MIG WELDING METHOD
20220402078 · 2022-12-22
Assignee
Inventors
- Kyohei KONISHI (Tokyo, JP)
- Chikaumi Sawanishi (Tokyo, JP)
- Hiroshi Matsuda (Tokyo, JP)
- Yoshiaki Murakami (Tokyo, JP)
Cpc classification
B23K35/3066
PERFORMING OPERATIONS; TRANSPORTING
B23K35/383
PERFORMING OPERATIONS; TRANSPORTING
B23K9/093
PERFORMING OPERATIONS; TRANSPORTING
B23K35/3073
PERFORMING OPERATIONS; TRANSPORTING
B23K35/308
PERFORMING OPERATIONS; TRANSPORTING
B23K35/3053
PERFORMING OPERATIONS; TRANSPORTING
C22C38/12
CHEMISTRY; METALLURGY
International classification
B23K35/02
PERFORMING OPERATIONS; TRANSPORTING
B23K35/30
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A MIG welding method for carbon steels using an Ar shielding gas. The method includes short-circuiting a welding wire and a base material. The average short-circuiting frequency in welding is 20 Hz to 300 Hz and the maximum short-circuiting period is 1.5 s or less.
Claims
1. A MIG welding method for carbon steels using an Ar shielding gas, the method comprising short-circuiting a welding wire and a base material, wherein an average short-circuiting frequency in welding is in a range of 20 Hz to 300 Hz, and a maximum short-circuiting period is 1.5 s or less.
2. The MIG welding method according to claim 1, wherein a welding current in the welding is a pulse current and a value X calculated by the following formula (1) satisfies 50≤X≤250:
X=I.sub.pt.sub.p/L+(I.sub.p+I.sub.b)(t.sub.up+t.sub.down)/(2L) (1) where, I.sub.p is a peak current (A), I.sub.b is a base current (A), t.sub.p is a peak term (ms), t.sub.up is a rise term (ms), t.sub.down is a fall term (ms), and L is a distance (mm) between a contact tip and the base material.
3. The MIG welding method according to claim 1, wherein the welding wire is a solid wire.
4. The MIG welding method according to claim 3, wherein the solid wire has a wire chemical composition comprising, by mass %: C: 0.020% to 0.150%; Si: 0.20% to 1.00%; Mn: 0.50% to 2.50%; P: 0.020% or less; S: 0.03% or less, and the remainder being Fe and incidental impurities.
5. The MIG welding method according to claim 4, wherein the wire chemical composition further comprises at least one selected from the group consisting of, by mass %: Ni: 0.02% to 3.50%, Cr: 0.01% to 1.50%, Ti: 0.15% or less, and Mo: 0.8% or less.
6. The MIG welding method according to claim 2, wherein the welding wire is a solid wire.
7. The MIG welding method according to claim 6, wherein the solid wire has a wire chemical composition comprising, by mass %: C: 0.020% to 0.150%; Si: 0.20% to 1.00%; Mn: 0.50% to 2.50%; P: 0.020% or less; S: 0.03% or less, and the remainder being Fe and incidental impurities.
8. The MIG welding method according to claim 6, wherein the wire chemical composition further comprises at least one selected from the group consisting of, by mass %: Ni: 0.02% to 3.50%, Cr: 0.01% to 1.50%, Ti: 0.15% or less, and Mo: 0.8% or less.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0019]
[0020]
[0021]
[0022]
[0023]
DETAILED DESCRIPTION
[0024] The disclosed embodiments are described below in detail with reference to drawings.
[0025] In the disclosed embodiments, as shown in, for example,
[0026] On the other hand, when carbon steels are aimed, conventional MIG welding has a problem that welding is extremely unstable. MAG welding or MIG welding is reverse-polarity welding in which an electrode (wire) is an anode and therefore a cathode spot originating from a location which has a low work function like an oxide and in which electron emission is likely to occur is formed on a surface of a base material. In an aluminium alloy having a strong oxide film on a surface of a base material, a cathode spot originating from an oxide film on a weld line is stably formed and therefore good welding is possible. However, in a carbon steel having a relatively thin oxide film or no oxide film and in MIG welding in which no oxide derived from O.sub.2 or CO.sub.2 is produced unlike MAG welding, a cathode spot is not stationary but moves rapidly on a surface of a base material in pursuit of a location with a low work function. Therefore, welding is unstable and a weld bead has a meandering or wavy shape.
