Welder Handbookpart 21Word文档格式.docx

1、惰性气体保护焊/活性气体保护焊MIG/MAG welding is a fusion welding process, without expenditure of external forces, whereby the joint area must be partly fused. The required heat is supplied by way of an electrically-generated arc. The arc burns between a continuously supplied, melting wire electrode and the workpi

2、ece. The temperatures around the arc are dependent upon many factors. Temperatures of up to 4500C can occur at the arc starting point. In the arc column, temperatures can reach up to 12 000C. The arc and the weld pool are shielded by an active or inert gas. The process can be implemented for most me

3、tallic materials and there is a wide range of welding consumables available. 惰性气体保护焊/活性气体保护焊是一种熔合焊接方法，没有使用外力，接头区域必须部分熔合。所需的热量是通过电弧产生的。电弧连续不断的在熔化电极和工件之间提供热量。电弧周围的温度取决于很多因素。起弧点的温度高达4500C，弧柱的温度高达12000C。电弧和熔池被活性或惰性气体保护着。这种焊接方法适用于大多数金属材料并且有大量的焊接材料。MIG/MAG welding is considerably more productive than manu

4、al metal arc welding. The frequent change of electrodes is no longer necessary and the net yield is considerably greater as there is no residue. From every kilogram of electrodes used, only 65% goes into the weld metal. For wire electrodes, this value is already at 85-90%. 惰性气体保护焊/活性气体保护焊生产效率大大超过手工电

5、弧焊。不再需要频繁的更换焊条并且不会有焊条头。从每公斤使用的焊条只有65%进入焊缝金属，现在这个值已经达到85%-90%。MIG/MAG welding is an extremely versatile process, allowing high deposition rates to be achieved in all positions. It is applied in just about every area in which welding tasks on non-alloyed or low-alloyed steels, high-alloyed steels, nic

6、kel-based materials, as well as aluminium are required. MIG/MAG pulse welding is regularly applied for high-alloyed steels and aluminium. As well as increasing productivity to yet another level, tubular core is being used more and more frequently as it also proves advantageous in many other areas.MI

7、G/MAG是一种非常灵活的焊接方法，允许在所有位置焊接，它适用于非合金钢或低合金钢，高合金钢，镍基材料，以及铝等几乎所有材料的焊接。就像提高生产率一样，管子的焊接也适用的越来越频繁，这也证明了它在许多其他的领域也有优势。Assembly of a shielding gas welding unit气体保护焊机的组装Main groups and subgroups主要组和子组Shielding gas supply 保护气体供应5. Shielding gas cylinder 气瓶6. Pressure reducer with gas flow meter 带气体流量计的减压器7. Sh

8、ielding gas solenoid valve保护气体电磁阀Cable assembly 电缆组件8. Switch harness 开关线束 9. Wire electrode 焊丝10. Shielding gas guide 保护气体导向管11. Welding current cable 焊接电缆Welding current source焊接电源1. Mains supply交流电源2. Welding rectifier 焊接整流器Wire feed system 送丝系统2. Wire electrode coil送丝盘3. Wire feed device （drive

9、motor and drive rollers） 送丝装置（驱动电机和驱动辊）Welding torch 焊枪12.Welding torch with On/Off switch 焊枪开关Workpiece connection 工件连接13. Welding return cable焊接回路电缆（地线）Welding current source The welding current source must convert the mains current into a welding current indicating the following characteristics:焊

10、接电源必须转换电源电流为显示以下特点的焊接电流- As a rule, the welding current is a direct current; 通常焊接电流为直流电 Positive pole on the wire electrode, negative pole on the workpiece 焊丝接电源正极，工件接电源负极 - The level of welding voltage is set to correspond with the respective welding task. 焊接电压符合焊接任务- The level of welding current i

11、s set via the wire feed. 焊接电流是通过送丝速度实现Designs: 外观设计- Conventional design （welding voltage setting via on-load tap changer） 常规设计（电弧电压是通过有载抽头开关实现的）- Electronic design （stepless adjustment of parameters） 电子设计 （参数的无级调速）Principle of a welding current source conventional design 焊接电源的工作原理常规设计Assemblies 组装1

12、. Mains supply 交流电源2. On/Off switch for mains current 电源开关3. Transformer with on-load tap changer for adjustment of the welding voltage: Minimises the mains voltage to welding voltage. The effective number of windings, and thus the transmission ratio is changed progressively by tapping the primary w

13、inding via a switch.通过有载调压变压器调整电弧电压：把电源电压减至最低的焊接电压，绕组的有效数量和传动比是通过交换机的初级绕组逐步增多的。4. Rectifier: Converts alternating current （or three-phase current） into direct current 整流器： 将交流电（或三相电流）转换成直流电。5. Regulator: Smoothes current peaks in the welding current circuit 稳压器： 在焊接电流回路内使电流峰值平滑。送丝系统Compact system 压紧

14、系统 Universal system 普通系统 Small coil system小线圈系统 Push-Pull system 推拉系统Wire feed system 送丝系统in the welding system outside the welding system in the torch in the welding system and in the torchWire feed device 送丝装置The wire feed device draws the wire electrode evenly from the wire electrode coil and pus

15、hes it into the cable assembly to the welding torch. The conveyance speed can be adjusted from 1 to 18 m/min, this remains constant during the welding process. Imperfections in wire conveyance will have an effect on the arc and on the drop transfer and may consequently result in imperfections in the

