CN115070212A - Laser-assisted MIG (metal-inert gas) composite welding process for thin aluminum alloy plate - Google Patents
Laser-assisted MIG (metal-inert gas) composite welding process for thin aluminum alloy plate Download PDFInfo
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/346—Working by laser beam, e.g. welding, cutting or boring in combination with welding or cutting covered by groups B23K5/00 - B23K25/00, e.g. in combination with resistance welding
- B23K26/348—Working by laser beam, e.g. welding, cutting or boring in combination with welding or cutting covered by groups B23K5/00 - B23K25/00, e.g. in combination with resistance welding in combination with arc heating, e.g. TIG [tungsten inert gas], MIG [metal inert gas] or plasma welding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
- B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
- B23K35/24—Selection of soldering or welding materials proper
- B23K35/28—Selection of soldering or welding materials proper with the principal constituent melting at less than 950 degrees C
- B23K35/286—Al as the principal constituent
- B23K35/288—Al as the principal constituent with Sn or Zn
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C21/00—Alloys based on aluminium
- C22C21/06—Alloys based on aluminium with magnesium as the next major constituent
- C22C21/08—Alloys based on aluminium with magnesium as the next major constituent with silicon
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C21/00—Alloys based on aluminium
- C22C21/12—Alloys based on aluminium with copper as the next major constituent
- C22C21/14—Alloys based on aluminium with copper as the next major constituent with silicon
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C21/00—Alloys based on aluminium
- C22C21/12—Alloys based on aluminium with copper as the next major constituent
- C22C21/18—Alloys based on aluminium with copper as the next major constituent with zinc
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Abstract
The invention discloses a laser-assisted MIG (metal inert gas) composite welding process for a thin aluminum alloy plate, which comprises the following steps of: taking a thin aluminum alloy plate with the thickness less than or equal to 0.5mm as a base material, taking an aluminum magnesium alloy wire as a welding wire, and welding by adopting a paraxial compound mode of laser in front of MIG electric arc and behind; during welding, the laser is in a continuous mode or a pulse mode, and the MIG electric arc is in a pulse mode; for thin aluminum alloy plates: a thin aluminum alloy plate with the thickness of less than or equal to 3mm and more than 0.5mm is used as a base material, an aluminum magnesium alloy wire is used as a welding wire, and the laser welding is carried out in a paraxial composite mode after the front MIG arc; during welding, the laser is in continuous mode or pulse mode, and the MIG arc is in non-pulse mode. The welding process has good stability, can effectively reduce the deformation of the thin or ultrathin aluminum alloy plate in the welding process, realizes full penetration of welding seams, obtains smooth and flat butt welding seams of the upper surface and the lower surface, and simultaneously achieves higher welding speed.
Description
Technical Field
The invention relates to the technical field of aluminum alloy sheet welding. In particular to a laser-assisted MIG composite welding process of a thin aluminum alloy plate.
Background
The aluminum alloy has the advantages of light weight, high strength, good corrosion resistance and the like, and can greatly reduce the weight of structural products when used for replacing steel plate materials for welding, so that the aluminum alloy is widely applied to various products with welded structures at present, such as aerospace, petrochemical industry, electrician and other industries. However, aluminum alloy is easily oxidized during welding, and welding problems such as air holes, cracks, burning through and the like are easily caused, so that the welding difficulty is high, the welding speed is low, and the welding efficiency is low.
At present, laser-assisted arc welding is used for welding aluminum alloy, but the reflectivity of the aluminum alloy is strong, most laser is reflected, and the heat input of the laser is less, so that the welding stability is not easy to control, and particularly for thin aluminum alloy plates (the thickness is less than or equal to 3mm) or ultrathin aluminum alloy plates (the thickness is less than or equal to 0.5mm), the welding process interval is narrow, the process optimization is difficult, and the problems of plate deformation, poor welding stability, poor welding seam forming and the like are more likely to occur in the welding process.
For the ultra-thin aluminum alloy plate with the thickness of 0.5mm, the welding difficulty mainly comprises the following points: (1) because the aluminum alloy has poor weldability, the plate is too thin, the welding specification is small, the requirement on a welding power supply and related matched equipment is high, the welding process interval of the ultrathin aluminum plate is narrow, and the process optimization is difficult; (2) the butt joint of the ultrathin aluminum alloy materials needs to accurately control welding heat input, and the stability of molten drop transition and a welding process can be ensured only by reasonable energy input and control; (3) deformation is inevitably generated in the welding process of the aluminum alloy plate, and the deformation is particularly prominent for the ultrathin aluminum alloy material, so that the welding process is difficult to perform; (4) for the ultrathin aluminum alloy material, the deformation control in the welding process is very important. On one hand, the welding heat input is reduced as much as possible on the premise of ensuring the welding quality; on the other hand, it is required to increase the welding speed as much as possible in achieving stable welding. The welding speed of the existing thin or ultra-thin aluminum alloy is generally low, which results in limited application of the thin aluminum alloy plate and the ultra-thin aluminum alloy plate in welded structure products.
Disclosure of Invention
Therefore, the technical problem to be solved by the present invention is to provide a laser-assisted MIG hybrid welding process for a thin aluminum alloy plate, so as to solve the problems of unstable welding process, poor weld forming effect, serious deformation of the aluminum alloy plate, low welding speed, etc. when the existing aluminum alloy plate welding process is used for welding a thin aluminum alloy plate or an ultrathin aluminum alloy plate.
