CN100551603C - A kind of consumable electrode surfacing method of electromagnetic complex field, equipment and expansion thereof are used - Google Patents

A kind of consumable electrode surfacing method of electromagnetic complex field, equipment and expansion thereof are used Download PDF

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CN100551603C
CN100551603C CN 200710078434 CN200710078434A CN100551603C CN 100551603 C CN100551603 C CN 100551603C CN 200710078434 CN200710078434 CN 200710078434 CN 200710078434 A CN200710078434 A CN 200710078434A CN 100551603 C CN100551603 C CN 100551603C
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exciting coil
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CN101032788A (en
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罗键
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Chongqing University
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Abstract

The present invention discloses a kind of electromagnetic complex field overlaying method, equipment and expansion thereof and uses, and is electromagnetic complex field control flux cored wire molten drop spray transfer consumable electrode gas-arc overlaying method.Surfacing equipment of the present invention is provided with field power supply, energizing apparatus, auxiliary electric field equipment and water-cooling system; Energizing apparatus is provided with electromagnetic stirring exciting coil and electromagnetic heat treatment exciting coil; Auxiliary electric field equipment is a pair of positive and negative electrode additional conductive electrode that can move.It is by the compound action of electromagnetic agitation, electromagnetic heat treatment, auxiliary electric field and welding torch, realizes the process of efficient, high-quality, low-cost build-up welding alloy material; Break through the limitation of conventional stack welding technology; functional material built-up welding cost and harsh process conditions have been reduced; prolonged service life; solve of the dependence of efficient technique for overlaying to rich helium-atmosphere gas; perfect built-up welding control device; realized effective coupling of built-up welding functional layer floor height competency and high toughness plasticity, opened up new range of application in the Surface Engineering field.

Description

A kind of consumable electrode surfacing method of electromagnetic complex field, equipment and expansion thereof are used
Technical field
The present invention relates to Surface Engineering built-up welding field, particularly a kind of electromagnetic complex field control flux cored wire molten drop spray transfer consumable electrode gas-arc overlaying method, equipment and expansion thereof are used.
Background technology
With the transition of molten drop rotating jet is that the consumable electrode gas protection welding method of feature is considered to be one of a kind of efficient solder technology.The similar technology that is widely used both at home and abroad is to be the mist consumable electrode solder technology (as TIME, RAPID MELT, LINFAST etc.) of major components with high helium, and for China, the helium resource is relatively deficienter, and cost is higher; This protective gas prescription also has international intellectual property simultaneously, makes that the use of its technology and equipment is relatively more expensive.At present; domestic researcher adopts the method for externally-applied magnetic field welding to replace helium; realized the stable transition of molten drop; disclose the patent application of three these aspects: one is that the high cladding rate of magnetic control mixed gas protected consumable-electrode weld connects (MAG) method and special equipment (application number 02116241.7); it adopts single air core coil to be fixed on the welding gun; the constant excitation megnet electric current; produce the stationary magnetic field; can partly control welding arc and droplet transfer, only be applicable to medium welding current (welding current is less than 600A); shallow groove; the welding of the part ferrous metal of common iron needs.One is the big current MAG Welding Method ﹠ Equipment of magnetic control (application number 200410086897.0) that can be used for the deep groove welding, it is only hollow magnet exciting coil to be improved on the former basis, add and designed conducting magnet core, only increased welding deep groove joint form workpiece.The 3rd is the patent application that I propose: a kind of magnetic control melting electrode welding method and expansion thereof are used and common apparatus (application number 200510019637.6).
Above-mentioned three patent applications or mandate all are at the welding engineering technical field, and not towards the built-up welding field that belongs to Surface Engineering.Though built-up welding belongs to the welding category, universal performance with common solder technology, but built-up welding and conventional solder technology have to a certain degree different, its distinguishing feature is not to be in order to connect zero (portion) part as common welding method, but utilize the method (being that overlay cladding and mother metal have typical metallurgical binding) of welding (connection), according to the hardfacing alloy that specific workpiece service demand is selected or design is relevant, the functional layer that has certain performance at material or worker (portion) part surface cladding, make material or surface of the work have special function (as high strength, high tenacity, wear-resisting, anti-oxidant etc.), to satisfy the needs of parts specific work environments.For example; the research of efficient mixed gas protected consumable electrode (MAG) solder technology (molten drop spray transfer form) stresses obtaining high cladding rate and high penetration ratio (highly diluted rate), if carry out the reasonable coupling control that the research of efficient MAG technique for overlaying then needs to carry out high cladding rate and low penetration ratio (low dilution rate).Therefore, technique for overlaying has the specific (special) requirements of self.
Novel technique for overlaying is mainly considered the factor of three aspects: deposition rate, dilution rate and overlay cladding performance, promptly lower mother metal dilution rate, higher cladding speed and good overlay cladding performance.For preceding two factors " deposition rate " and " dilution rate ", when the built-up welding of arc source, generally adopt following approach to reduce dilution rate: (1) reduces the heat input of electric arc to mother metal; (2) reduce the concentrated degree of heat of electric arc to mother metal; (3) reduce electric arc to digging action of mother metal etc.On the other hand, need adopt following measure in order to improve deposition rate: (1) strengthens the arc heat input; (2) improve the electric arc intensity; (3) improve wire feed or powder feed rate approach such as (built-up welding speed).This shows that high deposition rate and low dilution rate be mutual restriction often, need coordinate the contradictory relation that exists between the two effectively, high deposition rate and low dilution rate can organically be united.Core content for the third element " overlay cladding performance " of technique for overlaying is paid close attention to will obtain high-quality built-up welding functional layer exactly.But, for example on common material during built-up welding high strength at high temperature hard alloy, between the different overlay claddings (between the built-up welding boundary layer), usually be easy to generate the phenomenon that overlay cladding cracking and overlay cladding and matrix are peeled off, this has just related to the problem of high strength at high temperature hard alloy overlay cladding malleableize.And the overlay cladding with high-wearing feature (high rigidity) in general has lower toughness, and the bead-welding technology of its requirement simultaneously or heat-treat condition all compare strict and complicated, often also are easy to generate defective, even causes the built-up welding functional layer to lose efficacy.Therefore, novel technique for overlaying need be coordinated the competency of material built-up welding functional layer and the contradictory relation between the toughness plasticity.
At present, advantage such as manual electric arc pile up welding and flame spurt welding are minimum because of cost, simple and flexible and adaptive surface are big, be the most frequently used bead-welding technology, but shortcomings such as automaticity is lower, labour intensity is big, surfacing quality is wayward are arranged, its application is subjected to restriction to a certain degree.And the research of modern technique for overlaying concentrates on aspects such as plasma surfacing, submerged arc (electroslag) built-up welding, Gas Shielded welding, laser melting coating and friction stir built-up welding, mainly concentrates on the electric arc thermal source in the selection of built-up welding thermal source.Comparatively speaking, efficient gas protection technique for overlaying is because of having higher production efficiency, preferable quality, and lower cost easily is automated process, can give full play to built-up welding robot advantage, becomes one of new direction that technique for overlaying develops.Therefore, need further to improve and development, with efficient, the high-quality on the complete meaning of real realization, novel technique for overlaying cheaply.
Summary of the invention
At the prior art above shortcomings; the purpose of this invention is to provide a kind of efficient; low-cost; the electromagnetic complex field of high stability and high-quality built-up welding function is controlled new and effective consumable electrode gas-arc overlaying method and common apparatus; so that the limitation that breaks through the conventional stack welding technology is to the high preparation cost of functional material built-up welding; harsh process conditions; (particularly) pining down for a long time than short service life; solve of the dependence of new and effective technique for overlaying to the polynary protective gas of rich helium; improve the built-up welding control device; realize effective coupling of high competency of built-up welding functional layer and high toughness plasticity; break the use limitation of efficient solder technology, thereby in the new range of application of Surface Engineering field developing.
The technical solution adopted for the present invention to solve the technical problems is as follows:
1. electromagnetic complex field overlaying method provided by the invention, it is electromagnetic complex field control flux cored wire molten drop spray transfer consumable electrode gas-arc overlaying method, concrete grammar is: in the top of built-up welding workpiece, use a pair of electromagnetic stirring exciting coil and electromagnetic heat treatment exciting coil, electromagnetic stirring exciting coil is coaxial with welding torch; Provide exciting current by field power supply, produce electromagnetic agitation and electromagnetic heat treatment outside Longitudinal Magnetic-field Has; On bead-on-plate weld, apply movably two auxiliary electric field electrodes, produce auxiliary electric field; The source of welding current provides built-up welding and auxiliary electric field electric current, an auxiliary electric field electrode and welding torch ignition tip same polarity; This electromagnetic complex field is controlled the built-up welding of high cladding consumable electrode gas-arc to welding work pieces realization electromagnetic complex field.
