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1. 南京理工大学 受控电弧智能增材技术工业和信息化部重点实验室, 江苏 南京 210094
2. 北京航空航天大学 机械工程及自动化学院, 北京 100191
Received:04 August 2023,
Published Online:30 October 2024,
Published:31 October 2024
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Li MA, Jikang FAN, Baoqiang CONG, et al. Droplet Transfer Characteristics of High Nitrogen Steel in Ultrasonic Frequency Pulsed GMA Additive Manufacturing[J]. Acta Armamentarii, 2024, 45(10): 3686-3695.
Li MA, Jikang FAN, Baoqiang CONG, et al. Droplet Transfer Characteristics of High Nitrogen Steel in Ultrasonic Frequency Pulsed GMA Additive Manufacturing[J]. Acta Armamentarii, 2024, 45(10): 3686-3695. DOI: 10.12382/bgxb.2023.0721.
针对高氮钢增材制造熔滴过渡过程中氮元素逸出及飞溅问题
进行超音频脉冲熔化极气体保护(Ultrasonic Frequency Pulsed Gas Metal Arc
UFP-GMA)增材制造熔滴过渡试验
研究不同超音频脉冲电流叠加模式和脉冲电流频率对高氮钢熔滴过渡稳定性的影响
获取能够实现高氮钢增材稳定熔滴过渡的工艺参数。试验结果表明:在脉冲熔化极气体保护(Pulsed Gas Metal Arc
P-GMA)增材工艺条件下可以实现一脉一滴过渡
但是过渡稳定性较差
飞溅明显;在P-GMA基值阶段或基值和峰值阶段都叠加超音频脉冲电流均不利于熔滴过渡
容易出现短路、熔滴爆炸等问题;在P-GMA峰值阶段叠加低频(20kHz)脉冲电流时
对熔滴过渡影响较弱
叠加中频(40~60kHz)脉冲电流能抑制高氮钢熔滴过渡中大颗粒飞溅生成
提高熔滴过渡稳定性
但是当频率超过60kHz时在过渡中会形成许多小飞溅。
For solving the problems of nitrogen escape and splash in the droplet transfer process of high-nitrogen steel additive manufacturing
the experiment of droplet transfer in an ultrasonic frequency pulsed gas metal arc (UFP-GMA) additive manufacturing is carried out
and the influences of different ultrasonic frequency pulsed current superposition modes and pulse current frequencies on the stability of high-nitrogen steel droplet transfer are studied
The process parameters that can realize the stable droplet transfer of high-nitrogen steel additives were obtained. The experimental results show that the of one-pulse-one-droplet transfer can be realized under the pulsed gas metal arc (P-GMA) process conditions
but the transition stability is poor and the splash is obvious. Superimposing the ultrasonic frequency pulse current at the base current stage of P-GMA or both at the base and peak current stages is not conducive to the droplet transfer
and the problems such as short circuit and droplet explosion are prone to occur. When the low-frequency (20kHz) pulse current is applied during the peak stage
its effect on droplet transfer is minimal. However
the medium-frequency (40-60kHz) pulse currents can be superimposed to inhibit the generation of large particle splash
leading to improved stability in droplet transfer
but many small splashes will be formed during the transition when the frequency exceeds 60kHz.
WANG X X , TIAN J H , LI S , et al . Weldability of high nitrogen steels: a review [J ] . Reviews on Advanced Materials Science , 2023 , 62 ( 1 ): 20220325 .
