万瓦级激光扫描焊接驼峰焊道的形成规律及控制措施

Formation law and control measures of hump weld bead in ten-thousand-watt laser scanning welding

  • 摘要:
    目的 该文研究了 8 mm 厚碳钢板万瓦级激光扫描全熔透焊接羽辉形态和背面熔池流动特征,分析了焊缝背面驼峰形成原因,旨在提出改善驼峰焊道形成的方法,以实现万瓦级激光扫描焊的单面焊背面稳定成形。
    方法 利用2台高速摄像系统对 8 mm 厚碳钢板进行万瓦级激光扫描全熔透焊接试验采集信息,研究羽辉形态和背面熔池流动特征,分析驼峰形成原因,提出通过激光扫描的方式改善驼峰焊道的形成。同时,尝试利用激光扫描热源方式抑制羽辉的反冲效果,通过工艺优化有效增加背面熔池面积及表面张力,促进大尺寸液柱熔体的快速回流。
    结果 研究结果表明,熔透焊接时,焊缝背面熔池在匙孔蒸汽反作用力下首先形成凸起状液柱,随着焊接持续,不断有新的金属熔体涌进液柱内,同时在熔池表面张力作用下,液柱内的熔体不断被牵引出并回流至后端熔池内。当液柱涌入的金属速度过快超出回流速度时,会出现较大尺寸液柱沿回流方向整体后移的现象,由于该部分金属熔体体积较大,难以通过表面张力重新回到熔池内,最终冷却凝固形成驼峰。
    结论 通过利用激光扫描热源方式抑制羽辉的反冲效果,同时通过工艺优化有效增加背面熔池面积及表面张力,促进大尺寸液柱熔体的快速回流,成功实现了万瓦级激光扫描焊的单面焊背面稳定成形。

     

    Abstract: Objective This paper studies the plume morphology and the flow characteristics of the back molten pool during ten-thousand-watt laser scanning full-penetration welding of 8 mm thick carbon steel plates, analyzes the formation reasons of the humps on the back of the weld, aims to propose methods to improve the formation of hump weld beads, so as to achieve stable single-sided welding with back formation in ten-thousand-watt laser scanning welding. Methods Two high-speed camera systems are used to collect information of ten-thousand-watt laser scanning full-penetration welding tests on 8 mm thick carbon steel plates. The plume morphology and the flow characteristics of the back molten pool are studied, the reasons of hump formation are analyzed, and it is proposed to improve the formation of hump weld beads by means of laser scanning. Meanwhile, an attempt is made to suppress the recoil effect of the plume by using a laser scanning heat source. Through process optimization, the area and surface tension of the back molten pool are effectively increased to promote the rapid backflow of the large-sized liquid column melt. Results The research results show that, during full-penetration welding, a raised liquid column is first formed in the back molten pool of the weld under the reaction force of the keyhole steam. As the welding continues, new metal melts continuously flow into the liquid column. At the same time, under the action of the surface tension of the molten pool, the melt in the liquid column is continuously drawn out and flows back to the rear molten pool. However, when the velocity of metal flowing into the liquid column is too fast and exceeds the backflow speed, a large-sized liquid column will move backward as a whole along the backflow direction. Since the volume of this part of the metal melt is too large to return to the molten pool through surface tension, it finally cools and solidifies to form a hump. Conclusion Using a laser scanning heat source suppresses the recoil effect of the plume. The area and surface tension of the back molten pool are effectively increased through process optimization. The rapid backflow of the large-sized liquid column melt is promoted, stable back formation of single-sided welding in ten-thousand-watt laser scanning welding is successfully achieved.

     

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