CN105414743A - Consumable nozzle electroslag overlaying welding repair method for roll - Google Patents
Consumable nozzle electroslag overlaying welding repair method for roll Download PDFInfo
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- CN105414743A CN105414743A CN201510947821.0A CN201510947821A CN105414743A CN 105414743 A CN105414743 A CN 105414743A CN 201510947821 A CN201510947821 A CN 201510947821A CN 105414743 A CN105414743 A CN 105414743A
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- roll
- consumable
- welding
- consumable nozzle
- lead
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Classifications
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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
- B23K25/00—Slag welding, i.e. using a heated layer or mass of powder, slag, or the like in contact with the material to be joined
- B23K25/005—Welding for purposes other than joining, e.g. built-up welding
-
- 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
- B23K35/36—Selection of non-metallic compositions, e.g. coatings, fluxes; Selection of soldering or welding materials, conjoint with selection of non-metallic compositions, both selections being of interest
- B23K35/362—Selection of compositions of fluxes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P6/00—Restoring or reconditioning objects
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Butt Welding And Welding Of Specific Article (AREA)
Abstract
The invention discloses a consumable nozzle electroslag overlaying welding repair method for a roll. The consumable nozzle electroslag overlaying welding repair method comprises the following steps: removing a fatigue layer and defects of a roll body through turning, welding a lead-in plate and a lead-out plate on the upper part and the lower part of the roll respectively, and carrying out overlaying welding pre-treatment on the roll; hoisting and vertically placing the roll on a base, and clamping and fixing the roll; assembling a water-cooling crystallizer, sleeving the roll with the annular water-cooling crystallizer, and enabling the inner wall of the water-cooling crystallizer to form an annular groove with the outer surface of the roll body, and the lead-in plate; uniformly arranging a plurality of consumable nozzles in the annular groove through a consumable fixation device, and enabling welding wires to enter the annular groove through the consumable nozzles and make contact with a bottom surface; and after the completion of overlaying welding, removing the crystallizer, the lead-in plate, the lead-out plate, and a level thin-slag layer on an overlaying welding surface, and carrying out the subsequent machining treatment. According to the invention, production for the flux-cored welding wires and the consumable nozzles is simple in process and low in cost compared with production for rod-shaped alloy electrodes; insulation coatings are arranged outside the consumable nozzles to guarantee that each consumable electrode is located at the central line position of the corresponding cavity, ensure the forming quality, and reduce the control difficulty; and the alloy ingredients of overlaying welding metal can be flexibly adjusted according to performance requirements through the flux-cored welding wires, so that the alloying effect is more obvious.
Description
Technical field
The present invention relates to ESW device technique field, particularly a kind of method of consumable nozzle electroslag Bead weld repair roll.
Background technology
Roll is one of the vitals during iron and steel is produced, and needs in process of production to bear high stress cycle and high friction, easily weares and teares, peels off and the phenomenon such as routed limit, lose using function, need repair damage roll, ensure roll quality, reduce financial cost.
At present, domestic application the most widely roll repair welding method be automatic arc surfacing.Roll horizontal positioned in automatic electric arc weld deposit process and at the uniform velocity axle turn, welding wire is along roll mandrel to uniform motion, and two kinds of motions cooperatively interact, and applies the metal of certain thickness and size at roller surface heap.This restorative procedure can ensure wearability, but easily produces the defects such as pore, crackle, slag inclusion and overlap, and complex process, productivity ratio is low.And automatic ESW, roll is vertically placed, and own wt can be directly delivered on base, assembling and clamping difficulty less, eliminate the axial-movement devices of welding wire, technics comparing is simple, and heat input is comparatively large, the defect such as crackle, pore obviously reduces, and overlay properties is excellent.
