【摘要】：閃光對焊技術(shù)屬于電阻壓力焊的一種,因其自動化程度高、焊接質(zhì)量好、高效且可焊金屬范圍廣等優(yōu)點(diǎn),在油氣輸送、石油化工、海洋工程、能源電力等行業(yè)的應(yīng)用前景極為廣闊。國內(nèi)已將其廣泛應(yīng)用于鋼軌焊接,但針對管道的閃光對焊國內(nèi)尚無實際應(yīng)用,中國烏克蘭巴頓焊接研究院率先從國外引進(jìn)了K584Ch管道閃光對焊設(shè)備,在國內(nèi)首次針對把閃光對焊技術(shù)應(yīng)用于管道的焊接開展了大量的研究工作。本文首先針對K584Ch管道閃光對焊設(shè)備利用圖形化編程語言LabVIEW開發(fā)設(shè)計管道閃光對焊在線監(jiān)測系統(tǒng),實現(xiàn)了閃光對焊工藝參數(shù)的采集、顯示與存儲,通過采集閃光對焊過程中的焊接電流、焊接電壓、位移和壓力信號,分析閃光對焊過程工藝參數(shù)對焊接質(zhì)量的影響。本文針對X65管線鋼和20G鍋爐鋼分別進(jìn)行了正交試驗和單因素試驗。X65管線鋼正交試驗是以激發(fā)閃光階段進(jìn)給量Sj、激發(fā)閃光階段焊接電流閥值Ⅰ、穩(wěn)定閃光階段進(jìn)給量Sw和加速閃光階段的進(jìn)給速度V為試驗因素,根據(jù)以往的工藝經(jīng)驗手冊和試焊結(jié)果,每因素確定三個水平,不考慮各因素間的交互關(guān)系,按照L9(34)正交表進(jìn)行9次正交試驗和1次優(yōu)化驗證試驗。20G鍋爐鋼單因素試驗是以加速閃光階段的進(jìn)給速度V為參變量,取三個水平,研究加速閃光階段的進(jìn)給速度V對焊接質(zhì)量的影響。兩組試驗均以接頭力學(xué)性能作為試驗考核指標(biāo),選出合理工藝方案,實現(xiàn)了對焊接工藝參數(shù)的優(yōu)化。通過對K584Ch管道閃光對焊在線監(jiān)測系統(tǒng)采集到的焊接電流數(shù)據(jù)進(jìn)行分析,可以初步判定焊接質(zhì)量的優(yōu)劣,且判定結(jié)果與力學(xué)性能檢測和金相組織分析的結(jié)果基本保持一致,在一定程度上為管道閃光對焊的工藝優(yōu)化提供了支持。通過力學(xué)性能檢測,發(fā)現(xiàn)管道閃光對焊接頭的強(qiáng)度和硬度基本都能滿足使用需求,但塑性和韌性較差,管道內(nèi)壁180°位置存在大焊瘤使該位置處硬度下降。管道閃光對焊接頭的斷裂多為脆性斷裂,有明顯的金屬光澤,刻槽錘斷試樣的斷口呈現(xiàn)出河流花樣的解理斷裂形貌,接頭內(nèi)部普遍存在灰斑缺陷,且屬于硅酸鹽夾雜型灰斑。對20G鍋爐鋼對焊接頭金相分析,發(fā)現(xiàn)其焊縫寬度約為0.7mm,焊縫顯微組織為粗大塊狀鐵素體、魏氏組織鐵素體和少量珠光體,存在脫碳現(xiàn)象,這種組織導(dǎo)致了焊縫硬度和強(qiáng)度的下降、韌性欠佳。熱影響區(qū)較寬,約為24mm,粗晶區(qū)的魏氏組織較為嚴(yán)重,較為嚴(yán)重的魏氏組織導(dǎo)致材料的韌性(沖擊功)明顯下降。
[Abstract]:Flash butt welding is a kind of resistance pressure welding, because of its high degree of automation, good welding quality, high efficiency and wide range of weldable metals, it is widely used in oil and gas transportation, petrochemical, offshore engineering, etc. The application prospect of energy power and other industries is extremely broad. It has been widely used in rail welding in China, but there is no practical application in China for pipeline flash butt welding. China Button Welding Research Institute of Ukraine first imported K584Ch pipe flash butt welding equipment from abroad. For the first time in China, a lot of research work has been carried out on the application of flash butt welding technology in pipeline welding. In this paper, the on-line monitoring system of pipeline flash butt welding is developed by using graphical programming language LabVIEW for K584Ch pipeline flash butt welding equipment. The acquisition, display and storage of technological parameters of flash butt welding are realized. By collecting welding current, welding voltage, displacement and pressure signals during flash butt welding, the influence of process parameters on welding quality is analyzed. In this paper, orthogonal test and single factor test are carried out for X65 pipeline steel and 20G boiler steel respectively. The orthogonal test of X65 pipeline steel is based on stimulating flash stage feedrate Sj, to stimulate flash stage welding current threshold. The feed rate Sw of stable flash stage and feed velocity V of accelerated flash stage are the experimental factors. According to the previous process experience manual and welding results, three levels are determined for each factor, without considering the interaction between each factor. According to the orthogonal table of L9 (34), nine orthogonal tests and one optimized verification test were carried out. The single-factor test of 20G boiler steel was based on the feed velocity V of accelerating flash stage as parameter variable, taking three levels. The effect of feed speed V in accelerating flash stage on welding quality was studied. The mechanical properties of the joints were taken as the test index in both groups, and the reasonable process scheme was selected to optimize the welding process parameters. Through the analysis of welding current data collected by K584Ch pipeline flash butt welding on-line monitoring system, the quality of welding can be preliminarily determined, and the result is basically consistent with the results of mechanical property test and metallographic analysis. To some extent, it provides support for the process optimization of pipeline flash butt welding. It is found that the strength and hardness of the pipe flash butt welded joint can meet the requirement of application, but the ductility and toughness are poor, and the hardness of the pipe is decreased due to the existence of a large welding nodule at 180 擄position of the inner wall of the pipe. The fracture of the pipe flash butt welding joint is mostly brittle and has obvious metallic gloss. The fracture surface of the groove hammer fracture specimen presents the cleavage fracture appearance of the river pattern, and there is a common gray spot defect in the joint, and it belongs to silicate inclusion type gray spot. By metallographic analysis of butt welded joints of 20G boiler steel, it is found that the weld width is about 0.7 mm, the microstructure of the weld is coarse block ferrite, the ferrite of Weiss structure and a small amount of pearlite exist decarbonization phenomenon. This microstructure leads to a decrease in the hardness and strength of the weld and poor toughness. The heat affected zone is wider, about 24mm. The Weiss structure in the coarse crystal region is more serious, and the toughness (impact work) of the material decreases obviously because of the more serious Weichen structure.
【學(xué)位授予單位】：昆明理工大學(xué)
【學(xué)位級別】：碩士
【學(xué)位授予年份】：2016
【分類號】：TG457.11

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