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Fortune Group to grasp the development trend look electrode welding innovations
Essen Organizing Committee and the “Machinist” magazine, co-organized “Beijing Essen Welding Fair and the China Welding Industry” Essay Contest is “Beijing Essen Welding & Cutting Fair,” part of the 20th anniversary commemoration.
Contributions received by the organizer has more than 60 papers, including 28 selected outstanding essay.
From the essay the author level, both engaged in welding for many years, passionately devoted to the cause of the old comrades have just joined the welding industry long passion rookie. Their love is holding an exhibition, a soft spot; their memories and gratitude for his swing and engaging, so deeply touched us; expectations and their message to the show, let’s not blinking, not only the past can not lie where the idle on the results, but also by “the tower alone, monopoly End of the World Road” state of mind to climb a peak in the next show. Also use the “wide pine does not regret, to eliminate the Iraqi people to languish,” the pursuit of the show even better, to meet the welding industry a better tomorrow.
Since 1987, the “Beijing Essen Welding Show,” in addition to display products and business activities, domestic and international welding technology exchange is an important window, showing the 20-year global product innovation process of welding technology.
The rapid development of 21st century science and technology and fierce market competition, we must pay more attention to China’s national welding industry innovation and competitiveness, more attention to integration of all relevant disciplines to advance welding technology innovation, more emphasis on the progress of China’s steel welding innovation requirements, and attention to long-term prospects for innovation in welding.
First, in open market conditions, to pay more attention to welding and industrial innovation to enhance national competitiveness
In today’s world, more countries to promote open markets, the more the emphasis on enhancing the competitiveness of domestic enterprises to open up the world market.
In December 2005, the United States issued a new “National Innovation Act”, the Bill provides a series of administrative measures and increased funding to maintain U.S. global competitiveness and leadership. Commerce Department authorization bill for the development of modern manufacturing systems and use.
In 2006 the EU introduced an ambitious innovation plan “to turn knowledge into applications – EU wide innovation strategy.” The plan: by promoting knowledge-intensive products and services to the EU market leadership position in the world, as European companies to create the conditions for global competitive advantage.
Japan in 2006 issued a “Phase III Technology Basic Plan.” The plan in addition to the life sciences, information science, environmental science, materials science and nanotechnology as focus on promoting the area, but also the “manufacturing” as advancing the field. In the proposed policy objectives, included in the “making Japan the world’s first manufacturing country” and “relying on science and technology to enhance industrial competitiveness in the world-leading position,” the target.
So the 21st century, science and technology as core competence has become the focus of competition between countries.
In 2006 China’s State Council issued a 2006 to 2020 “Long-term Scientific and Technological Development”, asked after 15 years of efforts, by 2020 China an innovative country ranks. Program emphasis: building an innovative country, the core is to enhance the independent innovation capability as the strategic basis for the development of science and technology is to enhance the independent innovation capability as the adjustment of industrial structure, changing the growth mode of the central link, change the key technology depends on the person, the kinds of situation.
From the previous 20 years, “Beijing Essen Welding Show,” you can see, the size of welding industry has grown rapidly, the performance of a number of welding equipment have also made great progress. But a lot of welding equipment and a number of welding materials, welding is still well-known foreign companies with a large spread of products, as Lin Shangyang Academy of Sciences said: “The country must also see the lack of more advanced with their own brand of welding equipment, high-end welding materials and efficient welding technology, enterprises are using these advanced welding equipment and materials are mostly dependent on foreign imports. the surface of the domestic production of this brilliant welding technology hollow situation is a serious strategic weakness. ”
Therefore, how to go through ten years of efforts, China’s national welding industry as a whole to achieve “innovation-oriented country” requirement, the competent departments of China, the relevant units and Society / Association should be seriously considered and planning.
Second, the integration of advanced technology related disciplines, to promote innovation in welding
American Rand Corporation issued in 2001, “Global Technology Revolution” report, released in 2006 and “Global Technology Revolution 2020″ report. In two reports, the Rand Corporation that the global technology revolution is an important trend, is materials technology, nanotechnology, information technology, manufacturing technology and multi-disciplinary integration faster and faster, to accelerate the integration of this kinds of applied technology development is of paramount importance.
Recalling the history of development of welding technology, it can be said of its major processes, are integrated advanced technology related subjects. 100 years ago, in the late 19th to early 20th century industrial revolution in the electrical, will be used for arc welding, arc welding began the era. Mid-20th century, with advances in physics, began a variety of high-energy beam (electron beam, plasma beam, the laser beam) used in welding, so far in the ascendant. To the 1970s, with advances in information technology, to speed up the process of welding automation, is now moving to intelligent, flexible and fully digital control of the direction.