Although also have a kind of ESW device abroad, this device is using metal bar as consumable electrode, and while forming current loop, electrode melting enters molten bath as filling metal.Refer to shown in Fig. 1 and Fig. 2, during built-up welding, roll 1 is vertically fixed on pedestal 8 and also at the uniform velocity rotates, the fit-up gap of crystallizer 9 and roll 1 coverlay makeup ring to be repaired shape, ESW process occurs in this gap, and crystallizer is mobile with the rising in slag bath and molten bath.Heat melts electrode and part mother metal that slag bath produces, after liquid state of molten pool metal cooled and solidified, namely obtain the uniform overlay cladding of thickness at roller surface.Consumable electrode 2 cross section can be circle also can be square.Roll is inner to be required different with surface performance, and coating metal alloy content is higher, and hardness is large, and wearability is good, and this just requires the consumable electrode 2 corresponding with it to the roll melting and casting of different performance requirement, considerably increases economy and time cost; Plant produced medium-and-large-sized roll barrel length is very large; consider the needs of assembly space; the limiting length of consumable electrode 2 can close to 3 meters and electrode surface does not have insulation protection; in ESW process; electrode is easily shaken; standoff position of center line, causes the problems such as crystallizer fusing and butt-joint, controls to add difficulty to forming process.
Summary of the invention
Technical problem to be solved by this invention is to provide a kind of method of consumable nozzle electroslag Bead weld repair roll, overcome existing consumable electrode ESW consumable electrode metal bar manufacturing step loaded down with trivial details, dumb, the defects such as forming process is wayward, in conjunction with consumable nozzle electroslag technique for overlaying, there is improvement consumable electrode, obtain electrode fabrication simple, with low cost, deposited metal composition is controlled and forming process holds manageable advantage.
In order to realize the object solved the problems of the technologies described above, present invention employs following technical scheme:
A method for consumable nozzle electroslag Bead weld repair roll, is characterized in that: comprise the following steps:
Step one, car go body of roll fatigue layer and defect, lead-in plate and end tab are welded to bottom and the bottom of roll, and breaker roll do heap pre-welding treatment.Beginning and ending segment are drawn out to roll barrel outside by lead-in plate and end tab, ensure that body of roll Bead weld repair layer does not have defect, and built-up welding terminates rear lead-in plate and end tab can machining be removed.Lead-in plate on the one hand can carry solder, and built-up welding incipient stage solder melts forms slag bath on the other hand, and temperature is lower, easily forms the defects such as slag inclusion, and lead-in plate can be formed and stablize slag bath for solder fusing and provide space.Slag bath can be drawn body of roll part by end tab, is beneficial to follow-up slagging-off.
Concrete, described end tab is ring-type, and outer annular diameter is consistent with barrel diameter; Lead-in plate is an annular boss, and boss the first half diameter is consistent with barrel diameter, and boss the latter half diameter is not less than water mold external diameter.Therefore the diameter of lead-in plate, end tab and crystallizer is all determined by roll barrel diameter to be repaired.For avoiding burn through, the thickness of lead-in plate, end tab is generally not less than 35mm.
Step 2, by roll lifting be vertically placed on base, be fixedly clamped; Assembling water mold ring-type water mold is sleeved on roll, and built-up welding starts front water mold and lead-in plate lower part surface contact, makes water mold inwall and body of roll outer surface, lead-in plate form endless groove, in order to the striking slag making of built-up welding incipient stage; Water mold rises along with the rising in slag bath and molten bath in weld deposit process, plays and takes away waste heat, accelerates metal bath directional solidification and forces the effect that is shaped;
Step 3, many consumable nozzles are evenly arranged in endless groove by fusible fixture, and welding wire enters endless groove by consumable nozzle and contacts with bottom surface;
Step 4, enter solder flux to uniform spreading in endless groove; The welding incipient stage suitably tunes up parameter, is formed fast and stablizes slag bath, reduce parameter after stable; Observe slag bath state in welding process and repeatedly add solder flux on a small quantity in good time, avoid once adding too much solder flux and cause slag inclusion;
Step 5, built-up welding terminate rear removal crystallizer, lead-in plate and end tab, remove the smooth thin slag blanket of facing surface, carry out following process process.
