CN101862926A - Welding material for quickly welding and repairing defects of large-scale steel-casting and repairing method - Google Patents

Welding material for quickly welding and repairing defects of large-scale steel-casting and repairing method Download PDF

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CN101862926A
CN101862926A CN 201010204149 CN201010204149A CN101862926A CN 101862926 A CN101862926 A CN 101862926A CN 201010204149 CN201010204149 CN 201010204149 CN 201010204149 A CN201010204149 A CN 201010204149A CN 101862926 A CN101862926 A CN 101862926A
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welding material
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CN101862926B (en
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翟秋亚
徐锦锋
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Xian University of Technology
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Abstract

The invention discloses a welding material for quickly welding and repairing defects of a large-scale steel-casting. When being applied to large-scale ZG35CrMo steel-castings, the welding material comprises the following components in percentage by weight: 33%-38% of ferric oxide, 24%-28% of aluminum, 1.4%-1.6% of soda, 4%-7% of borax, 8%-12% of fluorite, 6%-8% of calcium oxide, 4%-5% of mid-carbon ferromanganese, 6%-8% of silica, 3%-5% of chromic oxide and 1%-2% of ferromolybdenum; and the total weight is 100%. When being applied to large-scale ZG20 steel-castings, the welding material comprises the following components in percentage by weight: 35%-38% of ferric oxide, 20%-25% of aluminum, 1.4%-1.6% of soda, 5%-7% of borax, 8%-10% of fluorite, 10%-12% of calcium oxide, 6.5%-7.5% of silica and 3.5%-5% of manganese oxide; and the total weight is 100%. The invention also discloses a method for quickly welding and repairing the defects of the large-scale steel-casting, comprising the following steps: filling the welding materials into grooves and dams, carrying out exothermic reaction on the welding materials, rapidly cooling and eliminating part of metal, which is higher than a casting surface in a welding area. Welding line components welded by the method in the invention are provided with fine and compact tissue and consistent performance as well as color and luster with castings.

Description

Rapid welding is repaired the welding material and the restorative procedure of defects of large-scale steel-casting
Technical field
The invention belongs to foundry goods Welding Repair Technology field, relate to the welding material that a kind of rapid welding is repaired defects of large-scale steel-casting, the invention still further relates to the method that a kind of rapid welding is repaired defects of large-scale steel-casting.
Background technology
Casting is first procedure of material forming, because the complexity of foundry production inevitably causes various casting flaws.The foundry goods that defective causes is scrapped except bringing to manufacturing enterprise the direct economic loss, and the subsequent treatment of waste product spare is also brought pressure to society, and environment is damaged.The dismemberent of especially large-scale waste product spare and shattering process need spend a large amount of energy; The production again of foundry goods needs melting again, and this is in consumes energy, and exhaust gas discharged and slag have also caused secondary pollution to environment.Certainly, this does not also comprise the waste of labour and time cost.Therefore, large-scale misrun casting saved repair the behave that to be that enterprise spends more money on energy-conservation, increase economic efficiency, help the sustainable development of environmental resource and the health of human society.
The difficulty of defects of large-scale steel-casting REPAIR WELDING is: the weld zone lack of fusion that causes because of foundry goods heat conduction is too fast, or because of the deposited metal amount causes more thermal stress is excessive to ftracture.Adopt the electroslag welding correction of the defect then easily to cause the weld zone metal grain thick, cause that the welding zone performance reduces.
Summary of the invention
The object of the present invention is to provide a kind of rapid welding to repair the welding material of defects of large-scale steel-casting, realize at room temperature direct repair by welding misrun casting, and can suppress the welding zone grain coarsening effectively, and reducing the crackle tendency, the weld zone color and luster is consistent with the foundry goods body.
Another object of the present invention is to provide a kind of utilizes above-mentioned welding material that defects of large-scale steel-casting is carried out the method that rapid welding is repaired.
