Study on Full-position Semi-automatic FCAW Process of Thick Wall Pipeline

With the continuous development of industrial technology and increasing demand, thick wall pipes are more and more widely used in petrochemical, chemical, electric power and other fields. For these thicker pipes, welding processes are generally used to connect them. In recent years, with the continuous development of modern welding technology, semi-automatic welding technology has gradually replaced manual welding, becoming a more efficient and accurate welding method. Therefore, this paper mainly studies the full-position semi-automatic FCAW process of thick wall pipeline.

I, Semi-automatic welding technology of thick wall pipeline

Semi-automatic welding technology is a technology between automatic welding technology and manual welding technology. Compared with manual welding, the automatic control information is larger, the service life is long, the stability is high, the welding quality is more reliable; Compared with automatic welding, it requires manual operation, but machine-assisted welding makes the quality of work further improved.

II, FCAW welding technology

FCAW (Flux-Cored Arc Welding) is a new semi-automatic arc welding technology developed in recent decades. It has high production efficiency and good welding quality, especially suitable for full-position welding of thick wall pipes.

Process characteristics of FCAW

The FCAW process is to cover the welded metal filling material in the cartridge core. In the welding process, no external air source is used, but the gas generated by the volatile matter in the cartridge core is used to protect the arc and weld. FCAW process is suitable for welding large diameter (≥φ8mm) and thick (≥3mm) metal materials, high efficiency, can be single-side welding and all-position welding. In the welding process of metal materials such as steel plate, plate, shaft and wheel hub, FCAW process is often used, and its advantages can be expressed as follows:

1) Fast welding speed and high production efficiency;

2) The core material of the nozzle contains a component other than molten metal, that is, a cartridge, which can provide more reinforcement;

3) Suitable for single-side welding and all-position welding, stable welding quality;

4) Welding can still be performed even under harsh conditions such as outdoor;

5) Easy to control arc, stable welding quality.

III, Optimization of FCAW process for thick wall pipeline

Although the FCAW process is widely used in the welding of thick wall pipes, there are still some problems to be solved, such as welding speed is not fast enough, weld brittleness, welding burr and other welding defects. In order to further improve welding quality and working efficiency, it is necessary to optimize the FCAW process.

IV, Conclusion

The semi-automatic FCAW process is undoubtedly a very good welding scheme, especially suitable for welding thick wall pipes. In the process of practical application, we should constantly explore optimization schemes and try new materials and technologies. It is believed that under the guidance of a new round of industrial science and technology revolution, we will see the application and development of FCAW technology in more fields.

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