Described electroslag solder flux mass percent formula is: fluorite: 40% ~ 50%; Marble: 20% ~ 30%%; Quartz: 5% ~ 15%; Corundum 5% ~ 15%; Waterglass 5% ~ 15%; White clay: 5% ~ 15%.Describedly determine flux constituent, when in welding wire, high-melting point alloy element is more, the marble content in formula is tried one's best capping.Described solder flux, granularity should be 8 to 40 orders, and consumable nozzle core wire material is No. 10 steel steel pipes, coating wall thickness 1mm.For ensureing that welding slag bath slag system is stablized, built-up welding flux composition is 80% flux composition+10% white clay+10% waterglass, so that coating is more easily attached on core wire.
This technical scheme has 3 requirements to solder flux and consumable nozzle coating performance: first, the oxidisability of slag bath is weak, avoids the undue scaling loss of alloying element; Secondly, fusing point is relatively high, and high-melting point alloy element in flux-cored wire is fully spread, ensure deposited metal composition and performance even; Again, slag bath wants modest viscosity, good fluidity, avoids the defect such as splashing and slag inclusion in welding process.Solder flux is specifically filled a prescription as shown in table 1.When in welding wire, high-melting point alloy element is more, marble content capping in table 1.
table 1 roll repair welding electroslag flux composition wt.%
| Raw material | Fluorite | Marble | Quartz | Corundum | Waterglass |
| Percentage | 40~50 | 20~30 | 5~15 | 5~15 | 5~15 |
Described flux particle degree should be 8 to 40 orders, and consumable nozzle core wire material is No. 10 steel steel pipes, coating wall thickness 1mm.Conventional core wire model has 10-3,12-3(external diameter-wall thickness), be commercially available non-customized, can select flexibly according to fit-up gap during built-up welding.
Consumable nozzle is the tubular body of long 2000mm, outer diameter D 12mm, internal diameter d4mm.The core wire material of described consumable nozzle is No. 10 steel steel pipes, coating wall thickness 1mm.The spacing of adjacent consumable nozzle in endless groove is 80-120mm.
Concrete, curvature and the roll surface curvature of described fusible fixture and the contact surface of roll are consistent, and fusible fixture is arranged on water mold between roll by matched in clearance.Fixture locating hole center should be positioned on die cavity center line, aperture 0.5mm larger than consumable nozzle external diameter.
Usually, consumable nozzle length is that barrel length adds about 30cm, is conveniently retained as suitable with welding machine clamp.When consumable nozzle length installs fusible fixture additional more than needing during 1000mm, fusible fixture locating hole center should be positioned on die cavity center line, aperture 0.5mm larger than consumable nozzle external diameter, fusible fixture contact roll place curvature is identical with roll crown curvature, consumable nozzle is downward from place concordant with body of roll top edge, installs a fixture every 400mm.General adjacent consumable nozzle air line distance is about 100mm; Welding wire stretches out consumable nozzle and touches bottom lead-in plate, extension elongation 50 ~ 70mm.For ensureing that molten bath is formed fast, reduce and splash, solder paste thickness is exposed 10mm with welding wire and is advisable.More specifically, consumable nozzle is 50mm apart from endless groove bottom surface distance.Bottom endless groove, solder paste thickness is 40mm.Cavity bottom spreads into solder flux, and for ensureing that molten bath is formed fast, reduce and splash, solder paste thickness exposes 8-12mm with welding wire.
By adopting technique scheme, the present invention has following beneficial effect:
1, make flux-cored wire and consumable nozzle simpler than making bar-shaped alloy electrode technique, cost is lower.
2, there is insulation coating outside consumable nozzle, and have insulation retainer ring, can guarantee that consumable electrode is in die cavity position of center line, ensure forming quality, reduce and control difficulty.
3, flux-cored wire can adjust the alloying component of deposited metal flexibly according to performance requirement, and alloying action is more obvious.
Accompanying drawing explanation
Fig. 1 is the device schematic diagram of existing ESW repaired roller, and local is section.
