CONSUMABLE ELECTRODE TYPE GAS SHIELD ARC WELDING METHOD AND ARC WELDING PORTION
20180369945 · 2018-12-27
Assignee
Inventors
- Shinji Kodama (Tokyo, JP)
- Tasuku ZENIYA (Tokyo, JP)
- Shoko Oami (Tokyo, JP)
- Masahiro MATSUBA (Tokyo, JP)
Cpc classification
B23K35/383
PERFORMING OPERATIONS; TRANSPORTING
B23K9/295
PERFORMING OPERATIONS; TRANSPORTING
B23K35/3073
PERFORMING OPERATIONS; TRANSPORTING
B23K35/226
PERFORMING OPERATIONS; TRANSPORTING
B23K9/325
PERFORMING OPERATIONS; TRANSPORTING
B23K9/23
PERFORMING OPERATIONS; TRANSPORTING
International classification
B23K35/22
PERFORMING OPERATIONS; TRANSPORTING
Abstract
The present invention provides a consumable electrode type gas shield arc welding method for performing arc welding of two steel sheets using a welding torch having a consumable electrode. The consumable electrode type gas shield arc welding method includes performing arc welding while a shielding gas having an oxygen potential a which is indicated by the following Expression (1) and ranges from 1.5% to 5% is supplied from the welding torch toward the consumable electrode, and blowing an oxidation promotion gas having an oxygen potential which is indicated by the following Expression (2) and ranges from 15% to 50% at a flow velocity ranging from 1 to 3 m/sec over a weld bead and a weld toe portion which are formed by arc welding and are in a state of 700 C. or higher,
=100([V.sub.1(O.sub.2)]+[V.sub.1(CO.sub.2)]/5)/([V.sub.1(X)]+[V.sub.1(O.sub.2)]+[V.sub.1(CO.sub.2)]) Expression (1)
=100[V.sub.2(O.sub.2)]/([V.sub.2(X)]+[V.sub.2(O.sub.2)]+[V.sub.2(CO.sub.2)]) Expression (2)
here, [V.sub.1(X)] is a mixing ratio (volume %) of an inert gas included in the shielding gas, [V.sub.1(O.sub.2)] is a mixing ratio (volume %) of oxygen included in the shielding gas, [V.sub.1(CO.sub.2)] is a mixing ratio (volume %) of carbon dioxide included in the shielding gas, [V.sub.2(X)] is a mixing ratio (volume %) of an inert gas included in the oxidation promotion gas, [V.sub.2(O.sub.2)] is a mixing ratio (volume %) of oxygen included in the oxidation promotion gas, and [V.sub.2(CO.sub.2)] is a mixing ratio (volume %) of carbon dioxide included in the oxidation promotion gas.
Claims
1. A consumable electrode type gas shield arc welding method for performing arc welding of two steel sheets using a welding torch having a consumable electrode, the method comprising: performing arc welding while a shielding gas having an oxygen potential a which is indicated by the following Expression (1) and ranges from 1.5% to 5% is supplied from the welding torch toward the consumable electrode; and blowing an oxidation promotion gas having an oxygen potential which is indicated by the following Expression (2) and ranges from 15% to 50% at a flow velocity ranging from 1 to 3 m/sec over a weld bead and a weld toe portion which are formed by arc welding and are in a state of 700 C. or higher,
=100([V.sub.1(O.sub.2)]+[V.sub.1(CO.sub.2)]/5)/([V.sub.1(X)]+[V.sub.1(O.sub.2)]+[V.sub.1(CO.sub.2)]) Expression (1)
=100[V.sub.2(O.sub.2)]/([V.sub.2(X)]+[V.sub.2(O.sub.2)]+[V.sub.2(CO.sub.2)]) Expression (2) where, [V.sub.1(X)] is a mixing ratio (volume %) of an inert gas included in the shielding gas, [V.sub.1(O.sub.2)] is a mixing ratio (volume %) of oxygen included in the shielding gas, [V.sub.1(CO.sub.2)] is a mixing ratio (volume %) of carbon dioxide included in the shielding gas, [V.sub.2(X)] is a mixing ratio (volume %) of an inert gas included in the oxidation promotion gas, [V.sub.2(O.sub.2)] is a mixing ratio (volume %) of oxygen included in the oxidation promotion gas, and [V.sub.2(CO.sub.2)] is a mixing ratio (volume %) of carbon dioxide included in the oxidation promotion gas.
2. The consumable electrode type gas shield arc welding method according to claim 1, wherein the oxidation promotion gas is blown via a space formed between the welding torch and an outer circumferential wall which is provided to be separated outward from an outer circumferential surface of the welding torch.
3. The consumable electrode type gas shield arc welding method according to claim 1, wherein in a state where at least an upper region of a part of the weld bead or the weld toe portion in a state of 700 C. or higher is surrounded, the oxidation promotion gas is blown within the upper region.
4. The consumable electrode type gas shield arc welding method according to claim 1, wherein a shortest separation distance in a horizontal direction between a portion over which the oxidation promotion gas is blown and a tip position of the consumable electrode in the weld bead and the weld toe portion is 35 mm or shorter.
5. An arc welding portion formed by the consumable electrode type gas shield arc welding method according to claim 1, wherein a surface of a weld bead and a surface of a weld toe portion of the weld bead are covered with a conductive iron oxide slag containing any one of or both magnetite and wustite.
6. The arc welding portion according to claim 5, wherein a thickness of the conductive iron oxide slag ranges from 10 m to 50 m.
7. The arc welding portion according to claim 5, wherein all of the surface of the weld bead and the surface of the weld toe portion of the weld bead are covered with the conductive iron oxide slag.
8. The consumable electrode type gas shield arc welding method according to claim 2, wherein in a state where at least an upper region of a part of the weld bead or the weld toe portion in a state of 700 C. or higher is surrounded, the oxidation promotion gas is blown within the upper region.