The technical solution adopted in the present invention is, a kind of rapid welding is repaired the welding material of defects of large-scale steel-casting, when being used for large-scale ZG35CrMo steel-casting REPAIR WELDING, evenly mix by weight percentage by the powder of following component and to form: di-iron trioxide 33%-38%, aluminium 24%-28%, soda ash 1.4%-1.6%, borax 4%-7%, fluorite 8%-12%, calcium oxide 6%-8%, mid-carbon fe-mn 4%-5%, silica 6%-8%, chrome green 3%-5%, molybdenum-iron 1%-2%, gross weight is 100%;
When being used for large-scale ZG20 steel-casting REPAIR WELDING, evenly mixed by weight percentage by the powder of following component and to form: di-iron trioxide 35%-38%, aluminium 20%-25%, soda ash 1.4%-1.6%, borax 5%-7%, fluorite 8%-10%, calcium oxide 10%-12%, silica 6.5%-7.5%, manganese oxide 3.5%-5%, gross weight is 100%.
Another technical scheme of the present invention is, a kind of rapid welding is repaired the method for defects of large-scale steel-casting, and this method is implemented according to following steps:
Step 1, process groove at the rejected region of misrun casting;
Step 2, along the moulding of groove opening upper limb periphery: build dykes and dams along defective groove top periphery, the upper limb of dykes and dams is provided with the lead-ingroove of igniter fuse;
Step 3, filling welding material: at the steel-casting of the concrete trade mark, the welding material of corresponding preparation is packed in the space that groove and dykes and dams form, imbeds compacting behind the igniter fuse, fill up welding material, press foundary weight in the dykes and dams upper edge at last;
Step 4, light igniter fuse, make exothermic mixture generation exothermic reaction in the welding material, the whole fusings of all components in the welding material are become deposited metal, and the iron liquid density in the deposited metal is higher than slag and sinks in the groove, and slag come-up and iron liquid generation layering;
After step 5, the exothermic reaction 0.5-1 minute, with water jet deposited metal is cooled off fast immediately, obtain comprising the weld zone metal of slag and excess metal layer;
Step 6, district to be welded metal are cooled to remove foundary weight and dykes and dams below 400 ℃, remove the part that the weld zone metal exceeds cast(ing) surface.
The invention has the beneficial effects as follows, use the casting heat release and emit vocal imitation skill and thermite heating principle, weld zone mechanical protection function well; The speed of welding controllability is good, and the feature of environmental protection is good; Welding temperature is low, and little to the fusing degree of foundry goods body, the fusion area is narrow; Weld zone dense structure by adjusting the welding powder material composition, obtains and the corresponding weld metal of different trade mark steel-castings, is fit to very much the REPAIR WELDING of the various defectives of all kinds of large-scale steel-castings.
Description of drawings
Fig. 1 is the position shape figure to be welded after adopting the inventive method to the casting defect polishing;
Fig. 2 adopts the inventive method that dykes and dams moulding figure is built on defective top;
Fig. 3 is the welding welding powder filling schematic diagram before that adopts the inventive method;
Fig. 4 is the postwelding weld zone structure chart that adopts the inventive method;
Fig. 5 is the foundry goods weld zone that adopts after the inventive method is processed.
Wherein, 1. misrun casting, 2. dykes and dams, 3. foundary weight, 4. welding material, 5. igniter fuse, 6. deposited metal, 7. weld zone metal, 8. groove.
The specific embodiment
The present invention is described in detail below in conjunction with the drawings and specific embodiments.
Rapid welding of the present invention is repaired the welding material of defects of large-scale steel-casting, comprises the powder of three parts according to its function:
First is an exothermic mixture, comprises Fe 2O 3And Al, after heat-producing chemical reaction takes place for both, both providing the Welding Metallurgy energy needed, product Fe can be used as main deposited metal again and forms weld seam, Al 2O 3Enter slag, also can participate in the slag making reaction in the molten bath.
Second portion is a slag former, comprises Na 2CO 3, Na 2B 4O 7, CaF 2And CaO, Na wherein 2B 4O 7And CaF 2Also have the effect of diluent concurrently, can be used to regulate viscosity coefficient of dross.
Third part is an alloying constituent, need use different welding filling powders at different types of steel-casting, with the weld zone metal that obtains to be complementary with institute's steel-casting tissue of being repaired and performance, the corresponding specific aim of carrying out is additional, both can form weld metal after the fusing, have alloying action again.
In the above-mentioned welding material component, exothermic mixture and slag former have versatility; And need at the REPAIR WELDING of different trade mark steel-castings, alloying constituent has certain difference aspect kind and the content.
