CN102528311B - Welding material for quickly welding and repairing defects of HT300 grey iron castings and repair method - Google Patents
Welding material for quickly welding and repairing defects of HT300 grey iron castings and repair method Download PDFInfo
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- CN102528311B CN102528311B CN2012100069474A CN201210006947A CN102528311B CN 102528311 B CN102528311 B CN 102528311B CN 2012100069474 A CN2012100069474 A CN 2012100069474A CN 201210006947 A CN201210006947 A CN 201210006947A CN 102528311 B CN102528311 B CN 102528311B
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Abstract
The invention discloses a welding material for quickly welding and repairing defects of HT300 grey iron castings, comprising powder components including, by mass percentage, from 30 to 35% of Fe2O3, from 25 to 30% of Al, from 1.0 to 1.6% of Na2CO3, from 4.0 to 6.0% of Na2B407, from 4.0 to 6.0% of CaF2, from 7.0 to 10.0% of CaO, from 0.5 to 1.5% of SiO2, from 3.0 to 4.0% of graphite, from 6.0 to 8.0% of pig iron, from 3.5 to 5.0% of 75 ferrosilicon, from 0.5 to 1.2% of nickel, from 0.1 to 0.5% of bismuth, from 1.0 to 2.0% of 60 calcium silicon, from 0.5 to 1.8% of 30 ferrotitanium, from 1.2 to 2.0% of 75 ferromanganese, from 1.0 to 1.5% of 50 ferrochromium, from 0.5 to 1.0% of 50 ferromolybdenum, from 0.5 to 0.6% of tin bronze, from 0.1 to 0.5% of 18 ferro-boron and from 0.1 to 0.5% of 60 ferrovanadium which are uniformly mixed. The total weight percent of the components is 100%. The invention further discloses a method for quickly welding and repairing defects of large-sized HT300 grey iron castings by the aid of the welding material. By the aid of the material and the method, the defects of the large-sized HT300 grey iron castings can be quickly welded and repaired at room temperature.
Description
Technical field
The invention belongs to the salvage for castings field of engineering technology, relate to the welding material that a kind of rapid welding is repaired large-scale HT300 gray iron casting defect, the invention still further relates to the method for utilizing this kind of welding material to carry out the rapid welding reparation to large-scale HT300 gray iron casting defect.
Background technology
The casting process complex process, casting defect is unavoidable, and it is that enterprise spends more money on energy-conservation Important Action that misrun casting is implemented to save reparation, is conducive to environmental protection and economizes on resources.
Due to the intrinsic coagulating property of cast iron, very easily produce soldering district spoken parts in traditional operas and crackle in welding process.The method of at present, gray iron casting being carried out to the high-quality reparation is the hot weldering of gas welding and electric arc.It is simple to operate that these two kinds of methods are used for the middle-size and small-size foundry goods of soldering, and effect is fine; If but can be large because of adding (in advance) hot difficulty for heavy castings, gas welding can't realize the fusion welding; The arc welding cooling rate is excessive, the weld zone poor processability.And the defect probability of HT300 ironcastings such as heavy machine tool lathe bed, large gear and wind-powered electricity generation device is higher, and the REPAIR WELDING added value of this synthetic cast iron is larger.Especially for larger defect, can easily cause because of the excessive input of welding process heat excessive foundry goods spoken parts in traditional operas, distortion or the appearance cracking of causing of weld zone stress, the welding difficulty is larger.Castings production enterprise often seems at a loss what to do for the defect on important machined surface, can only scrap.The dismemberent of large-scale discard and shattering process need to spend a large amount of energy; The production again of foundry goods needs again melting, and this is when consuming the energy, and waste gas and the slag of discharge have also caused secondary pollution to environment.This does not also comprise the waste of labour and time cost.
Therefore, research and develop not only very necessaryly for rapid welding restorative procedure and the welding material of large-scale HT300 gray iron casting defect, and there is higher economic worth and social benefit.
Summary of the invention
The purpose of this invention is to provide a kind of rapid welding and repair the welding material of large-scale HT300 gray iron casting defect, solved the reluctant problem of gray iron casting defect under the prior art condition.