9. The consumable electrode type gas shield arc welding method according to claim 2, wherein a shortest separation distance in a horizontal direction between a portion over which the oxidation promotion gas is blown and a tip position of the consumable electrode in the weld bead and the weld toe portion is 35 mm or shorter.
10. The consumable electrode type gas shield arc welding method according to claim 3, wherein a shortest separation distance in a horizontal direction between a portion over which the oxidation promotion gas is blown and a tip position of the consumable electrode in the weld bead and the weld toe portion is 35 mm or shorter.
11. An arc welding portion formed by the consumable electrode type gas shield arc welding method according to claim 2, wherein a surface of a weld bead and a surface of a weld toe portion of the weld bead are covered with a conductive iron oxide slag containing any one of or both magnetite and wustite.
12. An arc welding portion formed by the consumable electrode type gas shield arc welding method according to claim 3, wherein a surface of a weld bead and a surface of a weld toe portion of the weld bead are covered with a conductive iron oxide slag containing any one of or both magnetite and wustite.
13. An arc welding portion formed by the consumable electrode type gas shield arc welding method according to claim 4, wherein a surface of a weld bead and a surface of a weld toe portion of the weld bead are covered with a conductive iron oxide slag containing any one of or both magnetite and wustite.
14. The arc welding portion according to claim 6, wherein all of the surface of the weld bead and the surface of the weld toe portion of the weld bead are covered with the conductive iron oxide slag.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0032]
[0033]
[0034]
[0035]
[0036]
[0037]
[0038]
[0039]
[0040]
[0041]
EMBODIMENT OF THE INVENTION
[0042] In consumable electrode type gas shield arc welding, from a viewpoint of arc stability, a predetermined amount of an oxidized gas has to be mixed in a shielding gas. As in the countermeasures in the related art performed to prevent poor electrodeposition coating, in a case of employing a countermeasure in which the amount of an oxidized gas in a shielding gas is reduced or a countermeasure in which the amount of a Si/Mn-based slag is reduced by reducing oxidation components in a consumable electrode (welding wire), there is concern that the quality of welding may be adversely affected.
[0043] Therefore, the inventors of this application have evaluated a slag generation status and electrodeposition coating characteristics of a welding portion under various welding conditions using ordinary shielding gas and welding wires. As a result, it has been found that Si/Mn-based slag tends to be reduced under a condition in which a weld heat input is excessively increased, and electrodeposition coating characteristics are improved. Moreover, as a result of observing surfaces of a weld bead and a weld toe portion under the foregoing welding conditions, it has been checked that a conductive iron oxide (FeO, Fe.sub.3O.sub.4) is formed in a surface layer of the weld bead.
[0044] Since the cooling rate of a weld metal falls under a welding condition of a high heat input, a weld bead and a weld toe portion in a high temperature state after melting and solidification are likely to deviate from a region protected by a shielding gas. As a result, it is assumed that the weld bead and the weld toe portion in a high temperature state are exposed to the atmosphere, oxidation is promoted, and the surface layers of the weld bead and the weld toe portion are covered with an iron oxide film.
[0045] The invention of this application has been devised based on the findings described above. According to the invention, instead of preventing oxidation of a welding portion, the solidified surfaces of a weld bead and a weld toe portion are initiatively oxidized, so that a conductive iron oxide (FeO, Fe.sub.3O.sub.4) is generated and a Si oxide or a Mn oxide is covered with the iron oxide. Consequently, the surfaces of the weld bead and the weld toe portion become conductive.
[0046] Such a tendency has also been checked in the case where the welding rate is increased and a molten pool is widened rearward in a progressing direction. However, generally, the welding conditions are uniquely determined depending on the thickness of a steel sheet or the type of a joint to be applied. Accordingly, the welding conditions cannot be freely set for the purpose of controlling the amount of a generated slag. An excessive increase of a heat input causes burn-through of a steel sheet, and a raised welding rate leads to poor shapes of weld beads.
[0047] Therefore, the inventors of this application have progressed investigation aiming at forming a stable iron oxide film on a surface of a weld bead without depending on the weld heat input or the rate.
[0048] As a result, it is has been newly ascertained that if an oxidation promotion gas G2 having a high oxygen potential is blown over a weld bead and a weld toe portion in a high temperature state behind an ordinary arc welding torch in the welding progressing direction, a shielding gas G1 having a low oxygen potential a and remaining on the surfaces of the weld bead and the weld toe portion can be eliminated and oxidation of iron on the surfaces of the weld bead and the weld toe portion is promoted, so that the surfaces of the weld bead and the weld toe portion can be covered with a conductive iron oxide including a Si oxide or a Mn oxide formed due to reaction to an oxidized gas in the shielding gas, and the present invention is thereby realized.
[0049] Hereinafter, an embodiment of the present invention devised based on the foregoing findings will be described in detail based on the drawings.
[0050]
[0051] In the gas shield arc welding method according to the present embodiment, as shown in
[0052] In the present embodiment, a surface of a weld bead 81 and a surface of a weld toe portion 82, which is a boundary portion between the weld bead 81 and a steel (base metal), are covered with a conductive iron oxide slag 9 generated in a process of the consumable electrode type gas shield arc welding. Accordingly, an insulating Si/Mn-based slag generated during welding is enclosed within the conductive iron oxide slag 9.
[0053] As conductive slag which can be generated during welding, magnetite (Fe.sub.3O.sub.4) and wustite (FeO) are known.
[0054] Here, there is a need to acquire an arc welding portion which promotes oxidation of iron on a surface of a molten pool 8 or on the surfaces of the weld bead 81 and the weld toe portion 82 and is covered with the conductive iron oxide slag 9 having magnetite or wustite as a main constituent.
