CN102409337B - Plasma cladding method and automatic cladding equipment for manufacturing wear resistant clad steel plate - Google Patents
Plasma cladding method and automatic cladding equipment for manufacturing wear resistant clad steel plate Download PDFInfo
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- CN102409337B CN102409337B CN201110229545.6A CN201110229545A CN102409337B CN 102409337 B CN102409337 B CN 102409337B CN 201110229545 A CN201110229545 A CN 201110229545A CN 102409337 B CN102409337 B CN 102409337B
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Abstract
The invention relates to a plasma cladding method and automatic cladding equipment for manufacturing a wear resistant clad steel plate. The method is characterized by adopting a four-gun automatic plasma cladding method, selecting and spreading a wear resistant alloy powder bulk material with thickness being 3-15mm on a base steel plate, putting the base steel plate on a cast iron cladding table with thickness being 80-120mm, fixing the periphery of the base steel plate with the cast iron cladding table through platen clamps, fixing the middle part of the base steel plate with the cast iron cladding table through stop pins, utilizing high energy beam plasma arcs with nozzle aperture ratio being (0.75-0.85):1 as the cladding heat sources and utilizing four guns to synchronously and automatically clad the wear resistant alloy powder bulk material and metallurgically bond the wear resistant alloy powder bulk materials with the base steel plate. The method and the equipment have the following beneficial effects: the manufacturing cost is low; the production efficiency is high; the wear resistant clad steel plate with large area can be manufactured; and the obtained wear resistant clad steel plate has the characteristics of narrow fusion area, small deformation and good product quality.
Description
Technical field
The present invention relates to a kind of manufacture method and producing apparatus of Wear-Resistant Compound Steel Plate, particularly relate to a kind of plasma melting coating method and automatic deposited equipment of plasma of manufacturing Wear-Resistant Compound Steel Plate.
Background technology
Mechanical industry has the steel of half every year for the manufacture of spare part, and the inefficacy of 80% component of machine is caused by wearing and tearing.In the industries such as mine, metallurgy, cement, coal, electric power, petrochemical complex, communications and transportation, machinofacture, most of production unit in use, heavy wear due to component, cause key components and parts or whole plant, even whole production line can not normally be moved, need often to stop production and change parts or keep in repair, directly affect the normal production order, thereby to enterprise, bring very large financial loss, the problem that therefore solution wearing and tearing work-ing life and key components and parts recycle seems most important.Wear-Resistant Compound Steel Plate is exactly a kind of wear resistant products with very high use value in high-abrasive material field, can wholely use, also can cut or be processed into parts uses, to improving work-ing life and the safe operation of equipment, can not only produce huge economic worth, and have can saving resource and the great social benefit of the energy.
Wear-resisting steel plate is divided into two large classes from structure formation at present, one class is monoblock casting wearing plate, advantage is that the even performance of global tissue is consistent, but to the large wearing plate of casting area, during much higher hard, because fragility is large, in use easily cracked, so lower hardness, and wear resistance conventionally and weldability are poor; Another kind of is Wear-Resistant Compound Steel Plate, someone also claims bimetal wear resistant plate, by wearing layer and matrix steel plate is compound makes, because wearing layer can be manufactured very high hardness, matrix steel plate has high intensity and toughness, so Wear-Resistant Compound Steel Plate has shock resistance and wear resistance is good, welding processing is good, wearing layer composition and performance are easy to the distinguishing feature of controlling, and has become the outstanding person who is most widely used in wear resisting steel iron material.
Existing wear-resistant composite steel board fabrication method has composite casting, certainly spreads the method for synthetic, laser melting coating, spraying, surfacing, plasma arc powder surfacing, welding electrode manual build up welding, powder mass carbon arc manual build up welding, the automatic arc surfacing of silk (plate) material, these methods are for the manufacture of Wear-Resistant Compound Steel Plate, all show advantage separately, but also have certain shortcoming and defect.Wherein, composite casting, welding electrode manual build up welding, powder mass carbon arc manual build up welding, certainly spread method synthetic, surfacing, be only limited to and manufacture the wear-resistant composite board of small area and the wear-resisting composite component of small volume.The method of laser melting coating, spraying, is only limited to the clad steel plate of manufacturing the thin wearing layer of < 2mm.
At present, manufacture Wear-Resistant Compound Steel Plate application that area is large maximum be flux-cored wire electric arc automatic surfacing method, be characterized in adopting the automatic electric arc surfacing equipment of silk material, select wear-resisting welding wire with flux core, the certain thickness wearing layer material of built-up welding on matrix steel plate, with the Wear-Resistant Compound Steel Plate of matrix steel plate formation metallurgical binding.This method is a kind of old technique of comparative maturity, and advantage is automated job, conventionally selects the welding wire built-up welding of Φ 2.8mm diameter, and production efficiency is high.Shortcoming is that fusion penetration is large due to large electric current built-up welding, and thinning ratio is high, causes the hardness of wearing layer top layer and bottom to differ larger, has reduced the thickness wear resistance of composite bed; Because fusion penetration is large, fusion area is wide, and while manufacturing big area Wear-Resistant Compound Steel Plate, distortion is large; Because the wear-resisting composition adding proportion adding in flux-cored wire is limited, the hardness of further raising overlay cladding is restricted; The thickness that has determined every built-up welding one deck wearing layer due to silk material bead-welding technology itself can not be blocked up, so need multiple-bead deposit during the thick wearing layer of built-up welding; There is significantly welding ripple in overlay cladding surface, can strengthen wearing resistance, reduces friction durability.In recent years, offshore company adopts the method for plasma arc powder surfacing to manufacture big area Wear-Resistant Compound Steel Plate, it is characterized in that adopting plasma powder automatic bead welding equipment, select self-fluxing nature wear resistant alloy powders, the certain thickness wearing layer material of built-up welding on matrix steel plate, with the Wear-Resistant Compound Steel Plate of matrix steel plate formation metallurgical binding.This method is also a kind of old technique of comparative maturity, advantage is automated job, because material therefor is self-fluxing alloyed powder, so good product quality of the Wear-Resistant Compound Steel Plate mass ratio silk material built-up welding of manufacturing, shortcoming is that built-up welding efficiency is low, material price is high, and powdered material needs powder conveyer system, and easily blows and spread waste in weld deposit process.Another method is well-known powder mass carbon arc manual build up welding, and feature is to select powdered alloy piece high-abrasive material, adopts manual carbon arc fusing overlaying method, built-up welding one deck wear resistant alloy on matrix steel plate.Because powdered alloy piece resurfacing welding material is simpler and easy than surfacing welding electrode preparation, composition is easily adjusted, built-up welding is simple to operation, economical and practical, so be to repair a kind of the most frequently used method of wear resistant products, but overlay cladding surface quality is poor, can not realize automated job, labour intensity is large, so be not suitable for the built-up welding of big area Wear-Resistant Compound Steel Plate.