In order to solve the technical problems, the invention provides the following technical scheme:
the laser-assisted MIG hybrid welding process of the thin aluminum alloy plate comprises the following steps of: welding by using an ultrathin aluminum alloy plate with the thickness of less than or equal to 0.5mm as a base material and an aluminum-magnesium alloy wire as a welding wire in a paraxial composite mode of laser in front of MIG electric arc and behind; during welding, the laser is in a continuous mode or a pulse mode, and the MIG electric arc is in a pulse mode;
for thin aluminum alloy plates: a thin aluminum alloy plate with the thickness of less than or equal to 3mm and more than 0.5mm is used as a base material, an aluminum magnesium alloy wire is used as a welding wire, and the laser welding is carried out in a paraxial composite mode after the front MIG arc; during welding, the laser is in a continuous mode or a pulse mode, and the MIG electric arc is in a non-pulse mode; the micro-adjustment control of the laser to the MIG electric arc can be realized by adopting the pulse type laser beam to assist the MIG, the stability of the MIG electric arc is more favorable, and the welding quality of the thin aluminum alloy plate is ensured. As the aluminum alloy with the thickness of 0.5mm does not need larger penetration, and the minimum output power of the PLW3000 is 15 percent of the full power, the laser beam is unstable below the value, the average output power is reduced by adopting the laser in a pulse mode, and the MIG electric arc can be better assisted. However, when the pulse laser process is adopted to weld the 3mm aluminum alloy lap joint, a larger fusion depth cannot be obtained.
The laser-assisted MIG hybrid welding process of the thin aluminum alloy plate comprises the following steps of: adopting a paraxial composite welding torch for MIG composite heat source welding assisted by laser; the side-shaft type composite welding torch consists of a laser welding head and a gooseneck MIG welding gun; the laser is a PLW3000 light laser provided by Tianjin Merchant numerical control technology, Inc., the maximum output power is 3KW, the laser wavelength is 1070 μm under continuous mode output, and the diameter of a focus spot is 300 μm; cooling the laser by using a water cooling machine; the gooseneck MIG welding gun is a Fornis TPS2700 accessory;
the arc welding power supply adopts a TPS2700 welding machine, the protective gas in an MIG welding gun is 100% argon, and the flow of the protective gas is 15L/min. In general, pure argon or a mixed gas of argon and helium is generally adopted for aluminum alloy welding, and helium has far higher thermal conductivity than argon, so that the fusion depth of the mixed gas is larger, and the aluminum alloy welding is not suitable for thin aluminum alloy plates or ultrathin aluminum alloy plates with the thickness of 3mm or 0.5 mm. For the thin aluminum alloy plate or the ultrathin aluminum alloy plate, 100% argon is adopted for welding, so that the electric arc is stable and easy to strike. In addition, when the flow of the protective gas is less than 15L/min, the gas flow is small, so that the protective effect on electric arcs and a molten pool is poor, and welding defects such as splashing, air holes and the like are easily generated; however, if the flow rate of the protective gas is greater than 15L/min, turbulence is easily caused due to the large gas flow rate, the protection effect of the molten pool is poor, molten pool metal is easily reacted with air, and the structure performance of the joint is changed.
The laser-assisted MIG hybrid welding process of the thin aluminum alloy plate comprises the following steps of:
during welding, the laser is in a pulse mode, and the MIG electric arc is in a pulse mode;
the laser peak power of the laser is 300W, and the duration time is 10 ms; the laser basic value power is 187W, and the duration is 40 ms; the pulse frequency is 20Hz, the laser defocusing amount is 0 [ as the aluminum alloy plate is thin, the low-power laser is only used as an auxiliary heat source to assist the arc to stably burn; when the positive defocusing amount or the negative defocusing amount is adopted, the area of a laser spot is increased, the energy density is reduced, the amount of generated charged particles is reduced, and the stability of an electric arc is deteriorated; the vertical inclination angle of the laser beam is 5 degrees (vertical inclination angle is the included angle between the laser beam and the normal line of the aluminum alloy plate); because the reflectivity of the aluminum alloy plate to laser is extremely high, when the aluminum alloy plate is welded, the laser needs to be inclined at a certain angle, and the laser head is prevented from being burnt by the original laser path in a reflecting way; when the thin aluminum alloy is welded, if the angle of the laser beam is less than 5 degrees, the laser head is extremely likely to be burnt, and if the angle of the laser beam is more than 5 degrees, the laser beam under the power of the invention is difficult to form an etching point on the surface of the aluminum alloy plate, and meanwhile, under the condition of compounding the laser and the MIG, the reflected laser is easy to act on a welding wire and heats and melts the welding wire, so that the arc is unstable; the welding mode of the ultrathin aluminum alloy plates is butt joint; the laser mainly plays a role of assisting electric arc in the laser-assisted MIG composite heat source welding process, and the consideration is that the absorption rate of the aluminum alloy plate to the laser is extremely low, the welding speed is slow and the laser only exists in an energy form; the process laser is only used as an auxiliary heat source, and a thermal conduction welding mode is mainly used, so that pulse laser with lower average power is selected; when the laser peak power or the base power is too large, the laser can realize a deep fusion welding mode under the action of electric arcs when the pulse frequency is 20Hz, and the laser thermal conduction welding mode is unstable when the laser peak power or the base power is too small. If the laser peak power duration is too long, the base value power duration is reduced, the laser average power is increased, and the number of charged particles is increased; if the peak duration is reduced, it will result in an increase in the base duration, reducing the number of charged ions, and the time ratio of the two will have a strong impact on arc stability. And when the laser peak power duration is 10ms and the base power duration is 40ms, the effect on arc stability is best. In addition, under the condition of a certain welding speed, when the pulse frequency is higher than 20Hz, the heat input of the laser acting on the base material is increased, so that the deformation of the base material is increased; if the pulse frequency is less than 20Hz, the heat input of the laser beam to the base material is reduced, the number of charged particles is reduced, and the arc is unstable.
