CN104772577B - 一种用于船体、海洋钻井平台超低温药芯焊丝 - Google Patents
一种用于船体、海洋钻井平台超低温药芯焊丝 Download PDFInfo
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
- B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
- B23K35/24—Selection of soldering or welding materials proper
- B23K35/30—Selection of soldering or welding materials proper with the principal constituent melting at less than 1550 degrees C
- B23K35/3053—Fe as the principal constituent
- B23K35/3066—Fe as the principal constituent with Ni as next major constituent
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
- B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
- B23K35/24—Selection of soldering or welding materials proper
- B23K35/30—Selection of soldering or welding materials proper with the principal constituent melting at less than 1550 degrees C
- B23K35/3053—Fe as the principal constituent
- B23K35/3073—Fe as the principal constituent with Mn as next major constituent
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
- B23K35/40—Making wire or rods for soldering or welding
- B23K35/406—Filled tubular wire or rods
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Abstract
本发明涉及一种用于船体、海洋钻井平台超低温药芯焊丝,包括外皮和药芯,其特征在于:所述外皮采用低碳钢带制成,所述低碳钢的重量百分比为:0.025‑0.035%,所述外皮宽度×厚度的尺寸采用:14mm×0.8mm;所述药芯组分及其重量百分比分别为:硅锰合金10‑12.5%;钛铁合金1.5‑3.0%;硅铁合金5‑6.5%;镍粉10‑13.5%;萤石1‑2.5%;钼粉4‑5.5%;铝矾土1‑2.5%;铼氟粉:1‑2.5%;锆硅合金0.8‑1.9%;余量为铁粉,药芯填充率为:13‑20%。本发明采用的焊丝不仅生产成本相对较低且具有较高的强度,还能在超低温环境下保证其良好的冲击性且能够实现自动及半自动焊接。
Description
技术领域
本发明涉及焊接材料领域,尤其涉及一种用于船体、海洋钻井平台超低温药芯焊丝,该焊丝在船体、海洋钻井平台的关键部位采用CO2气体保护焊接能够在超低温的情况下,保证焊丝良好的冲击性,且能实现半自动与自动焊接。
背景技术