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崔博 , 张宏 , 刘双宇 , 等 . 高氮钢复合焊接接头氮含量和气孔控制方法研究 [J ] . 兵工学报 , 2019 , 40 ( 11 ): 2311 - 2318 . DOI: 10.3969/j.issn.1000-1093.2019.11.016 http://doi.org/10.3969/j.issn.1000-1093.2019.11.016 为解决高氮钢熔焊过程中出现的气孔和氮损失问题,采用激光-电弧复合焊接技术对高氮钢进行焊接试验。研究了保护气体成分、焊丝成分和超声振动对焊接接头气孔率和氮含量的影响。结果表明:当保护气体为Ar+N 2 时,随着保护气体中N 2 比例的增大,焊缝氮含量升高,气孔率呈先降低、后升高的趋势;当向Ar+N 2 中添加2%的O 2 后,氮含量和气孔率明显升高,且随着N 2 比例的增大,焊缝氮含量增多,但气孔率呈无规律变化;随着焊丝氮含量的增加,焊缝氮含量呈先升高、后降低趋势,气孔率呈先降低、后升高趋势;随着超声功率的增加,焊缝氮含量略有降低,气孔率呈先降低、后升高趋势;适当的保护气体和焊丝成分可提高焊缝氮含量的同时并能够抑制焊缝气孔形成,超声功率为180 W时抑制气孔效果最好。
CUI B , ZHANG H , LIU S Y , et al . Research on control method of nitrogen content and porosity in hybrid welding joint of high nitrogen steel [J ] . Acta Armamentarii , 2019 , 40 ( 11 ): 2311 - 2318 . (in Chinese) DOI: 10.3969/j.issn.1000-1093.2019.11.016 http://doi.org/10.3969/j.issn.1000-1093.2019.11.016 The laser-arc hybrid welding test of high nitrogen steel was carried out to solve the porosity and nitrogen loss of high nitrogen steel during welding. The effects of shielding gas composition, welding wire composition and ultrasonic vibration on the porosity and nitrogen content of welded joint were investigated. The results show that, when the shielding gas is Ar+N 2 , the nitrogen content of welded point increases with the proportion of nitrogen in the shielding gas, and the porosity decreases first and then increases. When 2% O 2 is added to Ar+N 2 , the nitrogen content and porosity increase obviously. With the increase in the proportion of nitrogen, the nitrogen content in welded joint increases, but the porosity changes irregularly. With the increase in nitrogen content in the welding wire, the nitrogen content of welded joint increases first and then decreases, and the porosity decreases first and then increases. With the increase in ultrasonic power, the nitrogen content of welded joint decreases slightly, and the porosity decreases first and then increases. Appropriate shielding gas and welding wire composition can be used to improve the nitrogen content of welded joint, and inhibit the formation of weld porosity. The porosity is suppressed in the best effect when the ultrasonic power is 180 W. Key
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明珠 , 王克鸿 , 王伟 , 等 . 焊丝成分对高氮不锈钢GMAW稳定性及熔滴过渡行为的影响 [J ] . 焊接学报 , 2018 , 39 ( 7 ): 24 - 28 , 130. DOI: 10.12073/j.hjxb.2018390168 http://doi.org/10.12073/j.hjxb.2018390168 文中主要对高氮奥氏体不锈钢专用焊丝焊接过程的稳定性进行研究,分析了不同氮含量焊丝的电流电压信号,并用高速摄像和汉诺威质量检测分析仪分析焊接过程的熔滴过渡.结果表明,随焊丝含氮量增加,焊接过程中虽然存在飞溅现象,但焊接过程更加稳定,这是由于为了使焊后熔敷金属为全奥氏体组织,将焊丝的含氮量增高的同时,减少Ni元素的加入,提高Mn元素含量,从而使熔滴的表面张力增加,焊接过程稳定性相对提高,并且在N元素和合金元素共同作用下,焊丝的喷射过渡临界电流降低,射滴过渡和射流过渡更加容易发生.
MING Z , WANG K H , WANG W , et al . Effect of welding wire compositions on welding process stability and droplet transfer behavior of high nitrogen stainless steel GMAW [J ] . Transactions of the China Welding Institution , 2018 , 39 ( 7 ): 24 - 28 , 130. (in Chinese) DOI: 10.12073/j.hjxb.2018390168 http://doi.org/10.12073/j.hjxb.2018390168 In order to analyze the stability of the special welding wires for high nitrogen stainless steel, high-speed camera was used to track the droplet transfer morphology and analyzer of Hannover was used to evaluate the droplet transfer. The results show that although weld spatter produced along with the increase of nitrogen content, the stability of the droplet transfer and the signals of currents and voltages are improved. This is because to make deposited metal astenitized, the Ni content was reduced while the Mn content was increased with increasing nitrogen content, so that surface tension of the material was improved. And the adjustment of elements reduces the critical current of spray transfer so that the spray transfer is more likely to happen.
