A Comprehensive Technical Guide to Laser Beam Welding of Stainless Steels

Kwiinjineli, abaqulunqi, kunye nabaphathi bemisebenzi, umceli mngeni uhlala uhleli: indlela yokujoyina amacandelo ensimbi engenasici ngaphandle kwe-warping, discoloration, kunye nokunciphisa ukuxhathisa kwe-corrosion ehlasela iindlela eziqhelekileyo. Isisombululo kukubalaser welding steel stainless, iteknoloji yokuguqula ehambisa isantya esingenakulinganiswa, ukuchaneka, kunye nomgangatho onokuthi i-TIG yendabuko kunye ne-MIG idibanise.

Ukuwelda kweLaser kusebenzisa umqadi ogxininiswe kakhulu wokukhanya ukunyibilika kunye nokufaka intsimbi engatyiwayo kunye nobushushu obuncinci, obulawulwayo. Le nkqubo eqhutywa ngokuchanekileyo isombulula ngokuthe ngqo iingxaki eziphambili zokuphazamiseka kobushushu kunye nomthamo we-weld.

IziNzuzo eziPhambili zeLaser Welding Stainless Steel:

• Isantya esikhethekileyo:Isebenza amaxesha ama-4 ukuya kwali-10 ngokukhawuleza kune-TIG welding, yandisa kakhulu imveliso kunye ne-throughput.

• Ukugqwesa okuncinci:Ubushushu obugxilileyo budala iNdawo eNchatshazelwe ngubushushu (HAZ) encinci kakhulu, ethi icuthe kakhulu okanye iphelise ukulwa, igcina ukuchaneka komda wenxalenye.

• Umgangatho ophezulu:Ivelisa iiweldi ezicocekileyo, ezinamandla, kunye nobuhle obukholisayo obufuna kancinci ukuya kuthi ga emva kokusila okanye ukugqiba.

• Iinkcazelo Ngeempawu Zezinto Ezigciniweyo:Igalelo lobushushu eliphantsi ligcina amandla endalo entsimbi engenastainless kunye nokumelana nomhlwa okubalulekileyo, kuthintelwa imiba efana “nokubola kweweld”.

Esi sikhokelo sibonelela ngolwazi lobuchwephesha olufunekayo ukusuka ekuqondeni okusisiseko ukuya kwisicelo esiqinisekileyo, siqinisekisa ukuba ungasebenzisa amandla apheleleyo obu buchule bokuvelisa obuphezulu.

Laser Weldingvs. IiNdlela zeMveli: Ukuthelekisa iNtloko ukuya kwiNtloko

Ukukhetha inkqubo ye-welding efanelekileyo kubalulekile kwimpumelelo yeprojekthi. Nantsi indlela i-laser welding enamathela ngayo ngokuchasene ne-TIG kunye ne-MIG kwizicelo zentsimbi engenasici.

Laser Welding vs. TIG Welding

I-welding ye-Tungsten Inert Gas (TIG) iyaziwa ngekhwalithi ephezulu, i-welds manual kodwa inzima ukugcina isantya kwindawo yokuvelisa.

• Isantya kunye nemveliso:I-Laser welding ikhawuleza kakhulu, iyenza ibe lukhetho olucacileyo lokwenziwa kwe-automated kunye ne-volume ephezulu.

• Ubushushu kunye nokuGqwetha:I-arc ye-TIG ngumthombo wobushushu ongasebenziyo, osasazekileyo owenza i-HAZ enkulu, ekhokelela ekugqwethekeni okukhulu, ngakumbi kwisinyithi esicekethekileyo. Umqa we-laser ogxile ekuthinteleni lo monakalo uxhaphakileyo wobushushu.

• Ukuzenzekela:Iinkqubo zeLaser zilula ngokwemvelo ukuzenzela, zenza umthamo ophezulu, imveliso ephindaphindwayo kunye nesakhono semanyuwali esifunekayo esingaphantsi kune-TIG.

Laser Welding vs. MIG Welding

I-Metal Inert Gas (MIG) welding yinkqubo eguquguqukayo, ephezulu yokubeka, kodwa ayinakho ukuchaneka kwelaser.