Fig. 2 is existing ESW repaired roller device schematic top plan view.
Fig. 3 is consumable nozzle electroslag Bead weld repair roll device schematic diagram of the present invention, and local is section.
Fig. 4 is consumable nozzle electroslag Bead weld repair roll device schematic top plan view of the present invention.
Fig. 5 and Fig. 6 is fixture schematic diagram of the present invention.
Fig. 7 is that the present invention assembles lead-in plate place partial schematic diagram.
In figure: 1 is roll to be repaired, 2 is stick electrode of existing ESW device, and cross section can be that circle also can for square, 3 is the present invention's consumable nozzle electrodes used, and 4 is slag baths, and 5 is metal baths, 6 is deposited metals, and 7 is lead-in plates, and 8 is Rotatable bases, 9 is ring-type crystallizers, and 10 is end tabs, 11 sliding sleeves being support and driving crystallizer to move up and down, 12 is slide bars of fixing sliding sleeve 11,13 is fixtures, and 14 is welding wires, and 15 is solder flux.
Detailed description of the invention
Below in conjunction with drawings and Examples, further explanation is explained to this patent.But the protection domain of this patent is not limited to concrete embodiment.
Below in conjunction with instantiation, the present invention is described in further detail, for the experiment parameter do not indicated especially, can refer to normal experiment parameter and carry out.Embodiments of the present invention are not limited to this example, therefore this example is only for explaining the present invention, does not form limiting the scope of the present invention.
As shown in drawings, the method for a kind of consumable nozzle electroslag Bead weld repair roll of this patent, repairs the composite casting steel rider of barrel length 1500mm, barrel diameter 500mm.Reparation step is as follows:
(1) first car goes body of roll fatigue layer and defect, welding lead-in plate and end tab, and breaker roll does conventional treatment before built-up welding.
(2) roll lifting be vertically placed on base, be fixedly clamped, assembling water mold, crystallizer inwall and body of roll outer surface, lead-in plate form endless groove, and in order to the striking slag making of built-up welding incipient stage, groove width is about 50mm.
(3) consumable nozzle and welding wire is assembled in the ring-type die cavity of roll outer surface and crystallizer.The long 2000mm of consumable nozzle, outer diameter D 12mm, internal diameter d4mm, gage of wire 3.2mm.Adjacent consumable nozzle distance about 100mm, need 12 altogether, consumable nozzle is downward from place concordant with body of roll top edge, and install a fixture every 400mm, fixture roll contact face is consistent with roll surface curvature, tight pressing.Consumable nozzle is apart from endless groove bottom surface distance 50mm, and welding wire enters endless groove by consumable nozzle and contacts with bottom surface.
(4) enter solder flux to endless groove middle berth, solder paste thickness is about 40mm, ensures that solder paste thickness is even everywhere.The welding incipient stage suitably tunes up parameter, and formed fast and stablize slag bath, reduce parameter after stable, stabilization sub stage parameter can not arbitrarily be changed.Need to observe slag bath state in welding process and add solder flux in good time, adding principle is on a small quantity repeatedly, avoids once adding too much solder flux and causes slag inclusion.
(5) built-up welding terminates rear removal crystallizer, lead-in plate and end tab, removes the smooth thin slag blanket of facing surface, carries out following process process.