Former assistant manager Tsang Chinese Welding Society lok, who had been engaged in welding research, served as deputy chief engineer and part-time some of the Baosteel project consultant, he believes people of different professions and cross a lot of good work, call to learn German and American, participation of experts familiar with welding steel development, development of welding consumables steel experts, engaged in automatic control and mechanical design experts to participate in the development of welding equipment.
Welding industry in China is a major flaw, is the pattern of small enterprises, limited professional management, while relying on the lack of electric welding machine group companies (such as Japan, Panasonic), the lack of relying on Iron and Steel Group’s welding business (such as Japan, Kobelco, Bole Thyssen), lack of welding equipment and related set in one of the joint venture company (such as the United States, Lincoln, ATW Group). This basis and joint, not only can enhance the strength, more importantly, timely access to technology and components and new technology, new materials, support and promote the product’s “combination of innovation,” enhance the competitiveness in the international market.
How to make up for the shortcomings of welding industry? Should pay attention and take measures, including promoting the reform of enterprises and joint, to promote research in close cooperation, and expand information channels, to open up as the eyes, enhance the absorption-related disciplines and the sensitivity of advanced technology related industries, thus more efficiently to promote welding innovation.
Third, focus on the progress of China’s steel welding innovation requirements
China is the world’s largest steel welding state. According to the International Iron and Steel Association statistics, in 2006 the world steel production 1.239 million t, China’s steel production of 4.2 million t, accounting for 34% of world steel production has more than the United States, Japan, Russia, Germany, Britain, India and South Korea 7 countries, the total steel production. So the world’s leading welding companies to enter China in the welding market.
2010, China’s steel output will reach 500 million t, while China is trying to steel from steel power to a power of direction. 2006 Chinese Society for Metals and China Steel Industry Association jointly issued the “2006 to 2020 China Steel Industry Science and Technology Development Guide”, made of steel the next 15 years development goals:
1.2006 to 2010 the main objective the development of steel
(1) 20% plain carbon steel in the case of essentially the same toughness, strength increased by 1.
(2) stable production of high strength, high toughness and low yield ratio of the various types of steel, such as the yield strength of 400 ~ 800MPa, tensile strength of 600 ~ 1400MPa grade high strength and toughness plate, X80 pipeline board.
(3) stable production of high quality fire-resistant, weatherproof, shock plate, and the tensile strength of greater than 1000 ~ 1400MPa class super clean, new high-strength steels.
(4) fine-grain and fine grain, high purity, high uniformity of steel not less than 10% coverage.
(5) fully completed with Chinese characteristics and international metallurgical new materials system, including thermal power, hydropower, nuclear power equipment with new steel, shipbuilding welding without preheating and high heat input welding steel, -160 ℃ low temperature steel, automobile with 600 ~ 800MPa grade high strength steel, high-speed train with a variety of steel products, petroleum and marine engineering with a new steel manufacturing industry with all kinds of metallurgy and new materials.
(6) and the use of ferritic stainless steel, manganese, nitrogen generation of nickel, chromium and stainless steel to achieve mass production.
2.2011 to 2020 the main objective the development of steel
(1) all kinds of advanced steel materials, including strength increased by 1 to 4 times the service life increased by 1 to 4 times, resource conservation and environment-friendly advanced steel structural materials; contain alloying elements, wFe = 99.995%, high uniformity , high purity, ultra-fine organization of steel corrosion resistant material; ultra-supercritical thermal power units with super heat-resistant steel; corrosion resistance 3 to 5 times the nanocrystalline stainless steel; can be> 1100 ℃ 3h and intensity of the fire burned almost no become super-resistant steel; surface alloying of stainless steel, acid-resistant steel, wear-resistant steel, anti-oxidation of steel; ultra-light steel structural materials (light hollow steel), etc.
(2) mastery of advanced high strength, high toughness steel stable production of key technologies, including the precise control of chemical composition and high cleanliness steel metallurgy; micro-alloying technology; inclusion deformation and distribution control technology; controlled rolling and cooling technologies; over control and fine-grained steel production technology; high-precision rolling and testing technology; steel performance prediction control technology.
(3) low-nickel, chromium low-cost, environmentally friendly stainless steel products into the mainstream, nitrogen alloyed super duplex stainless steel and austenitic stainless steel form a series, stable production and is widely used in petrochemical, marine, automotive and construction industries.
To our existing welding materials and welding technology, control the development of the steel target, we can see there is a big gap (this limited space, not setting them). So the next 15 years China’s progress and performance of the varieties of steel, welding materials and welding technology and welding industry, is a great challenge. Must track the progress of the steel and promote the appropriate welding innovation.
