CN102029486A - Thermit welding flux for high hardness steel rail and welding method thereof - Google Patents
Thermit welding flux for high hardness steel rail and welding method thereof Download PDFInfo
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- CN102029486A CN102029486A CN2009100934087A CN200910093408A CN102029486A CN 102029486 A CN102029486 A CN 102029486A CN 2009100934087 A CN2009100934087 A CN 2009100934087A CN 200910093408 A CN200910093408 A CN 200910093408A CN 102029486 A CN102029486 A CN 102029486A
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Abstract
The invention discloses a thermit welding flux for a high hardness steel rail and a welding method thereof. The thermit welding flux consists of aluminum powder, ferric oxide and alloy additives, wherein the aluminum power is pure aluminum powder, the content of active aluminum is more than 98 percent, and the granularity is between 30 and 60 meshes; the ferric oxide is formed by oxidation in the process of heating a rolled steel material, and the granularity of the ferric oxide is between 18 and 80 meshes; and other alloy additives comprise iron shots, silicon iron, ferromanganese, ferrochrome, ferrovanadium, ferromolybdenum and rare-earth alloy. The method for performing thermit welding on the high hardness steel rail by using the thermit welding flux comprises the following steps of: (a) filling the thermit welding flux in a reaction crucible, and igniting the welding flux to initiate a thermit reaction; (b) casting thermit molten steel generated in the reaction into a closed cavity formed by a sand mould and the steel rail to be welded; and (c) cooling and solidifying the thermit molten steel and the steel rail together to weld the steel rails at two ends into a whole. When the thermit welding flux is used for welding, the welding joint has high hardness, the welding flux is stable in reaction, and the requirement for welding the high hardness steel rail can be met.
Description
Technical field
The present invention relates to a kind of rail aluminothermy flux for solder and welding method, particularly a kind of aluminothermy flux for solder and welding method thereof of high rigidity rail.
Background technology
Along with the development of rail track heavy haul transport, for improving the service life of rail, reduce rail wear, taked several different methods.Wherein increasing rail hardness is to improve the rail effective means in service life.Along with the increase of rail hardness, wearability increases, the auxilliary on the line if usefulness of increasing high rigidity rail, and therefore developing high rigidity rail exothermic welding connection technology becomes inevitablely, and the aluminum heat flux that aluminothermy welding glass hard steel rail is used has proposed requirement.
Summary of the invention
Primary and foremost purpose of the present invention is to provide a kind of high rigidity rail aluminum heat flux, this high rigidity rail aluminum heat flux stable reaction, and welding point hardness height satisfies the needs that the exothermic welding of high rigidity rail connects.
Another object of the present invention provides a kind of method of using high rigidity rail aluminum heat flux to weld.
According to first aspect present invention, high rigidity rail aluminum heat flux is by evenly being mixed by aluminium powder, iron oxide and alloy additive.
Wherein, described aluminium powder weight portion is 17～19, and its active aluminium content is greater than 98% percentage by weight, and granularity is 30～60 orders.
The oxidation in heating rolling steel process of wherein said iron oxide forms, and its weight portion is 65～71, and granularity is 18～80 orders.
Wherein said alloy additive comprises: shot, ferrosilicon, ferromanganese, ferrochrome, vanadium iron, molybdenum-iron, rare earth alloy, wherein:
Described shot weight portion is 10～12, and wherein phosphorus content is 3%～3.4% percentage by weight, and granularity is 10～18 orders;
Described ferrosilicon weight portion is 0.24～0.44, and its silicon content is 72.0～80.0% percentage by weights, and granularity is 10～18 orders;
Described ferromanganese weight portion is 1.31～3.31, and its manganese content is 65.0～72.0% percentage by weights, and granularity is 10～80 orders;
Described ferrochrome weight portion is 0.05～0.17, and its chrome content is 50%～55% percentage by weight, and granularity is 10～80 orders;
Described vanadium iron weight portion is 0.06～0.11, and its vanadium content is 50%～55% percentage by weight, and granularity is 10～80 orders;
Described molybdenum-iron weight portion is 0.23～0.29, and wherein containing the molybdenum amount is 55%～60% percentage by weight, and granularity is 10～80 orders;
Described rare earth alloy weight portion is 0.08～0.14, and wherein containing the chromium rare earth content is 35%～60% percentage by weight, and silicon content is less than 40% percentage by weight, and granularity is 10～80 orders.
