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Kemppi 窄間隙焊接技術

作者:西安鈞同  來源:西安鈞同   更新時間:2020-06-23  閱讀數:1975

Kemppi 窄間隙焊接技術 

Kemppi's Reduced Gap Technology (RGT) challenges conventional joint design principles

Kemppi 的縮小間隙技術(RGT)挑戰了傳統的接頭設計原則。

 Reducing the groove angle can add significantly to efficiency and productivity of welding of heavy metal structures. Conventional narrow gap welding can be applied with most welding processes, but it has a disadvantage: it is practically impossible without equipment especially designed for the application. To overcome this constraint, Kemppi has developed a new solution, Reduced Gap Technology (RGT). This technology allows reliable and efficient narrow gap welding with no need for special equipment or accessories for material thicknesses of up to 30 mm. The solution combines intelligent arc control with Kemppi's high-tech power source, wire feeder and mechanization equipment.

 

 減小坡口角度可顯著提高重型金屬結構焊接的效率和生產率。傳統的窄間隙焊接可以應用于大多數焊接工藝,但它有一個缺點:沒有專門為應用設計的設備幾乎是不可能的。為了克服這一限制,Kemppi開發了一種新的解決方案,即縮小間隙技術(RGT)。這種技術允許可靠和有效的窄間隙焊接,不需要特殊設備或附件,材料厚度可達30 mm。該解決方案將智能電弧控制與Kemppi的高科技電源、送絲機和機械化設備相結合。

RGT changes our understanding of narrow gap welding

RGT改變了我們對窄間隙焊接的理解

In narrow gap welding, the groove angle is typically less than 20 degrees instead of the normal 45 to 60 degrees. This decreases the number of weld passes needed to complete the joint, and it reduces the welding time and the consumption of filler material. It also makes the material less prone to distortion. In other words, reducing the groove volume has a multitude of positive effects on welding quality, efficiency and productivity.

在窄間隙焊接中,坡口角度通常小于20度,而不是通常的4560度。這減少了完成接頭所需的焊道數量,減少了焊接時間和填充材料的消耗。它也使材料不易變形。換言之,減小坡口體積對焊接質量、效率和生產率有許多積極的影響。

However, reducing the groove angle also brings more challenges to welding. In a narrow groove, the welding arc is difficult to control. This may result in quality issues, unless you invest in welding torch and accessories that are specially designed for the application.

然而,減小坡口角度也給焊接帶來了更多的挑戰。在間隙坡口內,焊接電弧難以控制。這可能導致質量問題,除非您投資于專門為應用設計的焊槍和附件。

 

 

 

 

 

 

 

 

 

 

 

 

For narrow gap MIG/MAG applications with material thickness below 30 mm, Kemppi's Reduced Gap Technology (RGT) is an ideal new solution. It allows using standard welding equipment and welding application software for narrow gap welding of butt joints and fillet joints. The RGT solution combines the benefits of Wise application software, FastMig or X8 MIG Welder equipment, and A5 MIG Rail System 2500 welding mechanization system.

對于材料厚度低于30 mm的窄間隙MIG/MAG應用,Kemppi的縮小間隙技術(RGT)是一種理想的新解決方案。它允許使用標準焊接設備和焊接應用軟件進行對接接頭和角接接頭的窄間隙焊接。RGT解決方案結合了WISE應用軟件、FASTMIGX8 MIG焊機設備和A5 MIG軌道系統2500焊接機械化系統的優點。

A control system ensures consistent power and precisely focused arc

控制系統確保穩定的功率和精確的聚焦電弧。

At the core of Kemppi's RGT solution is the most advanced arc control system available, which delivers consistent arc power at contact-tip-to-work distances of up to about 30 mm. In addition, the system adaptively adjusts the arc to keep its energy density at the maximum level (see Figure 1). A short, stable, and efficient arc minimizes the risk of incomplete penetration and lack of fusion, because the arc is always focused precisely at the desired point in the groove. The RGT control system enables reliable narrow gap welding of materials with thicknesses up to 30 mm, without the need for special equipment or accessories.

Kemppi的RGT解決方案的核心是最先進的電弧控制系統,使得導電嘴到工作最大距離接近30mm的情況下,依然能夠提供一致的電弧力量。此外,系統自適應調整電弧,使其能量密度保持在最大水平(見圖1)。短、穩定和有效的電弧可將未焊透和未熔合的風險降至最低,因為電弧總是精確聚焦在坡口中所需的點上。RGT控制系統能夠可靠地對厚度達30 mm的材料進行窄間隙焊接,無需特殊設備或附件。

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Figure 1. The principle of the RGT control system is that WisePenetration maintains consistent arc power regardless of variation in the contact-tip-to-work distance while WiseFusion provides adaptive regulation that keeps the arc focused and optimally short. In X8 MIG Welder, all of this functionality is combined in WisePenetration+  function.