现有焊接工艺中,气体保护焊具有生产效率高、适应全位置焊接、便于实现自动化焊接生产等特点,在石油化工、汽车制造、造船、航母建造等行业中应用极为广泛,同时对不同用途的焊接工艺而言,焊接的要求也不同。气体保护焊丝的保护气体一般分为富氩和CO2,富氩中以20%CO2+80%Ar为主,通常来说,CO2气体生产原料来源广使得其具有成本低且相对环保,CO2气保焊焊接效率高,但是如果焊丝成分设计不合适会导致焊接飞溅大、焊接金属冲击韧性不佳,也即是说焊接效果不理想。
随着我们国家船舶行业的快速发展,国内造船工业对药芯焊丝的需求越来越大,对药芯焊丝的要求也是越来越高的。对于需要采用高强气体保护焊丝,使用者通常对富氩气体保护焊丝关注较多,CO2焊丝由于品种较少,常见的包括:ER49,ER50,ER55系列及ER69-3。上述前两者为500MPa普通焊丝,后两者中因为添加了钼和镍使得焊缝具有较好的韧性,然而成本也大幅度上升,对于一般生产企业而言,无形中生产成本也大大地加重了。
焊丝制作工艺通常包括冶炼、钢带轧制、拉拔及表面涂油等,然而微量元素Ti、B、Als等级气体含量根据焊丝设计要求加以控制是焊丝冶炼的难点。现在的造船行业有较多深海行驶的船只,尤其对高强度低温的产品要求越来越高,对于现有的焊丝而言,在低温下对其抗裂性、耐腐蚀性要求更高,并且要保证在焊接施工过程中做到:焊缝表面脱渣及光洁度要好,且不能出现凹坑及麻点等缺陷;焊接时电弧稳定,熔敷速度快,飞溅小,不能出现大颗粒飞溅物;在焊接完成后表面不能出现裂纹,或经过一个阶段后出现裂纹。再者,在焊接抗拉强度为650-1000MPa,同时具有优异的低温韧性的高强度钢时,使用现有的焊接材料,焊缝金属的碳含量高于母材的碳含量,焊缝金属和进化程度偏高,淬硬性明显大于母材,焊缝金属中易出现冷裂。因而急需一种生产成本低且在超低温环境下药芯焊丝,该药芯焊丝不仅具有较高的强度,还保证其良好的冲击性且能实现半自动及自动焊接。
发明内容
针对现有技术中出现的缺陷,本发明的目的在于提供一种用于船体、海洋钻井平台超低温药芯焊丝,该焊丝不仅生产成本相对较低且具有较高的强度,还能在超低温环境下保证其良好的冲击性且能够实现自动及半自动焊接。
为了达到上述目的,本发明采用如下技术方案:
一种用于船体、海洋钻井平台超低温药芯焊丝,包括外皮和药芯,其特征在于:所述外皮采用低碳钢带制成,所述外皮宽度×厚度的尺寸采用:14mm×0.8mm;所述药芯组分及其重量百分比分别为:硅锰合金10-12.5%;钛铁合金1.5-3.0%;硅铁合金5-6.5%;镍粉10-13.5%;萤石1-2.5%;钼粉4-5.5%;铝矾土1-2.5%;铼氟粉:1-2.5%;锆硅合金0.8-1.9%;余量为铁粉,药芯填充率为:13-20%。
作为上述方案的进一步改进,焊丝药芯各组分的重量百分比如下:硅锰合金12%;钛铁合金2%;硅铁合金6%;镍粉13%;萤石2%;钼粉5%;铝矾土2%;铼氟粉:2%;锆硅合金1%;铁粉55%,药芯填充率为16%。
作为上述方案的进一步改进,焊丝药芯各组分的重量百分比如下:硅锰合金10%;钛铁合金1.5%;硅铁合金5%;镍粉10%;萤石1%;钼粉4%;铝矾土1%;铼氟粉:1%;锆硅合金0.8%;铁粉65.2%,药芯填充率为18.2%。
作为上述方案的进一步改进,焊丝药芯各组分的重量百分比如下:硅锰合金12.5%;钛铁合金3%;硅铁合金6.5%;镍粉13.5%;萤石2.5%;钼粉5.5%;铝矾土2.5%;铼氟粉:2.5%;锆硅合金1.9%;铁粉49.6%,药芯填充率为15.3%。