During welding, the pulse MIG welding current is 19A, the arc voltage is 13.2V, the frequency of the pulse MIG is 50Hz (the pulse frequency is 50 Hz), and the requirement of a droplet transition form of pulse MIG welding is met, so that at least one droplet is transited by one pulse; if the pulse frequency is too low, the electric arc is unstable due to the increase of the electric arc, and a short circuit phenomenon occurs between a welding wire and a molten pool; if the pulse frequency is too high, the heat input is increased, and the ablation problem appears; the horizontal inclination angle of the MIG welding gun is 66 degrees (the horizontal inclination angle is the included angle between the welding wire and the aluminum alloy plate surface), the distance between the optical wires is 1mm, and the elongation of the welding wire between the contact nozzle of the MIG welding gun and the surface of the aluminum alloy plate is 10 mm; the welding speed was 1.50 m/min.
The laser-assisted MIG hybrid welding process of the thin aluminum alloy plate comprises the following steps of:
during welding, the laser is in a continuous mode, and the MIG electric arc is in a pulse mode;
the power of the laser is constant at 300W, and the defocusing amount of the laser is 0; the vertical inclination angle of the laser beam is 5 degrees; the welding mode of the ultrathin aluminum alloy plates is butt joint;
during welding, the pulse MIG welding current is 19A, the arc voltage is 13.2V, and the frequency of the pulse MIG is 50 Hz; the horizontal inclination angle of the MIG welding gun is 66 degrees, the distance between the light wires is 1mm, and the elongation of the welding wire between the contact nozzle of the MIG welding gun and the surface of the aluminum alloy plate is 10 mm; the welding speed was 1.50 m/min.
The laser-assisted MIG hybrid welding process of the thin aluminum alloy plate comprises the following steps of: the ultrathin aluminum alloy plate is a 2219 aluminum alloy plate; 2219 aluminum alloy: 6.48 wt% of copper, 0.32 wt% of manganese, 0.23 wt% of iron, 0.06 wt% of titanium, 0.49 wt% of silicon, 0.04 wt% of zinc, 0.2 wt% of zirconium, and the balance of aluminum.
The laser-assisted MIG hybrid welding process of the thin aluminum alloy plate comprises the following steps of: the aluminum-magnesium alloy wire is an ER5356 welding wire; ER5356 welding wire: 0.15 wt% of manganese, 0.04 wt% of silicon, 0.07 wt% of chromium, 0.08 wt% of titanium, 5.1 wt% of magnesium, less than or equal to 0.07 wt% of copper, less than or equal to 0.01 wt% of zinc, and the balance of aluminum.
The laser-assisted MIG hybrid welding process of the thin aluminum alloy plate comprises the following steps: adopting a paraxial composite welding torch for MIG composite heat source welding assisted by laser; the side-shaft type composite welding torch consists of a laser welding head and a gooseneck MIG welding gun; the gooseneck MIG welding gun is a Fornis TPS2700 accessory; the laser is a PLW3000 light laser provided by Tianjin Merchant numerical control technology, Inc., the maximum output power is 3KW, the laser wavelength is 1070 μm in a continuous mode, and the diameter of a focus spot is 300 μm; cooling the laser by using a water cooling machine;
the arc welding power supply is a TPS2700 welding machine, the protective gas in an MIG welding gun is 100% argon, and the flow of the protective gas is 15L/min.
The laser-assisted MIG hybrid welding process of the thin aluminum alloy plate comprises the following steps: during welding, the welding mode of the thin aluminum alloy plates is lap joint, and the angle of inclination of the thin aluminum alloy plates during lap joint is 22 degrees (the lap joint angle of inclination refers to the included angle between the horizontal plane and the junction of the lap joint plates and the base plate when to be welded); the shape difference of the welding bead under different lapping inclination angles of the aluminum alloy plate is large, the traveling of an MIG welding gun is influenced when the lapping angle is too large, and the MIG electric arc is unstable when the lapping angle is too small, so that the liquid molten metal is deflected to one side of the welding bead, and the welding seam undercut is generated; the included angle between the laser beam and the thin aluminum alloy plate is 110 degrees (namely the laser beam is vertical to the surface of a welding seam and inclines for 20 degrees in the opposite direction of the welding gun); according to the invention, the ultra-thin aluminum alloy plate with the thickness of 0.5mm is butted by adopting a pulse mode, and the thin aluminum alloy plate with the thickness of 3mm is lapped by adopting a non-pulse mode; in general, fiber lasers can generate metal vapor and plasma; the ultra-thin aluminum alloy sheet of 0.5mm was made by using a pulse mode laser, which generated much less amount of metal vapor than the non-pulse mode 3mm thin aluminum alloy. The metal vapor influences the electric arc in the welding process, so under the conditions of welding of 0.5mm ultrathin aluminum alloy plates and pulse mode laser, the influence of the metal vapor can be ignored, and the influence of the metal vapor needs to be considered for 3mm aluminum alloy, the invention changes the movement direction of the metal vapor by changing the laser incident angle, reduces the influence of the metal vapor on the electric arc, the laser power is 500W, and the laser defocusing amount is 0; the horizontal inclination angle of the MIG welding gun is 66 degrees, the MIG arc voltage is 19.2V, the wire feeding speed is 8.2m/min, and the welding speed is 1.20 m/min; the distance between the optical fibers is 2mm, and the elongation of the welding wire between the contact nozzle of the MIG welding gun and the surface of the aluminum alloy plate is 10 mm.
