中部槽焊接工艺技术研究及应用
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摘要
近年来,随着我国煤炭行业的快速发展,与之密切相关的煤机行业竞争也日趋激烈。煤矿井下工作面刮板输送机不断向着重型、超重型、大运量、长远距、高可靠、自动化方向发展。中部槽是刮板输送机的关键部件,位于输送机的中部,其可靠性和耐磨性直接关系着整套设备的过煤量和综合性能。因此,提高槽帮与中板,槽帮与封底板的焊缝质量,可直接提高刮板输送机的整体焊接质量,进而提高整个采煤系统的寿命。
本文通过化学成分、碳当量、冷裂敏感指数理论分析及试验验证了中部槽槽体材料超高强耐磨钢JEF-EH400、JEF-EH450及ZG30MnSi钢的焊接性。结果表明,三种材料均具有较差的可焊性,同时超高强耐磨钢与ZG30MnSi钢两者焊接亦存在较大难度。
在理论研究的基础上,通过试验方法对中部槽中板、底板用高强耐磨钢JEF-EH400、JEF-EH450和槽帮ZG30MnSi钢进行了焊接工艺评定。焊接方法、焊接材料、预热温度、层间温度、焊接参数都达到了最优的配合,得出了ZG30MnSi与超高强耐磨钢之间合理而可行的焊接工艺。
应用X射线对焊接接头处进行探伤试验,对根部未焊透、中部槽焊接易产生裂纹、气孔等缺陷进行了研究。结果表明,通过控制焊接参数、提高操作技术、加强焊后清理等方面可解决上述缺陷,并制定了防止缺陷产生的工艺措施。另外,针对中部槽焊接变形情况研究了其形成原因,并通过采用预变形、控制焊接热输入、选择合理的焊接顺序、重视定位焊、采用焊前预热及焊后缓冷等工艺措施有效控制了焊接变形。
In recent years, with the rapid development of our country’s coal industry, the competition among relevant colliery mechanical industry is also becoming more and more vigorous. The underground coal mining scraper conveyor of our company is developing towards severe type, super heavy, large-capacity, long distance, high reliability and automation. The central trough located in the middle is the key part of scraper conveyor; its reliability and wear resistance are directly related to the coal quantity and comprehensive property of the complete set of the equipment. So, improving the welding quality between ledge and middle plate, ledge and seal baseboard, will directly increase the welded joint quality of the scraper conveyor, and the life of the whole coal mining system.
This paper researched on the chemical composition, carbon equivalent and cold crack sensitive index, and testifies the weldability of Super-high wear-resistant steel JEF-EH400, JEF-EH450, and ZG30MnSi. The results showed that the three kinds of steel had poor weldability; it is difficult to weld the Super-high wear-resistant steel to ZG30MnSi.
On the basis of theoretical analysis, this paper researched the welding procedure qualification through the central trough plate, baseboard JEF-EH400、JEF-EH450 and ledge ZG30MnSi. The Welding method, welding material, preheating temperature, interlayer temperature, welding parameters had reached the optimal coordination, and then obtained the feasible welding process between super-high wear-resistant steel and ZG30MnSi.
Application of X-ray detection test to welding joints, this paper researched the welding defects, as incomplete root penetration, cracks, porosity. The result showed that through welding parameters, improving operation technology and strengthening welding cleaning can solve such flaws, and then formulated the technical measures to prevent defects. In addition, according to welding deformation of the central trough, using advanced deformation, controlling welding heat input, choosing proper welding sequence, adopting positioning weld and slow cold process after weld can effectively control the deformation.
