CN103675039B - The lossless detection method of friction welding joint quality under large electric current - Google Patents
The lossless detection method of friction welding joint quality under large electric current Download PDFInfo
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- 238000003466 welding Methods 0.000 title claims abstract description 69
- 238000001514 detection method Methods 0.000 title claims abstract description 31
- 238000000034 method Methods 0.000 claims abstract description 24
- 238000009659 non-destructive testing Methods 0.000 claims abstract description 14
- 238000012545 processing Methods 0.000 claims abstract description 5
- 238000003672 processing method Methods 0.000 claims abstract description 4
- 229910052782 aluminium Inorganic materials 0.000 claims description 10
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 9
- 238000002474 experimental method Methods 0.000 claims description 6
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- 210000000078 claw Anatomy 0.000 description 2
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 239000010953 base metal Substances 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
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Abstract
大电流下摩擦焊接头质量的无损检测方法，其步骤为：1.在焊件的焊缝两侧各加工一个螺纹孔，用螺钉将导线紧固在螺纹孔内，导线另一端连接电压表，且保证不同焊件的螺纹孔加工方式及位置完全相同；2.将焊件放置于检测装置中，在电极和限位桩作用下使焊件固定；3.在电极之间接通垂直于焊缝方向的强电流；4.采用高精度电压表检测焊缝两侧等距压降；5.数据处理，将检测到的压降值代入接头压降-有效焊合面积拟合方程，换算得到接头的有效焊合面积和理论抗拉性能，判断接头焊接质量。
The non-destructive testing method for the quality of friction welding joints under high current, the steps are: 1. Process a threaded hole on both sides of the weld of the weldment, fasten the wire in the threaded hole with screws, and connect the other end of the wire to a voltmeter. And ensure that the threaded hole processing methods and positions of different weldments are exactly the same; 2. Place the weldments in the detection device, and fix the weldments under the action of electrodes and limit piles; 3. Connect electrodes perpendicular to the weld 4. Use a high-precision voltmeter to detect the equidistant pressure drop on both sides of the weld; 5. Data processing, substituting the detected pressure drop value into the joint pressure drop-effective welding area fitting equation, and converting to get the joint The effective welding area and theoretical tensile properties of the joints can be used to judge the welding quality of the joints.
Description
技术领域technical field
本发明涉及摩擦焊接头质量的无损检测领域，特别是大截面（焊接面积大于2000mm2）摩擦焊焊后质量的无损检测领域。The invention relates to the field of non-destructive testing of the quality of friction welding joints, in particular to the field of non-destructive testing of quality after friction welding of large cross-sections (welding area greater than 2000mm 2 ).
背景技术Background technique
目前在我国摩擦焊方法已得到广泛的应用,而其质量的检测是必不可少的,尤其在汽车、石油钻具、飞机制造、和工具行业等部门,要求零件的摩擦焊质量必须百分之百的可靠,尽管采取了各种质量保证措施,但摩擦焊缺陷却时有发生。摩擦焊接头的焊接缺陷主要是未焊透和焊接裂纹,前者发生在焊接表面上,后者在焊接表面和母材上都有可能产生。针对摩擦焊的无损检测一直是一道技术难题，目前有的单位采用超声波检验方法来检测摩擦焊接头的缺陷。但该法探测未焊透缺陷有一定困难,并且由于对被测件的表面状况有一定要求,且操作麻烦、检测速度也比较慢,因此应用受到限制。At present, the friction welding method has been widely used in our country, and its quality inspection is indispensable, especially in the automobile, oil drilling, aircraft manufacturing, and tool industries, etc., the friction welding quality of parts must be 100% reliable. , despite various quality assurance measures, friction welding defects occur from time to time. Welding defects of friction welded joints are mainly lack of penetration and welding cracks, the former occurs on the welding surface, and the latter may occur on both the welding surface and the base metal. Nondestructive testing for friction welding has always been a technical problem. At present, some units use ultrasonic testing methods to detect defects in friction welding joints. However, this method is difficult to detect incomplete penetration defects, and because it has certain requirements on the surface condition of the tested part, and the operation is cumbersome and the detection speed is relatively slow, so the application is limited.