2. electromagnetic complex field overlaying method provided by the invention, described electromagnetic stirring exciting coil and electromagnetic heat treatment exciting coil connect with different frequency, variable strength, the time become exciting current, utilize higher-frequency and carry out function composite by electromagnetic stirring than the magnetic field that weak intensity is complementary, welding arc during with control rotating jet transition, welding wire end molten drop comes off and the stability of liquid a fluid stream, and the effect with auxiliary induction heating impels wire melting and molten drop to form, and the welding pool melt is fully stirred; And adopt than low frequency with than carrying out the electromagnetic heat treatment effect in the magnetic field that big intensity is complementary, can change the crystalline condition of molten pool metal, change process of setting and Temperature Distribution (tissue, phase structure also can change), impel the weld grain refinement, reduce chemical inhomogeneities, reduce the sensitiveness of pore, help improving toughness plasticity, form the high-quality overlay cladding; The built-up welding workpiece is realized meeting the electromagnetic complex field weld deposit process of built-up welding requirement;
Perhaps, electromagnetic stirring exciting coil and electromagnetic heat treatment exciting coil are executed simultaneously and are connect field power supply, produce with frequency, homophase, with intensity the time become constant vertical electromagnetic field of vertical electromagnetic field or uniform strength, realization meets the electromagnetic complex field weld deposit process of bead-welding technology requirement to workpiece;
Perhaps, electromagnetic stirring exciting coil and electromagnetic heat treatment exciting coil are used separately, and execute and connect a field power supply, become constant vertical electromagnetic field of vertical electromagnetic field or uniform strength when producing one, carry out independent electromagnetic agitation or electromagnetic heat treatment effect;
Comprise following process conditions: built-up welding welding current 80～800A; wire feed rate 0～50m/min; welding wire is directly through 0.8～6mm; shield gas flow rate 1～50L/min; weldingvoltage 1～60V, speed of welding 0.01～6m/min, exciting current 0～60A; excitation frequency 0～100Hz, auxiliary electric field electric current 0～300A.
3. electromagnetic complex field control consumable electrode gas-arc surfacing equipment provided by the invention is provided with field power supply, energizing apparatus, auxiliary electric field equipment and water-cooling system; Energizing apparatus is electromagnetic stirring exciting coil and electromagnetic heat treatment exciting coil, and electromagnetic stirring exciting coil and electromagnetic heat treatment exciting coil provide exciting current by field power supply; Field power supply adopt can produce multiple frequency and varying strength the time become the power supply of exciting current or constant current exciting current; Electromagnetic stirring exciting coil and electromagnetic heat treatment exciting coil are axial symmetry cylindrical coil structure, are located at respectively on two supports; Electromagnetic stirring exciting coil is fixed on the welding torch, and coaxial with welding torch; End at the support of electromagnetic stirring exciting coil is provided with the clamping and locking mechanism that links to each other with welding torch, and it is fixed on magnet exciting coil on the torch-tip, makes magnet exciting coil and workpiece that the free adjustment degree of certain distance be arranged; The distance of welding torch and electromagnetic heat treatment exciting coil can be regulated, and water-cooling system is housed in the support;
Auxiliary electric field equipment mainly is made of two auxiliary electric field electrodes movably, and one connects negative pole, and another root connects positive pole, provides electric current by the source of welding current or other independent power supplys; Auxiliary electric field electrode and welding torch same polarity.The auxiliary electric field electrode can be replaced by the built-up welding welding torch of other kinds, forms compound welding torch built-up welding mode.
The structure and the using method of additional conductive (field) equipment are: adopt a pair of conductive electrode that can move, be just (preceding) side with welding direction, do not melt the metal position of (not built-up welding) in the front portion, molten bath, select or operating position (as positive polarity or reversed polarity) according to built-up welding welding torch polarity, the conductive electrode and the molten bath of decision identical polar keep certain distance, move with welding torch, or fixing (at workpiece motion s, under the situation that welding torch does not move); The conductive electrode of another polarity then is being positioned at the rear portion that bead-on-plate weld solidifies low-temperature metal, and additional conductive field consistent with bead-on-plate weld (coincidence) is called vertical auxiliary electric field in this case.Additional conductive (field) plays comprehensive regulation effects such as preceding preheating, the shunting of built-up welding principal current and after-baking in weld deposit process.
4. electromagnetic complex field consumable electrode gas-arc surfacing equipment provided by the invention is respectively equipped with conducting magnet core in described electromagnetic stirring exciting coil and the electromagnetic heat treatment exciting coil; In the electromagnetic stirring exciting coil and electromagnetic heat treatment exciting coil that conducting magnet core is movably arranged on, can its position in magnet exciting coil of free adjustment until all from coil, removing; The shape of conducting magnet core end is funnel type, straight barrel type, pyramid type or curved face type; The lower surface shape of conducting magnet core is shunk, so that the more concentrated bead-on-plate weld that acts on of the magnetic line of force.
5. electromagnetic complex field consumable electrode gas-arc surfacing equipment provided by the invention, described electromagnetic heat treatment exciting coil is rigidly connected by an adjustable fixed arm and magnet exciting coil, welding torch and is one, adjustable fixed arm can change the distance of welding torch and magnet exciting coil, realizes that rational electromagnetic complex field built-up welding applies mode under the different speeds of welding;
Perhaps, electromagnetic stirring exciting coil is not directly become one with torch-tip by support, adopt insulating materials to make the outer wall of torch-tip and the wire turn maintenance state of insulation of coil, and cool off by the water-cooling system of torch-tip internal build.
6. electromagnetic complex field control consumable electrode gas-arc surfacing equipment provided by the invention, water-cooling system in the support of electromagnetic stirring exciting coil and the support of electromagnetic heat treatment exciting coil adopts cover-plate type rectangular pulse shape condensation flow pattern, be provided with current groove and staggered two drainings stream next door in two supports, two drainings stream dividing plate links to each other with the outer baffle of current groove both sides respectively;
Water-cooling system in the described torch-tip can adopt cover-plate type spirality condensation flow flow pattern, its structure is: design has spiral helicine screw thread current groove in the torch-tip wall, formed omnibearing condensation water channel in the torch-tip in conjunction with the torch-tip baffle plate, making condensed water center on torch-tip flows twist, arrive the end of torch-tip, welding torch is indeformable.
Electromagnetic complex field overlaying method provided by the invention and the surfacing equipment purposes aspect following:
Be used for the built-up welding of high cladding rate (at a high speed) consumable electrode gas-arc, or common consumable electrode gas-arc built-up welding, or the non-melt pole Gas Shielded welding, or plasma surfacing, or the laser built-up welding;
Be used for the built-up welding of following material (or alloy powder): medium high carbon antifriction alloy (cast iron), high-temperature rigid alloy, other metal and alloys (or alloy powder) thereof such as stainless steel and alloy thereof;
The single-layer surfacing, the multiple-bead deposit that are used for homogenous material, or the single-layer surfacing of multiple material, multiple-bead deposit, or the multiple-bead deposit of functionally gradient material (FGM);
Electromagnetic complex field overlaying method provided by the invention and the surfacing equipment expansion purposes aspect following welding:
Be used for the welding of following material: mild steel, steel alloy, special steel, stainless steel, copper and alloy thereof, aluminium and alloy thereof, magnesium and alloy thereof, other black and non-ferrous metal and alloys thereof such as titanium and alloy thereof;
Be used for solid welding wire, the welding of flux-cored wire and flux cored wire;
Be used for butt joint, overlap joint, corner connection, the multiple welding point form of all-position welding;
Be used for the welding of pure gas protection consumable electrode, or binary or multi component mixed gas body protection consumable electrode welding field;
Be used for high cladding rate (at a high speed) gas metal-arc welding and connect, or common consumable electrode gas-arc built-up welding, or common gas metal-arc welding connects, or the plasma welding, or laser weld, or compound welding technology (as TIG+MIG);
The present invention compared with prior art has following remarkable result:
One. compare with traditional gas protection welding process, broken through of the restriction of stable jet mode of metal transfer welding current.Compare with traditional flux-cored wire or flux cored wire gas protection welding process, be beneficial to and realize stable molten drop rotating jet transition, appearance of weld is good, and cost is low.
They are two years old. and compare with external efficient solder technology (as the TIME solder technology etc.), solved dependence, adopt no helium-atmosphere gas (as carbon dioxide) significantly to reduce welding cost the polynary protective gas of rich helium.
They are three years old. and compare with magnetic control MAG solder technology, increased the means and the method that add electromagnetic complex field control welding process, the flexibility that has improved the magnetic control welding condition has strengthened applicability efficient, the low cost magnetic control solder technology.