[0027] For this phenomenon, the inventors have observed arc behavior in a welding experiment and have concluded that the main cause of a meandering or wavy shape of weld beads that is problematic for MIG welding intended for carbon steels is unstable metal transfer.
[0028]
[0029] Therefore, in the disclosed embodiments, it has been found that the completion of bonding by so-called short-circuiting transfer in which a non-short circuit condition in
[0030] Since welding is destabilized when the volume of the droplet 7 at the tip of the welding wire 1 is too small or too large, the volume of the droplet 7 at the tip of the welding wire 1, the droplet 7 being transported to the molten pool 8 by short circuiting once, is preferably substantially equal to the volume of a sphere with the same diameter as the diameter of the wire. Therefore, in the disclosed embodiments, the average frequency (average short-circuiting frequency) F (Hz) of short-circuiting transfer is 20 Hz to 300 Hz. In addition, the maximum short-circuiting period t.sub.cyc (s (seconds)) is 1.5 s or less because in order to obtain a good bead shape, short circuiting preferably occurs periodically.
[0031] Herein, the maximum short-circuiting period t.sub.cyc is not necessarily constant every time and means the maximum one of short-circuiting periods in one welding pass. Thus, the fact that the maximum short-circuiting period t.sub.cyc is 1.5 s or less is synonymous with the fact that each short-circuiting period does not exceed 1.5 s. This allows regular metal transfer to be achieved in MIG welding in which an Ar shielding gas is used, thereby obtaining a stable weld bead.
[0032] When the average short-circuiting frequency F is such that F<20 Hz, the presence of spray transfer is significant and metal transfer is irregular. When F>300 Hz, a molten pool is disturbed by the restriking of an arc in association with short circuiting. Therefore, in every case, it is difficult to eliminate the meandering or waving of a weld bead. Incidentally, F is preferably 40 Hz to 280 Hz.
[0033] Even if the average short-circuiting frequency F satisfies the condition 20≤F (Hz)≤300, when the maximum short-circuiting period is such that t.sub.cyc>1.5 s, the wandering of an arc occurs and no good weld bead is obtained. It is preferable that t.sub.cyc<1.0 s. It is more preferable that t.sub.cyc is 0.2 s or less.
[0034] Herein, the average frequency (average short-circuiting frequency) F (Hz) of short-circuiting transfer can be measured in such a manner that the change in arc voltage while welding is in progress is monitored with, for example, an oscilloscope; the number of times the arc voltage reaches zero is counted; and the number of counts per second is determined by dividing the number of counts by the monitoring time. When the monitoring time is too short, variations in the number of the counts is large. Therefore, the monitoring time is preferably 10 s or more. Adjusting welding conditions such that the measured value of the average short-circuiting frequency F should be a target value enables 20≤F (Hz)≤300 to be achieved.
[0035] Examples of the preferred range of welding conditions include a welding current of 150 A to 300 A, an arc voltage of 20 V to 35 V, a contact tip-to-base material distance (hereinafter also referred to as CTWD) of 5 mm to 30 mm, and an Ar shielding gas flow rate of 15 L/min to 25 L/min. The welding current and the arc voltage are average values in each welding pass.
[0036] Furthermore, a technique for adjusting each of the average short-circuiting frequency and the maximum short-circuiting period within the above range is not particularly limited. For example, current waveform control is applied using a pulse current as shown in
X=I.sub.pt.sub.p/L+(I.sub.p+I.sub.b)(t.sub.up+t.sub.down)/(2L) (1)
[0037] When X is too small, less than 50 A.Math.s/m, the wandering of an arc or the destabilization of metal transfer that is problematic for conventional MIG welding occurs in some cases. When X is too large, more than 250 A.Math.s/m, a wire dips into a molten pool or a grown droplet splashes at the time of short circuiting, thereby causing the deterioration of a bead shape, spatter adhesion, or the like in some cases. The value of X (A.Math.s/m) is more preferably such that 60≤X≤230.
