Welding Process Experiment of U-Rib Welds on Verrazano-Narrows Bridge in New York with Welding Robot

LI Lin; LIU Chun; ZHANG Kuo

doi:10.7512/j.issn.1001-2303.2024.03.12

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Welding Process Experiment of U-Rib Welds on Verrazano-Narrows Bridge in New York with Welding Robot
Vol. 54, Issue 3, Pages: 72-79(2024)
Published： 25 March 2024 ，
DOI： 10.7512/j.issn.1001-2303.2024.03.12

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李林，刘纯，张阔.美国纽约韦拉扎诺大桥U肋焊缝机器人焊接研究［J］.电焊机，2024，54（3）：72-79.

LI Lin, LIU Chun, ZHANG Kuo.Welding Process Experiment of U-Rib Welds on Verrazano-Narrows Bridge in New York with Welding Robot[J].Electric Welding Machine, 2024, 54(3): 72-79.
李林，刘纯，张阔.美国纽约韦拉扎诺大桥U肋焊缝机器人焊接研究［J］.电焊机，2024，54（3）：72-79. DOI： 10.7512/j.issn.1001-2303.2024.03.12.

LI Lin, LIU Chun, ZHANG Kuo.Welding Process Experiment of U-Rib Welds on Verrazano-Narrows Bridge in New York with Welding Robot[J].Electric Welding Machine, 2024, 54(3): 72-79. DOI： 10.7512/j.issn.1001-2303.2024.03.12.

摘要

正交异性钢桥面板因其自重轻、承载能力大，广泛应用于大跨度现代钢桥，其U形肋焊接技术是桥面板制作的关键。以美国纽约韦拉扎诺大桥U肋焊接试验为例，介绍了U肋与桥面板坡口角焊缝的自动焊接工艺。区别于传统需4次焊接的方式，通过调整U肋焊缝的坡口角度（将坡口角度调整为54°，使焊缝形状更接近三角形，增加焊缝成型系数）、钝边尺寸（2.5~3.0 mm）、焊接规范参数以及采用具有电弧跟踪系统的焊接机器人进行施焊，实现了U肋两侧坡口角焊缝机器人单道对称水平位置施焊一次成形。该工艺克服了熔深不足、烧穿、裂纹、咬边等技术难题，焊接效率是传统焊接的4倍，熔深可达U肋板厚的80%，无焊漏，焊缝外观质量良好，在业主随机抽样检验中全部合格，填补了国内外U肋焊接领域的技术空白。

Abstract

Orthotropic steel bridge deck is widely used in large-span modern steel bridges due to its lightweight and high bearing capacity

with the U-shaped rib welding technology being a key factor in the production of bridge panels. Taking the U-rib welding test on the Verrazano-Narrows Bridge in New York as an example

this paper introduces the welding process for U-rib and deck groove fillet welds. Unlike the traditional method requiring 4 weld passes

this study achieved a single pass for both sides of the U-rib groove fillet welds by adjusting the U-rib weld groove angle (54° for triangular shape and increased weld formation factor)

root face size (2.5~3.0 mm)

welding parameters

and using a welding robot with arc tracking system for welding. This process overcomes the technical issues of insufficient penetration

burn-through

cracks

and edge bite

and the welding efficiency is four times higher than the traditional method. The penetration depth reaches 80% of the U-rib thickness

with no weld leakage and good appearance quality. All samples passed the random sampling inspection by the owner

filling the technical gap in the field of U-rib welding at home and abroad. The focus of this study is the efficient and high-quality U-rib welding

with the innovation lying in the proposed single pass symmetric horizontal position welding process. The successful application of this process provides an important reference for steel bridge manufacturing at home and abroad.

关键词

正交异性钢桥面板U形肋坡口角焊缝单道对称焊接焊接工艺优化机器人焊接

Keywords

orthotropic steel bridge deckU-shaped ribgroove weldsingle pass symmetric weldingwelding process optimizationrobot welding

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