X80管线钢用自保护药芯焊丝工艺研究
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摘要
随着国民经济的发展和对石油、天然气资源需求的急剧增加,管线建设如火如荼。以适合野外施工,抗风能力强的自保护药芯焊丝得到了广泛的应用。但是,我国管道焊接用的全位置自保护药芯焊丝主要依靠进口美国林肯公司和哈伯特公司的产品,国内迫切需要提高自保护药芯焊丝的质量。
药粉预处理对焊丝的工艺性能具有很大的影响。本文首次提出用水代替钾钠水玻璃作为药粉粘结剂,效果很好,既节约了粘结剂的费用,又可以充分利用筛分掉的细粉,具有很大的经济效益。同时确立烧结温度在700~850°之间,保温半小时。经过预处理,不但提高了药粉的均匀性、耐潮性、流动性,而且还除去了药粉中有害化学成分,改善了焊丝的工艺性能。
熔滴过渡形式影响药芯焊丝的工艺性能和力学性能,本文借助高速摄影设备对研制的X80管线钢用自保护药芯焊丝的熔滴过渡形态及冶金因素对熔滴过渡的影响进行了研究。发现电弧燃烧过程中不存在滞熔性渣,药芯的熔化先于钢带,熔滴过渡以附渣过渡和爆炸过渡为主。
渣系中Fe_2O_3、Li_2CO_3、Al-Mg等对熔滴过渡行为有较大的影响,本文设计三组试验,对采集的焊接电弧的电压电流信号进行统计分析,总结出其对熔滴过渡及焊接工艺的影响规律。Fe_2O_3降低熔滴的表面张力,细化熔滴,但提高药粉的熔点,增大飞溅。Li_2CO_3的影响比较复杂,含量较少时,细化熔滴作用不明显,含量多时,增大飞溅。Al-Mg增加电弧温度,降低熔滴表面张力,细化熔滴,但焊接时增大烟雾。综合考虑,Fe_2O_3含量为10,Li_2CO_3含量为2,Al-Mg含量为14时,整体效果较好。
成功研制了BaF_2- Al-Mg渣系的自保护药芯焊丝,按照西气东输二线管道工程线路焊接技术规范,对焊丝的工艺性能和接头的力学性能进行了综合评定,评定结果良好。
Pipeline construction has been increased with the nation economy development and increased dramatically demand of oil and natural gas. The Self-Shielded Flux Cored Wire( SSFCW) as is suitable for construction field and strong wind resistance is widely used for all-position welding of pipeline,but the majority of consumed SSFCW in China relies on importing the product of Lincoln and Hobart corporation due to the poor quality of domestic SSFCW. So there is an urgent need to develop the domestic SSFCW.
Pre-treatment process of the powder has a great impact on performance of the wire. In this paper, the water was first proposed as a powder binder, which is more effective than sodium silicate binder. It not only saves the cost of the binder but also can take full advantage of the fine powder screened out , so it has great economic benefits. At the same time, the sintering temperature of the powder is established between 700~850°,and the holding time is half an hour. It improve the uniformity of powder, powder flow, reduce water absorption, remove the harmful chemical components in the power and improve the performance of wire.
Metal transfer can affect process and mechanical properties of SSFCW. In this paper, metal transfer patterns of SSFCW were studied by high-speed photographic equipment, and the impact of metallurgical factors on metal transfer was also studied. The result is that there is no hysteresis slag in arc combustion, the flux melts before strip, the main forms of the metal transfer are explosive transition and slag attached transition.
Fe_2O_3, Li_2CO_3, Al-Mg in slag have a great impact on metal transfer. Through three sets of tests, the signals of welding voltage and current were statistically analyzed, summarized their impact on droplet transfer and welding technology, Fe_2O_3 in the flux can reduce the surface tension of metal droplet, make droplet refined, but it increase the melting point of powder and spatter. The impact of Li_2CO_3 in the flux on metal transfer is more complicated than Fe_2O_3. When the content of Li_2CO_3 in the flux is less, the effect on droplet refinement is not obvious, but when it is more, the spatter is increased. Al-Mg in the flux can increase arc temperature, lower the surface tension of droplet, but it increase welding fumes. At last the conclusion is considered : when the content of Fe_2O_3 is 10, the content of Li_2CO_3 is 2, the content of Al-Mg is 14, the overall effect is good.
