超低碳铜时效强化钢的焊接冶金研究
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摘要
本文以大工程为背景,通过焊接热模拟和实际焊接试验,对主要用于船舶及海洋采油平台领域的铜时效强化钢的焊接冶金进行了系统地研究。
绘制了超低碳铜时效强化钢焊接CCT图,从焊接CCT图可以发现：t8/5=3.7-7秒时,模拟焊接热影响区主要为马氏体+贝氏体组织,贝氏体铁素体主要为板条状。在贝氏体铁素体板条间分布着残余奥氏体。当t8/5≥15秒时,开始出现少量粒状贝氏体组织。当t8/5>45秒时,在晶界开始形成先共析铁素体,此时主要获得粒状贝氏体组织。在很宽的热输入范围内(t8/5=3.7～2500秒)均有贝氏体组织产生。随着t8/5的增大,模拟焊接热影响区中的铁素体量逐渐增多。在极快的冷却速度条件下(t8/5=3.7秒),试验钢焊接热影响区粗晶区硬度仅为286HV,说明钢种的淬硬倾向小,有利于防止冷裂纹的产生。t8/5>7秒后,热影响区的硬度开始低于基材,粗晶区将发生软化。t8/5=2500秒时,维氏硬度值降为187HV。因此,为避免焊接热影响区的软化,焊接时应注意控制焊接线能量。从焊接CCT图可以大致确定实际冷却时间t8/5最佳范围为7-35秒,即以中小线能量为宜。
研究了单次焊接热循环条件下铜时效钢模拟焊接热影响区粗晶区的组织和性能变化特征。研究发现：热连轧的铜时效强化钢焊接热输入或线能量范围较窄,在较大热输入或线能量条件下,焊接热影响区粗晶区出现脆化。脆化的原因是t8/5较大时生成了大量的粒状贝氏体,降低了冲击韧性,t8/5较小时生成的板条贝氏体使含铜钢冲击韧性增加。t8/5大于7秒后,粗晶区开始出现软化。软化的原因是ε-Cu粒子的回溶和组织软化共同作用的结果。研究了M-A组元对铜时效强化钢粗晶热影响区韧性的影响。研究发现：M-A组元的尺寸和体积百分数对冲击韧性均有影响,其有效直径平均小于1gm,体积百分数小于5%,对冲击韧性影响不大；大于1μm,体积百分数大于5%,冲击韧性显著下降。通过控制焊接热输入来减少焊接热影响区粗晶区中M-A组元的有效直径和体积百分数,可有效提高铜时效强化钢的低温韧性。
研究了铜时效钢模拟焊接热影响区不同区域的组织和性能变化特征。研究发现：当t8/5=15秒时,两相区的硬度最低,硬度值较基材下降了约50个HV单位,细晶区的硬度有所增加,粗晶区的硬度最高。母材中部分析出物的回溶以及铁素体组织的存在导致了两相区硬度降低。细晶区因晶粒细化使硬度有所恢复。粗晶区中铜的固溶强化以及贝氏体的产生又使硬度有所增加。细晶区冲击韧性最高,两相区其次,粗晶区冲击韧性最差。粗晶区低温韧性较低的原因是奥氏体晶粒长大及冷却之后得到的贝氏体尺寸也较大所致；细晶区的组织细化及得到的板条和块状混合结构使其具有良好的低温韧性。
研究了二次焊接热循环条件下铜时效钢模拟焊接热影响区粗晶区的组织和性能变化特征。研究发现：二次焊接热循环条件下,临界粗晶区的韧性最低,具有明显的局部脆化倾向。冷却速度越慢,脆化现象越严重,脆化的原因是富碳的孪晶马氏体降低了冲击韧性。因此,实际多层多道焊时必须严格控制焊接热输入或线能量。
建立了铜在焊接过程中回溶的动力学模型,从模型可以看出,ε-Cu颗粒的体积分数随焊接过程发生变化。ε-Cu粒子初始尺寸,焊接加热的峰值温度是影响ε-Cu粒子回溶速度的主要因素。Cu在α-Fe中的扩散系数是间接影响因素。焊接加热的峰值温度越高,ε-Cu粒子初始尺寸越小,ε-Cu粒子的回溶速度越快。模拟试验结果与动力学模型计算结果具有一致性,当峰值温度高于1000℃时,ε-Cu粒子几乎完全固溶于基体中。
为铜时效强化钢研制了气体保护焊配套焊丝,与国内外同类焊丝相比,无Mo元素,Ni含量降低,采用Mn-Ni-Cr-Cu为主要强化元素,并利用Ti、B微合金化,来保证焊丝良好的性能。研制的焊丝冲击功优于同类焊丝,V型缺口-40℃平均冲击功可达97J以上,具有优良的低温冲击韧性。
进行了铜时效钢埋弧焊、气体保护焊和手工电弧焊对接试验。研究发现：所选择的焊接材料和焊接工艺,试验钢接头的抗拉强度完全能满足钢种的技术条件要求,接头三区-40℃平均冲击功大于73J,具有较大的韧性储备余量。无论是埋弧焊、气体保护焊、还是手工电弧焊,焊缝组织均为针状铁素体加少量先共析铁素体。粗晶区为贝氏体组织。针状铁素体使焊缝具有优良的低温韧性。气体保护焊、手工电弧焊热影响区因铜回溶而引起的软化现象不明显；埋弧焊靠近母材的热影响区存在轻微软化现象,这与模拟焊接热影响区不同区域得到的维氏硬度结果一致,两相区硬度最低,粗晶区硬度最高,说明实际焊接接头与模拟焊接热影响区具有较好的对应性。
不等温应力松弛试验研究发现：铜时效强化钢再热裂纹敏感温度为669℃,断裂时间为63秒,再热裂纹敏感温度区间为669～695℃,属于再热裂纹敏感型的钢种。粗晶区经再次加热到650～700℃时,由于有Cr、Mo等碳化物在晶内析出,使晶内与晶界产生强度差,开裂就在高温强度较弱的晶界发生,形成再热裂纹的粗晶区沿晶特征。
This thesis based on physical simulation technology and arc welding is focused on the welding metallurgy of ultra low carbon copper-bearing age strengthening steels which are used in construction of shipbuilding and oil platform.
The determination of SH-CCT diagram, single and double thermal cycles simulating the behavior of HAZ during welding were performed on a dynamic thermal machine. As can be seen from SH-CCT diagram, martensite and bainite are obtained in simulated CGHAZ with t8/5from3.7s to7s. Bainite is characterized by lath. Retained austenite is found among the bainitic ferrite laths. Granular bainite begins to form when t8/5is more than15s. Ferrite starts to be observed when t8/5is more than45s. The more heat is input, the more ferrite forms. The