They are four years old. and break the use limitation of magnetic control solder technology, opened up new usage space.
They are five years old. compare with other conventional technique for overlaying; integrated correlation technique and achievement in research; stable high deposition rate, the low dilution rate realized coordinated the innovative approach of the electromagnetic complex field efficient gas protection built-up welding of coupling, for " facing a difficult choice " problem that solves built-up welding provides new way.
They are six years old. compare with other magnetic control technique for overlaying (as plasma surfacing); adopt electromagnetic complex field efficient gas protection built-up welding new technology; realize the high-quality overlay cladding that high competency and toughness organic coordination are unified at low cost; reduced its strict demand, realized the technological innovation of built-up welding functional layer technique for overlaying and Technology for Heating Processing.
They are seven years old. and compare with conventional built-up welding or welding procedure, when using flux-cored wire or flux cored wire built-up welding or welding, perhaps when CO 2 gas-shielded built-up welding or welding, droplet transfer stability improves, and splashing reduces, and appearance of weld is good, and quality improves.
They are eight years old. and have wide range of applications, equipment needed thereby is simple, is easy to promote the use of.Promote advanced technique for overlaying field green, sustainable, the high-tech technology that satisfies the recycling economy demand and the development of equipment, improved and enriched the basic theory and the engineering practice ability of built-up welding Surface Engineering.
The present invention has opened up novel, the advanced technique for overlaying in Surface Engineering field, it comprises: broken through two conflicting restrictions of high cladding rate and low dilution rate, realized that the effective coordination of high rigidity and high tenacity overlay cladding performance is with rationally unified, reduced harsh requirement to bead-welding technology and post processing link, adopt perfect electromagnetic complex field technology successfully to overcome the use limitation of single externally-applied magnetic field, thereby contributing aspect the exploitation of sustainable, as to satisfy the recycling economy demand advanced technique for overlaying technology and equipment and actual the utilization.The present invention the mould manufacturing with make the circulation manufacturing and the utilization of plant equipment, critical component reparation, material preparation, resource circulation utilization, and green circulation is made with fields such as equipment and had wide application value and development prospect again.The present invention realizes efficiently, the comprehensive easily weld deposit process of control of low cost, high-quality, high stability, many applicabilities, multimode.
In a word, the present invention is by the compound action of electromagnetic agitation, electromagnetic heat treatment, auxiliary electric field and welding torch, realizes the process of efficient, high-quality, low cost, high stability ground build-up welding alloy material or functionally gradient material (FGM); Pining down for a long time of the limitation that breaks through the conventional stack welding technology high preparation cost during, harsh process conditions, short service life to the high performance material built-up welding; solve of the dependence of new and effective technique for overlaying to the polynary protective gas of rich helium; improve the built-up welding control device; realize effective coupling of high competency of built-up welding functional layer and high toughness plasticity, in the new range of application of Surface Engineering field developing.
Description of drawings
Fig. 1 is welding method of the present invention and equipment schematic diagram;
Fig. 2 is that electromagnetic agitation and electromagnetic heat treatment exciting coil support water-cooling system structure and cooling water flow are to schematic diagram;
Fig. 3 is that built-up welding moment welding nozzle water-cooling system structure and cooling water flow are to schematic diagram.
Among the figure, 1. support; 2. torch-tip; 3. welding torch ignition tip; 4. conducting magnet core; 5. welding and auxiliary electric field power supply; 6. welding wire; 7. workpiece; 8. electromagnetic stirring exciting coil; 9. electromagnetic heat treatment exciting coil; 10. field power supply; 11. conducting magnet core; 12. support; 13. auxiliary electric field electrode; 14. auxiliary electric field electrode; 15. connection locating support; 16. current groove; 17. outer baffle; 18. water flow partition board in the support; 19. torch-tip baffle plate; 20. torch-tip wall; 21. screw thread current groove.
The specific embodiment
What the present invention mainly comprised the built-up welding of a kind of electromagnetic complex field consumable electrode gas-arc adds compound field control method of electromagnet and relevant common apparatus and the application in other built-up welding and welding technique.
The invention will be further described below in conjunction with embodiment and accompanying drawing.
One. electromagnetic complex field control consumable electrode surfacing method
This method is a kind of high cladding consumable electrode gas-arc of no helium overlaying method of electromagnetic complex field control molten drop spray transfer.Concrete grammar is as follows:
As shown in Figure 1: in the top of built-up welding workpiece 7, use a pair of band conducting magnet core 4 and 11 or not with the electromagnetic stirring exciting coil 8 and the electromagnetic heat treatment exciting coil 9 of conducting magnet core 4 and 11, electromagnetic stirring exciting coil 8 is coaxial with welding torch 3, provide exciting current respectively by identical field power supply 10 or different field power supplies, become during generation or constant, double frequency or single-frequency, with the electromagnetic agitation of intensity or varying strength and two outside Longitudinal Magnetic-field Has of electromagnetic heat treatment; As required, simultaneously or do not apply movably auxiliary electrode 13 and 14 simultaneously on bead-on-plate weld is vertical or horizontal, produce auxiliary electric field, power supply 5 provides built-up welding and auxiliary electric field electric current, auxiliary electric field electrode 13 and welding torch ignition tip 3 (or welding wire 6) same polarity.This electromagnetic complex field Comprehensive Control welding arc, wire melting, droplet transfer, molten bath stir, weld seam solidifies, weld preheating and post weld heat treatment process; under the cooperation of protective gas that high wire feed rate, no helium are mixed and big electric current, realize the high cladding consumable electrode gas-arc of the electromagnetic complex field no helium of control weld deposit process.
Electromagnetic complex field is realized the Comprehensive Control weld deposit process by six aspects: the kind (time-varying magnetic field or the stationary magnetic field that change magnetic field; single-frequency magnetic field or double frequency magnetic field); change the frequency (different frequency) in magnetic field; change the intensity (electric field of varying strength and magnetic field) of electromagnetic field; (weld seam vertically applies electric field to the mode that applies of change electromagnetic field; or weld seam laterally applies electric field; or apply magnetic field directly over the weld seam; or both sides, weld seam top apply magnetic field; or workpiece does not apply on both sides up and down simultaneously or simultaneously; or apply mode with welding torch out-of-alignment magnetic field), change the composition and the proportioning (Ar+20%CO of built-up welding protective gas according to the built-up welding object 2, or CO 2, or Ar, or other multicomponent gas composition and proportioning) and with the reasonable adjusting and the coupling of bead-welding technology parameter (welding current, wire feed rate, gage of wire, gas flow, speed of welding, weldingvoltage etc.).
1. electromagnetic stirring exciting coil 8 and electromagnetic heat treatment exciting coil 9 are used with field power supply 10 pairings, and following three kinds of modes are arranged:
(1) electromagnetic stirring exciting coil 8 and electromagnetic heat treatment exciting coil 9 can connect simultaneously with field power supply 10 double frequency that produces, variable strength, the time become exciting current, its benefit is: stablize under the electromagnetic field condition of rotating jet transition not influencing molten drop, can use the plant mode of parameter and means of multiplex (MUX), flexibly, reliably, control the temperature field of built-up welding effectively, the molten drop forming process, the motion state of liquid a fluid stream, the molten bath stirring extent, weld seam curing condition and built-up welding tissue generate, to realize that magnetic-control high efficiency does not have helium consumable electrode surfacing temperature field, the Best Coupling in the flow field and the field of force finally forms the high-quality bead-on-plate weld, the quality requirement that meets overlay cladding; Simultaneously, this multiplex (MUX) reliable built-up welding control mode under the parameter controlled condition of planting can realize the weld deposit process that different specific materials, different resurfacing welding material and built-up welding functional layer need.Its principle is: utilize higher-frequency and carry out function composite by electromagnetic stirring than the magnetic field that weak intensity is complementary, welding arc during with control rotating jet transition, welding wire end molten drop comes off and the stability of liquid a fluid stream, and the effect with auxiliary induction heating impels wire melting and molten drop to form, and the welding pool melt is fully stirred.And adopt than low frequency with than carrying out the electromagnetic heat treatment effect in the magnetic field that big intensity is complementary, can change the crystalline condition of molten pool metal, change process of setting and Temperature Distribution (tissue, phase structure also can change), impel the weld grain refinement, reduce chemical inhomogeneities, reduce the sensitiveness of pore, help improving toughness plasticity, form the high-quality overlay cladding; Built-up welding workpiece 7 is realized meeting the electromagnetic complex field weld deposit process of built-up welding welding requirements.
(2) electromagnetic stirring exciting coil 8 and electromagnetic heat treatment exciting coil 9 can be executed simultaneously and connect field power supply 10, produce with frequency, homophase, with intensity the time become constant vertical electromagnetic field of vertical electromagnetic field or uniform strength, 7 realizations meet the electromagnetic complex field weld deposit process of bead-welding technology requirement to workpiece.
