3%, with the balance being water. The compound chemical plating solution is composed of the following components by weight percentage: ammonium fluorozirconate 15%, sodium molybdate 1%, triethanolamine 0.5%, with the balance being water.

[0041] The pH value of the compound alkaline cleaning solution is controlled at 8.0, and the temperature is maintained at 70℃. The contact time of the welding wire in the compound alkaline cleaning solution is 30 seconds. The pH value of the compound chemical plating solution is controlled at 8.0, and the temperature is maintained at 30℃. The contact time of the welding wire in the compound chemical plating solution is 30 seconds.

[0042] S3. The polished welding wire is first rinsed in a clean water rinsing tank for initial cleaning. Then, it must be placed in an ultrasonic cleaning tank to remove stubborn residues adhering to the surface. Finally, the welding wire is thoroughly dried in a hot air circulating oven at 120°C to form a clean, dry finished product surface.

[0043] S4. A layer winding device is used in conjunction with a precision wire guide to ensure that the welding wire is neatly arranged on the I-beam reel without crossing or wire compression. The layer winding speed is synchronized with the speed of the aforementioned processes.

[0044] Example 2 A manufacturing process for aluminum alloy welding wire with excellent wire feeding performance includes the following steps: S1. An aluminum alloy rod blank with a diameter of 9.5 mm is gradually reduced to an intermediate welding wire with a diameter of 1.2 mm through multiple drawing passes. The compression rate of each drawing pass is controlled at 18%. The drawing process is carried out in a compound water-based wire drawing solution. The compound water-based wire drawing solution is composed of the following components in weight percentage: coconut oil diethanolamide 20%, nitrogen-containing borate ester 5%, AEO-3 3%, methylbenzotriazole 2%, polydimethylsiloxane emulsion 0.2%, and the balance is deionized water. S2. The drawn intermediate welding wire is continuously and uniformly passed through two chemical polishing tanks. The chemical polishing process includes two tanks. The first tank contains a compound alkaline cleaning solution, and the second tank contains a compound chemical plating solution. The compound alkaline cleaning solution is composed of the following components by weight percentage: sodium bicarbonate 3%, diethanolamine 2%, sodium citrate 1%, fatty alcohol polyoxyethylene ether carboxylate 2%, with the balance being water. The compound chemical plating solution is composed of the following components by weight percentage: ammonium fluorotitanate 10%, sodium tungstate 0.5%, sodium hydroxide 0.1%, with the balance being water.

[0045] The pH value of the compound alkaline cleaning solution is controlled at 7.5, the temperature is maintained at 65℃, and the contact time of the welding wire in the compound alkaline cleaning solution is 15 seconds. The pH value of the compound chemical plating solution is controlled at 7.5, the temperature is maintained at 25℃, and the contact time of the welding wire in the compound chemical plating solution is 25 seconds.

[0046] S3. The polished welding wire is first rinsed in a clean water rinsing tank for initial cleaning. Then, it must be placed in an ultrasonic cleaning tank to remove stubborn residues adhering to the surface. Finally, the welding wire is thoroughly dried in a hot air circulating oven at 100°C to form a clean, dry finished surface.

[0047] S4. A layer winding device is used in conjunction with a precision wire guide to ensure that the welding wire is neatly arranged on the I-beam reel without crossing or wire compression. The layer winding speed is synchronized with the speed of the aforementioned processes.

[0048] Example 3 A manufacturing process for aluminum alloy welding wire with excellent wire feeding performance includes the following steps: S1. An aluminum alloy rod blank with a diameter of 9.5 mm is gradually reduced to an intermediate welding wire with a diameter of 1.2 mm through multiple drawing passes. The compression rate of each drawing pass is controlled at 12%. The drawing process is carried out in a compound water-based wire drawing solution. The compound water-based wire drawing solution is composed of the following components in weight percentage: 25% oleic acid diethanolamide, 8% sulfoboronate, 95% AEO-, 4% benzotriazole, 0.5% polyether modified siloxane emulsion, and the balance is deionized water. S2. The drawn intermediate welding wire is continuously and uniformly passed through two chemical polishing tanks. The chemical polishing process includes two tanks. The first chemical polishing tank contains a compound alkaline cleaning solution, and the second chemical polishing tank contains a compound chemical plating solution. The compound alkaline cleaning solution is composed of the following components by weight percentage: sodium silicate 8%, monoethanolamine 5%, disodium EDTA 3%, cocamidopropyl betaine 6%, and the balance is water. The compound chemical plating solution is composed of the following components by weight percentage: potassium fluorotitanate 20%, vanadate corrosion inhibitor 2%, potassium hydroxide 1%, and the balance is water.

[0049] The pH value of the compound alkaline cleaning solution is controlled at 8.5, the temperature is maintained at 75℃, and the contact time of the welding wire in the compound alkaline cleaning solution is 40 seconds. The pH value of the compound chemical plating solution is controlled at 8.5, the temperature is maintained at 40℃, and the contact time of the welding wire in the compound chemical plating solution is 40 seconds.