According to second aspect present invention, use above-mentioned high rigidity rail aluminum heat flux to carry out the method that the exothermic welding of high rigidity rail connects and may further comprise the steps:
(a) sand mold is installed to the end of two adjacent rail to be welded after, the crucible that described aluminum heat flux is housed is placed on the described sand mold, cause thermit reaction by the heating aluminum heat flux then, generate the aluminothermy molten steel;
(b) described aluminothermy molten steel by melt described crucible bottom from fused plug, be cast in the enclosed cavity of end formation of described sand mold and described two adjacent rail;
(c) the aluminothermy molten steel that is cast in the described enclosed cavity is filled metal and its cocrystallization as slit between the end of described two adjacent rail, after cooled and solidified two rails is welded into integral body.
Wherein said crucible top is placed with crucible cover, and described crucible cover comprises: the discharging lid that raises up; The door of the conduit wall of discharge-channel in the described discharging lid is tightly connected; And by described conduit wall be communicated with on the described door and under at least one flame exhaust stack of discharge-channel.
Wherein said flame exhaust stack has the flame discharging inlet that is positioned under the described door and is positioned at flame exhaust outlet on the described door.
Be placed with crucible lining in the wherein said crucible, this liner comprises: inner lining body; Be positioned on the inner lining body bottom centre position from the fused plug hole; Be embedded in described inner lining body bottom centre position and surround described quoit from the fused plug hole; And fill in described described in the fused plug hole from fused plug.
The size of wherein said sand mold and rail profile consistent size to be welded; And heat described solder flux by lighting high-temperature match.
The present invention has following technique effect:
(1) flux reaction is stable.The time that solder flux is cast from lighting a fire to is at 27 ± 5S, tranquil time 5～10S;
(2) hardness of welding point is 320HB ± 10HB, and welding point metal average tensile strength is greater than 830Mpa, in kind tired 2,000,000 times constantly, be applicable to the aluminothermy welding of the 75kg/mPG4 rail that China is present.
(3) simple to operate, convenient and easy.
The present invention is described in detail below in conjunction with accompanying drawing.
Description of drawings
Fig. 1 is the schematic diagram that shows the preparatory stage of welding method of the present invention;
Fig. 2 shows the schematic diagram in the casting stage of welding method of the present invention;
Fig. 3 is the schematic diagram that shows the solidification stages of welding method of the present invention;
Fig. 4 is the schematic diagram that shows the crucible cover front of the present invention's use;
Fig. 5 is the schematic diagram that shows the crucible cover reverse side of the present invention's use;
Fig. 6 is the schematic diagram that shows the crucible liner of the present invention's use;
Fig. 7 is the schematic diagram of filling in from the crucible liner of fused plug.
The specific embodiment
High rigidity rail aluminum heat flux of the present invention is used for two sections rail welding are become whole by evenly being mixed by aluminium powder, iron oxide and alloy additive.
The aluminium powder weight portion can be 17～19, is preferably 18.03, and its active aluminium content is greater than 98% percentage by weight, and granularity is 30～60 orders.
Iron oxide oxidation in heating rolling steel process forms, and its weight portion can be 65～71, is preferably 67.94, and granularity is 18～80 orders.
Alloy additive comprises: shot, ferrosilicon, ferromanganese, ferrochrome, vanadium iron, molybdenum-iron, rare earth alloy, wherein:
The shot weight portion can be 10～12, is preferably 10.8, and its phosphorus content is 3%～3.4% percentage by weight, and granularity is 10～18 orders;
The ferrosilicon weight portion can be 0.24～0.44, is preferably 0.34, and its silicon content is 72.0～80.0% percentage by weights, and granularity is 10～18 orders;
The ferromanganese weight portion can be 1.31～3.31, is preferably 2.31, and its manganese content is 65.0～72.0% percentage by weights, and granularity is 10～80 orders;
The ferrochrome weight portion can be 0.05～0.17, is preferably 0.11, and its chrome content is 50%～55% percentage by weight, and granularity is 10～80 orders;
The vanadium iron weight portion can be 0.06～0.11, is preferably 0.09, and its vanadium content is 50%～55% percentage by weight, and granularity is 10～80 orders;
The molybdenum-iron weight portion can be 0.23～0.29, is preferably 0.26, and it contains the molybdenum amount is 55%～60% percentage by weight, and granularity is 10～80 orders;
The rare earth alloy weight portion is 0.08～0.14, is preferably 0.11, and it contains the chromium rare earth content is 35%～60% percentage by weight, and silicon content is less than 40% percentage by weight, and granularity is 10～80 orders.
Above-mentioned shot is the shot of low S, P preferably, such as S＜0.07%, and P＜0.08%.
