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高频直缝焊管焊接过程中的工艺介绍

文章出处:   发布时间:2018-09-12 12:46:05   浏览:37

高频直缝焊管在焊接过程中主要环节有六点应该值得注意,下面我就这六个环节给大家详细说明一下:1、 焊缝间隙的控制.将带钢送入焊管机组,经多道轧辊滚压,带钢逐渐卷起,形成有开口间隙的圆形管坯,调整挤压辊的压下量,使焊缝间隙控制在1~3mm,并使焊口两端齐平。如间隙过大,则造成邻近效应减少,涡流热量不足,焊缝晶间接合不良而产生未熔合或开裂。如间隙过小则造成邻近效应增大,焊接热量过大,造成焊缝烧损;或者焊缝经挤压、滚压后形成深坑,影响焊缝表面质量。

There are six main links in the welding process of high frequency straight seam welded pipe which should be noticed. The following six links are explained in detail: 1. Control of seam clearance. Reduce the weld clearance to 1~3mm and make the ends of the weld level flush. If the gap is too large, the proximity effect will be reduced, the eddy current heat is insufficient, and the weld grain will not fuse or crack due to poor indirect bonding. If the gap is too small, the adjacency effect will be increased, and the welding heat will be too large, resulting in weld burning loss; or the weld will be extruded and rolled to form a deep pit, affecting the surface quality of the weld.

2、焊接温度控制

2. Welding temperature control

焊接温度主要受高频涡流热功率的影响,根据公式(2)可知,高频涡流热功率主要受电流频率的影响,涡流热功率与电流激励频率的平方成正比;而电流激励频率又受激励电压、电流和电容、电感的影响。激励频率公式为:

The welding temperature is mainly affected by the high frequency eddy current thermal power. According to the formula (2), the high frequency eddy current thermal power is mainly affected by the current frequency, and the eddy current thermal power is proportional to the square of the current excitation frequency. The excitation frequency formula is:

f=1/[2π(CL)1/2]...(1)

F=1/[2 PI (CL) 1/2]... (1)

式中:f-激励频率(Hz);C-激励回路中的电容(F),电容=电量/电压;L-激励回路中的电感,电感=磁通量/电流

Formula: f-excitation frequency (Hz); C-excitation loop capacitance (F), capacitance = electricity / voltage; L-excitation loop inductance, inductance = magnetic flux / current

上式可知,激励频率与激励回路中的电容、电感平方根成反比、或者与电压、电流的平方根成正比,只要改变回路中的电容、电感或电压、电流即可改变激励频率的大小,从而达到控制焊接温度的目的。对于低碳钢,焊接温度控制在1250~1460℃,可满足管壁厚3~5mm焊透要求。另外,焊接温度亦可通过调节焊接速度来实现。

As can be seen from the above formula, the excitation frequency is inversely proportional to the square root of capacitance and inductance in the excitation loop, or proportional to the square root of voltage and current, so long as the capacitance, inductance, voltage and current in the circuit are changed, the excitation frequency can be changed, so as to control the welding temperature. For low carbon steel, the welding temperature is controlled at 1250~1460 C, which can meet the requirement of 3~5mm penetration. In addition, the welding temperature can also be achieved by adjusting the welding speed.

当输入热量不足时,被加热的焊缝边缘达不到焊接温度,金属组织仍然保持固态,形成未熔合或未焊透;当输入热时不足时,被加热的焊缝边缘超过焊接温度,产生过烧或熔滴,使焊缝形成熔洞。

When the input heat is insufficient, the edge of the weld can not reach the welding temperature, and the metal structure remains solid, forming non-fusion or non-penetration; when the input heat is insufficient, the edge of the heated weld exceeds the welding temperature, resulting in over-burning or droplets, so that the weld formed a hole.

