焊接參數(shù)設(shè)置指引

1、焊接參數(shù)選用規(guī)定WELDING PARAMETER CHART一.概述本指導(dǎo)書為車身車間焊接工程師進(jìn)行焊接參數(shù)調(diào) 節(jié)提供參考。適用范圍本指導(dǎo)書適用于車身車間焊接質(zhì)量控制-1 -/ 11錯誤樂指定書簽焊接參數(shù)選用規(guī)定WELDING PARAMETER CHARTDT的選擇Figure 2-1: Determining Thickness (DT)DT=B=CA-C<BDT=A=CABC#7DT=A=B#10DT=AB<A=CDT=A=CA.基本參數(shù)的選擇-2 -/ 11錯誤樂指定書簽焊接參數(shù)選用規(guī)定WELDING PARAMETER CHART低碳鋼1、 非鍍層鋼板與非鍍層鋼板的焊接

2、（B-B）MFDC （中頻直流）DT Range(mmLWeld Force(kN)Weld Current(kA)Number of ImpulsesImpulse Weld Time Ims)Cool Time(ms1Hold Time(ms)0 65 - 0.792,08.011500400.80 - 1,092.68.011500401.10 - 1.292.68.511700401 30 - 1.593.69.012000401.60-1,893.610.02120201001 90 - 2.094.010.53100201002.10-2.394.011.0312020ioo12.

3、40-2.594.011.53130401802.60 - 3.005.012.03130401803.01 - 3.505.012.5412040180：AC 50Hz (交流)DT Range(mm)Weld Force(kN)Weld Current(kA)Number of PulsesPulse Weld Time (cy)Cool Time(cy)Hold： Time(cy)0.65-0.792.08.018020 80 - 1.092.68.013021 10- 1.292.68.518021.30- 1.59369.0110021 60 1.893.610.026151.90-

4、2.094.010.535152J0-2.394.011.036152 40 -2.594.011.545292.60 -3 005.012.045293.01 . 3.505.012.546292、 非鍍層鋼板與鍍鋅鋼板的焊接（B-G）-3 -/ 11錯誤樂指定書簽焊接參數(shù)選用規(guī)定WELDING PARAMETER CHARTMFDCDT Range(mm)WeldForce(kN)Weld Current(kA)Number of ImpulsesImpulse Weld Time (ms)Cool Time(ms)Hold Time(ms)0 65-0.792.09.011700400.

5、80 . 1.092.69。11700401.10-1.292.69.51200Q401.30 - L593.610.0212020401 60 - 1.893.6P 10.53100201001.90-2,094,01t03120201002.10-2.394.011.54100201002.40-2.594.012.04120401802.60-3.005,012.54120401803.01 -3505.013.0413040180AC 50HzDT Range(mm)Weld Force(kN)Weld Current(kA)Number of PulsesPulse Weld Tim

6、e (cy)Cool Time(cy)Hold Time(cy>0.65-0.792,09.01g020.80- 1.092.69.01902L10 - 1.292,69.5110021.30 - 1.593.610.026121.60 - 1.893.610.535151.90 -2 094.0117036152.10-2.394.011.545152.40 - 2 594.012.046292.60 - 3 005.012.546293.01 - 3.505.013.047293、 鍍鋅鋼板和鍍鋅鋼板的焊接 （G-G）MFDC-4 -/ 11錯誤樂指定書簽焊接參數(shù)選用規(guī)定WELDIN

7、G PARAMETER CHARTDT Range(mm)Weld Force(kN)Weld Current(kA)Number ofImpulsesImpulse Weld Time (ms)Cool Time(ms)Hold Time(ms)0.65 - 0.792.010.012300400.80 - 1.092.610.0I2300401.10 - 1.292.610.512700401.30 - 1.593.6111.0312020100 J1.60 - 1.893.61 1/53130401001.90 -2.094.012.04120401002,10-2.394.012.54

8、130401002.40-2.594,013.05120401802.60-3.005.013.5512040_803.01 - 3.505.014.051304018dAC 50HzDT Range(mm)Weld Force(kN)Weld Current(kA)Number of PulsesPulse Weld Time (cy)Cool Time(cy)Hold Time(cy>0.65-0.792.010.01I2020.80- 1.092.610.01121021.10 - L292.610,5114021 30 - 1.593.611.03611 51.60- 1.893

