双丝窄间隙gmaw熔滴过渡及立焊工艺分析-analysis on droplet transition and vertical welding process of double wire narrow gap gmaw.docxVIP

AbstractAsahighefficientweldingtechnology,narrowgapweldinghasbeenwidelyemployedintheindustrytomanufacturethickplatesorpipelinesbecauseofitslowheatinput,highefficiency,lowthermalstressandweakdamagetothemicrostructureofweldbeads.TandemnarrowgapGMAWisabletoimprovetheefficiencyofmetaldepositionandavailablysolvetheproblemofpoorsidewallfusionwhichstemsfromthetraditionalnarrowgapGMAW.InthispaperthecharacteristicsofmetaltransferandarcbehaviorsintandemNG-GMAWhavebeensuccessfullyobservedandstudied.Moreover,thetandemNG-GMAWprocessandthesingle-molten-poolbehaviorsinverticalpositionhavealsobeenresearched.TheprevioustandemNG-GMAWtorchwasmodifiedinthetermsofinnerstructure,insulationperformanceandairtightness.Newwater-cooledcoppernozzlewasdesignedandmadetoreplacetheformernozzlewhosecoolingeffectwasbadintheweldingmodeofsingle-molten-pool.Additionally,aspecializednozzlewithtwoinertgaschannelswasalsofabricatedtoservethepurposeofdouble-molten-poolmodeweldingandatandemNG-GMAWtorchwithcompactstructureandstableperformancewasfinallyobtained.Twomethodswereusedtoanalyzethecharacteristicsofmetaltransferandthearcbehaviors,inwhichoneisbacklitandtheotherisbasedonpositivevision.Duetotherestrictionofnarrowgapandthemutualheatcomplementationofdoubleelectrodes,bettermetaltransfermodewaspronetotakeplaceundertheconditionofnarrowgapweldingthanthatofplatewelding.Moreover,thetransfermodeofleadingwirewasdifferentfromthatoftrailingwireandthepeakpulsevoltage,pulsefrequencyandpulsetimeallhadeffectsonthemetaltransferandarcshape.Inverticalposition,propermodesuchasglobulartransfercouldbeobtainedwithhigherweldingcurrent,orhigherpulsefrequencyorlongerpulsetimesincethegravitationalforcehadfailedtopromotethedropletsbreakingawayfromthetipoftheconsumedelectrodesintheaxialdirectionoffeedingwires.Byemployinglargerweldingcurrent,theeffectsofweldingparameterssuchasdistancebetweentwoelectrodes,angleofthebendingcontacttube,matchingofleadingwirerateandtrailingwirefeedingrate,travelspeed,andpeaktimevoltageontheweldingprocess,