[0050] S3. The polished welding wire is first rinsed in a clean water rinsing tank for initial cleaning. Then, it must be placed in an ultrasonic cleaning tank to remove stubborn residues adhering to the surface. Finally, the welding wire is thoroughly dried in a hot air circulating oven at 150°C to form a clean, dry finished product surface.

[0051] S4. A layer winding device is used in conjunction with a precision wire guide to ensure that the welding wire is neatly arranged on the I-beam reel without crossing or wire compression. The layer winding speed is synchronized with the speed of the aforementioned processes.

[0052] Comparative Example 1 A process for producing aluminum alloy welding wire differs from Example 1 in that the compounded water-based drawing fluid is composed of the following components in weight percentage: 22% polyethylene glycol monostearate, 6% borate, 4% fatty alcohol polyoxyethylene ether, 3% benzotriazole derivative, 0.4% silicone emulsion, and the balance being deionized water.

[0053] Comparative Example 2 A process for producing aluminum alloy welding wire differs from Example 1 in that the compounded water-based drawing fluid is composed of the following components in weight percentage: tall oleic acid diethanolamide 22%, isostearic acid 6%, fatty alcohol polyoxyethylene ether 4%, benzotriazole derivative 3%, organosilicon emulsion 0.4%, and the balance being deionized water.

[0054] Comparative Example 3 A process for producing aluminum alloy welding wire differs from Example 1 in that: only one chemical polishing tank is used in step S2, and the bath solution in the chemical polishing tank is the compound alkaline cleaning solution in Example 1.

[0055] Comparative Example 4 A process for producing aluminum alloy welding wire differs from Example 1 in that: only one chemical polishing tank is used in step S2, and the solution in the chemical polishing tank is the compound chemical plating solution in Example 1.

[0056] Comparative Example 5 A process for producing aluminum alloy welding wire differs from Example 1 in that the compound alkaline cleaning solution is composed of the following components in weight percentage: 5% sodium carbonate, 2% sodium gluconate, 3% alkyl glycoside, and the remainder is water.

[0057] Comparative Example 6 A process for producing aluminum alloy welding wire differs from Example 1 in that the compound alkaline cleaning solution is composed of the following components in weight percentage: 3% triethanolamine, 2% sodium gluconate, 3% alkyl glycoside, and the remainder is water.

[0058] The aluminum alloy welding wires prepared in Examples 1-3 and Comparative Examples 1-6 were tested as follows: (1) Characterization of the microstructure of the welding wire surface (distinguishing the differences in the underlying layers of four types of samples) Testing equipment: microscope, infrared spectrophotometer for oil content analysis; Testing indicators: ① Surface quality of welding wire; ② Residual oil content on the surface of welding wire (mg / m³) 2 ); Judgment criteria: The fewer the scratches and the lower the residual oil, the better the surface quality of the welding wire.

[0059] (2) Test of wire feeding resistance and wire feeding stability Equipment: Fully automatic welding wire feeding resistance tester; Test conditions: A 3m standard wire feeding hose is used to form a loop with a diameter of 0.5m, the wire feeding speed is 0.2m / s, and the wire is fed continuously at a constant speed for 180s; Indicators: Average wire feeding resistance (N), Wire feeding resistance fluctuation range (N); Judgment criteria: The lower the average resistance and the smaller the fluctuation range, the smoother and more stable the wire feeding.

[0060] (3) Arc stability and droplet transfer test Supporting equipment: Welding voltage and current waveform acquisition instrument; Standardized welding parameters: current 220A, arc voltage 24.5V, argon flow rate 18L / min, welding wire extension length 12mm; Testing indicator: Arc voltage fluctuation range; Judgment criteria: The smaller the voltage fluctuation, the more stable the wire feeding.

[0061] (4) Quantitative testing of welding spatter Tooling: Sealed splash collection cylinder + quantitative filter paper; Procedure: Weld steadily for 1 minute per group, collect all spatter particles, dry and weigh; Index: Total mass of splash per unit time (mg / min), the lower the value, the less splashing.

[0062] The test results of the aluminum alloy welding wires prepared in Examples 1-3 and Comparative Examples 1-6 are shown in Table 1, and the surface quality photographs are as follows. Figure 1-9 As shown.

[0063] Table 1 Test results of various aluminum alloy welding wires From Table 1 and Figures 1-9 It can be seen that the aluminum alloy welding wire produced by the production process of the present invention has improved the surface residual oil content, average wire feeding resistance, resistance fluctuation range, arc voltage fluctuation and total spatter compared with the comparative example. This proves that the production process of the present invention improves the consistency and stability of the welding wire surface, fundamentally improves the wire feeding performance of the welding wire, and ensures the stability of the subsequent welding process.

