Improving current window in keyhole welding with double-layers hybrid arc heat source

IF 6.7 2区 材料科学 Q1 ENGINEERING, INDUSTRIAL Journal of Materials Processing Technology Pub Date : 2024-10-28 DOI:10.1016/j.jmatprotec.2024.118646
ZuMing Liu , BoHan Jia , XuMin Guo , XingChuan Zhao
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Abstract

Keyhole welding can be easily achieved with a plasma arc, but the process window is narrow because too high arc pressure will damage the keyhole stability. Double-layers hybrid arc heat source was developed by compositing an outer layer of free arc into the center plasma arc jet, the arc heat power can be adjusted in wide range with suppression of arc pressure changing. Keyhole stability was tested to be improved with 6mm-thick stainless steel in previous works, but the stability principle is not yet discussed. In this paper, keyhole welding tests were carried out with thicker steel plates to evaluate the usable welding current window improvement and the weld pool stabilization principle. Results show that the usable current window with the hybrid arc is nearly double wider over that with plasma arc in the 6mm-, 8mm- and 16mm-thick plates. The added free arc heat is deposited into the keyhole bottom with limited ratio, the backside weld width increases much more (about 2.4–6 folders) slowly by increasing the free arc current than by increasing the plasma arc current. Keyhole weld pool stabilization principle is outlined: if the plasma arc is given, arc pressure is almost fixed, surface tension in backside weld surface decreases slowly with the free arc current, weld pool force balance can be achieved in much wider range of welding current. Smooth front and backside weld surfaces are easily obtained with hybrid arc. The research indicates that, for application of the developed hybrid arc system in keyhole welding field, the plasma arc should get the fully penetration threshold, the free arc current is used as the process adjuster, the usable welding current range is very wide.
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利用双层混合电弧热源改善锁孔焊接的电流窗口
利用等离子弧可以轻松实现锁孔焊接,但由于过高的电弧压力会破坏锁孔的稳定性,因此工艺窗口较窄。双层混合电弧热源是通过在中心等离子弧射流中合成外层自由弧来开发的,电弧热功率可在大范围内调节,并可抑制电弧压力的变化。在以前的工作中,对 6 毫米厚的不锈钢进行了测试,以提高锁孔的稳定性,但尚未讨论其稳定性原理。本文使用更厚的钢板进行了锁孔焊接试验,以评估可用焊接电流窗口的改善情况和焊池稳定原理。结果表明,在 6 毫米、8 毫米和 16 毫米厚的钢板上,混合电弧的可用电流窗口比等离子电弧宽近一倍。增加的自由弧热量以有限的比例沉积到锁孔底部,增加自由弧电流比增加等离子弧电流,背面焊缝宽度的增加速度要慢得多(约 2.4-6 倍)。概述了锁眼焊池稳定原理:如果给定等离子弧,电弧压力几乎固定,背面焊缝表面张力随自由弧电流缓慢减小,焊池力平衡可在更宽的焊接电流范围内实现。使用混合电弧很容易获得光滑的正面和背面焊接表面。研究表明,将所开发的混合电弧系统应用于锁孔焊接领域,等离子弧应达到完全熔透阈值,自由弧电流用作过程调节器,可用焊接电流范围非常宽。
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来源期刊
Journal of Materials Processing Technology
Journal of Materials Processing Technology 工程技术-材料科学:综合
CiteScore
12.60
自引率
4.80%
发文量
403
审稿时长
29 days
期刊介绍: The Journal of Materials Processing Technology covers the processing techniques used in manufacturing components from metals and other materials. The journal aims to publish full research papers of original, significant and rigorous work and so to contribute to increased production efficiency and improved component performance. Areas of interest to the journal include: • Casting, forming and machining • Additive processing and joining technologies • The evolution of material properties under the specific conditions met in manufacturing processes • Surface engineering when it relates specifically to a manufacturing process • Design and behavior of equipment and tools.
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