The laser-assisted MIG hybrid welding process of the thin aluminum alloy plate comprises the following steps: the thin aluminum alloy plate is a 2219 aluminum alloy plate; 2219 aluminum alloy: 6.48 wt% of copper, 0.32 wt% of manganese, 0.23 wt% of iron, 0.06 wt% of titanium, 0.49 wt% of silicon, 0.04 wt% of zinc, 0.2 wt% of zirconium and the balance of aluminum;
the laser-assisted MIG composite welding process of the thin aluminum alloy plate comprises the following steps: the aluminum-magnesium alloy wire is an ER5356 welding wire; ER5356 welding wire: 0.15 wt% of manganese, 0.04 wt% of silicon, 0.07 wt% of chromium, 0.08 wt% of titanium, 5.1 wt% of magnesium, less than or equal to 0.07 wt% of copper, less than or equal to 0.01 wt% of zinc, and the balance of aluminum.
The technical scheme of the invention achieves the following beneficial technical effects:
1. the invention uses an ultrathin aluminum alloy plate with the thickness of 0.5mm as a base material and an ER5356 welding wire as a welding material, and adopts a paraxial compound mode that laser is in front of MIG electric arc and behind; during welding, the laser is a continuous mode or pulse mode laser beam, and the MIG electric arc is a pulse mode electric arc; the welding process has good stability, can effectively reduce the deformation of the ultrathin aluminum alloy plate in the welding process, realizes full penetration welding seams, obtains smooth and flat butt welding seams of the upper surface and the lower surface, and simultaneously achieves higher welding speed (1.50 m/min).
2. When the ultra-thin aluminum alloy plate with the thickness of 0.5mm is welded, the laser beam is controlled in a pulse mode, an auxiliary continuous mode or a pulse mode through MIG electric arc, and technological parameters such as pulse frequency, electric arc voltage, wire feeding speed, an inclination angle between the aluminum alloy plate and a welding gun and between the aluminum alloy plate and the laser beam, the flow of shielding gas and the like are adjusted, so that the welded seam of the ultra-thin aluminum alloy plate is good in forming effect, the welding process is good in stability, the deformation of the ultra-thin aluminum alloy plate is small, and the welding speed is high.
3. The method takes a thin aluminum alloy plate with the thickness of 3mm as a base material, an ER5356 welding wire as a welding material, and adopts a paraxial composite mode of laser in front of MIG electric arc and behind; during welding, the laser is a continuous mode or pulse mode laser beam, and the MIG arc is a continuous mode arc; the welding process can also effectively reduce the deformation of the thin aluminum alloy plate, realize full penetration welding seams, and achieve higher welding speed (up to 1.80m/min) while obtaining smooth butt welding seams on the upper surface and the lower surface. Compared with CMT, the welding process of the thin aluminum alloy plate can reduce the metal filling amount of the welding line, reduce the extra height, increase the dimensional precision of the welding structure and effectively control the extra height and the weld fusion width on the basis of improving the stability of the welding process and the welding speed.
Drawings
FIG. 1a is a schematic view of the upper surface of a weld of an ultra-thin aluminum alloy sheet obtained by a welding process according to example 1 of the present invention;
FIG. 1b is a schematic view of the lower surface of the weld of the ultra-thin aluminum alloy sheet obtained by the welding process of example 1 of the present invention;
FIG. 2a is a schematic view of the upper surface of a weld of an ultra-thin aluminum alloy sheet obtained by a welding process according to example 2 of the present invention;
FIG. 2b is a schematic view of the lower surface of the weld of the ultra-thin aluminum alloy sheet obtained by the welding process of example 2 of the present invention;
FIG. 3a is a schematic view of the upper surface of a weld of an ultra-thin aluminum alloy sheet obtained by the welding process of comparative example 1 according to the present invention;
FIG. 3b is a schematic view of a lower surface of a weld of an ultra-thin aluminum alloy sheet obtained by the welding process of comparative example 1 according to the present invention;
fig. 4 is a schematic view of weld joint formation in a laser-MIG composite lap joint process in embodiment 3 of the present invention under different laser powers (the laser powers are 200W, 350W, 500W, 1000W, and 1500W from top to bottom in sequence);
FIG. 5 is a schematic diagram of weld formation at different welding speeds in a laser-MIG composite lap joint process in embodiment 3 of the present invention (the welding speeds are 20mm/s, 30mm/s, and 40mm/s in order from top to bottom);
fig. 6 is a schematic view of weld formation under different arc voltages in the laser-MIG composite lap joint process in embodiment 3 of the invention (the arc voltages are 17.2V, 18.2V, 19.2V, 20.2V, 21.2V, and 22.2V in sequence from top to bottom);
FIG. 7 is a schematic view of weld formation in the laser-MIG composite lap joint process of embodiment 3 of the present invention at different wire feed speeds (the wire feed speeds are 6.2m/min, 8.2m/min, and 10.2m/min from top to bottom in sequence);
FIG. 8 is a schematic diagram of single MIG weld formation in example 3 of the present invention;
FIG. 9 is a schematic view of weld formation under different welding parameters when the CMT process is adopted in embodiment 3 of the present invention (serial numbers in Table 4 are set to 1, 2 and 3);
FIG. 10 is a schematic view of weld formation under different welding parameters when the CMT process is adopted in embodiment 3 of the present invention (serial numbers in Table 4 are 4, 5 and 6);
FIG. 11 is a schematic view of weld formation under different welding parameters when the CMT process is employed in example 3 of the present invention ( serial numbers 7, 8, and 9 in Table 4).