针对电解铝阳极铝导杆-钢爪摩擦焊件而言，由于焊接面积大、焊件质量重，难以实现高效率的焊后检测，且由于钢爪铸造缺陷多，缩孔、夹杂等铸造缺陷极易影响超声波检测对焊缝性能的判断，因此不能采用超声波方法进行检测。For the electrolytic aluminum anode aluminum guide rod-steel claw friction weldment, due to the large welding area and heavy weldment quality, it is difficult to achieve high-efficiency post-weld inspection, and because the steel claw has many casting defects, shrinkage cavities, inclusions and other casting defects It is very easy to affect the judgment of ultrasonic testing on the performance of welds, so ultrasonic testing cannot be used for testing.
发明内容Contents of the invention
本发明的目的是提供一种大电流下摩擦焊接头质量的无损检测方法。The purpose of the present invention is to provide a non-destructive testing method for the quality of friction welding joints under high current.
本发明是大电流下摩擦焊接头质量的无损检测方法，其步骤为：The present invention is a non-destructive testing method for the quality of friction welding joints under high current, the steps of which are as follows:
（1）在焊件的焊缝5的两侧各加工一个螺纹孔6，用螺钉将导线紧固在螺纹孔6内，在导线的另一端连接电压表4，且保证不同焊件的螺纹孔6加工方式及位置完全相同；(1) Process a threaded hole 6 on both sides of the weld 5 of the weldment, fasten the wire in the threaded hole 6 with screws, connect the voltmeter 4 to the other end of the wire, and ensure that the threaded holes of different weldments 6 The processing method and position are exactly the same;
（2）将焊件放置于检测平台上，通过限位桩1和电极2将焊件固定；焊件夹紧，两块电极2在气缸3推动下分别压紧焊缝两侧的金属，并施加0.5-5MPa的检测压力；(2) Place the weldment on the detection platform, and fix the weldment through the limit pile 1 and the electrode 2; the weldment is clamped, and the two electrodes 2 are respectively pressed against the metal on both sides of the weld under the push of the cylinder 3, and Apply a detection pressure of 0.5-5MPa;
（3）在电极2间接通7000-10000安培的大电流；(3) Pass a large current of 7000-10000 amperes between the electrodes 2;
（4）读取并记录通电状态下电压表4检测到的接头两侧压降值，重复实验过程获取平均值；(4) Read and record the voltage drop on both sides of the connector detected by the voltmeter 4 in the energized state, and repeat the experiment process to obtain the average value;
（5）数据处理，将检测得到的接头两侧压降值代入已定检测条件下接头压降-有效焊合面积拟合方程：(5) Data processing, substituting the detected pressure drop on both sides of the joint into the joint pressure drop-effective welding area fitting equation under the determined detection conditions:
y=-0.00246x+150.1y=-0.00246x+150.1
式中：x为有效焊合面积，单位mm2；y为检测压降值，单位mv；In the formula: x is the effective welding area, the unit is mm 2 ; y is the detection pressure drop value, the unit is mv;
现标定当焊缝抗拉强度大于68吨时判为合格产品，低于68吨时判为不合格；It is now calibrated that when the tensile strength of the weld is greater than 68 tons, it is judged as a qualified product, and when it is lower than 68 tons, it is judged as unqualified;
工业纯铝的抗拉强度为90MPa，而拉伸承力区域主要为灰斑以外的有效焊合区域，计算可得极限有效焊合面积为7556mm2，代入拟合方程得到焊缝两端压降值为131.5mv，即当采用此方法检测时任一焊件接头压降大于极限值131.5mv时，可判定焊件质量为不合格焊件。The tensile strength of industrial pure aluminum is 90MPa, and the tensile bearing area is mainly the effective welding area other than the gray spots. The calculation can obtain the limit effective welding area of 7556mm 2 , which is substituted into the fitting equation to obtain the pressure drop at both ends of the weld The value is 131.5mv, that is, when the pressure drop of any weldment joint is greater than the limit value of 131.5mv when using this method, the quality of the weldment can be judged to be unqualified.
与现有技术相比，本发明的有益效果是可实现对摩擦焊接头简便、快速、可靠的无损检测。此外由于易实现自动化操作，可实现高效的焊后检验，保证产品质量，在摩擦焊无损检测领域具有广阔的应用前景。Compared with the prior art, the beneficial effect of the invention is that it can realize simple, fast and reliable non-destructive testing of the friction welding joint. In addition, because it is easy to realize automatic operation, it can realize efficient post-weld inspection and ensure product quality, and has broad application prospects in the field of friction welding non-destructive testing.
