At present, most of the aluminum and magnesium alloy components used in various industries need to be processed by a welding process. Such as welding of various types of aluminum alloy rocket barrels; welding of aluminum alloy shells of spacecraft; welding of aluminum alloy wheels and turrets of light tanks; welding of aluminum alloy fuel tanks for space shuttles; welding of large aluminum alloy storage tanks and aluminum alloy pressure vessels Wait. Welding processing has become one of the most important links in the aluminum and magnesium alloy processing and manufacturing industry.
The method of welding aluminum and magnesium alloys has undergone DC tungsten-bonded negative TIG welding (DCEN), DC-tung-positive TIG welding (DCEP) and AC TIG welding. At the same time, the emerging processes include: perforated plasma arcs ( VPPA) vertical welding, vacuum electron beam (EBW), PMIG, ACMIG, friction stir welding and laser (LBW). The AC TIG welding is widely used because of its advantages of “moderate cost, good welding quality, convenient use and simple operationâ€. It is most commonly used in the field of aluminum-magnesium alloy welding.
The WSE series of welding machines of the era include: WSE-160, WSE-250, WSE-315 and WSE-500. Since its entry into the market in 2001, the welder has been continuously driven by new welding process requirements. After continuous technical improvement and product upgrades, it has withstood the rigorous test of the market and has been well received by users. The main features of the welder are:
1. One machine multi-energy, with hand arc welding, DC argon arc, DC pulse argon arc, DC argon arc spot welding and AC argon arc welding function, each welding function has excellent performance quality, fully compatible The feature plane is comparable. For manual welding, adjustable parameters include welding current, arc current, thrust current, arcing time, etc., in addition to voltage display.
2. Storage and calling functions of welding parameters.
3. Foot remote control function.
4. Double machine double side synchronous welding function.
5. Long line, heavy load and large specification welding.
6. High arc success rate, high arc stability and high welding quality.
The welder has been widely used in the general field. This paper focuses on the application of the welder in the aluminum and magnesium bicycle industry, large air separation equipment industry and large heat exchanger industry.
Application of WSE welding machine in aluminum and magnesium alloy bicycle welding industry
From the perspective of metal materials, bicycles mainly include steel, aluminum alloy and magnesium alloy structures. At present, the welding process of steel structure bicycles mainly adopts the welding process of DC tungsten argon arc continuous welding, and the general DC argon arc welding machine can meet the technical requirements. Time Inc.'s WS and WSM series welders are widely used for welding in this area.
The welding process of aluminum alloy bicycles mainly adopts the welding process of AC argon arc pedal remote control continuous welding. The main feature of the process is that the welding current can be adjusted with any foot at any time, and the heat input amount of the base metal can be flexibly controlled, and the same weld can be realized for the same weld of different base materials and different orientations, thereby effectively reducing the welding. The number of joints reduces the degree of deformation of the structural members, resulting in a significant improvement in the quality of the weld. The main requirement of the welding process for the welding power source is that in addition to having excellent general performance indexes, success rate of arc ignition, good arc stability, and high reliability, it is also required to have a pedal remote control function. The Era WSE welder features a dedicated pedal remote control interface and a dedicated foot remote control. The appearance of the controller is beautiful, the return angle is suitable, the strength is moderate, the pedal panel is threaded, the foot feels comfortable, the service life is up to 1 million times, and the maximum and minimum current limit functions are available. The era WSE welding machine with pedal remote control function has been widely used in the bicycle industry.
Compared with aluminum alloys, magnesium alloys have the same toughness and lower specific gravity (density), so in recent years, the magnesium alloy bicycle industry has been vigorously developed and become another important member of the bicycle family. Since the magnesium alloy has a small thermal conductivity, a low melting point and a low boiling point, and is highly liable to spontaneous combustion, the magnesium alloy is more difficult to weld than the aluminum alloy, and the welding process is more complicated. At present, there are two main welding processes for magnesium alloy bicycles: one is AC argon arc foot intermittent welding, and the other is AC argon arc flexible arc continuous welding.
The pedal intermittent welding is derived from the continuous welding of the aluminum alloy's foot. The process is characterized by a high frequency start-stop arc, which rapidly increases and attenuates the current. To this end, we have made further improvements and upgrades on the basis of the original pedal remote control, specifically designed the "shoulder intermittent welding" function. The software program of the welding machine has been upgraded, and an operation mode (foot-and-break welding operation mode) has been added, which can realize the function of “foot-controlled AC pulseâ€. The AC pulse frequency can be arbitrarily adjusted by the foot, and the base current can be reduced to 10A. Therefore, the arc is not extinguished, and the high frequency arcing is avoided again. The current is increased and the decay speed is extremely fast, and can be completed within 20 ms.
The flexible arc continuous welding is essentially the stiffness control of the arc. The process characteristics are that the arc is soft and stable, and the impact and jitter are small, so that the liquid magnesium alloy in the molten state can be effectively controlled without blasting, and the welding quality is improved. Personal safety. The era's WSE welder has a unique current waveform control algorithm that effectively controls the current waveform to achieve quasi-square wave current output. At present, the era of WSE-315 has been widely and extensively used in several magnesium alloy bicycle factories.
