STT焊接工艺培训.pptx

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1、1 Basics 基本概念基本概念Neither CC Nor CV既不是恒流源也不是恒压源Based on interactive WAVEFORM CONTROL TECHNOLOGYTM基于交互式波形控制技术Based on High Speed Inverter Technology 基于高速逆变技术Precision Current Controlled Short Arc精密电流控制的短路过渡焊接第1页/共87页2Advantages 优点优点1.Low spatter 低飞溅量2.Low fume 低烟尘3.Low cost Gas 低气体成本4.Controlled Heat

2、Input 可控制的热输入量5.All Position 可进行全位置焊接6.Good Fusion 良好的焊接成型7.Handles Poor Fit-up 适用较差的接头形式第2页/共87页3Manual Welding:STT vs Short Arc 手工焊接手工焊接:表面张力过渡表面张力过渡 vs 短路过渡短路过渡Standard GMAW标准的气保护焊接标准的气保护焊接Surface Tension Transfer表面张力过渡表面张力过渡第3页/共87页4Traditional GMAW 传统传统 气保护焊接气保护焊接第4页/共87页5STT Welding 表面张力过渡焊接表面

3、张力过渡焊接第5页/共87页6Standard GMAW标准的气保护焊接标准的气保护焊接Surface Tension Transfer表面张力过渡表面张力过渡Robotics Welding:STT vs Short Arc 机器人焊接机器人焊接:表面张力过渡表面张力过渡 vs 短路过渡短路过渡第6页/共87页7G.M.A.W=Gas Metal Arc Welding 熔化极气体保护焊接MIG/MAG Welding MIG/MAG 焊接MIG=Metal Inert Gas 惰性气体熔化极保护焊MAG=Metal Active Gas 活性气体熔化极保护焊Solid Wire with

4、External Shielding Gas实芯焊丝和外部保护气体DC+Polarity 直流正接What is GMAW?什么是什么是GMAW?第7页/共87页8Overview of GMAW processes 气保护焊接工气保护焊接工艺概述艺概述Consistent Voltage GMAW(CV)恒压气保护焊接Pulse GMAW(MIG/MAG)脉冲气保护焊接STT(Surface Tension Transfer)表面张力气保护焊接第8页/共87页9CV Power Source Output 恒压电源输出恒压电源输出Welding Circuit Consists of CV

5、Power Sources with a Wire Feeder 焊接回路由恒压电源和送丝机组成Voltage is Proportional to Arc Length 电压与电弧长度成正比Current Changes Dramatically to Maintain Constant Arc Length 电流动态变化以维持恒定的电弧长度第9页/共87页10Modes of Arc Transfer 熔滴过渡形式熔滴过渡形式Short Circuit(Short Arc)Transfer 短路过渡 Globular Transfer 滴状过渡Spray Transfer 喷射过渡Conv

6、entional 常规形式Waveform Control Technology TM波形控制技术 Pulse Spray Transfer 脉冲喷射过渡Surface Tension Transfer 表面张力过渡第10页/共87页11Short Arc Transfer 短路过渡短路过渡 Low Voltages&Low Amperages 低电压&低电流Typically Smaller Wire Diameters 典型的小直径焊丝Typical Shielding Gases Include CO2,75/25 Ar/CO2 典型保护气体 100%CO2,72/25 Ar/CO2Th

7、e Wire Shorts to Workpiece.焊丝与工件短路The Voltage=0 电压为零The Amperage Accelerates Rapidly 电流快速增加Wire Breaks off Producing a Weld Bead and Spatter 焊丝断开产生焊缝和飞溅第11页/共87页12Short Arc Transfer 短路过渡短路过渡第12页/共87页13Low Heat Input低热输入All Position Welding全位置焊接Low Cost低成本Poor Fit Up 适应较差的接头形式Spatter飞溅大Potential Lack

