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How to prevent defects in the welding process?

Posted by: Zhouhanping 2021-10-30 Comments Off on How to prevent defects in the welding process?

With the development of science and technology, more and more new welding technologies, welding equipment and advanced welding processes are continuously invented and used by people. Welding technology has become petroleum, chemical, electric power, metallurgy, transportation, electronics, national defense, and civilian use. As the most important and basic method of metal processing in all walks of life, welding has been widely used in the process of manufacturing and repairing mechanisms and structural equipment. Welding has recognized advantages and generally replaces casting joints and forgings. These advantages increase the possibility of reducing metal wine consumption, reducing labor intensity, simplifying equipment structure, and shortening the manufacturing cycle, greatly expanding the mechanization ability of welding process operations, and opening up a good prospect for automation.

In fact, the welding process is a random complex process, and the working conditions are also very bad. In this case, it is difficult to achieve automatic control of the welding process by using traditional welding methods. Due to the development of modern control techniques, such as sensor technology, electronics The emergence of technology and computer control technology can realize automatic correction of deviations in the welding process and make a complex welding process automatically proceed according to a predetermined program

1. Laser welding

Laser welding is a new technology developed in recent years. It uses a high-energy-density laser as a heat source to melt the metal to form a welding joint. That is, a focused laser with a high power density (10*-10W/a2) On the welding metal, through the interaction of the beam and the material to be welded, the light energy is collected by the material, and finally converted into heat energy, from the special welding method that melts the metal material

2. Explosive welding

Explosive welding is a method of welding between metals with explosives as energy. This method uses the shock wave when the explosives explode to make all the welds subject to high-speed shocks, so that they are combined in a very short metallurgical process, and there is no interface. Or there is only a small amount of smoke, no heat-affected zone, phase welding, explosion welding is suitable for a wide range of material combinations, has good connection and mechanical properties, and is mainly used for the manufacture of metal composite materials and the connection of dissimilar metals in engineering

3. Ultrasound

Ultrasonic welding is a special welding method that uses the mechanical vibration energy of the ultrasonic rate (above 16kH) to connect the same or dissimilar metals. During ultrasonic welding, high temperature heat energy is not input to the workpiece, but the elastic vibration energy is converted under static pressure. To vibrate the workpiece to combine the workpieces. This kind of bonding between the joints without chemical is called solid-state welding.

How to prevent defects in the welding process?

How to prevent defects in the welding process?

Porosity occurs in welding when contaminants or gases enter the molten pool. These impure welds are often called cavities. The pores in the basic welding are weak, and the foam-filled weld does not meet the specifications. More importantly, it can cause a part of a project to become fragile and collapse in some cases. If you find your welding impurities must be reworked immediately. These are 4 tips to prevent blowholes in welding and save yourself time and money to redo a project.

1. Keep it clean

Before preparing the surface of the material for welding, it can prove to be as important as a clean weld of the welding itself. After the effect is produced, if proper care is not taken to clean it leads to surface contamination and porosity. This in turn can lead to poor welds with poor mechanical properties, requiring rework or replacement at the expense of time and money. In order to eliminate the worry of contamination in the weld area and to ensure high-quality welds, wipe wipes can be developed. The concentrated cleaning fluid of wet wipes can easily remove cutting fluid lubricating oil, oil, ink, grease and some adhesives.

2. Check your airflow

Monitor gas protection from your flow. The stronger the airflow, the more disturbed the air. This can cause contaminants to mix with the molten pool, leading to impure welds. Although the flow rate can vary, it is important to choose the correct flow rate for each application. Doing so can improve efficiency and ensure welding quality. If you do not know what the correct flow rate is, you should consult your gas supplier.

3. Check your equipment

Over time, the hose may leak or the line may touch or wear out. Checking all connections in a striking arc will help ensure that you get the precise flow of your gas shield. Check the tip of the welding torch to give you a clean tip, sometimes the tip may become clogged, which will eventually lead to impurities in the weld. Check the tension of your drive roller or the winding hub. Poor tension will cause poor wire feed performance.

4. Working conditions

The welding shop will be very hot, but you should open the door and let the breeze think twice. You must monitor your workplace where strong air or water currents may affect the molten pool or gas protection. See your voltage/arc length. The far gun is from the welding part, more air and gas will penetrate into the molten pool and cause the formation of foam, which makes the welding weaker.

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