• Ukuchaneka kunye noMgangatho:Ukuwelda kweLaser yinkqubo engaqhagamshelwanga evelisa iiweldi ezicocekileyo, ezingenazitshizi. I-MIG welding ithanda ukutshiza efuna ukucocwa kwe-post-weld.

• Ukunyamezelwa kweGap:Ukuwelda kwe-MIG kuxolela ngakumbi ukungadibani kakuhle kwamalungu kuba ucingo lwayo olusebenzisekayo lusebenza njengesizalisi. Ukuwelda ngeLaser kufuna ulungelelwaniso oluchanekileyo kunye nokunyamezelana okuqinileyo.

• Ukutyeba kwezinto:Ngelixa iilaser ezinamandla amakhulu zinokuphatha amacandelo ashinyeneyo, iMIG ihlala isebenziseka ngakumbi kwipleyiti enzima kakhulu. Ukuwelda kweLaser kuyagqwesa kubunzima bezinto ezicekethekileyo ukuya kobuphakathi apho ulawulo olugqwethekileyo lubalulekile.

Itheyibhile yokuthelekisa ngokuthe ngqo

ISayensi eNgemva kwe-Weld: Imigaqo engundoqo icacisiwe

Ukuqonda indlela i-laser edibana ngayo nensimbi engenasici ngundoqo ekulawuleni inkqubo. Isebenza ikakhulu kwiimowudi ezimbini ezahlukileyo ezimiselwe kukuxinana kwamandla.

Imo Yokuqhuba vs. Imowudi yesitshixo

• Ukwenziwa kweWelding:Xa uxinano lwamandla asezantsi, i-laser itshisa umphezulu wezinto eziphathekayo, kwaye ubushushu "buhambisa" kwindawo. Oku kudala i-weld engekho nzulu, ebanzi, kunye ne-aesthetically egudileyo, efanelekileyo kwizinto ezincinci (ngaphantsi kwe-1-2 mm) okanye i-seams ebonakalayo apho imbonakalo ibaluleke kakhulu.

• Umngxuma wesitshixo (Ukungena nzulu) Ukuwelda:Kuxinaniso lwamandla oluphezulu (malunga ne-1.5 MW/cm²), i-laser iyenza ibe ngumphunga isinyithi ngoko nangoko, yenze umngxuma onzulu, omxinwa obizwa ngokuba “ngumngxuma wesitshixo.” Lo mngxuma wesitshixo ubamba amandla e-laser, uwafake nzulu kwizinto eziqinileyo, zokungena ngokupheleleyo kumacandelo ashinyeneyo.

I-Wave eqhubekayo (CW) vs. I-Pulsed Lasers

• I-Wave eqhubekayo (CW):I-laser ihambisa umqadi wamandla rhoqo, ongaphazamisekiyo. Le modi ifanelekile ekudaleni ixesha elide, i-seams eqhubekayo kwisantya esiphezulu kwimveliso ezenzekelayo.

• ILaser ePulsed:I-laser ihambisa amandla ngokufutshane, ukuqhuma okunamandla. Le ndlela ibonelela ngolawulo oluchanekileyo kwigalelo lobushushu, icutha i-HAZ kwaye iyenze ilungele ukuwelda izinto ezithambileyo, ezingeva bubushushu okanye zenze iindawo zokuwelda ezidlulanayo zetywina eligqibeleleyo.

ISikhokelo seNyathelo ngeNyathelo sokuLungiselela okungenasiphako

Kwiwelding ye-laser, impumelelo imiselwa phambi kokuba umqadi usebenze. Ukuchaneka kwenkqubo kufuna ukulungiswa ngononophelo.

Inyathelo 1: Uyilo oluDityanisiweyo kunye neFit-Up

Ngokungafaniyo ne-arc welding, i-laser welding inonyamezelo oluphantsi kakhulu lwezithuba okanye ukungahambi kakuhle.