(3) electromagnetic stirring exciting coil 8 and electromagnetic heat treatment exciting coil 9 can be used separately, and execute and connect a field power supply 10, become constant vertical electromagnetic field of vertical electromagnetic field or uniform strength when producing one, carry out independent electromagnetic agitation or electromagnetic heat treatment effect, workpiece 7 is realized meeting the electromagnetic complex field weld deposit process of bead-welding technology requirement.
2. auxiliary electric field electrode 13 and auxiliary electric field electrode 14, and built-up welding welding torch ignition tip 3 is used with power supply 5, and following five kinds of main modes are arranged:
(1) auxiliary electric field electrode 13 and welding wire 6 same polarities, and provide the electric current of variable strength simultaneously by power supply 5, auxiliary electric field electrode 13 a little less than, and the built-up welding welding current is stronger, and auxiliary electric field electrode 14 is opposed polarities with auxiliary electric field electrode 13 and welding wire 6, its benefit is: under the identical fusion penetration condition of built-up welding, can reduce the size of main welding current, reduce concentrated degree of heat and the digging action of electric arc to the built-up welding base material, help reducing dilution rate, the minimizing droplet transfer splashes, and improves the cladding rate, and form good built-up welding welding current loop, workpiece 7 is realized meeting the electromagnetic complex field weld deposit process of bead-welding technology requirement.
(2) the auxiliary electric field streamline of auxiliary electric field electrode 13 and 14 formation of auxiliary electric field electrode can overlap with bead-on-plate weld, promptly forms vertical auxiliary electric field; Also can be vertical with cross-seam, promptly form horizontal auxiliary electric field, and laterally the electric current line of auxiliary electric field and weld seam can be in the molten baths or generation joint in diverse location place before and after the molten bath; Auxiliary electric field electrode 13 and auxiliary electric field electrode 14 are used with power supply 5, power transformation flow field in the time of can producing a pulse, or the current field of constant uniform strength, and 7 realizations meet the electromagnetic complex field weld deposit process of bead-welding technology requirement to workpiece.
(3) auxiliary electric field that produces of auxiliary electric field electrode 13 and auxiliary electric field electrode 14 can be simultaneously or the electromagnetic heat treatment magnetic field that produces of the electromagnetic agitation magnetic field that do not produce with electromagnetic stirring exciting coil 8 simultaneously and electromagnetic heat treatment exciting coil 9, or combination in twos, or generation effect in weld deposit process separately, 7 realizations meet the electromagnetic complex field weld deposit process of bead-welding technology requirement to workpiece.
(4) auxiliary electric field electrode 13 and auxiliary electric field electrode 14, can be replaced by the built-up welding welding torch (electrode) of other kinds, form the composite overlaying mode, substituted by a TIG built-up welding welding torch (electrode), form TIG+MAG/MIG or TIG+CO as auxiliary electric field electrode 13 2Be total to the composite overlaying mode of single molten bath form, workpiece 7 realized meeting the electromagnetic complex field weld deposit process of bead-welding technology requirement.
(5) auxiliary electric field electrode 13 and auxiliary electric field electrode 14 can be various ways such as bar-shaped, strip; With workpiece can be sliding friction, also can be rolling friction; Can be Cu alloy material, also can be other materials.Workpiece 7 is realized meeting the electromagnetic complex field weld deposit process of bead-welding technology requirement.
The present invention adopts electromagnetic complex field consumable electrode gas-arc weld deposit process to adopt to comprise following process conditions: built-up welding welding current 80～800A; wire feed rate 0～50m/min; welding wire is directly through 0.8～6mm; shield gas flow rate 1～50L/min; weldingvoltage 1～60V, speed of welding 0.01～6m/min, exciting current 0～60A; excitation frequency 0～100Hz, auxiliary electric field electric current 0～300A.
Above-mentioned protective gas can adopt magnetic control gas a, or magnetic control gas b, or magnetic control gas c, or magnetic control gas d, or magnetic control gas e, and is specific as follows:
Magnetic control gas a is made up of 100% carbon dioxide, and this kind gas is widely used in the built-up welding of high-carbon antifriction alloy;
Magnetic control gas b is made up of 100% argon gas.This kind gas is widely used in the built-up welding of multiple metal and alloy material;
Magnetic control gas c is made up of argon gas and carbon dioxide mix, and its percent by volume is: the argon gas of 10～20% carbon dioxide+residue percentage.This kind gas is widely used in the built-up welding of multiple metal and alloy material;
Magnetic control gas d takes as the leading factor with argon gas, and ternary gas mixes to be formed, and its percent by volume is: the carbon dioxide gas of 80～90% argon gas+1～2% oxygen+residue percentage.This kind gas is widely used in the built-up welding of multiple metal and alloy material;
Magnetic control gas e is mixed by argon gas and nitrogen and forms, and its percent by volume is: the argon gas of 5～25% nitrogen+residue percentage.This kind gas is typically applied in metal and the alloy welding deposit thereof that this gas is inertia, as the built-up welding of copper and alloy thereof.
Binary or polynary protective gas that above-mentioned protective gas also can adopt other common protective gas compositions or have helium to add.
Above-mentioned bead welding wire can use solid welding wire, or flux-cored wire, or metal powder core solder wire.
Electromagnetic complex field overlaying method provided by the invention, flux cored wire can adopt welding wire a, or welding wire b, or welding wire c, and it is as follows specifically to fill a prescription:
Welding wire a forms metal-powder-core by C, Cr, Ni, Mo, Mn, Si, N alloy powder, and its composition range is (Wt%): C 0.28～0.40%, Cr12.1～14.2%, Ni2.9～5.2%, Mo 0.78～0.91%, Mn 0.65～1.61, Si 0.16～0.96%, S≤0.01%, P≤0.025%, N0.02～0.04%, rare earth 0.01～3.2%.Adopt argon gas and nitrogen to mix the protective gas of forming, its percent by volume is: 10～30% nitrogen+residue percentage argon gas have original position complex nitride built-up welding function;
Welding wire b forms metal-powder-core by C, Cr, Ni, Si, B, Mn alloy powder, and its composition range is (Wt%): C0.08～0.17%, Cr10.2～18.3%, Ni3.4～5.8%, Si0.38～0.81%, B0.14～0.34%, Mn0.68～1.61%.Protective gas adopts carbon dioxide and argon gas to mix composition, and its percent by volume is: the argon gas of 10～20% carbon dioxide+residue percentage has the mixed gas protected built-up welding function of effective carbon-dioxide;
Welding wire c forms metal-powder-core by C, Cr, W, Mo, V, Nb alloy powder, and its composition range is (W t%): C 0.4～0.9%, Cr16.2～26.4%, W2.9～6.2%, Mo 0.38～3.41%, V0.24～0.38%, Nb2.3～5.8%, rare earth 0.01～4.6%.Protective gas adopts 100% argon gas, has the efficient built-up welding function of Hardmetal materials.
Two. electromagnetic complex field control consumable electrode gas-arc built-up welding common apparatus
This equipment is the common apparatus that the efficient gas metal-arc welding of the electromagnetic complex field no helium of control connects; as shown in Figure 1: be provided with field power supply, energizing apparatus, auxiliary electric field equipment and water-cooling system, energizing apparatus is provided with electromagnetic stirring exciting coil 8 and electromagnetic heat treatment exciting coil 9.
1. electromagnetic stirring exciting coil 8 and electromagnetic heat treatment exciting coil 9:
According to the actual welding needs, described magnet exciting coil can use simultaneously or separately, and their distance is adjustable, and electromagnetic stirring exciting coil 8 is coaxial with welding torch 2.Supporting with it field power supply 10 adopts four-way numeral inverter or two independently digital inverter of cover or common powers, can produce the adjustable constant excitation megnet electric current of stepless continuous and the time become exciting current (as intermittent alternative bidirectional pulse electric current, its frequency, dutycycle and amplitude all can be regulated).
Structure, annexation and effect below in conjunction with the above-mentioned magnet exciting coil of description of drawings:
As shown in Figure 1: a pair of electromagnetic stirring exciting coil 8 and electromagnetic heat treatment exciting coil 9 lay respectively at workpiece 7 tops, are referential with the built-up welding positive direction, and electromagnetic stirring exciting coil 8 is preceding, electromagnetic heat treatment exciting coil 9 after.
Electromagnetic stirring exciting coil 8 is fixed on the welding torch 3, and coaxial with welding torch 3.The distance of welding torch 3 and electromagnetic heat treatment exciting coil 9 can free adjustment, according to the size of speed of welding, regulates both relative positions, the high-temperature solid metal position that makes electromagnetic heat treatment exciting coil 9 be positioned at welding pool rear portion next-door neighbour, solidify.