附图说明Description of drawings
图1是大电流下摩擦焊接头质量的无损检测装置示意图，图中：1-限位桩，2-电极，3-气缸，4-高精度电压表，5-铝钢摩擦焊缝，6-螺纹孔（检测点）。Figure 1 is a schematic diagram of a non-destructive testing device for the quality of friction welding joints under high current. In the figure: 1-limiting pile, 2-electrode, 3-cylinder, 4-high precision voltmeter, 5-aluminum steel friction weld, 6- Threaded hole (detection point).
具体实施方式detailed description
如图1所示，本发明是大电流下摩擦焊接头质量的无损检测方法，其步骤为：As shown in Figure 1, the present invention is a non-destructive testing method for friction welding joint quality under high current, and its steps are:
（1）在焊件的焊缝5的两侧各加工一个螺纹孔6，用螺钉将导线紧固在螺纹孔6内，在导线的另一端连接电压表4，且保证不同焊件的螺纹孔6加工方式及位置完全相同；(1) Process a threaded hole 6 on both sides of the weld 5 of the weldment, fasten the wire in the threaded hole 6 with screws, connect the voltmeter 4 to the other end of the wire, and ensure that the threaded holes of different weldments 6 The processing method and position are exactly the same;
（2）将焊件放置于检测平台上，通过限位桩1和电极2将焊件固定；焊件夹紧，两块电极2在气缸3推动下分别压紧焊缝两侧的金属，并施加0.5-5MPa的检测压力；(2) Place the weldment on the detection platform, and fix the weldment through the limit pile 1 and the electrode 2; the weldment is clamped, and the two electrodes 2 are respectively pressed against the metal on both sides of the weld under the push of the cylinder 3, and Apply a detection pressure of 0.5-5MPa;
（3）在电极2间接通7000-10000安培的大电流；(3) Pass a large current of 7000-10000 amperes between the electrodes 2;
（4）读取并记录通电状态下电压表4检测到的接头两侧压降值，重复实验过程获取平均值；(4) Read and record the voltage drop on both sides of the connector detected by the voltmeter 4 in the energized state, and repeat the experiment process to obtain the average value;
（5）数据处理，将检测得到的接头两侧压降值代入已定检测条件下接头压降-有效焊合面积拟合方程：(5) Data processing, substituting the detected pressure drop on both sides of the joint into the joint pressure drop-effective welding area fitting equation under the determined detection conditions:
y=-0.00246x+150.1y=-0.00246x+150.1
式中：x为有效焊合面积，单位mm2；y为检测压降值，单位mv；In the formula: x is the effective welding area, the unit is mm 2 ; y is the detection pressure drop value, the unit is mv;
现标定当焊缝抗拉强度大于68吨时判为合格产品，低于68吨时判为不合格；It is now calibrated that when the tensile strength of the weld is greater than 68 tons, it is judged as a qualified product, and when it is lower than 68 tons, it is judged as unqualified;
工业纯铝的抗拉强度为90MPa，而拉伸承力区域主要为灰斑以外的有效焊合区域，计算可得极限有效焊合面积为7556mm2，代入拟合方程得到焊缝两端压降值为131.5mv，即当采用此方法检测时任一焊件接头压降大于极限值131.5mv时，可判定焊件质量为不合格焊件。The tensile strength of industrial pure aluminum is 90MPa, and the tensile bearing area is mainly the effective welding area other than the gray spots. The calculation can obtain the limit effective welding area of 7556mm 2 , which is substituted into the fitting equation to obtain the pressure drop at both ends of the weld The value is 131.5mv, that is, when the pressure drop of any weldment joint is greater than the limit value of 131.5mv when using this method, the quality of the weldment can be judged to be unqualified.
如图1所示，检测平台和限位桩1的表面覆盖绝缘材料。电极2固定于气缸3的顶杆前端，能够在气缸3的作用下做定向移动和传递压力。通强电流的电流方向垂直于焊缝5，通电持续时间为2-5s，通电间隙时间大于10s。As shown in FIG. 1 , the surfaces of the detection platform and the limit pile 1 are covered with insulating materials. The electrode 2 is fixed on the front end of the ejector rod of the cylinder 3, and can move directionally and transmit pressure under the action of the cylinder 3. The current direction of the strong current is perpendicular to the weld 5, the duration of the current is 2-5s, and the time between the currents is greater than 10s.