At large-scale steel-casting, specifically comprise following two kinds of schemes:
First kind of technical scheme is: be used for the welding material of large-scale ZG35CrMo steel-casting REPAIR WELDING, evenly mixed by weight percentage by the powder of following component and form:
Di-iron trioxide 33%-38%, aluminium 24%-28%, soda ash 1.4%-1.6%, borax 4%-7%, fluorite 8%-12%, calcium oxide 6%-8%, mid-carbon fe-mn 4%-5%, silica 6%-8%, chrome green 3%-5%, molybdenum-iron 1%-2%, gross weight is 100%.
In the welding material of this programme, each component and content limit as follows:
In order to make welding process be carried out, added a large amount of Fe 2O 3With the Al powder as exothermic mixture.The energy that reaction produces not only can be kept proceeding of exothermic reaction, and can also be enough to melt various metal powder materials, and makes the mother metal local melting, forms weld seam jointly, reaches the purpose of welding.
In order to make welding slag assemble, float and separate with deposited metal, prevention weld metal slag inclusion has added CaF 2, CaO, Na 2CO 3, Na 2B 4O 7Deng as slag former and diluent.For reducing the weld porosity that high-temperature oxydation caused of weld zone metal, Fe 2O 3Addition is too much unsuitable.In addition, in the middle of welding powder, also added a certain amount of SiO 2And Cr 2O 3, be used for replenishing exothermic reaction, transition alloy elements Cr and being used for slag making.
In order to make weld metal obtain tissue and the performance that is complementary with steel-casting, purify weld metal, reduce the influence of objectionable impurities elements such as S, P, manganese content is higher in the welding powder, and has added CaO.
Second kind of technical scheme of the present invention is: be used for the welding material of large-scale ZG20 steel-casting REPAIR WELDING, evenly mixed by weight percentage by the powder of following component and form:
Di-iron trioxide 35%-38%, aluminium 20%-25%, soda ash 1.4%-1.6%, borax 5%-7%, fluorite 8%-10%, calcium oxide 10%-12%, silica 6.5%-7.5%, manganese oxide 3.5%-5%, gross weight is 100%.
In the welding material of this programme, each is formed and content qualification reason is described below respectively:
In order to make welding process be carried out, added a large amount of Fe 2O 3With the Al powder as exothermic mixture.The energy that reaction produces not only can be kept proceeding of exothermic reaction, and can also be enough to melt various metal powder materials, and makes the mother metal local melting, forms weld seam jointly, reaches the purpose of welding.
In order to make welding slag assemble, float and separate with deposited metal, prevention weld metal slag inclusion has added Na 2CO 3, Na 2B 4O 7, CaF 2With CaO etc. as slag former.In addition, in the middle of welding powder, also added a certain amount of SiO 2, be used for replenishing exothermic reaction, transition alloy elements Si and being used for slag making.
In order to make weld metal obtain tissue and the performance that is complementary with foundry goods, purify weld metal, reduce the adverse effect of S element, contain 3.5%-5%MnO in the welding powder.
Rapid welding of the present invention is repaired the method for defects of large-scale steel-casting, at the large-scale steel-casting of the different trades mark, uses above-mentioned welding material, specifically implements according to following steps:
Step 1, the rejected region of misrun casting 1 is implemented polishing, process groove 8, as Fig. 1;
Step 2, along the moulding of groove 8 opening upper limbs peripheries.Use molding sand or cement to build moulding dykes and dams 2(defective top molding body along defective groove 8 top periphery), in order to slagging-off and the overflow of prevention molten metal, the upper limb of dykes and dams 2 need leave the lead-ingroove of igniter fuse 5, as Fig. 2;
Step 3, filling welding material: at the steel-casting of the concrete trade mark, the welding material 4 of corresponding preparation is packed in the space of groove 8 and dykes and dams 2 formation, tamp, fill up welding material after imbedding igniter fuse 5, press foundary weight 3 in dykes and dams 2 upper edges at last, as Fig. 3;
Step 4, light igniter fuse 5, with all components in the welding material 4 all fusing become deposited metal 6, the iron liquid density in the deposited metal 6 is higher than slag and sinks in the groove 8, and slag come-up and iron liquid generation layering;
Step 5, begin to react the back 0.5-1 minute, to dykes and dams and foundry goods upper surface on every side thereof deposited metal 6 is cooled off with water jet fast immediately, obtain comprising the weld zone metal 7 of slag and excess metal layer;
Step 6, district to be welded metal 7 are cooled to remove foundary weight 3 below 400 ℃, take down moulding dykes and dams 2, as Fig. 4, remove the part that weld zone metal 7 exceeds cast(ing) surface by machine-tooled method, again that the weld zone surface finish is smooth, form soldering zone as shown in Figure 5.
