【Rayclass | 锐课堂】第7期：攻破铝合金的焊接难点——轨道列车的激光焊接工艺
关注我们焊接领域解决方案的朋友们，一定没有错过近期的这样两篇好文：
【Rayclass | 锐课堂】第4期：让1mm以内紫铜焊接变得更加简单高效
我们收到留言问道：
We received a message and asked:
？
是否有其他材质的焊接解决方案？
Is there a welding solution for other materials?
？
除了实验方案，是否有真实使用案例？
In addition to the test plan, is there a real use case?
今天
我们不仅带来了6000W光纤激光器
焊接铝合金的解决方案
而且
不仅仅停留在理论和实验
是真实应用在火车车身上的案例
话不多说
【Rayclass | 锐课堂】第7期
现在开讲
Today
we not only bring a 6000W fiber laser
welding aluminum alloy solution
but also
provide the case of real application
on the train manufacture
随着我国城市规模的不断扩大，城市经济的快速发展和现代化水平的不断提高，轨道交通已成为我国各城市公共交通体系的最佳选择。
With the continuous expansion of Chinese urban scale, urban economy and the modernization level, rail transit has become the best choice for public transportation system in China.
作为运送乘客的重要工具，列车的制造水平直接影响着轨道交通的发展规模和速度，各种先进的技术也在轨道交通车辆制造中得到了广泛应用。其中，激光焊接技术在不锈钢车体制造过程中更具有得天独厚的优势，必将成为未来焊接之利器。
As an important tool for transporting, the manufacturing level of trains directly affects the scale and speed of rail transit development. Various advanced technologies have also been widely used in the manufacture of rail transit vehicles. Among them, laser welding technology has a unique advantage in the manufacturing process of stainless steel, and it will become a shining pearl for future welding.
轨道列车轻量化，特别是高铁和双层客车以及地铁列车的轻量化是轨道运输现代化的中心议题，而大量采用铝合金材料是提高车辆轻量化的有效途径。
The lightweight of rail trains, especially the high-speed rail and double-decker buses and the weight reduction of subway trains are central issues in the modernization of rail transport, and the large use of aluminum alloy materials is the most effective way to improve vehicle lightweight.
为了适应车辆设计的要求，铝合金材料被大量用于高铁、地铁等的制造。
To meet the requirements of vehicle design, aluminum alloy materials are widely used in the manufacture of high-speed rail, subway, etc.
但你是否知道，铝合金却是公认的“难焊”材料：
However, aluminum alloys are recognized as difficult-to-weld materials. The main performances are,
○
焊缝易变性；
weld variability.
○
焊缝接头软化严重，强度降低；
weld joints are softened, and the strength is reduced.
○
焊缝内部气孔多、易开裂；
the weld has many internal pores and is easy to crack.
○
焊缝易塌陷，导致咬边严重。
the weld seam is liable to collapse, resulting in serious undercut.
既然铝合金焊接有这么多缺陷，
那我们是否无计可施？
在轨道交通制造过程中，对于激光焊接的焊缝有着严格的要求，需要达到激光焊接标准《GB/T 22085.2-2008/ISO 13919-2,2001》，具体有以下几个方面内容：
In the rail manufacturing process, there are strict requirements for laser welding seam, and it is necessary to meet the laser welding standard "GB/T 22085.2-2008/ISO 13919-2, 2001". Specifically, there are the following aspects,
○
焊缝内部气孔大小及数量；
the size and number of pores inside the welding seam.
○
焊缝裂纹；
welding seam crack.
○
焊缝成型——余高、塌陷、咬边等。
welding seam forming - residual height, collapse, undercut, etc.
使用常规的单激光焊接很难满足要求，尤其是焊接相对较厚的3～6mm铝合金材料。为了能够解决该问题，现有两种方案可以推荐给大家。
It is difficult to meet the requirements using conventional single laser welding, especially for welding relatively thick 3 to 6 mm aluminum alloy materials. To solve this problem, there are two existing solutions that can be recommended.