Adopt above-mentioned high rigidity rail aluminum heat flux welded rails to have the following advantages:
1, flux reaction is stable.The time that solder flux is cast from lighting a fire to is at 27 ± 5S, tranquil time 5～10S.
2, the hardness of welding point is 320HB ± 10HB, and welding point metal average tensile strength is greater than 830Mpa, in kind tired 2,000,000 times constantly.Fit and weld in the aluminothermy of the present 75kg/mPG4 rail of China.
3, welding operation is easy.
Fig. 1 to Fig. 3 has shown that respectively the present invention carries out the preparatory stage of rail welding, casting stage and solidification stages.
Need to prove that welding method of the present invention is not only applicable to high rigidity rail aluminum heat flux of the present invention, is applicable to other solder flux yet.
As shown in Figure 1 to Figure 3, the above-mentioned high rigidity rail of use of the present invention aluminum heat flux carries out the method that the exothermic welding of high rigidity rail connects and may further comprise the steps:
(a) sand mold 2 is installed to the end 3 of two adjacent rail to be welded after, the crucible 5 that described aluminum heat flux is housed is placed on the described sand mold 2, cause thermit reaction by the heating aluminum heat flux then, generate the aluminothermy molten steel;
(b) described aluminothermy molten steel by melt described crucible 5 bottoms from fused plug 15, be cast in the enclosed cavity that the end 3 of described sand mold 2 and described two adjacent rail forms;
(c) the aluminothermy molten steel that is cast in the described enclosed cavity is filled metal and its cocrystallization as slit between the end 3 of described two adjacent rail, after cooled and solidified two rails is welded into integral body.
After welding is finished, can carry out following processing:
Unpack: the steel column that links to each other with the flange of rail of sand mold and both sides is removed;
Push away knurl: the weld metal of welding point tread and rail head side is removed with pushing away the knurl machine;
Polishing:, make it mutually smooth-going with the rail mother metal with sander polishing welding point end face and rail head side;
Cleaning: the sand mold around the cleaning weld metal.
The dried pot that the present invention uses can be disposable crucible.
Because the reaction temperature height of rail aluminum heat flux, reaction is fierce, has a large amount of high-temperature particles in the process that solder flux reacts and splash and produce a large amount of flame simultaneously in crucible.Contain high-temperature slag and high-temperature molten steel in the particle that sputters, this this high-temperature particle directly threatens welding operation personnel's safety, and this this high-temperature particle also might be fallen the on-the-spot periphery of welding in addition, brings potential safety hazard, and threatens on-the-spot safety.For this reason, the present invention is provided with a kind of crucible cover 6 that prevents that high-temperature slag and high-temperature molten steel from splashing especially.As shown in Figure 1 to Figure 3, this crucible cover 6 is placed on the top of crucible 5.
Fig. 4 has shown the Facad structure of crucible cover 6 of the present invention, and Fig. 5 has shown the reverse side structure of crucible cover 6 of the present invention.
As shown in Figure 4 and Figure 5, crucible cover 6 of the present invention comprises:
The discharging lid 10 that raises up is used for the soot to the high heat of airborne release high temperature, and these discharging lid 10 inside have a discharge-channel;
The be tightly connected door 9 of the conduit wall of discharge-channels 12 in the described discharging lid 10 is used to block and carries out rail exothermic welding practice midwifery living high-temperature particle and flame; And
By described conduit wall be communicated with on the described door 9 and under at least one flame exhaust stack of discharge-channel 12, that is to say that this discharge-channel is communicated with the discharge-channel 12 of door about in the of 9 by flame discharging inlet 8 shown in Figure 4 and flame exhaust outlet shown in Figure 5 15.
High-temperature particle and flame that this present invention utilizes door 9 to stop to splash utilize the flame exhaust stack discharging flame that is communicated with by the conduit wall of door 9 about and high temperature, high hot soot simultaneously.
In order to strengthen the bonding strength that door 9 is connected with conduit wall, discharging lid 9 is provided with a plurality of door brace rods 14 that are used to support described door 9 that extend from conduit wall, can effectively avoid door 9 like this and discharge separating of lid, promptly can effectively avoid door 9 to come off from discharging lid 10.As shown in Figure 5, door brace rod 14 can have four.
As mentioned above, the flame exhaust stack has flame discharging inlet 15 that is positioned under the door 9 and the flame exhaust outlet 8 that is positioned on the described door 9, so that the flame of crucible is discharged in the atmosphere via flame discharging inlet 15, flame exhaust outlet 8.
