铁基高温耐磨堆焊焊条及焊接工艺研究
摘要
我国当前耐磨堆焊材料研制应用生产的大部分是沿用过去研制的铁铬碳系，铁铬硼系，高铬铸铁合金系统和等离子弧用的粉末钴基、镍基材料。国外用于高温耐磨堆焊材料主要是钴基的司太立合金和一些镍基合金，它们在抗蚀、耐磨及热稳定性等方面均有突出的优点，但在实际应用中有一定的困难，钴和镍是价格昂贵的稀有金属，研究出高温耐磨而且价格低廉的堆焊材料是非常有必要的。本文针对高温耐磨料磨损的使用工况，采用不锈钢焊芯，通过药皮向堆焊层中过渡合金元素的方法，合成多种硬质相，达到多元复合强化的目的。研制出了一种铁基高温耐磨堆焊焊条，并对其耐磨机理进行了探讨和研究。
本文采用了正交回归设计的方法与试验相结合，对堆焊焊条的合金系统进行了优化设计。通过一系列的实验和计算，针对高温耐磨堆焊的特点，确定了焊条药皮的最初配方。并针对高温磨损失重，对焊条药皮配方进行了一次正交回归优化设计，建立了磨损失重与药皮中合金含量之间的回归方程，设计出了焊条药皮的最优配方。并通过对堆焊层组织及硬质相分布的分析，找到了其对堆焊层性能的影响规律，最终获得了良好的堆焊层性能。
最后对本焊条的焊接工艺进行了试验研究，找到了最适宜的焊接工艺。并针对焊条配方优化设计问题，开发了一套焊条计算机辅助设计软件，可以用科学的方法设计试验，建立数学模型，优化焊条药皮配方，从而实现了设计的定量化。
本文的研究成果不仅在实际中得到了良好的应用，具有巨大的社会效益和经济效益，而且还对研究高温耐磨料磨损具有指导意义。
Now in our country the wear resistant surfacing material studied , utilized and made is Fe-Cr-C , Fe-Cr-B and high chromium cast iron alloy system and powder Cobalt and Nickel-based alloys used in plasma arc. At the same time, abroad wear resistant surfacing materials used at the high temperature are mainly Stellite NO.12 based on Cobalt and . they all have extraordinary virtues in the corrosion resistance , wear resistance, heat stability etc. But in fact there are difficulties because Cobalt and Nickel are rare and expensive, so it is indispensable to investigate the high temperature wear resistant surfacing material with low price. In allusion to the using condition of high temperature grind particle wear, stainless steel core wire is used in the electrode, the alloy elements are transferred into the surfacing layer through coating, and many kinds of hard phases are synthesized, which obtain many elements compounded strengthening. A new type of iron-based high temperature wear resistant surfacing electrod
e was invented and its wear resistant mechanism was investigated.
This paper integrated orthogonal regression design into experiment, optimized electrode alloy system. According to the characteristic of high temperature wear resistance surfacing, the initial prescription of the electrode was determined through series of experiments and calculation. Corresponding to the weightless of high temperature abrasion, the prescription was designed through one time orthogonal regression, the regression equation between the weightless of abrasion and alloy composition in coating was established. At the same time, corresponding to the analysis of structure of surfacing layer and distributing of hard phase, its effect regular was found and finally favorable performance of surfacing layer was formed.
In the end, welding procedure of the electrode was studied by experiment to find the most suitable procedure. Furthermore, a kind of electrode computer aided design system was developed. Scientific approach was used to design experiment, construct mathematical model
and optimize welding material component. Thus quantitative design of welding material was realized.
Research achievement in this paper not only apply in practice and has favorable social and economic benefit but also it is of great direct importance to study on high temperature wear resistance.
