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Stainless Steel Welding Wires

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.

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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.

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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.

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

Stainless Steel Welding Wires

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.

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? 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.

Carbon Steel Welding Rod

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 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.

Stainless Steel Welding Wires

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.

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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.

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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.

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.

Stainless Steel Welding Wires

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.

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(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.

Carbon Steel Welding Rod

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.

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.

Stainless Steel Welding Wires

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.

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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.

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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.

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.

Stainless Steel Welding Wires

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.

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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.

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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.