Fourth, innovation and attention to prospects for welding
About the prospect of welding innovation in recent years have been many articles all have our say, last year, Lin Shangyang academicians and for the next 10 years the goal of independent innovation are discussed, this also involves the preceding sections of this issue, so will not repeat them. Only a combination of conditions, then a brief statement of the following:
1. Welding in addition to government and academic-oriented innovation, the market demand is the biggest driving force
The face of several million tons of steel each year a large workload and the need for welding rising labor costs, fully automated and efficient pursuit of welding welding welding innovation will become the main direction.
Now Japan, Europe and the United States in the use of welding materials, the proportion of manual electrode respectively less than 14% to 18%, indicating that automated and semi-automatic welding rate greater than 80%.
A few industries and some of China’s enterprises and semi-automatic welding automation rate to 70%. But the country, the 2006 consumption of welding consumables in the country, still accounts for about 55% of hand-welding, automatic and semi-automatic welding that is not the rate to 50%. Significantly accelerate progress in recent years, boldly predicted five years later, China’s semi-automatic welding automation and the rate will reach 70%.
2. Welding welding equipment and welding materials is the subject of innovation, but also the welding industry, the material basis of manufacturing technology innovation
Present in all developed countries, the use of solid welding wire for gas shielded welding a variety of automatic and semi-automatic welding, all welding work accounted for 50% or more. Strong momentum of development is a combination of methods: the “special coating (no copper) solid wires + multifunction digital inverter welding machine + the various implementing agencies.” Therefore, in this regard should focus on product innovation and series.
At present domestic and foreign manufacturers have introduced so-called non-copper wire, welding wire should be called the special coating, the coating composition is different because the manufacturers and surface treatment of the differences in the performance of wire are also different. Excellent performance of the coating and surface treatment process, not only from the anti-rust and lubricating effect, but also to enhance stability and reduce the arc welding spatter, and precision control of the digital transition inverter arc welding machine compatible, can achieve high efficiency , high current low spatter CO2 welding, flux-cored welding process to achieve the equivalent effect.
3. The development of new welding technology will replace traditional welding methods
1960s invention of the laser, after 40 years of development in the 21st century will enter rapid development period. As the laser welding or laser composite arc welding, with high efficiency, high-quality, narrow heat-affected zone, joint deformation and for a new generation of ultra-fine grain high strength steel welding and other metal material advantages, with the power of the laser generator , and the light of the development of economic, foreign, after it was predicted that in another decade or two, laser welding may be widely replace conventional arc welding.
4. New technology trends
Japan Science and Technology Policy Institute, “Science and Technology from 2006 to 2035 and long-term prediction”, the welding technology will be included in a high degree of social infrastructure and related manufacturing technology, the predicted number of new technologies to achieve the time. Which predicted in 2014 and 2015 to achieve the following new technologies:
(1) ships, bridges, fire equipment, the weight of large welded structure deformation, temperature deformation, welding deformation and residual stress, etc., to simulate and forecast accuracy, correction and non-free repair of manufacturing technology.
(2) the use of lightweight composite materials instead of traditional high-strength steel materials, manufacturing various types of machinery and equipment, buildings, ships and other large-scale structure of the technology.
(3) large-scale structure, using solid phase diffusion welding technology instead of the traditional combination of fusion welding techniques, combined with its deformation, only one-thousandth of the original.
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Tagged Brazing Alloy, Carbon Steel Welding Rod, Copper Brazing Alloys
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Precision laser welding sheet structure
More than a few are from Utah State University Logan Utah
Lattice structure used to connect large technology welding, resistance welding, brazing, soldering and bonding, but the use of such technology in connection 0.25mm (0.010 inch) thick or thinner lattice structure of the foil material When is a problem. When using traditional welding techniques, the foil will melt wear, deformation, or a bad connection. As the current limitations of welding technology, materials, specifications foil lattice structure component design has become a limiting factor.
Most welding is relying on the traditional production technology, will support staff and wire / strip as two separate parts welded together to form a lattice structure, shown in Figure 1A. Traditional welding methods require thicker connecting material, to avoid the formation of defects. However, if in order to facilitate welding to increase the thickness of parts, materials or design performance optimization can not be fully utilized. When the lattice design of thick-section structural components, the greater use of electric arc welding. When thin sections are often used in resistance welding. The production of the well screen, the resistance welding can not be seen as limited to the production of thick foil sections. Resistance welding requires high pressure and high current, and this high pressure would foil deformation. Since the melting of laser welding has also started to apply more solder foil material, but it is limited to a certain degree of joint geometry, because the assembly is very stringent accuracy requirements [1] [2]. The advantage of solder connections can form metallurgical bond, the heat pipe structure has good thermal conductivity. But the main flaw of all welding methods is when the welding heat can cause distortion. The characteristics of electric arc welding process used to reduce its feasibility foil welding.