The outer, bottom of discharging lid 10 have with its all-in-one-piece annular edge along 11, this annular edge can cooperate with crucible surface along 11, prevents that the solid splash from flying out.Discharging lid 10 has the outward extending annular boss 13 from the bottom surface, and this annular boss 13 stretches out to crucible 5 inside, can play the effect of horizontal location crucible, can prevent that again solid particulate matter from flying out.
Fig. 1 is placed with the crucible lining (not shown) to crucible 5 shown in Figure 3, common crucible liner is after repeatedly using, and will becoming from fused plug hole 19 greatly of its bottom makes and can't correctly install from fused plug, causes crucible lining to use.The present invention has designed a kind of crucible liner with special construction for this reason.Fig. 6 and Fig. 7 have shown the structure of crucible liner of the present invention.
As shown in Figure 6 and Figure 7, the crucible liner comprises: inner lining body 16; Be positioned on inner lining body 16 bottom centre positions from fused plug hole 18; Be embedded in described inner lining body 16 bottom centre positions and surround described quoit 17 from fused plug hole 18; And fill in described described in fused plug hole 18 from fused plug 19.
Because the utility model is an embedding quoit in the bottom of inner lining body 1, make this quoit contact with outer wall from fused plug 7, so should locate temperature can be very not high, and quoit rub resistance, not easy to wear, can prolong many service lifes greatly, make rail aluminothermy welding of the present utility model with how can reuse with crucible lining with crucible lining.
Experiment shows, of the present utility model many with the crucible lining access times more than 50 times, how and excessive wear can not take place with crucible bottom from the fused plug hole.
In addition, Fig. 1 to the size of sand mold 2 shown in Figure 3 should with rail profile consistent size to be welded.
In addition, above-mentioned steps a) in, heat described solder flux by lighting high-temperature match, so that cause thermit reaction, in this course of reaction, emit a large amount of heat fusing alloy additive, form molten steel with the iron of reaction generation, because its density is sunken to crucible 5 bottoms greatly, the slag that reaction generates gently floats over top, in very short time, the aluminothermy molten steel fusion crucible of high temperature bottom from fused plug 19.
Above-mentioned welding method can make the hardness of welding point arrive 320HB ± 10HB, and welding point metal average tensile strength is greater than 830Mpa, in kind tired 2,000,000 times constantly.Fit and weld in the aluminothermy of the present 75kg/mPG4 rail of China.
The safety that can avoid high-temperature particle directly to threaten the welding operation personnel is accelerated weld job on the other hand.
In addition, crucible liner of the present invention can be repeatedly used, thereby can save welding cost.
Although above the present invention is had been described in detail, the invention is not restricted to this, those skilled in the art of the present technique can carry out various modifications according to principle of the present invention.Therefore, all modifications of doing according to the principle of the invention all should be understood to fall into protection scope of the present invention.
Claims (10)
1. a high rigidity rail aluminum heat flux is evenly mixed by aluminium powder, iron oxide and alloy additive.
2. high rigidity rail aluminum heat flux as claimed in claim 1, wherein said aluminium powder weight portion is 17～19, and its active aluminium content is greater than 98% percentage by weight, and granularity is 30～60 orders.
3. the oxidation in heating rolling steel process of high rigidity rail aluminum heat flux as claimed in claim 1, wherein said iron oxide forms, and its weight portion is 65～71, and granularity is 18～80 orders.
4. high rigidity rail aluminum heat flux as claimed in claim 1, wherein said alloy additive comprises: shot, ferrosilicon, ferromanganese, ferrochrome, vanadium iron, molybdenum-iron, rare earth alloy.
5. high rigidity rail aluminum heat flux as claimed in claim 4, wherein:
Described shot weight portion is 10～12, and its phosphorus content is 3%～3.4% percentage by weight, and granularity is 10～18 orders;
Described ferrosilicon weight portion is 0.24～0.44, and its silicon content is 72.0～80.0% percentage by weights, and granularity is 10～18 orders;
Described ferromanganese weight portion is 1.31～3.31, and its manganese content is 65.0～72.0% percentage by weights, and granularity is 10～80 orders;
Described ferrochrome weight portion is 0.05～0.17, and its chrome content is 50%～55% percentage by weight, and granularity is 10～80 orders;
Described vanadium iron weight portion is 0.06～0.11, and its vanadium content is 50%～55% percentage by weight, and granularity is 10～80 orders;
Described molybdenum-iron weight portion is 0.23～0.29, and it contains the molybdenum amount is 55%～60% percentage by weight, and granularity is 10～80 orders;
Described rare earth alloy weight portion is 0.08～0.14, and it contains the chromium rare earth content is 35%～60% percentage by weight, and silicon content is less than 40% percentage by weight, and granularity is 10～80 orders.