Another object of the present invention is to provide a kind of method of utilizing above-mentioned welding material to carry out the rapid welding reparation to large-scale HT300 gray iron casting defect.
The technical solution used in the present invention is, a kind of rapid welding is repaired the welding material of large-scale HT300 gray iron casting defect, by the powder of following component, evenly mixed by mass percentage:
Fe
2O
330%-35%, Al 25%-30%; Na
2CO
31.0%-1.6%, Na
2B
4O
74.0%-6.0%, CaF
24.0%-6.0%, CaO 7.0%-10.0%, SiO
20.5%-1.5%; Graphite 3.0%-4.0%, pig iron 6.0%-8.0%, 75 ferrosilicon 3.5%-5.0%, nickel 0.5%-1.2%, bismuth 0.1%-0.5%, 60 silico-calcium 1.0%-2.0%, 30 ferrotianium 0.5%-1.8%, 75 ferromanganese 1.2-2.0%, 50 ferrochrome 1.0-1.5%, 50 molybdenum-iron 0.5-1.0%, tin bronze 0.5-0.6%, 18 ferro-boron 0.1-0.5%, 60 vanadium iron 0.1-0.5%, gross weight is 100%.
Another technical scheme that the present invention adopts is, a kind of method of utilizing above-mentioned welding material rapid welding to repair large-scale HT300 gray iron casting defect is utilized above-mentioned component and content preparation welding material, more specifically implemented according to following steps:
Step 3, be packed into groove and dykes and dams inside after the welding material prepared is mixed, imbed compacting after igniter fuse, fill up, finally press gland in the above;
Step 4, light igniter fuse, make the exothermic mixture generation exothermic reaction in welding material, all components in welding material is all melted, the liquid-tight degree of iron produced after fusing sinks in groove higher than slag, and slag floating and iron liquid generation layering;
Step 5, sprinkle wood powder and perlitic mixture on the surface, weld zone, the deposited metal slow cooling is solidified obtain comprising the weld zone metal of slag and excess metal layer;
Step 6, district to be welded are cooled to, lower than after 200 ± 10 ℃, remove gland, destroy the moulding dykes and dams, expose the weld zone metal;
Step 7, application machine-tooled method remove slag and the metal level that the weld zone metal exceeds the Surface of Gray Iron Castings part, forms smooth soldering zone.
The invention has the beneficial effects as follows, can realize the rapid welding reparation of the high trade mark large-scale grey iron of HT300 part defect, the welding duration is only used 2-5 minute, time saving and energy saving; Can effectively reduce spoken parts in traditional operas and crackle tendency, and composition of weld line, tissue, color and luster are consistent with the ironcasting body; Weld seam composition and be organized as typical structure of cast iron; Weld strength is with basically identical with hardness and ironcasting body; The weld seam crack resistance strengthens, and has good processability and cracking resistance.
The accompanying drawing explanation
Fig. 1 is the position shape figure to be welded after adopting the inventive method to the polishing of gray iron casting defect;
Fig. 2 adopts the inventive method, with molding sand or cement, dykes and dams moulding figure is built in defect 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 weld zone structure chart after the machined of employing the inventive method.
Wherein, 1. gray iron casting, 2. dykes and dams, 3. gland, 4. welding material, 5. igniter fuse, 6. deposited metal, 7. weld zone metal, 8. groove.
The specific embodiment
Below in conjunction with the drawings and specific embodiments, the present invention is described in detail.
Rapid welding of the present invention is repaired the welding material of large-scale HT300 gray iron casting defect, by the powder of following component, is evenly mixed by mass percentage:
Fe
2O
330%-35%, Al 25%-30%; Na
2CO
31.0%-1.6%, Na
2B
4O
74.0%-6.0%, CaF
24.0%-6.0%, CaO 7.0%-10.0%, SiO
20.5%-1.5%; Graphite 3.0%-4.0%, pig iron 6.0%-8.0%, 75 ferrosilicon 3.5%-5.0%, nickel 0.5%-1.2%, bismuth 0.1%-0.5%, 60 silico-calcium 1.0%-2.0%, 30 ferrotianium 0.5%-1.8%, 75 ferromanganese 1.2-2.0%, 50 ferrochrome 1.0-1.5%, 50 molybdenum-iron 0.5-1.0%, tin bronze 0.5-0.6%, 18 ferro-boron 0.1-0.5%, 60 vanadium iron 0.1-0.5%, gross weight is 100%.