3、 挤压力的控制

3. Control of extrusion pressure

管坯的两个边缘加热到焊接温度后,在挤压辊的挤压下,形成共同的金属晶粒互相渗透、结晶,最终形成牢固的焊缝。若挤压力过小,形成共同晶体的数量就小,焊缝金属强度下降,受力后会产生开裂;如果挤压力过大,将会使熔融状态的金属被挤出焊缝,不但降低了焊缝强度,而且会产生大量的内外毛刺,甚至造成焊接搭缝等缺陷。

After the two edges of the billet are heated to the welding temperature, the common metal grains are formed under the extrusion of the extrusion roll, which permeate and crystallize with each other, and finally form a solid weld. If the extrusion force is too small, the number of common crystals will be small, the strength of weld metal will be reduced, cracking will occur after the force is applied; if the extrusion force is too large, the molten metal will be extruded from the weld, which not only reduces the weld strength, but also produces a large number of internal and external burrs, and even causes weld lap defects.

4、 高频感应圈位置的调控

4. Position control of high frequency induction coil

高频感应圈应尽量接近挤压辊位置。若感应圈距挤压辊较远时,有效加热时间较长,热影响区较宽,焊缝强度下降;反之,焊缝边缘加热不足,挤压后成型不良。

The high frequency induction coil should be close to the position of the extrusion roller as far as possible. If the induction coil is far from the extrusion roll, the effective heating time is longer, the heat affected zone is wider, and the weld strength decreases; on the contrary, the weld edge is not heated enough, and the forming is not good after extrusion.

5、阻抗器是一个或一组焊管专用磁棒,阻抗器的截面积通常应不小于钢管内径截面积的70%,其作用是使感应圈、管坯焊缝边缘与磁棒形成一个电磁感应回路,产生邻近效应,涡流热量集中在管坯焊缝边缘附近,使管坯边缘加热到焊接温度。阻抗器用一根钢丝拖动在管坯内,其中心位置应相对固定在接近挤压辊中心位置。开机时,由于管坯快速运动,阻抗器受管坯内壁的磨擦而损耗较大,需要经常更换。

5. The impedance is a special magnetic rod for welded pipe. The cross-sectional area of the impedance should not be less than 70% of the cross-sectional area of the inner diameter of the pipe. Its function is to form an electromagnetic induction loop between the induction coil, the weld edge of the blank and the magnetic rod, which produces a proximity effect. To the welding temperature. The impedance device is dragged in the billet with a steel wire, and its center position should be relatively fixed near the center of the extrusion roll. During startup, due to the rapid movement of the tube blank, the impedance is worn down by the friction of the inner wall of the tube blank, so it needs to be replaced frequently.

6、焊缝经焊接和挤压后会产生焊疤,需要清除。清除方法是在机架上固定刀具,靠焊管的快速运动,将焊疤刮平。焊管内部的毛刺一般不清除。

6. The weld will be welded and pressed to produce weld scar and need to be removed. The cleaning method is to fix the tool on the rack and scrape the weld scar by the fast movement of the welded pipe. The burrs inside the welded pipe are generally not removed.

工艺举例 现以焊制φ32×2mm 直缝焊管为例,简述其工艺参数:

For example, the welding parameters of welded 32 2mm welded pipe are described.

带钢规格:2×98mm 带宽按中径展开加少量成型余量

Strip specification: 2 * 98mm bandwidth expanded according to medium diameter and small amount of molding allowance.

钢材材质:Q235A

Steel material: Q235A

输入 励磁电压:150V 励磁电流:1.5A 频率:50Hz

Input excitation voltage: 150V excitation current: 1.5A frequency: 50Hz

输出 直流电压:11.5kV 直流电流:4A 频率:120000Hz

Output DC voltage: 11.5kV DC current: 4A frequency: 120000Hz

焊接速度:50米/分钟

Welding speed: 50 m / min

参数调节:根据焊接线能量的变化及时调节输出电压和焊接速度。参数固定后一般不用调整。

Parameter adjustment: adjust the output voltage and welding speed according to the change of welding line energy. Generally, the parameters are not adjusted.

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