To optimize the material and / or foil material lattice structure design, need for a new connection and production methods. Not the rod and wire / strip welded together, but the use of solid free forming manufacturing methods, the integration of the wire rod / strip, where it acts as an integrated weld on the rod, as shown in Figure 1B. Laser and powder material to form a solid weld, to achieve the connection of foil; weld acts as a rod, while foil is within the weld joints, the method and the choice of laser sintering (SLS), a similar effect.
GTS sericite in the electrode industry applications
E4303, E4313 welding electrodes welding material in China’s leading product, accounting for 80% of the total production of rod around. Recent years, the welding industry are looking for with little or no use of rutile titanium dioxide or reduced prices of raw materials to reduce production costs way, sepiolite, clay, pyrophyllite and other non-metallic mineral aluminosilicate used E4303, E4313 electrodes in, have achieved a certain effect, but it is not entirely a good slip and plasticity. The sericite overall performance is much better, help and improve the E4303, E4313 welding quality.
1: mica flakes are potassium aluminum silicate layer structures for KAl2 [Si3AlO10] (OH, F)
Suitable for welding rod industry, the chemical composition of sericite as follows:
Chemical composition SiO2Al2O3K2OH2OSP
Content (%) 50-6025-307-11 ≤ 5 ≤ 0.03 ≤ 0.03
2: GTS sericite application functions and features:
? And sepiolite, clay, pyrophyllite, compared sericite in the K2O content (pyrophyllite, 7.41%; sericite ,7.5-11%; clay, sepiolite does not contain K2O), and therefore have a lower ionization potential in the arc burning process, facilitate the provision of conductive ions, so that the arc burning stable.
? GTS sericite S, P low impurity content (S content of 0.015-0.018%), help to reduce the deposited metal in the S, P, reducing its tendency to crack, to improve crack resistance.
? Low water swelling (pyrophyllite, 70.5%; sepiolite, 5.2%; titanium dioxide, 32.6%; sericite, 4.3%), drugs for skin cracks useful to reduce the electrode.
? Absorbed water content is low (after 110OC × 2h baking, the moisture content per cent: pyrophyllite, 1.8; clay, 5.2%; sepiolite, 5.8%; titanium dioxide, 2.4%; sericite, 2.5%), can increase its moisture resistance properties, reduce the spread of deposited metal hydrogen content, lower stomatal sensitivity to improve the level of X-ray film scratches.
? As was fine scaly, with a certain elasticity, plasticity, increase the slip resistance welding rod coatings and powder flow in the cylinder, coated with pressure to improve its performance.
? Sericite sharp particle size distribution grid, excluding large particles of foreign impurities, does not produce when burned in the arc blast, thereby reducing spatter, while reducing the burning sound.
Conclusion: GTS sericite is a new drug skin electrode materials. It contains 7% -11% K2O, can improve arc stability, reduce spatter, welding process to improve the performance of the production process to solve the electrodes of the electrode often drug skin cracking problems in the E4303, E4313 electrode in applications such as acidic recommended ratio of 3% -5%, can improve the coating slip, viscosity, instead of titanium dioxide, reducing the cost of electrodes.
Laser welding technology in automotive applications has matured
Laser processing technology is fast, flexible features, in the automotive industry for cutting, welding, surface treatment, drilling and micro-processing and other processing. With the laser output power increases, especially the emergence of high-power lasers, laser welding technology has been developing rapidly.
Currently, the largest welding laser welding technology aspect ratio has reached 12:1, laser welding strip thickness range from 6.5mm ~ 0.1mm; range of laser welding of steel, including low-alloy steel, medium alloy steel, high strength low Alloy Steel, IF Steel, multi-phase steel, TRIP steel, and most stainless steel, electrical steel, coated steel; laser welding speeds of up to tens of meters per minute; tensile strength of steel after welding up 1450MPa.
Volkswagen has developed a laser device 14 has the structure of platform, not only for Golf welding and copper, can also handle small and medium-mass model to Lupo, large Touareg SUV. The structure platform floor area requirements than similar spot-welding equipment to 40% less.
New technology followed
In recent years, laser welding, laser hybrid welding, laser welding and other new dual-focus laser welding technology in the automotive production line has begun to apply.
Currently developed industrial countries in Europe and America, 50% to 70% of auto parts is done with laser processing. The laser welding technique is extensively used in the body.