作为上述方案的进一步改进,所述硅锰合金中:Si为19-21%,Mn为60-63%;所述钛铁合金中:Ti≤20%;所述硅铁合金中:Si≥70%,Cr≤0.02%;所述镍粉中:Ni≥98%,S≤0.01%,P≤0.01%;所述萤石中:CaF≥97%,SiO2≤2.0%;所述钼粉:Mo≤3.5%;所述铝矾土中:Al2O3为≥80%,SiO2≤5.0%,Fe2O3≤3.0%;所述铼氟粉:Re≤1.2%,F≥48%;所述锆硅合金中:Zr≤40%,Si≥50%。
与现有技术相比,本发明采用的药芯焊丝,适用于低温区域作业的海洋平台结构、船舶修造对接及角焊接,具有较好的焊接工艺性能,并且可以进行平焊、横焊、平角焊、仰焊、立向上等全位置焊接。本发明采用的药芯焊丝经过配粉、生产的工艺处理,一方面能够使焊丝具有良好的电弧稳定性,另一方面能够使大量的合金粉料在焊接过程中提高其强度及韧性,还提高了其耐腐蚀性,同时在低温条件下能够使焊缝处的熔敷金属具有较高的韧性。
具体实施方式
本发明具体实施方式提供一种适用于石油管道高强度、低氢CO2药芯焊丝,该焊丝与现有焊丝的区别点在于成分及重量比例不同。具体如下:
一种用于船体、海洋钻井平台超低温药芯焊丝,包括外皮和药芯,其特征在于:所述外皮采用低碳钢带制成,所述外皮宽度×厚度的尺寸采用:14mm×0.8mm;所述药芯组分及其重量百分比分别为:硅锰合金10-12.5%;钛铁合金1.5-3.0%;硅铁合金5-6.5%;镍粉10-13.5%;萤石1-2.5%;钼粉4-5.5%;铝矾土1-2.5%;铼氟粉:1-2.5%;锆硅合金0.8-1.9%;余量为铁粉,药芯填充率为:13-20%;所述硅锰合金中:Si为19-21%,Mn为60-63%;所述钛铁合金中:Ti≤20%;所述硅铁合金中:Si≥70%,Cr≤0.02%;所述镍粉中:Ni≥98%,S≤0.01%,P≤0.01%;所述萤石中:CaF≥97%,SiO2≤2.0%;所述钼粉:Mo≤3.5%;所述铝矾土中:Al2O3为≥80%,SiO2≤5.0%,Fe2O3≤3.0%;所述铼氟粉:Re≤1.2%,F≥48%;所述锆硅合金中:Zr≤40%,Si≥50%。
本实施方式中所述焊丝的制造方法如下:
(1)冶炼
通过转炉、电炉或中频感应等方式进行钢材的冶炼,选择低碳钢,同时对C、Si、Mn、S、P的含量进行控制;
(2)钢带加工
将冶炼后的低碳钢加工成钢带,提高钢带的延伸性能,降低合金元素的偏析;
(3)药芯焊丝的制作
将裁剪好的钢带进行小分条,在生产时经过轧辊轧制成“U”型,填充粉料,进行拉拔至指定规格的焊丝,钢带的延伸性能有利于提高其拉拔性能;
(4)涂油
将拉拔好的焊丝在缠绕前进行高压静电涂油,能够增强焊接送丝的稳定性能,同时大大减少对送丝管、导电嘴的磨损;并且能够延长焊丝的储存时间,因此,在焊丝的制造中该步骤尤为重要。
上述焊丝药芯中各组分的作用如下:
(1)锰:确保熔敷金属的强度和降低氧、硫含量,降低熔敷金属固态相变温度,细化晶粒,提高熔敷金属强度及低温冲击韧性。
(2)硅:增加电弧稳定性。作为脱氧剂确保熔敷金属的强度和降低氧含量。含量过高则使熔敷金属塑性和冲击韧性降低。
(3)铬:起到明显的固溶强化作用,同时降低熔敷金属相变温度,含量过高易导致低温韧性急剧降低。
(4)镍:通过细化晶粒和固溶强化获得强化效果,同时也是最好的韧化元素,能够显著改善焊缝金属的低温韧性。
(5)钼:通过固溶强化以提高强度,与Cr一起调控熔敷金属组织类型及比例。
(6)锆硅合金:通过在熔敷金属中形成锆的非金属氧化夹杂物,在淬硬性较大的情况下为针状铁素体的晶内形核提供质点。
(7)铼氟粉:药芯中的各种氟化物在高温下易汽化和分解,产生大量的氟蒸汽而大大降低电弧气氛中的氢分压,同时,在焊接时铼氟粉能够与电弧气氛中氢原子及水蒸汽发生反应,形成不溶于钢液的氟化氢气体,从而降低焊缝氢含量。
(8)钛铁合金:钛在熔敷金属中与锆一起形成的非金属氧化夹杂物,有效细化晶粒提高韧性。
