特种耐磨药芯焊丝的制备工艺和性能优化研究
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摘要
近年来,耐磨药芯焊丝在国内外堆焊修复领域的使用越来越广泛,药芯焊丝的质量和修复层的耐磨性能决定了堆焊零部件的使用寿命。因此,对耐磨药芯焊丝的生产工艺和耐磨性评价进行研究具有重大的实际意义。
本课题在经过多次的焊接试验基础上,对药芯焊丝的配方要求提出了飞溅小、造气少和成型好等一系列的建议,为药芯焊丝配方设计的改进提供了依据。本课题采用的生产工艺是生产有缝药芯焊丝中的轧拔法。在研究药芯焊丝成型过程的基础上,采用了包括带钢边缘弯曲法与圆周组合弯曲法在内的精密带钢冷弯成型方法,设计出一套使药芯焊丝的断口截面为O型搭接的辊型,使有缝药芯焊丝在生产中的掉粉情况明显改善,提高了药芯焊丝的质量。
针对目前国内耐磨实验对真实工况模拟不够的情况,本文提出了两级耐磨实验法思想,设计了能够满足试件焊接要求的焊接平台和两种堆焊试件即平板试件和回转试件。经过多次的焊接试验调试出最佳的焊接参数。同时,建立了测试药芯焊丝堆焊层耐磨性的耐磨实验平台。本课题中的实验采用Q235钢和两种自制的药芯焊丝作对比实验,将3种试件在耐磨试验平台上进行耐磨实验。通过测量每个试件失重,分析扫描电镜和金相组织的照片,从宏观和微观角度比较了试件的耐磨性,选出最优的试件。研究表明本课题所建立的耐磨性评价试验平台可以快速、合理地评价出各种药芯焊丝的耐磨性能。
Recently, the wear-resistant flux-cored wire has been applied more widely in the surfacing field. The quality and wear resistance of the flux-cored wire affect the layer repair results. Therefore, the research and development of the production process and evaluation of the wear resistance of flux-cored wire are of great practical significance.
By the orthogonal test design,the formula of flux-cored wire was adjusted. It made the wear resistant of flux-cored wire reach the high level. Meanwhile, the welding process was simplified. The welding quality of flux-cored wire without the gas protection also met the requirement. The production process that used in this work was the rolling and drawing method for the seam-flux-cored wire. On the basis of the forming process of, many pass design methods were integrated including strip edge bending method and circumference combination bending method, a sets of rolls that can made the fracture cross-section of flux-cored wire with a lap-O-Roll were designed. The situation that powder out of flux-cored wire in production with the lap seam-flux-cored was better than with docking O-type one.
At present, wear experiment that simulated the real situation was not enough. According to this situation, two-level wear resistance test method was proposed, two welding samples were used in this work, one was flat-panel sample and another was rotary sample. A welding platform was designed to meet the requirements of the welding samples. After several welding tests, the best welding parameters were debugged. The experimental platform that tests the wear resistance of the flux-cored wire welding was established. Steel Q235 and two types of flux-cored wire made by ourselves were used for comparison test. Samples in the wear resistance test platform for wear resistance experiments were prepared. By measuring each sample’s weight loss, the pictures of the SEM and microstructure were analyzed, and the wear resistance of samples was compared, in which the optimum sample was select. Meanwhile, the establishment of the wear resistance experimental platform in this work can quickly and reasonably evaluate the wear resistance properties of the flux-cored wire.
