深熔K-TIG辅助焊接全数字磁控电源系统及增韧机理研究

doi:10.3901/JME.2025.18.086

摘要/Abstract

摘要： 针对锁孔效应深熔氩弧焊(Keyhole tungsten inert gas welding，K-TIG)热输入大、焊接接头冲击韧性低等问题，采用外加纵向交变磁场的方式加以优化。首先分析了励磁线圈的物理特性，针对性地研制了一台深熔K-TIG辅助焊接全数字磁控电源。结合一系列先进电能变换技术，不仅实现了宽频率和幅值范围的正弦交流电能输出，而且功率因数高，对电网的谐波污染小，功率开关管工作于软开关状态。该磁控电源输出电能供给励磁线圈，产生强度和方向呈正弦规律变化的外加纵向交变磁场，与电弧等离子体及带电熔池金属相互作用，促使电弧旋转，对熔池产生周期性的搅拌作用，显著降低了深熔K-TIG焊的熔透电流，热输入降低了14.5%，不仅晶粒得以细化，而且焊接接头冲击韧性提升高达96%，且抗拉强度也有一定提高。

关键词: 磁控电源, K-TIG, 数字控制, 晶粒细化, 交变磁场

Abstract: In order to tackle problems like large heat input and low impact toughness of the welded joint in Keyhole Tungsten Inert Gas (K-TIG) welding, an alternating magnetic field with longitudinal direction for K-TIG welding was proposed in this research. The characteristics of the excitation coil were analyzed, and a digital magnetic control power supply was developed. The newly developed magnetic control power supply boasts the capability to output a broad spectrum of frequencies and amplitudes, featuring a high power factor and a soft-switching working state for the MOSFET. By inducing an external longitudinal alternating magnetic field with sinusoidal changes in intensity and direction, the K-TIG welding arc rotates and agitates the weld pool, leading to a significant reduction in penetration current. Moreover, since there is a 14.5% reduction in heat input compared to K-TIG welding without magnetic assistance, the grains in the welding joint are refined, and the impact toughness of the welded joint is enhanced by up to 96%. At the same time, tensile strength is also improved to a certain extent.

Key words: magnetic control power supply, K-TIG, digital control, gain refine, alternating magnetic field

中图分类号:

TG439

詹家通, 石永华, 刘志忠, 叶雄越, 梁焯永. 深熔K-TIG辅助焊接全数字磁控电源系统及增韧机理研究[J]. 机械工程学报, 2025, 61(18): 86-97.

ZHAN Jiatong, SHI Yonghua, LIU Zhizhong, YE Xiongyue, LIANG Zhuoyong. Study on Digital Magnetic Control Power Supply for Deep Penetration K-TIG Assisted Welding and Toughening Mechanism[J]. Journal of Mechanical Engineering, 2025, 61(18): 86-97.