本文采用了正交回归设计的方法与试验相结合，对堆焊焊条的合金系统进行了优化设计。通过一系列的实验和计算，针对高温耐磨堆焊的特点，确定了焊条药皮的最初配方。并针对高温磨损失重，对焊条药皮配方进行了一次正交回归优化设计，建立了磨损失重与药皮中合金含量之间的回归方程，设计出了焊条药皮的最优配方。并通过对堆焊层组织及硬质相分布的分析，找到了其对堆焊层性能的影响规律，最终获得了良好的堆焊层性能。
最后对本焊条的焊接工艺进行了试验研究，找到了最适宜的焊接工艺。并针对焊条配方优化设计问题，开发了一套焊条计算机辅助设计软件，可以用科学的方法设计试验，建立数学模型，优化焊条药皮配方，从而实现了设计的定量化。
本文的研究成果不仅在实际中得到了良好的应用，具有巨大的社会效益和经济效益，而且还对研究高温耐磨料磨损具有指导意义。
Now in our country the wear resistant surfacing material studied , utilized and made is Fe-Cr-C , Fe-Cr-B and high chromium cast iron alloy system and powder Cobalt and Nickel-based alloys used in plasma arc. At the same time, abroad wear resistant surfacing materials used at the high temperature are mainly Stellite NO.12 based on Cobalt and . they all have extraordinary virtues in the corrosion resistance , wear resistance, heat stability etc. But in fact there are difficulties because Cobalt and Nickel are rare and expensive, so it is indispensable to investigate the high temperature wear resistant surfacing material with low price. In allusion to the using condition of high temperature grind particle wear, stainless steel core wire is used in the electrode, the alloy elements are transferred into the surfacing layer through coating, and many kinds of hard phases are synthesized, which obtain many elements compounded strengthening. A new type of iron-based high temperature wear resistant surfacing electrod
e was invented and its wear resistant mechanism was investigated.
This paper integrated orthogonal regression design into experiment, optimized electrode alloy system. According to the characteristic of high temperature wear resistance surfacing, the initial prescription of the electrode was determined through series of experiments and calculation. Corresponding to the weightless of high temperature abrasion, the prescription was designed through one time orthogonal regression, the regression equation between the weightless of abrasion and alloy composition in coating was established. At the same time, corresponding to the analysis of structure of surfacing layer and distributing of hard phase, its effect regular was found and finally favorable performance of surfacing layer was formed.
In the end, welding procedure of the electrode was studied by experiment to find the most suitable procedure. Furthermore, a kind of electrode computer aided design system was developed. Scientific approach was used to design experiment, construct mathematical model
and optimize welding material component. Thus quantitative design of welding material was realized.
Research achievement in this paper not only apply in practice and has favorable social and economic benefit but also it is of great direct importance to study on high temperature wear resistance.
引文
[1] 邵荷生，张清等．金属的磨粒磨损与耐磨材料．北京：机械工业出版社，1987．9．
[2] 北京大学数学系概率统计组编．正交设计法．北京：石油化学工业出版社．1976．9．
[3] 方开泰，金辉，陈庆云。实用回归分析．北京：科学技术出版社．1988．10．
[4] 张文钺．焊接物理冶金．天津：天津大学出版社，1991．
[5] 周振丰，张文钺．焊接冶金与金属焊接性．北京：机械工业出版社．1988：140．
[6] 曲靖信 汪鸿宏．表面工程手册．化学工业出版社．1998．3．
[7] J.D. Watson. Evaluation of the wear resistance of hard surfacing alloys. Welding Research Abroad, 1983(3).
[8] 刘家浚．材料磨损原理及其耐磨性．清华大学出版社，1993．
[9] 顾钰熹．超硬质相对堆焊层耐磨性的影响．沈阳工业大学学报，1987(2)．
[10] 潘春旭等．耐磨堆焊层显微组织特征及其与耐磨性关系的研究．兵器材料科学与工程，2000(2)：8～17．
[11] 彭维林．Fe-Cr-B耐磨堆焊焊条在高温料钟上的应用研究．沈阳工业大学学报，1999(2)：11～12
[12] P.A.Swanson, A.F.Veffer. The measurement of abrasive parts shape and its effect on wear. Suth Annual Meeting in Chicago, 1984(5): 7p—10p.
