【作者】 李磊；

【导师】 温家伶； 杜学铭；

【作者基本信息】 武汉理工大学 ， 材料加工工程， 2008， 硕士

【摘要】 随着社会的进步、国民经济和科学技术的发展,焊接技术必然向着优质、高效、节能和生产合理化、自动化的方向发展。单面焊就是符合时代要求的一种高效、节能和新型焊接工艺。与传统的双面焊相比,它可以改仰焊为平焊、改内部焊接为外部焊接,并可省去背面清根工序,易于实现自动化焊接,从而改善工人的劳动条件,降低工人的劳动强度。调查表明,它可提高焊接生产效率3倍以上,节省材料10%左右,节约电能50%左右,并且操作简单、使用方便、能简化装配工序、缩短焊接生产周期,具有十分显著的经济效益和社会效益。从国内实际出发,针对目前市场上主要是CO2气体保护焊用高温烧结型陶瓷衬垫的现状,对手工电弧焊用陶瓷衬垫进行研究。本文分析了单面焊双面成形的两种基本成形方式及其实现条件和影响单面焊双面成形的因素,提出衬垫材料及其性能是影响单面焊质量的注意因素之一。同时介绍了手工电弧焊用烧结型陶瓷衬垫的配方设计原则和设计过程。衬垫研制过程中采用了正交试验进行筛选,并对衬垫工艺和单面焊质量进行了总和评分和分析,讨论了衬垫的酸性系数和始熔温度对衬垫性能和焊接质量的影响。在参考衬垫性能参数和总和分析大量试验结果的基础上,确定了手工电弧焊用陶瓷衬垫的最佳配方。本文介绍了衬垫的制作工艺流程,从原材料的选配以及处理出发,根据衬垫的成分特点和性质特征,对影响衬垫压制成形和烧结性能的因素进行了分析和讨论,同时根据试验结果和对衬垫烧结质量的分析,制定了衬垫的压制工艺和烧成制度。结果表明:衬垫原材料的选择、处理、压制成形工艺及烧成制度对衬垫的质量有着极其重要的影响。本文还讨论了手工电弧焊焊接工艺实验方法及过程。根据对试验结果的分析,认为反面焊缝的形状与焊接电流、电弧电压、焊接速度、运条方式、坡口形状及装配间隙等有密切关系。工艺评定结果表明:焊接接头的机械性能优良,焊缝内部无缺陷,焊缝金属的化学成分完全满足规范要求。更多还原

【Abstract】 With the development of our society, the national economy and the technology, the welding technology will inevitably develop toward the way of high quality, efficient, energy saving, production rationalization and automation. These qualities can be seen in the new welding technology of One-sided welding that suits the requirement of the times. Compared with the two-sided, it can change overhead position welding to flat position welding, change internal welding to external welding, save procedure on the clearance of the backside, easy to realize the automation, so as to improve the working conditions of workers and reduce labor intensity. Investigation shows that it can increase production efficiency by 3 times, save raw materials about 10% and energy about 50%, easy to use, simplify the assembly process and shorten the production cycle of welding, with very significant economic and social benefit.From the reality of domestic, a list of research has been done on high temperature sintered ceramic backing used for the need of one-sided shielded metal arc welding as the status quo of the current market is mainly CO₂ gas shielded ceramic backing.This paper analyzed two basic forming patterns of one-sided welding, suggested that backing materials and its properties is one of the main factors of influence quality of one-sided welding. Meanwhile introduced the principles of ingredient design of sintering type backing of SMAW, and design procedure of backing development ,and had given composite marks and analysis to manufacture process and quality of one-sided welding ,discussed thee influence of acid coefficient and beginning melting temperature on properties of backing and welding quality. In terms of the property parameters of backing and mass experimental results of composite analysis, determined the optional ingredient of ceramic backing of SMAW.This paper introduced manufacture procedure of ceramic backing. Start with the selecting and treating of raw materials based on the composition characteristics and shape of backing, analysis and discussed factors of influence pressure shaping and sintering properties of backing. Meanwhile in terms of experimental results and analysis to sintering quality of backing, decided the pressure process and sintering system. The results showed that the selecting treating of raw materials of backing, pressure shaping process and sintering system has important influence on quality of backing.This paper also discussed welding process experimental method and procedure of one-sided welding of SMAW. In terms of analysis the experimental results shown that the shape of back weld is closely related to welding current, arc voltage, welding velocity, operating electrode way, groove form and gap of assembling.The results of procedure qualification indicated that mechanical properties of welded joints are of good quality and internal weld with non-deficiency; elementary analysis indicated chemical components of weld metal satisfy the requirements.更多还原