Patent Application
20210039187
The present invention relates to a one-side submerged arc welding method and a one-side submerged arc welding device.
One-side submerged arc welding is a highly efficient welding method applied to a wide range of fields, mainly shipbuilding as plate joint welding. On the other hand, in the one-side submerged arc welding, cracks may occur at an end part of a weld joint, and various proposals have been made as its preventive measure.
For example, Patent Literature 1 describes a technique of preventing cracking at an end part in automatic welding by using a stepped sealing cascade bead in a plurality of layers from a terminal part of an end part of a weld joint toward a start end.
Patent Literature 2 discloses a multi-electrode submerged arc welding method capable of obtaining a good welded joint for a wide range of joint thickness by defining a groove shape of a butt portion, a current value of each electrode, and the like.
Patent Literature 1: JP-A-H08-99177
Patent Literature 2: JP-A-2007-268551
In the technique using the sealing cascade bead in Patent Literature 1, prevention of cracks is achieved by preventing deformation of the end part of the weld joint with the sealing cascade bead. However, since a penetration bead is not formed at the portion where the sealing cascade bead is formed, reworking is necessary after the welding. In addition, since it is necessary to form the sealing cascade bead in advance, there is a problem that the number of welding steps increases, and there is room for improvement.
Further, in the multi-electrode submerged arc welding method described in Patent Literature 2, the setting of the welding conditions depending on a specific welding speed is not considered, and a better welding quality is required.
The present invention has been made in view of the above problems, and an object thereof is to provide a one-side submerged arc welding method and a one-side submerged arc welding device, which can be applied to steel plates of a wide range of thickness, can prevent rotational deformation, can prevent cracks of the weld metal at the end part of the weld joint, and can avoid reworking after the welding.
The above object of the present invention is achieved by the following configuration.
The present invention is a one-side submerged arc welding method, including joining two steel plates butted against each other by submerged arc welding from one side using a plurality of electrodes,
in which during the submerged arc welding, at least one of electrode distances between adjacent electrodes in an end part region of the steel plates is reduced to be smaller than the at least one of electrode distances in a region in front of the end part region,
in which variation in heat input into the electrode moved so as to reduce the at least one of electrode distances in a transitional region in which the at least one of electrode distances is reduced is within 20% relative to the heat input at a starting point of the transitional region.
In the one-side submerged arc welding method, current and voltage in the transitional region are preferably changed based on a change rate of the at least one of electrode distances such that the variation in heat input into the electrode moved is constant.
The present invention is a one-side submerged arc welding device for joining two steel plates butted against each other by submerged arc welding from one side, the one-side submerged arc welding device including:
a welding unit, including a plurality of electrodes and a plurality of power sources to supply power to the plurality of electrodes, and being movable in a predetermined direction to perform welding from a start end to an end part of each of the steel plates by the plurality of electrodes;
a drive mechanism disposed in the welding unit and capable of moving at least one of the plurality of electrodes in an advancing and retracting direction with respect to the welding unit; and
a control unit configured to control the drive mechanism to reduce, during the submerged arc welding, at least one of electrode distances between adjacent electrodes in an end part region of the steel plates to be smaller than the at least one of electrode distances in a region in front of the end part region,
in which variation in heat input into the electrode moved so as to reduce the at least one of electrode distances in a transitional region in which the at least one of electrode distance is reduced is within 20% relative to the heat input at a starting point of the transitional region.
In the one-side submerged arc welding method and one-side submerged arc welding device of the present invention, during the submerged arc welding, at least one of the electrode distances between adjacent electrodes in the end part region of the steel plates is reduced to be smaller than the at least one of electrode distances in a region in front of the end part region. In addition, variation in heat input into the electrode moved so as to reduce the at least one of electrode distances in a transitional region in which the at least one of electrode distances is reduced is within 20% relative to the heat input at a starting point of the transitional region. Thanks to this configuration, the penetration shape and strain rate in the end part region can be controlled, and the same bead width as that before the transition can be obtained in the transitional region. Accordingly, the techniques of the present invention can be applied to steel plates of a wide range of thickness, can reduce rotational deformation and prevent cracks of the weld metal in the end part of the weld joint, and can decrease rework after the welding.