本课题在经过多次的焊接试验基础上,对药芯焊丝的配方要求提出了飞溅小、造气少和成型好等一系列的建议,为药芯焊丝配方设计的改进提供了依据。本课题采用的生产工艺是生产有缝药芯焊丝中的轧拔法。在研究药芯焊丝成型过程的基础上,采用了包括带钢边缘弯曲法与圆周组合弯曲法在内的精密带钢冷弯成型方法,设计出一套使药芯焊丝的断口截面为O型搭接的辊型,使有缝药芯焊丝在生产中的掉粉情况明显改善,提高了药芯焊丝的质量。
针对目前国内耐磨实验对真实工况模拟不够的情况,本文提出了两级耐磨实验法思想,设计了能够满足试件焊接要求的焊接平台和两种堆焊试件即平板试件和回转试件。经过多次的焊接试验调试出最佳的焊接参数。同时,建立了测试药芯焊丝堆焊层耐磨性的耐磨实验平台。本课题中的实验采用Q235钢和两种自制的药芯焊丝作对比实验,将3种试件在耐磨试验平台上进行耐磨实验。通过测量每个试件失重,分析扫描电镜和金相组织的照片,从宏观和微观角度比较了试件的耐磨性,选出最优的试件。研究表明本课题所建立的耐磨性评价试验平台可以快速、合理地评价出各种药芯焊丝的耐磨性能。
Recently, the wear-resistant flux-cored wire has been applied more widely in the surfacing field. The quality and wear resistance of the flux-cored wire affect the layer repair results. Therefore, the research and development of the production process and evaluation of the wear resistance of flux-cored wire are of great practical significance.
By the orthogonal test design,the formula of flux-cored wire was adjusted. It made the wear resistant of flux-cored wire reach the high level. Meanwhile, the welding process was simplified. The welding quality of flux-cored wire without the gas protection also met the requirement. The production process that used in this work was the rolling and drawing method for the seam-flux-cored wire. On the basis of the forming process of, many pass design methods were integrated including strip edge bending method and circumference combination bending method, a sets of rolls that can made the fracture cross-section of flux-cored wire with a lap-O-Roll were designed. The situation that powder out of flux-cored wire in production with the lap seam-flux-cored was better than with docking O-type one.
At present, wear experiment that simulated the real situation was not enough. According to this situation, two-level wear resistance test method was proposed, two welding samples were used in this work, one was flat-panel sample and another was rotary sample. A welding platform was designed to meet the requirements of the welding samples. After several welding tests, the best welding parameters were debugged. The experimental platform that tests the wear resistance of the flux-cored wire welding was established. Steel Q235 and two types of flux-cored wire made by ourselves were used for comparison test. Samples in the wear resistance test platform for wear resistance experiments were prepared. By measuring each sample’s weight loss, the pictures of the SEM and microstructure were analyzed, and the wear resistance of samples was compared, in which the optimum sample was select. Meanwhile, the establishment of the wear resistance experimental platform in this work can quickly and reasonably evaluate the wear resistance properties of the flux-cored wire.
引文