microstructure is predominantly bainite in a wide heat input range from3.7s to2500s. The SH-CCT diagram indicates that even under the condition of fairly rapid cooling (t8/5=3.7s), entire martensite in simulated CGHAZ has not been attained and Vickers hardness is only286HV. So the copper-bearing steel possesses a small hardening quenching tendency and an excellent resistance to cold cracking under the condition of no preheating and no postheating. While t8/5is more than7s, CGHAZ starts softening; that is to say, the hardness begins to be less than the one of base metal. The higher heat input leads to the more softening. The hardness decreases to187HV when t8/5is2500s. So it is proposed to choose t8/5ranging from7s to35s during welding to prevent softening.
Single thermal cycle experiments show that copper-bearing steel has a narrow range of heat input or line energy. Under the condition of higher heat input or line energy, brittlement is easy to happen in CGHAZ. Granular bainite transformed from austenite leads to brittlement. On the contrary, lath bainitic ferrite formed with lower heat input can increase toughness. Softening begins to occur in CGHAZ (t8/5>7s). The dissolution of ε-Cu and coarser lath bainitic ferrite and more ferrite cause softening in CGHAZ. The effect of M-A constituents on the impact toughness in simulated CGHAZ was studied. The dimensions and area fraction of granular M-A constituents also influence the impact toughness. There is no visible effect on the toughness when the dimensions of M-A constituents are less than1μm and the area fraction is less than5%. The toughness decreases greatly once the dimensions exceed1μm and the area fraction is more than5%. Therefore, decreasing the dimensions and area fraction of M-A constituents by controlling welding heat input will do good to improve the impact toughness of copper-bearing steel.
Experiments simulating the whole HAZ show that the softening phenomena take place in the whole heat-affected zones when t8/5is15s. The hardness in intercritical (ICHAZ) decreases by50HV compared with that of the base metal and it is the most softened region due to re-dissolving of precipitate phase and ferrite compared with other regions in HAZ. The slight increase in hardness in FGHAZ is connected with microstructure refinement. The formation of lath bainitic ferrite and the enhancement of copper solid solution strengthening cause the hardness recovery for CGHAZ. Even so, the hardness value in CGHAZ is still less than that of the base metal but the softening phenomenon is not evident. CGHAZ has relatively low impact toughness owing to the growth of austenite grain size and coarse lath bainitic ferrite when t8/5is15s. FGHAZ achieves better impact toughness for its short time maintaining at higher temperature after austenization to reduce the austenite grain size. ICHAZ has also good impact toughness.