Hereinafter, a one-side submerged arc welding method and a one-side submerged arc welding device in a first embodiment of the present invention are described in detail with reference to the drawings.
First, an outline of main portions of a one-side submerged arc welding device 10 (hereinafter, also referred to as welding device 10) is described.
As shown in
The welder beam 13 allows the welders 12 to move along a longitudinal direction of the steel plate 20.
Each of the welders 12 is disposed in a casing 12a along the longitudinal direction of the steel plate 20, and includes a first electrode 15a preceding during welding, and a second electrode 15b following the first electrode 15a. The electrodes 15a and 15b are disposed to be inserted into a first torch 16a and a second torch 16b, respectively. In addition, the torches 16a and 16b are connected via cables to a first power source (not shown) and a second power source (not shown), respectively, for supplying a current at a specified voltage. The first electrode 15a and the second electrode 15b are supplied with a current via the first torch 16a and the second torch 16b, respectively. The electrodes 15a and 15b are welding wires.
The welder 12 includes a first drive mechanism (slider) 17a which allows the first torch 16a to move along the longitudinal direction of the steel plate 20 with respect to the casing 12a and a second drive mechanism (slider) 17b which allows the second torch 16b to move along the longitudinal direction of the steel plate 20 with respect to the casing 12a. The first drive mechanism 17a and the second drive mechanism 17b are each disposed in the casing 12a. The first torch 16a and the second torch 16b are moved by the first drive mechanism 17a and the second drive mechanism 17b, so that the first electrode 15a and the second electrode 15b are moved.
The welder 12 is disposed above the base frame 11 (above the steel plate 20). The welder 12 moves at a specified speed along an extension direction (specified direction) of the welder beam 13 and welds the steel plate 20 by one-side submerged arc welding with the electrodes 15a and 15b from the front side of a groove M (see
Further, the welder 12 drives and controls the first drive mechanism 17a and the second drive mechanism 17b by the control unit 18, so that the first electrode 15a and the second electrode 15b can be moved along the welder beam 13, and an electrode distance L1 between the first electrode 15a and the second electrode 15b can be changed (see
In
Therefore, the welder 12 may include, for example, first to third electrodes 15a, 15b and 15c as shown in
As shown in
The steel plate 20 to which the one-side submerged arc welding method of the present embodiment is applied is, for example, a steel plate for shipbuilding. As shown in
The groove M is formed in a joint surface 22 in which the two steel plates 20 are butted each other. The shape of the groove M may be any shape such as a Y groove or a V groove.
In addition, in the present embodiment, intermittent or continuous in-plane tacking is performed on the joint surface 22 of the steel plates 20. That is, in the present embodiment, no sealing cascade bead is formed.
Further, tab plates 30 are each attached to a start end 28 and an end part 29 of the steel plate 20. The tab plate 30 is used for the purpose of escaping a molten pool (crater) finally solidified from the welded joint in the one-side submerged arc welding, and for more effectively preventing cracks of the weld metal at the end part of the weld joint by the one-side submerged arc welding. Particularly, the tab plate 30 restrains the steel plate 20 at the end part of the weld joint, so that the thermal deformation due to the welding is prevented and the cracks at the end part of the weld joint are prevented.
Thereafter, the main welding (one-side submerged arc welding) of the steel plates 20 is performed from the start end 28 to the end part 29 of the steel plates 20. The main welding speed is, for example, 300 mm/min to 1,500 mm/min (30 cpm to 150 cpm). When the main welding speed is 300 mm/min to 1,500 mm/min, the welding quality can be ensured stably for the steel plate 20 having a thickness of 5 mm or more and 40 mm or less.
The “main welding” refers to welding to be performed on the steel plate 20 on which tack welding has been performed. In addition, “the main welding speed” refers to a speed of the submerged arc welding which is generally performed in the related art. Generally, the welding speed in the main welding is constant, but the speed may be slightly reduced depending on the welding position for the convenience of the welding process. However, the welding speed of the main welding is an optimum speed of the main welding conditions, that is, the preset main welding speed.
