How does Plasma Tunnel Welding Machine handle dissimilar metal welding?
When dealing with interface problems in dissimilar metal welding, Plasma Tunnel Welding Machine can solve them in three aspects: process parameter control, interface pretreatment, and equipment technology optimization. First of all, in terms of process, the pulse plasma welding mode is adopted to control the heat input by adjusting the ratio of peak current (100-200A) to base current (30-80A) to reduce the generation of brittle phases at the interface. For example, when welding dissimilar metals of copper and steel, setting the pulse frequency to 20-30Hz and the duty cycle to 40%-60% can reduce the tendency of overheating on the copper side. At the same time, the arc energy distribution can be controlled by adjusting the ion gas flow rate (1.0-1.8L/min) to avoid excessive melting of the metal on one side.
In terms of interface pretreatment, the surface of dissimilar metals is plated (such as nickel or copper transition layer), and the thickness is controlled at 5-10μm, and the interface metallurgical reaction is alleviated through the intermediate layer. Before welding, laser cleaning is used to remove the surface oxide film (residual oxide content <5μg/cm²), and mechanical grinding is used to make the surface roughness Ra≤1.6μm to enhance the interface bonding strength.
In terms of equipment technology, it is equipped with a double-wire feeding system, which can simultaneously fill the transition wire (such as silver-based or nickel-based wire) with good compatibility with the metals on both sides during the welding process. The diameter is 0.8-1.2mm, and the interface component ratio is adjusted by accurately controlling the wire feeding speed (2-5m/min). At the same time, the arc swing function (swing amplitude 1-3mm, frequency 5-10Hz) is used to evenly mix the molten pool metal and reduce component segregation, thereby effectively improving the interface bonding quality of dissimilar metal welding.
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