CN112404797A - 新型复合钢321+Q370qENH过渡层焊接用焊丝及方法 - Google Patents
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Abstract
本发明涉及一种能够满足Q370qENH耐候钢与321不锈钢复合钢过渡层焊接用焊丝及方法，包括不锈钢外皮及填充药粉，所述不锈钢外皮采用304L奥氏体不锈钢钢带，钢带厚度为0.35mm，宽度为10mm，所述填充药粉的各成分含量占药粉重量百分比为：98金红石25～30%，石英砂3～6%，钾长石1.5～2.5%，太酸钾3～5%，铝镁合金0.5～2.5%，氟化镁1～3%，氟化稀土1～3%，金属铬20～24%，镍粉：20～23%，电解锰2～5%，钼铁11～13%，铜粉3～6%，钛铁2～5%，余量铁粉，药粉填充率为20~24%。优点：按照“基层‑过渡层‑覆层”的焊接顺序，通过控制焊接参数、过渡层厚度及过渡层与覆层界面位置，有效降低了焊接工作量、提高了焊接效率，焊缝性能可靠，质量稳定。本发明填补了321+Q370qENH不锈钢耐候复合钢板焊接技术方面的空白。
Description
技术领域
本发明涉及一种能够满足Q370qENH耐候钢与321不锈钢复合钢过渡层焊接用焊丝及方法。
背景技术
近年来，随着钢结构桥梁的建设的飞速发展，桥梁结构形式出现多样化，新技术、新材料等能够突出创新性技术成为钢结构桥梁设计者追求的目标，高强度易焊接钢、免涂装耐候钢、不锈钢复合钢等在铁路钢桥梁上应用越来越广泛。不锈钢复合钢可根据钢桥设计要求合理选择不锈钢和基材组合和厚度配比，这种广泛的材料组合和厚度比，使材料在性能上和尺寸上达到完美的匹配，充分发挥覆层不锈钢材料和基层碳钢材料各自的优点，得到既有基层碳钢材料的强度和韧性，又有覆层不锈钢材料的良好耐腐蚀性能，还可以减轻钢桥重量，延长钢桥使用寿命，降低钢桥保养维护成本，已经成为桥梁设计者在解决复杂和重要工程结构时首选的材料。但是，321+Q370qENH不锈钢耐候复合钢能否成功应用于钢桥制造的关键技术之一就是此种不锈钢复合钢板自身的焊接难题，而焊接此类钢种并无成熟的焊接技术可借鉴，由于基材和覆材化学成分、力学性能和焊接性有重大差异，市场上并无适用于焊接Q370qENH耐候钢与321不锈钢复合钢过渡层的焊接材料。
发明内容
设计目的：针对背景技中的关键技术，设计一种能够满足Q370qENH耐候钢与321不锈钢复合钢过渡层焊接用焊丝及方法。
设计方案：321+Q370qENH不锈钢耐候复合钢板是由Q370qENH耐候钢与321不锈钢复合而成，是耐候钢与不锈钢首次合成，并应用于钢桁梁桥面板中，也是在钢桥制造中首次使用，321+Q370qENH不锈钢耐候复合钢能否成功应用于钢桥制造的关键技术之一就是此种不锈钢复合钢板自身的焊接难题，为了解决这一技术难题，本申请人在经过无数次的焊丝填充药粉实验室反复设计、试验、测试、定型，到中试反复优化设计、反复试验、反复测试，最终在实际大型钢结构桥梁得到应用。新型复合钢321+Q370qENH过渡层用焊丝及焊接方法，解决了新型复合钢321+Q370qENH过渡层焊接难题，确保基材焊缝力学性能满足Q370qENH指标，同时补偿覆层321由于稀释所引起的合金元素（如铬镍等）的降低，使覆层焊缝的合金成分与覆层321保持在同一水平，设计的焊接方法有效降低了焊接工作量、提高了焊接效率，保证了焊接质量，为铁路五分部钢桁梁复合桥面板焊接及其他类似结构制造提供了技术支撑。