圖1.RGT控制系統的原理是,無論接觸端到工作距離的變化如何,智能熔透都能保持一致的電弧功率,而智能熔透則提供自適應調節,以保持電弧的聚焦和最佳的短路。在X8 MIG焊機中,所有這些功能都結合在WISENTRATION+功能中。

Kemppi’s RGT narrow gap welding solution – for many direct benefits

KemppiRGT窄間隙焊接解決方案——有許多直接好處

Narrow gap welding provides many benefits, and in addition to those, Kemppi’s RGT solution offers many further advantages, for still greater cost savings and added value:

窄間隙焊接提供了許多好處,除此之外,KemppiRGT解決方案還提供了許多進一步的優勢,以實現更大的成本節約和附加值:

?Investment costs are low, since no special equipment is needed in welding with material thicknesses under 30 mm.

?投資成本低,因為材料厚度小于30 mm的焊接不需要特殊設備。

?WiseFusion keeps the arc stable, improves the control of the weld pool and reduces the magnetic arc blow. This decreases the risk of incomplete penetration and lack of fusion, and it results in lower repair costs.

?WiseFusion可保持電弧穩定,改善焊接熔池的控制,減少電弧吹掃。這降低了未焊透和未熔合的風險,從而降低了維修成本。

 

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?WisePenetration keeps the arc power consistent, regardless of variations in the contact-tip- to-work distance. This enables a higher welding speed and deposition rate, and it results in lower labor costs.

?WisePenetration使電弧功率保持一致,無論接觸端到工作距離的變化如何。這使得焊接速度和沉積速度更高,從而降低了人工成本。

?The high energy density of WiseFusion minimizes heat input, which improves impact toughness with high-strength steels and reduces deformation, so there is less need for straightening.

?WiseFusion的高能量密度使熱輸入最小化,從而提高了高強度鋼的沖擊韌性,減少了變形,因此對矯直的需求更少。

?WiseFusion keeps the arc length stable. The user doesn’t need to adjust it, for less hassle and a better arc time ratio.

?WISEFusion保持弧長穩定。用戶不需要調整它,以減少麻煩和更好的弧時比。

 Savings potential illustrated by a preliminary WPS

初步WPS說明節約的潛力

Kemppi’s RGT narrow gap welding solution has produced good results with a 20° groove angle and material thickness of up to 30 mm. The pWPS shown in Figure 2 is approved via tests in compliance with the standard on welding procedure qualification testing. It provides all the information required for the utilization of Kemppi's narrow gap solution in production welding. It was created for a butt joint with a 20° groove angle and a thickness of 25 mm. Figure 3 shows a calculation of the savings potential that the method yields. The smaller, 20° groove angle will result in a groove volume about 25% lower than with a 45° groove angle.

KemppiRGT窄間隙焊接解決方案在20°坡口和材料厚度高達30mm的情況下產生了良好的效果。圖2所示的PWP通過符合焊接工藝評定試驗標準的試驗獲得批準。它提供了在生產焊接中使用Kemppi窄間隙解決方案所需的所有信息。它是為具有20°坡口和25 mm厚度的對接接頭而創建的。圖3顯示了該方法產生的節省潛力的計算。較小的20°坡口將導致槽體積比45°坡口小25%。

 


Figure 2. Preliminary Welding Procedure Specification (pWPS) for narrow gap welding of a butt joint.

圖2.對接接頭窄間隙焊接的初步焊接工藝規范(PWPS)

Five weld passes

Groove dimensions

Current 45° groove

New 20° groove

Material thickness

s = 25.0 mm

s = 25.0 mm

Bevel angle

α/2 = 22.5°

α/2 = 10°

Root gap

b = 4.0 mm

b = 6.0 mm

Root face

c = 1.5 mm

c = 0 mm

Root reinforcement

y = 2.0 mm

y = 2.0 mm

Reinforcement

d = 2.0 mm

d = 2.0 mm

Groove volume

A = 372 mm2

A = 281 mm2

Weight of weld metal

G = 2.9 kg/m

G = 2.2 kg/m

Figure 3. Benefits of Kemppi's RGT narrow gap solution in terms of groove volume and filler material consumption. The 45° angle includes 1.5 mm root faces (c). The difference in the root gap is also considered (b). The 20° groove has sharp root edges.