8、 of Fusion容易产生熔合缺陷Limited to Thin Material只适用于薄板材料焊接Advantages优点Limitations 缺点Short Arc Transfer 短路过渡短路过渡第13页/共87页14 Globular Transfer 滴状过渡滴状过渡High Voltage&High Amperages高电压和高电流Typically Larger Wire Diameters典型的大直径焊丝100%CO2,75/25 Ar/CO2 Gas Mix(Lower Cost Shielding Cost)100%CO2,75/25 Ar/CO2混合气体(低成本保

9、护气体)第14页/共87页15Globular Transfer 滴状过渡滴状过渡Ball Forms on the End of the Electrode球形熔滴在焊丝端部形成Before a Short Circuit Occurs,the High Amperage and Gravity Pull the Ball off to form weld and SPATTER在形成短路之前,高电流电磁力和重力将熔滴推离焊丝,过渡到熔池形成焊缝和飞溅 第15页/共87页16Globular Transfer 滴状过渡滴状过渡Deep Penetration较深的熔深High Deposit

10、ion高熔敷率Low Cost Gas低成本气体Excessive Spatter过多的飞溅Flat&Horizontal Only只能进行平焊和横焊Advantages 优点Limitations 缺点第16页/共87页17Spray Arc Transfer 喷射过渡喷射过渡High Voltages&High Amperages高电压和高电流Typically used with Wire Diameters of.035 and Larger一般使用0.035直径以上的焊丝直径A Minimum of 80%Argon in the Gas Mix使用最少含有80%以上氩气的混合气第1

11、7页/共87页18Spray Arc Transfer 喷射过渡喷射过渡Sharp Point Forms on End of Electrode在焊丝端部形成铅笔状Fine Droplets Are Directed in a Straight Line From the Wire to Weld Puddle 很细小的熔滴形成一条直线从焊丝过渡到熔池中，形成焊缝。第18页/共87页19Spray Arc Transfer 喷射过渡喷射过渡Smooth Weld Bead光滑的焊缝成型Deep Penetration熔深很深High Deposition高熔敷率Little to No Sp

12、atter很少或没有飞溅Potential Undercut容易出现咬边Expensive Shielding Gas保护气体成本高Flat&Horizontal Only只能平焊和横焊Advantages 优点Limitations 缺点第19页/共87页20Stable CV Transfer Modes 稳定的稳定的CV过渡模式过渡模式Short Arc 短路过渡Globular Arc滴状过渡 Spray Arc 喷射过渡WFS (current)Increasing送丝速度（电流）增加Voltage Range电压范围第20页/共87页21Surface Tension 表面张力Pi

13、nch Forces 电磁收缩力Jet Forces 电弧推力Forces in Arc 电弧的作用力第21页/共87页22Surface Tension 表面张力表面张力PinPoutRg gPoutPing gPin-Pout =2 g gR第22页/共87页23Surface Tension 表面张力表面张力Droplet on wire焊丝上的熔滴Weld Puddle第23页/共87页24Surface Tension 表面张力表面张力The small drop is absorbed into the big drop小的熔滴被大的熔滴吸收了第24页/共87页25Surface

14、Tension and Pinch Forces表面张力和电表面张力和电磁收缩力磁收缩力Surface Tension Forces 表面张力Wet Droplet to Weld Puddle 润湿熔滴到熔池Pinch Forces电磁收缩力Separate Shorted Electrode from Puddle将短路的焊丝与熔池分离第25页/共87页26Pinch Force 电磁收缩力电磁收缩力II2(R2-r2)p R41.45x10-7P=PSIR=Outer Conductor Radius(cm)r=Inner Conductor Radius(cm)Maximum at r

15、=0第26页/共87页27 Jet Forces 电弧推力Thermal Mechanism 热机械过程Caused by Vaporized and Accelerated Metal in the Anode and Cathode Drop Regions 由在阳极和阴极之间蒸发和被加速的金属粒子产生Complex Phenomenon复杂的现象Very Pronounced at High Currents大电流时非常显著FAnodeFCathode第27页/共87页28Transition Current 过渡电流过渡电流Below Transition Current 低于过渡电流