Application of WSE welding machine in large aluminum air separation equipment and other industries
The large-scale air separation unit's aluminum container and large aluminum pipe have large welding workload and strict quality requirements. Currently, a new welding process called “double double-machine double-sided synchronous ACTIG vertical welding†is widely used. The front weld is on the outside of the workpiece, and the main gun is used for welding. The welding wire is pressed close to the workpiece to fill the molten pool; the reverse weld is on the inside of the workpiece, and the sub-gun is used for welding, and the welding wire is generally not filled. It is advisable to maintain the angle between the main and auxiliary welding torches and the workpiece at 70~80, and use an arc force and an argon blowing force to form an upward supporting force, and together with the surface tension of the molten pool, support the molten pool, thereby preventing The molten pool metal is squatted and the weld quality obtained is good. The operation point of the process is: regardless of the shape of the workpiece, the part to be welded must be in a vertical position; the main and auxiliary welding guns must be welded at the same time, the main gun is in front, the sub-gun is behind, and the welding speed varies according to the moving speed of the main gun. Change, strictly require that the spacing between the two guns is always maintained at a length of a molten pool; the interface gap is large, and the optimum value is kept equal to or slightly larger than the diameter of the used wire. The utility model has the advantages that the porosity in the weld seam is very low, the slag inclusion is rare, the welding leakage or the non-welding defect is small, the deformation is small, the welding quality is high, the groove is not required to be opened, the root is cleaned, the process device is simple, and the assembly labor intensity is low. The production efficiency is improved; the number of processes is greatly reduced, the utilization rate of plant, equipment and manpower is high, energy saving, auxiliary equipment investment is small, and cost is saved.
There are two main types of AC argon arc welding power supply that are compatible with this process: one is a transformer-type single-phase AC machine, and its AC output frequency is consistent with the grid frequency; the other is advanced electronic equipment with controlled rectifier or inverter. The AC output frequency and duty cycle are independently adjustable. Regardless of the type of power supply, the core requirement of the process is that the output current of the two welders in the welding process should be stable, avoiding the phenomenon of conviction or shunting, thus ensuring the stability of the arc. The electrical principle of the double welder is shown in Figure 4. That is, the double-machine double-sided AC argon arc-to-head welding process requires that the output current frequency, duty cycle and phase of the two welders are the same. For transformer-type AC machines, this can be achieved by simply changing the wiring sequence of the input cables. For inverter or controlled rectifier welding power supplies, special design is required.
The WSE welding machine of the era has a special "synchronous communication control interface". Through the communication cable, two welding machines can easily realize the two-phase phase synchronization function. Its main technical features are:
1. There is no master or slave on the hardware of the welder. Any two welders with this communication interface can be paired. When welding, the first arc, the current welding machine is the main machine, and the arc welding is followed. The machine is a slave. The output current of the slave is the same as the set value of the output current. The output frequency, duty cycle and phase polarity are consistent with the host (the error is about 150μs, which can fully meet the requirements of the welding process). In addition, once the main body is arc-stopped during the welding process (such as changing the welding wire), the slave automatically becomes the host, outputting at its own frequency, duty cycle, etc., and the original host automatically becomes the slave.
2. The communication protocol between the two machines is simple and efficient, the hardware circuit is novel and unique, and the anti-interference is very strong. The two machines do not interfere with each other even in the high-frequency arc-inducing stage, which ensures the high reliability of the welding machine.
3. Easy to use, just use a dedicated control cable to connect the two welding machines, plug and play, welding parameters can be set independently according to actual use requirements.
Application of WSE welding machine in large heat exchanger industry
At present, aluminum alloy heat exchangers are widely used in industries such as airplanes, central air conditioners, and refrigerators. These heat exchangers are generally characterized by large workpieces, long-distance, high-altitude welding operations. Therefore, it is required that the welder must have a high load duration and a long extension welding function. The WSE-500 welder of the era still has a high load duration of 500A/60% or more and can meet the welding process requirements of continuous welding of about 420A at an ambient temperature of up to 40 °C. The welding gun wire and the ground wire cable are all lengthened to 30m. When the single cable coil is wound and wound on the iron column (the equivalent inductance is about 100~180uH), the welding current can be stably outputted and the arc is stable. That is to say, in normal applications (generally, the welding machine needs to use the extension cord, the line can be lengthened appropriately, but it cannot be coiled), and the extension line of the era WSE-500 welding machine can be extended to about 50m, and it can be guaranteed. Normal welding application.
After many years of continuous technical improvement, functional upgrade and improvement, WSE series welding machine of the era has been widely used in the light metal welding industry such as aluminum-magnesium alloy, and has withstood the rigorous test of the market and won the praise of users. In addition to a large number of applications in the general field, it has also been widely used in special applications such as aluminum and magnesium alloy bicycle industry, large air separation aluminum equipment industry and large aluminum heat exchangers.
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