[0038] In Formula (1), when L is too small, the wear of a torch is significant and welding is destabilized. When L is too large, the wandering of an arc occurs. Therefore, L is preferably 5 mm to 30 mm and more preferably 8 mm to 20 mm.
[0039] When I.sub.p is too small, sufficient heat input cannot be ensured and the deterioration of a bead shape occurs. When I.sub.p is too large, burn-through occurs or an increase in spatter is caused. Therefore, I.sub.p is preferably 250 A to 600 A. I.sub.p is more preferably 400 A or more and 500 A or less.
[0040] When I.sub.b is too small, an arc is destabilized. When I.sub.b is too large, burn-through occurs. Therefore, I.sub.p is preferably 30 A to 120 A. I.sub.p is more preferably 40 A or more and 100 A or less.
[0041] When t.sub.p is too short, sufficient heat input cannot be ensured. When t.sub.p is too long, burn-through occurs. Therefore, t.sub.p is preferably 0.1 ms to 5.0 ms. It is more preferable that t.sub.p is 1.0 ms or more and 4.5 ms or less.
[0042] When t.sub.up and t.sub.down are too short, the wandering of an arc occurs. When t.sub.up and t.sub.down are too long, the deterioration of a bead shape is caused. Therefore, t.sub.up and t.sub.down are preferably 0.1 ms to 3.0 ms. It is more preferable that t.sub.up and t.sub.down are 0.5 ms or more and 2.5 ms or less.
[0043] Supposing that a base term is t.sub.b (ms), when t.sub.b is too short, a droplet is too small. When t.sub.b is too long, a droplet is too large. Therefore, in either case, welding is destabilized. Thus, t.sub.b is preferably 0.1 ms to 10.0 ms. It is more preferable that t.sub.b is 1.0 ms or more and 8.0 ms or less.
[0044] In the disclosed embodiments, one short circuit need not be caused in every cycle of the pulse current and may be caused for one to several pulses. If one short circuit can be caused for one to several pulses, the pulse frequency of the pulse current is not particularly limited.
[0045] In the disclosed embodiments, an aim of introducing the pulse current is to promote the stable growth of a droplet with the wandering of an arc suppressed using a low current in the base term and to promote short circuiting in such a manner that the grown droplet is pushed down to a molten pool instead of separating the grown droplet from a wire by electromagnetic force or the shear force of an Ar shielding gas from the peak term to the fall term.
[0046] In a technique for stabilizing the above MIG welding according to the disclosed embodiments, the supply of oxygen or the addition of a special element is not necessary. Therefore, a solid wire which is more inexpensive than flux-cored wires is used as a welding wire, thereby enabling cost reduction.
[0047] In the disclosed embodiments, the wire composition of the solid wire used (the chemical composition of a wire) is not particularly limited. A wire composition containing, for example, C: 0.020% by mass to 0.150% by mass, Si: 0.20% by mass to 1.00% by mass, Mn: 0.50% by mass to 2.50% by mass, P: 0.020% by mass or less, and S: 0.03% by mass or less, the remainder being Fe and incidental impurities, is cited as a preferred wire composition. Such a wire composition can be applied to the MIG welding of steels in a wide range from mild steel to ultra-high tensile strength steel.
[0048] Herein, C is an element necessary to ensure the strength of a weld metal and has an effect of reducing the viscosity of molten metal to enhance the fluidity. However, when the content of C is less than 0.020% by mass, the strength of the weld metal cannot be ensured. On the other hand, when the C content is more than 0.150% by mass, the toughness of the weld metal decreases. Thus, the C content is preferably 0.020% by mass to 0.150% by mass.
[0049] Si is an element which has a deoxidizing action, which increases the hardenability of a weld metal by the addition of an appropriate amount, and which contributes to enhancing the toughness and strength of the weld metal. In MIG welding, the contamination of the weld metal with oxygen can be suppressed using an Ar shielding gas. The deoxidizing action of Si is not particularly necessary. When the content of Si is less than 0.20% by mass, a droplet or a molten pool swings in a welding operation and a large amount of spatter occurs. On the other hand, when the Si content is more than 1.00% by mass, the toughness of the weld metal decreases. Thus, the Si content is preferably 0.20% by mass to 1.00% by mass.