16、低于过渡电流Electrode is Melted 焊丝被熔化Surface Tension Holds Droplet on the Wire表面张力将熔滴留在焊丝端部Above Transition Current 高于过渡电流高于过渡电流Droplet is Expelled from Wire and Transferred to Work熔滴被推离焊丝，过渡到工件Current 电流Pulsed脉冲80 Amps410 Amps第28页/共87页29Transition Current 过渡电过渡电流流PpinchP g Pinch Forces Exceed the Surface

17、 Tension Forces,Molten Metal is Expelled and Transferred form the Electrode 电磁收缩力超过表面张力，熔化金属被推离焊丝第29页/共87页30Pulse Spray Transfer 脉冲喷射过渡脉冲喷射过渡time第30页/共87页31Pulse Arc Waveforms 脉冲电弧波型脉冲电弧波型第31页/共87页32Pulse Welding 脉冲焊接脉冲焊接Pinch Force 电磁收缩力Current Pulses Above Transition Current 电流脉冲高于转换电流Pinch Force

18、Exceeds Strength of Molten Extension电磁收缩力超过熔滴的表面张力Spray Transfer Becomes Possible at Low Currents喷射过渡可以在较低的电流下形成Heat Input Effect 热输入影响Pulsing Increases the Melting Rate of Wire with Respect to Total Average Heat Input在总平均热输入量相当的情况下，脉冲焊可以增加焊丝的熔化效率。第32页/共87页33Surface Tension Transfer 表面张力过渡表面张力过渡第33页

19、/共87页34STT Waveforms STT 波型波型第34页/共87页35Stable Pulse Transfer Modes 稳定的脉冲过渡稳定的脉冲过渡模式模式STT 表面张力过渡Pulse Arc 脉冲过渡Spray Arc 喷射过渡Voltage Range电压范围WFS (current)Increasing送丝速度（电流）增加第35页/共87页36Heat Input of Different Transfer Mode 不同过渡不同过渡形式的热输入形式的热输入Heat input KW热输入量Short Arc 短路过渡STT 表面张力过渡Pulse脉冲过渡22.53第3

20、6页/共87页37Waveform Controlled Machines 波波形控制设备形控制设备High SpeedAmplifierWaveform GeneratorArcComputerInterface第37页/共87页38WaveDesignerTM 波形设计软件波形设计软件Graphical program for designing custom welding waveforms.Characteristics may be customized Live,while welding第38页/共87页39Wave Form 波形波形A picture-of a wave 一

21、种波形Vt第39页/共87页40Wave Form 波形波形Different shapes 不同形状XtXt第40页/共87页41Wave Form 波形波形Cycle 循环第41页/共87页42Wave FormDont have to be regular 不必是规则的第42页/共87页43Pulse Transfer(GMAW-P)脉冲脉冲过渡过渡Wide Range of Voltage and Amperage电压电流范围宽Variation of Spray Arc Capable of All Position Welding使喷射过渡电弧适应全位置焊接变为可能Two Curr

22、ent Levels are Utilized:Peak&Background两个电流水平：峰值和基值第43页/共87页44Wave Forms 波形波形STT.00001 sec第44页/共87页45STT Process Theory 工艺原理第45页/共87页46STT High Speed Video STT 高速摄影录像第46页/共87页47 Background Current 基值电流Arc current level prior to shorting to the weld pool 短路前的电弧电流Contributes the overall heat input 决定绝

23、大部分的热输入Keep arc lit 保持电弧燃烧第47页/共87页48Initial Shorting 开始短路阶段Response to the“arc voltage”detector sensing that the arc has shorted 检测到电弧电压短路信号,作出反应Current is reduced even further at actual ball/weld puddle contact在熔滴与熔池实际接触前电流下降Extremely low current promotes ball wetting instead of repelling极低的电流改进了熔

24、滴的润湿性Reason for lower spatter in STT 这是STT飞溅小的原因第48页/共87页49Pinch Current 压缩电流High current is applied immediately after the initial short 在开始短路阶段后马上采用大电流Current increases,causing the molten droplet to separate from the electrode 电流增加,导致熔滴与焊丝分离STT electronically calculates when the droplet separation

