Effect of cold wire position on the welding process in twin-arc integrated cold wire hybrid welding
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摘要: 搭建了雙電弧集成冷絲復合焊接系統，研究了冷絲不同位置對焊接過程的影響機理，其中包括冷絲作用位置對其加熱熔化作用及表面成形的影響。實驗結果表明：冷絲從兩引導焊絲正前方送入時，熔池前端對冷絲的加熱熔化作用不充分，冷絲末端會頂觸熔池底部，隨著冷絲的持續送進和母材的向后移動，某一時刻冷絲回彈，焊絲末端的熔滴彈出落在母材表面形成大顆粒飛濺。當冷絲從側面送入時，熔池一側的溫度較低，影響熔池金屬的流動，導致最終的焊縫成形不對稱分布。當冷絲從兩引導焊絲正后方送入熔池時，冷絲始終插入熔池中，焊接過程穩定，是理想的冷絲作用位置。此外，隨著冷絲送絲速度的增加，兩種脈沖電流模式（同相和反相）下，熔敷率均隨之增加，且相差不大。同相脈沖電流下電弧對冷絲的加熱熔化作用最強烈，反相脈沖電流下次之，直流模式下最弱。
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關鍵詞:
- 雙電弧集成冷絲復合焊 /
- 冷絲作用位置 /
- 冷絲送絲速度 /
- 熔敷率 /
- 電流模式
Abstract: With rapid social and economic development, high-efficiency welding technology has become an important development direction in the field of welding. In recent years, scholars and professionals in many countries have devoted themselves to further increasing the welding efficiency by improving welding materials, welding process, and arc-welding equipment. The welding efficiency can be increased using two approaches: one is increasing the welding speed, the other is increasing the welding deposition rate. Considering these two methods, typical technologies such as multiwire submerged arc welding (SAW) and multiwire gas metal arc welding (GMAW) were proposed. A twin-arc integrated cold wire hybrid welding system was established. The mechanical effect of the cold wire position on the welding process was studied, including its effects on heating, melting, and weld surface formation. Results show that the melting of cold wire depends on the front end of the weld pool, and the melting effect of the weld pool on the cold wire is not sufficient when the cold wire is fed in front of two leading wires. The end of the cold wire makes contact with the bottom surface of the weld pool with the continuous feeding of the cold wire. Droplets melted at the wire ends are ejected and fall on the base metal surface to generate a globular spatter with the backward motion of the base metal. The thermal distribution on the side of the weld pool decreases as the cold wire is fed inside of the two leading wires. Hence, the flow of molten metal is affected, ultimately leading to an uneven weld formation. The cold wire is stably inserted into the weld pool when fed behind the two leading wires, representing the optimum cold wire position. Moreover, the deposition rates increase with an increase in the cold wire feed speed and show little change under two-pulse phase differences (in-phase and reverse-phase pulse differences). The effect of arc heating and melting on the cold wire was most intense at the in-phase pulse current, followed by the reverse-phase pulse current and subsequently direct current. -
圖 1 雙電弧集成冷絲復合焊焊接系統示意圖
Figure 1. Schematic of twin-arc integrated cold wire hybrid welding system
圖 2 冷絲不同作用位置的示意圖。（a）位于兩引導焊絲正后方；（b）位于兩引導焊絲正前方；（c）位于兩引導焊絲側面
Figure 2. Schematic of cold wire different locations: (a) right behind the two leading wires; (b) in front of the two leading wires; (c) in side of the two leading wires
圖 6 冷絲不同作用位置時的焊縫宏觀形貌。（a）冷絲在后；（b）冷絲在側面；（c）冷絲在前
Figure 6. Welding appearances at different cold wire positions: (a) cold wire in the rear; (b) cold wire in the side; (c) cold wire in the front
圖 7 冷絲送絲速度與熔敷速度的關系
Figure 7. Relationship between the cold wire feed speed and deposition rate
圖 8 三種電流模式下冷絲在熔池中的狀態與送絲速度間的對應關系。（a）同相脈沖電流；（b）反相脈沖電流；（c）直流
Figure 8. Corresponding relationships between the states of cold wire in the weld pool and feed wire speeds under three current modes: (a) in-phase pulse current; (b) reverse-phase pulse current; (c) direct current
表 1 兩引導焊絲上的基本脈沖電參數
Table 1. Basic pulse parameters of the two leading wires
Preset current/A Preset voltage/V Pulse peak current/A Pulse peak voltage/V Pulse base current/A Pulse base voltage/V Pulse peak time/ms Pulse basic time/ms Frequency/Hz 140 24 600 40 100 20 3.2 8 89 
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