本文通过化学成分、碳当量、冷裂敏感指数理论分析及试验验证了中部槽槽体材料超高强耐磨钢JEF-EH400、JEF-EH450及ZG30MnSi钢的焊接性。结果表明,三种材料均具有较差的可焊性,同时超高强耐磨钢与ZG30MnSi钢两者焊接亦存在较大难度。
在理论研究的基础上,通过试验方法对中部槽中板、底板用高强耐磨钢JEF-EH400、JEF-EH450和槽帮ZG30MnSi钢进行了焊接工艺评定。焊接方法、焊接材料、预热温度、层间温度、焊接参数都达到了最优的配合,得出了ZG30MnSi与超高强耐磨钢之间合理而可行的焊接工艺。
应用X射线对焊接接头处进行探伤试验,对根部未焊透、中部槽焊接易产生裂纹、气孔等缺陷进行了研究。结果表明,通过控制焊接参数、提高操作技术、加强焊后清理等方面可解决上述缺陷,并制定了防止缺陷产生的工艺措施。另外,针对中部槽焊接变形情况研究了其形成原因,并通过采用预变形、控制焊接热输入、选择合理的焊接顺序、重视定位焊、采用焊前预热及焊后缓冷等工艺措施有效控制了焊接变形。
In recent years, with the rapid development of our country’s coal industry, the competition among relevant colliery mechanical industry is also becoming more and more vigorous. The underground coal mining scraper conveyor of our company is developing towards severe type, super heavy, large-capacity, long distance, high reliability and automation. The central trough located in the middle is the key part of scraper conveyor; its reliability and wear resistance are directly related to the coal quantity and comprehensive property of the complete set of the equipment. So, improving the welding quality between ledge and middle plate, ledge and seal baseboard, will directly increase the welded joint quality of the scraper conveyor, and the life of the whole coal mining system.
This paper researched on the chemical composition, carbon equivalent and cold crack sensitive index, and testifies the weldability of Super-high wear-resistant steel JEF-EH400, JEF-EH450, and ZG30MnSi. The results showed that the three kinds of steel had poor weldability; it is difficult to weld the Super-high wear-resistant steel to ZG30MnSi.
On the basis of theoretical analysis, this paper researched the welding procedure qualification through the central trough plate, baseboard JEF-EH400、JEF-EH450 and ledge ZG30MnSi. The Welding method, welding material, preheating temperature, interlayer temperature, welding parameters had reached the optimal coordination, and then obtained the feasible welding process between super-high wear-resistant steel and ZG30MnSi.
Application of X-ray detection test to welding joints, this paper researched the welding defects, as incomplete root penetration, cracks, porosity. The result showed that through welding parameters, improving operation technology and strengthening welding cleaning can solve such flaws, and then formulated the technical measures to prevent defects. In addition, according to welding deformation of the central trough, using advanced deformation, controlling welding heat input, choosing proper welding sequence, adopting positioning weld and slow cold process after weld can effectively control the deformation.
引文
[1]赵运才,庞偌霞.刮板输送机中部槽磨损与磨蚀问题探讨[J].矿山机械, 2000(5):55～56.
[2]葛长路,叶荣昌.刮板输送机中部槽大面积耐磨花纹的堆焊[J].焊接技术,1996(4):24～25.
[3]魏鹏. 700Mpa以上低合金超高强结构钢板焊接工艺研究[J].工程技术,1994-2009:298～300.
[4]邹增大.低合金条质高强度钢焊接及工程应用[M].北京:北京化学出版社,2000
[5]张强勇,尹素平. Hardox耐磨钢的焊接[J].电焊机,2008,38(11):44～45.
[6]刘少坤,高基耀.ZG35与35CrMnSi异种钢的焊接工艺[J].金属加工, 2008,(18):61～62.
[7]张超军,张志民.刮板输送机中部槽的耐磨处理[J].煤矿机械, 2007,28(6):109.
[8]王巧梅.提高刮板输送机圆环链与中部槽耐磨性的研究[J].Shanxi Coking Coal Science & Technology, 2007(9):34～37.
[9]期重遥.焊接手册(第三卷)[M].北京:机械工业出版社,1992.
[10]严正凯.低合金高强钢的焊接工艺研究[J].机械工程与自动化, 2007(1):171～172.
[11]周振丰.金属熔焊原理及工艺(下册)[M].北京:北京工业出版社,1987.
[12]期重遥.焊接手册(第二卷)[M].北京:机械工业出版社,1992.
[13]刘汉谊.焊接碳当量计算及公式应用[J].承钢技术, 2007,(1):36～38.
[14]栗卓新,刘秀龙.高强钢焊材及焊接性的国内外研究发展[J].新技术新工艺, 2007(5):15～18.
[15]徐亚军王国法.高强度结构钢的焊接性与液压支架结构强度的研究[D].北京:煤炭科学研究总院,2003.
[16]任芝兰.超高强度钢的焊接分析[J].新技术新工艺, 2008(1):48～49.
[17]唐慕尧.焊接测试技术[M].北京:北京机械工业出版社,1988.
