新型抗磨铸钢与20钢的焊接特性及机理研究
摘要
新型低合金抗磨铸钢具有硬度高、耐磨性好的优点，已广泛用于建筑机械等领域中。但因其切削加工性极差，对于那些需经切削加工方能保证尺寸精度和互换性的易损件，制造非常困难。为扩大该抗磨材料的应用范围，解决切削加工的困难，本文根据异种钢焊接原理，用焊接复合的方法克服了抗磨铸钢件在制造的上述难题。文中对该抗磨铸钢与20钢异种金属的焊接方法、焊接材料、焊接工艺及其参数等进行了全面的试验研究，做了一些创新性工作，获得了一些具有科学指导意义及工程应用价值的研究成果：指出了合理设计焊接接头可避免或减少异种钢焊接接头缺陷，在生产及设计中，应尽量避免采用短小、不规则的焊缝；抗磨铸钢与20钢焊接时，选用碱性低氢型焊条，直流反接，焊后缓冷，是防止裂纹产生的有效措施。同时还阐述了后热处理对减小或消除延迟裂纹有利，异种钢焊后缓冷至200～250℃时，再保温2～4小时，对控制延迟裂纹，改善接头组织，提高接头力学性能是十分重要的。文中还就异种钢焊接缺陷的产生及形成机理、控制措施；组织的形成过程及对力学性能的影响等作了详细的分析论证。本文所得焊接接头的拉伸强度与抗磨铸钢相等或接近(σ_b≈400 MPa)，冲击韧性优于抗磨铸钢(α_k≈25 J.cm~(～2))。应用所得试验结果制造了40余块磨耗板，经10余家用户装机运行两年多证明，该磨耗板工作可靠，效果良好，有较高应用价值和显著的经济效益，其综合经济效益较进口混泥土输送泵磨耗板高5～7倍，已部分代替此类进口件。
The new-style mild alloy wearing resistant cast steel combines the advantages of high hardness and good wearing resistant capability and has wide application in fields of architecture and mechanism etc. But ,at the same time , it's mechanical properties are worse , and it's very difficult to manufacture and assure dimension precision for the damageable workpiece when machining. For the sake of broadening the applied range of such wearing resistant material, this paper is about the work on solving the above-mentioned mechanical difficult problem with the method of weld-compound according to the principium of heterogeneous-steels-welding. In this paper, we roundly tested and researched the welding methods, electrodes, programme and parameters employed on wearing resistant cast steel and 20 steel, and, we made some innovations and acquired many instructional returns which have their applied cost: rationally designed weld tie-in can avoid or abate the flaws of heterogeneous-steels-weiding; a
voiding small and irregular weld gaps in design and manufacture to the best of our abilities; selecting alkaline and low-hydrogen welding-rods and direct-current reverse-connection and slowly cooling after welding. These measures can effectively prevent the weld flaws. Simultaneously, we expatiated that the later-heat-treatment(slowly cooling down to 200-250C after welding and then keep temperature for 2~4 hours) is in the favor of abating and eliminating the weld flaws, and this is very important to improve the weld microstructure and the mechanical properties of weld tie-in. In addition, we detailedly analyzed and demonstrated the generation and growing mechanism of the heterogeneous-steels-welding flaws and the restraining measures; we discussed the way to modify weld microstructure and then- influence on the mechanical
properties. The weld tie-in acquired in this research is equal or close to the wearing resistant cast steel in tensile strength( o b=400 MPa) and precede in impact ductility(ak=25J.cm-2). We have manufactured forty or more abrasion-plates and these plates have been applied in ten or more factories for two years. As a result, such abrasion-plates can work well and economically and remarkably course economic benefit which is 5~7 times of the imported concrete conveying pump abrasion-plate, and even part of them can substitute the imported ones.
