焊接参数设置指南

焊接参数选用规定一.概述本指导书为车身车间焊接工程师进行焊接参数调节提供参考。适用范围本指导书适用于车身车间焊接质量控制。焊接参数选用规定DT的选择Figure2-1:DeterminingThickness(DT)A.基本参数的选择焊接参数选用规定WELDINGPARAMETERCHART1、 非镀层钢板与非镀层钢板的焊接(B-B)MFDC(中频直流)DTRange(mm)WeldForce(kN)WeldCurrent(kA)NumberofImpulsesImpulseWeldTime(ms)CoolTime(ms)HoldTime(ms)0.65-0.7EI2.08.011500400.80-1.OEI2.68.0I150040I.I0-1.2EI2.68.51170040I.3O-1.5EI3.69.0I2000401.60-1.893.610.0212020100I.EIO-2.0EI4.010.53100201002.10-2.3EI4.011.03120201002.40-2.5EI4.011.53130401802.60-3.005.012.03130401803.01-3.505.012.5412040180AC50Hz(交流)DTRange(mm)WeldForce(kN)WeldCurrent(kA)NumberofPulsesPulseWeldTime{cy)CoolTime(W)HoldTime(cy)0.65-0.792.08.018020.80-1.0EI2.68.018021.10-1.2EI2.68.518021.30-1.593.69.0110021.60-1.893.610.026151.EI0-2.0EI4.010.53515210-2.394.011.036152.40-2.5EI4.011.545292.60-3.005.012.045293.01-3.505.012.546292、 非镀层钢板与镀锌钢板的焊接(B-G)WELDINGPARAMETERCHARTbbMFDCDTRange(mm)WeldForce(kN)WeldCurrent(kA)NumberofImpulsesImpulseWeldTime(ms)CoolTime(ms)HoldTime(ms)0.65-0.7EI2.0S.OI1700400.80-1.092.69.01170040I.IO-1.2EI269.512000401.30-1.5EI3.610.0212020401.60-1.8EI3.610.5310020100I.EIO-2.0EI4.011.03120201002.I0-2.3EI4.011.54100201002.40-2.5EI4.012.04120401802.60-3.005.012.54120401803.01-3.505.013.0413040180AC50HzDTRange(mm)WeldForce(kN)WeldCurrent(kA)NumbercfPulsesPulseWeldTime(cy}CoolTime(cv)HoldTime(cv)0.65-0.7U2.09.019020.80-1.0EI2.69.019021.10-1.2EI2.69.5110021.30-1.吴l3.610.026121.60-1.893.610.535151.EI0-2.0EI4.011.03615210-2.394.011.545152.40-2.5EI4.012.046292.60-3.005一012.546293.01-3.505.013.0472g3、 镀锌钢板和镀锌钢板的焊接(G-G)MFDC

WELDINGPARAMETERCHARTbbDTRange(mm)WeldForce(kN)WeldCurrent(kA)NumberofImpulsesImpulseWeldTime(ms)CoolTimeg)HoldTime(ms)0.65-0.7EI2.010.012300400.80-1.OEI2.610.01230040I.IO-1.2EI2.610.512700401.30-1.5EI3.611.03120201001.60-1.8EI3.611.53130401001.90-2.094.012.04120401002.I0-2.3EI4.012.54130401002.40-2.5EI4.013.05120401802.60-3.005.013.55120401803.01-3.505.014.0S13040180AC50HzDTRange(mm)WeldForce(kN)WeldCurrent(kA)NumberofPulsesPulseWeldTime(cy)CoolTime(cy)HoldTime(cy)0.65-0.7EI2.010.0112020.80-1,0£l2.610.0112021.10-1.292.610.5114021.30-1.5EI3.611.036151.60-1.893.611.531251.EI0-2.0EI4.012.046252.10-2.3EI4.012.547252.40-2.5EI4.013.0562El2.60-3.005.013.556293.01-3.505.014.0572El二.高强钢及超高强钢1、 非镀层钢板与非镀层钢板的焊接(VB-VB)MFDCDTRange(mm)WeldFcrce(kN)WeldCurrent(kA)NumbercfImpulsesImpulseWeldTime(ms)CcolTime(ms)HoldTime(ms)0.65-0.7EI2.08.0115002500.80-1.OEI2.68.011500250I.IO-1.2EI268.5117002501.30-1.5EI3.69.0120002501.60-1.8EI3.610.0212020250I.EIO-2.0EI4.010.5310020250210-2.394.011.03120202502.40-2.5EI4.011.53130402502.60-3.005.012.03130402503.01-3.505.012.5412040250AC50HzDTRange(mm)WeldForce(kN)WeldCurrent(kA)NumberofPulsesPulseWeldTime(cy)CoolTime(cy)HoldTime(cy)0.65-0.7EI2.08.0180130.80-1.OEl2.68.0180131.10-1.2EI2.68.5190131.30-1.5EI3.69.01100131.60-1.893.610.0261131.EI0-2.0EI4.010.535113210-2.394.011.0361132.40-2.5EI4.011.5452132.60-3.005.012.0452133.01-3.505.012.5462132、 非镀层钢板与镀层钢板的焊接(VB-VG)MFDCDTRange(mm)WeldForce(kN)WeldCurrent(kA)NumberofImpulsesImpulseWeldTime(ms)CoolTime(ms)HoldTime(ms)0.65-07EI2.05.0117002500.80-1.OEI2.6g.oI17002501.10-1.292.69.5120002501.30-1.5EI3.610021202。2501.60-1.8U3.6105310020250190-2.094.011.031202D2502.10-2.394.011.541002。25Q2.40-2.594.012041204C-25D2.eo-3.005.0125412040250S.D1-3.5D5.013.0413040250AC50HzDTRange(mm)WeldForce(kN)WeldCurrent(kA)NumberofPulsesPulseWeldTime(cy}CoolTime(cy)HoldTime(cy)0.65-0.7EI2.09.01g0130.80-1.092.69.0190131.10-1.2EI2.69.51100131.30-1.5EI3.610.0261131.60-1.8EI3.610.5351131.EI0-2.0EI4.011.0361132.I0-2.3EI4.011.5451132.40-2.5EI4.012.0462132.60-3.005.012.5462133.01-3.505.013.047213