[0055] Magnetite or wustite (iron oxide) can be formed by exposing the surfaces of the weld bead 81 and the weld toe portion 82 in a high temperature state to an oxidizing atmosphere during welding, and the surface of the weld bead 81 and the surface of the weld toe portion 82 can be covered with a conductive iron oxide slag containing any one of or both magnetite and wustite.
[0056] It is preferable that not only the surface of the weld bead 81 and the surface of the weld toe portion 82 but also the surface of the molten pool 8, which is out of a shielding region formed by the shielding gas G1 from the welding torch 1, is exposed to an oxidizing atmosphere.
[0057] In the present embodiment, oxidation of iron is promoted by blowing the oxidation promotion gas G2 having a high oxygen potential independently from the shielding gas G1 toward at least the surface of the weld bead 81 and the surface of the weld toe portion 82, such that the surfaces of the weld bead 81 and the weld toe portion 82 are covered with the conductive iron oxide slag 9.
[0058] In the gas shield arc welding method according to the present embodiment, when the consumable electrode type gas shield arc welding is performed, a shielding gas having a low oxygen potential a and including an inert gas or an oxidized gas and an inert gas is supplied to the consumable electrode. Immediately thereafter, the oxidation promotion gas G2 having a high oxygen potential including a mixed gas of an oxidized gas and an inert gas is blown toward at least the weld bead 81 and the weld toe portion 82 in a high temperature state. Accordingly, the weld bead 81 and the weld toe portion 82 are entirely covered with the conductive iron oxide slag 9, and it is possible to acquire a welding portion in which an insulating Si/Mn-based slag is buried in the conductive iron oxide slag 9.
[0059] It is possible to check whether or not the conductive iron oxide slag 9 is formed by examining the composition on the surfaces of the weld bead 81 and the weld toe portion 82 through element mapping performed by means of an EPMA, or examining conductivity.
[0060] The range of the weld bead 81 and the weld toe portion 82 thereof after being welded by using the oxidation promotion gas G2 is cut and the cut section is polished. Then, element mapping is performed by means of the EPMA. Accordingly, it is possible to check that the vicinity of the surface observed in the cross section of the weld bead 81 and the weld toe portion 82 thereof is covered with the conductive iron oxide slag 9, the outermost surface of the conductive iron oxide slag 9 has become a substantial iron oxide, and a Si oxide or a Mn oxide forming an insulating Si/Mn-based slag is scarcely present on the outermost surfaces of the weld bead 81 and the weld toe portion 82.
[0061] Moreover, as a result of a measurement for conductivity between the surface of the iron oxide slag 9 and a steel sheet surface on the outer side of the weld bead 81 and the weld toe portion 82 using a commercially available tester, conductivity with a resistance value ranging from 40 to 1,000 has been checked. if an insulating Si/Mn-based slag is present on the surfaces of the weld bead 81 and the weld toe portion 82, electrical resistance becomes infinite or deviates from the measurement range of an ordinary conductor, so that a measurement cannot be performed by using a general tester which is commercially available.
[0062] (Welding Torch 1)
[0063] The welding torch 1 has a configuration in which a gap between a consumable electrode 5 and a peripheral wall section surrounding the consumable electrode 5 serves as a passage for the shielding gas G1. While the shielding gas G1 is supplied from the welding torch 1 toward the consumable electrode 5, arc welding is performed along a weld line formed between steel members disposed at welding positions.
[0064] (Consumable Electrode 5)
[0065] The consumable electrode 5 is not particularly limited. However, in order to reduce generation of a Si/Mn-based slag in the molten pool 8 as much as possible, it is desirable that the Si content is 1 mass % or less and the Mn content is 2 mass % or less.
[0066] (Shielding Gas G1)
[0067] The shielding gas G1 is a mixed gas in which an inert gas, such as Ar or He, is mixed with O.sub.2 and/or CO.sub.2 as a main constituent. The shielding gas G1 flows out from the welding torch 1 toward a region surrounding the consumable electrode 5 (welding wire) and arc plasma. Since the shielding gas G1 plays a role of ensuring stability of an arc, in addition to causing the atmosphere in a region in which arc plasma has occurred to be replaced with the air, the mixing ratio of an inert gas, O.sub.2, and CO.sub.2 is adjusted such that the oxygen potential a indicated by the following Expression (1) becomes 1.5% or higher, preferably becomes 2.0%, and more preferably becomes 4.0%.
=100([V.sub.1(O.sub.2)]+[V.sub.1(CO.sub.2)]/5)/([V.sub.1(X)]+[V.sub.1(O.sub.2)]+[V.sub.1(CO.sub.2)]) Expression (1)
[0068] In Expression (1), [V.sub.1(X)] is the mixing ratio (volume %) of an inert gas included in the shielding gas G1, [V.sub.1(O.sub.2)] is the mixing ratio (volume %) of oxygen included in the shielding gas G1, and [V.sub.1(CO.sub.2)] is the mixing ratio (volume %) of carbon dioxide included in the shielding gas G1.
[0069] Meanwhile, in a case where the oxygen potential a of the shielding gas G1 exceeds 5%, a Si/Mn-based slag is excessively generated on the surface of the molten pool 8. Therefore, even if the oxidation promotion gas G2 is blown afterward, the surfaces of the weld bead 81 and the weld toe portion 82 cannot be covered with a conductive iron oxide.
[0070] Therefore, the amount of O.sub.2 and/or CO.sub.2 is adjusted such that the oxygen potential a of the shielding gas G1 becomes 5% or lower, preferably becomes 4.5% or lower, and more preferably becomes 4.0% or lower.