6. one kind is used each described high rigidity rail aluminum heat flux of claim 1 to 5 to carry out the method that the exothermic welding of high rigidity rail connects, and may further comprise the steps:
(a) sand mold (2) is installed to the end (3) of two adjacent rail to be welded after, the crucible (5) that described aluminum heat flux is housed is placed on the described sand mold (2), cause thermit reaction by the heating aluminum heat flux then, generate the aluminothermy molten steel;
(b) described aluminothermy molten steel by melt described crucible (5) bottom from fused plug (15), be cast in the enclosed cavity that the end (3) of described sand mold (2) and described two adjacent rail forms;
(c) the aluminothermy molten steel that is cast in the described enclosed cavity is filled metal and its cocrystallization as slit between the end (3) of described two adjacent rail, after cooled and solidified two rails is welded into integral body.
7. method as claimed in claim 6, wherein said crucible (5) top is placed with crucible cover (6), and described crucible cover (6) comprising:
The discharging lid (10) that raises up;
The door (9) of conduit wall of the interior discharge-channel of described discharging lid (10) (12) is tightly connected; And
By described conduit wall be communicated with on the described door (9) and under at least one flame exhaust stack of discharge-channel (12).
8. method as claimed in claim 7, wherein said flame exhaust stack have the flame discharging inlet (15) that is positioned under the described door (9) and are positioned at flame exhaust outlet (8) on the described door (9).
9. method as claimed in claim 6, wherein said crucible is placed with crucible lining in (5), and this liner comprises:
Inner lining body (16);
Be positioned on inner lining body (16) bottom centre position from fused plug hole (18);
Be embedded in described inner lining body (16) bottom centre position and surround described quoit (17) from fused plug hole (18); And
Fill in described described in fused plug hole (18) from fused plug (19).
10. method as claimed in claim 6, the size of wherein said sand mold (2) and rail profile consistent size to be welded; And heat described solder flux by lighting high-temperature match.
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| Application Number | Priority Date | Filing Date | Title |
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| CN2009100934087A CN102029486A (en) | 2009-09-29 | 2009-09-29 | Thermit welding flux for high hardness steel rail and welding method thereof |
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| CN2009100934087A CN102029486A (en) | 2009-09-29 | 2009-09-29 | Thermit welding flux for high hardness steel rail and welding method thereof |
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| CN102151982A (en) * | 2011-05-17 | 2011-08-17 | 武汉大学 | Portable welding pen |
| CN102554187A (en) * | 2012-02-08 | 2012-07-11 | 中国铁道科学研究院金属及化学研究所 | Steel rail thermite welding system and method |
| CN102862005A (en) * | 2012-10-19 | 2013-01-09 | 成都桑莱特科技股份有限公司 | Thermit iron welding flux special for welding steel grounding materials and welding method thereof |
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| CN102151982A (en) * | 2011-05-17 | 2011-08-17 | 武汉大学 | Portable welding pen |
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| CN102862005A (en) * | 2012-10-19 | 2013-01-09 | 成都桑莱特科技股份有限公司 | Thermit iron welding flux special for welding steel grounding materials and welding method thereof |
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| CN103639589A (en) * | 2013-12-20 | 2014-03-19 | 武汉大学 | Aluminum-steel heat release welding method |
| CN104625480A (en) * | 2014-12-22 | 2015-05-20 | 中国铁路总公司 | Steel rail aluminothermy welding flux and welding method thereof |
| CN104668815A (en) * | 2015-01-28 | 2015-06-03 | 武汉金泉铝热焊接器材有限公司 | Aluminum hot welding flux and welding method for welding cathode square steel of aluminum electrolytic baths in high-intensity magnetic field environments |
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| CN105921881A (en) * | 2016-05-20 | 2016-09-07 | 张绵胜 | Exothermic welding flux and application thereof |
| CN105921881B (en) * | 2016-05-20 | 2018-08-03 | 张绵胜 | A kind of exothermic welding solder flux and its application |
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| CN113894463A (en) * | 2021-09-30 | 2022-01-07 | 武汉钢铁有限公司 | Corrosion-resistant thermite welding flux suitable for U68CuCr steel rail and welding method thereof |
| CN115213381A (en) * | 2022-09-19 | 2022-10-21 | 北京坤飞装备科技有限公司 | Connecting method for super-thick steel plates |
| CN115213381B (en) * | 2022-09-19 | 2022-12-09 | 北京坤飞装备科技有限公司 | Connecting method for super-thick steel plates |
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Application publication date: 20110427 |