Detailed Description
Example 1
In the laser-assisted MIG composite heat source welding process for the ultrathin aluminum alloy plate in the embodiment, the ultrathin aluminum alloy plate with the thickness of 0.5mm is used as a base material, ER5356 is used as a welding wire, and the welding is carried out in a paraxial composite mode that laser is in front of MIG electric arc and is behind the MIG electric arc; adopting a paraxial composite welding torch for MIG composite heat source welding assisted by laser; the side-shaft type composite welding torch consists of a laser welding head and a gooseneck MIG welding gun; the gooseneck MIG welding gun is a Fornis TPS2700 accessory; the fiber laser is provided by Tianjin Merchant numerical control technology, Inc.; the ultrathin aluminum alloy plate is a 2219 aluminum alloy plate; 2219 aluminum alloy: 6.48 wt% of copper, 0.32 wt% of manganese, 0.23 wt% of iron, 0.06 wt% of titanium, 0.49 wt% of silicon, 0.04 wt% of zinc, 0.2 wt% of zirconium and the balance of aluminum; ER5356 welding wire: 0.15 wt% of manganese, 0.04 wt% of silicon, 0.07 wt% of chromium, 0.08 wt% of titanium, 5.1 wt% of magnesium, less than or equal to 0.07 wt% of copper, less than or equal to 0.01 wt% of zinc and the balance of aluminum.
During welding, the laser is in a pulse mode, and the MIG arc is in a pulse mode. The low-power fiber laser PLW3000 used in this embodiment is provided by a laser of PLW3000 model number produced by tianjin business numerical control technology ltd, the maximum output power of which is 3KW, the laser wavelength in continuous mode is 1070 μm, and the focal spot diameter is 300 μm; cooling the laser by using a water cooling machine; the arc welding power supply adopts a TPS2700 welder manufactured by Fronius of Austria, the protective gas in an MIG welding gun is 100% argon, and the flow rate of the protective gas is 15L/min.
During welding, the laser peak power of the laser is 300W, the duration time is 10ms, the laser base value power is 187W, the duration time is 40ms, the pulse frequency is 20Hz, and the laser defocusing amount is 0; the vertical inclination angle of the laser beam is 5 degrees; the welding mode of the ultrathin aluminum alloy plates is butt joint. During welding, the pulse MIG welding current is 19A, the arc voltage is 13.2V, and the frequency of the pulse MIG is 50 Hz; the horizontal inclination angle of the MIG welding gun is 66 degrees, the distance between the light wires is 1mm, and the elongation of the welding wire between the contact nozzle of the MIG welding gun and the surface of the aluminum alloy plate is 10 mm; the welding speed was 1.50 m/min.
Example 2
The difference between the laser-assisted MIG composite heat source welding process for the ultrathin aluminum alloy plate in the embodiment and the embodiment 1 is only that: the laser beam is a continuous mode laser beam, and the power of the laser is constant at 300W during welding. Other welding operations, tools, materials and process parameters were the same as in example 1.
Comparative example 1
The difference between the laser-assisted MIG composite heat source welding process of the ultrathin aluminum alloy plate in the comparative example and the welding process of the example 2 is only that: the MIG arc was a continuous mode arc and the welding speed was 0.9 mm/min. Other welding operations, tools, materials and process parameters were the same as in example 2.
Fig. 1a and 1b are views illustrating the formation of the upper and lower surfaces of the weld of the ultra-thin aluminum alloy sheet welded by the welding process of example 1, respectively. FIG. 2a and FIG. 2b are views showing the formation of the upper and lower surfaces of the weld of the ultra-thin aluminum alloy sheet welded by the welding process of example 2, respectively; fig. 3a and 3b are views illustrating the formation of the upper and lower surfaces of a weld of an ultra-thin aluminum alloy sheet welded using the welding process of comparative example 1, respectively.
As can be seen from FIGS. 3a and 3b, due to poor weldability of the aluminum alloy sheet and excessively thin sheet material, at a low MIG welding current (19A), the droplet transition behavior is irregular and unstable, and large droplet-shaped droplets are easily formed during welding, which makes the welding process unstable. The continuous mode laser-direct current MIG composite heat source welding cannot obtain better weld formation.
As can be seen from fig. 2a and 2b, by using the continuous mode laser-pulse MIG composite heat source welding process, good flat butt weld formation can be obtained, the upper and lower surfaces of the weld are smooth and flat, and the upper surface of the weld has uniform fish scale lines; the penetration depth reaches more than 0.4mm, and the full penetration welding seam can be realized. The introduction of the electric arc pulse is assisted by a low-power laser beam, so that the welding heat input can be accurately controlled and controlled, the molten drop transition process is stabilized, and the regular molten drop transition behavior is realized, so that the continuous mode laser-direct current pulse MIG composite heat source welding can obtain the stable welding process at a higher welding speed, and the good weld seam forming can be obtained. As can be seen from fig. 1a and 1b, good flat butt weld formation can be obtained by using the pulsed laser-pulsed MIG composite heat source welding process. Compared with the continuous mode laser-pulse MIG composite heat source welding process, the pulse laser is added, so that the welding heat input can be controlled in a larger range, the deformation of a workpiece is further reduced, and the weld fusion width is reduced.