25、is to occur and reduces the current before this happens,eliminates the explosive spatter STT电子电路计算熔滴分离的时间并降低在它发生之前降低电流,杜绝爆炸造成的飞溅第49页/共87页50Second Current Reduction 第二次电流下降Current is quickly reduced before electrode separates,eliminating spatter 电流在焊丝分离前快速降低，减少飞溅。STT circuitry re-establishes the weld

26、 arc at a low current level STT电路在一个很低的电流水平重新建立焊接电弧第50页/共87页51Peak Current 峰值电流High Current is applied immediately after the arc is re-established电弧建立后立即采用高电流Arc is momentarily broadened,producing high heating of the plate,insuring good fusion and setting the proper arc length电弧即刻变宽，在板上产生高热量，确保良好的熔合

27、和建立合适的电弧长度第51页/共87页52Tail out 收尾电流Current is reduced from peak to background level 电流从峰值降到基值Reduce the agitation of the weld puddle 降低对熔池的搅拌作用This control is coarse heat control 这个可以少量地控制热输入量第52页/共87页53Root STT High Speed Video 工艺原理第53页/共87页54STT Waveform 波型波型第54页/共87页55STT Waveform 波型波型Background C

28、urrent基值电流:Controls bead shape and provides minimum heat to maintain a liquid ball(T7-T1)控制焊缝成型和提供最小热量维持焊丝端部形成球形熔滴(T7-T1)Peak Current峰值电流:Controls arc length and promotes good fusion(T5-T6)控制电弧长度和促进良好的熔合(T5-T6)Tailout 收尾电流:Reduces puddle agitation,eliminates premature shorts,and smoothes bead(T6-T7)

29、降低对熔池的搅拌作用，杜绝提前短路，确保平滑的焊缝成型(T6-T7)第55页/共87页56Surface Tension 表面张力Material is Transferred by Surface Tension Forces表面张力使材料过渡Pinch Forces 电磁收缩力Control of Fusing Depends on Consistent Pinch Mechanism依靠稳定的电磁收缩过程控制熔化Jet Forces 电弧推力Spatter is Controlled by Lowering Current at Fusing通过在熔化时降低电流来控制飞溅Surface

30、Tension Transfer(STT)第56页/共87页57STT Metal Transfer 表面张力金属过渡表面张力金属过渡Liquid surface tension 液体表面张力No“explosion”没有“爆炸”No spatter 没有飞溅Puddle control 熔池可控制第57页/共87页58Major Advantages 主要优点主要优点Low Heat Input热输入量低Minimal Spatter飞溅少Bead Contour焊缝成型好Process Efficiency工艺效率高Reduced Distortion减少变形和烧穿Reduced Clea

31、ning减少清理工作量Less Grinding减少打磨工作量Fusion Even on Gaps 可以熔合有间隙的焊缝 第58页/共87页59Major Advantages 主要优点主要优点Uses Larger Wire可以使用更大的焊丝直径Can Use CO2使用CO2气体Easy容易使用Environmental环保Lower Cost降低成本Lower Cost降低成本Minimal Training减少培训工作量Less Smoke烟尘少第59页/共87页60STT Replacing Short-arc STT 代替短路过渡焊接代替短路过渡焊接Advantages 优点No

32、 Cold Fusion 没有未熔合Consistent X-ray Quality Welds 稳定的焊接质量Good Puddle Control良好的熔池控制Shorter Training Time 缩短了培训时间Low Fume Generation 降低了烟尘Low Spatter 降低了飞溅Not Sensitive to Composition of Shielding Gas 对保护气体成分不敏感第60页/共87页61STT Replacing TIG STT代替代替 TIGAdvantages 优点4 Times Faster 4倍的焊接速度Vertical Down We