At this time, when the welding is performed under the same welding conditions (for example, specified number of electrodes, welding speed, total heat input, and electrode distance) from the start end 28 to the end part 29, cracks may occur at the end part of the weld joint. For example, under the condition of a high welding speed, rotational deformation may occur at the end part of the weld joint from the inner side to the outer side of the steel plate 20, and cracks may occur at the end part. Specifically, the strain rate at which the steel plate 20 spreads from the inner side to the outer side increases, and the driving force in the direction of cracks of the steel plate 20 increases. In addition, depending on the welding conditions, there may be a case where a penetration shape with poor crack resistance is formed at the end part of the weld joint.
Here, in the present embodiment, as shown in
That is, in the present embodiment, by changing the electrode distance in the end part region D2 to a specified value depending on the welding conditions such as the number of electrodes, the welding speed, and the heat input in the region D1 in front of the end part region, the strain rate is reduced, the penetration shape is changed by the first and second electrodes 15a and 15b, and the penetration shape with good crack resistance is ensured. Accordingly, in the end part of the weld joint, the crack prevention can be achieved, and a welded joint having a good surface bead appearance can be produced. Particularly in a case where the welding speed is high, the end part is likely to crack, but in the welding method of the present embodiment, good penetration shape can be obtained, the strain rate can be reduced, and the prevention of the cracks of the end part can be achieved, even in the case where the welding speed is high. In the submerged arc welding method in the related art, there is no viewpoint of changing the electrode distance during the welding. On the other hand, the submerged arc welding method in the present embodiment has been completed as a result of intensive investigations by the inventors focusing on the penetration shape and the strain rate.
The evaluation of the penetration shape as an index indicating the strength of the material with respect to a crack is described. In a welded portion to be evaluated, cutting is performed in a plane perpendicular to the welding direction, and polishing and appropriate etching are performed to obtain a cross section as shown in
The penetration shape (H/W) is influenced by the change in the temperature of the molten pool when the second electrode 15b is used to perform the welding due to the time from the welding of the first electrode 15a to the arrival of the second electrode 15b (welding speed and electrode distance) and the heat input. When the temperature of the molten pool changes, the penetration depth of the second electrode 15b changes, and thus, the value of H/W changes.
As illustrated in
However, the weld metal MT1 constituting the surface bead may be formed by the second and third electrodes 15b and 15c, and the weld metal MT2 constituting the penetration bead may be formed by the first electrode 15a. In this case, it is preferable to change the electrode distance between the first electrode 15a and the second electrode 15b.
In addition, as illustrated in
However, the weld metal MT1 constituting the surface bead may be formed by the fourth electrode 15d, and the weld metal MT2 constituting the penetration bead may be formed by the first, second and third electrodes 15a, 15b and 15c. In this case, it is preferable to change the electrode distance between the third electrode 15c and the fourth electrode 15d.
Alternatively, the weld metal MT1 constituting the surface bead may be formed by the second, third and fourth electrodes 15b, 15c and 15d, and the weld metal MT2 constituting the penetration bead may be formed by the first electrode 15a. In this case, it is preferable to change the electrode distance between the first electrode 15a and the second electrode 15b.
The change of the electrode distance L1 between the first and second electrodes 15a and 15b may be performed at position(s) from any position in front of the end part to the end part 29 of the steel plate 20. However, it is desirable to change the electrode distance L1 from a position where the amount of deformation is small depending on the length La of the steel plate 20. For example, the change of the electrode distance L1 is preferably performed at a position which is 150 mm or more in front of the end part 29 of the steel plate 20, more preferably performed at a position which is 300 mm or more in front of the end part 29 of the steel plate 20, still more preferably performed at a position which is 500 mm or more in front of the end part 29 of the steel plate 20, and particularly preferably performed at a position which is 1000 mm or more in front of the end part 29 of the steel plate 20.
In addition, the change of the electrode distance L1 may be performed in a transitional region D3 between the region D1 which is in front of the end part region and the end part region D2.
That is, in the welding of the steel plate 20, when the first and second electrodes 15a and 15b come to the transitional region D3 which is slightly closer to the start end 28 than a position which is in front of the end part 29 of the steel plate 20 and is at least 150 mm away from the end part 29, control of at least one of the drive mechanisms 17a, 17b gradually starts, and when the first and second electrodes 15a and 15b come to the end part region D2, the change of the electrode distance L1 is completed. The length of the transitional region D3 is not particularly limited, but is, for example, 50 mm to 500 mm.