Above-mentioned magnet exciting coil is axial symmetry cylindrical coil structure, and it is with conducting magnet core 4 and conducting magnet core 11 or is not with conducting magnet core 4, and perhaps conducting magnet core 11 is center total cross-sections, in its support 1 and 12 water-cooling system is housed; These magnet exciting coils and the motion of welding torch 3 synchronous same-speeds, or static (under the situation of workpiece 7 motions).
Above-mentioned conducting magnet core 4 and conducting magnet core 11 are movably arranged on respectively in electromagnetic stirring exciting coil 8 and the electromagnetic heat treatment exciting coil 9, can its position in magnet exciting coil of free adjustment until all from coil, removing.The shape of conducting magnet core 4 and conducting magnet core 11 ends can be designed to different shapes according to actual needs, for example is funnel type, straight barrel type, pyramid type or curved face type etc.The conducting magnet core 4 of magnet exciting coil 8 and magnet exciting coil 9 uses can be identical with conducting magnet core 11 shapes, also can be different.Conducting magnet core 4 and conducting magnet core 11 can be made of single revolving body integral body, and perhaps the diverse location that rationally, organically is distributed in coil by the separate component of a plurality of strip and blocks constitutes.Simultaneously, but according to the distance between actual needs comprehensive adjustment magnet exciting coil, conducting magnet core, built-up welding workpiece, built-up welding torch-tip and the welding wire of weld deposit process.Conducting magnet core 11 apart from the position of workpiece than conducting magnet core 4 apart from workpiece the position closely many, and use total cross-section iron core form, the lower surface shape of conducting magnet core 11 is shunk, so that the more concentrated bead-on-plate weld that acts on of the magnetic line of force.
2. magnet exciting coil 8 is connected and water-cooling pattern with the several of welding torch 3 with magnet exciting coil 9:
(1) electromagnetic stirring exciting coil 8 is fixedlyed connected with welding torch 3 by clamping and locking mechanism (omitting among the figure):
End at the support 1 of electromagnetic stirring exciting coil 8 is provided with the clamping and locking mechanism that links to each other with welding torch 3, and it is fixed on magnet exciting coil on the torch-tip 2, makes magnet exciting coil 8 and workpiece 7 that the free adjustment degree of certain distance be arranged.
Water-cooling system in the support 1 of electromagnetic stirring exciting coil 8 adopts cover-plate type rectangular pulse shape condensation flow pattern, its structure is as shown in Figure 2: be provided with current groove 16 and staggered two drainings stream next door 18 in the support 1, two drainings stream dividing plate 18 links to each other with the outer baffle 17 of current groove 16 both sides respectively, and they have constituted interior efficient, the simple water-cooling system of support of the circulating condensing water flow mode of turning back up and down.Exquisite structure shown in Figure 2, although its whole integrated spatial design is simple in structure, cooling effect is strong, can adapt to the needs of the big electric current built-up welding of molten drop spray transfer form fully.Arrow is represented the passage and the direction of current among the figure.
The effect of water-cooling system coil heat radiation and the normal work when big electric current built-up welding that is the protection coil is the effective cooling protection effect that realizes in limited geometric space in the magnet exciting coil coil.
(2) electromagnetic stirring exciting coil 8 directly is connected with torch-tip 2 integrated forms:
In order to satisfy under the medium and small built-up welding welding current condition the good space accessibility of automatic surfacing welding torch under manual build up welding welding torch or the big welding current condition, can save support 1, directly electromagnetic stirring exciting coil 8 and torch-tip 2 are become one, adopt insulating materials to make the outer wall of torch-tip 2 and the wire turn of coil keep state of insulation, and the water-cooling system by torch-tip 2 internal build is cooled off, and makes welding torch and magnet exciting coil all be in good working order.
Water-cooling system in the torch-tip 2 can adopt cover-plate type spirality condensation flow flow pattern, its structure is as shown in Figure 3: design has spiral helicine screw thread current groove 20 in the torch-tip wall 21, formed omnibearing condensation water channel in the torch-tip in conjunction with torch-tip baffle plate 19, make condensed water center on torch-tip and flow twist, arrive the end of torch-tip.This water-cooling system has space structure compactness, simplicity of design, the strong advantage of cooling effect, can guarantee that under the big current condition, welding torch 3 is indeformable, can adapt to the needs of high cladding, big electric current built-up welding fully.
(3) electromagnetic heat treatment exciting coil 9 is rigidly connected with magnet exciting coil 8 and torch-tip 2 by regulating fixed arm 15:
Electromagnetic heat treatment exciting coil 9 is rigidly connected with magnet exciting coil 8 welding torches 3 by an adjustable fixed arm 15 and is one, adjustable fixed arm 15 can change the distance of welding torch 3 and magnet exciting coil 9, realizes that rational electromagnetic complex field built-up welding applies mode under the different speeds of welding.
3. auxiliary electric field application devices:
Adopt a pair of auxiliary electric field electrode 13 that can move and 14, one at auxiliary electric field electrode to connect negative pole, another root connects positive pole, provides electric current by the source of welding current 5.The auxiliary electric field electrode 13 of motion and auxiliary electric field electrode 14 have the excellent contact performance with workpiece, have certain high temperature wear resistant ability and good electrical conductivity, and simple in structure being easy to changed.
Auxiliary electric field electrode 13 can be by tungsten argon arc welding torch (TIG), or plasma welding torch (PAW), or laser torch (EBW), or electron beam welding torch (EBW) waits the built-up welding welding torch of other kinds to replace electrode, forms compound welding torch built-up welding mode.Substituted by a TIG built-up welding welding torch as auxiliary electric field electrode 13, form TIG+MAG/MIG or TIG+CO 2Two welding torches are total to the compound welding torch built-up welding mode of single built-up welding molten bath form; Such as auxiliary electric field electrode 13 by consumable electrode welding torch (MAG/MIG/CO2) replacement, form mariages composite overlaying mode.
4. the field power supply 10 and the source of welding current 5:
Can adopt can produce multiple frequency and varying strength the time become the power supply of exciting current or constant current exciting current.
Can adopt the digital inverter welding power source that can produce multiple waveform, and suitable auxiliary electric field electric current is provided.
Three. the expansion of above-mentioned electromagnetic complex field control consumable electrode surfacing method and common apparatus is used
1. use in the expansion of following gas metal-arc welding aspect connecing:
(1) be used for efficient consumable electrode welding, or common consumable electrode welding field.
(2) be used for the welding of following material: mild steel, steel alloy, special steel, stainless steel, copper and alloy thereof, aluminium and alloy thereof, magnesium and alloy thereof, other black and non-ferrous metal and alloys thereof such as titanium and alloy thereof.
(3) be used for square groove or bevelled butt joint, overlap joint, corner connection, the multiple welding point form of all-position welding.
(4) be used for the welding of pure gas protection consumable electrode, or binary or multi component mixed gas body protection consumable electrode welding field.
2. the application aspect other welding procedure:
Electromagnetic stirring exciting coil 8 directly and torch-tip 2 become one; or do not adopt water-cooling system in the torch-tip 2; use or do not use welding wire 6 and protective gas; and changing under welding torch 3 condition of (as adopting the specific welding torch of other welding techniques such as plasma welding torch, submerged arc welding torch); with field power supply 10, energizing apparatus and the water-cooling system that is positioned at magnet exciting coil support 1; be used for following welding procedure, workpiece 7 realized other electromagnetic complex field welding procedures:
The employing electromagnetic complex field is implemented: welding meets (MIG), or metal active gas welding meets (MAG), or gas tungsten arc welding meets (TIG), or submerged arc welding (SAW), or carbon dioxide welding (CO 2), or electroslag welding (ESW), or PLASMA ARC WELDING (PAW), or electron beam welding (EBW), or electric resistance welding (RW), or friction welding (FW) (FW), or friction stir welding (FSW), or laser weld (LBW).
