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At present, CO2 welding in Japan, Europe and the United States accounts for 60% to 80% of the total amount of welded metal for welding, while CO2 welding in China is still low, only 20%. One of the main reasons is insufficient understanding of the superiority and process characteristics of CO2 welding, which unduly exaggerates the inherent shortcomings of CO2 welding, and the application technology of CO2 welding is not popularized.
There are some improper understandings about CO2 welding (it has some disadvantages compared with hand arc welding and submerged arc welding): the quality of welded joints such as CO2 welding is lower than that of electrode arc welding, and the spatter is large during welding. Suitable for welding important welding products, such as boilers, pipelines, pressure vessels; CO2 welding equipment is more complex; poor wind resistance; strong arc and so on. These incorrect and inappropriate understandings hinder the widespread application of CO2 welding. Actually:
1. High efficiency of CO2 welding
(1) CO2 welding has a higher melting speed and melting coefficient. CO2 welding deposition rate is 3 kg / hr ~ 5 kg / hr, which is 1 ~ 2.25 times of electrode arc welding. The CO2 welding uses a fine wire with a diameter of 0.8 to 1.6 mm, a current density of 100 to 300 A/mm, and an electrode arc welding current density of 10 to 25 A/mm. CO2 welding arc heat concentration, melting coefficient is 1~3 times larger than electrode arc welding, which can improve work efficiency by 1~2 times;
(2) The weld bevel is generally 40~45 degrees, the pure side is larger, the gap is smaller, which is equivalent to increase the welding speed, and the welding work efficiency is increased by about 1 time;
(3) CO2 welding does not require auxiliary work such as cleaning, grinding and welding of welding rods. The auxiliary time is 50% of the electrode arc welding, thereby improving the working efficiency by 0.2 to 0.8 times.
2. CO2 welding joint quality is high
Welded low carbon steel and low alloy steel with CO2, as long as the welding material is properly matched, high quality welded joints can be obtained, and the comprehensive mechanical properties can meet or exceed the quality level of low hydrogen electrode arc welding.
CO2 welding is a low-hydrogen welding method. The content of diffusible hydrogen in the weld is much lower than that of the low-hydrogen welding rod. The possibility of white spots and hydrogen embrittlement in the weld is reduced, and the crack can be effectively prevented. CO2 welding is not sensitive to rust and moisture, and the tendency of generating pores in the weld is less than that of low-hydrogen welding rod, which is also a very valuable advantage of CO2 welding, and is the main reason for the reliable quality of CO2 welded joints;
The oxygen content and nitrogen content in the CO2 weld are comparable to those of the low hydrogen electrode weld. CO2 welding in the welding process due to the use of reliable deoxidation measures, can reduce the oxygen content in the weld to 0.02%, due to more reliable gas protection, can prevent nitrogen in the air into the pool, effectively prevent nitrogen holes Production
The current density of CO2 welding is large, the arc energy is concentrated, the heat affected zone of the weld is small, the deformation of the welded joint is small, and the ability of the welded joint to withstand the payload is improved, which is inferior to the arc welding of the electrode;
CO2 welding rationally replenishes the chemical components in the weld by welding metallurgy, and CO2 welding avoids the occurrence of weld defects such as slag inclusion, and the weld metal has good compactness.
3. The cost of CO2 welding is low
Despite the higher price of CO2 welders and welding wire, the actual cost of CO2 welding is significantly lower than that of electrode arc welding for the following reasons:
(1) Significant savings in welding consumables. Due to the small section groove form, the weld area can be reduced by 36%~54%, which can save 36%~54% of filler metal, saving the waste of welding rod and electrode head, which is the main cost reduction of CO2 welding. one of the reasons;
(2) CO2 welding can save a lot of energy. Compared with the silicon rectifier arc welder, the CO2 welder can save about 37% of electricity consumption, and saves more than 69% of electricity consumption compared with the AC arc welder;
(3) Due to the high efficiency of CO2 welding, the actual equipment station fee is reduced by 68%~80% compared with manual welding. Equipment station costs account for about 30% to 50% of welding costs. Using CO2 welding process can reduce welding cost by 20%~40%;
(4) The production efficiency of CO2 welding is high, and the actual welding time is reduced accordingly, that is, the welding labor and working hours are reduced. The total cost of welding is 10% to 16% lower than that of manual welding;
(5) CO2 welding reduces the process of cleaning and clearing the roots, and the weld grinding can be basically avoided, saving a lot of grinding wheel pieces, saving auxiliary time and assisting labor;
(6) CO2 welding deformation is small, saving the cost of correcting deformation.
In summary, CO2 welding can reduce the total cost of welding by 39.6%~78.7%, with an average reduction of 59%, and improve economic benefits.
CO2 gas shielded welding and energy saving
The application of new welding technology, new technology and new materials in engineering construction is a powerful guarantee for the safe and stable operation of enterprises, and is also a full manifestation of the strong strength of the engineering construction team. CO2 gas shielded welding is a high-efficiency, high-quality, low-cost welding method that has outstanding performance in engineering welding of large steel structures, storage tanks, towers and pipelines.