3、 镀层钢板与镀层钢板的焊接(VG-VG)MFDCDTRange(mm)WeldForce(kN)WeldCurrent(kA}NumberofImpulsesImpulseWeldTime(ms)CoolTime忡司HoldTime{ms)0.65-0.7EI2.010.0123002500.80-1.OEI2.610.012300250I.IO-1.2EI2.610.5127002501.30-1.5EI3.611.03120202501.60-1.8EI3.611.5313040250I.EIO-2.0EI4.012.04120402602.I0-2.3EI4.012.54130402502.40-2.5EI4.013.05120402502.60-3.005.013.55120402503.01-3.505.014.0513040250AC50HzDTRange(mm)WeldForce(kN)WeldCurrent(kA)NumbercfPulsesPulseWeldTime(cy)CoolTime(cy)HoldTime(cy)0.65-0.7EI2.010.0112□130.80-1.0&2.61C.01120131.10-1.292.610.51140131.30-1.5&3.611.0361131.60-1.8&3.611.5312131.EI0-2.0S4.012.046213210-2.394.012.547213240-2.594.013.0562132.60-3.005.013.5562133.01-3.505.014.05?2I3附注：根据GWS1-SECTIONA制定以上焊接参数。工程师可参考以上表格设置基本焊接参数。但在生产中，可根据实际情况，焊接参数的上下限允许有+/-10%的浮动范围。对于MFDC,焊接参数设置中电流可以根据表格内的数值下降500A焊接参数选用规定每个焊接程序预压时间为35CY(伺服焊枪预压时间为500ms)预热和后热总的时间为6CY,对于CY的调整可根据实际情况在+/-10%范围内浮动，另考虑预热和后热对主要是改善焊接条件为主要目的，对于电流设置由各车间工程师可以根据现场情况来设置。对于焊接时间，考虑到现场的实际情况，故只要求总时间在规定范围内，对焊接的脉冲数、每脉冲的焊接时间及相邻脉冲之间的冷却时间，可由焊接工程师根据实际情况自行设定。FCS的确定请参阅标准Ws1-SectA。当总材料厚度超过GMT板厚度的2.5倍时，可考虑将焊接时间需要提高0-2个等级，或提高焊接电流0-1000安培。当使用平头或大曲率球面电极时，可考虑将焊接时间需要提高0-2个等级，或提高焊接电流0-1000安培。上表所列焊接电流，假定是在GMTW1.84mm时选用size2(616)的圆顶电极帽(e.g.,MWP-6287)，GMT>1.85mm时选用size3(619)的圆顶电极帽(e.g.,MWP-6288)。如果使用尖顶或“A”电极帽，则焊接电流需要分别增加大约1000A。如是高强钢，则GMT1.65为切换线。B递增电流的选择递增电流的选择适用于徂6/19的电极帽STEP1STEP2STEP3STEP4STEF5逆增电流200硕700BOO400焊接点数100300500600200适用于。均的龟极帽STEF1STEP2STEP3STEP4STEF5IS增电蔬100200300400100焊接点数5015020030050附注：一、 以上的STEPPER设置，是针对不能进行修磨的常规电极帽，供焊接工程师参考。具体的递增电流和焊接点数点数，可根据现场的实际情况容许有+/-20%的浮动。二、 如果焊机内STEP为10个阶段的，则将上面五个阶段值设置在第1、2、3、4、10阶段。三、 特殊电极帽的STEPPER设置，根据实际焊接质量进行设置。焊接参数选用规定C保护气体电弧焊焊接参数的选择板厚焊丝直径焊接电流焊接电压焊接速度干伸长度气体流量平角焊搭接接头0.652.00.5-1.235-12017〜2115〜356-136〜152.04.50.8-1.2100〜23020〜2620〜306-1310〜15以上是电孤焊焊接参数，可作为现场焊接参数制定的参考，工程师在编制焊接程序时可根据实际情况在±10%范围内进行调整。D螺柱焊接参数选用参考焊接参数计算的基本公式：1、 焊接0.8mm裸钢板的焊接参数焊接电流：（螺柱端面直径-1）*100（A）焊接时间：（螺柱端面直径-1）*4（MS）2、 焊接0.8mm镀锌钢板的焊接参数焊接电流：（螺