3. the application aspect other built-up welding:
(1) be used for the built-up welding of high cladding rate (at a high speed) consumable electrode gas-arc, or common consumable electrode gas-arc built-up welding, or the non-melt pole Gas Shielded welding, or plasma surfacing, or the laser built-up welding, or the agitating friction built-up welding, or the welding rod arc built-up welding;
(2) be used for the built-up welding of following material (or alloy powder): medium high carbon antifriction alloy (cast iron), high-temperature rigid alloy, other metal and alloys (or alloy powder) thereof such as stainless steel and alloy thereof;
(3) be used for single-layer surfacing, the multiple-bead deposit of homogenous material, or the single-layer surfacing of multiple material, multiple-bead deposit, or the multiple-bead deposit of functionally gradient material (FGM);
The technological parameter of wherein relevant electromagnetic complex field control consumable electrode surfacing method reference is as follows:
(1) electromagnetic complex field control consumable electrode gas-arc bead-welding technology parameter is: welding current 60～800A; Electromagnetic agitation magnetic field intensity 0.01～10T, electromagnetic agitation field frequency 1～20Hz; Auxiliary electric field electric current 0～50A, auxiliary electric field electric current (doing the compound welding torch time spent) 0～300A; Electromagnetic heat treatment magnetic field intensity 0.01～20T, electromagnetic heat treatment field frequency 1～100Hz, built-up welding speed 0.01～5m/min, gas flow 1～40L/min;
(2) electromagnetic complex field control non-melt pole Gas Shielded welding technological parameter is: welding current 60～300A, electromagnetic agitation magnetic field intensity 0.01～6T, electromagnetic agitation field frequency 1～20Hz, auxiliary electric field electric current 0～50A, auxiliary electric field electric current (doing the compound welding torch time spent) 0～250A, electromagnetic heat treatment magnetic field intensity 0.01～10T, electromagnetic heat treatment field frequency 1～100Hz, built-up welding speed 0.01～2m/min, gas flow 2～30L/min;
(3) electromagnetic complex field control laser bead-welding technology parameter is: laser built-up welding power 0.1KW～10KWA, electromagnetic agitation magnetic field intensity 0.01～8T, electromagnetic agitation field frequency 1～20Hz, auxiliary electric field electric current 0～50A, auxiliary electric field electric current when welding torch (do compound) 0～300A, electromagnetic heat treatment magnetic field intensity 0.01～10T, electromagnetic heat treatment field frequency 0～50Hz, built-up welding speed 0.1～5m/min;
(4) the electromagnetic complex field controlling resistance welder parameter of planting is: electromagnetic agitation magnetic field intensity 0.02～10T, and electromagnetic agitation field frequency 1～20Hz, other is a common electrical welding resistance parameter;
(5) electromagnetic complex field control agitating friction bead-welding technology parameter is: electromagnetic agitation magnetic field intensity 0.01～10T, electromagnetic agitation field frequency 1～20Hz, auxiliary electric field electric current 0～200A, electromagnetic heat treatment magnetic field intensity 0.01～20T, electromagnetic heat treatment field frequency 1～100Hz, other is an agitating friction built-up welding parameter;
(6) electromagnetic complex field control submerged arc overlay welding technological parameter is: welding current 200～800A; electromagnetic agitation magnetic field intensity 0.01～8T; electromagnetic agitation field frequency 1～30Hz; auxiliary electric field electric current 0～80A; electromagnetic heat treatment magnetic field intensity 0.01～20T; electromagnetic heat treatment field frequency 1～100Hz, speed of welding 0.1～5m/min does not adopt protective gas.
Brief description is the course of work of this equipment once:
As shown in Figure 1, electromagnetic stirring exciting coil 8 of the present invention and electromagnetic heat treatment exciting coil 9 provide exciting current by identical or different field power supply 10, become during generation or the outside Longitudinal Magnetic-field Has of constant, double frequency or single-frequency; Auxiliary electrode of the present invention provides welding current and auxiliary current by identical or different power supply 5, produces the welding current of multiple waveform and suitable auxiliary electric field electric current.Wherein: the longitudinal magnetic field that electromagnetic stirring exciting coil 8 produces is mainly used in the formation of periodically the rotatablely moving of control welding arc, wire melting, wire tip molten drop and the motion state of disengaging, liquid a fluid stream, forms molten drop periodicity, stable rotation spray transfer state; Also control simultaneously the type of flow of melt in the molten bath and the stirring intensity in molten bath, change the setting condition of molten pool metal.The longitudinal magnetic field that electromagnetic heat treatment exciting coil 9 produces can effectively be controlled the transition process of weld seam solidified structure, play thermal processes act, promote grain refinement, reduce chemical inhomogeneities, improve the plasticity and the toughness of weld seam, improve grain size, distribution and the configuration state of seam organization, utilize system's control action of comprehensive parameters to reach the built-up welding functional layer of high-quality.
During actual built-up welding, according to different bead-welding technologies, built-up welding quality of parent material, resurfacing welding material and built-up welding form etc., adopt built-up welding control method provided by the invention and surfacing equipment, take all factors into consideration the reasonable coupling of electromagnetic complex field and bead-welding technology parameter, and these main technologic parameters are carried out system optimization, can guarantee the enforcement of efficient, high-quality, low-cost weld deposit process.
Four. specific embodiment:
Following embodiment implements according to overlaying method provided by the invention and equipment.
Example 1: add intermittent alternative longitudinal magnetic field control carbon dioxide flux-cored wire Fe-Cr-Mn-W-V when being high carbon high chromium alloy; the bead-welding technology parameter is following can to obtain good built-up welding functional layer: electromagnetic agitation magnetic field exciting current is 3～20A; the electromagnetic agitation field frequency is 1～6Hz; welding current is 100～200A; speed of welding 0.3～0.8m/min; 100% carbon-dioxide protecting gas, 5～20L/min, wire feed rate 3.5～0.8m/min.
Example 2: when adding electromagnetic complex field control MAG built-up welding Cr-W-Co series hard metal, the bead-welding technology parameter is following can to obtain good built-up welding functional layer: welding current is 120～180A, the electromagnetic agitation field frequency is 1～4Hz, auxiliary electric field intensity currents 10A～40A, speed of welding 0.3～1m/min.The electromagnetic heat treatment magnetic field intensity is 0.01T～0.2T, and the electromagnetic heat treatment field frequency is 1～20Hz, protective gas (100% pure argon) flow 5～20L/min.
Example 3: add electromagnetic complex field when controlling efficient MAG built-up welding Fe-Ni-Cr-B-Si and being alloy, the bead-welding technology parameter is following can to obtain good built-up welding functional layer: welding current is 350～700A, electromagnetic agitation magnetic field exciting current is 5～30A, the electromagnetic agitation field frequency is 1～8Hz, auxiliary electric field intensity currents 5A～30A, speed of welding 0.8～4m/min.Electromagnetic heat treatment magnetic field exciting current is 15～40A, and the electromagnetic heat treatment field frequency is 1～25Hz; Protective gas (100% pure argon) flow 20～30L/min.
Example 4. adds intermittent alternative longitudinal magnetic field control automatic submerged-arc bead welding Fe-Cr-Si-B when being alloy, the bead-welding technology parameter is following can to obtain good built-up welding functional layer: welding current is 280～450A, electromagnetic agitation magnetic field exciting current is 2～35A, the electromagnetic agitation field frequency is 1～12Hz, and speed of welding is 0.1～3.6m/min.
When example 5. adds electromagnetic complex field control MAG built-up welding; adopt flux cored wire a; the bead-welding technology parameter is following can to obtain good built-up welding functional layer: welding current is 100～250A; electromagnetic agitation magnetic field exciting current is 5～30A; the electromagnetic agitation field frequency is 1～8Hz; auxiliary electric field intensity currents 3A～20A; speed of welding 0.1～2m/min; electromagnetic heat treatment magnetic field exciting current is 10～35A; the electromagnetic heat treatment field frequency is 1～32Hz; the argon shield gas of 10～30% nitrogen+residue percentage, flow 8～20L/min.
When example 6. adds the built-up welding of electromagnetic complex field control carbon dioxide gas mixture high speed; adopt flux cored wire b; the bead-welding technology parameter is following can to obtain good built-up welding functional layer: welding current is 200～450A; electromagnetic agitation magnetic field exciting current is 3～28A; the electromagnetic agitation field frequency is 1～10Hz; auxiliary electric field intensity currents 2A～34A; speed of welding 0.4～2.5m/min; electromagnetic heat treatment magnetic field exciting current is 16～42A; the electromagnetic heat treatment field frequency is 1～32Hz; 10～20% protective gas are the argon gas of carbon dioxide+residue percentage, flow 5～30L/min.
When example 7. adds electromagnetic complex field control MAG built-up welding, adopt flux cored wire c, the bead-welding technology parameter is following can to obtain good built-up welding functional layer: welding current is 120～280A, electromagnetic agitation magnetic field exciting current is 2～24A, the electromagnetic agitation field frequency is 1～10Hz, auxiliary electric field intensity currents 6A～30A, speed of welding 0.1～2.4m/min.Electromagnetic heat treatment magnetic field exciting current is 10～38A, and the electromagnetic heat treatment field frequency is 1～28Hz, and protective gas is 100% argon gas, flow 4～30L/min.
