A ceramic backing for deep penetration submerged arc welding
By designing a ceramic backing for deep penetration submerged arc welding, the problems of low efficiency and numerous defects in the butt welding of hull plates were solved, achieving efficient and uniform welding results and reducing undercut and lack of fusion defects.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- QINGDAO BEIHAI SHIPBUILDING HEAVY IND CO LTD
- Filing Date
- 2025-08-07
- Publication Date
- 2026-07-07
AI Technical Summary
Existing technologies for butt welding of hull plates involve complex issues such as hoisting and turning, back-side grinding and cutting, resulting in low welding efficiency and defects such as undercut and lack of fusion. In particular, it is difficult to optimize the flow of the molten pool during deep penetration submerged arc welding.
Design a ceramic backing for deep penetration submerged arc welding, comprising a strip base layer, an adhesive layer, a ceramic gasket, a fiber layer, and a protective layer, with a center marker line and vent holes, to optimize molten pool flow and improve root formation.
It improves welding efficiency, reduces undercut and lack of fusion defects, ensures uniform temperature and forming quality of weld metal, and reduces operational difficulty and material consumption.
Smart Images
Figure CN224463886U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of shipbuilding technology, and more particularly to the field of hull welding technology, specifically a ceramic gasket for deep penetration submerged arc welding. Background Technology
[0002] Currently, submerged arc welding and flux-cored wire carbon dioxide gas shielded welding are the two main methods used for butt welding of 6-15mm thick hull plates.
[0003] When using submerged arc welding (SAW) to butt-joint ship hull plates, the front side of the hull plate must be welded first. After the front welding is completed, the hull plate is flipped over by a hoisting process. The back side of the hull plate then undergoes carbon planing and grinding. After the back side is cleaned, welding is then performed on the back side of the hull plate. The hoisting and flipping process occupies crane resources and consumes hoisting time, affecting the work progress. After the hull plate is flipped over by crane, consumables such as carbon rods and grinding wheels are still needed to grind the back side of the hull plate, which consumes a lot of manpower and time. At the same time, SAW has very high requirements for assembly gaps and bevel precision, which can easily cause the weld to burn through.
[0004] When using flux-cored wire carbon dioxide gas shielded welding to butt-joint ship hull plates, a 45° bevel must first be cut, and then a ceramic backing is applied to the back of the bevel for multi-layer, multi-pass welding. This method involves a complex cutting process, a large amount of welding, low welding efficiency, and significant welding deformation.
[0005] Deep penetration submerged arc welding can form double-sided shapes with a single pass, which can improve welding efficiency. However, the ceramic backing for deep penetration submerged arc welding has high requirements. Existing ceramic backings are difficult to optimize the flow of the molten pool during use, and are prone to defects such as undercut and lack of fusion, which affect the appearance of the hull.
[0006] Therefore, there is a need for a ceramic gasket that can improve the back root formation, reduce welding defects, and be used for deep penetration submerged arc welding of ship hull plates. Summary of the Invention
[0007] In view of the above-mentioned problems in the prior art, this utility model provides a ceramic backing for deep penetration submerged arc welding, which can optimize the flow of the molten pool and reduce or avoid defects such as undercut and lack of fusion when welding ship hull plates with deep penetration submerged arc welding, thereby obtaining a good weld.
[0008] To achieve the above objectives, the present invention adopts the following technical solution:
[0009] A ceramic backing for deep penetration submerged arc welding includes a strip base layer coated with an adhesive layer. In the middle of the adhesive layer, a plurality of ceramic pads are arranged sequentially and joined together along the length of the adhesive layer. A continuous fiber layer is arranged on the upper surface of the plurality of ceramic pads. A center marking line is arranged in the middle of each ceramic pad and the fiber layer along the length of the fiber layer.
[0010] Furthermore, the top surface of the ceramic gasket is set to be flat.
[0011] Furthermore, an adhesive strip is provided between the ceramic gasket and the fiber layer. There are two adhesive strips, which are symmetrically arranged on both sides of the center marking line.
[0012] Furthermore, two adhesive strips are provided on the upper surface of the fiber layer along the length of the fiber layer, symmetrically arranged on both sides of the central marking line.
[0013] Furthermore, the strip base layer is made of metal.
[0014] Furthermore, the strip base layer has a length of 600mm and a width of 90mm.
[0015] Furthermore, a protective layer is applied over the adhesive layer located on both sides of the ceramic gasket.
[0016] Furthermore, at corresponding positions of the strip base layer, adhesive layer, and protective layer, two rows of vent holes are provided along the length of the strip base layer, and the two rows of vent holes are symmetrically arranged on both sides of the ceramic patch.
[0017] Furthermore, the ceramic gasket measures 30mm x 40mm.
