45号钢锥筒焊接工艺研究

硕士学位论文（工程硕士）45号钢锥筒焊接工艺研究刘振波哈尔滨工业大学2011年4月国内图书分类号：TG404学校代码：10213国际图书分类号：621.791密级：公开硕士学位论文（工程硕士）45号钢锥筒焊接工艺研究硕士研究生：刘振波导师：陈维山申请学位：工程硕士学科、专业：机械工程所在单位：首都航天机械公司答辩日期：2011年4月授予学位单位：哈尔滨工业大学ClassifiedIndex：TM631+.2U.D.C.：621.3DissertationfortheMasterDegree（DegreeinEngineering）RESEARCHONWELDINGTECHNOLOGYOF45STEELCONECandidate：LiuZhenboSupervisor：Prof.ChenWeishanAcademicDegreeAppliedfor：MasterofEngineeringSpeciality：MechanicalEngineeringAffiliation：CapitalAerospaceMachineryCompanyDateofDefence：April,2011Degree-Conferring-Institution：HarbinInstituteofTechnology哈尔滨工业大学工程硕士学位论文-I-摘要45号钢锥筒由前段、中段、后段三部分组成，形成两条锁底对接焊缝，为完成45钢锥筒的焊接任务，本文对锥筒产品结构、45号钢焊接性能进行了分析，将车间现有的焊接方法：钨极氩弧焊、熔化极气体保护焊、等离子弧焊、埋弧焊、焊条电弧焊，从原理、分类、优缺点、适用范围四个方面进行了对比分析，最终确定使用埋弧自动焊的方法进行锥筒的焊接。焊接方法确定后，从焊接电流、电弧电压、焊接速度、焊丝倾角、焊件倾角、焊剂、焊前清理、焊前预热等12个方面进行了理论分析，在此基础上，初步预设平板试验件的焊接参数。按预设的焊接参数进行平板试验件焊接，完善了部分焊接参数，再进行锥筒试验件的焊接，最终确定了锥筒的焊接规范参数和坡口形式，形成了锥筒埋弧自动焊接方案。焊接方案实施后，锥筒产品出现了大量未焊透焊接缺陷，对锥筒产品数据、产品焊接过程中的各种影响因素入手，剖析焊接过程中产生的各种焊接缺陷及其产生的主要原因，针对产生焊接缺陷的原因，通过调整坡口尺寸、加强对焊前预热的控制、新制焊接托架工装等措施，在车间现有条件能实现的范围内，解决了锥筒焊缝未焊透缺陷的问题，得出了最适合锥筒焊接的埋弧自动焊技术方案，并成功应用于批生产。本课题研究得出的焊接技术方案经产品批生产应用证明：焊接技术方案适合45号钢锥筒的焊接，一次焊接合格率从10%提高到95%，焊缝抗拉强度、X光检测结果均满足设计要求，外观成型美观。关键词：埋弧焊；45号钢锥筒；焊接工艺；未焊透；哈尔滨工业大学工程硕士学位论文-II-AbstractToaccomplishthetaskofweldingtubesteelcone45,analysisthisproductstructure,theexistingweldingshop:TIGwelding,MIGwelding,plasmaarcwelding,submergedarcwelding,fromtheprinciple,classification,advantagesanddisadvantages,thescopeofacomparativeanalysisoffouraspects,andultimatelydeterminethemethodofsubmergedarcweldingweldingcone.Afterweldingmethodtodetermine,fromtheweldingcurrent,arcvoltage,weldingspeed,wireangle,weldmentangle,flux,cleaningbeforewelding,preheatingbeforeweldingin12aspectsofthetheory,onthisbasis,theinitialdefaultflatTestpiecesofweldingparameters.Weldingparameters,pre-plateweldingtestandimprovesomeoftheweldingparameters,andthentheconesandweldingoftestpieces,andultimatelydeterminetheconeoftheweldingparametersandgroove,formingaconesubmergedarcweldingprogram.Weldingprogramimplementation,theproducthasalargenumberofconepenetrationweldedwithoutdefects,weconesproductdata,productweldingprocessstartwithvariousfactorsaffectingtheuseofQCgroupproblemsolving,analysisoftheweldingprocessproducespeciesandtheirmaincausesofweldingdefects,weldingdefectsforproductionreasons,byadjustingthegroovesize,strengtheningthecontrolofpreheatingbeforewelding,weldingbracketstoolingthenewsystemandothermeasures,intheworkshoptoachievetherangeofexistingconditions,thesolutionoftheconepenetrationwelddefectisnottheproblem,obtainedthemostsuitableconeweldingsubmergedarcweldingtechnologyprograms,andsuccessfullyappliedtobatchproduction.Derivedfromtheresearchprogramofweldingtechnologyprovenbytheproductionandapplicationofapprovedproducts:WeldingTechnologyprogramforweldingtubesteelcone45,aweldingqualificationratefrom10%to95%,theweldtensilestrength,X-raytestresultsMeetthedesignrequirements,theappearanceofformingbeautiful.Keywords：submergedarcwelding,45steelcone,weldingprocedure,incompletepenetration哈尔滨工业大学工程硕士学位论文-III-目录摘要..............................................................................................................…..ⅠAbstract...............................................................................................................Ⅱ第1章绪论.........................................................................................................11.1课题背景.....................................................................................................11.2电弧焊种类及特点....................................................................................11.2.1手工电弧焊..........................................................................................11.2.2钨极氩弧焊..........................................................................................21.2.3熔化极气体保护焊...............................................................................31.2.4等离子弧焊..........................................................................................41.2.5埋弧焊..................................................................................................61.3埋弧自动焊接工艺国内外研究现状..........................................................71.3.1单面焊双面成形埋弧自动焊..............................................................81.3.2热丝埋弧自动焊工艺..........................................................................81.3.3多丝埋弧自动焊工艺..........................................................................81.3.4窄间隙埋弧自动焊工艺......................................................................91.3.5添加合金粉末的埋弧自动焊..............................................................91.3.6振动埋弧自动焊.................................................................................91.4本文研究的主要内容及实际意义.............................................................9第2章锥筒埋弧自动焊接方法的确定............................................................112.1锥筒结构及材料.......................................................................................112.1.1锥筒的结构..............................................................