[13] Douglas C. Montgomery. Design and Analysis of Experiments.中国统计出版社．1998．6．
[14] 洪永昌等．堆焊焊条组织和性能的研究．金属矿石，1997．25(3)：36～39．
[15] 李午申等．焊条优化设计．焊接1987(8)：5～10．
[16] 王宝．焊接电弧物理与焊条工艺性设计．北京：机械工业出版社．1998．4
[17] 郝行舟等．正交实验设计方法在试验设计中的应用．河南交通科技，1999(6)：26～28．
[18] 虞鸿祉．工业试验设计技术．南京：东南大学出版社．1990．1．
[19] 中国焊接协会．焊接标准汇编．北京：中国标准出版社．1997．1．
[20] 段福长．耐磨合金堆焊焊条研究．株洲工学院学报，1999(2)：26～28．
[21] 徐国建等．TiC-NbC超硬质相耐磨堆焊焊条的研究．硬质合金，1995(3)：178～182．
[22] 林文光等．稀土元素在耐磨堆焊焊条中的作用探讨．设备与材料，1996(2)：28～29．
[23] 皱增大等．TiC-VC耐磨堆焊焊条．材料科学与工艺．2001(4)：398～401．
[24] 廖立乾，文化明．焊条设计、制造与使用．北京：机械工业出版社．1988．10．
[25] 张子荣 电焊条．北京：机械工业出版社．1998．7．
[26] 张丙范等．碱性焊条组分与扩散氢相关性．电焊机．1989(6)：5～8．
[27] 孟庆森，王宝，陆文雄．焊条药皮组成物对熔滴包表张力的影响．焊接学报，1993，14(2)：63～68．
[28] 崔华阳．Microsoft Visual Basic 6.0实例精选．北京：电子工业出版社．2001．6．
[29] 陈伟．中文版Visual Basic 6.0开发指南．北京：人民邮电出版社．1999．
[30] 丁爱萍，刘瑞新．Visual Basic程序设计．西安：西安电子科技大学出版社．2001．2．
[31] 赵俊等．正交试验设计的计算实现方法．数值计算与计算机应用，1993(3)：201～208．
[32] 郑春勇等．多目标试验分析及优选．河北轻化工学院学报，1997(1)：16～17．
[33] S．Weisberg．Applied Linear Regression．中国统计出版社．1998．3．
[34] 余俊，廖道训．最优化方法及其应用．武昌：华中工学院出版社．1984．12
[35] 张丙范，李午申等．焊接最优基础．天津：天津大学出版社．1992．
[36] 李午申等．焊接材料计算机辅助设计软件系统．机械工程学报，1993，24(2)：39～45．
[37] 陈丙森．计算机辅助焊接技术．北京：机械工业出版社．1999．10．
[38] 朱伟勇，胡晨江．最优设计得计算机证明与构造．沈阳：东北工学院出版社．1987．6．
[39] Klass Hilbert. Research into Welding Electrodes Using Mathematical Models. Welding and Cutting, 1983 (11): 190～193.
[40] 刘政军等．多元复合强化铁基高温耐磨等离子弧堆焊合金及耐磨机理．焊接学报，1998，(12)：28～35．
[41] 冯安华等．含钇奥氏体基堆焊焊条堆焊层研究．材料开发与应用，1998(13)：1 12～16．
[42] 刘政军等．超硬质相WC、VC在堆焊层中的行为及高温抗磨机理．焊接技术，1997(6)：3～4．
[43] 刘政军等．Cr-B-W-V合金系统的优化设计．沈阳工业大学学报：1998．8(4)：23～28．
[44] D.G.Howen, D.R.Milner. Hxdrogen Absorption in Arc Welding. British Welding Journal, 1983 (4): 304～316.
[45] 刘钟华等译．摩擦学．机械工业出版社，1984．
[46] 唐伯钢等．低碳钢与低合金高强度钢焊接材料．北京：机械工业出版社．1987．7．
[47] W.B.Burnett. Development of cobalt free wear-resistant alloys for nuclear applications. Surfacing Engineering, 1992 (2).
[48] Lippold J C, Savage W F.Solidification of Austenitic Stainless Steel Weldment. Weld Journal, 1989 (12): 362～374.
[49] D.R.Richardson. The wear of metals by relatively soft abrasives. Wear, 1968(11): 245.
[50] D.Ellis. Weld deposition and properties of nickel base hard surfacing alloys. Welding Research Abroad. 1984 (15).
[2] 北京大学数学系概率统计组编．正交设计法．北京：石油化学工业出版社．1976．9．
[3] 方开泰，金辉，陈庆云。实用回归分析．北京：科学技术出版社．1988．10．
[4] 张文钺．焊接物理冶金．天津：天津大学出版社，1991．
[5] 周振丰，张文钺．焊接冶金与金属焊接性．北京：机械工业出版社．1988：140．
[6] 曲靖信 汪鸿宏．表面工程手册．化学工业出版社．1998．3．
[7] J.D. Watson. Evaluation of the wear resistance of hard surfacing alloys. Welding Research Abroad, 1983(3).
[8] 刘家浚．材料磨损原理及其耐磨性．清华大学出版社，1993．
[9] 顾钰熹．超硬质相对堆焊层耐磨性的影响．沈阳工业大学学报，1987(2)．
[10] 潘春旭等．耐磨堆焊层显微组织特征及其与耐磨性关系的研究．兵器材料科学与工程，2000(2)：8～17．
[11] 彭维林．Fe-Cr-B耐磨堆焊焊条在高温料钟上的应用研究．沈阳工业大学学报，1999(2)：11～12
[12] P.A.Swanson, A.F.Veffer. The measurement of abrasive parts shape and its effect on wear. Suth Annual Meeting in Chicago, 1984(5): 7p—10p.
