The German PTR company not only uses the electron beam to weld all parts of the car, but also the welding process is a fully automatic "fool" type control, the electron beam welder has been installed in the production line. For example, the welding equipment of the gear can automatically complete the cleaning, assembly and welding of the parts after the machine is added in the production line. Once someone or an abnormal object enters the work area, the equipment will automatically interrupt the operation and avoid damage. This equipment is very expensive. However, it is still favored by companies such as Mercedes-Benz and BMW [9].
Non-vacuum electron beam welding (EBW-NV) has received much attention in the automotive industry. For example, in the manual transmission, the non-vacuum electron beam welding of the synchronizing ring and the gear has a productivity of more than 500 pieces/h. The welding institute of the University of Aachen in Germany obtained high-quality welded joints at a welding speed of 11 m/min in a non-vacuum test, and is currently reaching a welding speed of 25 m/min to meet the needs of the automotive industry. The United States is the world's largest user of non-vacuum electron beam welding. According to information, there are already 50 non-vacuum electron beam welders in operation in the United States in the 1980s, including equipment imported from Europe, mainly used in the automotive industry.
From the 1980s, China began to study electron beam welding, with the focus on the welding of heavy-duty gears for automobiles. This is because with the development of automobiles, the demand for heavy-duty gears of automobiles is also increasing. The traditional welding methods are used to produce problems such as low labor productivity, large welding deformation, difficult joint quality, high consumption, and poor working conditions. The Beijing Aviation Technology Research Institute and the Beijing Institute of Electrical Engineering of the Chinese Academy of Sciences conducted in-depth research on this, and developed gear welding machines. The Institute of Electrical Engineering of the Chinese Academy of Sciences has formed a certain batch production scale. In addition, Harbin Welding Research Institute has carried out a lot of research work in the research and development of vacuum electron beam welding machine in the research field of non-vacuum electron beam welding technology and Guilin Electric Apparatus Research Institute, and it has been effective [8]. In addition, Shaanxi Automobile Factory has successfully applied a double-headed electron beam welded rear axle.
3.3 Plasma welding application
As early as the late 1960s and early 1970s, the Ukrainian Barton Welding Institute began research on microbeam plasma welding technology. The micro-bundle plasma arc has the characteristics of arc contraction and energy concentration. Compared with laser welding, the advantage is that the whole operation process is relatively simple, the cost is one-half of the laser welding, and the equipment maintenance skill requirements are not high, the weld strength reaches more than 90% of the base metal, and the weld structure and composition are also It is basically close to the base metal, but the welding quality is not as good as laser welding. Compared with electron beam welding, it does not need to be under vacuum conditions, and electron beam welding must be carried out under vacuum conditions, with low production efficiency and high cost, and the workpiece is also limited by the size of the vacuum chamber [10]. Plasma welding at home and abroad is mainly used for welding aluminum alloy and medium-thickness structural steel. For example, when welding 25mm long IEC car bottom plate, the double wire metal gas protection plasma welding process is adopted, and the average welding speed can reach 1.2-1.8m/min. The welding process is stable and the welding quality is reliable.
Researchers at the Advanced Connection Center of the University of Convertry in the UK have jointly developed a new plasma arc spot welding system with the experts of JAGUAR Automobile Factory for spot welding the latest design of the Jaguar chassis. There are about 40 solder joints. Special, conventional resistance spot welding robots cannot enter. Compared with resistance spot welding technology, plasma arc spot welding technology has the advantages of greatly reduced torch quality, greatly improved robot operation, greatly improved tensile strength and fatigue strength of solder joints, and 2 times larger diameter of solder joints. The potential technical advantages of plasma spot welding indicate that this new plasma arc welding process may replace the resistance spot welding process in a certain range [8].
The NASA Space Agency Marshall Aerospace Center developed a new plasma arc welding method called Ternary gas plasma arc welding, and applied for a US patent in May 1995. Compared with conventional plasma arc welding, this new method has made a major innovation in the welding torch. The tungsten is extremely hollow and has an inert gas in the middle. Therefore, there is a triple gas in the torch, and the gas and the surrounding tungsten are introduced from the middle of the tungsten electrode. The combination of ion and gas helps to obtain a more straight, more stable plasma arc. With this welding torch, the width of the heat affected zone of the weld is reduced, the controllability of the penetration depth is increased, and a thicker material can be welded under relatively low heat input conditions [8].
Domestic research is mainly on plasma arc welding equipment. Li Jinglong and Bai Gang of Northwestern Polytechnical University carried out research on pulsed plasma spray welding technology. Through the connection of high-frequency IGBT contactless switch between the workpiece and the nozzle anode and nozzle 2, the high frequency of transfer arc and non-transfer arc was successfully realized. Alternate operation and plasma spray welding under a single power source. Wang Yasheng and others from Xi'an Jiaotong University have carried out research on variable polarity plasma arc welding equipment suitable for Al, Mg and their alloys. The positive and negative half waves of the main arc are respectively powered by two DC power sources, and the workpiece (aluminum) Variable polarity welding is achieved, which not only stabilizes the arc, but also has a reliable cathode cleaning effect. Beijing Aeronautical Technology Research Institute carried out the "one pulse and one hole" process research of pulsed plasma arc welding. Xi'an Aero Engine Company realized the improvement of an engine process by using self-made power equipment and imported plasma welding torch [11].
in conclusion
In the 21st century, the automotive industry is entering a way of flexible modular production according to user requirements. The traditional processing technology can not meet the needs of new production methods, which provides an opportunity for large-scale application of high-energy beam welding technology. There must be greater development in the field, becoming the main processing method in the automotive industry, and eventually replacing resistance spot welding.
references:
Lin Rangxian. Spot welding defect analysis and process specification [J]. Guangxi Machinery, 1999, (4): 18-20.
Chen Yihong, Zhang Fawei. Laser welding in the automotive industry [EB/OL].
Wang Shengyu + laser application in automotive body [J]. Automotive Technology and Materials, 1994, (5): 1-4.
Golden River, Liu Guoshan, Xu Jiaping. Review and prospect of China's automotive welding technology [J]. Automotive Technology and Materials, 2004, (5): 5-7
Roessler D M.Update on laser percessing in the automovtive indusry[C].California:LASERS91.1991.
Forbis parrott C A.Laser Beam Welding is ready to Go to Word at Cadillac [J].Welding Journal,1991,(7):4-8
Liu Qingbin, Zhao Zhongyong, Guan Jingquan, et al. High power CO2 laser welding and application [J]. Advances in Laser and Optoelectronics, 1997, (8): 1-4
Guan Qiao, Liu Fangjun, Dong Chunlin + Application and development trend of high energy beam welding technology [C]. Tianjin: Proceedings of the Ninth National Welding Conference, 1999.
Song Yimei, Li Shaolin, Zhong Qinghua + Application of Electron Beam Technology in Industrial Field [J], Guangxi Machinery, 2003, (1): 17-21.
Pan Lihua + microbeam plasma welding [J]. Shanghai Aerospace, 1999, (3): 61-64.
Liu Jinhe + high energy beam and development of special welding technology
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