The problem on deformation of built-up welding big area Wear-Resistant Compound Steel Plate, perplexing the development of the industry always, due to the gross distortion in weld deposit process, cause a lot of advanced technique for overlaying can not implement automated job, to this, people have adopted the whole bag of tricks examination way to control distortion, but relatively effective means is few.Adopting clamp jig to control distortion is a kind of maximum method of applying, and this method, when built-up welding big area Wear-Resistant Compound Steel Plate, can only compress steel plate edge with clamp jig, middle part is still out of shape, if centre is increased pressure board fixture again, can hinder automatic surfacing walking, so inadvisable.People adopt the method for water-cooled to control distortion at present, a kind of mode is directly to spray water coolant at the back side of built-up welding steel plate, thereby play, reduce the heat input of matrix steel plate and accelerate speed of cooling and control distortion, the shortcoming and defect of this mode is to produce a large amount of water smoke, affects work-ing life and the safe working environment of automatic bead welding equipment.Another kind of mode is to adopt water cooled pipeline to be close to the built-up welding steel plate back side to dispel the heat with cooling, although overcome above-mentioned shortcoming, but well-known, water-cooled need to increase water cooling plant system, has increased equipment cost, and water-cooled can be taken away part built-up welding heat, wasted heat energy, water-cooled can be accelerated speed of cooling, affects the shaping of the sufficient metallurgical reaction in molten bath and weld face, and this is the shortcoming and defect that adopts water-cool control distortion to manifest.Also having a kind of method is to adopt the built-up welding of cylindrical structure mode, operation is: matrix steel coiled sheet is become to round shape, point of interface is welded solid, again that cylinder is round as a ball, device rotates on surfacing equipment, and cylinder top (front) has a material surfacing torch to carry out automatic surfacing, back spraying water cooling, heap postwelding unloads the cylinder with wearing layer, and interface weld seam is cut open, and with sheet-leveling machine, smooths.The Wear-Resistant Compound Steel Plate sex change of this technique heap postwelding is very large, need repeatedly smoothing repeatedly, in smoothing process, the easy cracking of wearing layer falls piece, and due to the limitation of this technique, current examples of suitable filamentary material automatic surfacing, matrix steel plate thickness is limited to 10～14mm, and suitable built-up welding is (one deck) wearing layer once.
Summary of the invention
The technical problem to be solved in the present invention is to provide a kind of low cost of manufacture, production efficiency is high and can manufacture large-area steel plate, and the clad steel plate wear resistance that obtains is high, manufacture method and the automatic deposited equipment of plasma of the Wear-Resistant Compound Steel Plate of good product quality.
A kind of plasma melting coating method of manufacturing Wear-Resistant Compound Steel Plate of the present invention, adopt the automatic cladding method of four rifle plasmas, selecting thickness is that 3～15mm wear resistant alloy powders bulk material is laid in above matrix steel plate, matrix steel plate is placed on the deposited platform of cast iron that thickness is 80-120mm, by clamp jig, matrix steel plate surrounding and deposited of cast iron is fixing, by position-limitting pin, deposited of matrix steel plate middle part and cast iron is fixing, utilize rifle mouth aperture ratio for (0.75-0.85): 1, preferably the high energy beam plasma arc of 0.8: 1 is as deposited thermal source, the synchronous automatic deposited wear resistant alloy powders bulk material of four rifles, make itself and matrix steel plate produce metallurgical binding.
A kind of plasma melting coating method of manufacturing Wear-Resistant Compound Steel Plate of the present invention, wherein said wear resistant alloy powders bulk material is the conventional wear resistant alloy powders block of material in this area, preferred high-chromium cast iron-type micro-slag wear resistant alloy powders bulk material or the micro-slag wear resistant alloy powders of high chromium nickel wolfram varbide type bulk material, market is on sale.
The Wear-Resistant Compound Steel Plate that aforesaid method of the present invention obtains, comprises matrix steel plate, wearing layer and fusion area, the thickness≤1.5mm of fusion area wherein, the distortion irregularity degree < 5mm/m of described Wear-Resistant Compound Steel Plate
2.
A kind of automatic deposited equipment of manufacturing Wear-Resistant Compound Steel Plate of the present invention, comprise deposited system of Wear-Resistant Compound Steel Plate, the deposited system of plasma power supply, plasma cladding rifle operational system and Controlling System, described automatic deposited equipment is the automatic deposited equipment of four rifle plasmas, deposited system of described Wear-Resistant Compound Steel Plate comprises deposited of Wear-Resistant Compound Steel Plate and clamp jig, the thickness that Wear-Resistant Compound Steel Plate is deposited is 80-120mm, be provided with equally distributed limit pin hole above, clamp jig is fixed on the surrounding of deposited of Wear-Resistant Compound Steel Plate with bolt, four limits of matrix steel plate are fixed and clamped, the rifle mouth aperture ratio of the deposited system ionic medium of described plasma power supply deposit gun is (0.75-0.85): 1, preferably 0.8: 1, described aperture ratio is the ratio of rifle mouth passage length and rifle mouth bore dia, this is this area technical term.