[0071] (Oxidation Promotion Gas G2)
[0072] The oxidation promotion gas G2 is a mixed gas in which at least two of an inert gas (nitrogen, argon, He, or the like), O.sub.2, and CO.sub.2 are mixed. It is convenient to use air (O.sub.2: 15% to 25%, nitrogen: 75% to 85%). In addition, even in a case where air is used, the degree of progress of oxidation can be adjusted by further adding an oxygen gas.
[0073] The oxidation promotion gas G2 is blown over a region of the weld bead 81 and the weld toe portion 82 at 700 C. or higher behind the molten pool 8. Since the oxidation promotion gas G2 plays a role of promoting oxidation of iron on the surfaces of the weld bead 81 and the weld toe portion 82 and causing an insulating Si/Mn-based slag formed in the molten pool 8 to be replaced with a conductive iron oxide (FeO, Fe.sub.3O.sub.4), the mixing ratio of an inert gas, O.sub.2, and CO.sub.2 is adjusted such that the oxygen potential indicated by the following Expression (2) becomes 15%, preferably becomes 20% or higher, and more preferably becomes 25% or higher.
=100[V.sub.2(O.sub.2)]/([V.sub.2(X)]+[V.sub.2(O.sub.2)]+[V.sub.2(CO.sub.2)]) Expression (2)
[0074] In Expression (2), [V.sub.2(X)] is the mixing ratio (volume %) of an inert gas included in the oxidation promotion gas G2, [V.sub.2(O.sub.2)] is the mixing ratio (volume %) of oxygen included in the oxidation promotion gas G2, and [V.sub.2(CO.sub.2)] is the mixing ratio (volume %) of carbon dioxide included in the oxidation promotion gas G2.
[0075] The action of CO.sub.2 is different between the shielding gas G1 and the oxidation promotion gas G2.
[0076] The CO.sub.2 included in the shielding gas G1 used in a region of generating arc plasma is dissociated due to heat of plasma, thereby acting as an oxidized gas.
[0077] Meanwhile, the CO.sub.2 included in the oxidation promotion gas G2 used in a region in which the temperature is equal to or lower than the melting point of iron (approximately 1,500 C.) is present as stable CO.sub.2, there by acting as an inert gas.
[0078] Therefore, unlike the oxygen potential a of the shielding gas G1, the oxygen potential of the oxidation promotion gas G2 does not include CO.sub.2 in the numerator in the computation expression.
[0079] The thickness of an iron oxide formed by the oxidation promotion gas ranges from 10 to 50 m, which is greater than the thickness of an iron oxide film formed on the surface of the weld bead 81 by only the ordinary shielding gas G1, that is, the thickness of an oxide film (approximately 5 m at the maximum) formed out of the region of a Si/Mn-based slag generation portion.
[0080] (Oxidation Promotion Gas Blowing Unit 20)
[0081] In the gas shield arc welding according to the present embodiment, when a steel member is welded by the gas shield arc welding while the shielding gas G1 is supplied, the oxidation promotion gas blowing unit 20 blows the oxidation promotion gas G2 including an oxidized gas over the surfaces of the weld bead 81 and the weld toe portion 82 behind the consumable electrode 5 and the welding torch 1. Accordingly, the surfaces of the weld bead 81 and the weld toe portion 82 are covered with a conductive iron oxide layer. The oxidation promotion gas G2 may also be blown over the molten pool 8 behind the consumable electrode 5 and the welding torch 1 as long as the external appearance of the bead does not deteriorate.
[0082] An oxidation promotion gas blowing unit 20 which blows the oxidation promotion gas G2 over the surfaces of the weld bead 81 and the weld toe portion 82 has an oxidation promotion gas supply portion 21 for supplying the oxidation promotion gas G2, and the oxidation promotion gas blowing nozzle 22 for blowing the oxidation promotion gas G2.
[0083] As an example of the oxidation promotion gas blowing nozzle 22,
[0084] The oxidation promotion gas G2 is supplied from the oxidation promotion gas supply portion 21 to the inside of the hood nozzle 22A in a state where the welding torch 1 is inserted through the torch insertion hole 30 and is integrated therewith. The oxidation promotion gas G2 is blown over the surface of the molten pool 8, and the surfaces of the weld bead 81 and the weld toe portion 82 in a state where a high oxygen potential is maintained.
[0085] The hood nozzle 22A may be formed to be integrated with the tip of the oxidation promotion gas supply portion 21 or may be detachably formed.
[0086] In addition, the hood nozzle 22A can employ any of a shape in which a lower portion is open as in
[0087] When welding is performed, the shielding gas G1 is discharged from the welding torch 1, and the welding torch 1 moves along a weld line 11 in the arrow direction while the periphery of an arc 6 generated by the consumable electrode 5 and the periphery of the molten pool 8 are shielded. In this case, the oxidation promotion gas G2 including an oxidized gas is supplied to the inside of the hood nozzle 22A from the oxidation promotion gas supply portion 21 provided at the rear portion of the hood nozzle 22A, and the oxidation promotion gas G2 is blown over the surfaces of the weld bead 81 and the weld toe portion 82.
[0088] (Blowing Range of Oxidation Promotion Gas G2)
[0089] In a case where the temperature of the surfaces of the weld bead 81 and the weld toe portion 82 is 700 C. or higher, oxidation reaction becomes noticeable between an oxidized gas in the oxidation promotion gas G2 and Fe. Therefore, in order to form the conductive iron oxide slag 9 on the surfaces of the weld bead 81 and the weld toe portion 82, the oxidation promotion gas G2 is blown over a portion in which the temperature of the surfaces of the weld bead 81 and the weld toe portion 82 is 700 C. or higher, a portion in which the temperature thereof is more preferably 750 C. or higher, and a portion in which the temperature thereof is more preferably 800 C. or higher.
[0090] The temperature of the surfaces of the weld bead 81 and the weld toe portion 82 can be measured with a radiation-type thermometer. In addition, the temperature of 700 C. or higher may be checked based on the relationship between the color and the temperature of iron.
