CO<sub>2</sub>气体保护焊短路过渡控制技术的研究现状与展望

doi:10.11896/cldb.18030132

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Abstract The features of low cost and high productivity enable the widespread application of CO₂ gas shielded welding in manufacturing industry. With the increasing demand for energy saving and emission reduction in the manufacturing industry and the promotion of the concept of lightweight automobile, the requirements of thin plate welding in manufacturing are continuously raising, which cause the traditional welding method can hardly meet the new requirements. Compared with the conventional welding approaches (traditional tungsten argon arc welding, argon-arc welding, laser welding, etc.), CO₂ short-circuit transition welding is superior due to its high thermal stability, low heat input, low penetration depth, etc. Yet, the large welding spatter and poor weld formation have blocked its promotion and wide application.
The CO₂ short-circuit transition welding process is a complex nonlinear time-varying system composed of the arcing phase and the short-circuit phase. The droplet transfer process plays a dominant role in affecting the stability of the welding process and the quality of weld molding. In the arcing stage, the droplets grow under the combined action of electromagnetic contraction force, surface tension, plasma flow force, metal evaporation reaction force, and are short-circuited with the molten pool to form a stable liquid bridge. In the short-circuit phase, as a result of the action of surface tension, electromagnetic contraction force and viscous force, the liquid bridge necks down and finally breaks. The size of droplets and oscillating characteristics in arcing phase, the oscillating characteristics of the molten pool and peak current in the short-circuit phase all profoundly impact the stability of the droplet transition. The research on the spatter generation mechanism of short-circuit transition welding shows that the primary factors causing the instability and splashing in the welding process lie in the redox reaction of the molten droplet pool, the instantaneous short circuit generated in the early stage of short circuit and the liquid bridge electrical explosion at the end of short circuit.
Great efforts have been put into the research and exploration on the CO₂ short-circuit transition welding droplet transfer process and its control technology. Specifically speaking, the research work can be divided into four aspects, including optimizing the composition of welding materials, modeling and controlling droplets transfer based on output electrical signals of welding power, controlling droplet transfer based on vision sensing technology and CO₂ short-circuit transition welding technology based on magnetron technology. The promotion of active welding wire and medicinal welding wire can effectively reduce welding spatter. Wave control technology and CMT technology achieve excellent welding effect under small welding current parameters. Magnetron welding technology exhibits notable advantage in solving welding spatter and forming problems under medium and small current parameters.
This paper summarizes the research status of the short-circuit transition control technology for CO₂ gas shielded welding both at home and abroad from four aspects: welding wire, power supply, external magnetic field form and technology. Firstly, the spatter generation mechanism of short-circuit transition in CO₂ welding is analyzed. Then, several typical principles, characteristics as well as limitations of short-circuit transition control technology for CO₂ gas shielded welding are introduced in detail. Besides, the characteristics of diverse short-circuit transition control techniques are analyzed. Finally, the existing problems and corresponding solutions in the current process of research and application of the short-circuit transition control technology are elaborated, and the developing trend in this field are also put forward.

Key words： CO₂ gas shielded welding short-circuit transition welding spatter weld molding

Published: 08 May 2019

CLC number:

TG434.5

Fund:This work was supported by the National Natural Science Foundation of China (51675269) and the Priority Academic Program Development of Jiangsu Higher Education Institutions (PAPD).

About author:: Tao Chen received his B.S. degree in mechanical and electrical engineering from China University of Petro-leum (Hua Dong) (UPC) in 2016. He is currently pursuing her Ph.D. at the College of Material Science and Technology in Nanjing University of Aeronautics and Astronautics (NUAA) under the supervision of Prof. Songbai Xue. His research has focused on advanced welding technology.Songbai Xue, who enjoys special government allowa-nces, is currently a level-2 professor and Ph.D. supervisor at the College of Material Science and Technology in Nanjing University of Aeronautics and Astronautics (NUAA). He has focused on welding materials and technology for decades. During these years, he formulated 5 national standards and 5 professional standards of Ministry of Machinery Industry. Besides, he earned more than thirty major research achievements, including a second prize of 2016 State Science and Technology Progress Award, a se-cond prize of 2014 technical invention award of the Ministry of Education, a third prize of National Defense Science and Technology Progress Award. He has published about 320 papers in journals, including 120 papers indexed by SCI and 160 papers indexed by EI. The total citations are no less than 300 while a single paper is cited 38 times.

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Cite this article:

CHEN Tao,XUE Songbai,SUN Zijian, et al. Short-circuit Transition Control Technology for CO₂ Gas Shielded Welding: Research Status and Prospect[J]. Materials Reports, 2019, 33(9): 1431-1442.

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http://www.mater-rep.com/EN/10.11896/cldb.18030132 OR http://www.mater-rep.com/EN/Y2019/V33/I9/1431

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