What impact does the quality of welding materials have on the performance and life of the NGW-L82-56 planetary reducer?

The NGW-L82-56 planetary reducer base is mostly made of welded structures such as low carbon steel and low alloy high-strength steel. The quality of the welding materials will affect the performance of the equipment from many aspects such as operating stability and load-bearing capacity. It will also determine the service life of the entire machine by causing failures and shortening the life of components. The specific effects are as follows:

1. Affect operational stability

Induced vibration and noise: If the welding material has many impurities and uneven composition, defects such as pores and slag inclusions may easily occur during welding, causing the weld to be loosely bonded to the machine base base material. The reducer will transmit a torque corresponding to 11KW power during operation. The defective parts will cause uneven support stiffness of the machine base, which will cause equipment vibration. At the same time, the vibration will be accompanied by abnormal noise, and as the operation time increases, the vibration amplitude will increase due to the expansion of defects, seriously damaging the operation stability.

Destruction of transmission accuracy: High-quality welding materials can ensure that the dimensional accuracy and geometric tolerances of the machine base after welding are up to standard. If the quality of the welding material is poor, large welding deformation will easily occur during welding, and the flatness of the machine base mounting surface and the coaxiality of the bearing seat will exceed standards. Planetary reducers have high requirements for the installation accuracy of transmission components. This installation deviation will lead to poor meshing of internal gears and bearings, causing the transmission gap to increase, affecting transmission accuracy, and unable to meet the use needs of high-precision transmission scenarios.

2. Affect load-bearing and impact resistance performance

High-quality welding materials can ensure that the mechanical properties of the weld metal and the base metal match through a reasonable alloy composition ratio, so that the machine base can stably withstand the alternating load and impact force of the reducer during operation. If the content of alloying elements in the welding material is insufficient, such as the lack of deoxidizing elements such as manganese and silicon, or harmful impurities such as sulfur and phosphorus exceeding the standard, the weld metal will have problems such as coarse grains and reduced toughness, and its tensile strength and yield strength will be far lower than the base metal standards. Under the load of long-term operation of the NGW-L82-56 reducer, the welds can easily become weak points, undergo plastic deformation or even cracking, and cannot support the normal operation of the equipment.

3. Affect corrosion resistance and wear resistance

If the reducer is used in harsh working conditions such as moisture and dust, the anti-corrosion and wear-resistant components of the welding material are particularly critical. If the selected welding materials lack corrosion-resistant alloy elements such as chromium and nickel, the welds and heat-affected zones are prone to corrosion preferentially in humid environments. Corrosion will gradually corrode the welds and reduce the structural strength of the machine base; at the same time, impurities produced by corrosion will enter the interior of the reducer and aggravate the wear of core components such as gears and bearings, which will not only reduce the performance of these transmission components, but also cause cascading failures. High-quality special welding materials can improve the corrosion resistance and wear resistance of the weld and reduce the occurrence of such problems.

4. Affect the service life of the whole machine

With qualified welding materials and standard welding processes, the machine base welds can basically match the service life of the entire machine. If the quality of the welding material is poor, hidden defects such as tiny cracks may easily occur in the weld. Under the long-term alternating load and vibration of the reducer, these cracks will continue to extend and expand, eventually causing the machine base to crack. If the cracked machine base is not dealt with in time, it will directly damage core components such as internal gears and transmission shafts, forcing the equipment to shut down for maintenance. Frequent maintenance not only increases costs, but also significantly shortens the overall service life of the reducer due to repeated damage to components. In serious cases, it may even lead to early scrapping of the entire machine.