接头压降-有效焊合面积拟合方程是通过同一检测方法下改变接头面积的压降检测拟合实验得到的，而将有效焊合面积与焊接材料中较弱一方抗拉强度的乘积视为该接头可承载的理论抗拉力。The joint pressure drop-effective welding area fitting equation is obtained through the pressure drop detection fitting experiment of changing the joint area under the same detection method, and the product of the effective welding area and the tensile strength of the weaker side of the welding material is regarded as The theoretical tensile force that the joint can carry.
判断接头焊接质量是根据生产要求划定焊件质量合格的最小抗拉力，当某焊件检测出的接头压降值超出最小抗拉力所对应的压降值时，判断为不合格焊件。Judging the welding quality of the joint is to define the minimum tensile force for qualified weldment quality according to the production requirements. When the joint pressure drop value detected by a certain weldment exceeds the pressure drop value corresponding to the minimum tensile force, it is judged as an unqualified weldment .
下面结合附图及实例对本发明作进一步描述。The present invention will be further described below in conjunction with accompanying drawings and examples.
摩擦焊接头中的缺陷主要有未焊透、夹渣、焊接裂纹和灰斑等，这些缺陷的产生主要是由于焊接规范的选择不合适所造成的，但对于成熟稳定的焊接规范也有几率出现焊接缺陷，因此对摩擦焊件进行百分百焊后检测十分必要。The defects in friction welding joints mainly include incomplete penetration, slag inclusions, welding cracks and gray spots, etc. These defects are mainly caused by inappropriate selection of welding specifications, but there is also a chance of welding for mature and stable welding specifications. Defects, so it is necessary to perform 100% post-weld inspection of friction weldments.
本实例检测对象为电解铝用阳极导杆铝-钢摩擦焊件，焊接面积达130×130mm2，属大截面摩擦焊。大截面摩擦焊的主要缺陷是中心区域易产生面积过大的“灰斑”，而焊接质量最佳的区域是2/3内接圆半径的环状区域。在导通大电流时“灰斑”因未形成有效结合而产生导电瓶颈，绝大部分的电流是从“灰斑”以外的有效焊合区域流通，因此有效焊接面积的大小直接影响接头部位的阻值。The detection object of this example is an aluminum-steel friction welded part of an anode guide rod for electrolytic aluminum, with a welding area of 130×130mm 2 , which belongs to large cross-section friction welding. The main defect of large cross-section friction welding is that the central area tends to produce excessively large "gray spots", and the area with the best welding quality is the annular area with a radius of 2/3 of the inscribed circle. When a large current is turned on, the "gray spot" does not form an effective connection, resulting in a conductive bottleneck. Most of the current flows from the effective welding area other than the "gray spot", so the size of the effective welding area directly affects the size of the joint. Resistance.
本检测方法所使用的装置包括一个面积为2m×4m的水平绝缘检测平台，平台表面固定有四个150mm(长)×100mm(宽)×200mm(高)限位桩和两个气缸，气缸前端固定有面积为90×90mm2的铜电极，电极可在气缸带动下作定向移动并能传递压力；一个200KW的低压大电流变压器，电流输出端分别与两个电极块连通，并在工作状态下提供检测电流；一个毫伏级高精度电压表及导线、螺钉若干，用于检测焊缝两侧的等距压降。The device used in this detection method includes a horizontal insulation detection platform with an area of 2m × 4m. Four 150mm (length) × 100mm (width) × 200mm (height) limit piles and two cylinders are fixed on the surface of the platform. A copper electrode with an area of 90×90mm2 is fixed, and the electrode can move directionally and transmit pressure under the drive of the cylinder; a 200KW low-voltage high-current transformer, the current output terminals are respectively connected to the two electrode blocks, and in the working state Provide detection current; a millivolt-level high-precision voltmeter, wires, and screws are used to detect the equidistant voltage drop on both sides of the weld.