[0091] As described above, the oxidation promotion gas G2 is required to be blown over a portion in which the temperature of the surfaces of the weld bead 81 and the weld toe portion 82 is 700 C. or higher. Therefore, a shortest separation distance D in a horizontal direction between a portion over which the oxidation promotion gas G2 is blown and a tip position of the consumable electrode 5 in the weld bead 81 and the weld toe portion 82 is preferably 35 mm or shorter and is more preferably 30 mm or shorter.
[0092] Meanwhile, in a case where the shortest separation distance D is 10 mm or longer, O.sub.2 or CO.sub.2 in the oxidation promotion gas G2 can be prevented from being incorporated into the shielding gas G1 in an arc generation region of the welding torch 1. Therefore, the form of discharging an arc can be stabilized, and a Si/Mn-based slag can be prevented from increasing. Thus, it is preferable that the shortest separation distance D is 10 mm or longer.
[0093] (Flow Rate of Oxidation Promotion Gas G2)
[0094] The flow rate of the oxidation promotion gas G2 is preferably 5 L/min or more, which is required for progress of oxidation of iron, and is more preferably 7 L/min or more. It is preferable that the flow rate of the oxidation promotion gas G2 is equal to or less than the flow rate of the shielding gas G1 such that shielding by the shielding gas G1 is not disrupted.
[0095] (Flow Velocity of Oxidation Promotion Gas G2)
[0096] The gas flow velocity of the oxidation promotion gas G2 at a nozzle outlet is set to range from 1 m/sec to 3 m/sec. The flow velocity of the oxidation promotion gas G2 is a value obtained by dividing the flow rate (L/min) of the oxidation promotion gas G2 by the cross-sectional area of a portion in the nozzle outlet through which the oxidation promotion gas G2 is discharged.
[0097] In order to promote oxidation on the surfaces of the weld bead 81 and the weld toe portion 82 by the oxidation promotion gas G2, the atmosphere of the surfaces of the weld bead 81 and the weld toe portion 82 having the components of the shielding gas G1 is required to be replaced with the atmosphere having the components of the oxidation promotion gas G2.
[0098] If the flow velocity of the oxidation promotion gas G2 is 1 m/sec or slower, the atmosphere having the shielding gas G1 as a main constituent in the upper region of the surfaces of the weld bead 81 and the weld toe portion 82 cannot be sufficiently replaced with the atmosphere having the oxidation promotion gas G2 as a main constituent. Meanwhile, if the flow velocity of the oxidation promotion gas G2 exceeds 3 m/sec, there is concern that the components of the oxidation promotion gas G2 may be incorporated into the shielding gas G1 of an arc generation portion and a Si/Mn-based slag may be excessively generated on the surface of the molten pool. In addition, since shielding by the shielding gas G1 is disrupted and an arc becomes unstable, there is concern that the weld bead may be hindered from being formed.
[0099] Therefore, the flow velocity of the oxidation promotion gas G2 is set to range from 1 m/sec to 3 m/sec and is more preferably set to range from 1.5 m/sec to 2.5 m/sec.
[0100] In order to ensure electrodeposition coating characteristics, it is preferable that all of the surfaces of the weld bead 81 and the weld toe portion 82 thereof are covered with only the conductive iron oxide slag 9.
[0101] In order to cause the weld bead 81 and the weld toe portion 82 to be conductive, it is preferable that the weld bead 81 and the weld toe portion 82 are covered with the iron oxide slag 9 having a thickness of 10 m or greater from the surface. The thickness of the iron oxide slag 9 is more preferably 15 m or greater.
[0102] Meanwhile, in a case where the iron oxide slag 9 having an excessive thickness is formed on the surfaces of the weld bead 81 and the weld toe portion 82 thereof, there is concern that peeling of coating may occur. Therefore, the thickness of the iron oxide slag 9 is preferably 50 m or smaller and is more preferably 40 m or smaller.
[0103] The arc welding method according to the present embodiment is applied to well-known consumable electrode type gas shield arc welding (also referred to as gas metal arc welding). The welding conditions are not particularly limited, and ordinary conditions can be used.
[0104] However, since submerged arc welding is welding in which no shielding gas is used, the submerged arc welding does not belong to the present invention. In addition, in the submerged arc welding, since flux scattered before welding melts and is solidified at the time of welding, a thick slag having a thickness ranging approximately from 5 to 10 mm covers the weld bead. A Si/Mn-based slag is scarcely present on the surface of the weld bead after the thick slag is removed, and the surface of the weld bead is covered with a thin iron oxide film having a thickness of approximately 5 m or smaller. That is, the forms of the weld bead and the toe portion in this application, in which an iron oxide having a thickness ranging from 15 to 50 m is formed on the surfaces of the weld bead and the toe portion using an oxidation promotion gas, differ from those in the submerged arc welding.
[0105] Welding may be lap welding or butt welding.
[0106] The thickness and the tensile strength of a steel sheet are not particularly limited. However, the sheet thickness ranging from 1.6 to 3.2 mm and the tensile strength ranging from 440 to 980 MPa are applied as standards. In addition, it is possible to use a hot-dip galvanized steel sheet, a galvannealed steel sheet, an aluminized steel sheet, and the like.
[0107] The components of a steel sheet and the components of a welding material are not particularly limited as well. However, in order to reduce generation of a Si/Mn-based slag in the molten pool as much as possible, it is desirable that the steel sheet and the welding material each have the Si content of 1 mass % or less and the Mn content of 2 mass % or less. In addition, homogeneous steel sheets may be welded together, or heterogeneous steel sheets may be welded together.
[0108] Hereinabove, the present invention has been described in detail based on the embodiment. However, the above-described embodiment presents merely a specific example for executing the present invention. The technical scope of the present invention should not be interpreted restrictively by the embodiment.