[0018] Furthermore, the strip base layer is made of tin foil.
[0019] Compared with the prior art, the beneficial effects of this utility model are as follows:
[0020] This utility model provides a ceramic gasket that can be used to weld hull plates by deep penetration submerged arc welding, avoiding the traditional submerged arc welding processes such as hoisting and turning, back carbon planing, back grinding and back welding, and greatly improving the welding efficiency of butt joint plates of hull steel plates with a thickness of 6-15mm.
[0021] The top surface of this ceramic gasket is set as a flat surface, which is simple in structure and has a flat contact surface with the workpiece. This allows for more uniform flow of molten metal in the pool, rapid filling of the bevel, and improved welding speed. It also has a higher tolerance for welding parameters and operating procedures, reduces the risk of molten pool sagging, and improves forming efficiency. When using deep submerged arc welding to weld ship hull plates, it can make the upper and lower surfaces of the weld metal have uniform temperature and produce a large penetration depth, effectively controlling the lateral angular deformation of the welded plates.
[0022] The ceramic gasket provided by this utility model is equipped with a fiber layer and a center marking line, which can further optimize the flow of molten pool metal, improve root forming, and reduce or avoid undercut and fusion defects in ship welds.
[0023] The ceramic gasket of this invention is used to weld hull plates using deep submerged arc welding, which can make the temperature of the upper and lower surfaces of the weld metal uniform and produce a large penetration depth, effectively controlling the lateral angular deformation of the welded plates. Attached Figure Description
[0024] To more clearly illustrate the specific embodiments of this utility model or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort. In the drawings:
[0025] Figure 1 A schematic diagram of the overall structure of this utility model is shown.
[0026] Figure 2 It shows Figure 1 Front view.
[0027] Figure 3 A schematic diagram of the structure of the ceramic gasket of this utility model is shown.
[0028] The reference numerals in the above figures are as follows:
[0029] 1. Strip base layer; 2. Adhesive layer; 3. Ceramic gasket; 4. Fiber layer; 5. Center marking line; 6. Adhesive strip; 7. Adhesive strip; 8. Ventilation hole; 9. Protective layer. Detailed Implementation
[0030] The technical solution of this utility model will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this utility model. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this utility model.
[0031] like Figure 1 , Figure 2 and Figure 3The ceramic backing material shown is for deep penetration submerged arc welding. It includes a strip-shaped base layer 1, which is 600 mm long and 90 mm wide. The strip-shaped base layer 1 is a thin metal sheet, preferably tin foil. An adhesive layer 2 is coated on the strip-shaped base layer 1. In the middle of the adhesive layer 2, several ceramic backing pieces 3 are sequentially joined together along its length. Adjacent ceramic backing pieces 3 are tightly connected, equivalent to two adjacent ceramic backing pieces 3 being tightly pressed together. A center marking line 5 is provided in the middle of each ceramic backing piece 3 and the fiber layer 4. All center marking lines 5 are collinear, and during welding, the center marking lines 5 are aligned with the center line of the weld. A protective layer 9 is affixed to the adhesive layer 2 located on both sides of the ceramic backing pieces 3. By setting a fiber layer 4 on top of the ceramic gasket 3, undercut and fusion defects caused by molten metal flow during welding can be avoided. Meanwhile, center marking lines 5 on the ceramic gasket 3 and fiber layer 4 provide a welding position reference, resulting in a more aesthetically pleasing weld. A protective layer 9 protects the adhesive layer 2. During use, the protective layer 9 is removed, and the ceramic gasket is adhered to the weld seam using the adhesive layer 2, with the center marking line 5 aligned with the weld centerline.
[0032] Specifically, the ceramic gasket 3 has dimensions of 30mm*40mm, equivalent to a length*width of 30mm*40mm. Typically, the ceramic gasket is thicker than 6mm, and its top surface is flat. Existing ceramic gaskets 3 often have an arc-shaped top surface. During welding, this arc-shaped gasket requires specific welding parameters to optimize the molten pool flow, demanding a high level of operator skill. Excessive current, excessively long arc, and excessively high molten pool temperature can lead to over-melting of the base metal edges, preventing timely replenishment by filler metal and resulting in undercut. Conversely, insufficient current or a short arc can lead to inadequate fusion on both sides of the bevel, resulting in incomplete fusion defects. Due to the high arc impact of deep penetration welding and the poor molten pool flow of submerged arc welding, arc-shaped gaskets are prone to undercut and incomplete fusion defects at the weld root when using deep penetration submerged arc welding to butt ship hull plates. When welding ship hull plates using submerged arc welding, by setting the top surface of the ceramic gasket 3 to a flat surface, the molten pool can be supported evenly. This can reduce the edge dripping of molten pool metal caused by gravity or arc blow, thereby reducing the risk of undercut. At the same time, the planar gasket is more adaptable to fluctuations in welding current and voltage. Even if there are deviations in parameter settings (such as a slightly larger current), the planar structure of the gasket can also prevent excessive concentration of molten pool metal by dispersing heat, thus reducing the risk of undercut.