Laser welding technology
Laser welding technology can be of different thickness and different coating of coated metal plate welded together, then put this into a semi-stamping body parts. Laser welding technology to improve the body parts of the performance, reduce vehicle mass, improve vehicle reliability and safety of the structure, and optimize the process.
At present, a rapid increase in demand for tailored blanks, made of high quality car models, such as: Passat, Buick, Audi, Accord and so began to use tailored blanks. China Wuhan ThyssenKrupp Tailored Blanks human and Shanghai Baosteel Co. Ltd. Arcelor laser welding tailored blanks are commercially available.
Not long ago, China’s heavy truck HOWO heavy truck in the truck used in the production development of ThyssenKrupp offer laser solder fight through a lot of experiments, improvements, successfully resolved the large-size cab materials development and production problems, greatly reduce the cost of raw materials procurement, the first domestic heavy-duty truck body sheet metal laser welding technology.
Laser hybrid welding
Fronius, Austria developed LaserHybrid laser hybrid welding technology is the laser beam and MIG arc simultaneously, can be welded 1 ~ 4mm aluminum, steel and stainless steel, high welding speed, welding process stability, high thermal efficiency and allow greater gap welding assembly , especially for laser beam welding can not be achieved or not economically viable wide gap welding assembly. Thereby reducing the investment costs, shorten production time, saving production costs and increase productivity with more competitive.
Germany’s Volkswagen’s concept car PhaetonD1 all doors are laser-MIG hybrid welding, BMW5 series BMW’s aluminum diaphragm is also using this technology to high-pressure welding deformation processing of aluminum alloy frame welded together.
Trumpf Ltd Shanghai Representative Office China Jia chief EvaSchwinghammer Dr., TRUMPF’s HL4006D (output power 350W ~ 4000W) and other advanced laser welding system has been used in Chinese auto and auto parts manufacturing.
In laser welding, laser welding technology dual focus can be formed on the welding of two closely spaced focal point, enabling the laser beam splitting and stacking. Superposition of two laser light beams to form a laser beam, can greatly improve the laser power, the stability of production, product quality and production flexibility. BMW has used a dual-focus laser welding technology for welding of the bulkhead.
High-quality laser equipment to enhance production efficiency
Can bring to enhance the processing efficiency of laser technology will become increasingly important. The world’s largest industrial lasers and laser systems manufacturer TRUMPF Group (TRUMPF) latest 4kW disk laser (HLD4002), to provide beam quality up to 8mm.mrad, enables users to truly remote welding applications, bringing productivity The greatly enhanced (up to 50%).
Germany’s Volkswagen have also been looking toward the next generation of laser equipment. They are looking for a 6kW equipment, up to 20% efficiency, beam quality to achieve 6mm.mrad, can be up to 100m of cable in flexible delivery, uptime of 99.9%, while the repair time does not exceed 30 minutes.
New technologies in steel welding applications
Steel structure with light weight, short construction period, adaptable, attractive appearance, easy maintenance, etc., its application more widely. The development of steel and steel production are closely related. China has become the world’s steel-producing countries in 2005, Chinese steel production has exceeded 300 million tons, of which up to 140 million steel production, energy, transportation, metallurgy, machinery, chemicals, electricity, construction and infrastructure areas such as steel construction industry has become a pillar of national economy.
From the 1980s, the Chinese construction steel has been an unprecedented development, construction steel in the national economy plays a very important position. Basis to evaluate the amount of steel in 2005, about 11.55 million tons of steel building steel structure, more than 836 million tons in 2002 38%%. At present, China’s top steel structure, steel structure, bridge steel, light steel and steel for residential steel and other industrial and civil buildings, springing up all over the country. According to statistics, so far, China has built more than 60 high-rise high-rise steel buildings; large-span space steel structure in a variety of stadium, exhibition center, theater, terminal, hangars and some industrial plants in the application; steel bridge in the ascendant, since the 1990s, according to incomplete statistics, Yibin section of the Yangtze River to Shanghai, the number has reached more than 50 bridges stabling block, half of them are steel bridge, “many among the ‘World class’ bridge, showing Chinese contemporary bridge technology has reached world advanced level “; After several years of intensive research and development into China’s steel housing has a new stage of development, a group of the Ministry of Construction of the demonstration project, pilot projects and key technology research projects have been built and achieved scientific research, in the “circular economy” “green building” policies under the guidance of future housing construction steel in China will flourish.
Welded steel construction features and difficulties
Looking at the current status of China’s steel structure engineering and development trend, more and more with modern architectural style and architectural features of high technology, its main features are:
1 novelty unique range of architecture, the node structure is complicated, multi-form welded joints, component production and field installation of the welding technology more and more difficult. For example: National Stadium “Bird’s Nest,” a large number of steel works complex truss columns, the main truss, sub-structure node welding, weld criss-cross, the construction is very difficult.