The new-style mild alloy wearing resistant cast steel combines the advantages of high hardness and good wearing resistant capability and has wide application in fields of architecture and mechanism etc. But ,at the same time , it's mechanical properties are worse , and it's very difficult to manufacture and assure dimension precision for the damageable workpiece when machining. For the sake of broadening the applied range of such wearing resistant material, this paper is about the work on solving the above-mentioned mechanical difficult problem with the method of weld-compound according to the principium of heterogeneous-steels-welding. In this paper, we roundly tested and researched the welding methods, electrodes, programme and parameters employed on wearing resistant cast steel and 20 steel, and, we made some innovations and acquired many instructional returns which have their applied cost: rationally designed weld tie-in can avoid or abate the flaws of heterogeneous-steels-weiding; a
voiding small and irregular weld gaps in design and manufacture to the best of our abilities; selecting alkaline and low-hydrogen welding-rods and direct-current reverse-connection and slowly cooling after welding. These measures can effectively prevent the weld flaws. Simultaneously, we expatiated that the later-heat-treatment(slowly cooling down to 200-250C after welding and then keep temperature for 2~4 hours) is in the favor of abating and eliminating the weld flaws, and this is very important to improve the weld microstructure and the mechanical properties of weld tie-in. In addition, we detailedly analyzed and demonstrated the generation and growing mechanism of the heterogeneous-steels-welding flaws and the restraining measures; we discussed the way to modify weld microstructure and then- influence on the mechanical
properties. The weld tie-in acquired in this research is equal or close to the wearing resistant cast steel in tensile strength( o b=400 MPa) and precede in impact ductility(ak=25J.cm-2). We have manufactured forty or more abrasion-plates and these plates have been applied in ten or more factories for two years. As a result, such abrasion-plates can work well and economically and remarkably course economic benefit which is 5~7 times of the imported concrete conveying pump abrasion-plate, and even part of them can substitute the imported ones.
引文
1．何康生 曹雄夫 异种金属焊接 北京：机械工业出版社 1986：1，210～240
2. Dilthey, U.; Bohm, S.; Trager, G.; Ghandehari, A. Laser-beam and electron-beam welding of material combinations consisting of cast iron and case-hardening or heat-treatable steels Schweissen and Schneiden/Welding & Cutting v 50 n 11 Nov 1998:214-216
3．[日]岛村昭治 编著 蔡可芬译 开拓未来的尖端材料 冶金工业出版社1984：33～39
4．[美]R．A林德伯格 N．R 布拉顿 焊接及其它连接方法 李政焕等译科学技术出版社重庆分社 1983：231
5. Ma, A.; Sharp, J.V. Fatigue design of cast steel nodes in offshore structures based on research data Proceedings of the Institution of Civil Engineers, Water Maritime and Energy v 124 n 2 Jun 1997:112-126
6．铸造手册(第一卷) 陶令桓主编 北京：机械工业出版社 1993：703～709
7．贾安东 焊接结构生产及生产设计 天津：天津大学出版社 1992：8