参考文献

[1] 陈金荣，石永华，占爱文. 纵向磁场对K-TIG焊接电弧形态及焊缝成形的影响[J]. 热加工工艺，2023，52(5)：25-30. CHEN Jinrong，SHI Yonghua，ZHAN Aiwen. Effect of longitudinal magnetic field on arc shape and weld formation of K-TIG welding[J]. Hot Working Technology，2023，52(5)：25-30.
[2] XU T，SHI Y H，JIANG Z X，et al. Improvement of cryogenic toughness for 9% Ni steel keyhole TIG butt- welded joints with a Ni interlayer[J]. Materials Science and Engineering：A，2022，835：1-17.
[3] CUI S W，SHI Y H，SUN K，et al. Microstructure evolution and mechanical properties of keyhole deep penetration TIG welds of S32101 duplex stainless steel[J]. Materials Science and Engineering A，2018，709：214-222.
[4] CUI S W，SHI Y H，ZHU T，et al. Microstructure，texture，and mechanical properties of Ti-6Al-4V joints by K-TIG welding[J]. Journal of Manufacturing Processes，2019，37：418-424.
[5] SU L H，FEI Z Y，DAVIS B，et al. Digital image correlation study on tensile properties of high strength quenched and tempered steel weld joints prepared by K-TIG and GMAW[J]. Materials Science and Engineering A-Structural Materials Properties Microstructure and Processing，2021，827：1-15.
[6] 段士华. 3mm厚高强钢K-TIG焊接工艺及电弧特性研究[D]. 哈尔滨：哈尔滨工业大学，2022. DUAN Shihua. Research on process and arc characteristics in K-TIG welding of high strength steel with thickness of three millimeters[D]. Harbin：Harbin Institute of Technology，2022.
[7] Cui Y X，Shi Y H，Ning Q，et al. Investigation into keyhole-weld pool dynamic behaviors based on HDR vision sensing of real-time K-TIG welding process through a steel/glass sandwich[J]. Advances in Manufacturing，2021，9(1)：136-144.
[8] Cui Y X，Kang Y P，SHI Y H，et al. Investigation into the arc profiles and penetration ability of axial magnetic field-enhanced K-TIG welding by means of a specially designed sandwich[J]. Journal of Manufacturing Processes，2021，68：32-41.
[9] 张抱日，顾盛勇，石永华. 基于焊缝熔透检测的机器人深熔K-TIG焊接系统[J]. 机械工程学报，2019，55(17)：14-21. ZHANG Baori，GU Shengyong，SHI Yonghua. Robotic deep penetration K-TIG welding system based on weld penetration detection[J]. Journal of Mechanical Engineering，2019，55(17)：14-21.
[10] Shi Y H，Wang Z S，Liang Z Y，et al. A welding seam tracking algorithm adaptive to variable groove type：An interactive segmentation passive vision method[J]. Optics & Laser Technology，2025，181：111861.
[11] Lin Z L，Shi Y H，Wang Z S，et al，Intelligent seam tracking of an ultranarrow gap during K-TIG welding：A hybrid CNN and adaptive ROI operation algorithm[J]. IEEE Transactions on Instrumentation and Measurement，2023，72：5001314.
[12] Chen Y K，Shi Y H，Cui Y X，et al. Narrow gap deviation detection in Keyhole TIG welding using image processing method based on Mask-RCNN model[J]. The International Journal of Advanced Manufacturing Technology，2021，112：2015-2025.
[13] WANG Y P，QI B J，CONG B Q，et al. Keyhole welding of AA2219 aluminum alloy with double-pulsed variable polarity gas tungsten arc welding[J]. Journal of Manufacturing Processes，2018，34：179-186.
[14] 齐铂金，杨舟，杨明轩，等. 超高频脉冲GTAW工艺特性分析[J]. 机械工程学报，2016，52(2)：26-32. QI Bojin，YANG Zhou，YANG Mingxuan，et al. Analysis on characteristic of ultra high frequency pulsed gas tungsten arc welding process[J]. Journal of Mechanical Engineering，2016，52(2)：26-32.