(2) building height is high, large span structures, seismic performance of welded steel design of the main requirements of high quality. Such as: frame beam-column connection weld, shear plate and column connection weld, beam web and column connections and column of the weld seam stitching, are the main parts of the structure, basically slope population penetration level seam, 100% ultrasonic testing, welding quality requirements are very high.
3 Use of steel specifications and more and more and more tend to use high-strength low-alloy structural steel and large thickness of the steel, iron and steel production process with increasing levels of, steel, austenitic stainless steel sheet has also been more to more applications. Therefore, the required on-site pre-construction, the steel used for the delivery status, real-time for a new steel to the welding test, explore the science of welding parameters, welding technology to develop appropriate measures.
4 factory production and field installation link many factors, many different types of cross-operation, on-site installation difficult.
High-tech welding and promote the development of a new round of pipeline construction
With a new round of pipeline construction boom of the season, planning ahead Pipeline Bureau, to the great cause of science and technology boost the development pipeline, to carry out a large number of scientific and technological efforts to address the pipeline design and construction of a series of technical problems. In early 2007, exploration and development pipeline Bureau in cooperation with two research projects carried out the research, cooperation projects in the Central Asian pipeline and provide technical support, and applied to the preliminary design of the Central Asian pipeline. Currently, the Pipeline Bureau Lan Zheng long borne the main pipeline has been completed welding for mechanical completion by the end of line, put into operation in June next year laid a solid foundation. Second West-East project is completed western section of the main welding 540 km, has started construction of the eastern section of the Yangtze River shield. Bureau of Indian pipeline project fully completed on April 5, personnel and equipment have been moved to Central Asia and the Second West-East pipeline project. Pipeline in the Russian Far East is also the subject through July 19.
The project has been able to speed, quality, complete, and technological innovation are inseparable. Pipeline Bureau has always pipe technology research in an important position, only the two units in 2007 Global Technology Innovation Award to report technical innovation award 17 and 73. The Bureau reported to the Group’s pipeline of “high-resolution magnetic flux leakage detector intelligent” project won first prize for technical innovation group.
Currently, the pipeline has successfully developed 10 sets of high-resolution pipeline inspection products. Pipe diameter 1016 mm high-resolution magnetic flux leakage detector has been put into industrial application, while winning the Western pipeline 3270 km of pipeline inspection projects, as well as Hong Kong and Suzhou date line pipeline inspection contract gas companies.
Oil and gas pipeline safety warning fiber technology and equipment research, as the Pipeline Bureau, the Authority has undertaken 863 projects the first time has entered the commercial stage. At the same time take the 863 projects, there are all-position welding of X80 pipeline steel material development. Ministry of Science, “Eleventh Five-Year” plan to support key projects, Second West-East Pipeline Project, including six key research topics, led by the Pipeline Bureau, to declare and undertake the task accounted for 4. West-East Gas Pipeline Project has attracted worldwide attention, it’s high-tech self-evident. The second project in the Western major projects in key technologies, were set research 8, 31 topics, including research by the Pipeline Bureau, to bear alone, there are 15. At present, most of the main tasks of the contents of the book have been basically completed. Developed for the West of X80 pipeline steel wire, diameter 1219 mm pipe heat simmer also completed a small batch trial, and through the identification of new products, now in volume production and application.
3 “863,” the research has made new progress, “oil and gas pipeline safety warning fiber technology and equipment research” complete transformation of scientific research industry, has 10 sets of mass-produced products into the natural gas field applications. “X80 pipeline steel all position welding material development of the” ongoing process performance self-shielded flux cored wire for all position welding research and adaptive research. “SCADA core software R & D” has been established, is according to plan. 15 Key West-wire technology research has been basically completed. Developed for the West of X80 pipeline steel wire, diameter 1219 mm pipe heat simmer for volume applications. The pipeline construction will make China’s technological level to move a major step forward.
Welding inverter applications and development status
The manufacture of welding power source has been 100 years of history into the 1960s, the rectifier components, high-power transistor (GTR), field effect transistor (MOSFET), insulated gate bipolar transistor (IGBT) and other devices have appeared , integrated circuit technology and control technology for the development of electronic welding power supply to provide a broader space, one of the most striking is the inverter welding power source.
Inverter welding power, small size, light weight, energy-saving materials, and control performance, fast dynamic response, easy to implement real-time control of the welding process, the performance has a great potential advantage. In the long term, the power inverter welding power source is the development direction of welding, inverter welding machine for development abroad fully illustrate this point. Present in industrial countries, manual metal arc welding / TIG welding / MIG / MAG welding inverter has been widely adopted. Welding the world’s several major manufacturers have already completed the series inverter welding machine products, and technical level as one of the signs.