[18]付延飞,王晓霞.新材料ZG30MnSi在刮板机中部槽上的应用[J].矿山机械, 2006,34(9):150~152.
[19]姚春发,苏航.HSLA80钢焊接冷裂纹敏感性研究[J].SHANGHAI METALS, 2008,30(4):31～34.
[20]王建利.高强钢的焊接工艺评定[J].YUNNAN WATER POWER, 2007,23(2):111～114.
[21] Tusek J . Metal-power twin-wire submerged-arc welding[J] . Welding & MetalFabrication,1998,66(07):21～25.
[22] YU Li-xing. Application of CO2 gas shield arc welding in thick Plate [J]. Ordnance Material Science And Engineering,2003,26(1):55～56.
[23]李福才.焊接工艺方案对异种钢接头力学性能的影响[J].焊接, 1992(8):5～6.
[24]高力生,潘际銮,闫炳义.碳素结构钢及低合金高强钢焊接方法选择[J].CHINA THREE GORGES CONSTRUCTION, 2001(1):14～17.
[25] Mukhopadhyay S,Pal T K.Effect of shielding gas mixture on gas metal arc welding of HSLA steel using solid and flux-cored wires[J]. Advance Manufacturing Technology, 2006,29(3-4):262～267.
[26]王黎明,王晓.钢零件焊接预热温度的确定[J].黑龙江八一农垦大学学报, 2002,14(3):40～43.
[27]曹继明.用碳当量CEN确定高强钢焊接预热温度[J].焊接,1995(1):17~19.
[28]魏桂花,赵素君.常见焊接缺陷及应对措施[J].机械管理开发, 2007(2):83～84.
[29]张超,刘建英.常见焊接缺陷的成因探讨及对策[J].煤矿机械, 2005(11):97～98.
[30]项阳.钢质船舶建造中船体焊接缺陷成因及预防措施[J]. JIANGSU SHIP, 2008,25(5):41～42.
[31]聂嵘.16Mn钢根部焊道中焊接热裂纹控制[J].结构件的焊接及质量控制,2003,32(3):49~51.
[32]赖祥生.关于高碳高强合金钢焊接裂纹的控制[J].重庆工商大学学报,2006,23(5):485～486.
[33] Newman JC, Raju IS.An empirical stresses-intensity factor Equation for the surface crack[J]. Engineering Fracture Mechanics,1981,15(1):185~192.
[34]舒兴楼.船用厚板高强度钢焊接性及其焊接裂纹的形成和预防[J]. SHIP&BOAT, 2009(4):9～11.
[35]高云中.结晶裂纹的成因分析及预防措施[J].现代焊接, 2006,43(7):34～36.
[36]谢文龙.低合金高强钢S550-Q焊接裂纹分析及控制措施[J].焊接技术, 2009,38(12):62～64
[37]崔岩.谈焊接气孔的成因、危害和防止[J].电焊机, 1997(4):45～46.
[38]刘伟.减少大型结构件焊接变形的工艺对策[J].酒钢科技, 2006(1):23~25.
[39]徐立媚.减少焊接应力与变形的工艺措施[J].金属加工, 2008(12):83~85.
[40]幸雁冰.焊接变形的预防[J].工程技术,1994-2009:280~281.
[41]回拥军.如何控制焊接应力和变形[J].山西建筑, 2004,30(6):53～54.
[2]葛长路,叶荣昌.刮板输送机中部槽大面积耐磨花纹的堆焊[J].焊接技术,1996(4):24～25.
[3]魏鹏. 700Mpa以上低合金超高强结构钢板焊接工艺研究[J].工程技术,1994-2009:298～300.
[4]邹增大.低合金条质高强度钢焊接及工程应用[M].北京:北京化学出版社,2000
[5]张强勇,尹素平. Hardox耐磨钢的焊接[J].电焊机,2008,38(11):44～45.
[6]刘少坤,高基耀.ZG35与35CrMnSi异种钢的焊接工艺[J].金属加工, 2008,(18):61～62.
[7]张超军,张志民.刮板输送机中部槽的耐磨处理[J].煤矿机械, 2007,28(6):109.
[8]王巧梅.提高刮板输送机圆环链与中部槽耐磨性的研究[J].Shanxi Coking Coal Science & Technology, 2007(9):34～37.