The self-shielded flux-cored wire in slag system of BaF_2-Fe_2O_3-Li_2CO_3-Al-Mg was successfully developed. In accordance with the specification of second West-East Gas Transmission Pipeline Project, the performance and mechanical properties of the wire was comprehensively assessed, the results is good.
药粉预处理对焊丝的工艺性能具有很大的影响。本文首次提出用水代替钾钠水玻璃作为药粉粘结剂,效果很好,既节约了粘结剂的费用,又可以充分利用筛分掉的细粉,具有很大的经济效益。同时确立烧结温度在700~850°之间,保温半小时。经过预处理,不但提高了药粉的均匀性、耐潮性、流动性,而且还除去了药粉中有害化学成分,改善了焊丝的工艺性能。
熔滴过渡形式影响药芯焊丝的工艺性能和力学性能,本文借助高速摄影设备对研制的X80管线钢用自保护药芯焊丝的熔滴过渡形态及冶金因素对熔滴过渡的影响进行了研究。发现电弧燃烧过程中不存在滞熔性渣,药芯的熔化先于钢带,熔滴过渡以附渣过渡和爆炸过渡为主。
渣系中Fe_2O_3、Li_2CO_3、Al-Mg等对熔滴过渡行为有较大的影响,本文设计三组试验,对采集的焊接电弧的电压电流信号进行统计分析,总结出其对熔滴过渡及焊接工艺的影响规律。Fe_2O_3降低熔滴的表面张力,细化熔滴,但提高药粉的熔点,增大飞溅。Li_2CO_3的影响比较复杂,含量较少时,细化熔滴作用不明显,含量多时,增大飞溅。Al-Mg增加电弧温度,降低熔滴表面张力,细化熔滴,但焊接时增大烟雾。综合考虑,Fe_2O_3含量为10,Li_2CO_3含量为2,Al-Mg含量为14时,整体效果较好。
成功研制了BaF_2- Al-Mg渣系的自保护药芯焊丝,按照西气东输二线管道工程线路焊接技术规范,对焊丝的工艺性能和接头的力学性能进行了综合评定,评定结果良好。
Pipeline construction has been increased with the nation economy development and increased dramatically demand of oil and natural gas. The Self-Shielded Flux Cored Wire( SSFCW) as is suitable for construction field and strong wind resistance is widely used for all-position welding of pipeline,but the majority of consumed SSFCW in China relies on importing the product of Lincoln and Hobart corporation due to the poor quality of domestic SSFCW. So there is an urgent need to develop the domestic SSFCW.
Pre-treatment process of the powder has a great impact on performance of the wire. In this paper, the water was first proposed as a powder binder, which is more effective than sodium silicate binder. It not only saves the cost of the binder but also can take full advantage of the fine powder screened out , so it has great economic benefits. At the same time, the sintering temperature of the powder is established between 700~850°,and the holding time is half an hour. It improve the uniformity of powder, powder flow, reduce water absorption, remove the harmful chemical components in the power and improve the performance of wire.
Metal transfer can affect process and mechanical properties of SSFCW. In this paper, metal transfer patterns of SSFCW were studied by high-speed photographic equipment, and the impact of metallurgical factors on metal transfer was also studied. The result is that there is no hysteresis slag in arc combustion, the flux melts before strip, the main forms of the metal transfer are explosive transition and slag attached transition.
Fe_2O_3, Li_2CO_3, Al-Mg in slag have a great impact on metal transfer. Through three sets of tests, the signals of welding voltage and current were statistically analyzed, summarized their impact on droplet transfer and welding technology, Fe_2O_3 in the flux can reduce the surface tension of metal droplet, make droplet refined, but it increase the melting point of powder and spatter. The impact of Li_2CO_3 in the flux on metal transfer is more complicated than Fe_2O_3. When the content of Li_2CO_3 in the flux is less, the effect on droplet refinement is not obvious, but when it is more, the spatter is increased. Al-Mg in the flux can increase arc temperature, lower the surface tension of droplet, but it increase welding fumes. At last the conclusion is considered : when the content of Fe_2O_3 is 10, the content of Li_2CO_3 is 2, the content of Al-Mg is 14, the overall effect is good.
