气电横焊工艺技术改进

为了解决船舶横位置对接焊缝中存在的焊接效率低、质量可靠性差等问题，开展了针对船舶对接焊缝的气电横焊技术研究。通过对水冷铜滑块、陶瓷衬垫等关键条件的设计优化，将气电焊技术扩展至船舶建造横位置对接焊缝的焊接。随后对坡口形式、焊枪位置、摆动幅度等关键焊接工艺参数进行了合理的设计，结合船舶结构特点及工艺覆盖的要求，进行了3组不同板厚的横位置对接焊试验，测量了不同板厚的抗拉强度、硬度及冲击吸收能量，以验证工艺的可行性。结果表明，由于焊缝表面采用水冷铜滑块强制成形及焊缝根部采用陶瓷衬垫成形的影响，得到的焊缝成形美观，避免了焊后打磨处理，大大减轻了劳动强度；各个板厚的抗拉强度、硬度及冲击吸收能量等试验数据均满足船级社规范要求，并具有较大的工艺裕量；热输入最高可达93 kJ/cm，焊接效率相较于常规FCAW横焊提高了8倍左右。 创新点： (1)对陶瓷衬垫以及水冷铜滑块设计优化，有效解决了船舶横位置对接焊缝中根部焊缝的熔合问题。(2)将气电横焊技术用于船舶横位置对接焊缝的焊接，提高了横位置对接焊缝的焊接效率。

Improvement of gas-electric transverse welding process technology

In order to solve the problems of low welding efficiency and poor quality reliability in ship butt seam welding, this paper carries out research on gas-electric transverse welding technology for ship butt seams. By optimizing the design of key equipment such as water-cooled copper slider and ceramic liner, the gas-electric welding technology is extended to ship construction transverse position butt joints. Subsequently, the key welding parameters such as bevel form, torch position and swing amplitude were reasonably set, and three sets of cross-position butt welding tests with different plate thicknesses were conducted in combination with the structural characteristics of the ship and the requirements of process coverage, and the tensile strength, hardness and impact work of different plate thicknesses were measured to verify the feasibility of the process. The experimental results show that, due to the influence of water-cooled copper slider forced forming on the weld surface and ceramic liner forming at the root of the weld, the resulting weld is beautifully formed, avoiding post-weld grinding and greatly reducing labor intensity; the experimental data of tensile strength, hardness and impact work of each plate thickness meet the requirements of classification society specifications and have a large process margin; the maximum linear energy can reach 93 kJ/cm, welding efficiency can be increased by up to 8 times compared to conventional FCAW cross-welding. Highlights: (1) Optimization of ceramic liner and water-cooled copper slider design, effectively solving the fusion problem of root welds in transverse position butt seam welding of ships.(2) The use of gas-electric transverse welding technology for the welding of transverse posi.The use of gas-electric transverse welding technology for the welding of transverse position butt welds on ships has improved the welding efficiency of transverse position butt welds.