N'ichepụta ụlọ ọrụ ọgbara ọhụrụ, teknụzụ Resistance Spot Welding (RSW) abụrụla usoro bụ isi maka ijikọ akụrụngwa igwe anaghị agba nchara na ngalaba dịka ụgbọ ala, ikuku ikuku, na ngwa ụlọ, n'ihi arụmọrụ ya na ntụkwasị obi ya.
Agbanyeghị, ogo weld ntụpọ na-adabere na nha, ọdịdị, na iguzosi ike n'ezi ihe nke Weld Nugget hibere n'oge usoro a. Weld nugget bụ "mpaghara ngwakọta" dị oke egwu na-ejikọta mpempe akwụkwọ ígwè abụọ ma ọ bụ karịa, na àgwà ya na-ekpebi ike nkwonkwo na ntụkwasị obi n'usoro.
Ntuziaka a na-achọ ịnye ndị injinia na ndị na-ahụ maka ọrụ aka usoro na usoro bara uru maka ịlele àgwà igwe anaghị agba nchara weld nugget. Ọ na-ekpuchi atụmatụ zuru oke site na ihe nrịbama isi yana nnwale na-adịghị emebi emebi ruo na njikarịcha oke, na-ahụ na nkwonkwo welded ruru ụkpụrụ ụlọ ọrụ kachasị elu.
I. Ngosipụta isi na ụkpụrụ ụlọ ọrụ maka ogo Weld Nugget
Iji nyochaa ogo nke igwe anaghị agba nchara weld nugget, a ga-ebu ụzọ guzobe ụkpụrụ nha doro anya. A na-ekpebikarị ịdị mma nugget site na njiri isi atọ ndị a:
1. Nugget dayameta
Dayameta nugget bụ ihe ngosi kachasị mkpa maka ịlele ibu{0}} ibu nke nkwonkwo. Dayameta ezughi oke na-eduga n'ibelata ike nkwonkwo na ọdịda nwere ike ịda n'okpuru nrụgide.
| Ihe ngosi nyocha | Standard Industrylọ ọrụ izugbe (Ntụaka) | Nkwanye bara uru |
| Dayameta Nugget kacha nta | Na-achọkarị $D \\ge 4\\sqrt{t}$ ($t$ bụ otu ọkpụrụkpụ mpempe akwụkwọ, na mm) | Maka mpempe akwụkwọ igwe anaghị agba nchara 1.0mm, dayameta nugget kacha nta kwesịrị ịbụ ihe na-erughị 4.0mm. |
| Ọkọlọtọ Metallographic | Ọkọlọtọ ogo nyocha metalographic: Maka ọkpụrụkpụ 3mm, dayameta nugget $\\ge 4 ederede{mm}$. | Nke a bụ uru nrụtụ aka nke nchekwa; n'ezie mmepụta kwesịrị na-ezo aka kpọmkwem ụkpụrụ dabere na ihe onwunwe na mpempe akwụkwọ ọkpụrụkpụ. |
2. Ọnụ nbanye nugget
Ọnụego ntinye bụ pasent nke ọkpụrụkpụ nugget n'ihe metụtara mkpokọta ọkpụrụkpụ nke mpempe akwụkwọ welded.
- Ọkọlọtọ chọrọ: Ọnụ ọgụgụ ntinye dị mma kwesịrị ịdị n'etiti 20% na 80%.
- Ntinye dị ala (<20%): Small contact area between the nugget and the base metal, resulting in insufficient strength.
- High Penetration (>80%): Ọ na-adị mfe ịchụpụ (spatter), ntinye oke elu, ma ọ bụ ọbụna na-ere ọkụ{1} site na, na-emetụta ọdịdị na ike ọgwụgwụ.
3. Mmejọ nke ime
Nkwarụ dị n'ime weld nugget bụ ihe egwu zoro ezo nke nwere ike ibute ọdịda nkwonkwo. Ndị a gụnyere:
- Porosity: Ọpụpụ na-etolite mgbe a na-achụpụ gas nke ọma n'oge ịgbado ọkụ.