[0109] For example, in the description above, as shown in
[0110] As a first modification example, as shown in
[0111] In the oxidation promotion gas blowing unit 20, the after nozzle 22B having a rectangular shape in a plan view is disposed behind the welding torch 1 to move together with the welding torch 1. Then, the oxidation promotion gas G2 is supplied from the oxidation promotion gas supply portion 21 provided on the upper surface of the after nozzle 22B, and the oxidation promotion gas G2 is mainly blown over the surfaces of the weld bead 81 and the weld toe portion 82 from a lower end of the after nozzle 22B. Accordingly, oxidation of iron can progress, and the weld bead 81 and the weld toe portion 82 can be covered with the conductive iron oxide slag 9.
[0112] The shape of the after nozzle 22B may be a circular shape in a plan view as in
[0113] As a second modification example, as shown in
EXAMPLE
[0114] Based on the following Examples, the practicability of the present invention and the feasibility of the effect of the invention of this application will be described.
[0115] Lap fillet welding of gas shield arc welding was performed with respect to Steel sheets (A) and steel sheets (B) having the components, the sheet thickness, and the tensile strength as shown in Table 1 by causing end portions of the steel sheets (A) to overlap each other and causing end portions of the steel sheets (B) to overlap each other. In this case, pulse magnetron welding was performed by using a solid wire (J1S Z 3312, YGW16) having the components and the diameter as shown in Table 2. Table 3 shows specific welding conditions.
TABLE-US-00001 TABLE 1 Sheet Steel Component (mass %) thickness TS sheet sign C Si Mn Al P S Ti Nb (mm) (MPa) Remarks A 0.06 0.8 1.8 0.02 0.01 0.004 0.02 0.03 2.6 780 Non-plating material B 0.09 0.01 1.4 0.003 0.01 0.005 0.001 0.03 2.0 590 GA plating material
TABLE-US-00002 TABLE 2 Component (mass %) Diameter C Si Mn P S (mm) 0.06 0.8 1.5 0.01 0.005 1.2
TABLE-US-00003 TABLE 3 Separation distance Inclination Target value of Welding Heat input between tip end and angle of width of weld Current Voltage Power rate amount steel sheet torch bead (A) (V) source (cm/min) (kJ/cm) (mm) () (mm) 150 19 Pulse 60 2.9 15 60 8
[0116] Table 4 shows the experimental conditions and the evaluation result of each of Experimental Examples 1 to 19.
[0117] In the shielding gas G1, the oxygen potential a was adjusted by adjusting the amounts of Ar, O.sub.2, and CO.sub.2.
[0118] In Table 4, a indicates an oxygen potential of the shielding gas G1 calculated by Expression (1), and indicates an oxygen potential of the oxidation promotion gas G2 calculated by Expression (2). The gas flow rates of the shielding gas G1 and the oxidation promotion gas G2 are values divided by the cross-sectional area of a portion in the nozzle outlet through which the oxidation promotion gas G2 is discharged.
[0119] In regard to the oxidation promotion gas G2, the nozzle type, the blowing position, and the gas flow velocity are also indicated.
[0120] The nozzle type is specified as Aft.N (after nozzle) in the case where an after nozzle is used as shown in
[0121] In Experimental Examples using the after nozzle, welding was performed while the oxidation promotion gas G2 was supplied to the inside of the after nozzle at the same time the shielding gas G1 flowed from the welding torch.
[0122] The width of the after nozzle (with respect to the weld line) was set to 25 mm such that the surface of the toe portion of the weld bead (melting solidification portion) can also be covered with an iron oxide.
[0123] In these Experimental Examples, the distance from a location immediately below the arc to the rearmost location of the after nozzle was approximately 50 mm, and the temperature of the bead surface at the position was approximately 700 C.
[0124] As the welding torch, a circular torch having an inner diameter of 16 mm (outer diameter of 20 mm) in a cross section of the passage for the shielding gas G1 was used.
[0125] The field of Blowing position in Table 4 is filled with the shortest separation distances D in the horizontal direction between a portion over which the oxidation promotion gas is blown and the tip position of the consumable electrode in the weld bead and the weld toe portion. In the case where the after nozzle is used as shown in
[0126] The gas flow velocity is a flow velocity at the nozzle tip.
[0127] As the evaluation result, Table 4 shows (1) the adhesion area ratio of the Si/Mn-based slag, (2) the conductivity, (3) the area ratio of poor coating, (4) the presence or absence of the iron oxide after an examination of a cross section. The evaluation method will be described below.
[0128] (1) Adhesion Area Ratio of Si/Mn-based Slag
[0129] A photograph of the surfaces of the weld bead and the weld toe portion was captured. From the image thereof, the dark brown glassy slag was considered as a Si/Mn-based slag, and the ratio of the slag area to the weld bead area was measured.
[0130] (2) Conductivity
[0131] Resistance between the slag on the surfaces of the weld bead and the weld toe portion and the steel sheet was measured for conductivity at ten locations applying a general purpose tester (POCKET TESTER MODEL: CDM-03D). In the case where the resistance value was infinite, the slag was determined to be insulated and x was applied. The bead surface covered with oxidized iron indicated the resistance value ranging from 40 to 1,000.
[0132] (3) Area Ratio of Poor Coating
[0133] After a welding test piece was subjected to degreasing and chemical conversion, electrodeposition coating was performed to realize a target film thickness of 20 m. Similar to measuring of the slag area ratio, a photograph of a weld bead coating portion was captured. From the image thereof, the ratio of the poorly coated area to the weld bead area was measured.
[0134] (4) Presence or Absence of Iron Oxide after Examination of Cross Section
[0135] In the case where an iron-based oxide having the concentration of iron of 30% or higher and the thickness of 10 m or greater was checked in an observation of a cross section by means of the EPMA, was applied.