为了实现本发明设计目的，本发明通过加入一定的合金成分一方面保证了基材Q370qENH耐候桥梁钢力学性能、基层焊缝金属耐腐蚀性；另一方面，通过合理的化学成分设计，能够补偿覆层由于稀释作用所引起的合金元素Cr、Ni等元素的降低，同时避免了因基层焊缝向覆层焊缝中渗入过多的C元素，导致覆层焊缝中产生马氏体组织，增大结晶裂纹倾向，通过补偿机制确保覆层焊缝的合金成分与覆材321合金成分匹配性。其次，针对新型复合钢321+ Q370qENH焊接性较差，对接焊缝易出现热裂纹等特点，本发明提出一种底线能量，易焊接的焊接方法，即焊接时，按照“先焊接基层，后焊接过渡层，最后焊接复层”的顺序，并通过控制焊接参数、过渡层厚度及其与覆层界面位置，有效降低了焊接工作量、提高了焊接效率，焊缝性能可靠，质量稳定。
技术方案1：一种新型复合钢321+Q370qENH过渡层用焊丝，包括不锈钢外皮及填充药粉，所述不锈钢外皮采用304L奥氏体不锈钢钢带，钢带厚度为0.35mm，宽度为10mm，所述填充药粉的各成分含量占药粉重量百分比为：98金红石25～30%，石英砂3～6%，钾长石1.5～2.5%，太酸钾3～5%，铝镁合金0.5～2.5%，氟化镁1～3%，氟化稀土1～3%，金属铬20～24%，镍粉：20～23%，电解锰2～5%，钼铁11～13%，铜粉3～6%，钛铁2～5%，余量铁粉。
技术方案2：一种新型复合钢321+Q370qENH过渡层用焊丝制作方法，将权利要求1所述填充药粉按组分设计称重，并混合均匀，放入保温炉中烘干处理待用；不锈钢钢带轧制成U型后，填充药粉制得粗丝，药粉填充率为20～24%，粗丝经轧制、拉拔工序减径，最终成品焊丝直径分别为Φ1.0mm、Φ1.2mm、Φ1.4mm。
技术方案3：一种新型复合钢321+Q370qENH过渡层用焊丝焊接方法，按照“先焊接基层，后焊接过渡层，最后焊接覆层”的顺序，基层焊丝选用与Q370qENH性能匹配的耐候焊丝 E491T1-GC，直径为φ1.2，采用CO2气体保护；过渡层焊接参数为：采用权利要求5所述焊丝，焊接电流I=220±10A，焊接电压28±2V，焊接速度V=26±4cm/min，过渡层下边缘距复合界面2mm，过渡层厚度t=4±1mm；覆层焊丝选用与321不锈钢化学成分相匹配的不锈钢焊丝TS347L-FC11，直径为φ1.2，采用CO2气体保护。
本发明与背景技术相比，一是药芯焊丝开发，不仅适用于新型不锈钢耐候复合钢321+Q370qENH对接焊缝过渡层的可靠焊接，而且填补了321+Q370qENH不锈钢耐候复合钢板过渡层焊接技术方面的空白；二是在药芯焊丝中通过加入一定的合金成分保证了基材Q370qENH耐候桥梁钢力学性能、基层焊缝金属耐腐蚀性；三是药芯焊丝通过合理的化学成分设计，能够补偿覆层由于稀释作用所引起的合金元素Cr、Ni等元素的降低，避免了因基层焊缝向覆层焊缝中渗入过多的C元素，导致覆层焊缝中产生马氏体组织，增大结晶裂纹倾向，通过补偿机制确保覆层焊缝的合金成分与覆材321合金成分匹配性；四是本发明提出底线能量，易焊接的焊接方法，焊接过程稳定，焊缝外观成型美观，通过控制过渡层厚度，过渡层与复合界面位置，确保焊缝性能可靠，质量稳定。
附图说明