Characteristics of the present invention are, build the dykes and dams moulding along the defective upper limb, must reserve high about 3mm, the fuse groove of wide about 5mm, the attention groove wide and high-order to, in case the excessive outflow of slag and molten metal in the welding process; Using high-velocity flow is the key point that realizes that rapid welding is repaired to the weld zone Quench.
This welding method had both been simplified the wlding production technology, saved the energy again, environmentally safe, but also can obtain the weld zone that is complementary with foundry goods body composition, tissue, performance and color and luster, realize that the high-performance rapid welding of the big defective of large-scale steel-casting is repaired.
Embodiment 1
At first, preparation is used for the welding material of large-scale ZG35CrMo steel-casting REPAIR WELDING, is evenly mixed by weight percentage by the powder of following component and forms:
Di-iron trioxide 36%, aluminium 26%, soda ash 1.5%, borax 6%, fluorite 8%, calcium oxide 6%, mid-carbon fe-mn 5%, silica 6.5%, chrome green 3.5%, molybdenum-iron 1.5%, gross weight are 100%.
Then, utilize the above-mentioned welding material for preparing, specifically implement according to following step:
Step 1, the rejected region of misrun casting 1 is implemented polishing, process groove 8;
Step 2, along the moulding of groove 8 upper limbs peripheries.Use molding sand or cement to build dykes and dams 2 along defective groove 8 top periphery, the upper limb of dykes and dams 2 leaves the lead-ingroove of igniter fuse 5;
Step 3, filling welding material: the welding material 4 of preparation is packed in groove 8 and the dykes and dams 2, tamps, fill up after imbedding igniter fuse 5, press foundary weight 3 at last in the above;
Step 4, light igniter fuse 5, make exothermic mixture generation exothermic reaction in the welding material 4, the whole fusings of all components in the welding material 4 are become deposited metal 6, and the iron liquid density in the deposited metal 6 is higher than slag and sinks in the groove 8, and slag come-up and iron liquid generation layering;
Step 5, begin to react the back 0.5-1 minute, to dykes and dams and foundry goods upper surface on every side thereof deposited metal 6 is cooled off with water jet fast immediately, obtain comprising the weld zone metal 7 of slag and excess metal layer;
Step 6, district to be welded metal are cooled to remove foundary weight 3 below 400 ℃, beat dykes and dams 2, remove the part that weld zone metal 7 exceeds cast(ing) surface again.
In the present embodiment 1, the chemical composition such as the table 1 of welding powder deposited metal show that basic identical with the composition of reparation steel-casting material, i.e. metallographic structure is identical, has reached the Welding Repair of Cast Iron requirement.
Welding powder deposited metal chemical analysis (weight %) in table 1 embodiment of the invention 1
Figure 363186DEST_PATH_IMAGE001
Embodiment 2
At first, preparation is used for the welding material of large-scale ZG35CrMo steel-casting welding, is evenly mixed by weight percentage by the powder of following component and forms:
Di-iron trioxide 33%, aluminium 28%, soda ash 1.6%, borax 4%, fluorite 9%, calcium oxide 8%, mid-carbon fe-mn 4%, silica 6%, chrome green 5%, molybdenum-iron 1.4%, gross weight are 100%.
Then, adopt the step of embodiment 1, implement repair welding.
Embodiment 3
At first, preparation is used for the welding material of large-scale ZG35CrMo steel-casting REPAIR WELDING, is evenly mixed by weight percentage by the powder of following component and forms:
Di-iron trioxide 37%, aluminium 24%, soda ash 1.4%, borax 7%, fluorite 8%, calcium oxide 7%, mid-carbon fe-mn 4%, silica 7%, chrome green 3%, molybdenum-iron 1.6%, gross weight are 100%.
Then, adopt the step of embodiment 1, implement repair welding.