Double thermal cycle experiments demonstrate that obvious brittlement happens in the intercritically reheated CGHAZ. The reason is martensite twin formed and coarse granular bainite, which reduce the impact toughness. The higher heat is input, the more serious brittlement becomes. Thus, during multilayer welding, it is proposed to control strictly heat input.
Kinetic model of ε-Cu re-solution during welding was established. The volume fraction of ε-Cu re-solution keeps changing during welding. The initial size of ε-Cu and the peak temperature mainly influence re-solution kinetics of ε-Cu. The diffusion coefficient of ε-Cu in α-Fe is the indirect reason to influence re-solution of s-Cu. The smaller the initial size of ε-Cu is, the higher the peak temperature is, and the more ε-Cu re-dissolve. Calculation results of the kinetic model and simulation results in HAZ reach an agreement, that is to say, when the peak temperature is more than1000℃, ε-Cu completely re-dissolve into matrix phase.
Wire for GMAW was developed by using Mn-Ni-Cr-Cu as the main reinforcing elements, and Ti and B micro alloying without Mo and less Ni. Compared with the same strength grade for other wires in the world, this developed wire has excellent low temperature impact toughness and Charpy V-notch impact energy at-40℃is over97J.
GMAW, SAW and SMAW tests were investigated using patent welding wires. The tests show that the joints get good impact toughness at low temperature for three welding methods and the average impact energy (-40℃) in the welding joints is more than73J with great allowance compared with the requirement. The tensile strengths completely meet the strength requirement of base metal. Acicular ferrites (AF) and some proeutectoid ferrites exist in the weld metal. The great amount of AF in the weld metal can significantly improve both the strength and the toughness of weld metal. Bainite is attained in actual CGHAZ. Softening phenomena are not obvious in welding joints for GMAW and SMAW. There exists a slight softening phenomenon approaching the base metal, which and simulation results have a consistency. That is to say ICHAZ has the lowest hardness value.
Non-isothermal stress relief test results show that susceptible temperature of reheat cracking of copper-bearing steel is669℃and relevant cracking time is63seconds. The susceptible temperature interval is from669℃to695℃. So test steels have reheat cracking susceptibility. When CGHAZ is reheated to the temperature between650℃and700℃, intracrystalline strength is high for the distribution of carbonide of Cr and Mo. Intercrystalline failure cracking takes place owing to low strength on the grain boundary.
绘制了超低碳铜时效强化钢焊接CCT图,从焊接CCT图可以发现：t8/5=3.7-7秒时,模拟焊接热影响区主要为马氏体+贝氏体组织,贝氏体铁素体主要为板条状。在贝氏体铁素体板条间分布着残余奥氏体。当t8/5≥15秒时,开始出现少量粒状贝氏体组织。当t8/5>45秒时,在晶界开始形成先共析铁素体,此时主要获得粒状贝氏体组织。在很宽的热输入范围内(t8/5=3.7～2500秒)均有贝氏体组织产生。随着t8/5的增大,模拟焊接热影响区中的铁素体量逐渐增多。在极快的冷却速度条件下(t8/5=3.7秒),试验钢焊接热影响区粗晶区硬度仅为286HV,说明钢种的淬硬倾向小,有利于防止冷裂纹的产生。t8/5>7秒后,热影响区的硬度开始低于基材,粗晶区将发生软化。t8/5=2500秒时,维氏硬度值降为187HV。因此,为避免焊接热影响区的软化,焊接时应注意控制焊接线能量。从焊接CCT图可以大致确定实际冷却时间t8/5最佳范围为7-35秒,即以中小线能量为宜。
