High Efficiency Magnetic Control Arc Welding Process of Aluminum Alloy Long and Thin Wall Pulse Composite for Rail Vehicles

WU Yongshou; HAN Xiaohui; CHEN Ji; LI Gangqing; LI Shuaizhen; ZUO Shuai

doi:10.7512/j.issn.1001-2303.2024.09.02

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High Efficiency Magnetic Control Arc Welding Process of Aluminum Alloy Long and Thin Wall Pulse Composite for Rail Vehicles
Vol. 54, Issue 9, Pages: 14-23(2024)
Published： 25 September 2024 ，
DOI： 10.7512/j.issn.1001-2303.2024.09.02
稿件说明：

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武永寿，韩晓辉，陈姬，等.轨道车辆铝合金长大薄壁脉冲复合磁控高效弧焊工艺研究［J］.电焊机，2024，54（9）：14-23.

WUYongshou, HAN Xiaohui, CHEN Ji, et al.High Efficiency Magnetic Control Arc Welding Process of AluminumAlloy Long and Thin Wall Pulse Composite for Rail Vehicles[J].Electric Welding Machine, 2024, 54(9): 14-23.
武永寿，韩晓辉，陈姬，等.轨道车辆铝合金长大薄壁脉冲复合磁控高效弧焊工艺研究［J］.电焊机，2024，54（9）：14-23. DOI： 10.7512/j.issn.1001-2303.2024.09.02.

WUYongshou, HAN Xiaohui, CHEN Ji, et al.High Efficiency Magnetic Control Arc Welding Process of AluminumAlloy Long and Thin Wall Pulse Composite for Rail Vehicles[J].Electric Welding Machine, 2024, 54(9): 14-23. DOI： 10.7512/j.issn.1001-2303.2024.09.02.

摘要

利用外加磁场改善电弧焊焊接工艺，具有成本低、附加耗能少、易操作等优点，已成为当今研究的热点之一。针对高速MIG焊时焊缝成形不良及焊接接头质量差等问题，在焊枪上装配一紧凑型脉冲复合磁场发生器，同时调控电弧和熔滴的左右摆动及前倾行为；并开展不同焊接参数下的铝合金车体长大薄壁型材对接接头焊接工艺试验，以研究高速焊条件下的最佳焊接工艺。研究发现，对于铝合金车体焊缝，励磁参数为8 A、120 Hz，焊接参数为265 A、23.5 V、1.2 m/min时，焊缝成形质量最佳。利用金相显微镜以及背向散射电子衍射（EBSD）技术表征了不同焊接参数下焊接接头的微观组织，分析了外加脉冲复合磁场对焊接接头组织的影响。结果表明，在高速焊接条件下（>1.0 m/min），焊接接头的晶粒相较于常规焊速时明显粗化，且熔合区宽度有所增加。然而，引入脉冲复合磁场后，晶粒尺寸和熔合区宽度均降低至与常规焊速相当的水平。开展不同焊接参数下的焊接接头力学性能测试，结果表明，外加脉冲复合磁场对焊接接头的机械性能具有显著的改善作用，焊缝区的平均硬度提高了21.37%，而接头的平均抗拉强度达到187 MPa，与传统焊接速度时的193 MPa相当接近。在保证焊缝成形质量和接头机械性能的前提下，最终将焊接速度从0.75 m/min提高到1.2 m/min，实现了优质高效的焊接过程。

Abstract

The use of external magnetic field to improve the arc welding process has the advantages of low cost

low additional energy consumption and easy operation

which has become one of the hot spots in today's research. In order to solve the problems of poor weld forming and poor quality of welded joints during high-speed MIG welding

this paper carried out the welding process test of butt joints of aluminum alloy car body with large and thin wall profiles under different welding parameters to study the optimal welding process under high-speed welding conditions. It is found that for the weld of the aluminum alloy car body

the welding quality is the best when the excitation parameters are 8 A

120 HZ

and the welding parameters are 265A

23.5V

and 1.2 m/min. Metallurgical microscopy and backscatter electron diffraction (EBSD) were used to characterize the microstructure of welded joints under different welding parameters

and the effects of applied pulsed composite magnetic fields on the microstructure of welded joints were analyzed. The results show that under the condition of high-speed welding

the grain of the welded joint is significantly coarser compared with the conventional welding speed

and the width of the fusion zone is increased. However

with the introduction of pulsed composite magnetic fields

both the grain size and the width of the fusion zone are reduced to a level comparable to that of conventional welding. The results show that the mechanical properties of welded joints under different welding parameters are significantly improved

the average hardness of the weld zone is increased by 21.37%

and the average tensile strength of the joint reaches 187MPa

which is quite close to the 193MPa at the traditional welding speed. Under the condition of ensuring the forming quality of the weld and the mechanical properties of the welded joint

the welding speed was finally increased from 0.75m/min to 1.2m/min

and the high-quality and efficient welding process was realized.

关键词

铝合金复合磁场励磁参数磁控弧焊微观组织力学性能高效焊接

Keywords

aluminum alloycomposite magnetic fieldexcitation parametersmagnetron arc weldingmicrostructuremechanical propertieshigh efficiency welding

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