Embodiment 4
At first, preparation is used for the welding material of large-scale ZG20 steel-casting REPAIR WELDING, is evenly mixed by weight percentage by the powder of following component and forms:
Di-iron trioxide 35%, aluminium 25%, soda ash 1.5%, borax 6%, fluorite 10%, calcium oxide 11%, silica 7.5%, manganese oxide 4%, gross weight are 100%.
Then, adopt the step of embodiment 1, implement repair welding.
In the present embodiment 4, the chemical composition such as the table 2 of welding powder deposited metal show that basic identical with the composition of reparation steel-casting material, i.e. metallographic structure is identical, has reached the Welding Repair of Cast Iron requirement substantially.
Welding powder deposited metal chemical analysis (weight %) in table 2 embodiment of the invention 4
Figure 280326DEST_PATH_IMAGE002
Embodiment 5
At first, preparation is used for the welding material of large-scale ZG20 steel-casting REPAIR WELDING, is evenly mixed by weight percentage by the powder of following component and forms:
Di-iron trioxide 38%, aluminium 21%, soda ash 1.6%, borax 7%, fluorite 9%, calcium oxide 12%, silica 7%, manganese oxide 4.4%, gross weight are 100%.
Then, adopt the step of embodiment 1, implement repair welding.
Embodiment 6
At first, preparation is used for the welding material of large-scale ZG20 steel-casting REPAIR WELDING, is evenly mixed by weight percentage by the powder of following component and forms:
Di-iron trioxide 37%, aluminium 24%, soda ash 1.4%, borax 7%, fluorite 8%, calcium oxide 11%, silica 6.6%, manganese oxide 5%, gross weight are 100%.
Then, adopt the step of embodiment 1, implement repair welding.
Among above-mentioned other embodiment, the chemical composition of welding powder deposited metal is basic identical with the composition of the steel-casting material of repairing, i.e. metallographic structure is identical, has reached the Welding Repair of Cast Iron requirement substantially.
Rapid welding of the present invention is repaired the material and the method for defects of large-scale steel-casting, uses the casting heat release and emits vocal imitation skill and thermite heating principle, does not need electricity, gas and other facilities to realize welding; Weld zone mechanical protection function well; Safely, reliable speed of welding controllability is good; Pollution-free, the feature of environmental protection is good; The solidification shrinkage of additional molten pool metal under the gravity, weld zone dense structure, defective is few; Welding temperature is low, and little to the fusing degree of foundry goods body, the fusion area is narrow; The welding duration is short; By adjusting the welding powder material composition, obtain and the corresponding weld metal of different trade mark steel-castings, be fit to very much the REPAIR WELDING of the various defectives of all kinds of heavy castings.

Claims (4)

1. a rapid welding is repaired the welding material of defects of large-scale steel-casting, it is characterized in that, when being used for large-scale ZG35CrMo steel-casting REPAIR WELDING, evenly mixed by weight percentage by the powder of following component and to form: di-iron trioxide 33%-38%, aluminium 24%-28%, soda ash 1.4%-1.6%, borax 4%-7%, fluorite 8%-12%, calcium oxide 6%-8%, mid-carbon fe-mn 4%-5%, silica 6%-8%, chrome green 3%-5%, molybdenum-iron 1%-2%, gross weight is 100%.
2. a rapid welding is repaired the material of defects of large-scale steel-casting, it is characterized in that, when being used for large-scale ZG20 steel-casting REPAIR WELDING, evenly being mixed by weight percentage by the powder of following component and to form:
Di-iron trioxide 35%-38%, aluminium 20%-25%, soda ash 1.4%-1.6%, borax 5%-7%, fluorite 8%-10%, calcium oxide 10%-12%, silica 6.5%-7.5%, manganese oxide 3.5%-5%, gross weight is 100%.