9、.611.537251.90-2 094.012.046252.10-2.394.012.547P 2F 52.40-2.594.013.056292.60 - 3.005.013.556293.01 -3.505.014.05129-5 -/ 11錯誤樂指定書簽焊接參數(shù)選用規(guī)定WELDING PARAMETER CHART高強(qiáng)鋼及超高強(qiáng)鋼1、 非鍍層鋼板與非鍍層鋼板的焊接(VB-VB)MFDCDT Range(mm)Weld Force(kN)Weld Current(kA)Number of ImpulsesImpulse Weld Time (m動Cool Time(ms)IHold T

10、ime(ms)0.65-0.792.08.0115002500.80 - 1.092.68.01150°2501.10 - 1.292.68.5117002501.30-1.593.69.01200025。1.60 - 1.893.610.02120202501 .90 -2.094.010.53100202502.10-2.394.011.03120202502.40-2.594.011,53130402502.60-3.005.012.03130402503.01 -3 505.012.5412040250AC 50 HzDT RangeJmmLWeld Force(KN)Wel

11、d Current(kA)Number of PulsesPulse Weld Time (cy)Cool Time(cy)Hold Time(cy)0 65- 0.792.08.0180130.80-1.092.68.0180131J0- 1.292.68.5190131.30 - 1.593.69.01100131.60-1,893.6W.O261131.90 - 2.094.010,5351132.10 -2.394.011.0361132.40-2.594.011.5452132.60 - 3.005.012.0452133.01 - 3.505.012.546213-6 -/ 11錯

12、誤樂指定書簽焊接參數(shù)選用規(guī)定WELDING PARAMETER CHART2、 非鍍層鋼板與鍍層鋼板的焊接 (VB-VG)MFDCDT Range(mm)Weld Force(kN)Weld Current(kA)Number of ImpulsesImpulse Weld Time (ms)Cool Time(ms)Hold Time(ms)0 65 - 0 792,09,0117002500 .80 - 1.092.69.0I117廠0P 2501.10 - 1.29269.5120002501.30 - 1.5936100212020_2501.60* 1.893.610 5310020

13、國。1.90 2.094.011.03120202502. IO - 2.394.0115410020_2502.40 - 2.594。12.0A12040P 2502.60 - 3.005.012.541204D2503.01 - 3.505.013 04130 ：40250AC 50HzDT Range(mm)Weld Force(kN)Weld Current(kA)Number of PulsesPulse Weld Time (cy)Cool Time(cy)Hold Time(cy)0 65 -0.792.09.0190130 80 - 1.092.69.0190131.10-1.

14、292.69.51IO0131 30 - 1.593.610.0261131.60- I 893.610.535131.90-2994.011.0361132.10-2.394.011.5451132.40-2.594.012.0462132.60 - 3.005.012.5462133.01-3505.013.0417213-7 -/ 11錯誤樂指定書簽焊接參數(shù)選用規(guī)定WELDING PARAMETER CHART3、 鍍層鋼板與鍍層鋼板的焊接(VG-VG)MFDCDT Range(mm)Weld Force(kN)Weld Current(kA)Number of ImpulsesImpu

15、lse Weld Time (ms)Cool Time(ms)Hold Time(ms)0.65-0.792.010.0123002500.80 - 1.092.610.0123002501.10 - 1.292.610.5127002501,30 - 1.593,611.0312020250|Weld Scl1.60 - 1.893.611.53130I 402501.90-2.094.012.04120402502.10-2394,012.54130402502.40 -2.594.013.j5120r 402502.60-3.005,013.55120402503.01 -3.505.0

16、14.0513040250AC 50 HzDT RangemmWeld Force(kN)WeldCurrent(kA)Number of PulsesPulse Weld Timfr («y)Cool Time(cy)Hold Time(cy)0 65-0792010.01120130.80-1.0910,0112013j1 10-1.292610 51146131 SO- 1.593611.03 161-131.60-1.893611,531213 JI 90-2 094012 046T132.10-2.394.012.54 17213 12.40-2,594013.056213