A kind of automatic deposited equipment of manufacturing Wear-Resistant Compound Steel Plate of the present invention, the tungsten electrode diameter of wherein said plasma cladding rifle is 4～8mm, and transferred arc electric current is 0～500A, and untransferable arc electric current is 0～250A, plasma voltage 30～70V.
A kind of automatic deposited equipment of manufacturing Wear-Resistant Compound Steel Plate of the present invention, the diameter of wherein said limit pin hole is 8-12mm, the distance between pin-and-hole is 450-550mm, preferably 500mm.
It is deposited of the large thickness cast iron (cast iron is not yielding) of 100mm that the present invention adopts thickness, additional surrounding clamp jig is fixed, the spacing mode of middle part pin, effectively solved the problem of convex-concave distortion in deposited process, overcome above-mentioned shortcoming and defect simultaneously, on the large deposited platform of thickness, be furnished with the pin-and-hole being evenly distributed, on matrix steel plate, be drilled with the through hole of corresponding diameter, matrix steel plate is placed on deposited platform, at through hole interpolation pin, run through deposited pin-and-hole, pin allows to expose matrix surface of steel plate 0～3mm, fixing tight with clamp jig in matrix steel plate surrounding, wear resistant alloy powders bulk material is laid in above matrix steel plate, then automatic deposited the completing of start, pin in the Wear-Resistant Compound Steel Plate unloading is cut flat, the effect manifesting is: the phenomenon at deposited process light plate without convex-concave distortion, the Wear-Resistant Compound Steel Plate distortion irregularity degree < 5mm/m unloading from deposited platform
2, by screw block, the position of steel plate injustice can be smoothed.For the above results by thinking: large deposited of thickness can absorb the also deposited heat of storage compartment, and the heat storing can be delivered on deposited steel plate, make the further homogenizing of temperature distribution of deposited steel plate, be beneficial to Reducing distortion, be beneficial to the abundant metallurgical reaction in molten bath, be beneficial to appearance of weld, be beneficial to raising deposition rate.Clamp jig and pin can play the heat expansion of deposited process light plate and the effect of contraction of pining down, as everyone knows, steel plate is heated and just can produces expansion, together in deposited process together, swell increment runs up to and to a certain degree can cause steel plate to bulge, at inhomogeneous process of cooling light plate, shrink subsequently, produce irregular distortion thereupon.Theoretically, cladding layer above steel plate is from liquid state to solidifying, shrinkage is greater than matrix steel plate, state of nature lower steel plate should be to recessed distortion, but there is the pressure of deposited support and surrounding clamp jig to tighten up below matrix steel plate, along with concentrating of string stress, steel plate shrinks towards centre, the gross distortion that causes steel plate to raise up after string stress runs up to a certain degree, but these distortion all need the process of a strain energy of distortion and the accumulation of distortion quantity, as long as accumulation volume is lower than the deformation intensity of steel plate itself, steel plate is can not produce distortion.The present invention adopts clamp jig and pin can effectively play an accumulation that pins down and disperse dilation, and clamp jig can solve the problem on deformation of steel plate surrounding perk, the effect that can also force to a certain extent steel plate to shrink inwards and outwards expand simultaneously.Pin can pin down the displacement that steel plate outwards expands and shrinks inwards effectively, that is to say, steel plate allows free expansion and contraction within the scope of the small area of pin restriction, once surpass this scope, pin just can play and hinder the displacement that steel plate further expands and shrinks, expand so and the total amount of shrinking by separated equably, the stress of the Wear-Resistant Compound Steel Plate after deposited has also obtained disperseing and is unconcentrated, so it is very little that the stress at each position just seems, be difficult to cause the distortion of steel plate.Adopt in addition four rifle plasma melting compress apparatus, deposited mode is the width (laterally) by deposited steel plate, plasma cladding rifle is put apart from the welding position that rises arranging separately by 1/4th decile, then to steel plate length direction (longitudinally), synchronously carry out deposited, that is to say, each plasma cladding rifle is the long-pending wear resistant alloy powders bulk material of deposited 1/4th independent faces separately, this is similar with the principle that manual segmentation welds to reduce stress concentration, the spread heat that four plasma cladding rifles can be inputted to steel plate simultaneously comes, avoid heat undue concentration, thereby also can play a role to reducing deposited distortion.So, adopt deposited of large thickness, surrounding clamp jig, the spacing mode of pin-and-hole, controlled dexterously a difficult problem for Wear-Resistant Compound Steel Plate convex-concave distortion in deposited process, effectively solved the problem of arc heat input waste simultaneously, also the difficulty that has alleviated Wear-Resistant Compound Steel Plate smoothing, this innovative point is conducive to open up the manufacture that other advanced bead-welding technology is realized big area clad steel plate.
The present invention selects wear resistant alloy powders bulk material to make the complex abrasion-proof layer material of clad steel plate, reason is: the block high-abrasive material of powdered alloy has been successfully used to manual carbon arc built-up welding and has repaired worn parts, embodied easy to use, the feature that manifests that wear resistance is good, cost is low, compare with Self-fusing powder material with silk material, easily, production technique is simple in preparation, and do not need wire feed, powder conveyer system, can meet the requirement of the automatic deposition techniques of the present invention.This wear resistant alloy powders bulk material is known in the art conventional material, preferred FeO5 abrasion-resistant alloy cake material, and market is on sale.