Example 3
In the laser-MIG composite heat source welding process of the thin aluminum alloy plate, an ultrathin aluminum alloy plate with the thickness of 3mm is used as a base material, ER5356 is used as a welding wire, and a paraxial composite mode that laser is used for welding before MIG electric arc is used for welding after MIG electric arc is used; adopting a paraxial composite welding torch for MIG composite heat source welding assisted by laser; the side-shaft type composite welding torch consists of a laser welding head and a gooseneck MIG welding gun; the gooseneck MIG welding gun is a Fornis TPS2700 accessory; the fiber laser is provided by Tianjin Shangke numerical control technology, Inc.; the ultrathin aluminum alloy plate is a 2219 aluminum alloy plate; 2219 aluminum alloy: 6.48 wt% of copper, 0.32 wt% of manganese, 0.23 wt% of iron, 0.06 wt% of titanium, 0.49 wt% of silicon, 0.04 wt% of zinc, 0.2 wt% of zirconium and the balance of aluminum; ER5356 welding wire: 0.15 wt% of manganese, 0.04 wt% of silicon, 0.07 wt% of chromium, 0.08 wt% of titanium, 5.1 wt% of magnesium, less than or equal to 0.07 wt% of copper, less than or equal to 0.01 wt% of zinc and the balance of aluminum.
During welding, the laser is in continuous mode, and the MIG arc is in pulse mode. The optical fiber laser used in the embodiment is provided by Tianjin Merchant numerical control technology, Inc., the model number of the optical fiber laser is PLW3000, the maximum output power is 3KW, the laser wavelength is 1070 mu m in a continuous mode, and the diameter of a focus spot is 300 mu m; cooling the laser by using a water cooling machine; the arc welding power supply adopts a TPS2700 welding machine, the protective gas in an MIG welding gun is 100% argon, and the flow of the protective gas is 15L/min.
When in welding, the thin aluminum alloy plates are welded in a lap joint mode, and the inclination angle of the thin aluminum alloy plates in the lap joint mode is 22 degrees; the included angle between the laser beam and the thin aluminum alloy plate is 110 degrees, and the defocusing amount of the laser is 0; the horizontal inclination angle of the MIG welding gun is 66 degrees; the distance between the light wires is 2mm, and the elongation of the welding wire between the contact nozzle of the MIG welding gun and the surface of the aluminum alloy plate is 10 mm; under the parameter conditions, the laser power is changed to 200W, 350W, 500W, 1000W and 1500W respectively, the MIG arc voltage is changed to 17.2V, 18.2V, 19.2V, 20.2V, 21.2V and 22.2V respectively, the wire feeding speed is 6.2m/min, 8.2m/min and 10.2m/min, and the welding speed is 1.20m/min, 1.80m/min and 2.40m/min respectively, and the welding seam forming conditions during the welding of the thin aluminum alloy plate under different parameter conditions are researched respectively.
1. Effect of laser Power on weld formation
TABLE 1
Fig. 4 shows the formation of a 3mm aluminum alloy laser-MIG composite heat source lap weld under different laser powers, the laser powers are respectively selected from 200W, 350W, 500W, 1000W and 1500W, the welding parameters are shown in table 1, when the laser power is less than 500W, the weld formation is shown in (1) and (2) in fig. 4, and the weld formation has undercut defects at weld toes. When the laser power is 500W, the weld formation is relatively good. With the continuous increase of the laser power, when the laser power is more than 500W, as shown in (4) and (5) in fig. 4, there is no significant change in the weld surface profile. It can be seen that when the laser power is increased from 500W, the influence of the aluminum alloy on the weld forming is not changed due to the high reflection effect of the aluminum alloy, and the 500W laser can play a role in stabilizing the electric arc and the molten drop transition; therefore, the optimal laser power should be 500W.
2. Effect of welding speed on weld formation
TABLE 2
As shown in FIG. 5, the weld formation at different welding speeds is shown, and the welding parameters are shown in Table 2, it can be found by comparing FIG. 5 that the weld width becomes narrower and the weld formation becomes worse as the welding speed increases, and when the welding speed is 2.40m/min, metal spatters appear at the edge of the weld and the weld formation is worst, while the welding speeds of (1) and (2) in FIG. 5 are 1.20m/min and 1.80m/min, from which it can be seen that the weld formation of both is good, so the welding speed can reach the range of 1.20 m/min-1.80 m/min.
3. Influence of arc voltage on weld formation
TABLE 3
To further optimize the weld formation, the MIG arc voltage was adjusted. Fig. 6 shows the laser-MIG composite heat source lap weld formation at different arc voltages, with the corresponding welding parameters shown in table 3. It can be seen from the figure that the weld surface becomes smoother as the arc voltage increases, and the weld formation is best when the welding voltage is 19.2V, fig. 6 (3). Continuing to increase the arc voltage, finding that the weld metal filling is enlarged and the fusion width is widened; when the pressure is increased to 21.2V, fine metal particles appear at the periphery of the welding line, and the splashing is increased; when the welding voltage is 22.2V, the heat input is too large, the welding seam is collapsed, and the optimal welding voltage is 19.2V.
4. Effect of wire feed speed on weld formation
TABLE 4
Fig. 7 shows the laser-MIG composite heat source lap weld formation at different wire feed speeds, with the welding parameters shown in table 4. As can be seen by comparing and observing weld forming, for an aluminum plate with the thickness of 3mm, the filling amount of weld metal is most suitable to be 8.2m/min, when the wire feeding speed is 6.2m/min, the weld is not filled, when the wire feeding speed is 10.2m/min, the filling metal is in transition, the residual height of the weld is higher than that of the upper plate, and therefore, the wire feeding speed is more suitable to be 8.2 m/min.
