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Forging Flash Butt Welding and Its Applications

Release time:

2024-07-12

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Abstract

Flash welding involves assembling the workpieces into a butt joint, connecting the power supply, and slowly bringing the welded end faces of the workpieces into partial contact. The resistance heat generated is used to rapidly heat the contact point to a high temperature, causing intense metal spattering and forming a flash (i.e., the melting process). Then, the workpieces are further brought closer together at the welded end faces to continue the flashing and heating until the entire welding end face reaches the predetermined temperature within a certain depth range. A forging pressure is then quickly applied to complete the welding process.

Flash butt welding is the process of assembling the workpieces into a butt joint, connecting the power supply, and slowly bringing the welded end faces of the workpieces into local contact. The resistance heat generated is used to rapidly heat the contact point to a high temperature, causing melting and producing intense metal spatter, forming a flash (i.e., the melting process). Then, continue to bring the workpieces closer to the welded end faces to further flash and heat until the entire welding end face reaches the predetermined temperature within a certain depth range, and quickly apply forging pressure to complete the welding process.

Flash butt welding can improve material utilization, reduce machining allowances, shorten manufacturing cycles, and lower costs. Various types of rings produced domestically are mainly processed using two traditional methods: free forging and ring rolling, which have large machining allowances and low material utilization, resulting in significant waste of labor, energy, and materials, especially in the production of irregular thin-walled rings. Compared to rings produced by rolling, flash butt welding is closer to the shape of the parts, with less machining allowance and higher material utilization, which can save raw materials and significantly reduce production costs. With the rapid development of the aerospace industry, the production of rings used in aircraft and their engines is inevitably moving towards precision, low cost, and high reliability; therefore, flash butt welding near-net-shape technology will become one of the mainstream technologies in ring manufacturing. Currently, all titanium alloy flash butt welded rings on aircraft engines in our country rely on imports, so researching the flash butt welding technology for rings has significant production guidance significance.

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Key Control Points in the Forging Process

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Heat treatment of large forgings for mining vehicles after forging.

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