Plasma melting coating method of the present invention is higher than the temperature of carbon arc built-up welding; energy is melted alloy material fully; argon gas can play the effect of protection molten bath metallurgical reaction simultaneously; adopt the Wear-Resistant Compound Steel Plate of the deposited manufacture of FeO5 abrasion-resistant alloy cake material; significantly effect is all better than the inner quality of carbon arc manual build up welding and visual appearance effect; by coal, wear and tear to contrast and use, 0.4 times of high life.
A kind of plasma melting coating method and automatic deposited equipment of manufacturing Wear-Resistant Compound Steel Plate of the present invention, adopt the automatic cladding method of four rifle plasmas, utilize high energy beam plasma arc to make deposited thermal source, adopt deposited of large thickness Wear-Resistant Compound Steel Plate, matrix steel plate surrounding is fixed with clamp jig, the spacing mode of pin for middle part, select wear resistant alloy powders bulk material to make wear-resistant composite bed material, automatic deposited powdered alloy bulk material on matrix steel plate, wear-resistant composite steel panel products with matrix steel plate formation metallurgical binding, effectively solved the problem of Wear-Resistant Compound Steel Plate distortion in deposited process, realize low cost of manufacture, production efficiency is high, the measured beneficial effect of deposited matter.
Accompanying drawing explanation
Fig. 1 is Wear-Resistant Compound Steel Plate structural representation of the present invention;
Fig. 2 is the automatic deposited device structure schematic diagram of the present invention's four rifle plasma;
Fig. 3 is plasma cladding rifle lifting running orbit schematic diagram;
Fig. 4 is the deposited running orbit schematic diagram of plasma cladding rifle;
Fig. 5 is weld bead form schematic diagram;
Fig. 6 is Wear-Resistant Compound Steel Plate wearing layer tissue topography scanning electron microscope picture.
Description of reference numerals: deposited system of 1-Wear-Resistant Compound Steel Plate; The deposited system of 2-plasma power supply; 3-plasma cladding rifle operational system; 4-Controlling System; 5-matrix steel plate; 6-fusion area; 7-wearing layer; 8-wear resistant alloy powders bulk material; Deposited of 11-Wear-Resistant Compound Steel Plate; 12-clamp jig; Deposited travel mechanism of 13-Wear-Resistant Compound Steel Plate; 14-limit pin hole; 15-pin; 16-through hole; 21-plasma power supply; 22-plasma cladding rifle; 23-airing system; 24-water-cooling system; 31-plasma cladding rifle lifting device; 32-plasma cladding rifle horizontal mobile device; 33-plasma cladding rifle horizontal walking device; The longitudinal running gear of 34-plasma cladding rifle; 41-arranges display screen; 42-carries out switch; 43-manual parameters adjusting knob; Article one welding bead that 51-is deposited; Next welding bead that 52-is deposited; The deposited zero position of 53-; B-mobile width; L-movable length; X-plasma cladding rifle transverse shifting direction; Y-plasma cladding rifle vertically moves direction; The distance of H-manual regulation ion deposit gun height location; The adjustable range of H1-plasma cladding arc length positions; The adjustable range of H2-plasma striking; H3-plasma cladding rifle stops the adjustable range of rifle position.
Embodiment
Below in conjunction with drawings and Examples, to the present invention is above-mentioned, be described in more detail with other technical characterictic and advantage.
As shown in Figure 2-5, the automatic deposited equipment of the present invention's four rifle plasma, the wear-resistant composite steel panel products that is 2000mm * 3000mm for the manufacture of area, this equipment is comprised of deposited system 1 of Wear-Resistant Compound Steel Plate, the deposited system 2 of plasma power supply, plasma cladding rifle operational system 3 and Controlling System 4.
(1) deposited system 1 of Wear-Resistant Compound Steel Plate, by deposited 11 of Wear-Resistant Compound Steel Plate, clamp jig 12, deposited travel mechanism of Wear-Resistant Compound Steel Plate 13 forms.Deposited 11 of Wear-Resistant Compound Steel Plate for placing, fixing base steel plate 5, deposited 11 thickness 80-120mm of Wear-Resistant Compound Steel Plate, preferred 100mm, length 3400mm, width 2600mm, deposited 11 of Wear-Resistant Compound Steel Plate has equally distributed limit pin hole 14 above, pin-and-hole diameter of phi 11mm, hole depth 50mm, the spacing distance 500mm distributing between pin-and-hole 14, pin-and-hole 14 is for limiting the distortion of the deposited process of Wear-Resistant Compound Steel Plate.Clamp jig 12, for four limits fixing and compression matrix steel plate 5, is controlled the distortion in the deposited process of Wear-Resistant Compound Steel Plate.Deposited travel mechanism 13 of Wear-Resistant Compound Steel Plate walked towards longitudinal direction (device length direction) for dragging deposited 11 of Wear-Resistant Compound Steel Plate.
(2) the deposited system 2 of plasma power supply, by 21, four plasma cladding rifles 22 of four plasma power supplies, airing system 23, water-cooling system 24 forms.Plasma power supply 21 is power supply types of conjunct arc, is used to plasma cladding rifle 22 to produce plasma arcs electric energy is provided, and the electric energy of the different parameters of transferred arc and untransferable arc needs can be provided.Plasma cladding rifle 22 is devices that high energy beam plasma arc occurs, and by high energy beam plasma arc, for deposited wear resistant alloy powders bulk material 8, manufactures wear-resistant composite steel panel products.The gas of airing system 23 is argon gas, is used to plasma cladding rifle 22 to produce plasma arc argon gas is provided.Water-cooling system 24 is for cooling plasma cladding rifle 22.Plasma power supply 21, plasma cladding rifle 22, airing system 23, water-cooling system 24 are state of the art, present device adopts four plasma cladding rifles 22, the rifle mouth aperture ratio of plasma cladding rifle 22 is (0.75-0.85): 1, and preferably 0.8: 1.