In summary, for 3mm aluminum alloy plate lap welding, the optimal welding parameters for lap welding by using a laser-MIG composite heat source are as follows: the inclination angle of the aluminum alloy plate is 22 degrees, the inclination angle of the laser is 110 degrees, the inclination angle of the welding gun is 66 degrees, pure argon is adopted as the shielding gas (the gas flow is 15L/min), the welding speed is 1.20m/min, the laser power is 500W, the wire feeding speed is 8.2m/min, and the arc voltage is 19.2V.
According to the invention, researchers adopt a single MIG welding method to weld the aluminum alloy with the thickness of 3mm, the welding speed during welding is 0.48m/min, the welding current is changed to 120A-140A, and other process parameters are the same as the optimal welding parameters of the laser-MIG composite heat source lapping adopted in the embodiment. Fig. 8 is a schematic view of weld formation obtained by welding at welding currents of 120A, 130A, and 140A, respectively. When the welding current is 120A, the seam has undercut defect, when the welding current is 140A, the weld bead width is too wide, the droplet transition form is carried out by short-circuit transition and droplet ejection transition, and the splash is increased, so that the seam forming when the welding current is 130A is optimal, but at the moment, the welding speed is lower, and the integral seam forming is not as good as the forming effect of the laser-MIG composite heat source lapping process parameter in the embodiment. The above test results show that the weld formation obtained by the single MIG welding method under the condition of lower welding speed is still not the same as the formation effect of the laser-MIG composite heat source lapping process parameter adopted in the embodiment under the condition of higher welding speed
In addition, according to the invention, researchers adopt a CMT welding process to weld the aluminum alloy with the thickness of 3mm, a welding test adopts a two-factor three-level full-factor test, test parameters are shown in table 5, the test adopts a welding gun with the inclination angle of 30 degrees, adopts pure argon as protective gas, adopts the gas flow of 15L/min, and totally performs 9 groups of tests.
Weld profiles corresponding to the welding parameters in table 5 are shown in fig. 9, 10, and 11, and no weld penetration is given for the back side weld profiles. When the welding speed is fixed, the CMT welding line increases in width with the increase of welding current, the back welding line is gradually penetrated, and the trend is increased with the increase of heat input, such as the welding line forming of serial numbers 3, 6 and 9 and the back welding line forming.
When the welding current is constant, the fusion width of the welding wire is narrowed along with the increase of the welding speed, when the welding current is 110A, the welding wire is well formed only at the welding speed of 0.48m/min, and the welding wire forming of the welding wires with the serial numbers 4 and 7 has the defects of non-fusion, undercut and the like due to insufficient heat input. When the welding current is 130A, with the increase of the welding speed, the back welding seam of the serial number 2 is formed and penetrated, the back welding seam of the serial number 8 is not formed and completely penetrated, and the welding seam of the serial number 5 is formed and has just appeared the penetration sign; when the welding single flow is 150A, the weld joint on the back surface is formed and is completely melted, which is not favorable for the size requirement of the structure. Finally, for a 3mm aluminum alloy sheet, the optimal parameters for the CMT lap joint are: the welding current was 130A, and the welding speed was 0.60m/min, as shown in FIG. 10. Therefore, the CMT welding process is adopted to carry out lap welding on the aluminum alloy plate with the thickness of 3mm, and the welding speed is only 0.60m/min, which is far lower than that of the laser-MIG composite lap welding process in the embodiment.
Because the reflectivity of aluminum alloy is strong, most laser is reflected, and the heat input that leads to laser is less, and at the in-process of welding aluminum alloy, the effect of laser lies in stabilizing arc and molten drop transition, can solve single MIG welding inefficiency, welds unstable scheduling problem. The laser is added on the basis of an MIG heat source, so that the rapid welding process can be realized, and the highest welding speed can reach 1.80 m/min.
Compared with CMT, on the basis of improving the welding speed, the laser-MIG composite heat source welding process can reduce the metal filling amount of the welding seam, reduce the extra height, increase the dimensional precision of the welding structure and effectively control the extra height and the weld fusion width. In addition, the welding speed is improved, so that the welding heat input can be effectively reduced, and the deformation after welding is reduced.
Claims (10)
1. The laser-assisted MIG hybrid welding process of the thin aluminum alloy plate is characterized in that for the ultrathin aluminum alloy plate: welding by using an ultrathin aluminum alloy plate with the thickness of less than or equal to 0.5mm as a base material and an aluminum-magnesium alloy wire as a welding wire in a paraxial composite mode of laser in front of MIG electric arc and behind; during welding, the laser is in a continuous mode or a pulse mode, and the MIG electric arc is in a pulse mode;
for thin aluminum alloy plates: a thin aluminum alloy plate with the thickness of less than or equal to 3mm and more than 0.5mm is used as a base material, an aluminum magnesium alloy wire is used as a welding wire, and the laser welding is carried out in a paraxial composite mode after the front MIG arc; during welding, the laser is in continuous mode or pulse mode, and the MIG arc is in non-pulse mode.
2. A laser assisted MIG hybrid welding process of thin aluminium alloy sheet according to claim 1, characterised in that for ultra thin aluminium alloy sheet: adopting a paraxial composite welding torch for MIG composite heat source welding assisted by laser; the side-shaft type composite welding torch consists of a laser welding head and a gooseneck MIG welding gun; the laser is a PLW3000 fiber laser provided by Tianjin Merchant numerical control technology, Inc., the maximum output power is 3KW, the wavelength of the laser beam is 1070 μm in a continuous output mode, and the diameter of a focus spot is 300 μm; cooling the laser by using a water cooling machine;
the arc welding power supply adopts a TPS2700 welding machine, the protective gas in an MIG welding gun is 100% argon, and the flow of the protective gas is 15L/min.