A welding inverter development and application status
Inverter is called “Tomorrow’s power” and its application in the welding equipment for welding equipment has brought a revolutionary change.
First, the inverter welding power and welding power than the frequency efficiency of 20% to 30% efficiency up to 80% to 90%; second, inverter welding power, small size, light weight, the whole weight of only the traditional frequency rectifier welding power supply 1 / 5 to 1 / 10, to reduce material consumption 80% to 90%. In particular, inverter welding power source has the advantage of fast dynamic response, the dynamic frequency response faster than conventional rectifier welding power increase of 2 to 3 orders of magnitude, and to realizing the welding process automation and intelligent control. These are harbingers of inverter welding power source has a broad application prospects and market potential. At present, Japan Panasonic, Osaka transformer arc welder in the company, inverter welding machine in excess of 50%. Major U.S. manufacturer of welding machine inverter welding machine produced more than 30%. Inverter welding power source other industrialized countries the pace of development soon.
China’s research and development of inverter welding machine started in the late 1970s, in the 1980s began to develop. In 1982, Chengdu Electric Welding Institute began a thyristor inverter arc welding Rectifier, China in 1983 developed the first commercially ZX7-250 inverter welding power source, and through the project the ministry-level appraisal. Subsequently, Tsinghua University, Harbin Institute of Technology, South China University of Technology and other units of Time Inc. have introduced the use of a variety of switching elements of inverter welding machine. Now, the formation of our inverter welding power supply has 4 generation: the first generation as the main rate is based on SCR SCR inverter device; second generation transistor inverter; third generation FET inverter; fourth generation IGBT inverter, the inverter frequency is high, the saturation pressure to reduce power consumption, high efficiency, no noise, and compared to previous-generation inverters, more obvious advantages.
2 inverter development
Inverter overall development trend is toward large-capacity, lightweight, high efficiency, modular, intelligent development and to improve reliability, performance and broaden the use of the core, more and more widely used method of arc welding, resistance welding, cutting and other processes. Efficiency and high power density (small) is an international welding inverter from one of the main objectives pursued. High-frequency and lower power consumption of the main components to achieve this goal is the main technical way. Currently, in Japan, Europe and other countries and regions, 20KHz about arc welding inverter technology has matured, the quality is high and the product has been serialized.
3 Problems
(1) quality: inverter welder although in some cases replace the arc rectifiers, but its reliability compared with the general arc welding machine there are still gaps. Inverter welder restrain the domestic promotion and a major factor is widely used welding reliability. Some well-known foreign manufacturers of inverter welding machine welding machine, continuous improvement, so that its reliability is close to the general welding failure rate, that is about 1%. Another problem is that compared with other countries, equipment, instruments, tools, tooling, testing methods, quality of personnel and the gap between the level of raw material components, are unable to guarantee the reliability of the welding machine, high failure rates.
(2) research and development: the development of broad prospects for inverter welding machine attracted a large number of universities and research institutes. However, due to inverter welding power combined electric and electronic, in the development of traditional experimental methods used not only to consume a large amount of manpower, material and time, and some experimental methods is difficult to detect and resolve. Therefore need to propose new design methods and tools.
4 responses
Inverter welding machine reliability and quality problems exist, the main reasons are: (1) immature technology, lack of new product development efforts; (2) design and manufacturing processes and structural arrangements wiring unreasonable to protect the areas not reached optimization with; (3) quality assurance system is imperfect, test test, backward; (4) raw materials, components (such as IGBT, MOSFYT, core materials, etc.) manufacturing quality is not reliable; (5) small-scale production, failed to use the production line and mold assembly debugging.
Therefore recommended the following strategies to solve: (1) pay close attention to human resource development and foreign information gathering, strengthening special, equipment research and testing base of the building to ensure product quality and performance; (2) theoretical calculations and experimental correction combine to make the decision level of reliability and quality of key aspects of the main circuit design and optimization of protection as reasonable as possible with the best use of computer simulation and CAD, can save debugging inverter design and manufacturing time and reduce the inverter main circuit components The burning; (3) improve the quality of the workforce, improve the detection means. Characteristics of power devices by electronic tester, the key device (IGBT |, fast diodes, etc.) for serious testing and selection, match. The use of circuit board components and dedicated testers and test machine for the aging test; (4) maximize the scale of production in order to use the production line, automatic operation of machines, molds and other advanced means to ensure product consistency and accuracy of manufacturing processes to ensure the consistency of each product quality and reliability.