Above-mentioned welding material of the present invention comprises that according to its function tetrameric powdery components forms:
First is exothermic mixture (or claiming thermite), comprises Fe
2O
3And Al, after heat-producing chemical reaction occurs for both, both provided Welding Metallurgy needed heat, product Fe can be used as again main deposited metal and forms weld seam, Al
2O
3Enter slag, also can participate in the slag making reaction in molten bath.
Second portion is slag former, comprises Na
2CO
3, Na
2B
4O
7, CaF
2, CaO and SiO
2.Na wherein
2B
4O
7And CaF
2Have the diluent effect concurrently, can be used to regulate viscosity coefficient of dross; CaF
2And SiO
2The effect that also there is dehydrogenation, prevention welding cold cracking.
Third part is deoxidation, desulfurizing agent, comprises aluminium, 30 ferrotianiums, 60 silico-calciums, 75 ferromanganese and CaO etc.
The 4th part is alloying constituent, for HT300 gray iron casting composition and performance requirement, selects a plurality of compounds and alloy powder as welding filling material, with obtain with the weld zone metal that is complementary of the foundry goods tissue of being repaired and performance.Mainly comprise the components such as graphite, the pig iron, 75 ferrosilicon, nickel, 60 silico-calciums, 30 ferrotianiums, 75 ferromanganese, 50 ferrochrome, 50 molybdenum-irons, 18 ferro-borons, 60 vanadium iron, tin bronze (bits).Both can form weld metal after fusing, there is again alloying action.Add appropriate bismuth metal and also have Grain refinement, be conducive to improve weld properties.
Exothermic mixture and slag former in welding material component of the present invention have versatility; And the REPAIR WELDING needs that are the HT300 gray iron casting for the trade mark, alloying constituent all has corresponding diversity aspect contamination.
In above-mentioned welding material composition, it is as follows respectively that each component and content limit reason:
In order to make welding process be carried out, added a large amount of Fe
2O
3With aluminium powder as exothermic mixture.The energy that reaction produces not only can maintain exothermic reaction to be continued to carry out, and also has the various metal powder materials of enough heat melts, and makes the mother metal local melting, jointly forms weld seam, reaches the purpose of welding.
In order to make welding slag assemble, float and separate with deposited metal, prevention weld metal slag inclusion, added Na
2CO
3, Na
2B
4O
7, CaF
2With CaO etc. as slag former and diluent.
In order to make weld metal obtain microstructure of grey cast iron, prevent that weld seam and fusion area from producing spoken parts in traditional operas, guarantee the machining property in welding (benefit) district, in powder, phosphorus content and silicon content are controlled all stricter; In order to improve the mechanical performance of weld seam, ensure matrix medium pearlite content and promote graphitization, add a small amount of nickel, aluminium and copper; In order to purify weld metal, reduce the adverse effect of element sulphur, also added calcium; For crystal grain thinning, promotion graphite forming core and Fast Growth, the elements such as micro-Bi, Ti have also been added.Like this, both simplified the wlding production technology, saved again the energy, environmentally safe, but also can guarantee wlding strong graphitizability relatively, obtain the weld zone be complementary with foundry goods body composition, tissue, performance and color and luster, realize the high-performance rapid welding reparation of the large defect of large-scale HT300 gray iron casting.
The method that large-scale HT300 gray iron casting defect is carried out to the rapid welding reparation of the present invention, utilize above-mentioned welding material, according to following steps, specifically implements:
Step 3, filling welding material: the welding material 4 prepared is packed in the space of the groove 8 shown in Fig. 2 and dykes and dams 2 formations, imbeds the rear compacting of igniter fuse 5, fill up, finally press gland 3 (refractory brick) in the above, as Fig. 3;
Step 4, light igniter fuse 5, make the exothermic mixture generation exothermic reaction in welding material 4, all components in welding material 4 is all melted and becomes deposited metal 6, and the liquid-tight degree of the iron in deposited metal 6 sinks in groove 8 higher than slag, and slag floating and iron liquid generation layering;
Step 5, sprinkle wood powder and perlitic mixture on the surface, weld zone, make deposited metal 6 slow cooling solidify the weld zone metal 7 that obtains comprising slag and excess metal layer;
Step 6, district to be welded are cooled to, lower than after 200 ± 10 ℃, remove gland 3 (refractory brick), destroy moulding dykes and dams 2, expose weld zone metal 7 as shown in Figure 4;
Step 7, application machine-tooled method are removed the part that weld zone metal 7 exceeds cast(ing) surface, form smooth soldering zone as shown in Figure 5.