图1是双面V型坡口示意图。
图2是单面V型带间隙坡口示意图。
图3是单面V型无带间隙坡口示意图。
图4是图1焊缝示意图，其中δ—板厚，H1、H2—坡口深度。
图5是图2焊缝示意图，其中δ—板厚，H1、H2—坡口深度。
图6是图3焊缝示意图，其中δ—板厚，H1、H2—坡口深度。
具体实施方式
实施例1：一种新型复合钢321+Q370qENH过渡层焊接用焊丝，1、药芯焊丝包括不锈钢外皮及填充药粉：（1）所述药芯焊丝药粉的各成分及其含量占药粉百分比为：98金红石23%，石英砂3%，钾长石1%，太酸钾3.5%，铝镁合金1%，氟化镁1.5%，氟化稀土2%，金属铬20%，镍粉23%，电解锰2%，钼铁12%，铜粉4%，钛铁2%，铁粉2%，药粉填充率22%；（2）根据（1）中所述的98金红石、石英砂、钾长石、太酸钾经过800℃以上高温烘焙，去除游离水和结晶水；（3）根据（1）中所述药粉中金属粉末和合金中颗粒度及化学成分要求如下表所示：
（4）所述的不锈钢外皮采用304L奥氏体不锈钢钢带，钢带厚度为0.35mm，宽度为10mm。
2. 采用不锈钢药芯焊丝生产设备，通过粗拉机组将不锈钢带通过成型轧辊加工成U型槽，填入药粉，药粉填充率22%，轧成管状，经过精拉机组多道拉拔减径，制成Φ1.2mm焊丝H1。
3.选用板厚为17mm不锈钢复合钢321+Q370qENH，其中基材厚14mm，覆材厚3mm，接头形式为结构简图2所示坡口形式，焊接方法及焊接参数见下表：
实施例2：一种新型复合钢321+Q370qENH过渡层用焊丝，1. 药芯焊丝包括不锈钢外皮及填充药粉：（1）所述药芯焊丝药粉的各成分及其含量占药粉百分比为：98金红石26%，石英砂5%，钾长石2.5%，太酸钾3%，铝镁合金2%，氟化镁2%，氟化稀土2.5%，金属铬19%，镍粉21%，电解锰2%，钼铁9%，铜粉3%，钛铁3%。药粉填充率24%；（2）根据（1）中所述的98金红石、石英砂、钾长石、太酸钾经过800℃以上高温烘焙，去除游离水和结晶水；（3）根据（1）中所述药粉中金属粉末和合金中颗粒度及化学成分要求如下表所示：
（4）所述的不锈钢外皮采用304L奥氏体不锈钢钢带，钢带厚度为0.35mm，宽度为10mm。
2. 采用不锈钢药芯焊丝生产设备，通过粗拉机组将不锈钢带通过成型轧辊加工成U型槽，填入药粉，药粉填充率24%，轧成管状，经过精拉机组多道拉拔减径，制成Φ1.2mm焊丝H2。
3.选用板厚为17mm不锈钢复合钢321+Q370qENH，其中基材厚14mm，覆材厚3mm，接头形式为结构简图3所示坡口形式，焊接方法及焊接参数见下表：
焊后分别对以、上2组实施例中焊接接头进行了外观检测、无损检测、力学性能检测维氏硬度检测、制定寿命下疲劳极限检测、覆层焊缝金属化学成分分析、抗腐蚀性能检测，结果如下：
（1）焊缝外观质量良好，无损检测满足GB/T 3323-2005 Ⅱ级要求。
（2）力学性能见下表，均满足Q370qENH指标要求。
（3）最大维氏硬度分别为207、209，均低于HV380，未出现马氏体组织。
（4）疲劳试验频率为15Hz，指定循环寿命为2×106次的条件下疲劳极限不低于140Mpa。
（5）覆层焊缝金属化学成分与覆层母材化学成分相似，保证了覆层焊缝具有与母材相近的抗腐蚀性。
（6）晶间腐蚀试验结果符合GB/T4237-2007《不锈钢热轧钢板和钢带》标准规定。