Songxing welding in the 2007 National Symposium
September 3, 2007 –6, China Welding Association special committee welding equipment, welding technology, the China Electrotechnical Society special committee,
Qingdao Shipbuilding Engineering Institute in Qingdao, Shandong Province jointly held 2007 National Welding Symposium. On-site meeting, our Technical Director on behalf of Mr. Zhou Yeji (Figure 2) CO2/MAG/MIG submerged arc welding and forming side welding combination of flat panels out automatic welding equipment in the shipbuilding industry in the application of published speech.
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Tagged Carbon Steel Welding Rod, Stainless Steel Welding Wires
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RMD welding technology for the “West-wire” project
Recently, two from the China Petroleum Pipeline Company, the company CPP214 unit area of the world’s leading pipeline construction welding equipment for Second West-East pipeline construction.
It is reported that two companies with pipeline welding equipment for pipe welding expert system MILLERPIPEPRO-450-RFC welder, comes to the device, would have talked about RMD. RMD refers to the so-called short-arc control technology, with precise control of pulse technology, and traditional gas welding and self-cored arc welding are PIPEPRO-450-RFC’s proprietary technology, enabling all the pipe welding process, and is ideal for the wild environment of the construction work.
In addition, RMD as a precise control of short-circuit technology, time of occurrence through the timely detection of changes in short-circuit current welding current and voltage, into a dynamic control technology. Because it can take with conventional TIG welding (tungsten inert gas welding), instead of using cellulose electrodes, highlights the superiority of its welding wire.
Root welding using RMD technology integration is not only good performance, and size of the gap can be filled to achieve. In addition, welding spatter, heat-affected zone and the smooth transition of optimization are significantly stronger than conventional root pass (cellulose electrodes), so much the field of international pipeline welding of all ages.
Pipeline unit always keep in mind two companies CPP214 “pipeline construction, science and technology first” open concept, the beginning of project preparation, will be under the unified arrangements of the company, training centers in the base of a six-month technical training, is to master the advanced welding technology, nearly the armed team.
In CPP214 machine head of the Du Kim Woo-led crew members to adopt advanced welding equipment, superb welding process, to total welding 70 crossings, welding testing a 100% pass rate of success by the owners, supervision and company project department of the same praise for the the Second West-East playing a high-quality, efficient, green, environmentally friendly technology pipeline laid the foundation.
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Tagged Brazing Alloy, Carbon Steel Welding Rod, Copper Brazing Alloys
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BMW cars welded into the body welding undertake BX3
Recently, reporters from Dongfeng Peugeot Citroen Automobile R & D department access to exclusive news, an internal code name for BX3 car R & D work has been basically completed, the localization of the ongoing preparatory work is expected to formally launch in April 2009 the domestic market.
description, according to insiders, this BX3 DPCA is used Peugeot 307 car chassis, suspension front face of the Citroen logo, the design of the rear on the market today is somewhat similar to the BMW 3 Series, to meet European emission Ⅳ standard, this BX3 product design and manufacturing mainly in the PF2 platform.
in the current Peugeot Citroen Automobile factory of the first three production platforms, PFN main production platform, the old brand products Citroen Fukang, Elysee and other models, while the PF2 platform is the Dragon’s midsize sedan platform, able to produce Peugeot 307 (hatchback, sedan, station wagon, sports car), Citroen C4 series and discontinued the 406 in Europe. In addition, small car platform, the production of the Peugeot 206 and Citroen C2. BX3 is based on co-operation with the 307 and C4 Chevrolet PF2 platform.
with the public in the Chinese market in recent years, a similar strategy, PSA has also strengthened the model for the Chinese market development, not only the introduction of higher-level models of platform 3, is still under design their own more work.
The PSA is located in Shanghai China R & D is expected to invest 10 billion yuan within three years, involved 500 R & D personnel, officially put into operation in September this year, but this is just the first step in PSA in domestic development. In 2007, PSA Peugeot Citroen CEO Streiff took just 100 days, the chair issued a “Cap2010″ business revitalization plan, this PSA aims to make 2010 one of the world’s five largest automobile manufacturers plan, China market in which occupied the absolute importance. PSA CEO Streiff in accordance with the plan, they want to establish in China a “small PSA”, and to focus on strengthening its localization development.
cooperation with Dongfeng PSA Dragon project is the key to success in the Chinese market, while the BX3 is this cooperation in 2009, an important part of success. According to reporter understanding, undertake BX3 car body welding work in Sichuan as welding Welding Equipment Engineering Co., BMW and Citroen cooperation in four projects, two of which had the participation of the French PSA.