16、 weld.送丝装置平坦的从焊丝盘拉出焊丝通过送丝软管推至焊枪。传送速度可以在1米/分钟到18米/分钟范围内调节。送丝速度在焊接过程中保持不变。送丝过程中的不合格将会对电弧和熔滴过渡产生影响，并且可能因此导致焊缝的不合格。Two-roller drive 1 4 2 5 31. Pressure roller 压紧轮2. Wire intake nozzle 焊咀3. Wire electrode coil 焊丝盘4. Wire supply nozzle 供给喷嘴5. Wire conveyance roller （powered） 驱动轮Four-roller drive 四辊机Prefe

17、rable applications for tubular cores and solid wires 管状芯和实芯焊丝的最好应用 31. Wire supply nozzle 供给喷嘴2. Wire conveyance roller （powered） 驱动轮3. Pressure roller （powered） 压紧轮4. Wire guide nozzle 导向咀5. Wire intake nozzle 焊咀 2 Wire conveyance roller 驱动轮1. Wire conveyance roller with V-groove for steel wire ele

18、ctrodes 带V型槽的焊丝驱动轮2. Wire conveyance roller with round groove for aluminium wire electrodes 带循环槽的铝焊丝驱动轮Note:The wire feed roller must be selected in accordance with the respective diameter of the wire electrode, otherwise errors will occur in wire conveyance.Inspect the rollers regularly for wear an

19、d replace as necessary.注意： 送丝辊必须按照对应的焊丝直径选择，否则将发生焊丝传送错误。Shielding gas supply 保护气体供应The supply of shielding gas to the welding workplace can be resulted in different ways:- Single cylinder supply- Central supply from cylinder bundles or a cylinder bank- Central supply via cold converter system （deliv

20、ered in supercooled liquid form） 焊接车间的保护气体的供应可以导致不同的方式： - 单缸供应 - 气缸束或汽缸组的中央供应 - 通过冷却转换系统中央供应（在过冷液态形式交付） Workshop supply of shielding gases （e.g. argon, forming gas） 车间供应保护气体（如氩气、混合气体）Cold converter system for argonCylinder bundles or cylinder bank for argonArgon and forming gas Root protectionCylind

21、er bundles or cylinder bank for forming gas MSG welding torch with cable assembly软管式焊枪The welding torch is the tool“ of the welder. It is subjected to high mechanical and thermic stresses. The welder must handle the torch very carefully as malfunctions will cause problems during the welding process,

22、 which could in turn lead to imperfections in the weld焊枪是焊工的工具，它要受高机械压力和热流压力。焊工必须小心操作焊枪，操作故障将会在焊接过程中出现问题，这会导致焊缝的不合格。Water cooled Gas cooled Water 1. Torch handle 焊枪手柄2. Torch neck 焊枪颈部3. Torch switch 焊枪开关4. Cable assembly 软管5. Gas nozzle 气体喷嘴6. Current contact tube 导电嘴7. Contact tube holder （nozzle

23、holder） 导电嘴接头8. Insulator 绝缘套管9. Wire guide filament （steel spiral） 送丝弹簧或送丝软管10. Wire electrode 焊丝11. Shielding gas supply 气体输入12. Welding current supply 焊接电流输入Sectional drawing of an MIG/MAG welding torch in gas-cooled and water-cooled configurations.MIG/MAG 焊枪气冷和水冷构造的剖面图。Water-cooled welding torch

24、es are used when working with welding currents upwards of 200A.水冷焊枪在使用时的焊接电流在200A以上。Function 功能The welding current in the cable assembly is channelled to the contact tube holder with its own copper line, and then on to the current contact tube. The bore of the current contact tube should be approx.

25、0.2mm greater than the diameter of the wire electrode. When sliding the wire electrode through the contact tube, the welding current is fed into the wire electrode by way of sliding contact.The contact tube is a wear component which requires replacing whenever it sustains damage.The shielding gas is

26、 also channelled into the cable assembly. It is then exuded from the gas nozzle. The gas nozzle shapes the stream of shielding gas in such a way that the weld pool is protected against contact with air. Adhering spatter on the shielding gas nozzle and on the current contact tube can cause a swirling

27、 of the current, resulting in air coming into contact with the weld pool and as a consequence, pores forming in the weld.焊接电流以软管为渠道输送到带有铜线的导电嘴，然后到目前的导电嘴。导电嘴应该比焊丝直径达0.2mm. 焊丝通过接触管滑动，焊接电流通过导电嘴以滑动接触的方式传送。当导电嘴磨损后要进行更换。保护气体也是通过软管传输。它从喷气嘴缓慢流出。保护气体以气嘴形状的方式流动在熔池中组织与空气接触。气嘴和导电嘴上附着的飞溅可能会引起一个电流漩涡，导致空气接触熔池，并因此在

28、焊缝中形成气孔。Working rules Welding torch 操作细则-焊枪- Select a current contact tube suited to the respective diameter of the wire electrode 选择适合焊丝直径的导电嘴- Replace worn current contact tubes, ensure secure seating in the contact tube holder. 更换损坏的导电嘴，以确保导电嘴的牢固。- Clean the gas nozzle, current contact tube and c

29、ontact tube holder carefully ofadhering weld spatter at regular intervals.定期清理喷气嘴、导电嘴和导电嘴接头上附着的飞溅。- Spray the torch outlet lightly with a releasing agent to prevent the adherence ofspatter.在焊枪口喷防粘剂以阻止焊接飞溅。Working rules Cable assembly 操作细则-软管- Select the wire guide spiral （core filament） to suit the respective diam