TABLE-US-00004 TABLE 4 Shielding gas (G1) Oxidation promotion gas (G2) Steel Gas flow Blowing Gas flow sheet Ar O.sub.2 CO.sub.2 rate Nozzle position Ar O.sub.2 CO.sub.2 rate sign (vol. %) (vol. %) (vol. %) (%) (L/min) type (mm) (vol. %) (vol. %) (vol. %) (%) (L/min) Experimental A 80 0 20 4.0 20 C. N 10 80 20 0 20.0 20 Example 1 Experimental A 98 2 0 2.0 20 C. N 10 0 15 85 15.0 40 Example 2 Experimental A 87 3 10 5.0 25 C. N 10 50 50 0 50.0 40 Example 3 Experimental A 80 0 20 4.0 25 C. N 10 0 20 80 20.0 30 Example 4 Experimental B 87 3 10 5.0 25 C. N 10 80 20 0 20.0 30 Example 5 Experimental B 75 0 25 5.0 25 C. N 10 80 20 0 20.0 30 Example 6 Experimental B 80 0 20 4.0 25 Aft. N 15 80 20 0 20.0 30 Example 7 Experimental B 95 0 5 1.0 25 Aft. N 20 0 15 85 15.0 40 Example 8 Experimental A 80 0 20 4.0 25 C. N 10 0 70 30 70.0 40 Example 9 Experimental A 80 0 20 4.0 25 C. N 10 0 10 90 10.0 40 Example 10 Experimental A 80 0 20 4.0 25 C. N 10 0 20 80 20.0 60 Example 11 Experimental A 80 0 20 4.0 25 C. N 10 80 20 0 20.0 15 Example 12 Experimental A 60 0 40 8.0 25 C. N 10 0 20 80 20.0 40 Example 13 Experimental A 97 0 3 0.6 25 C. N 10 0 20 80 20.0 30 Example 14 Experimental A 80 0 20 4.0 25 Aft. N 35 0 20 80 20.0 40 Example 15 Experimental A 80 0 20 4.0 25 None Example 16 Experimental A 97 3 0 3.0 20 None Example 17 Experimental A 88 0 12 2.4 20 None Example 18 Experimental A 100 0 0 0.0 20 C. N 10 90 10 0 10.0 20 Example 19 Oxidation promotion Result gas (G2) Area ratio Presence or absence Gas flow Adhesion area of poor of iron oxide after velocity ratio of Si/Mn- Conductivity coating examination of cross (m/s) based slag (%) of slag (%) section Classification Remarks Experimental 1.2 0.0 0.0 Inventional Example 1 Example Experimental 2.3 0.0 0.0 Inventional Example 2 Example Experimental 2.3 1.4 0.0 Inventional Example 3 Example Experimental 1.7 0.8 0.0 Inventional Example 4 Example Experimental 1.7 0.0 0.0 Inventional Example 5 Example Experimental 1.7 2.4 0.0 Inventional Example 6 Example Experimental 1.7 0.0 0.0 Inventional Example 7 Example Experimental 1.5 0.0 0.0 Inventional Example 8 Example Experimental 2.3 0.0 X 14.3 Comparative Peeling of Example 9 Example coating Experimental 2.3 7.8 X 5.6 X Comparative Example 10 Example Experimental 3.5 14.5 X 11.4 X Comparative Example 11 Example Experimental 0.9 6.8 X 5.1 X Comparative Example 12 Example Experimental 2.3 11.1 X 7.7 X Comparative Example 13 Example Experimental 1.7 Comparative Poor bead Example 14 Example forming Experimental 1.5 6.6 X 5.9 X Comparative Example 15 Example Experimental None 7.8 X 6.3 X Comparative Example 16 Example Experimental None 5.2 X 4.6 X Comparative Example 17 Example Experimental None 4.7 X 3.8 X Comparative Example 18 Example Experimental 1.2 Comparative Poor bead Example 19 Example forming
[0136] In Experimental Examples 1 to 8 belonging to lnventional Examples, the oxidation promotion gas G2 was blown over the surfaces of the weld bead and the weld toe portion under appropriate conditions. Accordingly, the weld bead and the weld toe portion could be covered with a conductive iron oxide slag. Therefore, the adhesion area ratio of the Si/Mn-based slag on the outermost surfaces of the weld bead and the toe portion thereof is controlled, and there was no occurrence of poor coating as in the case where electrodeposition coating was performed.
[0137] In Experimental Example 9, since the oxygen potential of the oxidation promotion gas G2 was excessive, a conductive iron oxide slag was excessively formed on the surfaces of the weld bead and the weld toe portion. Therefore, peeling of coating occurred.
[0138] in Experimental Example 10, since the oxygen potential of the oxidation promotion gas G2 was deficient, a conductive iron oxide slag was not sufficiently formed on the surfaces of the weld bead and the weld toe portion. Therefore, poor coating occurred.
[0139] In Experimental Example 11, since the flow velocity of the oxidation promotion gas G2 was excessive, the components of the oxidation promotion gas G2 had been incorporated into the shielding gas of the arc generation portion. Therefore, a Si/Mn-based slag to be formed on the surface of the molten pool was excessively generated. Accordingly, even if the oxidation promotion gas G2 was within a proper range afterward, the surfaces of the weld bead and the weld toe portion could not be covered with a conductive iron oxide slag. Therefore, poor coating occurred.
[0140] In Experimental Example 12, since the flow velocity of the oxidation promotion gas G2 was deficient, the atmosphere of the surfaces of the weld bead and the weld toe portion could not be replaced with the oxidation promotion gas G2. Therefore, the surfaces of the weld bead and the weld toe portion could not be sufficiently covered with a conductive iron oxide slag. Therefore, poor coating occurred.