• Iintlobo ezidityanisiweyo:Amalungu empundu ngawona asebenza kakuhle kodwa afuna umsantsa okufutshane no-zero (ubukhulu bungaphantsi kwe-0.1 mm kumacandelo amancinci). Amalungu eLap axolela ngakumbi ukwahluka kwe-fit-up.

• Ulawulo lweSikhewu:Umsantsa ogqithisileyo uya kuthintela ichibi elincinci elityhidiweyo ukuba livale umdibaniso, okukhokelela ekudibaneni okungaphelelanga kunye ne-weld ebuthathaka. Sebenzisa iindlela zokusika ezichanekileyo eziphezulu kunye ne-clamping eyomeleleyo ukuqinisekisa ukulungelelaniswa okugqibeleleyo.

Inyathelo lesi-2: Ukucocwa koMphezulu kunye nokuSuswa kweNgcombolo

Amandla amakhulu e-laser aya kwenza umphunga naziphi na izinto ezingcolisa umphezulu, zibarhintyele kwi-weld kwaye zibangele iziphene ezifana ne-porosity.

• Ucoceko lubalulekile:Umphezulu kufuneka ungabinaoyile ngokupheleleyo, igrisi, uthuli, kunye neentsalela zokuncamathelisa.

• Indlela yokucoca:Sula indawo edibeneyo ngelaphu elingena-lint elifakwe kwi-solvent eguquguqukayo njenge-acetone okanye i-99% ye-isopropyl yotywala ngokukhawuleza phambi kwe-welding.

Ukulawula uMatshini: Ukuphucula iiParamitha ze-Welding eziphambili

Ukufezekisa i-weld egqibeleleyo kufuna ukulungelelanisa izinto ezininzi ezidibeneyo.

IParameter Triad: Amandla, Isantya, kunye neNdawo ekuJoliswe kuyo

Ezi zicwangciso zintathu ngokudibeneyo zimisela igalelo lamandla kunye neprofayili ye-weld.

• Amandla eLaser (W):Amandla aphezulu enza ukuba kungene okunzulu kunye nezantya ezikhawulezayo. Nangona kunjalo, amandla agqithisileyo anokubangela ukutshiswa kwezinto ezincinci.

• Isantya seWelding (mm/s):Izantya ezikhawulezayo zinciphisa igalelo lobushushu kunye nokuphazamiseka. Ukuba isantya siphezulu kakhulu kwinqanaba lamandla, kunokubangela ukungena okungaphelelanga.

• Indawo ekugxilwe kuyo:Oku kulungelelanisa ubungakanani bendawo yelaser kunye nokuxinana kwamandla. Ugxininiso kumphezulu ludala eyona weld inzulu, imxinwa. Ugxininiso ngaphezulu komphezulu (i-positive defocus) yenza i-weld ebanzi, engenanzulu ye-cosmetic. Ugxininiso olungaphantsi komphezulu (negative defocus) lunokuphucula ukungena kwizinto ezishinyeneyo.

UKhetho lweGesi yokuKhusela: IArgon vs. Nitrogen

Irhasi yokukhusela ikhusela i-weld pool etyhidiweyo ekungcolisekeni kwe-atmospheric kwaye izinzisa inkqubo.

• IArgon (Ar):Olona khetho luqhelekileyo, ukubonelela ngokhuseleko oluhle kakhulu kunye nokuvelisa i-welds ezinzileyo, ecocekileyo.

• Nitrogen (N2):Idla ngokukhethwa kwintsimbi engatyiwayo, njengoko inokomeleza uxhathiso lwelungu lokugqibela lokutya.

• Umgangatho wohambo:Umyinge wokuhamba kufuneka uphuculwe. Kuncinci kakhulu kuya kusilela ukukhusela i-weld, ngelixa kuninzi kunokudala isiphithiphithi kunye nokuzoba kwizinto ezingcolisayo. Izinga lokuhamba kwe-10 ukuya kwi-25 ilitha ngomzuzu (L / min) luhlobo lokuqala oluqhelekileyo.