(3) plasma cladding rifle operational system 3, by plasma cladding rifle lifting device 31, plasma cladding rifle horizontal mobile device 32, plasma cladding rifle horizontal walking device 33, the longitudinal running gear 34 of plasma cladding rifle forms.Plasma cladding rifle lifting device 31 can be manually and is automatically regulated the distance up and down of plasma cladding rifle 22, with the high and low position of manual coarse adjustment plasma cladding rifle 22, with automatically regulate plasma cladding rifle 22 striking H2, deposited H1, stop rifle H3 position, see Fig. 3.Plasma cladding rifle horizontal mobile device 32, for regulating the size of plasma arc side throw amplitude B, is shown in Fig. 4, for driving plasma cladding rifle 22 to make the next deposited wear resistant alloy powders bulk material of motion that transverse reciprocating swings.Plasma cladding rifle horizontal walking device 33 is for driving plasma cladding rifle 22 to make gap operation and continuous walking at horizontal direction.The longitudinal running gear 34 of plasma cladding rifle is for driving plasma cladding rifle 22 to make gap operation and continuous walking at longitudinal direction.The running orbit of plasma cladding rifle operational system 3 and deposited parameter are that the setting by Controlling System 4 realizes, and operational system is state of the art.
(4) Controlling System 4, by display screen 41 is set, carry out switch 42, and manual parameters adjusting knob 43 forms.Display screen 41 is set for setting running orbit and the deposited parameter value of plasma cladding rifle operational system 3.Carry out switch 42 for the deposited system 2 of plasma power supply, plasma cladding rifle operational system 3, airing system 23, the startup of water-cooling system 24, shut-down operation.Manual parameters adjusting knob 43 is for the adjusting of plasma voltage, electric current and plasma gas flow, and Controlling System is state of the art.
The technical performance index of described equipment is as follows:
(1) plasma cladding rifle operational system 3 parameter regulation technical indicators
1. the deposited running orbit of plasma cladding rifle 22 is set as " bow " font, as shown in Figure 4:
0～60mm/ is each for plasma cladding rifle lateral clearance mobile width B scope, translational speed 0～55mm/s
0～1000mm/ is each for the horizontal continuous walking global extent of plasma cladding rifle, the speed of travel 0～55mm/s
Movable length L scope 0～15mm/ is each in plasma cladding rifle longitudinal gap, translational speed 0～55mm/s
0～3200mm/ is each for the longitudinal continuous walking global extent of plasma cladding rifle, the speed of travel 0～55mm/s
2. the lifting running orbit of plasma cladding rifle 22 is set, and sees shown in accompanying drawing 3:
The distance H scope 0～500mm of manual regulation plasma cladding rifle height location
The adjustable range H1 scope 0～50mm of plasma cladding arc length positions
The adjustable range H2 scope 0～20mm of plasma striking position
Plasma cladding rifle stops the adjustable range H3 scope 0～120mm (after being deposited shutdown, plasma cladding rifle automatically raises stops rifle position) of rifle position
(2) deposited system of Wear-Resistant Compound Steel Plate 1 parameter regulation technical indicator
Deposited longitudinal walking global extent 10000mm of Wear-Resistant Compound Steel Plate, the speed of travel 0～100mm/s
(3) deposited system 3 technical indicators of plasma power supply
Plasma electric Source Type: associative form arc
4 of plasma power supply quantity
4 of plasma cladding rifle quantity
Plasma electric source power 80KVA * 4
Plasma power supply water holdup 100%
Plasma cladding rifle tungsten electrode diameter range of choice Φ 4～8mm
Deposit gun mouth aperture ratio 1/d=0.8: 1
Transferred arc current setting scope 0～500A, untransferable arc current setting scope 0～250A, plasma voltage regulation range 30～70V.
The present invention adopts the automatic deposited equipment of above-mentioned four rifle plasma, selects wear resistant alloy powders bulk material 8 to manufacture wear-resistant composite steel panel products, and as shown in Fig. 1-6, deposition techniques technical scheme is as follows:
(1) place matrix steel plate
The through hole 16 of drill diameter Φ 10mm on matrix steel plate 5, pitch-row is 500mm, with deposited 11, the thickness cast iron that is 100mm pin-and-hole 14 position corresponding matching above.By 5 deposited sandblast purifying treatment of matrix steel plate, by 5 placing flat of matrix steel plate on deposited 11 of Wear-Resistant Compound Steel Plate.The pin of Φ 10mm 15 is inserted in the pin-and-hole 14 of deposited 11 of the through hole 16 of matrix steel plates 5 and Wear-Resistant Compound Steel Plate, pin 15 allows to expose matrix surface of steel plate 0～3mm, with clamp jig 12, matrix steel plate 5 four limits is fixed.
(2) put wear resistant alloy powders bulk material
The wear resistant alloy powders bulk material 8 that to dry (300 ℃ of bake out temperatures are incubated 2 hours) is laid in above matrix steel plate 5, requires to put closely.
(3) set running orbit and deposited parameter
Open deposited device power supply (DPS), adopt manual mode that the distance between four deposit guns 22 is set, four deposit guns 22 are run to deposited zero position 53.Automatic running orbit and the deposited parameter of setting plasma cladding rifle 22 on display screen 41 is being set.With manual parameters adjusting knob 43, regulate voltage, current value and the argon flow amount of plasma power supply 21.