Claims (8)
1. a method for consumable nozzle electroslag Bead weld repair roll, is characterized in that: comprise the following steps:
Step one, car car go body of roll fatigue layer and defect, lead-in plate and end tab are welded to bottom and the bottom of roll, and breaker roll do heap pre-welding treatment;
Described end tab is ring-type, and outer annular diameter is consistent with barrel diameter; Lead-in plate is an annular boss, and boss the first half diameter is consistent with barrel diameter, and boss the latter half diameter is not less than water mold external diameter;
Step 2, by roll lifting be vertically placed on base, be fixedly clamped; Assembling water mold ring-type water mold is sleeved on roll, and built-up welding starts front water mold and lead-in plate lower part surface contact, makes water mold inwall and body of roll outer surface, lead-in plate form endless groove, in order to the striking slag making of built-up welding incipient stage;
Step 3, many consumable nozzles are evenly arranged in endless groove by fusible fixture, and welding wire enters endless groove by consumable nozzle and contacts with bottom surface;
Step 4, enter solder flux to uniform spreading in endless groove; The welding incipient stage suitably tunes up parameter, is formed fast and stablizes slag bath, reduce parameter after stable; Observe slag bath state in welding process and repeatedly add solder flux on a small quantity in good time, avoid once adding too much solder flux and cause slag inclusion;
Step 5, built-up welding terminate rear removal crystallizer, lead-in plate and end tab, remove the smooth thin slag blanket of facing surface, carry out following process process.
2. the method for consumable nozzle electroslag Bead weld repair roll according to claim 1, is characterized in that: described electroslag solder flux mass percent formula is: fluorite: 40% ~ 50%; Marble: 20% ~ 30%%; Quartz: 5% ~ 15%; Corundum 5% ~ 15%; Waterglass 5% ~ 15%; White clay: 5% ~ 15%.
3. the method for consumable nozzle electroslag Bead weld repair roll according to claim 1, is characterized in that: described consumable nozzle is the tubular body of long 2000mm, outer diameter D 12mm, internal diameter d4mm.
4. the method for consumable nozzle electroslag Bead weld repair roll according to claim 1, is characterized in that: the spacing of described adjacent consumable nozzle in endless groove is 80--120mm.
5. the method for consumable nozzle electroslag Bead weld repair roll according to claim 1, it is characterized in that: curvature and the roll surface curvature of described fusible fixture and the contact surface of roll are consistent, and fusible fixture is arranged on water mold between roll by matched in clearance.
6. the method for consumable nozzle electroslag Bead weld repair roll according to claim 5, is characterized in that: described fixture locating hole center should be positioned on die cavity center line, aperture 0.5mm larger than consumable nozzle external diameter.
7. the method for consumable nozzle electroslag Bead weld repair roll according to claim 1, is characterized in that: described consumable nozzle is 50mm apart from endless groove bottom surface distance.
8. the method for consumable nozzle electroslag Bead weld repair roll according to claim 1, is characterized in that: bottom described endless groove, solder paste thickness is 40mm.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201510947821.0A CN105414743A (en) | 2015-12-17 | 2015-12-17 | Consumable nozzle electroslag overlaying welding repair method for roll |
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| CN201510947821.0A CN105414743A (en) | 2015-12-17 | 2015-12-17 | Consumable nozzle electroslag overlaying welding repair method for roll |
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Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN109604565A (en) * | 2018-12-24 | 2019-04-12 | 湖南三泰新材料股份有限公司 | A kind of device and preparation method of electroslag melting stainless steel composite base |
| CN109759802A (en) * | 2019-03-28 | 2019-05-17 | 二重（德阳）重型装备有限公司 | The support rim processing method of pressure vessel shell ring |
| CN114619019A (en) * | 2022-03-08 | 2022-06-14 | 朱龙华 | Equipment and process for compositely (re) manufacturing metallurgical roller by electroslag remelting and surfacing |
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Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN109604565A (en) * | 2018-12-24 | 2019-04-12 | 湖南三泰新材料股份有限公司 | A kind of device and preparation method of electroslag melting stainless steel composite base |
| CN109759802A (en) * | 2019-03-28 | 2019-05-17 | 二重（德阳）重型装备有限公司 | The support rim processing method of pressure vessel shell ring |
| CN114619019A (en) * | 2022-03-08 | 2022-06-14 | 朱龙华 | Equipment and process for compositely (re) manufacturing metallurgical roller by electroslag remelting and surfacing |
| CN114619019B (en) * | 2022-03-08 | 2023-06-23 | 朱龙华 | Equipment and process for manufacturing metallurgical roller by electroslag remelting and surfacing compound (re) method |
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Application publication date: 20160323 |