[0141] In Experimental Example 13, since the oxygen potential a of the shielding gas G1 was excessive, a Si/Mn-based slag to be formed on the surface of the molten pool was excessively generated. Accordingly, even if the oxidation promotion gas G2 was within a proper range afterward, the surfaces of the weld bead and the weld toe portion could not be covered with a conductive iron oxide slag. Therefore, poor coating occurred.
[0142] In Experimental Example 14, since the oxygen potential a of the shielding gas G1 was deficient, the arc welding state became unstable. Therefore, a poorly formed bead was caused.
[0143] In Experimental Example 15, since the blowing position of the oxidation promotion gas G2 was excessively far from the consumable electrode 5, the oxidation promotion gas G2 was blown over the position in which the temperature of the surfaces of the weld bead and the weld toe portion was lower than 700 C., so that the surfaces of the weld bead and the weld toe portion could not be covered with a conductive iron oxide slag. Therefore, poor coating occurred.
[0144] In Experimental Example 16, since no oxidation promotion gas G2 was used, the surfaces of the weld bead and the weld toe portion could not be covered with a conductive iron oxide slag. Therefore, poor coating occurred.
[0145] Similar to Experimental Example 16, Experimental Example 17 and Experimental Example 18 were also experimental examples in which no oxidation promotion gas G2 was used. The conditions in Patent Document 1 were postulated, and the shielding gas G1 was set to have Ar=97% and O.sub.2=3%, or Ar=88% and CO.sub.2=12%. In these Experimental Examples as well, since the components of the shielding gas remaining on the surfaces of the weld bead and the weld toe portion immediately after welding was not replaced by the oxidation promotion gas G2, the surfaces of the weld bead and the weld toe portion could not be covered with a conductive iron oxide. Therefore, poor coating occurred.
[0146] In Experimental Example 19, the conditions in Patent Document 2 and Experimental Example 3 were postulated. The oxygen potential a of the shielding gas G1 was set to 0.0% and the oxygen potential of the oxidation promotion gas G2 supplied from the co-axial nozzle was set to 10.0%.
[0147] In this Experimental Example, since the oxygen potential a of the shielding gas G1 was deficient, the arc welding state became unstable, and a poorly formed bead was caused. Moreover, since the oxygen potential of the oxidation promotion gas G2 was deficient, a conductive iron oxide slag was not sufficiently formed on the surfaces of the weld bead and the weld toe portion, and poor coating occurred.
[0148]
[0149] As shown in
[0150]
[0151] Moreover, in Comparative Example (Experimental Example 19) in which the oxygen potential of the oxidation promotion gas G2 was set to 10.0%, and in Inventional Example (Experimental Example 2) in which the oxygen potential of the oxidation promotion gas G2 was set to 15.0%, the weld bead after welding before electrodeposition coating was cut along a line perpendicular to the weld line, was embedded in a resin, and was polished. Thereafter, element mapping (Fe, C, O, Si, and Mn) was performed by means of the EPMA. As a result, in an observation of the Si/Mn-based slag in Comparative Example (Experimental Example 19), the Fe concentration generally ranged from 3% to 7%, which was low. In contrast, in an observation of the Fe-based oxide in Inventional Example (Experimental Example 2), the Fe concentration increased to a range from 40% to 70%, and it could be checked that the thickness was 30 m, which was thick. In regard to the surface of the weld bead in Comparative Example (Experimental Example 19), it could also be checked that an iron oxide film was formed on the bead surface out of the range in which the Si/Mn-based slag was generated, but the thickness was approximately 5 m, which was thin, and the generation form differed from that of the iron oxide in Inventional Example (Experimental Example 2).
[0152]
[0153] Meanwhile, according to the present Inventional Example, the oxidation promotion gas G2 is blown over the weld bead and the weld toe portion in a high temperature state of 700 C. or higher at the flow velocity of 1 m/sec or faster. Accordingly, the shielding gas G1 tends to flow to the top of the weld bead from the welding torch is eliminated. Therefore, the weld bead and the weld toe portion in a high temperature state are in a contact state with the oxidation promotion gas 2. Since the oxygen potential of the oxidation promotion gas G2 is increased to 15% or higher, oxidation reaction on the surfaces of the weld bead and the weld toe portion is promoted, so that a conductive iron oxide slag can be sufficiently formed. Therefore, an effect of preventing poor coating can be achieved. Moreover, in a case where the oxidation promotion gas G2 is blown by using the hood nozzle, the after nozzle, or the co-axial nozzle, the oxidation promotion gas G2 can be focused on a desired location. Thus, the effect can be enhanced.
INDUSTRIAL APPLICABILITY
[0154] According to the present invention, it is possible to provide a welding portion in which no poor electrodeposition coating portion is generated due to the Si/Mn-based slag, and a consumable electrode type gas shield arc welding method able to form the welding portion.
BRIEF DESCRIPTION OF THE REFERENCE SYMBOLS
[0155] 1 WELDING TORCH
[0156] 5 CONSUMABLE ELECTRODE
[0157] 6 ARC
[0158] 8 MOLTEN POOL
[0159] 81 WELD BEAD
[0160] 82 WELD TOE PORTION
[0161] 9 CONDUCTIVE IRON OXIDE SLAG
[0162] 10 GAS LENS
[0163] 11 WELD LINE
[0164] 20, 20, 20 OXIDATION PROMOTION GAS BLOWING UNIT
[0165] 21, 21, 21 OXIDATION PROMOTION GAS SUPPLY PORTION
[0166] 22 OXIDATION PROMOTION GAS BLOWING NOZZLE
[0167] 22A HOOD NOZZLE
[0168] 22B AFTER NOZZLE
[0169] 22C CO-AXIAL NOZZLE
[0170] 20 TORCH INSERTION HOLE
[0171] G1 SHIELDING GAS
[0172] G2 OXIDATION PROMOTION GAS