[0050] Mn, as well as Si, is an element which has a deoxidizing action and which enhances mechanical properties of a weld metal. However, when the content of Mn is less than 0.50% by mass, the amount of Mn remaining in the weld metal is short and therefore no sufficient strength or toughness is obtained. On the other hand, when the Mn content is more than 2.50% by mass, the toughness of the weld metal decreases. Thus, the Mn content is preferably 0.50% by mass to 2.50% by mass.
[0051] P is an element which is trapped in steel in a steelmaking process and a casting process in the form of an impurity and which reduces the hot cracking resistance of a weld metal. The content of P is preferably reduced as much as possible. In particular, when the P content is more than 0.020% by mass, the hot cracking resistance of the weld metal decreases significantly. Thus, the P content is preferably 0.020% by mass or less.
[0052] S is an element which is inevitably contained in a steel strand and which reduces the hot cracking resistance of a weld metal. The content of S is preferably reduced as much as possible. In particular, when the S content is more than 0.03% by mass, the hot cracking of the weld metal is likely to occur. Thus, the S content is preferably 0.03% by mass or less.
[0053] The incidental impurities are specifically N and Cu. N is an impurity which is inevitably contained at a stage of obtaining steel billet by steelmaking or at a stage of manufacturing a steel strand. N has a negative influence on the toughness of a weld metal and therefore the content thereof is preferably suppressed to 0.01% by mass or less. Cu is an impurity which is inevitably contained in a steel strand and is an element which reduces the toughness of a weld metal. In particular, when the content of Cu is more than 3.0% by mass, the toughness of the weld metal decreases significantly. Thus, the Cu content is preferably 3.0% by mass or less.
[0054] Furthermore, one or more of Ni, Cr, Ti, and Mo may be appropriately added in addition to the above composition.
[0055] Ni is an element which increases the strength of a weld metal and which enhances the weather resistance thereof. However, when the content of Ni is less than 0.02% by mass, such an effect is not obtained. On the other hand, when the Ni content is more than 3.50% by mass, the reduction in toughness of the weld metal is caused. Thus, when Ni is added, the Ni content is preferably 0.02% by mass to 3.50% by mass.
[0056] Cr, as well as Ni, is an element which increases the strength of a weld metal and which enhances the weather resistance thereof. However, when the content of Cr is less than 0.01% by mass, such an effect is not obtained. On the other hand, when the Cr content is more than 1.50% by mass, the reduction in toughness of the weld metal is caused. Thus, when Cr is added, the Cr content is preferably 0.01% by mass to 1.50% by mass.
[0057] Ti is an element which acts as a deoxidizer and which enhances the strength and toughness of a weld metal. In addition, Ti has an effect of stabilizing an arc to reduce the amount of spatter. However, when the content of Ti is more than 0.15% by mass, a droplet becomes coarse in a welding operation, large drops of spatter occur, and the toughness of the weld metal decreases significantly. Thus, when Ti is added, the Ti content is preferably 0.15% by mass or less.
[0058] Mo is an element which enhances the strength of a weld metal. When the content thereof is more than 0.8% by mass, the toughness of the weld metal decreases. Thus, when Mo is added, the content of Mo is preferably 0.8% by mass or less.
EXAMPLES
[0059] Examples of the disclosed embodiments are described below. In the examples, the fillet welding of a lap joint was performed under MIG welding conditions shown in Table 2 using 2.6 mm thick steel sheets having a steel sheet composition shown in Table 1 as sample steel sheets. Welding wires used were solid wires 1.2 mm in diameter having a wire composition shown in Table 3.
[0060] Results obtained by evaluating a bead shape after welding are shown in Table 2.
As shown in Table 2, the “symbol ⊙” is a case where “the value (W.sub.min/W.sub.max) obtained by dividing the minimum (W.sub.min) of the width of a bead by the maximum (W.sub.max) of the width of the bead is 0.7 or more” and “the flank angle (θ) is 120° or more”.
The “symbol ◯” is a case where “the value (W.sub.min/W.sub.max) obtained by dividing the minimum of the width of a bead by the maximum of the width of the bead is 0.7 or more” and “the flank angle (θ) is 100° to less than 120°” or a case where “the value (W.sub.min/W.sub.max) obtained by dividing the minimum of the width of a bead by the maximum of the width of the bead is 0.6 or more to less than 0.7” and “the flank angle (θ) is 120° or more”.