By above-mentioned example as can be known; should take all factors into consideration the reasonable coupling of electromagnetic complex field and bead-welding technology parameter; as welding wire length, protective gas composition, welding arc voltage, auxiliary electric field intensity and mode, electromagnetic agitation magnetic field intensity and frequency, electromagnetic heat treatment magnetic field intensity and frequency etc.; and these main technologic parameters are carried out system optimization according to actual built-up welding object and material, could guarantee to obtain high-quality built-up welding functional layer like this.
The inventor finds in the research that the basic theory and the engineering of electromagnetic complex field solder technology are used, the electromagnetic complex field technique for overlaying has following main advantageous effect: (1) changes arc force and electric current distribution, reduce concentrated degree of heat and the digging action of electric arc, help reducing dilution rate mother metal; (2) can realize that the flux cored wire molten drop stablizes spray transfer, help improving the cladding rate; (3) agitation molten pool effectively changes process of setting and Temperature Distribution (tissue, phase structure also can change), crystal grain thinning, and evenly composition reduces the overlay cladding defective, helps improving toughness plasticity, the formation quality weld; (4) residual stress level of reduction overlay cladding, promote the reasonable of overlay cladding thermal stress distribution, influence overlay cladding secondary solidification structure and structure, help promoting that the disperse of carbide hard phase distributes, the generation of formation of malleableize tissue and precipitated phase nodularization structural form, reduce overlay cladding defective (as pore, be mingled with etc.), improve toughness plasticity, form the high-quality overlay cladding.(5) reduce splashing of efficient gas protection built-up welding; improve the built-up welding forming quality; help realizing at low cost the high-efficiency high-quality weld deposit process, cancellation or reduction are to the specification requirement (comprising the requirement to welding material and weld preheating) and the heat treated harsh conditions of bead-welding technology.(6) Welding Molten Drop transition behavior is the final result of the suffered various power comprehensive functions of molten drop; and efficient gas protection welding arc is a typical plasma (comprising charged particle and neutral particle); rotating jet transition molten drop is the fine metal drop of a kind of high temperature, high-speed motion; its behavior must be subjected to the particle motion and add the influence of electromagnetic field; controlled the motion of particle and small droplet in the electric arc; also just controlled the transition behavior of molten drop directly or indirectly; therefore just can replace helium, realize stable rotation jet droplet transfer process.(7) more help realizing the built-up welding of functionally gradient material (FGM).Basic principle of the present invention is to think under the effect of electromagnetic complex field, weld deposit process and overlay cladding are subjected to comprehensively inducing, produce favourable transformation and influence, make the high competency of built-up welding and toughness plasticity, high cladding rate get low dilution rate and reasonably coordinate, realize organic unity.
The inventor finds under study for action: adopt the flux cored wire built-up welding to have following effect: (1) can easily adjust material alloys composition and ratio neatly, obtain the overlay cladding or the gradient overlay cladding of variety classes alloy material, be beneficial to and realize mechanization and automation, metallurgical preparation process and smelting equipment that need not be complicated be broken through many restrictions such as space-time; (2) help improving built-up welding efficient and quality, reduce defective, reduce the built-up welding cost; (3) can avoid plasma and the cladding of laser stacks powder to be subjected to limitations (comprising submerged arc overlay welding) such as time and space; (4) can avoid piling the defective that powder cladding (built-up welding) produces because of powder feeding is inhomogeneous, and laser melting coating is expensive; (5) resurfacing welding material (welding rod, welding wire, solder flux etc.) kind is very abundant both at home and abroad, and welding wire manufacturing equipment and technology comparative maturity can be a lot of for the achievement in research of using for reference, and helps the selection of material built-up welding flux cored wire composition and development fast.

Claims (8)

1. consumable electrode surfacing method of electromagnetic complex field, it is characterized in that: be electromagnetic complex field control flux cored wire molten drop spray transfer consumable electrode gas-arc overlaying method, concrete grammar is: the top in built-up welding workpiece (7), use a pair of electromagnetic stirring exciting coil (8) and electromagnetic heat treatment exciting coil (9), electromagnetic stirring exciting coil (8) is coaxial with welding torch (3); Provide exciting current by field power supply (10), produce electromagnetic agitation and electromagnetic heat treatment outside Longitudinal Magnetic-field Has; On bead-on-plate weld, apply the movably first auxiliary electric field electrode (13) and the second auxiliary electric field electrode (14), produce auxiliary electric field; The source of welding current (5) provides built-up welding and auxiliary electric field electric current, the first auxiliary electric field electrode (13) and welding torch ignition tip (3) same polarity; This electromagnetic complex field is controlled the built-up welding of high cladding consumable electrode gas-arc to welding work pieces (7) realization electromagnetic complex field.
2. electromagnetic complex field control consumable electrode surfacing method according to claim 1, it is characterized in that: electromagnetic stirring exciting coil (8) and electromagnetic heat treatment exciting coil (9) connect with different frequency, variable strength and the time exciting current that becomes, utilize higher-frequency and carry out function composite by electromagnetic stirring than the magnetic field that weak intensity is complementary, welding arc during with control rotating jet transition, welding wire end molten drop comes off and the stability of liquid a fluid stream, and the effect with auxiliary induction heating impels wire melting and molten drop to form, and the welding pool melt is fully stirred; And adopt than low frequency with than carrying out the electromagnetic heat treatment effect in the magnetic field that big intensity is complementary, can change the crystalline condition of molten pool metal, change process of setting and Temperature Distribution, tissue, phase structure also can change, impel the weld grain refinement, reduce chemical inhomogeneities, reduce the sensitiveness of pore, help improving toughness plasticity, form the high-quality overlay cladding; Built-up welding workpiece (7) is realized meeting the electromagnetic complex field weld deposit process of built-up welding requirement;
Perhaps, electromagnetic stirring exciting coil (8) and electromagnetic heat treatment exciting coil (9) are executed simultaneously and are connect field power supply (10), produce with frequently, homophase and with intensity the time become constant vertical electromagnetic field of vertical electromagnetic field or uniform strength, workpiece (7) is realized meeting the electromagnetic complex field weld deposit process of bead-welding technology requirement;
Perhaps, electromagnetic stirring exciting coil (8) and electromagnetic heat treatment exciting coil (9) are used separately, and execute and connect a field power supply (10), become constant vertical electromagnetic field of vertical electromagnetic field or uniform strength when producing one, carry out independent electromagnetic agitation or electromagnetic heat treatment effect;
Comprise following process conditions: built-up welding welding current 80～800A, wire feed rate 0～50m/min, welding wire is directly through 0.8～6mm, shield gas flow rate 1～50L/min, weldingvoltage 1～60V, speed of welding 0.01～6m/min, exciting current 0～60A, excitation frequency 0～100Hz, auxiliary electric field electric current 0～300A;
Comprise three kinds of flux cored wires: welding wire a, or welding wire b, or welding wire c; The concrete prescription of flux cored wire is as follows:
Welding wire a forms metal-powder-core by C, Cr, Ni, Mo, Mn, Si, N, rare earth alloy powder, and its composition range is W t%:C 0.28～0.40%, Cr 12.1～14.2%, Ni2.9～5.2%, Mo 0.78～0.91%, Mn 0.65～1.61, Si 0.16～0.96%, N0.02～0.04%, rare earth 0.01～3.2%; S≤0.01%, P≤0.025%; Adopt argon gas and nitrogen to mix the protective gas of forming, its percent by volume is: 10～30% nitrogen+remain are argon gas;
Welding wire b forms metal-powder-core by C, Cr, Ni, Si, B, Mn alloy powder, and its composition range is W t%:C0.08～0.17%, Cr 10.2～18.3%, Ni 3.4～5.8%, Si 0.38～0.81%, B 0.14～0.34%, Mn 0.68～1.61%; Protective gas adopts carbon dioxide and argon gas to mix to form, and its percent by volume is: 10～20% carbon dioxide+remain are argon gas;
Welding wire c forms metal-powder-core by C, Cr, W, Mo, V, Nb, rare earth alloy powder, and its composition range is W t%:C 0.4～0.9%, Cr 16.2～26.4%, W 2.9～6.2%, Mo 0.38～3.41%, V 0.24～0.38%, Nb 2.3～5.8%, rare earth 0.01～4.6%; Protective gas adopts 100% argon gas.