[15] 姜自昊，肖宏，曾才有，等. 中厚铝合金DP-VPTIG焊接深熔小孔作用机制研究[J/OL]. 机械工程学报，2024：1-8[2024-12-20].http://kns.cnki.net/kcms/detail/11.2187.TH.20240722.1242.008.html. JIANG Zihao，XIAO Hong，ZENG Caiyou，et al. Study on the keyhole effects in DP-VPTIG welding of medium-thick aluminum alloys[J]. Journal of Mechanical Engineering，2024：1-8.[2024-12-20]. http://kns.cnki.net/ kcms/detail/11.2187.TH.20240722.1242.008.html.
[16] 张刚，徐梓龙，石玗，等. 双频调制脉冲TIG打底焊电弧-熔池行为分析[J]. 机械工程学报，2023，59(12)：245-252. ZHANG Gang，XU Zilong，SHI Yu，et al. Analysis of arc-weld pool behavior of double-frequency modulated pulse TIG root pass welding[J]. Journal of Mechanical Engineering，2023，59(12)：245-252.
[17] 王振民，唐嘉健，潘晓浩，等. 全数字大功率交流脉冲埋弧焊接电源[J]. 机械工程学报，2023，59(2)：96-103. WANG Zhenmin，TANG Jiajian，PAN Xiaohao，et al. Digital high-power AC-pulse submerged arc welding power source[J]. Journal of Mechanical Engineering，2023，59(2)：96-103.
[18] LIU Z M，FANG Y X，CUI S L，et al. Sustaining the open keyhole in slow-falling current edge during K-TIG process：Principle and parameters[J]. International Journal of Heat and Mass Transfer，2017，112：255-266.
[19] 赵建强，石永华，詹家通，等. 外加轴向磁场K-TIG横焊电弧形态及焊缝成形[J]. 焊接，2023(4)：1-6. ZHAO Jianqiang，SHI Yonghua，ZHAN Jiatong，et al. Transverse welding arc shape and joint formation in K-TIG welding under axial magnetic field[J]. Welding & Joining，2023(4)：1-6.
[20] 肖磊，樊丁，黄健康. 交变磁场作用下的GTAW非稳态电弧数值模拟[J]. 机械工程学报，2018，54(16)：79-85. XIAO Lei，FAN Ding，HUANG Jiankang. Numerical simulation of unsteady arc in GTAW with alternate axial magnetic field[J]. Journal of Mechanical Engineering，2018，54(16)：79-85.
[21] XIAO L，FAN D，HUANG J K. Numerical study on arc plasma behaviors in GMAW with applied axial magnetic field[J]. Journal of the Physical Society of Japan，2019，88：074502.
[22] XIAO L，FAN D，HUANG J K. Tungsten cathode-arc plasma-weld pool interaction in the magnetically rotated or deflected gas tungsten arc welding configuration[J]. Journal of Manufacturing Processes，2018，32：127-137.
[23] LIU S，LIU Z M，ZHAO X C，et al. Influence of cusp magnetic field configuration on K-TIG welding arc penetration behavior[J]. Journal of Manufacturing Processes，2020，53：229-237.
[24] XU T，Shi Y H，Jiang Z X，et al. An extraordinary improvement in cryogenic toughness of K-TIG welded 9Ni steel joint assisted by alternating axial magnetic field[J]. Journal of Materials Research and Technology，2023，25：3071-3077.
[25] 任永锦. 基于80C196KC控制的交变磁控电源研究[D].兰州：兰州理工大学，2019. REN Yongjin. Research on alternating current magnetron power supply based on 80C196KC[D]. Lanzhou：Lanzhou University of Technology，2019.
[26] 杜茵茵. 交变磁控电源研制及优化设计[D]. 兰州：兰州理工大学，2022. DU Yinyin. Development and optimal design of alternating magnetron power supply[D]. Lanzhou：Lanzhou University of Technology，2021.
[27] WU K Y，WANG Y F，CAO X W，et al. GMAW power supply based on parallel full-bridge LLC resonant converter[J]. International Journal of Electronics，2022，109(12)：2135-2157.
[28] WU K Y，HUANG H，CHEN Z W，et al. Novel and simplified implementation of digital high-power pulsed MIG welding power supply with LLC resonant converter[J]. Circuit World，2022，50(1)：54-66.
[29] WU K Y，LIU Z T，CHEN Q R，et al. Digital MIG welding power supply system based on bridgeless PFC and LLC[J]. Electrical Engineering，2024，10(1)：1-16.
[30] XU T，SHI Y H，CUI Y X，et al. Effects of magnetic fields in arc welding，laser welding，and resistance spot welding：A review[J]. Advanced Engineering Materials，2023，25(5)：1-22.