[13] Douglas C. Montgomery. Design and Analysis of Experiments.中国统计出版社．1998．6．
[14] 洪永昌等．堆焊焊条组织和性能的研究．金属矿石，1997．25(3)：36～39．
[15] 李午申等．焊条优化设计．焊接1987(8)：5～10．
[16] 王宝．焊接电弧物理与焊条工艺性设计．北京：机械工业出版社．1998．4
[17] 郝行舟等．正交实验设计方法在试验设计中的应用．河南交通科技，1999(6)：26～28．
[18] 虞鸿祉．工业试验设计技术．南京：东南大学出版社．1990．1．
[19] 中国焊接协会．焊接标准汇编．北京：中国标准出版社．1997．1．
[20] 段福长．耐磨合金堆焊焊条研究．株洲工学院学报，1999(2)：26～28．
[21] 徐国建等．TiC-NbC超硬质相耐磨堆焊焊条的研究．硬质合金，1995(3)：178～182．
[22] 林文光等．稀土元素在耐磨堆焊焊条中的作用探讨．设备与材料，1996(2)：28～29．
[23] 皱增大等．TiC-VC耐磨堆焊焊条．材料科学与工艺．2001(4)：398～401．
[24] 廖立乾，文化明．焊条设计、制造与使用．北京：机械工业出版社．1988．10．
[25] 张子荣 电焊条．北京：机械工业出版社．1998．7．
[26] 张丙范等．碱性焊条组分与扩散氢相关性．电焊机．1989(6)：5～8．
[27] 孟庆森，王宝，陆文雄．焊条药皮组成物对熔滴包表张力的影响．焊接学报，1993，14(2)：63～68．
[28] 崔华阳．Microsoft Visual Basic 6.0实例精选．北京：电子工业出版社．2001．6．
[29] 陈伟．中文版Visual Basic 6.0开发指南．北京：人民邮电出版社．1999．
[30] 丁爱萍，刘瑞新．Visual Basic程序设计．西安：西安电子科技大学出版社．2001．2．
[31] 赵俊等．正交试验设计的计算实现方法．数值计算与计算机应用，1993(3)：201～208．
[32] 郑春勇等．多目标试验分析及优选．河北轻化工学院学报，1997(1)：16～17．
[33] S．Weisberg．Applied Linear Regression．中国统计出版社．1998．3．
[34] 余俊，廖道训．最优化方法及其应用．武昌：华中工学院出版社．1984．12
[35] 张丙范，李午申等．焊接最优基础．天津：天津大学出版社．1992．
[36] 李午申等．焊接材料计算机辅助设计软件系统．机械工程学报，1993，24(2)：39～45．
[37] 陈丙森．计算机辅助焊接技术．北京：机械工业出版社．1999．10．
[38] 朱伟勇，胡晨江．最优设计得计算机证明与构造．沈阳：东北工学院出版社．1987．6．
[39] Klass Hilbert. Research into Welding Electrodes Using Mathematical Models. Welding and Cutting, 1983 (11): 190～193.
[40] 刘政军等．多元复合强化铁基高温耐磨等离子弧堆焊合金及耐磨机理．焊接学报，1998，(12)：28～35．
[41] 冯安华等．含钇奥氏体基堆焊焊条堆焊层研究．材料开发与应用，1998(13)：1 12～16．
[42] 刘政军等．超硬质相WC、VC在堆焊层中的行为及高温抗磨机理．焊接技术，1997(6)：3～4．
[43] 刘政军等．Cr-B-W-V合金系统的优化设计．沈阳工业大学学报：1998．8(4)：23～28．
[44] D.G.Howen, D.R.Milner. Hxdrogen Absorption in Arc Welding. British Welding Journal, 1983 (4): 304～316.
[45] 刘钟华等译．摩擦学．机械工业出版社，1984．
[46] 唐伯钢等．低碳钢与低合金高强度钢焊接材料．北京：机械工业出版社．1987．7．
[47] W.B.Burnett. Development of cobalt free wear-resistant alloys for nuclear applications. Surfacing Engineering, 1992 (2).
[48] Lippold J C, Savage W F.Solidification of Austenitic Stainless Steel Weldment. Weld Journal, 1989 (12): 362～374.
[49] D.R.Richardson. The wear of metals by relatively soft abrasives. Wear, 1968(11): 245.
[50] D.Ellis. Weld deposition and properties of nickel base hard surfacing alloys. Welding Research Abroad. 1984 (15).
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