8．中国机械工程学会焊接学会 编 焊接手册(材料的焊接) 北京：机械工业出版社 1992：581～602
9．藩春旭 孙国正 异种钢焊接性现状和发展 水利电力机械 1998(6)：42～46
10. Savage.W, Nippes. E and Szekeres. E A Study of weld interface phenomena in a low alloy steel. Welding Journal, 1976,55(9):260
11．忻云彪 雷月葆 李培宁 等 奥氏体不锈钢焊条焊接 Cr5Mo工艺管线接头长期高温服役前后熔合区的组织和性能 压力容器 1992，13(2)：112
12．杨世柏 藩春旭 杨红霞 母材碳含量对A-F异种钢焊接熔合区断口形态的影响 武汉交通科技大学学报1995，19(3)：223
13. Lundin. C D. Dissimilar metal welds-transition joints literature review Welding Journal 1982,61(2):58
14. Faber. G. and Gooch .T G. Welded joints between stainless and low alloy steels current position. Welding in the World 1982,20(5/6):87
15. P.J.Boothby. predicting hardness in steel HAZ Metal Construction.1995,17(6):363
16．刘仲青 刘凯编著 异种金属焊接技术指南 北京：机械工业出版社 1997：7～8
17．[日]副岛一雄 仁能贤次著 铸钢铸铁焊接要点 张锐译 黑龙江人民出版社 1980：1～17
18．杨继武 郑民会 刘会立 ZG50MnSi可焊性工艺研究及应用 电焊机1998(4)：45～48
19．胡秀彬 龚淑钟等 ZG75CrMo 热轧工作辊堆焊工艺的研究 焊接技术 1999(4)：13～14
20．储凯 许斌 等 机械工程材料 重庆大学出版社 1998：107
21. Schubert, Joachim; Urlichs, Karl; Scholler, Hermann Weldability of heterogeneous joints between the cast steel GX12CrMoWVNbN 10-11 and low-alloyed steels Schweissen und Schneiden/Welding & Cutting v 49 n 9 Sep 1997:688-690
22．黄岳林 等 汽车起重机吊臂焊接变形控制 焊接技术1999(1)：13～14
23．曾乐 主编 现代焊接技术手册 上海：上海科学技术出版社 1993
24．薛迪苷 主编 焊接概论 北京：机械工业出版社1996：22～23
25．吴树雄编著 电焊条运用指南(第二版) 北京：化学工业出版社 1996：101
26．张子荣 李昴鹤 电焊条 北京：机械工业出版社1998：142～165
27．凌开宇 等 铸铁冷焊实践 焊接 1995(10)：27～28
28．陈伯蠡 焊接工程缺欠分析与对策 北京：机械工业出版社 1997：282～314
29．周振丰 张文钺 焊接冶金与金属焊接性(第二版) 北京：机械工业出版社1992：37～60
30．周敏惠等 焊接缺陷与对策 上海：上海科学技术文献出版社 1989：31～37
31. D.Uwer Welding Carbon Manganese Steels. Metal construction and Bristrish welding Journal. 1993,2(10) :443
32．姜焕中 电弧焊及电渣焊 北京：机械工业出版社 1993：70～87
33. Bschorr, Thomas; Jenicek, Andrea; Nentwig, Andrea W.E. Composite structures consisting of steel and nodular-graphite cast iron manufactured by means of magnetically impelled arc butt welding Welding Research Abroad v 46 n 1 Jan 2000:18-23
34．张文钺 焊接物理冶金 天津：天津大学出版社 1991
35．江全昌 980S装载机铲刀板与斗壁材料焊接抗裂性试验 焊接技术 1997(2)：10～11
36．李文成、刘青林 大型铸钢件的无变形低应力焊补 电焊机1999(4)：25～26
37. J.H.Dudas et al. Preventing weld cracks in high-strength aluminum alloys. Welding Journal. 1996(6):25
38．周浩森 焊接结构生产及装备 北京：机械工业出版社 1996：1～2；40～87
39．肖太霖 剪板机大齿轮断齿的焊补 焊接1995(10)：24
40．吕德林等著 焊接金相分析 北京：机械工业出版社 1986：64～225，244～247
41．何肇基 金属力学性能试验 冶金工业出版社 1986：5～47
42．杜兵 李彦 等 异种钢接头熔合区的脆化与断裂行为 焊接学报 1998 vol19(1)：8～11
43. A.Dhooge et al.Rehea tracking—review of recent studies (1984-1990).Welding in the Word. 1992,30(3/4):44-71
44．许留栓 蒋同武等 异质钢电机转子轴的冷态焊接 机械工人(热加工)2000(6)：25～26
45．任怀亮 金属试验技术 冶金工业出版社 1986：45～47
46. Faure, F.; Leggatt, R.H. Residual stresses in austenitic stainless steel primary coolant pipes and welds of pressurized water reactors International Journal of Pressure Vessels and Piping v 65 n 3 1996:265-275
2. Dilthey, U.; Bohm, S.; Trager, G.; Ghandehari, A. Laser-beam and electron-beam welding of material combinations consisting of cast iron and case-hardening or heat-treatable steels Schweissen and Schneiden/Welding & Cutting v 50 n 11 Nov 1998:214-216
3．[日]岛村昭治 编著 蔡可芬译 开拓未来的尖端材料 冶金工业出版社1984：33～39