(4) startup is automatically deposited
With carrying out switch 42, start water-cooling system 24, water coolant begins to cool down plasma cladding rifle 22; With carrying out switch 42, open airing system 23, argon gas starts as plasma cladding rifle 22 air feed; With carrying out switch 42, start plasma cladding rifle operational system 3, plasma cladding rifle 22 drops to H2 striking position automatically by the lifting running orbit of setting; With carrying out switch 42, start the deposited system 2 of plasma power supply, plasma power supply 21 is plasma cladding rifle 22 electric arc of powering and ignite, after arc stability, plasma cladding rifle 22 automatic liftings are to the deposited position of H1, then start mobile plasma cladding rifle 22 and by the deposited run trace of setting and deposited parameter deposited completing automatically.
(5) stop finishing deposited
Deposited process is by setting track and parameter deposited carrying out automatically, after deposited completing, also automatically plasma cladding rifle 22 is risen to H3 stops rifle position to plasma cladding rifle 22 meeting automatic distinguishing electric arcs, automatically stop the operation of plasma cladding rifle 22 simultaneously, finish deposited program, with carrying out switch 42, close argon gas and water coolant.
(6) unload and get Wear-Resistant Compound Steel Plate
With carrying out switch 42, start deposited travel mechanism 13 of Wear-Resistant Compound Steel Plate, drag the deposited Wear-Resistant Compound Steel Plate completing and leave the residing position of plasma cladding rifle 22, be convenient to unload and get Wear-Resistant Compound Steel Plate.Clamp jig 12 is taken off, Wear-Resistant Compound Steel Plate is taken away.
(7) smoothing Wear-Resistant Compound Steel Plate
With cutter, the pin in Wear-Resistant Compound Steel Plate 15 is cut flatly, be then placed on the pallet frame of school, whole with screw block smoothing.Can, for user's requirement, to Wear-Resistant Compound Steel Plate, carry out cut edge, shaping processing, surfacing, the processing of spraying paint.
The feature of this manufacturing process is: matrix steel plate 5 is placed in deposited 11 of Wear-Resistant Compound Steel Plate, with clamp jig 12, matrix steel plate 5 four limits are compressed, pin 15 is inserted in steel plate through hole 16, wear resistant alloy powders bulk material 8 is laid in above matrix steel plate 5, plasma cladding rifle 22 is put to 53 by the decile of 1/4th steel plate widths apart from the welding position that rises arranging separately, as shown in Figure 5, then to matrix steel plate 5 length directions, synchronously carry out deposited.Thickness for wearing layer that Wear-Resistant Compound Steel Plate requires is different, selects the wear resistant alloy powders block of material 8 of different thickness.Its effect is: the wearing layer 7 after deposited is metallurgical binding with matrix steel plate 5, fusion area 6≤1.5mm, thinning ratio is low, the top layer of wearing layer and bottom hardness approach, hardness difference HRC < 5, the surfacing no-welding-seam ripple of wearing layer 7, the Wear-Resistant Compound Steel Plate distortion irregularity degree < 5mm/m after deposited
2, deposited area can reach 2000mm * 3000mm, and the Wear-Resistant Compound Steel Plate distortion embodying after deposited is little, and the smooth and global tissue performance of wearing layer smooth surface approaches, and benefits wear-resistant advantage.
Embodiment 1, the mine transfer loader flask liner of take is example, wear medium is ore, wear type is for impacting and abrasive wear, require every Wear-Resistant Compound Steel Plate to be of a size of: long 3000mm * wide 2000mm * thick 15mm, wearing layer thickness (comprising fusion area) >=6mm wherein, surface hardness HRC >=60.
Select the Q345B sheet material of long 3100mm * wide 2100mm * thick 10mm as matrix steel plate 5 (comprising clamp jig fixed position), select the micro-slag wear resistant alloy powders of the high-chromium cast iron-type bulk material (this material market is on sale) of long 80mm * wide 30mm * thick 7mm as wearing layer material.
(1) deposition techniques technical scheme steps as mentioned above, is set running orbit and deposited parameter as follows:
B:45mm/ is each for plasma cladding rifle lateral clearance swing width, speed of travel 9mm/s;
The horizontal continuous walking whole range distance of plasma cladding rifle: 505mm;
Movable length L:4mm/ is each in plasma cladding rifle longitudinal gap, translational speed 6mm/s;
The longitudinal continuous walking whole range distance of plasma cladding rifle: 3000mm;
Between deposited of plasma cladding rifle and Wear-Resistant Compound Steel Plate, manually heighten distance H: 120mm;
The arc length distance H 1:30mm of plasma cladding;
Isoionic striking distance H 2:15mm;
After deposited shutdown, plasma cladding rifle automatically raises stops rifle distance H 3:100mm;
Deposited longitudinal walking whole range distance 10000mm of Wear-Resistant Compound Steel Plate, speed of travel 60mm/s;
Plasma cladding rifle tungsten electrode diameter is Φ 5mm;
Deposit gun mouth aperture ratio 1/d=0.8: 1;
Transferred arc electric current 180A, untransferable arc electric current 70A;
Plasma voltage 50V.
(2) weld bead form and parameter, as shown in Figure 5:
Every deposited welding bead is along matrix steel plate length direction (longitudinally), length 3000mm;
Every weld bead (laterally) width 45mm;
Between every welding bead, be joint form, next welding bead 52 repeats the width 5mm on a deposited upper welding bead limit 51, guarantees that wearing layer surfacing after deposited is without welding bead vestige, successively deposited completion automatic stopping.
(3) result
In the process of deposited manufacture Wear-Resistant Compound Steel Plate, there is not convex-concave distortion in steel plate.
Unload the Wear-Resistant Compound Steel Plate of taking off, by cutting after flat-sale nail 15, Wear-Resistant Compound Steel Plate is bulge phenomenon slightly, the average irregularity degree < 4mm/m of distortion of measurement
2, with screw block, the position of heaving of Wear-Resistant Compound Steel Plate is smoothed.