33、lding Possible 可以立向下焊接Shorter Training Time 缩短了培训时间Not Sensitive to Composition of Shielding Gas 对保护气体成分不敏感100%CO2 可以用100%二氧化碳Welds Stainless,Nickel Alloys and Mild Steel Well 可以焊接不锈钢，镍基合金和低碳钢第61页/共87页62STT LIMITATIONS 局限性局限性More Expensive Equipment设备成本高“Low”Deposition Rate熔敷率低Less than 7 lbs/hour 低

34、于7磅/小时第62页/共87页63Industries 工业应用工业应用Automotive 汽车行业Pipe and Pressure Vessel 管子和压力容器Power Generation 发电设备Food and chemical processing 食品和化工设备Consumer products 消费品行业Hardsurfacing,etc.表面硬化等第63页/共87页64Applications 主要应用主要应用Ford Explorer roof seam 福特探险者顶棚焊缝BMW X5 Rear Post and roof宝马X5 C柱和车顶BMW Z4 Roadste

35、r Windshield Post宝马 Z4 Roadster A柱Auto body components 汽车车身部件 Motorcycle gas tanks 摩托车油箱Automotive exhaust components 汽车排气系统第64页/共87页65Configuration 配置配置Power Feed 10 RFanuc Robot 机器人机器人100iC/6L 最大半径1.63m120iC/10L最大半径2.01mWire Feeder 送丝机送丝机Lincoln Electric Auto Drive 4R90第65页/共87页66Configuration 配置配

36、置Power Feed 10 RWelder 焊机焊机Lincoln Electric Power Wave PW455M/STT第66页/共87页67Configuration 配置配置Power Feed 10 RTorch 焊枪焊枪Tregaskiss Through Arm A500 特雷克斯A500中空焊枪Torch Reamer 清枪装置清枪装置特雷克斯紧凑型清枪装置第67页/共87页68SENSE LEAD DIP Switch 电压反馈线和拨码开关电压反馈线和拨码开关Power Feed 10 RSwitch 8 work sense lead 电压反馈线电压反馈线off wo

37、rk sense lead not connected 关 电压反馈线没有连接on work sense lead connected 开 电压反馈线连接STT 必须使用电压反馈线必须使用电压反馈线连接到工件连接到工件与负极电缆分开与负极电缆分开不能任意更改长度不能任意更改长度 多电弧在同一工件上焊接时，多电弧在同一工件上焊接时，注意电压反馈线的连接位置。注意电压反馈线的连接位置。第68页/共87页69WaveForm Selection 波形选择波形选择Power Feed 10 RMenu-Setup-Weld Equipment-Search-Select Wire Gas STT第69

38、页/共87页70Materials 适应的材料适应的材料Carbon and Low Alloy Steels炭钢和低合金钢Galvanized/Zinc Coated镀锌板Stainless and Nickel Alloys不锈钢和镍基合金Silicon Bronze and Copper Alloys硅青铜和铜合金第70页/共87页71Wires 使用的焊丝使用的焊丝In General,Wire Diameter will be Increased One Size Compared to Conventional CV （0.9-1.2mm)一般焊丝直径可以选择比常规 CV模式增大一

39、个型号，一般使用0.9mm-1.2mm直径的焊丝The Larger the Wire Diameter the Higher the Deposition Rate(Up to 1/16”)较的直径的焊丝可以提高熔敷效率(至1/16”,1.6mm)Wire Sizes Below.035 are Unnecessary for Most Applications对一般应用，焊丝直径不会低于0.035”(0.9mm)Use.045 as much as possible.Even down to 2mm fillets.尽量使用1.2mm的焊丝。甚至低于2mm的角焊缝也可以。第71页/共87页

40、72Shielding Gas 保护气体保护气体100%CO2 or 75/25,80/20 Argon Blends100%二氧化碳 75/25,80/20 氩气混合气100%CO2 gives better side wall penetration than the Argon blends.100%CO2比氩气混合气，可以获得更好的熔深 Use as much CO2 as possible.尽量使用CO2保护气体 Dont use 90-10!不要使用超过90%氩气含量的混合气体Lower your gas flow to keep from interfering with the