- Ihe mgbawa: Ihe na-ebutekarị site na mgbakasị ahụ ike ọkụ ma ọ bụ ọnụego jụrụ oyi ngwa ngwa.
- Oghere Oghere Mkpọchi: Cavities a kpụrụ dị ka nugget a wụrụ awụ na-esiwanye ike ma na-ebelata.
- Oke Mpaghara Mmejọ: Ụkpụrụ ụlọ ọrụ na-achọkarị mpaghara ntụpọ ka ọ gafere 20% nke mkpokọta nugget.
II. Na-abụghị{1}}Nnwale na-emebi emebi (NDT): Nleba nke ọma na ezigbo oge{2}
Ụzọ nnwale ndị na-adịghị emebi emebi na-enye ohere 100% nyocha ngwa ngwa nke weld nugget na-emebighị akụkụ ahụ, na-eme ka ha dabara adaba maka njikwa mma n'ịntanetị na mmepụta oke{2}.
1. Nnwale Ultrasonic (UT)
UT bụ usoro NDT a na-ahụkarị maka weld ntụpọ. Ọ na-eji ngosipụta nke ebili mmiri ultrasonic na ihe dị iche iche ihe dị iche iche (dị ka eriri njikọ dị n'etiti nugget na metal base, ma ọ bụ ntụpọ) iji nyochaa nha nugget na iguzosi ike n'ezi ihe.
| Akụkụ nka nka | Nkọwa zuru ezu na ntụnye aka bara uru |
| Ụkpụrụ | Utilizes kpọmkwem echo mgbaama eme site ultrasonic ebili mmiri na rhomboid àgwà mpaghara (fusion akara) n'etiti weld nugget na isi metal. |
| Oge nke Flight (TOF) Analysis | Site n'ịtụle oge nke ụgbọ elu (TOF) mgbaàmà nke ultrasonic ebili mmiri, nugget ọkpụrụkpụ na dayameta nwere ike mere atụmatụ nke ọma. |
| Ntụaka data | Dịka ọmụmaatụ, n'otu ihe na ugboro ole, TOF nke 0.38μs nwere ike ịdekọ na dayameta nugget nke ihe dịka 4mm. Na ngwa bara uru, a ga-edozirịrị ọbá akwụkwọ ọkọlọtọ maka nhazigharị. |
| Uru | Ọsọ dị elu, na-eme ka-nyocha ahịrị; nwere mmetụta maka dayameta nugget na ntụpọ ahịrị fusion. |
2. Nnwale redio (RT)
RT na-eji ụzarị X- banye n'ime weldment. Site n'iji njiri dị iche iche nke X{{2} ray na mpaghara njupụta dị iche iche, a na-emepụta onyonyo, na-enye ohere ịhụ ntụpọ dị n'ime.
- Ngwa: Ọ dị irè nke ọma maka ịchọpụta ntụpọ n'ime volumetric dị ka porosity, cracks, na shrinkage voids.
- Uru: Na-enye ndekọ dị mma na-adịgide adịgide ma na-enye onyonyo nwere ọgụgụ isi maka nyocha ntụpọ qualitative.
- Mmachi: Ọnụ ahịa dị elu yana ezighi ezi maka nha nha nha dayameta nugget tụnyere UT.
III. Ntụle na-emebi emebi: Na-enyocha ike nkwonkwo na obere ihe
Nnwale na-emebi emebi bụ ụzọ kacha mma iji nyochaa ogo weld nugget yana arụ ọrụ nke nkwonkwo. A na-ejikarị ya maka nkwado oge nke usoro usoro yana mmepe ngwaahịa ọhụrụ.