Wearing layer smooth surface is smooth, solderless ripple mark mark, but there is the transverse crack of < 40mm many places.
For the Wear-Resistant Compound Steel Plate after smoothing, cutting sample carries out contextual analysis of organization and measurement of hardness, and result is: fusion area mean depth 1.4mm, wearing layer (not comprising fusion area) mean thickness 6mm, Wear-Resistant Compound Steel Plate mean thickness 15.5mm; Wearing layer top layer average hardness HRC67, bottom average hardness HRC63, middle layer average hardness HRC65; Wearing layer homogeneous microstructure, hard phase is evenly distributed, and proportion > 60%, and product tissue topography scanning electron microscope (SEM) photograph as shown in Figure 6, embodies deposited wearing layer inner quality good, possesses high wear-resisting feature.
The silk material build-up wear-resistant clad steel plate of this Wear-Resistant Compound Steel Plate and same size is used on the load wagon of mine, has improved 1.5 times work-ing life.Adopt this Wear-Resistant Compound Steel Plate to use on the chute of coal mine scraper machine, replaced original casting 360 type wearing plates, improved 8 times work-ing life, because weldability is good, solved in addition the in use problem of weld cracking of casting wear-resistant plate chute.Show the remarkable beneficial effect that Wear-Resistant Compound Steel Plate weldability is good, wear resistance is high that the method is manufactured.
This Wear-Resistant Compound Steel Plate possesses high life, the feature of low cost of manufacture, and also supply user's price is identical with silk material build-up wear-resistant clad steel plate, has fully demonstrated the high advantage of cost performance.
Embodiment 2, the refuse-burning plant waste discharge conduit of take is example, wear medium is that dust, sand grains, iron are cut, masonry piece, and wear type is erosive wear, and duct wall thickness is 20mm, the length of side is the square pipe of 600mm, every joint length is 1000mm, and for eight joints, what adopt at present is that Q345B steel plate is made, use after 1 month, tube wall mill leaks and scraps.
According to the environment for use of pipeline and wear type, consider the cost of this product, adopt the Q235 sheet material of long 2500mm * wide 2100mm * thick 12mm as matrix steel plate 5 (comprising that clamp jig compresses the surplus on matrix steel plate four limits), select the micro-slag wear resistant alloy powders of the high chromium nickel wolfram varbide type bulk material (this material market is on sale) of long 80mm * wide 30mm * thick 10mm.Adopt four rifle plasma melting compress apparatus and methods of the present invention, manufacture the Wear-Resistant Compound Steel Plate that this product is used, then with grow up 6 blocks of sheet materials of 1000mm * wide 600mm of plasma cutting, by welding process, be welded into square pipe product, wear resistance electrode build-up wear-resistant layer for weld bond surface.
(1) deposition techniques technical scheme steps as mentioned above, is set running orbit and deposited parameter as follows:
1. the deposited run trace of plasma cladding rifle and deposited parameter:
B:45mm/ is each for plasma cladding rifle lateral clearance swing width, speed of travel 9mm/s
The horizontal continuous walking whole range distance of plasma cladding rifle: 505mm
Movable length L:3mm/ is each in plasma cladding rifle longitudinal gap, translational speed 6mm/s
The longitudinal continuous walking whole range distance of plasma cladding rifle: 2400mm
2. the lifting running orbit of plasma cladding rifle and the setting of parameter are with identical described in embodiment 1
3. the setting of deposited system parameter of Wear-Resistant Compound Steel Plate is with identical described in embodiment 1
4. the setting of the deposited system parameter of plasma power supply
Plasma cladding rifle tungsten electrode diameter is Φ 6mm
Deposit gun mouth aperture ratio 1/d=0.8: 1
Transferred arc electric current 195A, untransferable arc electric current 70A
Plasma cladding voltage-regulation scope 55V
5. weld bead form is identical with the above
(2) result
In the process of deposited manufacture Wear-Resistant Compound Steel Plate, there is not convex-concave distortion in steel plate.
Unload the Wear-Resistant Compound Steel Plate of taking off, by slicing off after pin, be out of shape very little, average irregularity degree < 4mm/m
2, adopt screw block by steel plate leveling.
Wearing layer non-welding surface ripple mark mark, smooth.
Fusion area mean depth 1.5mm, wearing layer mean thickness 7.5mm, Wear-Resistant Compound Steel Plate mean thickness 19mm; Wearing layer top layer average hardness HRC60, bottom average hardness HRC57, contains a large amount of wiplas in wearing layer, and has the wolfram varbide hard phase being evenly distributed, and embodies the feature of high erosive wear.
This product, by using, has reached just mill leakage more than 2 years duration of service, has improved more than 20 times of work-ing life, and price is 5 times of former pipeline, fully demonstrates the advantage of high performance-price ratio.
Adopt method and apparatus of the present invention to manufacture wear-resistant composite steel panel products, embody following beneficial effect:
(1) the automatic deposited equipment of four rifle plasmas that the present invention adopts, can manufacture the large-area wear-resistant composite steel panel products of 2000mm * 3000mm, and also the Wear-Resistant Compound Steel Plate of suitable manufacture small area, has embodied the beneficial effect that the scope of application is wide, production efficiency is high.
(2) owing to adopting the synchronous plasma arc deposition techniques of four rifles, in the thick straight form of employing, strong deflection plasma arc is as deposited thermal source, single cladding width 4～10mm and once the wear resistant alloy powders bulk material of deposited 15mm thickness, embody deposited area large, penetration is strong, deposition efficiency is high, the beneficial effect feature that deposition rate is fast.Wearing layer quality after deposited and the quality of plasma arc powder surfacing have good equally effect, and deposition efficiency is higher more than 1 times than plasma arc powder surfacing.For the manufacture of Wear-Resistant Compound Steel Plate demand different thickness wearing layer, by changing tungsten electrode diameter, regulating voltage and current parameters, can control deposited width and the degree of depth effectively, can manufacture the wear-resistant composite steel panel products of different thickness.