41、 arc.降低气体流量，防止气体对电弧的干扰第72页/共87页73ESO or CTWD 干伸长干伸长3/16 ESO is better than 1/2 as a general rule.(very little radiation of heat will keep the tips cool)3/16”(4.8mm)干伸长要干伸长要优于优于1/2”(12.7mm)的常规的常规原则（热辐射范围很小，基本原则（热辐射范围很小，基本可以保持导电嘴很低的温度）可以保持导电嘴很低的温度）CTWD 8-10mm in generalCTWD一般一般8-10mmESOArc LengthCTWDW

42、FS第73页/共87页74Push Angle 焊接推角焊接推角Drag the arc,ALWAYS!Dont push it unless a very small weld is necessary and it is at high speed.永远采用拖枪焊接！除非需要焊接很小的焊缝和很高的焊接速度，否则不要用推枪焊接第74页/共87页75Setting Welding Schedule 设定焊接参数表设定焊接参数表DATA-Weld Schedule 1-32As Easy As 1-2-3 非常容易Wire Feed Speed Controls Deposition Rate送

43、丝速度控制熔敷率Peak Current Controls Arc Length峰值电流控制电弧长度Background Current Controls Bead Contour基值电流控制焊缝宽度Tailout Increases Power in the Arc 收尾电流增加电弧的能量第75页/共87页76Step 1-Set up 第一步第一步Example-.045 L-50 例如1.2mm L-50Set WFS for fill required（90225IPM)设定送丝速度以适应填充需要（90225IPM）Peak Current to 0(10 10)峰值电流Backgro

44、und to 1.0(0.5 1.5)基值电流第76页/共87页77STEP 2 第二步第二步Low 低低 Optimum适中适中High高高Adjust Arc Length with Peak Current用峰值电流调整电弧长度第77页/共87页78Step 3第三步第三步Low低低 Optimum适中适中High高高Adjust Bead Shape using Background Current用基值电流调整焊缝形状第78页/共87页79Contact Tip to Work DistanceShortOptimumLong第79页/共87页80Travel Speed 焊接速度焊

45、接速度焊接速度一般 6mm/s-12mm/s立向下焊，或下坡焊时，可以达到20mm/s第80页/共87页81Runin 起弧起弧Starts are better if the wire slides in at an angle rather than squarely to the joint.侧面有角度的使焊丝进入起弧效果要好于直接进入接头The second start is always better if the wire is hot from the first weld.如果焊丝是热的，二次起弧会好于第一次起弧第81页/共87页82Burnback 回烧回烧Same Para

46、meters as Welding与焊接参数用相同的参数Always use a short amount of Burnback.A large ball will form if it is too long and inhibit starting.一般使用短时的回烧时间，如果时间太长，会在焊丝端部形成大的球，影响下次起弧。第82页/共87页83Weaving 摆动焊接摆动焊接Data-Weave Scheduel-SetupWeaving should be kept to a minimum and if necessary,only weave the diameter of th

47、e wire.摆动幅度应尽量小，一般不超过焊丝直径。第83页/共87页84Weld Size 焊缝尺寸焊缝尺寸Dont try to make weld sizes of 8mm or larger.Another process can do it better.不要试图获得超过8mm的焊缝，可以选择其他工艺Flair bevel welds take approximately 50%more weld metal than Fillets.边接焊缝将比角焊缝多用约50%的填充金属Weld size should be calculated on strength of materials

48、 and not what used to be done with other processes.焊缝尺寸应该按照材料强度计算，而不应该和其他工艺进行类比。第84页/共87页85Heat Input 热输入量热输入量Use the smallest torch you can.The heat input is directly to the part and STT has very,very low radiated heat.尽量使用小功率的焊枪。热量被直接输入到工件，STT的热辐射非常低。Weld without a Back up.STTs heat input is affected by the quenching of attached parts.焊缝没有背面衬垫，STT的热输入会受到相连接的部件冷却的影响。第85页/共87页86Questions?问题？第86页/共87页