17、2.60-3,005013.5562133.0 I -3.505.014.05112131附注：1.根據(jù)GWS1-SECTION A制定以上焊接參數(shù)。工程師可參考以上表格設(shè)置基本焊接參數(shù)。但在生產(chǎn)中，可根據(jù)實(shí)際情況，焊接參數(shù)的上下限允許有 +/-10%的浮動范圍。2. 對于MFDC,焊接參數(shù)設(shè)置中電流可以根據(jù)表格內(nèi)的數(shù)值下降500A-8 -/ 11錯誤樂指定書簽焊接參數(shù)選用規(guī)定WELDING PARAMETER CHART3. 每個焊接程序預(yù)壓時間為35CY （伺服焊槍預(yù)壓時間為500ms）預(yù)熱和后熱總的時間為6CY,對于CY的調(diào)整可根據(jù)實(shí)際情況在+/-10%范圍內(nèi)浮動，另考慮預(yù)熱和后熱對主要

18、是改 善焊接條件為主要目的，對于電流設(shè)置由各車間工程師可以根據(jù)現(xiàn)場情況來設(shè)置。4. 對于焊接時間，考慮到現(xiàn)場的實(shí)際情況，故只要求總時間在規(guī)定范圍內(nèi)，對焊接的脈沖數(shù)、每脈沖的焊接時間及相鄰脈沖之間的冷卻時間，可由焊接工程師根據(jù)實(shí)際情況自行設(shè) 定。5. FCS的確定請參閱標(biāo)準(zhǔn) Ws1-SectA。6. 當(dāng)總材料厚度超過GMT板厚度的2.5倍時，可考慮將焊接時間需要提高 0-2個等級，或提高焊接電流0-1000安培。7. 當(dāng)使用平頭或大曲率球面電極時，可考慮將焊接時間需要提高0-2個等級，或提高焊接電流0-1000安培。8. 上表所列焊接電流，假定是在 GMT< 1.84mm時選用size 2

19、（小16）的圓頂電極帽（eg,MWP-6287） , GMT>1.85mm 時選用 size 3（小19）的圓頂電極帽（e.g.,MWP-6288）。如果使 用尖頂或“順電極帽，則焊接電流需要分別增加大約 1000 A 0如是高強(qiáng)鋼，則GMT 1.65為 切換線。B遞增電流的選擇遞增電流的選擇適用于花”19的電極帽STEP 1STEP 2STEP 3STEP 4STEP 5遞增電流200400700300400焊接點(diǎn)數(shù)100300500600200適用寸0L 5的電極帽STEF 1STEF 2STEP 3STEP 4STEP 5逢堵電流LQO200300100100焊接點(diǎn)數(shù)5015Q20

20、080050附注：一、以上的STEPPER設(shè)置，是針對不能進(jìn)行修磨的常規(guī)電極帽，供焊接工程師參考。具體的遞 增電流和焊接點(diǎn)數(shù)點(diǎn)數(shù)，可根據(jù)現(xiàn)場的實(shí)際情況容許有 +/-20%的浮動。二、如果焊機(jī)內(nèi)STEP為10個階段的，則將上面五個階段值設(shè)置在第 1、2、3、4、10階段 三、特殊電極帽的STEPPER設(shè)置，根據(jù)實(shí)際焊接質(zhì)量進(jìn)行設(shè)置。-9 -/ 11錯誤樂指定書簽焊接參數(shù)選用規(guī)定WELDING PARAMETER CHARTC保護(hù)氣體電弧焊焊接參數(shù)的選擇板厚焊絲直徑焊接電流焊接電壓焊接速 度干X 度氣體流 量平角焊搭接接頭0.652.00.5-1.235-12017 2115356-136152.04.50.8-1.2100 23020 2620 306-1310 15以上是電弧焊焊接參數(shù)，可作為現(xiàn)場焊接參數(shù)制定的參考，工程師在編制焊接程序時可根 據(jù)實(shí)際情況在± 10%范圍內(nèi)進(jìn)行調(diào)整。D螺柱焊接參數(shù)選用參考焊接參數(shù)計算的基本公式：1、焊接0.8mm裸鋼板的焊接參數(shù)焊接電流：（螺柱端面直徑-1 ） *100 （A）焊接時間：（螺柱端面直徑-1 ） *4（MS2、焊接0.8mm鍍鋅鋼板的焊接參數(shù)焊接電流：（螺柱端面直徑）*100 （A）焊接時間：（螺柱端面直徑）*4（MS3、提弧距離=1.2mm （伺服次I槍為0.8-1.2 ）4