[0033] Specifically, an adhesive strip 6 is provided between the ceramic gasket 3 and the fiber layer 4. There are two adhesive strips 6, symmetrically arranged on both sides of the center marking line 5. The continuous fiber layer 4 is adhered to the ceramic gasket 3 by the adhesive strip 6, and the presence of the adhesive strip 6 can further strengthen the tight connection between the ceramic gaskets 3.
[0034] Specifically, two adhesive strips 7 are provided on the upper surface of the fiber layer 4 along its length, symmetrically arranged on both sides of the center marking line 5. The ceramic gasket is adhered to the hull plate to be welded using the adhesive strips 7 and the adhesive layer 2.
[0035] Specifically, two rows of vent holes 8 are provided along the length of the strip base layer 1 at corresponding positions on the strip base layer 1, adhesive layer 2, and protective layer 9. These two rows of vent holes 8 are symmetrically arranged on both sides of the ceramic patch. The function of the vent holes 8 is to allow air during bonding and welding fumes to escape through the vent holes 8, preventing air bubbles and fumes from affecting the welding process. The root typically refers to the boundary area between the weld and the bottom of the base metal bevel, i.e., the deepest part of the weld that contacts the base metal. For ship hull plate welding, the root is usually located at the bottom of the bevel and is the most difficult part to weld and most prone to defects. Expelling the fumes generated at the root through the vent holes 8 improves root formation, and by improving root formation, defects such as incomplete fusion and slag inclusions can be avoided.
[0036] The ceramic backing provided by this utility model for deep penetration submerged arc welding has the following specific working state:
[0037] First, place the ceramic gasket close to the root of the weld, aligning the center mark line 5 with the center of the weld. Then, remove the protective layer 9, allowing the gasket to be firmly attached to the steel plates on both sides of the weld with the help of the adhesive layer and adhesive strip 7. The relevant operators then use submerged arc welding to weld along the center mark line 5.
[0038] During the welding process, the fumes generated at the root can be discharged through the vent 8 to avoid affecting the welding quality of the root weld.
[0039] After welding, the ceramic backing and surface slag are removed to obtain a weld with a good appearance.
[0040] Of course, the above description is not intended to limit the present utility model, and the present utility model is not limited to the examples given above. Any changes, modifications, additions or substitutions made by those skilled in the art within the scope of the present utility model should also fall within the protection scope of the present utility model.
Claims
1. A ceramic gasket for deep penetration submerged arc welding, characterized in that, It includes a strip base layer, on which an adhesive layer is coated. In the middle of the adhesive layer, a number of ceramic gaskets are arranged in sequence along the length of the adhesive layer. A continuous fiber layer is arranged on the upper surface of the ceramic gaskets. A center marking line is arranged in the middle of each ceramic gasket and the fiber layer along the length of the fiber layer.
2. A ceramic gasket for deep penetration submerged arc welding according to claim 1, characterized in that, The top surface of the ceramic gasket is set to be flat.
3. A ceramic gasket for deep penetration submerged arc welding according to claim 1, characterized in that, An adhesive strip is provided between the ceramic gasket and the fiber layer. There are two adhesive strips, which are symmetrically arranged on both sides of the center mark line.
4. A ceramic gasket for deep penetration submerged arc welding according to claim 1, characterized in that, The upper surface of the fiber layer is provided with two adhesive strips along the length of the fiber layer, which are symmetrically arranged on both sides of the center mark line.
5. A ceramic gasket for deep penetration submerged arc welding according to claim 1, characterized in that, The strip-shaped base layer is made of metal.
6. A ceramic gasket for deep penetration submerged arc welding according to claim 1, characterized in that, The strip base layer has a length of 600mm and a width of 90mm.
7. A ceramic gasket for deep penetration submerged arc welding according to claim 1, characterized in that, A protective layer is applied over the adhesive layer located on both sides of the ceramic gasket.
8. A ceramic gasket for deep penetration submerged arc welding according to claim 7, characterized in that, Two rows of vent holes are provided along the length of the strip base layer, adhesive layer and protective layer at corresponding positions. The two rows of vent holes are symmetrically arranged on both sides of the ceramic patch.
9. A ceramic gasket for deep penetration submerged arc welding according to claim 1, characterized in that, The ceramic gasket measures 30mm x 40mm.
10. A ceramic gasket for deep penetration submerged arc welding according to claim 5, characterized in that, The strip base layer is made of tin foil.