The “symbol Δ” is a case where “the value (W.sub.min/W.sub.max) obtained by dividing the minimum of the width of a bead by the maximum of the width of the bead is 0.6 or more to less than 0.7” and “the flank angle (θ) is 100° or more to less than 120°”.
The “symbol x” is a case that corresponds to at least one of a case where “the value (W.sub.min/W.sub.max) obtained by dividing the minimum of the width of a bead by the maximum of the width of the bead is less than 0.6” and a case where “the flank angle (θ) is less than 100°”.
[0061] The minimum of the width of a bead and the maximum of the width of the bead are measured in such a manner that a surface of a region of a weld bead 6 that excludes bead start and end sections (each having a length of 15 mm) is photographed and an obtained photograph is analyzed. When the length of the weld bead 6 is less than 130 mm, a surface of the whole excluding the bead start and end sections is photographed. When the length of the weld bead 6 is 130 mm or more, a surface of any section (a length of 100 mm) excluding the bead start and end sections is photographed. The flank angle is determined by shape measurement.
The above “W.sub.min/W.sub.max” is an indicator showing the degree of meandering and waving.
[0062] As is clear from Table 2, Examples (Nos. 5 to 21) in which a symbol indicating evaluation was ⊙, ◯, or Δ satisfied an average short-circuiting frequency F of 20 Hz or more to 300 Hz or less and a maximum short-circuiting period t.sub.cyc of 1.5 s or less. As a result, the formation of a weld bead was stable, the meandering or waving of a weld bead was slight, and a weld bead with a large flank angle (θ) and a smooth toe shape was obtained. In Examples in which a symbol was ◯, the above effects were remarkable. In Examples in which a symbol was ⊙, the above effects were more remarkable.
[0063] On the other hand, Comparative Examples (Nos. 1 to 4 and 22) in which a symbol for evaluation shown in Table 2 was x were such that the average short-circuiting frequency F was less than 20 Hz or the maximum short-circuiting period t.sub.cyc was 1.5 s or more and the formation of a weld bead was unstable. As a result, at least one of a weld bead with significant meandering or waving and a convex bead with a small flank angle (θ) appeared.
[0064] From Examples (Nos. 5, 7 to 9, 11, 12, 15, and 20) in which a symbol was ⊙, it could be confirmed that a stable weld bead was obtained using a welding wire for either of mild steel (the wire symbol W1 in Table 3) and ultra-high tensile strength steel (the wire symbol W2 in Table 3).
TABLE-US-00001 TABLE 1 (mass percent) C Si Mn P S N Cu Ni Ti B Nb Mo Cr 0.060 0.70 1.80 0.006 0.001 0.0030 0.017 0.015 0.106 0.0020 0.002 0.014 0.568 (Remainder: Fe and incidental impurities)