研究了单次焊接热循环条件下铜时效钢模拟焊接热影响区粗晶区的组织和性能变化特征。研究发现：热连轧的铜时效强化钢焊接热输入或线能量范围较窄,在较大热输入或线能量条件下,焊接热影响区粗晶区出现脆化。脆化的原因是t8/5较大时生成了大量的粒状贝氏体,降低了冲击韧性,t8/5较小时生成的板条贝氏体使含铜钢冲击韧性增加。t8/5大于7秒后,粗晶区开始出现软化。软化的原因是ε-Cu粒子的回溶和组织软化共同作用的结果。研究了M-A组元对铜时效强化钢粗晶热影响区韧性的影响。研究发现：M-A组元的尺寸和体积百分数对冲击韧性均有影响,其有效直径平均小于1gm,体积百分数小于5%,对冲击韧性影响不大；大于1μm,体积百分数大于5%,冲击韧性显著下降。通过控制焊接热输入来减少焊接热影响区粗晶区中M-A组元的有效直径和体积百分数,可有效提高铜时效强化钢的低温韧性。
研究了铜时效钢模拟焊接热影响区不同区域的组织和性能变化特征。研究发现：当t8/5=15秒时,两相区的硬度最低,硬度值较基材下降了约50个HV单位,细晶区的硬度有所增加,粗晶区的硬度最高。母材中部分析出物的回溶以及铁素体组织的存在导致了两相区硬度降低。细晶区因晶粒细化使硬度有所恢复。粗晶区中铜的固溶强化以及贝氏体的产生又使硬度有所增加。细晶区冲击韧性最高,两相区其次,粗晶区冲击韧性最差。粗晶区低温韧性较低的原因是奥氏体晶粒长大及冷却之后得到的贝氏体尺寸也较大所致；细晶区的组织细化及得到的板条和块状混合结构使其具有良好的低温韧性。
研究了二次焊接热循环条件下铜时效钢模拟焊接热影响区粗晶区的组织和性能变化特征。研究发现：二次焊接热循环条件下,临界粗晶区的韧性最低,具有明显的局部脆化倾向。冷却速度越慢,脆化现象越严重,脆化的原因是富碳的孪晶马氏体降低了冲击韧性。因此,实际多层多道焊时必须严格控制焊接热输入或线能量。
建立了铜在焊接过程中回溶的动力学模型,从模型可以看出,ε-Cu颗粒的体积分数随焊接过程发生变化。ε-Cu粒子初始尺寸,焊接加热的峰值温度是影响ε-Cu粒子回溶速度的主要因素。Cu在α-Fe中的扩散系数是间接影响因素。焊接加热的峰值温度越高,ε-Cu粒子初始尺寸越小,ε-Cu粒子的回溶速度越快。模拟试验结果与动力学模型计算结果具有一致性,当峰值温度高于1000℃时,ε-Cu粒子几乎完全固溶于基体中。
为铜时效强化钢研制了气体保护焊配套焊丝,与国内外同类焊丝相比,无Mo元素,Ni含量降低,采用Mn-Ni-Cr-Cu为主要强化元素,并利用Ti、B微合金化,来保证焊丝良好的性能。研制的焊丝冲击功优于同类焊丝,V型缺口-40℃平均冲击功可达97J以上,具有优良的低温冲击韧性。
进行了铜时效钢埋弧焊、气体保护焊和手工电弧焊对接试验。研究发现：所选择的焊接材料和焊接工艺,试验钢接头的抗拉强度完全能满足钢种的技术条件要求,接头三区-40℃平均冲击功大于73J,具有较大的韧性储备余量。无论是埋弧焊、气体保护焊、还是手工电弧焊,焊缝组织均为针状铁素体加少量先共析铁素体。粗晶区为贝氏体组织。针状铁素体使焊缝具有优良的低温韧性。气体保护焊、手工电弧焊热影响区因铜回溶而引起的软化现象不明显；埋弧焊靠近母材的热影响区存在轻微软化现象,这与模拟焊接热影响区不同区域得到的维氏硬度结果一致,两相区硬度最低,粗晶区硬度最高,说明实际焊接接头与模拟焊接热影响区具有较好的对应性。
不等温应力松弛试验研究发现：铜时效强化钢再热裂纹敏感温度为669℃,断裂时间为63秒,再热裂纹敏感温度区间为669～695℃,属于再热裂纹敏感型的钢种。粗晶区经再次加热到650～700℃时,由于有Cr、Mo等碳化物在晶内析出,使晶内与晶界产生强度差,开裂就在高温强度较弱的晶界发生,形成再热裂纹的粗晶区沿晶特征。
This thesis based on physical simulation technology and arc welding is focused on the welding metallurgy of ultra low carbon copper-bearing age strengthening steels which are used in construction of shipbuilding and oil platform.
The determination of SH-CCT diagram, single and double thermal cycles simulating the behavior of HAZ during welding were performed on a dynamic thermal machine. As can be seen from SH-CCT diagram, martensite and bainite are obtained in simulated CGHAZ with t8/5from3.7s to7s. Bainite is characterized by lath. Retained austenite is found among the bainitic ferrite laths. Granular bainite begins to form when t8/5is more than15s. Ferrite starts to be observed when t8/5is more than45s. The more heat is input, the more ferrite forms. The microstructure is predominantly bainite in a wide heat input range from3.7s to2500s. The SH-CCT diagram indicates that even under the condition of fairly rapid cooling (t8/5=3.7s), entire martensite in simulated CGHAZ has not been attained and Vickers hardness is only286HV. So the copper-bearing steel possesses a small hardening quenching tendency and an excellent resistance to cold cracking under the condition of no preheating and no postheating. While t8/5is more than7s, CGHAZ starts softening; that is to say, the hardness begins to be less than the one of base metal. The higher heat input leads to the more softening. The hardness decreases to187HV when t8/5is2500s. So it is proposed to choose t8/5ranging from7s to35s during welding to prevent softening.