The self-shielded flux-cored wire in slag system of BaF_2-Fe_2O_3-Li_2CO_3-Al-Mg was successfully developed. In accordance with the specification of second West-East Gas Transmission Pipeline Project, the performance and mechanical properties of the wire was comprehensively assessed, the results is good.
引文
[1]蒋昊,栗卓新,蒋建敏.自保护药芯焊丝的国内外研究进展焊接.2003,12 (5)
[2]陈邦固等.药芯焊丝一焊材工业面临的机遇与挑战(上).焊接技术,1993 (6),32~ 38
[3]卓鸿速等.药芯焊丝的发展及在船舶建造中的应用前景的探讨.造船技术,1986 (11)
[4]薛振奎,隋永莉.国内外油气管道焊接施工现状与展望.焊接技术,2001 (30)
[5]张文钺.焊接冶金学(基本原理).北京:机械工业出版社,1996,29~30
[6]张智,张文钺,陈邦固.高韧性自保护药芯焊丝.焊接学报,1996,17(2)
[7]中国专利1152490A
[8]周振丰,张文钱.焊接冶金与金属焊接性.北京:机械工业出版社,1987,51-52
[9]魏琪等.氧氮氢对自保护药芯焊丝气孔的影响.北京工业大学学报,1998,24(3),19 22
[10] Wei Qi,Hu Qiang. A study of weld pore sensitivity of self-shielded flux cored electrodes.Welding Joumal,2002(6)
[11]魏琪,熊第京,涨汁霞等.高氟化钙渣系自保护药芯焊丝焊缝气孔敏感性研究,第八次全国焊接会议论文集.北京:机械工业出版社,1997,95~97
[12]魏琪,胡强,蒋建敏等.铝对自保护药芯焊丝性能的影响.焊接学报,2000,21(2)
[13] M.A.QUINTANA,J.McLANE,S.S.BABU,S.A.DAVID.Inclusion Formation in Self-Shield Flux Cored Arc Weld.Welding Journa1,2001(4)
[14] S.S.BABU , S.A.DAVID , M.A.QUINTANA. Modeling Microstructure Development in Self-Shield Flux Cored Arc Welds. Welding Journal,2001(4),91s~97s
[15] Zhang Zhi,Chen Banggu,Zhang Wenyue. Investigation on mechanism of fixing nitrogen in self-shielded flux cored arc welding. China Welding,1997(3)
[16]胡强,魏琪,蒋建敏等.稀土元素对自保护药芯焊丝的影响.焊接学报,2001,22(2)
[17] Li Zhuoxin,Cheng Banggu,Jing Lihong. Mechanism of improving toughness of self-sh ielded flux cored wire. Transactions of the China Welding Institute,2001(8)
[18] M.ES-SOUNI,P.A.BEAVEN,GM.EVANS. Microstructure and AEM studies of self-shielded flux cored arc weldments. Welding Journal,I992(2),35S~45S
[19] D.C.SMITH. Development,propties and usability of low-hydrogene lectrodes. Welding Journal,1959,37S~3925
[20] D.C.SMITH,K.P.JOHANNES. Development of a notch-tough self-shielded flux-cored electrode. Welding Joumal,1968(3),207~214
[21] D.J.KOTECKI,R.A.MOLL. A toughness study of steel weld metal from self-shielded flux-cored electrodes-PartI. Welding Journal,1970(4),157s~165s
[22] D.J.KOTECKI,R.A.MOLL. A toughness study of steel weld metal from self-shielded flux cored electrodes-PartII. Welding Journal,1972(3),138s~155s
[23]周志良.多层自保护药芯焊丝电弧焊焊缝组织和性能.大连铁道学院学报,1997(9)