张建 , 李涛 , 林红霞 , 等 . 焊丝成分对高氮钢CMT+P焊工艺性的影响 [J ] . 兵工学报 , 2023 , 44 ( 3 ): 792 - 798 . DOI: 10.12382/bgxb.2021.0799 http://doi.org/10.12382/bgxb.2021.0799 为提升高氮钢焊接质量和优化焊接工艺,研究焊丝氮、锰含量带来的焊接工艺稳定性。采用冷金属过渡加脉冲(Cold Metal Transfer plus Pulse, CMT+P)焊技术对5种高氮钢焊丝进行焊接试验,研究焊丝成分对电信号、熔滴过渡、飞溅率的影响。研究结果表明:氮含量的增加会引起电信号波动变大且分布离散,而锰含量的变化对电信号的影响较小,焊丝中氮含量对高氮钢CMT+P焊接稳定性影响大于锰含量的影响;随着氮含量的增加,熔滴过渡模式由一脉一滴转变为多脉一滴,熔滴形状不规律且尺寸变大,焊丝工艺性变差;当焊丝中氮、锰含量较小,分别为0.42%、7.19%时,焊接工艺稳定性较好;氮逸出、锰蒸发导致高氮钢熔滴剧烈爆炸产生大量飞溅,焊接飞溅率随着氮、锰含量的增加而不断增大。
ZHANG J , LI T , LIN H X , et al . Effect of welding wire composition on welding usability of high nitrogen steel using cold metal transfer plus pulse welding method [J ] . Acta Armamentarii , 2023 , 44 ( 3 ): 792 - 798 . (in Chinese) DOI: 10.12382/bgxb.2021.0799 http://doi.org/10.12382/bgxb.2021.0799 To improve the welding quality of high nitrogen steel and optimize the welding process, the welding stability caused by nitrogen and manganese content was studied. Welding experiments were performed using five different welding wires made of high nitrogen steel by the Cold Metal Transfer plus Pulse welding method to investigate the effect of welding wire composition on electrical signal, droplet transfer, spatter rate. The results showed that: the increase of nitrogen content caused the fluctuation and discrete distribution of electrical signals, while the change in manganese content had less effect on electrical signals: the effect of nitrogen content in welding wire on welding stability using the CMT+P welding method was greater than that of manganese content; the mode of droplet transfer changed from one droplet per pulse to one droplet per multiple pulses as the nitrogen content increased, and the melting droplets becames irregular in shape and larger, meaning the welding usability of wires was worse; when the nitrogen and manganese contents in the welding wire was small, namely 0.42% and 7.19%, respectively, the welding process stability was better; the rapid escape of nitrogen and the evaporation of manganese caused high-nitrogen steel droplets to explode violently, producing a large amount of spatter; the welding spatter rate increased with the increasing nitrogen and manganese contents.
邱灵 , 范成磊 , 林三宝 , 等 . 高频脉冲变极性焊接电源及电弧压力分析 [J ] . 焊接学报 , 2007 ( 11 ): 81 - 84 , 117.
QIU L , FAN C L , LIN S B , et al . High-frequency pulse modulated variable polarity welding power and its arc pressure [J ] . Transactions of the China Welding Institution , 2007 ( 11 ): 81 - 84 , 117. (in Chinese)
樊丁 , 杨文艳 , 肖磊 , 等 . 高频交变磁场对大电流GMAW熔滴过渡和飞溅率的影响 [J ] . 焊接学报 , 2019 , 40 ( 7 ): 1 - 5 , 161. DOI: 10.12073/j.hjxb.2019400172 http://doi.org/10.12073/j.hjxb.2019400172 在熔化极气体保护焊过程中,采用大送丝速度,增大焊接电流和焊丝伸出长度是提高焊接熔敷率的直接途径.但当熔滴过渡转变为旋转射流过渡时,电弧不稳,飞溅增大,焊缝成形变差.施加不同频率的纵向交变磁场,对焊缝成形进行控制.采用高速摄像技术,拍摄焊接过程中的电弧形态和熔滴过渡,研究不同频率的磁场对熔滴过渡和焊接飞溅率的影响规律.结果表明,熔滴过渡形式不同,产生飞溅的机理不同;外加频率为1 000 Hz纵向交变磁场时,电弧的旋转半径减小,电弧的挺度增大,旋转射流过渡时电弧更稳定,焊接飞溅率降低,焊缝成形改善.
FAN D , YANG W Y , XIAO L , et al . Effect of high frequency longitudinal alternating magnetic field on droplet transfer and spatter rate in high current GMAW welding [J ] . Transactions of the China Welding Institution , 2019 , 40 ( 7 ): 1 - 5 , 161. (in Chinese) DOI: 10.12073/j.hjxb.2019400172 http://doi.org/10.12073/j.hjxb.2019400172 In the process of gas shielded arc welding (GMAW), it is a direct way to increase the welding deposit rate by adopting high wire feeding speed, increasing welding current and dry elongation. However, when the droplet transfer is changed into rotating jet transfer, the arc is unstable, the spatter increases and the weld formation becomes worse. A longitudinal alternating magnetic field with different frequencies is applied to control the weld formation. The arc shape and droplet transfer during welding were photographed by high-speed video camera. The effects of magnetic field with different frequencies on droplet transfer and welding spatter rate were studied. The results show that the mechanism of spatter is different with different droplet transfer modes; when the applied frequency is 1 000 Hz longitudinal alternating magnetic field, the rotating radius of arc decreases, the stiffness of arc increases, the arc is more stable, the welding spatter rate decreases, and the weld shape is improved.
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