需要理解到的是：上述实施例虽然对本发明的设计思路作了比较详细的文字描述，但是这些文字描述，只是对本发明设计思路的简单文字描述，而不是对本发明设计思路的限制，任何不超出本发明设计思路的组合、增加或修改，均落入本发明的保护范围内。
Claims (6)
1.一种新型复合钢321+Q370qENH过渡层焊接用焊丝，包括不锈钢外皮及填充药粉，其特征是所述填充药粉的各成分含量占药粉重量百分比为：98金红石25～30%，石英砂3～6%，钾长石1.5～2.5%，太酸钾3～5%，铝镁合金0.5～2.5%，氟化镁1～3%，氟化稀土1～3%，金属铬20～24%，镍粉：20～23%，电解锰2～5%，钼铁11～13%，铜粉3～6%，钛铁2～5%，余量铁粉。
2.根据权利要求1所述的新型复合钢321+Q370qENH过渡层焊接用焊丝，其特征是：98金红石、石英砂、钾长石、太酸钾经过800℃以上高温烘焙，去除游离水和结晶水，防止焊接时[H]进入焊缝金属。
3.根据权利要求1所述的新型复合钢321+Q370qENH过渡层焊接用焊丝，其特征是：所述药粉中金属粉末和合金中颗粒度及化学成分如下：
1）金属铬70～80目，化学成分含量Cr≥99.6%、C≤0.01%、S≤0.02%、P≤0.01%；
2）镍粉，70～80目，化学成分含量Ni≥99.5%、C≤0.03%、S≤0.002%、P≤0.001%；
3）电解锰60～80目，化学成份含量Mn≥99.5%、C≤0.020%、S≤0.02%、P≤0.01%；
4）钼铁60～70目，化学成分含量Mo≥50%、Fe≥49%、C≤0.020%、S≤0.01%、P≤0.05%；
5）铜粉60～80目，化学成分含量Cu≥99.8、C≤0.020、S≤0.002、P≤0.01；
6）铝镁合金70～80目，化学成分含量Mg≥55、Al≥45、C≤0.020、S≤0.001、P≤0.01；
7）钛铁80～100目，化学成分含量Ti≥65%、Fe≥35%、C≤0.020%、S≤0.01%、P≤0.05%。
4.根据权利要求1所述的新型复合钢321+Q370qENH过渡层焊接用焊丝，其特征是：所述不锈钢外皮采用304L奥氏体不锈钢钢带，钢带厚度为0.35mm，宽度为10mm。
5.一种新型复合钢321+Q370qENH过渡层焊接用焊丝制作方法，其特征是：将权利要求1所述填充药粉按组分设计称重，并混合均匀，放入保温炉中烘干处理待用；不锈钢钢带轧制成U型后，填充药粉制得粗丝，药粉填充率为20～24%，粗丝经轧制、拉拔工序减径，最终成品焊丝直径分别为Φ1.0mm、Φ1.2mm、Φ1.4mm。
6.一种新型复合钢321+Q370qENH过渡层焊接用焊丝焊接方法，其特征是：按照“先焊接基层，后焊接过渡层，最后焊接覆层”的顺序，基层焊丝选用与Q370qENH性能匹配的耐候焊丝 E491T1-GC，直径为φ1.2，采用CO2气体保护；过渡层焊接参数为：采用权利要求5所述焊丝，焊接电流I=220±10A，焊接电压28±2V，焊接速度V=26±4cm/min，过渡层下边缘距复合界面2mm，过渡层厚度t=4±1mm；覆层焊丝选用与321不锈钢化学成分相匹配的不锈钢焊丝TS347L-FC11，直径为φ1.2，采用CO2气体保护。
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