3. A laser assisted MIG hybrid welding process of thin aluminium alloy sheet according to claim 2, characterised in that for ultra thin aluminium alloy sheet:
during welding, the laser is in a pulse mode, and the MIG electric arc is in a pulse mode;
the laser peak power of the laser is 300W, and the duration time is 10 ms; the laser basic value power is 187W, and the duration is 40 ms; the pulse frequency is 20Hz, and the defocusing amount of the laser is 0; the vertical inclination angle of the laser beam is 5 degrees; the welding mode of the ultrathin aluminum alloy plates is butt joint;
during welding, the pulse MIG welding current is 19A, the arc voltage is 13.2V, and the frequency of the pulse MIG is 50 Hz; the horizontal inclination angle of the MIG welding gun is 66 degrees, the distance between the light wires is 1mm, and the elongation of the welding wire between the contact nozzle of the MIG welding gun and the surface of the aluminum alloy plate is 10 mm; the welding speed was 1.50 m/min.
4. A laser assisted MIG hybrid welding process of thin aluminium alloy sheet according to claim 2, characterised in that for ultra thin aluminium alloy sheet:
during welding, the laser is in a continuous mode, and the MIG electric arc is in a pulse mode;
the power of the laser is constant at 300W, and the defocusing amount of the laser is 0; the vertical inclination angle of the laser beam is 5 degrees; the welding mode of the ultrathin aluminum alloy plates is butt joint;
during welding, the pulse MIG welding current is 19A, the arc voltage is 13.2V, and the frequency of the pulse MIG is 50 Hz; the horizontal inclination angle of the MIG welding gun is 66 degrees, the distance between the light wires is 1mm, and the elongation of the welding wire between the contact nozzle of the MIG welding gun and the surface of the aluminum alloy plate is 10 mm; the welding speed was 1.50 m/min.
5. A laser assisted MIG hybrid welding process of thin aluminium alloy sheet according to claim 1, characterised in that for ultra thin aluminium alloy sheet: the ultrathin aluminum alloy plate is a 2219 aluminum alloy plate; 2219 aluminum alloy: 6.48 wt% of copper, 0.32 wt% of manganese, 0.23 wt% of iron, 0.06 wt% of titanium, 0.49 wt% of silicon, 0.04 wt% of zinc, 0.2 wt% of zirconium and the balance of aluminum.
6. A laser assisted MIG hybrid welding process of thin aluminium alloy sheet according to claim 1, characterised in that for ultra thin aluminium alloy sheet: the aluminum-magnesium alloy wire is an ER5356 welding wire; ER5356 welding wire: 0.15 wt% of manganese, 0.04 wt% of silicon, 0.07 wt% of chromium, 0.08 wt% of titanium, 5.1 wt% of magnesium, less than or equal to 0.07 wt% of copper, less than or equal to 0.01 wt% of zinc and the balance of aluminum.
7. A laser assisted MIG hybrid heat source welding process of a thin aluminum alloy sheet as claimed in claim 1 wherein for a thin aluminum alloy sheet: adopting a paraxial composite welding torch for MIG composite heat source welding assisted by laser; the side-shaft type composite welding torch consists of a laser welding head and a gooseneck MIG welding gun; the laser is a PLW3000 type fiber laser provided by Tianjin Merchant numerical control technology, Inc., the maximum output power is 3KW, the laser wavelength is 1070 μm under continuous mode output, and the diameter of a focus spot is 300 μm; cooling the laser by using a water cooling machine;
the arc welding power supply is a TPS2700 welding machine, the protective gas in an MIG welding gun is 100% argon, and the flow of the protective gas is 15L/min.
8. A laser assisted MIG hybrid welding process of a thin aluminium alloy sheet according to claim 7, wherein for a thin aluminium alloy sheet: when in welding, the thin aluminum alloy plates are welded in a lap joint mode, and the inclination angle of the thin aluminum alloy plates in the lap joint mode is 22 degrees; the included angle between the laser beam and the thin aluminum alloy plate is 110 degrees, the laser power is 500W, and the defocusing amount of the laser is 0; the horizontal inclination angle of the MIG welding gun is 66 degrees, the MIG arc voltage is 19.2V, the wire feeding speed is 8.2m/min, and the welding speed is 1.20 m/min; the distance between the light wires is 2mm, and the elongation of the welding wire between the contact tip of the MIG welding gun and the surface of the aluminum alloy plate is 10 mm.
9. A laser assisted MIG hybrid welding process of thin aluminium alloy sheet according to claim 1, wherein for thin aluminium alloy sheets: the thin aluminum alloy plate is a 2219 aluminum alloy plate; 2219 aluminum alloy: 6.48 wt% of copper, 0.32 wt% of manganese, 0.23 wt% of iron, 0.06 wt% of titanium, 0.49 wt% of silicon, 0.04 wt% of zinc, 0.2 wt% of zirconium and the balance of aluminum.
10. A laser assisted MIG hybrid welding process of thin aluminium alloy sheet according to claim 1, wherein for thin aluminium alloy sheets: the aluminum-magnesium alloy wire is an ER5356 welding wire; ER5356 welding wire: 0.15 wt% of manganese, 0.04 wt% of silicon, 0.07 wt% of chromium, 0.08 wt% of titanium, 5.1 wt% of magnesium, less than or equal to 0.07 wt% of copper, less than or equal to 0.01 wt% of zinc and the balance of aluminum.
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