Specifically, in the transitional region D3, the electrode distance L1 is reduced by changing the change rate VE of the electrode distance L1 as illustrated in
On this occasion, in the case where the traveling speed of the welder 12 and the currents and voltages of the first and second electrodes 15a and 15b are constant (see, the dashed-dotted line of
Accordingly, in the present embodiment, the variation in heat input into the electrode moved so as to reduce the electrode distance L1 in the transitional region D3 in which the electrode distance L1 is reduced is set, as denoted by the solid line of
Specifically, the heat input into the electrode moved so as to reduce the electrode distance L1 is given by the following formula.
In the formula, q: heat input [kJ/mm], I: current [A], E: voltage [V], ν0: welder traveling speed [mm/min.], and νE: change rate [mm/min] of electrode distance.
For example, in the case where the change rate VE is varied by activating the drive mechanism 17b so as to move the second electrode 15b close to the first electrode 15a, as denoted by the solid line in
The change of the change rate VE of the electrode distance L1 can also be achieved by activating the drive mechanism 17a to move the first electrode 15a close to the second electrode 15b. However, even in this case, if the traveling speed of the welder 12 and the currents and voltages of the first and second electrodes 15a and 15b are constant, the heat input changes in changing the electrode distance L1, and the penetration bead width or the penetration depth is changed. Specifically, the bead width of the penetration bead in the transitional region D3 becomes large, compared with those of the penetration beads in the region D1 before transition and the region D2 after transition.
However, also in this case, when the variation in heat input into the electrode moved in the transitional region D3 to reduce the electrode distance L1 is set to be within 20% relative to the heat input at the starting point of the transitional region D3, the variation in the heat input into the electrode moved in the transitional region D3 is reduced and in turn, a change in the penetration bead width or a change in the penetration depth is prevented, leading to a decrease in the weld defect rate, such that the rework man-hours can be reduced. Specifically, the current and voltage of the first electrode 15a in the transitional region D3 are preferably changed based on the change rate VE of the electrode distance L1 such that the variation in heat input q can be constant.
In addition, the manner of how the change rate VE in the transitional region D3 is increased or decreased is not limited to that illustrated in
Alternatively, as illustrated in
As for the change of the electrode distance L1, in the case where the welder 12 has two electrodes, i.e., a first electrode and a second electrode, the electrode distance L1 between the first electrode and the second electrode is changed within a range of 250 mm or less.
In addition, in the case where the welder 12 has three electrodes, i.e., a first electrode, a second electrode and a third electrode, it is preferable to change the electrode distance L1 between the first electrode and the second electrode within a range of 250 mm or less and change the electrode distance L2 between the second electrode and the third electrode within a range of 250 mm or less.
Furthermore, in the case where the welder 12 has four electrodes, i.e., a first electrode, a second electrode, a third electrode and a fourth electrode, it is preferable to change the electrode distance L1 between the first electrode and the second electrode within a range of 250 mm or less, change the electrode distance L2 between the second electrode and the third electrode within a range of 250 mm or less, and change the electrode distance L3 between the third electrode and the fourth electrode within a range of 250 mm or less.
In all cases, it is more preferable to change each electrode distance within a range of 5 mm or more and 250 mm or less.
Next, the one-side submerged arc welding method of a second embodiment is described. The welding device 10 used in the present embodiment is the same as that of the first embodiment.
In the one-side submerged arc welding method of the present embodiment, unlike the first embodiment in which the welding speed is constant from the start end 28 to the end part 29 of the steel plate 20, the welding is performed at a position which is 300 mm or more in front of the end part of the steel plate 20 to the end part 29 at a welding speed (hereinafter, referred to as a reduced welding speed appropriately) which is equal to or less than 75% of the welding speed of the main welding (hereinafter, referred to as the main welding speed appropriately).
At this time, when the total heat input in the main welding is Q (kJ/mm) and the total heat input in the welding at a welding speed of 75% or less is Q′ (kJ/mm), “Q′/Q=0.60 to 1.30” is satisfied.