TABLE-US-00002 TABLE 2 Welding Arc Welding F t.sub.cyc L current voltage speed l.sub.p l.sub.b t.sub.p t.sub.up No Hz s mm Wire A V cm/min Pulse A A ms ms 1 8 0.53 15 W2 160 24.6 70 Not pulsed — — — — 2 17 0.31 15 W2 216 25.2 70 Not pulsed — — — — 3 19 0.48 15 W2 182 24.9 70 Not pulsed — — — — 4 43 1.59 15 W2 268 23.8 70 Not pulsed — — — — 5 47 0.06 10 W2 237 27.1 70 Pulsed 450 50 1.5 1.0 6 54 0.39 15 W2 234 23.9 70 Not pulsed — — — — 7 57 0.07 10 W2 269 27 70 Pulsed 450 50 1.5 1.0 8 70 0.04 10 W1 295 25.6 70 Pulsed 450 50 1.5 1.0 9 85 0.01 15 W1 214 19.7 50 Pulsed 450 50 1.5 1.0 10 87 0.01 10 W2 226 25.4 70 Pulsed 450 50 1.5 1.0 11 293 0.005 10 W1 252 18.3 70 Pulsed 450 50 0.8 1.0 12 88 0.010 10 W2 221 25.1 70 Pulsed 300 50 1.5 1.0 13 55 0.120 10 W2 171 23.2 60 Pulsed 250 30 2.0 1.0 14 159 0.010 10 W2 235 26.4 100 Pulsed 580 50 1.5 1.0 15 186 0.007 10 W2 237 22.7 100 Pulsed 550 50 2.0 1.0 16 89 0.010 10 W2 205 24.1 70 Pulsed 400 30 4.5 1.5 17 101 0.010 10 W2 254 19.2 70 Pulsed 450 100 1.5 1.0 18 111 0.010 10 W2 255 20.3 70 Pulsed 450 120 1.5 1.0 19 122 0.008 10 W2 245 22.5 70 Pulsed 450 50 5.0 1.0 20 66 0.050 10 W2 252 18.3 70 Pulsed 450 50 0.8 0.5 21 219 0.005 10 W2 234 21.8 70 Pulsed 450 50 2.0 3.0 22 11 0.62 15 W2 194 21.8 100 Not pulsed — — — — t.sub.down t.sub.b X *.sup.1 θ No ms ms A .Math. s/m Wmin/Wmax ° Evaluation Remarks 1 — — — 0.48 135 X Comparative example 2 — — — 0.57 125 X Comparative example 3 — — — 0.53 125 X Comparative example 4 — — — 0.44 143 X Comparative example 5 1.0 1.9 118 0.76 134 ⊙ Example 6 — — — 0.63 116 Δ Example 7 1.0 1.1 118 0.72 125 ⊙ Example 8 1.0 0.6 118 0.75 128 ⊙ Example 9 1.0 3.2 78 0.81 121 ⊙ Example 10 1.0 4.8 118 0.68 137 ◯ Example 11 1.0 1.8 61 0.70 125 ⊙ Example 12 1.0 0.2 80 0.86 121 ⊙ Example 13 1.0 0.7 78 0.82 102 ◯ Example 14 1.0 3.8 153 0.69 104 Δ Example 15 1.0 4.0 113 0.71 122 ⊙ Example 16 1.5 5.6 245 0.77 119 ◯ Example 17 1.0 2.8 123 0.73 115 ◯ Example 18 1.0 2.6 125 0.68 117 Δ Example 19 1.0 5.3 275 0.68 110 Δ Example 20 0.5 1.9 153 0.70 123 ⊙ Example 21 3.0 2.9 169 0.82 102 ◯ Example 22 — — — 0.61 98 X Comparative example Polarity: direct-current reverse polarity Shielding gas: 100% Ar, a gas flow rate of 15 L/min Evaluation: ⊙ is a case where “the value (W.sub.min/W.sub.max) obtained by dividing the minimum of the width of a bead by the maximum of the width of the bead is 0.7 or more” and “the flank angle (θ) is 120° or more”. ◯ is a case where “the value (W.sub.min/W.sub.max) obtained by dividing the minimum of the width of a bead by the maximum of the width of the bead is 0.7 or more” and “the flank angle (θ) is 100° or more to less than 120°” or a case where “the value (W.sub.min/W.sub.max) obtained by dividing the minimum of the width of a bead by the maximum of the width of the bead is 0.6 or more to less than 0.7” and “the flank angle (θ) is 120° or more”. Δ is a case where “the value (W.sub.min/W.sub.max) obtained by dividing the minimum of the width of a bead by the maximum of the width of the bead is 0.6 or more to less than 0.7” and “the flank angle (θ) is 100° or more to less than 120°”. X is a case that corresponds to at least one of a case where “the value (W.sub.min/W.sub.max) obtained by dividing the minimum of the width of a bead by the maximum of the width of the bead is less than 0.6” and a case where “the flank angle (θ) is less than 100°”. *.sup.1. X = l.sub.pt.sub.p/L + (l.sub.p + l.sub.b)(t.sub.up + t.sub.down)/(2 L) . . . (1)
TABLE-US-00003 TABLE 3 (mass percent) Symbol C Si Mn P S Ni Cr Mo Ti W1 0.060 0.62 1.27 0.010 0.015 — — — — W2 0.068 0.57 1.08 0.006 0.006 0.030 1.34 0.60 <0.001 (Remainder: Fe and incidental impurities)