1. Mechanical Testing
Nnwale ọrụ igwe na-enyocha ngwa ngwa{0}ikike ibu na iguzosi ike n'ezi ihe nke weld nugget.
| Ụdị ule | Ebumnuche Nlele | Usoro nnabata (Igodo) |
| Nnwale bee | Na-enyocha ike ihu ihu na dayameta nke weld nugget. | Nsonaazụ kacha mma: ndọkasị na-apụta na igwe isi (ihe nne na nna), ọ bụghị na weld nugget interface. Ọ bụrụ na nugget na-ewepụ na interface (interfacial ọdịda), a na-ewere ya na ọ gaghị anabata ya. |
| Nnwale shiee tensile | Na-enyocha oke kacha {{0}ikike ibu nke nkwonkwo. | Ike shiee a tụrụ ga-ezute ma ọ bụ gafere ihe achọrọ, na ọnọdụ ọdịda kwesịrị ịbụ mgbaka ígwè. |
2. Metallographic Analysis
Metallographic analysis bụ usoro ziri ezi maka ịlele microstructure na akụkụ nke weld nugget, na-eje ozi dị ka ntọala maka iguzobe na nyochaa usoro ịgbado ọkụ.
Usoro:
- Bee ihe nlele site na mpaghara weld.
- Bulie, gwerie, ma kpochaa ihe nlele ahụ.
- Mee etching kemịkal site na iji ihe dị ka 2% Nital (nitric acid in alcohol) iji kpughee n'ụzọ doro anya microstructure na ahịrị njikọ dị n'etiti nugget na metal base.
Njiri mara mma:
- Nleba nha: Ntụnye nkenke nke dayameta nugget na ọnụego ntinye, nke na-eje ozi dị ka ihe ndabere maka mmezi oke usoro.
- Microstructure: Nlebanya maka oke ọka, mgbawa, ma ọ bụ mpaghara anaghị etinye n'ime mpaghara nugget.
IV. Atụmatụ Ntule Welding Spot: Inweta Stable, Elu -Ọdịmma Nuggets
Nkwụsi ike nke ogo weld nugget na-adabere na njikwa ziri ezi nke parampat isi atọ: ugbu a, oge na ike.
1. Njikwa ugbu a na oge (welding ugbu a na oge)
Ugbu a bụ isi iyi ọkụ nke na-etolite nugget a wụrụ awụ, na oge na-ekpebi mkpokọta okpomọkụ.
- Ike dị ugbu a: Oke kacha mma akwadoro bụ n'etiti 7.5 kA na 8.5 kA (maka ọkpụrụkpụ igwe anaghị agba nchara). Ihe dị ugbu a nke dị oke ala agaghị etolite nnukwu nugget zuru oke; ugbu a nke dị oke elu na-adịkarị mfe ịchụpụ na ikpo ọkụ.
- Ogologo oge ịgbado ọkụ: Oke akwadoro bụ milliseconds 400 ruo 500 milliseconds. Nke a na-achọ ịhazi ngwa ngwa nucleation na mgbochi nke ikpo oke ọkụ. Maka mpempe akwụkwọ buru ibu, ọtụtụ -pulse ma ọ bụ steepụ atụmatụ ịrị elu ugbu a nwere ike ịdị mkpa iji nweta uto nugget otu.
2. Ike Calibration (Electrode Force/Pressure)
Ebumnuche nke ike electrode (nrụgide) bụ iji hụ na kọntaktị eletrik dị mma n'etiti electrodes na workpieces, na n'etiti workpieces n'onwe ha, na-egbochi ịchụpụ n'oge ịgbado ọkụ.
- Ihe ndị dị mkpa (dịka ọmụmaatụ, n'okpuru 0.5mm): A na-atụ aro nrụgide kọntaktị dị ala, dị ka gburugburu 0.3 MPa, iji zere ntinye oke.
- Akụkụ dị oke (dịka ọmụmaatụ, n'elu 1.0mm): Achọrọ nrụgide dị elu, dị ka 0.5 MPa ma ọ bụ karịa, iji hụ na kọntaktị ihu ọma zuru oke na nkesa kwụsiri ike ugbu a.