Focusing on of the inventive method, the introducing of the moulding dykes and dams 2 of defect groove 8 upper limbs, the filling of welding material, igniter fuse 5 and the use of gland 3 structures, especially welding the insulation slow cooling in later stage, is the place of realizing the key technology of large-scale HT300 gray iron casting defect rapid welding reparation.When along defect groove 8 upper limbs, building the dykes and dams moulding, reserved high about 3mm, the fuse groove of wide about 5mm is absolutely necessary.Convenient operation is wanted in the orientation of offering of this fuse groove, and wide and high-order to not getting wrong, in case the excessive outflow of slag and molten metal in welding process.
Method of the present invention, can realize REPAIR WELDING under the room temperature of the various defects on large-scale HT300 gray iron casting, and weld seam composition and tissue are corresponding with institute salvaging casting body, and performance and foundry goods body are complementary, and the welding zone color and luster is consistent with the foundry goods body.The weld seam crack resistance is strong, can realize machined.
At first, preparation is for the welding material of large-scale HT300 gray iron casting welding, by the powder of following component, evenly mixed and forms by weight percentage:
Fe
2O
334%, Al 27%; Na
2CO
31.0%, Na
2B
4O
74.0%, CaF
24.0%, CaO 8.0%, SiO
21.5%; Graphite 3.0%, the pig iron 7.0%, 75 ferrosilicon 4.0%, nickel 0.5%, bismuth 0.2%, 60 silico-calciums 1.0%, 30 ferrotianiums 1.0%, 75 ferromanganese 1.4%, 50 ferrochrome 1.0%, 50 molybdenum-irons 0.5%, tin bronze 0.5%, 18 ferro-borons 0.2%, 60 vanadium iron 0.2%, gross weight is 100%.
Weld enforcement according to aforesaid restorative procedure again, in above-described embodiment, the chemical composition (Wt%) of the welding powder deposited metal after reparation respectively:
C is 2.70, Si is 1.70, Mn is 0.96, Mo is 0.03, Cr is 0.05, Cu is 0.06, Ti is 0.02, V is 0.01, S is 0.08, P is 0.15.
The weld metal mechanical property is: tensile strength sigma
bBe 296MPa, hardness HBS is 232.
At first, preparation is for the welding material of large-scale HT300 gray iron casting welding, by the powder of following component, evenly mixed and forms by weight percentage:
Fe
2O
332%, Al 28%; Na
2CO
31.5%, Na
2B
4O
75.0%, CaF
26.0%, CaO7.0%%, SiO
21.0%; Graphite 3.5%, the pig iron 6.0%, 75 ferrosilicon 3.5%, nickel 0.6%, bismuth 0.1%, 60 silico-calciums 1.5%, 30 ferrotianiums 0.5%, 75 ferromanganese 1.3%, 50 ferrochrome 1.2%, 50 molybdenum-irons 0.6%, tin bronze 0.5%, 18 ferro-borons 0.1%, 60 vanadium iron 0.1%, gross weight is 100%.
Weld enforcement according to aforesaid restorative procedure again, in above-described embodiment, the chemical composition (Wt%) of the welding powder deposited metal after reparation respectively:
C is 2.63, Si is 1.66, Mn is 0.91, Mo is 0.03, Cr is 0.06, Cu is 0.05, Ti is 0.01, V is 0.01, S is 0.07, P is 0.17.
The weld metal mechanical property is: tensile strength sigma
bFor 279MPa, hardness HBS is 229.