[24]张清辉,吴宪平等.焊接材料研制理论与技术.北京:冶金工业出版社,2002
[25]孟昭贵,许宝花.自保护药芯焊丝的工艺分析.煤炭机械,1998(6)
[26] Li Zhuoxin,Li Huan,Chen Banggu. Study on effects of droplet transfer on operation performance of self-shielded flux cored wire. Chinese Journal of Mechanical Engineering,2000(3)
[27] Li Zhuoxin,Chen Banggu,Ping Huangfu. Study on metal transfer modes of self-shielded flux cored welding wire. Chinese Journal of Mechanical Engineering,1999(12)
[28]王其隆,殷树言.钢焊丝熔化极气电焊的跳弧现象与射流过渡[J].材料科学与工艺,1982,(1):101~111
[29]王其隆,殷树言,张九海等.熔化极脉冲焊电弧形态的可控性及其与熔滴过渡的关系[J].哈尔滨工业大学学报,1980,(4):103~114
[30] J. Hu, H.L. Tsai. Heat and mass transfer in gas metal arc welding PartⅠ:The metal[J]. Heat and Mass Transfer, 2007,832~8137
[31] J. Hu, H.L. Tsai. Heat and mass transfer in gas metal arc welding PartⅡ:The metal[J]. Heat and Mass Transfer, 2007,808~810
[32]候英玮.材料成型工艺[M].北京:中国铁道出版社,2002,183~238
[33]栗卓新,皇甫平.自保护药芯焊丝熔滴过渡的控制.机械工程学报,2001.7
[34]栗卓新,陈邦固等.自保护药芯焊丝的研究进展评述[J].中国机械工程,1996
[35]喻萍,潘川,薛锦等.铝对自保护药芯焊丝焊缝组织及力学性能的影响.西安交通大学学报,2004.9
[36]李坤.几种组分对自保护药芯焊丝工艺性能和熔敷金属韧性的影响.机械科学研究院哈尔滨研究所,2005
[37]傅菊英,姜涛,朱德庆等.烧结球团学.湖南:中南工业大学出版社,1996年
[38]陈邦固,曹文山,栗卓新.熔炼型药芯焊丝药粉的理化性质.焊接学报,1997.9
[39]赵丽,张富巨.药芯焊丝电弧焊的熔滴过渡与相关技术特性.焊接技术,2002.12第31卷增刊
[40]唐伯钢,尹士科,王玉荣.低碳钢与低合金高强钢焊接材料.机械工业出版社,1987
[41]喻萍.自保护药芯焊丝冶金过程研究[D].西安:西安交通大学,2005.
[42]陈邦固,雷万钧.“滞熔”现象对碱性气保护药芯焊丝飞溅的影响.焊接技术,1995.6
[2]陈邦固等.药芯焊丝一焊材工业面临的机遇与挑战(上).焊接技术,1993 (6),32~ 38
[3]卓鸿速等.药芯焊丝的发展及在船舶建造中的应用前景的探讨.造船技术,1986 (11)
[4]薛振奎,隋永莉.国内外油气管道焊接施工现状与展望.焊接技术,2001 (30)
[5]张文钺.焊接冶金学(基本原理).北京:机械工业出版社,1996,29~30
[6]张智,张文钺,陈邦固.高韧性自保护药芯焊丝.焊接学报,1996,17(2)
[7]中国专利1152490A
[8]周振丰,张文钱.焊接冶金与金属焊接性.北京:机械工业出版社,1987,51-52
[9]魏琪等.氧氮氢对自保护药芯焊丝气孔的影响.北京工业大学学报,1998,24(3),19 22
[10] Wei Qi,Hu Qiang. A study of weld pore sensitivity of self-shielded flux cored electrodes.Welding Joumal,2002(6)
[11]魏琪,熊第京,涨汁霞等.高氟化钙渣系自保护药芯焊丝焊缝气孔敏感性研究,第八次全国焊接会议论文集.北京:机械工业出版社,1997,95~97
[12]魏琪,胡强,蒋建敏等.铝对自保护药芯焊丝性能的影响.焊接学报,2000,21(2)
[13] M.A.QUINTANA,J.McLANE,S.S.BABU,S.A.DAVID.Inclusion Formation in Self-Shield Flux Cored Arc Weld.Welding Journa1,2001(4)
[14] S.S.BABU , S.A.DAVID , M.A.QUINTANA. Modeling Microstructure Development in Self-Shield Flux Cored Arc Welds. Welding Journal,2001(4),91s~97s
[15] Zhang Zhi,Chen Banggu,Zhang Wenyue. Investigation on mechanism of fixing nitrogen in self-shielded flux cored arc welding. China Welding,1997(3)