- Ndụmọdụ bara uru: Nrụgide ezughị ezu na-eduga n'ịkwụsị kọntaktị dị elu na ịchụpụ; oke nrụgide na-abawanye shunting na accelerated electrode wear.
V. Njikwa Electrode na mmejuputa nkwenye dị mma
The electrode bụ "obi" nke ntụpọ ịgbado ọkụ igwe. Ọnọdụ ya na-emetụta njupụta dị ugbu a na nkesa okpomọkụ, na-eme ka ọ dị oke mkpa iji hụ na ịdị mma weld nugget.
1. Electrode ihe na mmezi
| Akụkụ | Ndụmọdụ bara uru na usoro |
| Nhọrọ ihe | akwadoro iji ọla kọpa-Tungsten composite electrodes ma ọ bụ Chromium Zirconium Copper (CuCrZr) electrodes. Matriks ọla kọpa na-eme ka nrụpụta dị elu, ebe tungsten alloy ma ọ bụ CuCrZr na-eme ka nguzogide okpomọkụ dị elu{2} na eyi nguzogide. |
| Usoro nlekọta | Na-ehicha elu ala mgbe niile iji wepụ ihe ndị na-emerụ emerụ na oxides. Ekwesịrị idowe ihu eletrọd nke ọma. |
| Oke nnọchi | Mgbe dayameta ihu eletrọd na-eyi ma ọ bụ mebie ihe karịrị 20% nke nha mbụ, ọ ga-eyiri ma ọ bụ dochie ya ka ọ gbochie ọdịda njupụta ugbu a yana nha nju na-akwụghị ọtọ. |
| Sistemụ jụrụ oyi | Gbaa mbọ hụ na sistemu ikuku electrode na-arụ ọrụ nke ọma. akwadoro njikwa okpomoku mmiri mbata akwadoro dị n'etiti ogo 5 na ogo 30 iji gbochie ikpo oke ọkụ na nrụrụ ọkụ. |
2. Usoro Nkwenye Ogo (QA).
Ịmepụta usoro QA zuru oke dị mkpa maka ịmepụta mmepụta kwụsiri ike:
- Parameter Benchmarking: Mepụta tebụl oke ịgbado ọkụ maka nchikota igwe anaghị agba nchara (dịka ọmụmaatụ, 304/316L, ọkpụrụkpụ dị iche iche).
- Njikwa Usoro Statistical (SPC): Mejuputa usoro SPC iji nyochaa na nyochaa usoro dị ugbu a, voltaji, na ike n'ime oge-, na-enye ohere nchọpụta n'oge na mmezi nke obere usoro.
- Nhazi akụrụngwa: hazie ngwa nleba anya nke ọma dịka ammeters na ihe mmetụta nrụgide mgbe niile iji hụ na data ziri ezi.
- Ọzụzụ ndị mmadụ: Na-aga n'ihu na-azụ ndị na-arụ ọrụ ka ha nweta ikike njirimara ntụpọ yana ihe ọmụma mmezi oke.
Mmechi
N'ime ngwa ịgbado ọkụ igwe anaghị agba nchara, ịtụle ịdịmma weld nugget bụ usoro injinia na-ahazi nke gụnyere ntọala ọkọlọtọ, nyocha ziri ezi na njikwa usoro. Site n'itinye usoro na-adịghị mma nke na-adịghị emebi{1} dị ka Ultrasonic Testing for in{{2}line production, jikọtara ya na Metallographic Analysis na Mechanical Testing for periodical validation, na na-agbasosi ike na njikarịcha paramita na ụkpụrụ njikwa electrode, ndị na-emepụta nwere ike guzobe usoro njikwa mma siri ike.
Naanị site n'inweta njikwa ziri ezi n'elu weld nugget size, penetration rate, na esịtidem ntụpọ nwere ike hụ na igwe anaghị agba nchara nkwonkwo ga-enwe elu ike na-adịgide adịgide structural iguzosi ike n'ezi ihe, si otú izute kasị stringent ulo oru ngwa chọrọ.