When the reduced welding speed in the end part region D2 is equal to or less than 75% of the main welding speed, in the end part region D2, the strain rate can be reduced, and the driving force of the crack can be reduced, and in some cases, contraction deformation which leads to rotational deformation occurring from the inner side to the outer side of the steel plate 20 occurs. The reduced welding speed is preferably equal to or less than 60% of the main welding speed, and is more preferably equal to or less than 50% of the main welding speed. When the reduced welding speed is equal to or more than 40% of the main welding speed, the welding efficiency is not significantly impaired. In addition, when the reduced welding speed is equal to or more than 40% of the main welding speed, the current value for ensuring a good weld metal is high, it is not difficult to maintain the arc and the bead appearance is good.
In addition, in the welding of the steel plate 20, in a case where the welding speed is changed, the heat input is excessive and it is difficult to ensure the effect of prevention of the cracks and the welding quality, due to a low speed. That is, when the total heat input in the welding at a reduced welding speed is more than 1.30 times the total heat input at the main welding speed, the crack prevention effect is not recognized, and regarding the welding quality, the reinforcement of the penetration bead is excessive, making it impossible to obtain a good weld metal. On the other hand, when the total heat input in the welding at the reduced welding speed is less than 0.60 times the total heat input at the main welding speed, the crack prevention effect is recognized, but it is difficult to maintain the arc, and it is impossible to obtain a good weld metal for both the surface and penetration beads. Therefore, when the total heat input in the main welding is Q (kJ/mm) and the total heat input in the welding at a welding speed of 75% or less is Q′ (kJ/mm), “Q′/Q=0.60 to 1.30” is satisfied.
From the viewpoint of making it easier to obtain a good weld metal, the value of Q′/Q is preferably 0.70 or more, and more preferably 0.80 or more. In addition, from the viewpoint of the crack prevention effect in the end part region D2 and making it easier to obtain a good weld metal, the value of Q′/Q is preferably 1.20 or less.
The total heat input Q can be calculated by the following formula.
In the above formula, Q represents the total heat input (kJ/mm), Ei represents the voltage (V), Ii represents the current (A), vi represents the welding speed (mm/min), i=1, 2, 3, . . . n, and i represents each electrode. The same applies to Q′ for the above formula. In addition, the total heat input here means the total of the heat inputs into the electrodes 15a, 15b. . . . In addition, the total heat input may be a value calculated by the above formula, or may be an actual measurement value (measurement value).
In the present embodiment, from the viewpoint of the amount of deformation at end part of a weld joint, it is preferable that the change range of the welding speed is the end part region D2 from a position which is 300 mm or more in front of the end part of the steel plate 20 to the end part 29. In addition, the transitional region D3 in which the welding speed is changed from the main welding speed to the reduced welding speed may be appropriately set in the range of 50 mm to 500 mm.
Further, the change of the electrode distance and the change of the welding speed may be performed simultaneously or separately within the above range. Therefore, the change of the electrode distance may be performed from any position in front of the end part of the steel plate 20 to the end part 29.
Accordingly, when the welding speed (moving speed of the casing 12a) is reduced, the strain rate of the steel plate 20 is reduced, so that the driving force of the cracks can be reduced, but a penetration shape with poor crack resistance may be obtained. In contrast, as in the present embodiment, in the case where the electrode distance is changed, the strain rate of the steel plate 20 is reduced, the penetration shape (H/W) with good crack resistance can be ensured, and crack prevention can be achieved.
For example, when the heat input is constant and the welding speed is reduced, since the temperature of the molten pool at the time of welding of the electrode to form the weld metal MT1 (see
Particularly, from the viewpoint of welding efficiency, the reduction in the welding speed is preferably as small as possible, and when the change of the electrode distance and the change of the welding speed are performed, for example, the crack prevention can be achieved while making the reduced welding speed higher than 70% of the main welding speed.
Other configurations and effects are similar to those of the first embodiment.
The present invention is not limited to the embodiments described above and Examples, and appropriate modifications, improvements, etc. can be made.