Embodiment 3
At first, preparation is for the welding material of large-scale HT300 gray iron casting welding, by the powder of following component, evenly mixed and forms by weight percentage:
Fe
2O
335%, Al 26%; Na
2CO
31.0%, Na
2B
4O
74.0%, CaF
24.0%, CaO 8.0%, SiO
20.5%; Graphite 3.5%, the pig iron 8.0%, 75 ferrosilicon 3.5%, nickel 0.5%, bismuth 0.2%, 60 silico-calciums 1.0%, 30 ferrotianiums 1.0%, 75 ferromanganese 1.4%, 50 ferrochrome 1.0%, 50 molybdenum-irons 0.5%, tin bronze 0.5%, 18 ferro-borons 0.2%, 60 vanadium iron 0.2%, gross weight is 100%.
Weld enforcement according to aforesaid restorative procedure again, in above-described embodiment, the chemical composition (Wt%) of the welding powder deposited metal after reparation respectively:
C is 2.89, Si is 1.84, Mn is 0.90, Mo is 0.03, Cr is 0.03, Cu is 0.05, Ti is 0.01, V is 0.01, S is 0.07, P is 0.16.
The weld metal mechanical property is: tensile strength sigma
bFor 305MPa, hardness HBS is 253.
The chemical composition of weld metal and mechanical property meet the GB9439-88 requirement, and basic identical with the composition of repaired HT300 gray iron casting material, i.e. metallographic structure is basic identical, have reached the REPAIR WELDING requirement of foundry goods.
Embodiment 4
At first, preparation is for the welding material of large-scale HT300 gray iron casting welding, by the powder of following component, evenly mixed and forms by weight percentage:
Fe
2O
330%, Al 25%; Na
2CO
31.1%, Na
2B
4O
75.5%, CaF
24.5%, CaO 8.6%, SiO
20.6%; Graphite 4%, the pig iron 6.5%, 75 ferrosilicon 4.5%, nickel 1%, bismuth 0.4%, 60 silico-calciums 2%, 30 ferrotianiums 0.7%, 75 ferromanganese 1.8%, 50 ferrochrome 1.5%, 50 molybdenum-irons 0.9%, tin bronze 0.6%, 18 ferro-borons 0.4%, 60 vanadium iron 0.4%, gross weight is 100%.
Weld enforcement according to aforesaid restorative procedure again.
Embodiment 5
At first, preparation is for the welding material of large-scale HT300 gray iron casting welding, by the powder of following component, evenly mixed and forms by weight percentage:
Fe
2O
330%, Al 30%; Na
2CO
31.0%, Na
2B
4O
74.1%, CaF
24.1%, CaO 9.2%, SiO
20.7%; Graphite 3.2%, the pig iron 6.2%, 75 ferrosilicon 3.6%, nickel 0.7%, bismuth 0.3%, 60 silico-calciums 1.2%, 30 ferrotianiums 1.5%, 75 ferromanganese 1.2%, 50 ferrochrome 1.1%, 50 molybdenum-irons 0.7%, tin bronze 0.6%, 18 ferro-borons 0.3%, 60 vanadium iron 0.3%, gross weight is 100%.
Weld enforcement according to aforesaid restorative procedure again.
In sum, material of the present invention and method, can realize the rapid welding reparation of large-scale high trade mark HT300 gray iron casting defect, and the welding duration is only used 2-5 minute, time saving and energy saving; The weld seam color and luster is consistent with the ironcasting body; Weld seam composition and be organized as typical structure of cast iron; Weld strength is with basically identical with hardness and ironcasting body; But the weld seam crack resistance strengthens machined.
Claims (3)
1. a rapid welding is repaired the welding material of large-scale HT300 gray iron casting defect, it is characterized in that, by the powder of following component, is evenly mixed by mass percentage:
Fe
2O
330%-35%, Al25%-30%; Na
2CO
31.0%-1.6%, Na
2B
4O
74.0%-6.0%, CaF
24.0%-6.0%, CaO7.0%-10.0%, SiO
20.5%-1.5%; Graphite 3.0%-4.0%, pig iron 6.0%-8.0%, 75 ferrosilicon 3.5%-5.0%, nickel 0.5%-1.2%, bismuth 0.1%-0.5%, 60 silico-calcium 1.0%-2.0%, 30 ferrotianium 0.5%-1.8%, 75 ferromanganese 1.2-2.0%, 50 ferrochrome 1.0-1.5%, 50 molybdenum-iron 0.5-1.0%, tin bronze 0.5-0.6%, 18 ferro-boron 0.1-0.5%, 60 vanadium iron 0.1-0.5%, gross weight is 100%.
