The Research Of MIG-ultrasonic Hybrid Welding System

MIG is the metal inert gas welding, while in Europe, the MIG welding is knownas MIG/MAG welding or MIG welding. Since its inception, owing to its highdeposition efficiency, stable welding quality, all-position welding characteristics canbe of great concern, which has been widely used in the actual production. This paperpresents a new welding method, namely the combination of ultrasonic vibration andMIG welding, the welding process, the ultrasonic vibration is applied to the end ofthe welding nozzle, by the transmission of ultrasonic energy then acting on the wire.which has a certain influence on the droplet transfer and arc shape; what’s more,promoting the droplet transfer, improving the weld efficiency.For the welding method of MIG compound ultrasonic,designed a set ofultrasonic MIG-hybrid welding system. The whole system is mainly composed ofthree parts: the mobile device for welding, welding experimental platform and controlsystem. The mobile device for welding acts on the welding workpiece in order to amoving of horizontal and linear and uniform, according to a comprehensivecomparison of transmission mode and drive mode, we choose a one-dimensional ballscrew slide as the actuator device; at the same time,equipped with57mm two-phasehybrid stepping motor as the driving mechanism. The overall size of the weldingexperimental platform is60cm*50cm*80cm (length*width*height), which iscomposed of equilateral hole angle structures and mainly used for fixing the torch andultrasonic vibration device, for convenience,I have designed three sets of specialfixture fixed in position. The design of control system is based on single chip,thoughthe transmission of step-pulse from drive gets the rotation of stepper motor driver.Toachieve open and stop operating screw slide, I adopt the delay of the time-interrupt. Inthe process of welding, first of all, starting the motor let the workpiece moving, afterthe workpiece at a suit place; then open the switch of the torch and ultrasonic device,when the welding path is completed, closing the switch; at last,the motor stops.After the welding parameters of35groups were compared with conventionalMIG and MIG-ultrasonic hybird welding, observing the change of the forming and joint size of welding surface. The experimental results show that, when the weldingcurrent is large, welding bead width increased, penetration depth decreased,melting area being more larger, the expand the scope of cathode clean area, whosereflect the expand the radial shape arc of the side of ultrasonic vibration to promotethe droplet transfer. In addition, the weld surface ripple disappear, become smoothand clean.Finally, a preliminary analysis of the causes of arc shape change and droplettransfer frequency increased is due to the effects of ultrasonic vibration by producinga transverse shear working on the wire. Separately from the arc force and dropletforce model, owing to the transverse shear break the original force balance, lead tothe arc expansion to both radial sides, and promote the droplet transfer.