Amanqaku okuQalisa iParameter: Itheyibhile yeReferensi

Oku kulandelayo ngamanqaku okuqalisa ngokubanzi kwi-welding 304/316 austenitic stainless steel. Soloko uqhuba iimvavanyo kwizinto ezilahliweyo ukuze ulungelelanise isicelo sakho esithile.

Ulawulo loMgangatho: Isikhokelo sokuCwangcisa iNgxaki kwiziphene eziqhelekileyo

Nokuba kukho inkqubo echanekileyo, iziphene zingenzeka. Ukuqonda unobangela wabo sisitshixo sokuthintela.

Ukuchonga iziphene ze-Laser Welding eziqhelekileyo

• I-Porosity:Amaqamza amancinci erhasi avaleleke kwiweld, edla ngokubangelwa kukungcoliseka komphezulu okanye ukuhamba kwerhasi ngendlela engafanelekanga.

• Ukuqhekeka okushushu:Ukuqhekeka kwe-Centerline okubumba njengoko i-weld iqina, ngamanye amaxesha ngenxa yokwakheka kwezinto okanye uxinzelelo oluphezulu lwe-thermal.

• Ukungena okungaphelelanga:I-weld iyasilela ukudityaniswa kubunzulu obudibeneyo bubonke, ngokuqhelekileyo ukusuka kumandla angonelanga okanye isantya esigqithisileyo.

• I-Undercut:I-groove inyibilika kwisiseko sesinyithi kumda we-weld, ehlala ibangelwa isantya esiphezulu okanye i-gap enkulu.

• I-Spatter:Amathontsi anyibilikisiweyo akhutshiweyo kwidama le-weld, ngokuqhelekileyo ukusuka kuxinzelelo olugqithisileyo lwamandla okanye ukungcoliseka komhlaba.

Itshathi yokulungisa ingxaki: oonobangela kunye nezisombululo

Amanyathelo okugqibela: Ukucocwa kwe-Post-Weld kunye ne-Passivation

Inkqubo yokuwelda iyonakalisa kanye iipropathi ezenza intsimbi engatyiwayo ibe "ingenasici." Ukuzibuyisela linyathelo lokugqibela elisisinyanzelo.

Kutheni ungatsibi Unyango lwasemva kweWeld

Ubushushu obuvela kwi-welding buyatshabalalisa umaleko ongabonakaliyo, okhuselayo wechromium-oxide kumphezulu wentsimbi. Oku kushiya i-weld kunye ne-HAZ eyingqongileyo isesichengeni somhlwa kunye nomhlwa.

Iindlela zePassivation zicacisiwe

I-Passivation lunyango lwekhemikhali olususa ungcoliseko olungaphezulu kwaye lunceda ukuguqula i-robust, i-uniform chromium-oxide layer.

• Ukuvunwa kwemichiza:Indlela yemveli kusetyenziswa iiasidi ezinobungozi ezifana ne-nitric kunye ne-hydrofluoric acid ukucoca kunye nokudlula umphezulu.

• Ukucocwa kweElectrochemical:Indlela yanamhlanje, ekhuselekileyo, kunye nekhawulezayo esebenzisa ulwelo lwe-electrolytic oluthambileyo kunye ne-low-voltage yangoku ukucoca kunye nokudlula i-weld kwinqanaba elinye.

Ukhuseleko kuQala: Izilumkiso eziBalulekileyo kwi-Laser Welding

Ubume obunamandla belaser welding buzisa iingozi ezinzulu zomsebenzi ezifuna imigaqo engqongqo yokhuseleko.

Ingozi efihlakeleyo: Hexavalent Chromium (Cr(VI)) Umsi

Xa intsimbi engenastainless ifudunyezwa kumaqondo obushushu e-welding, ichromium kwialloyi inokwenza i-chromium enehexavalent (Cr(VI)), ephuma emoyeni kumsi.

• Imingcipheko yeMpilo:I-Cr(VI) yi-carcinogen eyaziwayo yomntu edityaniswe nomngcipheko owonyukayo womhlaza wemiphunga. Kwakhona kunokubangela ukuphefumla kakhulu, ulusu, nokucaphuka kwamehlo.