(9)铁:调节成分,保证电弧稳定性,提高熔敷效率。
下面以焊缝强度为目标,确定了如前所属焊丝的化学成分,试验证明,所述成分的焊丝完全可以达到上述焊缝性能的要求。
实施例1
焊丝药芯各组分的重量百分比如下:硅锰合金12%;钛铁合金2%;硅铁合金6%;镍粉13%;萤石2%;钼粉5%;铝矾土2%;铼氟粉:2%;锆硅合金1%;铁粉55%,药芯填充率为16%。
实施例2:
焊丝药芯各组分的重量百分比如下:硅锰合金10%;钛铁合金1.5%;硅铁合金5%;镍粉10%;萤石1%;钼粉4%;铝矾土1%;铼氟粉:1%;锆硅合金0.8%;铁粉65.2%,药芯填充率为18.2%。
实施例3:
焊丝药芯各组分的重量百分比如下:硅锰合金12.5%;钛铁合金3%;硅铁合金6.5%;镍粉13.5%;萤石2.5%;钼粉5.5%;铝矾土2.5%;铼氟粉:2.5%;锆硅合金1.9%;铁粉49.6%,药芯填充率为15.3%。
所述焊丝按照GB10045-2001进行CO2焊接熔敷金属性能试验,研究焊丝的焊接工艺性能及熔敷金属力学性能,具体参见表1和表2。
表1
表2
通过对以上数据的分析可以得出:本实施方式经过配粉、生产的工艺处理,一方面能够是的焊丝具有良好的电弧稳定性,另一方面能够使大量的合金粉料在焊接过程中提高其强度及韧性,还提高了其耐腐蚀性,同时在低温条件下能够使焊缝处的熔敷金属具有较高的韧性。本发明并不局限于上述的具体实施方式,上述的具体实施方式仅仅是示意性的,而不是限制性的,本领域技术人员在本发明的技术启示下,在不脱离本发明宗旨的情况下,还可以做出多种变形,这些均属于本发明的保护范围之内。
Claims (4)
1.一种用于船体、海洋钻井平台超低温药芯焊丝,包括外皮和药芯,其特征在于:所述外皮采用低碳钢带制成,所述外皮宽度×厚度的尺寸采用:14mm×0.8mm;所述药芯组分及其重量百分比分别为:硅锰合金10-12.5%;钛铁合金1.5-3.0%;硅铁合金5-6.5%;镍粉10-13.5%;萤石1-2.5%;钼粉4-5.5%;铝矾土1-2.5%;铼氟粉:1-2.5%;锆硅合金0.8-1.9%;余量为铁粉,药芯填充率为:13-20%;所述硅锰合金中:Si为19-21%,Mn为60-63%;所述钛铁合金中:Ti≤20%;所述硅铁合金中:Si≥70%,Cr≤0.02%;所述镍粉中:Ni≥98%,S≤0.01%,P≤0.01%;所述萤石中:CaF≥97%,SiO2≤2.0%;所述钼粉:Mo≤3.5%;所述铝矾土中:Al2O3为≥80%,SiO2≤5.0%,Fe2O3≤3.0%;所述铼氟粉:Re≤1.2%,F≥48%;所述锆硅合金中:Zr≤40%,Si≥50%。
2.根据权利要求1所述的一种用于船体、海洋钻井平台超低温药芯焊丝,其特征在于:所述焊丝药芯各组分的重量百分比如下:硅锰合金12%;钛铁合金2%;硅铁合金6%;镍粉13%;萤石2%;钼粉5%;铝矾土2%;铼氟粉:2%;锆硅合金1%;铁粉55%,药芯填充率为16%。
3.根据权利要求1所述的一种用于船体、海洋钻井平台超低温药芯焊丝,其特征在于:所述焊丝药芯各组分的重量百分比如下:硅锰合金10%;钛铁合金1.5%;硅铁合金5%;镍粉10%;萤石1%;钼粉4%;铝矾土1%;铼氟粉:1%;锆硅合金0.8%;铁粉65.2%,药芯填充率为18.2%。
4.根据权利要求1所述的一种用于船体、海洋钻井平台超低温药芯焊丝,其特征在于:所述焊丝药芯各组分的重量百分比如下:硅锰合金12.5%;钛铁合金3%;硅铁合金6.5%;镍粉13.5%;萤石2.5%;钼粉5.5%;铝矾土2.5%;铼氟粉:2.5%;锆硅合金1.9%;铁粉49.6%,药芯填充率为15.3%。
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