Single thermal cycle experiments show that copper-bearing steel has a narrow range of heat input or line energy. Under the condition of higher heat input or line energy, brittlement is easy to happen in CGHAZ. Granular bainite transformed from austenite leads to brittlement. On the contrary, lath bainitic ferrite formed with lower heat input can increase toughness. Softening begins to occur in CGHAZ (t8/5>7s). The dissolution of ε-Cu and coarser lath bainitic ferrite and more ferrite cause softening in CGHAZ. The effect of M-A constituents on the impact toughness in simulated CGHAZ was studied. The dimensions and area fraction of granular M-A constituents also influence the impact toughness. There is no visible effect on the toughness when the dimensions of M-A constituents are less than1μm and the area fraction is less than5%. The toughness decreases greatly once the dimensions exceed1μm and the area fraction is more than5%. Therefore, decreasing the dimensions and area fraction of M-A constituents by controlling welding heat input will do good to improve the impact toughness of copper-bearing steel.
Experiments simulating the whole HAZ show that the softening phenomena take place in the whole heat-affected zones when t8/5is15s. The hardness in intercritical (ICHAZ) decreases by50HV compared with that of the base metal and it is the most softened region due to re-dissolving of precipitate phase and ferrite compared with other regions in HAZ. The slight increase in hardness in FGHAZ is connected with microstructure refinement. The formation of lath bainitic ferrite and the enhancement of copper solid solution strengthening cause the hardness recovery for CGHAZ. Even so, the hardness value in CGHAZ is still less than that of the base metal but the softening phenomenon is not evident. CGHAZ has relatively low impact toughness owing to the growth of austenite grain size and coarse lath bainitic ferrite when t8/5is15s. FGHAZ achieves better impact toughness for its short time maintaining at higher temperature after austenization to reduce the austenite grain size. ICHAZ has also good impact toughness.
Double thermal cycle experiments demonstrate that obvious brittlement happens in the intercritically reheated CGHAZ. The reason is martensite twin formed and coarse granular bainite, which reduce the impact toughness. The higher heat is input, the more serious brittlement becomes. Thus, during multilayer welding, it is proposed to control strictly heat input.
Kinetic model of ε-Cu re-solution during welding was established. The volume fraction of ε-Cu re-solution keeps changing during welding. The initial size of ε-Cu and the peak temperature mainly influence re-solution kinetics of ε-Cu. The diffusion coefficient of ε-Cu in α-Fe is the indirect reason to influence re-solution of s-Cu. The smaller the initial size of ε-Cu is, the higher the peak temperature is, and the more ε-Cu re-dissolve. Calculation results of the kinetic model and simulation results in HAZ reach an agreement, that is to say, when the peak temperature is more than1000℃, ε-Cu completely re-dissolve into matrix phase.
Wire for GMAW was developed by using Mn-Ni-Cr-Cu as the main reinforcing elements, and Ti and B micro alloying without Mo and less Ni. Compared with the same strength grade for other wires in the world, this developed wire has excellent low temperature impact toughness and Charpy V-notch impact energy at-40℃is over97J.
GMAW, SAW and SMAW tests were investigated using patent welding wires. The tests show that the joints get good impact toughness at low temperature for three welding methods and the average impact energy (-40℃) in the welding joints is more than73J with great allowance compared with the requirement. The tensile strengths completely meet the strength requirement of base metal. Acicular ferrites (AF) and some proeutectoid ferrites exist in the weld metal. The great amount of AF in the weld metal can significantly improve both the strength and the toughness of weld metal. Bainite is attained in actual CGHAZ. Softening phenomena are not obvious in welding joints for GMAW and SMAW. There exists a slight softening phenomenon approaching the base metal, which and simulation results have a consistency. That is to say ICHAZ has the lowest hardness value.
Non-isothermal stress relief test results show that susceptible temperature of reheat cracking of copper-bearing steel is669℃and relevant cracking time is63seconds. The susceptible temperature interval is from669℃to695℃. So test steels have reheat cracking susceptibility. When CGHAZ is reheated to the temperature between650℃and700℃, intracrystalline strength is high for the distribution of carbonide of Cr and Mo. Intercrystalline failure cracking takes place owing to low strength on the grain boundary.
引文
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