3. an electromagnetic complex field consumable electrode surfacing equipment is characterized in that being provided with field power supply, energizing apparatus, auxiliary electric field equipment and water-cooling system; Energizing apparatus is electromagnetic stirring exciting coil (8) and electromagnetic heat treatment exciting coil (9), and electromagnetic stirring exciting coil (8) and electromagnetic heat treatment exciting coil (9) provide exciting current by field power supply (10); Field power supply (10) adopt can produce multiple frequency and varying strength the time become the power supply of exciting current or constant current exciting current; Electromagnetic stirring exciting coil (8) and electromagnetic heat treatment exciting coil (9) are the axial symmetry column structure, are located at respectively on first support (1), second support (12); Electromagnetic stirring exciting coil (8) is fixed on the welding torch (3), and coaxial with welding torch (3); End at first support (1) of electromagnetic stirring exciting coil (8) is provided with the clamping and locking mechanism that links to each other with welding torch (3), it is fixed on electromagnetic stirring exciting coil (8) on the torch-tip (2), makes electromagnetic stirring exciting coil (8) and workpiece (7) that the free adjustment degree of certain distance be arranged; The distance of welding torch (3) and electromagnetic heat treatment exciting coil (9) can be regulated, and in first support (1) and second support (12) water-cooling system is housed;
Auxiliary electric field equipment mainly is made of the movably first auxiliary electric field electrode (13) and the second auxiliary electric field electrode (14), and one connects negative pole, and another root connects positive pole, provides electric current by the source of welding current (5); The first auxiliary electric field electrode (13) and welding torch ignition tip (3) same polarity; The first auxiliary electric field electrode (13) can be by tungsten argon arc welding torch TIG, or plasma welding torch PAW, or laser torch EBW, or electron beam welding torch EBW replaces, and forms consumable electrode and the compound welding torch built-up welding of non-melt pole mode; The first auxiliary electric field electrode (13) is replaced by consumable electrode welding torch MAG/MIG/CO2, forms mariages composite overlaying mode.
4. electromagnetic complex field according to claim 3 control consumable electrode surfacing equipment is characterized in that: described electromagnetic stirring exciting coil (8) and electromagnetic heat treatment exciting coil (9) are provided with first conducting magnet core (4) and second conducting magnet core (11) in respectively; In the electromagnetic stirring exciting coil (8) and electromagnetic heat treatment exciting coil (9) that first conducting magnet core (4) and second conducting magnet core (11) are movably arranged on, can its position in electromagnetic stirring exciting coil (8) and electromagnetic heat treatment exciting coil (9) of free adjustment until all from electromagnetic stirring exciting coil (8) and electromagnetic heat treatment exciting coil (9), removing; The shape of first conducting magnet core (4) and second conducting magnet core (11) end is funnel type, straight barrel type or pyramid type.
5. electromagnetic complex field control consumable electrode surfacing equipment according to claim 3, it is characterized in that: described electromagnetic heat treatment exciting coil (9) is rigidly connected with electromagnetic stirring exciting coil (8) and welding torch (3) by an adjustable fixed arm (15) and is one, adjustable fixed arm (15) can change the distance of welding torch (3) and electromagnetic heat treatment exciting coil (9), realizes that rational electromagnetic complex field built-up welding applies mode under the different speeds of welding;
Perhaps, with electromagnetic stirring exciting coil (8) directly and torch-tip (2) become one, adopt insulating materials to make the outer wall of torch-tip (2) and the wire turn of electromagnetic stirring exciting coil (8) keep state of insulation, and cool off by the water-cooling system of torch-tip (2) internal build.
6. electromagnetic complex field consumable electrode surfacing equipment according to claim 3, it is characterized in that: the water-cooling system in first support (1) of electromagnetic stirring exciting coil (8) and second support (12) of electromagnetic heat treatment exciting coil (9) adopts cover-plate type rectangular pulse shape condensation flow pattern, be respectively equipped with current groove (16) and staggered two drainings stream next door (18) in first support (1) and second support (12), two drainings stream dividing plates (18) link to each other with the outer baffle (17) of current groove (16) both sides respectively;
Water-cooling system in the torch-tip (2) adopts cover-plate type spirality condensation flow flow pattern, its structure is: design has spiral helicine screw thread current groove (20) in the torch-tip wall (21), formed omnibearing condensation water channel in the torch-tip in conjunction with torch-tip baffle plate (19), make condensed water center on torch-tip and flow twist, arrive the end of torch-tip.
7. one kind with claim 1 or 2 described electromagnetic complex fields control consumable electrode surfacing methods and with claim 3,4, the 5 or 6 described electromagnetic complex fields control consumable electrode surfacing equipment purposes aspect following:
Be used for the built-up welding of high cladding rate consumable electrode gas-arc, or common consumable electrode gas-arc built-up welding, or the non-melt pole Gas Shielded welding, or plasma surfacing, or the laser built-up welding, or the agitating friction built-up welding, or the welding rod arc built-up welding;
Be used for the built-up welding of following material: cast iron, medium high carbon antifriction alloy, nickel-base alloy, ferrous alloy, cobalt-base alloys, carbide alloy and stainless steel and alloy thereof;
The single-layer surfacing, the multiple-bead deposit that are used for homogenous material, or the single-layer surfacing of multiple material, multiple-bead deposit, or the multiple-bead deposit of functionally gradient material (FGM);
Be used for mould manufacturing and reparation, the reparation of plant equipment, the reparation of metallurgical equipment and mining equiment.
8. purposes according to claim 7 is characterized in that: adopt following welding procedure, workpiece (7) is realized other electromagnetic complex field welding procedures:
Be used for efficient consumable electrode welding, or common consumable electrode welding field;
Be used for solid welding wire, the welding of flux-cored wire and flux cored wire;
Be used for the welding of following material: mild steel, steel alloy, special steel, stainless steel, copper and alloy thereof, aluminium and alloy thereof, magnesium and alloy thereof and titanium and alloy thereof;
Be used for butt joint, overlap joint, corner connection, the multiple welding point form of all-position welding;
Be used for the welding of pure gas protection consumable electrode, or binary or multi component mixed gas body protection consumable electrode welding field;
The employing electromagnetic complex field is implemented: welding meets MIG, or metal active gas welding meets MAG, or gas tungsten arc welding meets TIG, or submerged arc welding SAW, or carbon dioxide welding CO 2, or electroslag welding ESW, or PLASMA ARC WELDING PAW, or electron beam welding EBW, or electric resistance welding RW, or friction welding (FW) FW, or friction stir welding FSW, or laser weld LBW;
Wherein:
(1) electromagnetic complex field control consumable electrode gas-arc bead-welding technology parameter is: welding current 60～800A; Electromagnetic agitation magnetic field intensity 0.01～10T, electromagnetic agitation field frequency 1～20Hz; Auxiliary electric field electric current 0～50A makes compound welding torch time spent auxiliary electric field electric current 0～300A; Electromagnetic heat treatment magnetic field intensity 0.01～20T, electromagnetic heat treatment field frequency 1～100Hz, built-up welding speed 0.01～5m/min, gas flow 1～40L/min;
(2) electromagnetic complex field control non-melt pole Gas Shielded welding technological parameter is: welding current 60～300A, electromagnetic agitation magnetic field intensity 0.01～6T, electromagnetic agitation field frequency 1～20Hz, auxiliary electric field electric current 0～50A, make compound welding torch time spent auxiliary electric field electric current 0～250A, electromagnetic heat treatment magnetic field intensity 0.01～10T, electromagnetic heat treatment field frequency 1～100Hz, built-up welding speed 0.01～2m/min, gas flow 2～30L/min;
(3) electromagnetic complex field control laser bead-welding technology parameter is: laser built-up welding power 0.1KW～10KWA, electromagnetic agitation magnetic field intensity 0.01～8T, electromagnetic agitation field frequency 1～20Hz, auxiliary electric field electric current 0～50A, auxiliary electric field electric current 0～300A when making compound welding torch, electromagnetic heat treatment magnetic field intensity 0.01～10T, electromagnetic heat treatment field frequency 0～50Hz, built-up welding speed 0.1～5m/min;
(4) the electromagnetic complex field controlling resistance welder parameter of planting is: electromagnetic agitation magnetic field intensity 0.02～10T, electromagnetic agitation field frequency 1～20Hz;
(5) electromagnetic complex field control agitating friction bead-welding technology parameter is: electromagnetic agitation magnetic field intensity 0.01～10T, electromagnetic agitation field frequency 1～20Hz, auxiliary electric field electric current 0～200A, electromagnetic heat treatment magnetic field intensity 0.01～20T, electromagnetic heat treatment field frequency 1～100Hz;
(6) electromagnetic complex field control submerged arc overlay welding technological parameter is: welding current 200～800A; electromagnetic agitation magnetic field intensity 0.01～8T; electromagnetic agitation field frequency 1～30Hz; auxiliary electric field electric current 0～80A; electromagnetic heat treatment magnetic field intensity 0.01～20T; electromagnetic heat treatment field frequency 1～100Hz, speed of welding 0.1～5m/min does not adopt protective gas.
CN 200710078434 2007-04-28 2007-04-28 A kind of consumable electrode surfacing method of electromagnetic complex field, equipment and expansion thereof are used Expired - Fee Related CN100551603C (en)

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