• Imida yokuvezwa:I-OSHA imisela uMda wokuBonelela oVunyiweyo ongqongqo (PEL) we-5 micrograms nge-cubic meter yomoya (5 µg/m³) ye-Cr(VI).

Imilinganiselo yoKhuseleko ebalulekileyo

• Ulawulo lobuNjineli:Eyona ndlela isebenzayo yokukhusela abasebenzi kukubamba ingozi kwindawo yayo. Ukusebenza okuphezuluinkqubo yokutsalwa komsinge-multi-stage HEPA filter kubalulekile ukubamba amasuntswana e-ultrafine eveliswa yi-laser welding.

• Isixhobo soKhuseleko soMntu (PPE):Bonke abasebenzi abakuloo ndawo kufuneka banxibe iiglasi zokhuseleko lwelaser ezilinganiswe kubude obuthile belaser. Ukuba ukutsalwa komphunga akukwazi ukunciphisa ukuba sesichengeni ngaphantsi kwe-PEL, iziphefumli ezivunyiweyo ziyafuneka. Umsebenzi we-welding kufuneka kwakhona uqhutywe ngaphakathi kwendawo evaliweyo yokukhanya kunye ne-interlocks yokukhusela ukukhusela ukuvezwa kwebhamu ngengozi.

Imibuzo Ebuzwa Rhoqo (FAQ)

Loluphi olona hlobo lulungileyo lwelaser lokuwelda intsimbi engatyiwayo?

I-Fiber lasers lolona khetho lulungileyo ngenxa yobude bawo obufutshane, obufunxwa lula yintsimbi engatyiwayo, kunye nomgangatho wabo obalaseleyo womgangatho wolawulo oluchanekileyo.

Ngaba unokuweldla i-laser ubutyebe obahlukeneyo bentsimbi engatyiwayo kunye?

Ewe, i-laser welding isebenza kakhulu ekudibaniseni ubukhulu obungafaniyo kunye nokugqwetheka okuncinci kwaye akukho kutshisa kwindawo encinci, umsebenzi onzima kakhulu nge-TIG welding.

Ngaba i-filler wire iyimfuneko kwi-laser welding steel stainless steel?

Amaxesha amaninzi, hayi. I-laser welding inokuvelisa i-welds eqinile, engena ngokupheleleyo ngaphandle kwezinto zokuzalisa (i-autogenously), eyenza inkqubo ibe lula. Ucingo lokuzalisa lusetyenziswa xa uyilo oludibeneyo lunomsantsa omkhulu okanye xa kufuneka iipropati ezithile zetsimbi.

Bubuphi ubungqingqwa obukhulu bentsimbi engatyiwayo enokuthi idityaniswe ngelaser?

Ngeenkqubo zamandla aphezulu, kuyenzeka ukuwelda intsimbi engatyiwayo ukuya kuthi ga kwi-1/4 ″ (6mm) okanye ngqindilili kwipasi enye. Iinkqubo ze-hybrid laser-arc zinokuwelda amacandelo ngaphezulu kwe-intshi enye ubukhulu.

Ukuqukumbela

Iinzuzo ze-Laser welding ngesantya, ukuchaneka, kunye nomgangatho ziyenza ibe lolona khetho lubalaseleyo kwimveliso yentsimbi yanamhlanje. Ivelisa amajoyina anamandla, ahlambulukileyo kunye nokugqwetheka okungenakuphikiswa, ukugcina ukunyaniseka kwezinto kunye nokubonakala.

Nangona kunjalo, ukuphumeza ezi ziphumo zikumgangatho wehlabathi kuxhomekeke kwindlela epheleleyo. Impumelelo kukuphela kwekhonkco lokuvelisa oluchanekileyo-ukusuka ekulungiseleleni ngokubambisana ngokucokisekileyo kunye nolawulo olucwangcisiweyo lwepharamitha ukuya kwi-post-weld passivation enyanzelekileyo kunye nokuzinikela okungagungqiyo kukhuseleko. Ngokufunda le nkqubo, unokuvula inqanaba elitsha lokusebenza kakuhle kunye nomgangatho kwimisebenzi yakho.