3. a rapid welding is repaired the method for defects of large-scale steel-casting, it is characterized in that this method is implemented according to following steps:
Step 1, process groove (8) at the rejected region of misrun casting (1);
Step 2, along the moulding of groove (8) opening upper limb periphery: build dykes and dams (2) along defective groove (8) top periphery, the upper limb of dykes and dams (2) is provided with the lead-ingroove of igniter fuse (5);
Step 3, filling welding material: at the steel-casting of the concrete trade mark, the welding material (4) of corresponding preparation is packed in the space of groove (8) and dykes and dams (2) formation, tamp, fill up welding material after imbedding igniter fuse (5), press foundary weight (3) in dykes and dams (2) upper edge at last;
Step 4, light igniter fuse (5), make exothermic mixture generation exothermic reaction in the welding material (4), the whole fusings of all components in the welding material (4) are become deposited metal (6), iron liquid density in the deposited metal (6) is higher than slag and sinks in the groove (8), and slag come-up and iron liquid generation layering;
After step 5, the exothermic reaction 0.5-1 minute, make deposited metal (6) cooling fast with water jet immediately, obtain comprising the weld zone metal (7) of slag and excess metal layer;
Step 6, district to be welded metal (7) are cooled to below 400 ℃, remove foundary weight (3) and dykes and dams (2), remove the part that weld zone metal (7) exceeds cast(ing) surface.
4. rapid welding according to claim 3 is repaired the method for defects of large-scale steel-casting, it is characterized in that the component and the content of described welding material 4 are:
When being used for large-scale ZG35CrMo steel-casting REPAIR WELDING, evenly mix by weight percentage by the powder of following component and to form: di-iron trioxide 33%-38%, aluminium 24%-28%, soda ash 1.4%-1.6%, borax 4%-7%, fluorite 8%-12%, calcium oxide 6%-8%, mid-carbon fe-mn 4%-5%, silica 6%-8%, chrome green 3%-5%, molybdenum-iron 1%-2%, gross weight is 100%;
When being used for large-scale ZG20 steel-casting REPAIR WELDING, evenly mixed by weight percentage by the powder of following component and to form: di-iron trioxide 35%-38%, aluminium 20%-25%, soda ash 1.4%-1.6%, borax 5%-7%, fluorite 8%-10%, calcium oxide 10%-12%, silica 6.5%-7.5%, manganese oxide 3.5%-5%, gross weight is 100%.
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CN102528325A (en) * 2012-01-10 2012-07-04 西安理工大学 Welding material for quickly welding and repairing defects of large-sized QT500-7 nodular cast iron parts and method
CN104816083A (en) * 2015-05-22 2015-08-05 武汉钢铁(集团)公司 Continuous casting plate blank surface vertical crack cleaning method based on aluminum heat self-propagating technology
CN106925920A (en) * 2017-03-08 2017-07-07 宁波高新区远创科技有限公司 A kind of preparation method of the special aluminothermy welding powder of novel grounded net materials
CN109822209A (en) * 2019-03-05 2019-05-31 郑州机械研究所有限公司 A kind of clad steel plate preparation method based on thermit reaction
CN110303297A (en) * 2019-07-02 2019-10-08 浙江开诚机械有限公司 CrMoV steel-casting reprocesses repair method
CN115007863A (en) * 2022-05-30 2022-09-06 南京工业大学 Method for repairing internal defects of large aluminum alloy casting

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CN102528325A (en) * 2012-01-10 2012-07-04 西安理工大学 Welding material for quickly welding and repairing defects of large-sized QT500-7 nodular cast iron parts and method
CN104816083A (en) * 2015-05-22 2015-08-05 武汉钢铁(集团)公司 Continuous casting plate blank surface vertical crack cleaning method based on aluminum heat self-propagating technology
CN104816083B (en) * 2015-05-22 2017-01-11 武汉钢铁(集团)公司 Continuous casting plate blank surface vertical crack cleaning method based on aluminum heat self-propagating technology
CN106925920A (en) * 2017-03-08 2017-07-07 宁波高新区远创科技有限公司 A kind of preparation method of the special aluminothermy welding powder of novel grounded net materials
CN109822209A (en) * 2019-03-05 2019-05-31 郑州机械研究所有限公司 A kind of clad steel plate preparation method based on thermit reaction
CN109822209B (en) * 2019-03-05 2023-04-28 郑州机械研究所有限公司 Preparation method of composite steel plate based on thermite reaction
CN110303297A (en) * 2019-07-02 2019-10-08 浙江开诚机械有限公司 CrMoV steel-casting reprocesses repair method
CN115007863A (en) * 2022-05-30 2022-09-06 南京工业大学 Method for repairing internal defects of large aluminum alloy casting
CN115007863B (en) * 2022-05-30 2023-02-28 南京工业大学 Method for repairing internal defects of large aluminum alloy casting

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