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26崔占全.一种新型锻钢冷轧工作辊材料.钢铁, 2000, 35(6):54-56
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31 J. S. Ocborn, D J. Kotechi. Abrasion resistance of Iron-based hardfacing alloys. Welding Journal, 1995, 74(8):269-278
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35陈俐,潘春旭,许勇静.耐磨堆焊金属组织分析.武汉交通科技大学学报, 1998, 22(3):327-329
36高峰,赵艳玲,杨瑞林,等.碳化钨硬质合金颗粒和堆焊基体对堆焊层耐磨性影响.煤炭学报, 1996, 21(l):85-89
37陈邦固,金立鸿,刘继元,等.国内外药芯焊丝制造工艺、设备现状及发展趋势.机械工人, 2003, (8):2-6
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2企业技术开发.第四代焊接材料—药芯焊丝.北京:清华大学出版社, 1996:19-20
3王有祁,莫永文.国内外药芯焊丝发展概况.兵器材料科学与工程, 1991, 4:54-55
4桂赤斌,黄毅.我国药芯焊丝的现状分析与发展建议.现代制造工程, 1996, (4):138-140
5马凤辉,李春范.中国药芯焊丝行业现状.焊接,2003, (2):5-8
6白范雄.高硬度高硬度高韧性耐磨埋弧堆焊用药芯焊丝的研. [湘潭大学硕士论文]. 2006:1-3
7孙咸.国产气保护药芯焊丝的质量问题及对策.全国焊工大赛暨焊接材料专辑.洛阳, 2003:15-18
8田志凌,潘川,梁东图.药芯焊丝.北京:冶金工业出版社, 1999:1-56, 188-193
9喻萍,薛锦,潘川.自保护药芯焊丝与气保护药芯焊丝的比较.焊接技术, 2004, 33(1):44-45
10孙威.国产气保护药芯焊丝的质量问题及对策.机械工人, 2003, (8):15-16
11温家伶,王强,陈明清,等.自保护药芯焊丝研究的现状.武汉理工大学学报, 2002, 26(6):733-735
12孟昭贵,许宝花.自保护药芯焊丝的工艺分析.煤矿机械, 1998, (6):24-25
13张清辉,肖逸锋.耐磨堆焊中的两重性.焊接设备与材料, 2003, (32):43-45
14李巍,石凯,周勇,等.碳化钨耐磨药芯焊丝电弧堆焊工艺与性能的研究.热加工工艺, 2005, (2):49-51
15 M. Kenneth. Cored wire repair welding in the power industry. Welding&Metal Fabrication, 1998, 66(7):4-5
16胡强,魏琪,蒋建敏.稀土元素对子保护药芯焊丝的影响.焊接学报, 2001, (3):7-8,21
17纪东莲.稀土在钢铁焊接材料中的应用.稀土,1999, 20(1):69-71
18张志明.碲、稀土对焊缝金属的降氢韧化作用研究.哈尔滨工业大学学报, 1985,(3):73-76
19石端虎,印有胜.稀土元素对堆焊层组织与性能的影响.沈阳工业大学学报, 2003, 25(5):383-386
20张元彬,任登义.合金元素对堆焊焊缝硬度的影响.热加工工艺, 2003, (2):15-16
21任怀亮.金相实验技术.北京:冶金工业出版社, 1986, (5):15-47
22吕德林.焊接金相分析.北京:机械工业出版社, 1987:20-40
23 G. M. Reddy, T. Mohandas, K. Papukutty. Enhancement of ballistic capabilities of soft weldsthrough hardfacing. International Journal of Impact Engineering, 1999, 11(22):775-791
24黄智泉,魏建军,潘健.堆焊用药芯焊丝的应用及发展前景.机械工人, 2004, (8):38-40,44
25单际国,董祖珏,徐滨士.我国堆焊技术的发展及其在基础工业中的应用现状.中国表面工程, 2002, (4):20-24
26崔占全.一种新型锻钢冷轧工作辊材料.钢铁, 2000, 35(6):54-56
27马风辉,李春范.中国药芯焊丝现状.焊接, 2003, (2):5-8
28唐伯钢.对我国药芯焊丝发展目标和应解决问题的探讨.焊接技术,1997, (6):40-41
29张文钺.国外焊接材料的发展动态及加快国产药芯焊丝发展的建议.材料开发与工艺, 2000, 15(l):30-34
30李春范,赵润娴.回顾与瞻望——21世纪中国焊接材料(上).焊接, 2001, (1):6-9
31 J. S. Ocborn, D J. Kotechi. Abrasion resistance of Iron-based hardfacing alloys. Welding Journal, 1995, 74(8):269-278
32材料耐磨抗蚀及其表面技术委员会.材料的磨料磨损.北京:机械工业出版社, 1990:53-92
33 W. T. Wu, L T. Wu. The wear behavior between hardfacing materials . metalluringical and materials Transactions, 1996, A27(11):3639
34 D. Arthar. Does moly improve hardfacing filler metals. Welding Journal, 1996, 75(2):29
35陈俐,潘春旭,许勇静.耐磨堆焊金属组织分析.武汉交通科技大学学报, 1998, 22(3):327-329
36高峰,赵艳玲,杨瑞林,等.碳化钨硬质合金颗粒和堆焊基体对堆焊层耐磨性影响.煤炭学报, 1996, 21(l):85-89
37陈邦固,金立鸿,刘继元,等.国内外药芯焊丝制造工艺、设备现状及发展趋势.机械工人, 2003, (8):2-6
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