Progress on Current-carrying Wear and Service Life of Contact Tube for GMAW
LI Zhuoxin1, CONG Xing1, LI Hong1, Kim Hee Jin2
1 School of Materials Science and Engineering, Beijing University of Technology, Beijing 100020,China 2 Advanced Joining Research Team, Korea Institute of Industrial Technology, Cheonan-si 330-825, Korea
Abstract: Modern manufacturing requires welding technology to be intelligence, continuous and environmentally friendly. At present, the high wear rate of the contact tube lead to frequent downtime and overhaul during welding, limiting the development of the gas metal arc welding. The current-carrying wear under electrical contact conditions is an important cause of excessive wear and it is mainly reflected in two aspects: (1) Joule heat generated by electrical contact causes the ambient temperature to increase greatly, and the local temperature even exceeds 500 ℃, causing softening of electrical contact materials; (2) constant movement and change of electrical contacts leads to microscopic arcing, causing intense melting and oxidation of local materials. The mechanical wear and electrical wear caused by electrical contact are mutually intensified, greatly reducing the service life of contact tube. Contact resistance is vital to the generation of Joule heat and micro-arc. The contact resistance between the copper-coated steel wire and the contact tube is 1.6 mΩ, while for copper-free steel wire this value is increased to 2.5 mΩ. The life of the contact tube decreases with the increase of contact resistance, welding current and wire feed speed; the normal contact load increases the mechanical wear on the one hand and reduces the electrical wear on the other hand, so it has a complicated influence on the life of the contactor. The use of high-strength and high-conductivity material is beneficial to improve the service life of the contactor. Cu-Cr-Zr based copper alloy strengthened by two-phase precipitation can significantly improve the material strength while minimizing the conductance loss caused by solid solution. In addition, graphite-based, powder metallurgy and composite material contact tube have certain practicability and is worth studying. A smooth and flat surface of the wire helps to extend the service life of the contact tube and surface lubricity coating prepared on non-copper coated wire can further improve its wear property. Welding conditions require the surface coating to have both high temperature stability and high electrical conductivity. The solid lubricant with surface effect and small size effect has great advantages and application prospects in this respect. In this paper, the research progress of the current-carrying mechanism of contact tube in GMAW is reviewed. The factors affecting the current-carrying wear and the feasible methods for improving the life of the contact tube are analyzed from the aspects of process parameters, contact tube material and surface state of the wire. It has certain guiding significance for reducing the wear of the contact tube, improving its life and promoting the development and manufacture of robotic automatic welding and non-copper coated solid wire.
栗卓新, 丛兴, 李红, Kim Hee Jin. 熔化极气体保护焊导电嘴载流磨损及使用寿命的研究进展[J]. 材料导报, 2020, 34(19): 19128-19133.
LI Zhuoxin, CONG Xing, LI Hong, Kim Hee Jin. Progress on Current-carrying Wear and Service Life of Contact Tube for GMAW. Materials Reports, 2020, 34(19): 19128-19133.
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