本检测方法的具体步骤是：The concrete steps of this detection method are:
第一步，在焊件的焊缝两侧分别加工两个螺纹孔，其与焊缝间距均为100mm，用螺钉将导线紧固在螺纹孔内，导线另一端连接电压表；The first step is to process two threaded holes on both sides of the weld of the weldment, and the distance between them and the weld is 100mm, fasten the wire in the threaded hole with screws, and connect the other end of the wire to a voltmeter;
第二步，将焊件放置于专用检测平台上，通过限位桩和气缸将焊件固定；两块电极与金属表面良好接触，并在气缸作用下施加压强为2MPA的压力。In the second step, the weldment is placed on a special testing platform, and the weldment is fixed by the limit pile and the cylinder; the two electrodes are in good contact with the metal surface, and a pressure of 2MPA is applied under the action of the cylinder.
第三步，在电极间接通7100安培的大电流，电流方向垂直于焊缝，每次通电时间持续2s，通电间隙时间20s，使导电部位检测温度保持基本恒定；The third step is to pass a large current of 7100 amperes between the electrodes, and the direction of the current is perpendicular to the weld seam. The time of each energization lasts 2s, and the time between energization is 20s, so that the detection temperature of the conductive part remains basically constant;
第四步，读取并记录通电状态下高精度电压表检测的电压值；重复通电、检测过程得到平均值；The fourth step is to read and record the voltage value detected by the high-precision voltmeter in the power-on state; repeat the power-on and detection process to obtain the average value;
第五步，数据处理，将检测到的压降值代入电流7100A条件下的铝钢接头“有效焊合面积-接头压降”拟合方程:The fifth step is data processing, and the detected pressure drop value is substituted into the fitting equation of the aluminum-steel joint "effective welding area-joint pressure drop" under the condition of current 7100A:
y=-0.00246x+150.1y=-0.00246x+150.1
（式中：x:有效焊合面积，单位mm2；y:检测压降值,单位mv）(In the formula: x: effective welding area, unit mm2 ; y: detection pressure drop value, unit mv)
换算得到接头的有效焊合面积，因铝钢焊接接头拉伸时有效焊合区断裂于铝母材，知纯铝抗拉强度为90-120MPa，因此可得焊接接头的理论抗拉力。The effective welding area of the joint is obtained by conversion, because the effective welding area of the aluminum-steel welded joint breaks in the aluminum base material when the aluminum-steel welded joint is stretched, and the tensile strength of pure aluminum is 90-120MPa, so the theoretical tensile strength of the welded joint can be obtained.
设计实验在相同检测方法下通过改变铝-钢接头实际焊合面积并进行电压降检测，标定了该电流、该检测方法下铝-钢接头“有效焊合面积-接头压降”之间的关系，实验结果显示摩擦焊接头处压降与焊合面积符合线性规律，其拟合方程为:The design experiment calibrates the relationship between the current and the "effective welding area-joint pressure drop" of the aluminum-steel joint under the same detection method by changing the actual welding area of the aluminum-steel joint and detecting the voltage drop , the experimental results show that the pressure drop at the friction welding joint and the welding area conform to a linear law, and the fitting equation is:
y=-0.00246x+150.1y=-0.00246x+150.1
（式中：x:有效焊合面积，单位mm2；y:检测压降值,单位mv）(In the formula: x: effective welding area, unit mm2 ; y: detection pressure drop value, unit mv)
结合生产实际要求，现标定当焊缝抗拉强度大于68吨时判为合格产品，低于68吨时判为不合格。因工业纯铝的抗拉强度为90MPa，而拉伸承力区域主要为灰斑以外的有效焊合区域，计算可得极限有效焊合面积为7556mm2，代入拟合方程得到焊缝两端压降值为131.5mv，即当采用此方法检测时任一焊件接头压降大于极限值131.5mv时，可判定焊件质量为不合格焊件。Combined with the actual production requirements, it is now calibrated that when the tensile strength of the weld is greater than 68 tons, it is judged as a qualified product, and when it is lower than 68 tons, it is judged as unqualified. Since the tensile strength of industrial pure aluminum is 90MPa, and the tensile load-bearing area is mainly the effective welding area outside the gray spot, the calculated limit effective welding area is 7556mm 2 , which is substituted into the fitting equation to obtain the pressure at both ends of the weld The drop value is 131.5mv, that is, when the pressure drop of any weldment joint is greater than the limit value of 131.5mv when this method is used to detect, the quality of the weldment can be judged to be unqualified.
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