(3) adopt deposited of large thickness Wear-Resistant Compound Steel Plate, additional surrounding clamp jig is fixed, the mode that middle part pin is spacing, and deposited process light plate does not produce convex-concave distortion, the Wear-Resistant Compound Steel Plate distortion irregularity degree < 5mm/m after deposited
2, the Wear-Resistant Compound Steel Plate embodying after deposited is out of shape little beneficial effect, by screw block, Wear-Resistant Compound Steel Plate can be smoothed, and has solved the difficulty of repeatedly smoothing with school board device.
(4) wearing layer and the matrix steel plate of the present invention after deposited is metallurgical binding, fusion area≤1.5mm, thinning ratio is low, the top layer of wearing layer and bottom hardness approach, hardness difference HRC < 5, improved the thickness volume wear-out life of wearing layer, the surfacing no-welding-seam ripple of wearing layer, benefits capable of reducing friction resistance and improves the beneficial effect in work-ing life.
(5) the wear resistant alloy powders bulk material that the present invention uses, because the deposited temperature of plasma arc is high, can fully melt thick wear resistant alloy powders bulk material and have argon shield effect, has manufacturing process simple, feature easy to use.By the wearing layer after deposited, result has obtained inner quality and the visual appearance same good with plasma arc powder surfacing.
Above-described embodiment is described the preferred embodiment of the present invention; not scope of the present invention is limited; design under the prerequisite of spirit not departing from the present invention; various distortion and improvement that those of ordinary skills make technical scheme of the present invention, all should fall in the definite protection domain of the claims in the present invention book.
Claims (4)
1. a plasma melting coating method of manufacturing Wear-Resistant Compound Steel Plate, it is characterized in that: adopt the automatic cladding method of four rifle plasmas, selecting thickness is that 3～15mm wear resistant alloy powders bulk material is laid in above matrix steel plate, matrix steel plate is placed on the deposited platform of cast iron that thickness is 80-120mm, by clamp jig, matrix steel plate surrounding and deposited of cast iron is fixing, by position-limitting pin, deposited of matrix steel plate middle part and cast iron is fixing, utilize rifle mouth aperture ratio for (0.75-0.85): 1 high energy beam plasma arc is made deposited thermal source, the synchronous automatic deposited wear resistant alloy powders bulk material of four rifles, make itself and matrix steel plate produce metallurgical binding, described Wear-Resistant Compound Steel Plate, comprise matrix steel plate (5), wearing layer (7) and fusion area (6), thickness≤the 1.5mm of fusion area (6) wherein, the distortion irregularity degree < 5mm/m of described Wear-Resistant Compound Steel Plate
2.
2. method according to claim 1, is characterized in that: described wear resistant alloy powders bulk material is high-chromium cast iron-type micro-slag wear resistant alloy powders bulk material or the micro-slag wear resistant alloy powders of high chromium nickel wolfram varbide type bulk material.
3. an automatic deposited equipment of manufacturing Wear-Resistant Compound Steel Plate, comprise deposited system of Wear-Resistant Compound Steel Plate (1), the deposited system of plasma power supply (2), plasma cladding rifle operational system (3) and Controlling System (4), it is characterized in that: described automatic deposited equipment is the automatic deposited equipment of four rifle plasmas, deposited system of described Wear-Resistant Compound Steel Plate (1) comprises Wear-Resistant Compound Steel Plate deposited (11) and clamp jig (12), the thickness of Wear-Resistant Compound Steel Plate deposited (11) is 80-120mm, be provided with equally distributed limit pin hole (14) above, clamp jig (12) is fixed on the surrounding of Wear-Resistant Compound Steel Plate deposited (11) with bolt, four limits of matrix steel plate (5) are fixed and clamped, the rifle mouth aperture ratio of the deposited system of described plasma power supply (2) ionic medium deposit gun (22) is (0.75-0.85): 1, the tungsten electrode diameter of described plasma cladding rifle (22) is 4～8mm, transferred arc electric current is 0～500A, untransferable arc electric current is 0～250A, plasma voltage 30～70V.
4. equipment according to claim 3, is characterized in that: the diameter of described limit pin hole (14) is 8-12mm, and the distance between limit pin hole (14) is 450-550mm.
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN1039202A (en) * | 1988-05-12 | 1990-01-31 | 国家机械工业委员会哈尔滨焊接研究所 | Single-power plasma welding method with molten electrode protected by gas |
| CN1443868A (en) * | 2002-03-11 | 2003-09-24 | 山东科技大学 | Method for depositing abrasion-resisting coating layer on vacuum beam-plasma surface |
| CN101433990A (en) * | 2008-11-19 | 2009-05-20 | 南京宝色股份公司 | Overlaying welding method of large area carbide alloy of workpiece wear layer |
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| JP3749434B2 (en) * | 2000-10-26 | 2006-03-01 | アイエヌジ商事株式会社 | Wear-resistant metal cladding method and double-sided wear-resistant clad steel sheet |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN1039202A (en) * | 1988-05-12 | 1990-01-31 | 国家机械工业委员会哈尔滨焊接研究所 | Single-power plasma welding method with molten electrode protected by gas |
| CN1443868A (en) * | 2002-03-11 | 2003-09-24 | 山东科技大学 | Method for depositing abrasion-resisting coating layer on vacuum beam-plasma surface |
| CN101433990A (en) * | 2008-11-19 | 2009-05-20 | 南京宝色股份公司 | Overlaying welding method of large area carbide alloy of workpiece wear layer |
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| JP特开2002-137059A 2002.05.14 |
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