In each embodiment described above, a tab plate 30 is attached to the start end 28 and end part 29 of the steel plate 20, but in the present invention, the submerged arc welding method may be performed without using the tab plate 30. In addition, in the case of using the tab plate, the following configuration can be employed: denoting t1 as the thickness of the steel plate and t2 as the thickness of the tab plate, the relationship between the thickness of the steel plate and the thickness of the tab plate satisfies t2≥t1, the width B1 of two steel plates satisfies B1≥300 mm, the width B2 of two tab plates satisfies B2≥10×t1 and 100 mm≤B2≤2000 mm, a groove of the steel plate and a groove of the tab plate, which are formed by butting two steel plates and two tab plates, respectively, have the same groove shape, and tack welding of the groove of the steel plate and the groove of the tab plate is performed from at least an end part of the steel plate to one end portion of the tab plate.
Examples in the present invention are described below. In this Example, in the submerged arc welding, a predetermined electrode is moved to reduce a predetermined electrode distance in an end part of a weld joint, and the heat input into the electrode moved is caused to make a predetermined variation. The number of electrodes in the submerged arc welding, the main welding conditions, the method for changing the electrode distance (the electrode moved), and the heat input (before transition and in the transitional region) into the electrode moved are shown in Table 1. Furthermore, as test results, the evaluation results of surface bead shape and penetration bead shape of a specimen and the evaluation results of hot cracking are shown in Table 1.
Here, two steel plates used in the test were a rolled steel material SM400B for welded structures, having a size of 20 mm in thickness, 750 mm in width, and 1,200 mm in length, the wire was a solid wire of JIS Z 3351 YS-S6, and the flux was a bonded flux of JIS Z 3352 SACI1.
As for the surface bead shape and the penetration bead shape, the bead shapes on the front and back surfaces were observed in the transitional region and are recorded in Table 1 as good in the case where the variation in the bead width is not changed from that before the transition, and as defective in the case where the bead width was decreased or increased in the transitional region.
As for the hot cracking, after the completion of welding, the presence or absence of internal cracks was confirmed by an X-ray transmission test (J1S Z3104) within the range of 400 mm in front of the end part of the steel plate, and the presence or absence of cracks are recorded in Table 1.
Furthermore, in the case where the number of electrodes is 2, the weld metal constituting the surface bead is formed by the second electrode, and the weld metal constituting the penetration bead is formed by the first electrode. In the case where the number of electrodes is 3, the weld metal constituting the surface bead is formed by the third electrode, and the weld metal constituting the penetration bead is formed by the first electrode and the second electrode. In the case where the number of electrodes is 4, the weld metal constituting the surface bead is formed by the third electrode and the fourth electrode, and the weld metal constituting the penetration bead is formed by the first electrode and the second electrode.
In Table 1, No. 1 to No. 21 are Examples of the invention and No. 22 to No. 30 are Comparative Examples. More specifically, in No. 28 to No. 30, the submerged arc welding was performed under the same welding conditions from the start end to the end part, and hot cracking was observed in the end part of the weld joint. In No. 22 to No. 27, the electrode was moved so as to reduce the electrode distance in the end part of the weld joint and in turn, hot cracking in the end part of the weld joint was prevented. However, in No. 22 to No. 27, the variation in heat input into the electrode moved so as to reduce the electrode distance in the transitional region exceeded 20% relative to the heat input into the electrode before transition and therefore, the bead width of the surface bead or penetration bead in the transitional region was changed.
On the other hand, in No. 1 to No. 21 where the electrode was moved so as to reduce the electrode distance in the end part of the weld joint and the variation in heat input of the electrode moved so as to reduce the electrode distance in the transitional region was within 20% relative to the heat input into the electrode before transition, hot cracking was prevented, and both the surface bead shape and the penetration bead shape in the transitional region were good, demonstrating the effects of the present invention.
The present invention is based on Japanese patent application No. 2018-015838 filed on Jan. 31, 2018, the contents of which are incorporated herein by reference.
10 One-side submerged arc welding device
11 Base frame
12 Welder (welding unit)
12
a Casing
13 Welder beam
15
a First electrode
15
b Second electrode
15
c Third electrode
15
d Fourth electrode
16
a First torch
16
b Second torch
17
a First drive mechanism (slider)
17
b Second drive mechanism (slider)
18 Control unit
20 Steel plate
22 Joint surface
28 Start end
29 End part
30 Tab plate
| Number | Date | Country | Kind |
|---|---|---|---|
| 2018-015838 | Jan 2018 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2019/002579 | 1/25/2019 | WO | 00 |