[0064] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A production process for aluminum alloy welding wire with excellent wire feeding performance, characterized in that: Includes the following steps: After the aluminum alloy rod blank is subjected to multiple drawing and chemical polishing processes, it is cleaned, dried, and wound to obtain an aluminum alloy welding wire with excellent wire feeding performance. The drawing process is carried out in a compound water-based drawing fluid, which is composed of the following components in weight percentage: 20%-25% lubricant, 5%-8% extreme pressure agent, 3%-5% first surfactant, 2%-4% antioxidant, 0.2%-0.5% defoamer, and the balance being deionized water. The first surfactant is selected from one or more of fatty alcohol polyoxyethylene ether, isomeric alcohol polyoxyethylene ether, and alkylphenol polyoxyethylene ether. The chemical polishing process includes two chemical polishing tanks. The first chemical polishing tank contains a compound alkaline cleaning solution, and the second chemical polishing tank contains a compound chemical plating solution. The compound alkaline cleaning solution is composed of the following components by weight percentage: 3%-8% inorganic alkali, 2%-5% organic alkali, 1%-3% chelating agent, 2%-6% second surfactant, and the balance being water. The second surfactant is selected from one or more of alkyl glycosides, fatty alcohol polyoxyethylene ether carboxylate, and cocamidopropyl betaine. The compound chemical plating solution is composed of the following components by weight percentage: 10%-20% film-forming agent, 0.5%-2% corrosion inhibitor, 0.1%-1% pH adjuster, and the balance being water.

2. The production process of aluminum alloy welding wire with excellent wire feeding performance according to claim 1, characterized in that: The lubricant in the compound water-based drawing fluid is a long-chain fatty acid alcohol amide lubricant; the extreme pressure agent is selected from one or more of borate esters, phosphorus-containing extreme pressure agents, and polyester extreme pressure agents; the antioxidant is selected from one or more of benzotriazole derivatives, thiadiazole derivatives, and phenolic antioxidants; and the defoamer can be selected from one or more of organosilicon emulsions, polyether defoamers, and mineral oil defoamers.

3. The production process of aluminum alloy welding wire with excellent wire feeding performance according to claim 2, characterized in that: The long-chain fatty acid alcohol amide lubricant is selected from one or more of tall oil diethanolamide, coconut oil diethanolamide, and oleic acid diethanolamide; the borate ester is one or two of nitrogen-containing borate ester and sulfur borate ester; the fatty alcohol polyoxyethylene ether is one or two of AEO-3 and AEO-9; the benzotriazole derivative is one or two of methylbenzotriazole and benzotriazole; and the organosilicon emulsion is one or two of polydimethylsiloxane emulsion and polyether-modified siloxane emulsion.

4. The production process of aluminum alloy welding wire with excellent wire feeding performance according to claim 1, characterized in that: The inorganic base in the compound alkaline cleaning solution is selected from one or more of sodium carbonate, sodium bicarbonate, sodium silicate, and sodium metasilicate; the organic base is selected from one or more of triethanolamine, diethanolamine, monoethanolamine, and alkanolamine derivatives; and the chelating agent is selected from one or more of sodium gluconate, sodium citrate, disodium EDTA, tetrasodium EDTA, and aminotrimethylenephosphonic acid.

5. The production process of aluminum alloy welding wire with excellent wire feeding performance according to claim 1, characterized in that: The alkyl glycoside is one or both of APG0810 and APG1214.

6. The production process of aluminum alloy welding wire with excellent wire feeding performance according to claim 1, characterized in that: The pH value of the compound alkaline cleaning solution is controlled at 7.5-8.5, the temperature is maintained at 60-80℃, and the contact time of the aluminum alloy billet in the compound alkaline cleaning solution is 15-60 seconds.

7. The production process of aluminum alloy welding wire with excellent wire feeding performance according to claim 1, characterized in that: The film-forming agent in the compound chemical plating solution is selected from one or more of ammonium fluorozirconate, potassium fluorozirconate, ammonium fluorotitanate, and potassium fluorotitanate; the corrosion inhibitor is selected from one or more of sodium molybdate, sodium tungstate, vanadate, and organophosphonic acid corrosion inhibitors; and the pH adjuster is selected from one or more of triethanolamine, sodium hydroxide, potassium hydroxide, and ammonia.

8. The production process of aluminum alloy welding wire with excellent wire feeding performance according to claim 1, characterized in that: The pH value of the compound chemical plating solution is controlled at 7.5-8.5, and the temperature is maintained at 20-45℃; the contact time of the aluminum alloy billet in the compound chemical plating solution is 15-60 seconds.

9. The production process of aluminum alloy welding wire with excellent wire feeding performance according to claim 1, characterized in that: The compression rate of each drawing pass in the multi-pass drawing process is controlled between 12% and 18%.

10. An aluminum alloy welding wire prepared by the production process described in any one of claims 1-9.

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