[9]期重遥.焊接手册(第三卷)[M].北京:机械工业出版社,1992.
[10]严正凯.低合金高强钢的焊接工艺研究[J].机械工程与自动化, 2007(1):171～172.
[11]周振丰.金属熔焊原理及工艺(下册)[M].北京:北京工业出版社,1987.
[12]期重遥.焊接手册(第二卷)[M].北京:机械工业出版社,1992.
[13]刘汉谊.焊接碳当量计算及公式应用[J].承钢技术, 2007,(1):36～38.
[14]栗卓新,刘秀龙.高强钢焊材及焊接性的国内外研究发展[J].新技术新工艺, 2007(5):15～18.
[15]徐亚军王国法.高强度结构钢的焊接性与液压支架结构强度的研究[D].北京:煤炭科学研究总院,2003.
[16]任芝兰.超高强度钢的焊接分析[J].新技术新工艺, 2008(1):48～49.
[17]唐慕尧.焊接测试技术[M].北京:北京机械工业出版社,1988.
[18]付延飞,王晓霞.新材料ZG30MnSi在刮板机中部槽上的应用[J].矿山机械, 2006,34(9):150~152.
[19]姚春发,苏航.HSLA80钢焊接冷裂纹敏感性研究[J].SHANGHAI METALS, 2008,30(4):31～34.
[20]王建利.高强钢的焊接工艺评定[J].YUNNAN WATER POWER, 2007,23(2):111～114.
[21] Tusek J . Metal-power twin-wire submerged-arc welding[J] . Welding & MetalFabrication,1998,66(07):21～25.
[22] YU Li-xing. Application of CO2 gas shield arc welding in thick Plate [J]. Ordnance Material Science And Engineering,2003,26(1):55～56.
[23]李福才.焊接工艺方案对异种钢接头力学性能的影响[J].焊接, 1992(8):5～6.
[24]高力生,潘际銮,闫炳义.碳素结构钢及低合金高强钢焊接方法选择[J].CHINA THREE GORGES CONSTRUCTION, 2001(1):14～17.
[25] Mukhopadhyay S,Pal T K.Effect of shielding gas mixture on gas metal arc welding of HSLA steel using solid and flux-cored wires[J]. Advance Manufacturing Technology, 2006,29(3-4):262～267.
[26]王黎明,王晓.钢零件焊接预热温度的确定[J].黑龙江八一农垦大学学报, 2002,14(3):40～43.
[27]曹继明.用碳当量CEN确定高强钢焊接预热温度[J].焊接,1995(1):17~19.
[28]魏桂花,赵素君.常见焊接缺陷及应对措施[J].机械管理开发, 2007(2):83～84.
[29]张超,刘建英.常见焊接缺陷的成因探讨及对策[J].煤矿机械, 2005(11):97～98.
[30]项阳.钢质船舶建造中船体焊接缺陷成因及预防措施[J]. JIANGSU SHIP, 2008,25(5):41～42.
[31]聂嵘.16Mn钢根部焊道中焊接热裂纹控制[J].结构件的焊接及质量控制,2003,32(3):49~51.
[32]赖祥生.关于高碳高强合金钢焊接裂纹的控制[J].重庆工商大学学报,2006,23(5):485～486.
[33] Newman JC, Raju IS.An empirical stresses-intensity factor Equation for the surface crack[J]. Engineering Fracture Mechanics,1981,15(1):185~192.
[34]舒兴楼.船用厚板高强度钢焊接性及其焊接裂纹的形成和预防[J]. SHIP&BOAT, 2009(4):9～11.
[35]高云中.结晶裂纹的成因分析及预防措施[J].现代焊接, 2006,43(7):34～36.
[36]谢文龙.低合金高强钢S550-Q焊接裂纹分析及控制措施[J].焊接技术, 2009,38(12):62～64
[37]崔岩.谈焊接气孔的成因、危害和防止[J].电焊机, 1997(4):45～46.
[38]刘伟.减少大型结构件焊接变形的工艺对策[J].酒钢科技, 2006(1):23~25.
[39]徐立媚.减少焊接应力与变形的工艺措施[J].金属加工, 2008(12):83~85.
[40]幸雁冰.焊接变形的预防[J].工程技术,1994-2009:280~281.
[41]回拥军.如何控制焊接应力和变形[J].山西建筑, 2004,30(6):53～54.