4．[美]R．A林德伯格 N．R 布拉顿 焊接及其它连接方法 李政焕等译科学技术出版社重庆分社 1983：231
5. Ma, A.; Sharp, J.V. Fatigue design of cast steel nodes in offshore structures based on research data Proceedings of the Institution of Civil Engineers, Water Maritime and Energy v 124 n 2 Jun 1997:112-126
6．铸造手册(第一卷) 陶令桓主编 北京：机械工业出版社 1993：703～709
7．贾安东 焊接结构生产及生产设计 天津：天津大学出版社 1992：8
8．中国机械工程学会焊接学会 编 焊接手册(材料的焊接) 北京：机械工业出版社 1992：581～602
9．藩春旭 孙国正 异种钢焊接性现状和发展 水利电力机械 1998(6)：42～46
10. Savage.W, Nippes. E and Szekeres. E A Study of weld interface phenomena in a low alloy steel. Welding Journal, 1976,55(9):260
11．忻云彪 雷月葆 李培宁 等 奥氏体不锈钢焊条焊接 Cr5Mo工艺管线接头长期高温服役前后熔合区的组织和性能 压力容器 1992，13(2)：112
12．杨世柏 藩春旭 杨红霞 母材碳含量对A-F异种钢焊接熔合区断口形态的影响 武汉交通科技大学学报1995，19(3)：223
13. Lundin. C D. Dissimilar metal welds-transition joints literature review Welding Journal 1982,61(2):58
14. Faber. G. and Gooch .T G. Welded joints between stainless and low alloy steels current position. Welding in the World 1982,20(5/6):87
15. P.J.Boothby. predicting hardness in steel HAZ Metal Construction.1995,17(6):363
16．刘仲青 刘凯编著 异种金属焊接技术指南 北京：机械工业出版社 1997：7～8
17．[日]副岛一雄 仁能贤次著 铸钢铸铁焊接要点 张锐译 黑龙江人民出版社 1980：1～17
18．杨继武 郑民会 刘会立 ZG50MnSi可焊性工艺研究及应用 电焊机1998(4)：45～48
19．胡秀彬 龚淑钟等 ZG75CrMo 热轧工作辊堆焊工艺的研究 焊接技术 1999(4)：13～14
20．储凯 许斌 等 机械工程材料 重庆大学出版社 1998：107
21. Schubert, Joachim; Urlichs, Karl; Scholler, Hermann Weldability of heterogeneous joints between the cast steel GX12CrMoWVNbN 10-11 and low-alloyed steels Schweissen und Schneiden/Welding & Cutting v 49 n 9 Sep 1997:688-690
22．黄岳林 等 汽车起重机吊臂焊接变形控制 焊接技术1999(1)：13～14
23．曾乐 主编 现代焊接技术手册 上海：上海科学技术出版社 1993
24．薛迪苷 主编 焊接概论 北京：机械工业出版社1996：22～23
25．吴树雄编著 电焊条运用指南(第二版) 北京：化学工业出版社 1996：101
26．张子荣 李昴鹤 电焊条 北京：机械工业出版社1998：142～165
27．凌开宇 等 铸铁冷焊实践 焊接 1995(10)：27～28
28．陈伯蠡 焊接工程缺欠分析与对策 北京：机械工业出版社 1997：282～314
29．周振丰 张文钺 焊接冶金与金属焊接性(第二版) 北京：机械工业出版社1992：37～60
30．周敏惠等 焊接缺陷与对策 上海：上海科学技术文献出版社 1989：31～37
31. D.Uwer Welding Carbon Manganese Steels. Metal construction and Bristrish welding Journal. 1993,2(10) :443
32．姜焕中 电弧焊及电渣焊 北京：机械工业出版社 1993：70～87
33. Bschorr, Thomas; Jenicek, Andrea; Nentwig, Andrea W.E. Composite structures consisting of steel and nodular-graphite cast iron manufactured by means of magnetically impelled arc butt welding Welding Research Abroad v 46 n 1 Jan 2000:18-23
34．张文钺 焊接物理冶金 天津：天津大学出版社 1991
35．江全昌 980S装载机铲刀板与斗壁材料焊接抗裂性试验 焊接技术 1997(2)：10～11
36．李文成、刘青林 大型铸钢件的无变形低应力焊补 电焊机1999(4)：25～26
37. J.H.Dudas et al. Preventing weld cracks in high-strength aluminum alloys. Welding Journal. 1996(6):25
38．周浩森 焊接结构生产及装备 北京：机械工业出版社 1996：1～2；40～87
39．肖太霖 剪板机大齿轮断齿的焊补 焊接1995(10)：24
40．吕德林等著 焊接金相分析 北京：机械工业出版社 1986：64～225，244～247
41．何肇基 金属力学性能试验 冶金工业出版社 1986：5～47
42．杜兵 李彦 等 异种钢接头熔合区的脆化与断裂行为 焊接学报 1998 vol19(1)：8～11
43. A.Dhooge et al.Rehea tracking—review of recent studies (1984-1990).Welding in the Word. 1992,30(3/4):44-71
44．许留栓 蒋同武等 异质钢电机转子轴的冷态焊接 机械工人(热加工)2000(6)：25～26
45．任怀亮 金属试验技术 冶金工业出版社 1986：45～47
46. Faure, F.; Leggatt, R.H. Residual stresses in austenitic stainless steel primary coolant pipes and welds of pressurized water reactors International Journal of Pressure Vessels and Piping v 65 n 3 1996:265-275