3.KemppiRGT窄間隙解決方案在槽體積和填充材料消耗方面的優勢。45°角包括1.5 mm的根部面(C)。還考慮了根部間隙的差異(b)。20°槽有鋒利的根部邊緣。

 

Device and software requirements with the RGT solution

RGT解決方案的設備和軟件需求

The narrow gap welding solution is available for Kemppi’s FastMig KMS, FastMig M, FastMig Pulse, FastMig X and X8 MIG Welder equipment. Use of this solution requires that the machine is equipped with the WisePenetration and WiseFusion application software. With X8 MIG Welder, only WisePenetration+ is needed, as it includes all necessary functions. The required Wise application software products are easy to purchase and install after machine purchase.

窄間隙焊接解決方案適用于KemppiFastMig KMS、FastMig M、FastMig Pulse、FastMig XX8 MIG焊機設備。使用此解決方案需要機器配備WISE透和WISEFusion應用軟件。對于X8 MIG焊機,只需要WISENTRATION+,因為它包括所有必要的功能。所需的WISE應用軟件產品易于在機器購買后購買和安裝。肯倍氬弧焊,肯倍手工焊,肯倍MIG焊

Arctech Helsinki Shipyard uses Kemppi's technology

赫爾辛基ARCTECH造船廠采用KEMPI的技術

Among the users of Kemppi's RGT narrow gap welding solution is Arctech Helsinki Shipyard (see Figure 5), which has managed to reduce the groove angles from 45 to 30 degrees with the new technology. The shipyard uses WPS documents based on welding procedure qualification records (WPQRs) for mechanized welding in the construction of icebreakers. “Adoption of the new technology has brought us cost savings and improved the welding quality,” says Arctech’s Hull Production Manager Niko Rautiainen. “Welding work has gained speed, because the groove volume and the number of beads to be welded have decreased. Also less filler material is needed. Mechanization has also improved the arc time ratio and made the welds more consistent in quality,” he adds.

KemppiRGT窄間隙焊接解決方案的用戶包括Arctech赫爾辛基造船廠(見圖4),該造船廠利用新技術將槽角從45度減少到30度。在破冰船建造過程中,造船廠使用基于焊接工藝評定記錄(WPQRS)的WPS文件進行機械化焊接。ARCTECH的船體生產經理Niko Rautiainen說:采用新技術為我們節約了成本,提高了焊接質量。”“由于槽體積和待焊焊道數量減少,焊接工作加快了。也需要更少的填充材料。機械化還提高了電弧時間比,使焊接質量更加一致,他補充說。

 


Figure 4. Welding of block sections of an icebreaker, using Kemppi's narrow gap welding solution, with Kemppi's A5 MIG Rail System 2500 and FastMig M 520 power source. Photos: Arctech Helsinki Shipyard.

圖4.使用Kemppi的窄間隙焊接解決方案,使用Kemppi的A5 MIG軌道系統2500和Fastmig M 520電源焊接破冰船的分段。照片:赫爾辛基Arctech造船廠。 肯倍氬弧焊,肯倍手工焊,肯倍MIG焊

Summary

總結

The RGT narrow gap welding solution developed by Kemppi is based on an intelligent control system that keeps the arc power consistent regardless of the variations in the contact-tip-to- work distance. In addition, the system controls the arc adaptively, to keep its energy density at the maximum level. A short, stable, and efficient arc minimizes the risk of incomplete penetration and lack of fusion, because the arc is always focused precisely at the desired point in the groove. The control system enables reliable narrow gap welding of materials with thicknesses of up to 30 mm, with a 20° groove angle, from one side, and without the need for special equipment or accessories. Smaller groove volume yields significant cost savings through reductions in welding time and filler-material consumption. The method is excellently suited to both butt and fillet joints, no matter the welding position.

Kemppi開發的RGT窄間隙焊接解決方案基于一個智能控制系統,該系統可使電弧功率保持一致,而不管接觸端到工作距離的變化。此外,系統對電弧進行自適應控制,使其能量密度保持在最大水平。短、穩定和有效的電弧可將未焊透和未熔合的風險降至最低,因為電弧總是精確聚焦在坡口中所需的點上。該控制系統能夠可靠地從一側以20°槽角、厚度不超過30 mm的材料進行窄間隙焊接,無需特殊設備或附件。通過減少焊接時間和填充材料消耗,較小的槽體積可顯著節約成本。無論焊接位置如何,該方法都非常適用于對接接頭和角接接頭。

肯倍Master Tig氬弧焊機,肯倍Master手工焊機,肯倍Pulse鋁焊機,肯倍A3機器人焊機,肯倍A7機器人焊機,肯倍KempArc機器人焊機,肯倍MIG焊機,肯倍X8 MIG焊機,肯倍不銹鋼MIG焊機,肯倍MAG焊機, 西安肯倍焊機,武功肯倍焊機,渭南肯倍焊機,寶雞肯倍焊機,漢中肯倍焊機,咸陽肯倍焊機,延安肯倍焊機,榆林肯倍焊機,鄠邑肯倍焊機,長安肯倍焊機。

 

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