方案一：激光填丝焊接
Laser Welding with Filler Wire
基本设备：RFL-C6000激光器、焊接头、送丝机、软枪头
Basic equipment: RFL-C6000 laser, welding head, wire feeder, soft shot
焊接平台：（如下图所示）
Welding platform: robot
焊接参数Welding parameters：
板厚（mm）
Plate thickness
激光功率（w）
Laser power
焊接速度（m/min）
Welding speed
送丝速度（m/min）
Wire feed speed
3
5000
3
4
4
5800
3
5
焊接效果Welding effect：
3mm铝合金对接接头
3mm aluminum alloy butt joint
正面
反面
4mm铝合金对接接头
4mm aluminum alloy butt joint
正面
反面
方案二：激光-电弧复合焊接
Laser-arc Hybrid Welding
基本设备：RFL-C6000激光器、焊接头、焊机、送丝机、硬枪头
Basic equipment: RFL-C6000 laser, welding head, welding machine, wire feeder, hard shot
焊接平台：（如下图所示）
Welding platform: robot
焊接参数Welding parameters：
板厚（mm）
Plate thickness
激光功率（w）
Laser power
焊接速度（m/min）
Welding speed
送丝速度（m/min）
Wire feed speed
5
4000
1.5
6
6
4500
1.5
7
焊接效果Welding effect：
5mm铝合金对接接头
5mm aluminum alloy butt joint
正面
反面
6mm铝合金对接接头
6mm aluminum alloy butt joint
正面
反面
两种应用方案均在我司终端客户（青岛某轨道交通设备制造公司）进行了装机应用，其生产的产品其中之一就是火车头部件，如下图所示，取得了较好的焊接效果。
Both application solutions were installed in our terminal customers (a rail transit equipment manufacturing company in Qingdao). One of the products produced was the locomotive parts, as shown in the figure below, and achieved good welding results.
对比两种方案
其应用范围各有不同
Comparing the two options
the scope of application is different
1
焊接同样厚度的材料，激光填丝焊需要更高一些的激光功率，但是可以获得更高的焊接效率，在焊接较薄的板材时有更大优势；对于RFL-C6000的激光器，激光填丝焊接铝合金的推荐厚度为1～4mm；
For materials with the same thickness of welding, Laser Welding with Filler Wire requires higher laser power, but higher welding efficiency can be obtained, and it has a greater advantage in welding thinner plates. For the RFL-C6000 laser, the recommended thickness of the aluminum alloy is 1 to 4 mm.
2
激光-电弧复合焊接因为有电弧热参入焊接过程，所以相对可以用较低的激光功率取得同样的焊缝熔深，但是为了保证焊缝成型，其焊接速度不能过快，而且设备成本会有一定的增加，不过激光-电弧复合焊接能够完成较厚的铝合金的焊接；对于RFL-C6000的激光器，激光-电弧复合焊接铝合金的推荐厚度为4～7mm。
Laser-arc Hybrid Welding can achieve the same weld penetration with lower laser power because of the arc heat into the welding process. However, to ensure the formation of the weld, the welding speed cannot be too fast, and the equipment cost will increase, but the Laser-arc Hybrid welding can complete the welding of the thick aluminum alloy. For the RFL-C6000 laser, the recommended thickness of the aluminum alloy is 4 to 7 mm.
激光焊与传统的电弧焊和电阻焊相比，具有焊接速度快，生产效率高，焊缝和热影响区窄，焊接变形小等优点。因此，在轨道交通领域对不锈钢车体激光焊接技术的研究已受到越来越多的重视。
Compared with traditional arc welding and resistance welding, laser welding has the advantages of fast welding speed, high production efficiency, narrow weld and heat affected zone, and small welding deformation. Therefore, research on the laser welding technology of stainless steel body in the field of rail transportation has received increasingly attention.
除了车身“面子问题”，未来我们还会用激光焊来解决轨道交通的关键零部件加工制造问题。我们也期待，未来能用激光技术助力我国轨道交通乃至整个制造业的快速发展。
We will use laser welding to solve the problem for the manufacturing of key components of rail transit. We also expect that laser technology will be used to help the rapid development of China's rail transit and the entire manufacturing industry in the future.
寒冬来临
全国大部分地区即将进入“零下”
【Rayclass | 锐课堂】
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