2. a method of utilizing welding material rapid welding claimed in claim 1 to repair large-scale HT300 gray iron casting defect, is characterized in that, utilizes component claimed in claim 1 and content preparation welding material, more specifically implement according to following steps:
Step 1, the rejected region of defective gray iron casting (1) is implemented to polishing, process groove (8);
Step 2, along the moulding of groove (8) upper limb periphery, use molding sand or cement to build dykes and dams (2) along defect groove (8) top periphery, the upper limb of dykes and dams (2) need leave the lead-ingroove of igniter fuse (5);
Step 3, be packed into groove (8) and dykes and dams (2) inside after the welding material (4) prepared is mixed, tamp, fill up after imbedding igniter fuse (5), finally press gland (3) in the above;
Step 4, light igniter fuse (5), make the exothermic mixture generation exothermic reaction in welding material (4), all components in welding material (4) is all melted, and the liquid-tight degree of iron produced after fusing sinks in groove (8) higher than slag, and slag floating and iron liquid generation layering;
Step 5, sprinkle wood powder and perlitic mixture on the surface, weld zone, make deposited metal (6) slow cooling solidify the weld zone metal (7) that obtains comprising slag and excess metal layer;
Step 6, district to be welded metal are cooled to, lower than after 200 ± 10 ℃, remove gland (3), destroy moulding dykes and dams (2), expose weld zone metal (7);
Step 7, application machine-tooled method remove slag and the metal level that weld zone metal (7) exceeds the Surface of Gray Iron Castings part, forms smooth soldering zone.
3. rapid welding according to claim 2 is repaired the method for large-scale HT300 gray iron casting defect, it is characterized in that the high 3mm of described lead-ingroove, wide 5mm.
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| CN103008876A (en) * | 2012-12-07 | 2013-04-03 | 中冶陕压重工设备有限公司 | Method for repairing internal defects of large-sized forge pieces through electroslag welding with tube electrode |
| CN105880869A (en) * | 2014-11-17 | 2016-08-24 | 国家电网公司 | Exothermic soldering flux for iron-based grounding grid |
| CN105149862B (en) * | 2015-10-21 | 2017-10-03 | 武汉大学 | A kind of restorative procedure for being broken defect bronze relic |
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| CN101850479A (en) * | 2010-06-21 | 2010-10-06 | 西安理工大学 | Welding material for rapidly welding and repairing defects of large-scale ductile iron castings and repairing method |
| CN101850478A (en) * | 2010-06-21 | 2010-10-06 | 西安理工大学 | Welding material for rapidly welding and repairing defects of large-scale grey iron casting and repairing method thereof |
| CN102181780A (en) * | 2011-01-31 | 2011-09-14 | 潍柴动力股份有限公司 | Gray pig iron and production process thereof |
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2012
- 2012-01-10 CN CN2012100069474A patent/CN102528311B/en not_active Expired - Fee Related
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|---|---|---|---|---|
| US4054775A (en) * | 1975-09-12 | 1977-10-18 | Patsie Carmen Campana | Process and welding rod for welding gray cast iron |
| CN1994655A (en) * | 2006-12-28 | 2007-07-11 | 山东建筑大学 | Grey cast iron welding process and self-fluxing homogeneous welding powder |
| CN101554689A (en) * | 2009-05-15 | 2009-10-14 | 西安理工大学 | Flux-cored alloyed cast iron homogeneous gas-welding wire and electric welding rod |
| CN101850479A (en) * | 2010-06-21 | 2010-10-06 | 西安理工大学 | Welding material for rapidly welding and repairing defects of large-scale ductile iron castings and repairing method |
| CN101850478A (en) * | 2010-06-21 | 2010-10-06 | 西安理工大学 | Welding material for rapidly welding and repairing defects of large-scale grey iron casting and repairing method thereof |
| CN102181780A (en) * | 2011-01-31 | 2011-09-14 | 潍柴动力股份有限公司 | Gray pig iron and production process thereof |
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