[16]胡强,魏琪,蒋建敏等.稀土元素对自保护药芯焊丝的影响.焊接学报,2001,22(2)
[17] Li Zhuoxin,Cheng Banggu,Jing Lihong. Mechanism of improving toughness of self-sh ielded flux cored wire. Transactions of the China Welding Institute,2001(8)
[18] M.ES-SOUNI,P.A.BEAVEN,GM.EVANS. Microstructure and AEM studies of self-shielded flux cored arc weldments. Welding Journal,I992(2),35S~45S
[19] D.C.SMITH. Development,propties and usability of low-hydrogene lectrodes. Welding Journal,1959,37S~3925
[20] D.C.SMITH,K.P.JOHANNES. Development of a notch-tough self-shielded flux-cored electrode. Welding Joumal,1968(3),207~214
[21] D.J.KOTECKI,R.A.MOLL. A toughness study of steel weld metal from self-shielded flux-cored electrodes-PartI. Welding Journal,1970(4),157s~165s
[22] D.J.KOTECKI,R.A.MOLL. A toughness study of steel weld metal from self-shielded flux cored electrodes-PartII. Welding Journal,1972(3),138s~155s
[23]周志良.多层自保护药芯焊丝电弧焊焊缝组织和性能.大连铁道学院学报,1997(9)
[24]张清辉,吴宪平等.焊接材料研制理论与技术.北京:冶金工业出版社,2002
[25]孟昭贵,许宝花.自保护药芯焊丝的工艺分析.煤炭机械,1998(6)
[26] Li Zhuoxin,Li Huan,Chen Banggu. Study on effects of droplet transfer on operation performance of self-shielded flux cored wire. Chinese Journal of Mechanical Engineering,2000(3)
[27] Li Zhuoxin,Chen Banggu,Ping Huangfu. Study on metal transfer modes of self-shielded flux cored welding wire. Chinese Journal of Mechanical Engineering,1999(12)
[28]王其隆,殷树言.钢焊丝熔化极气电焊的跳弧现象与射流过渡[J].材料科学与工艺,1982,(1):101~111
[29]王其隆,殷树言,张九海等.熔化极脉冲焊电弧形态的可控性及其与熔滴过渡的关系[J].哈尔滨工业大学学报,1980,(4):103~114
[30] J. Hu, H.L. Tsai. Heat and mass transfer in gas metal arc welding PartⅠ:The metal[J]. Heat and Mass Transfer, 2007,832~8137
[31] J. Hu, H.L. Tsai. Heat and mass transfer in gas metal arc welding PartⅡ:The metal[J]. Heat and Mass Transfer, 2007,808~810
[32]候英玮.材料成型工艺[M].北京:中国铁道出版社,2002,183~238
[33]栗卓新,皇甫平.自保护药芯焊丝熔滴过渡的控制.机械工程学报,2001.7
[34]栗卓新,陈邦固等.自保护药芯焊丝的研究进展评述[J].中国机械工程,1996
[35]喻萍,潘川,薛锦等.铝对自保护药芯焊丝焊缝组织及力学性能的影响.西安交通大学学报,2004.9
[36]李坤.几种组分对自保护药芯焊丝工艺性能和熔敷金属韧性的影响.机械科学研究院哈尔滨研究所,2005
[37]傅菊英,姜涛,朱德庆等.烧结球团学.湖南:中南工业大学出版社,1996年
[38]陈邦固,曹文山,栗卓新.熔炼型药芯焊丝药粉的理化性质.焊接学报,1997.9
[39]赵丽,张富巨.药芯焊丝电弧焊的熔滴过渡与相关技术特性.焊接技术,2002.12第31卷增刊
[40]唐伯钢,尹士科,王玉荣.低碳钢与低合金高强钢焊接材料.机械工业出版社,1987
[41]喻萍.自保护药芯焊丝冶金过程研究[D].西安:西安交通大学,2005.
[42]陈邦固,雷万钧.“滞熔”现象对碱性气保护药芯焊丝飞溅的影响.焊接技术,1995.6