一、电阻对焊两个工件的端面始终压紧,通过电阻热加热到塑性状态,然后快速施加顶锻压力(或在没有顶锻压力的情况下保持焊接压力)称为电阻对焊。
Resistance butt weldingThe end faces of two workpieces are always pressed tightly, heated to the plastic state by resistance heat, and then quickly apply the upsetting pressure (or maintain the welding pressure without upsetting pressure) is called resistance butt welding. 电阻对焊的工艺参数主要有以下三项。
The process parameters of resistance butt welding mainly include the following three items.(1)伸出长度:在确定工件从夹钳电极端面伸出的长度时,应考虑顶锻时工件的稳定性和对夹钳的散热。
(1) Extension length: when determining the extension length of the workpiece from the electrode end face of the clamp, the stability of the workpiece during upsetting and the heat dissipation to the clamp shall be considered.(2)焊接时间和焊接电流。
在电阻对焊中有两个决定性因素,焊接时间和焊接电流,两者可以在一定范围内进行相应调整。
大电流、短时间均可使用;也可以使用小电流和长时间。
但配差过大时,影响焊接接头的强度,容易产生接头氧化、晶粒粗大等缺陷。
(2) Welding time and welding current. There are two decisive factors in resistance butt welding, welding time and welding current. The two can be adjusted accordingly within a certain range. Large current and short time can be used; Small current and long time can also be used. However, when the matching difference is too large, it will affect the strength of the welded joint, and it is easy to produce defects such as joint oxidation, coarse grain and so on.(3)顶锻压力、焊接压力。
加热时宜用较小的顶锻压力,用较大的焊接压力顶锻。
(3) Upsetting pressure, welding pressure. Smaller upsetting pressure and larger welding pressure should be used for upsetting during heating 二、闪光对焊通常闪光对焊可分为预热闪光对焊、连续闪光对焊(连续闪光对焊又分为顶锻阶段和闪光阶段两部分)。
Flash butt weldingGenerally, flash butt welding can be divided into preheating flash butt welding and continuous flash butt welding (continuous flash butt welding is divided into upsetting stage and flash stage).1、 闪光阶段在闪光阶段,先通电,主要功能是为了加热工件,然后使两个工件的端面轻微接触,形成许多触点。
当电流通过时产生热量,触点被熔化,并变成连接两端的液态金属过梁。
过梁中的液态金属蒸发,由于液态金属梁中的电流密度极高,过梁爆破。
操作中动夹钳缓慢推进,过梁的过程中仍会不断产生爆破。
在电磁力的作用下,液态金属颗粒不断形成火花,从界面喷出,即闪光。
1. Flash stageIn the flash stage, power on first, and the main function is to heat the workpiece. Then make the end faces of the two workpieces slightly contact to form many contacts. When the current passes, heat is generated, and the contact is melted and becomes a liquid metal lintel connecting both ends. The liquid metal in the lintel evaporates, and the lintel explodes due to the high current density in the liquid metal beam. During operation, the moving clamp is pushed slowly, and blasting will continue to occur during the lintel. Under the action of electromagnetic force, liquid metal particles continue to form sparks and eject from the interface, that is, flash. 2、顶锻阶段闪光阶段结束后,需要马上对工件进行顶锻压力,接口间隙迅速缩小,就停止过梁爆破,进入顶锻阶段。
顶锻的作用是挤压端面上的液态金属和氧化夹杂物,封闭工件端面之间的间隙,同时使干净的塑性金属紧密接触,形成牢固的接头。
2. Upsetting stageAfter the flash stage, it is necessary to carry out upsetting pressure on the workpiece immediately, and the interface gap is rapidly reduced, then stop lintel blasting and enter the upsetting stage. The function of upsetting is to squeeze the liquid metal and oxide inclusions on the end face, close the gap between the end faces of the workpiece, and make the clean plastic metal in close contact to form a firm joint.