CN108546847B - Ultrahigh-strength large-diameter steel wire main cable strand anchoring material and anchoring method - Google Patents
Ultrahigh-strength large-diameter steel wire main cable strand anchoring material and anchoring method Download PDFInfo
- Publication number
- CN108546847B CN108546847B CN201810438786.3A CN201810438786A CN108546847B CN 108546847 B CN108546847 B CN 108546847B CN 201810438786 A CN201810438786 A CN 201810438786A CN 108546847 B CN108546847 B CN 108546847B
- Authority
- CN
- China
- Prior art keywords
- alloy
- casting
- steel wire
- rare earth
- anchoring
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Active
Links
Images
Classifications
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C18/00—Alloys based on zinc
- C22C18/04—Alloys based on zinc with aluminium as the next major constituent
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/02—Making non-ferrous alloys by melting
- C22C1/03—Making non-ferrous alloys by melting using master alloys
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C18/00—Alloys based on zinc
- C22C18/02—Alloys based on zinc with copper as the next major constituent
-
- E—FIXED CONSTRUCTIONS
- E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
- E01D—CONSTRUCTION OF BRIDGES, ELEVATED ROADWAYS OR VIADUCTS; ASSEMBLY OF BRIDGES
- E01D19/00—Structural or constructional details of bridges
- E01D19/16—Suspension cables; Cable clamps for suspension cables ; Pre- or post-stressed cables
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Reinforcement Elements For Buildings (AREA)
Abstract
The invention relates to an ultra-high strength major diameter steel wire main cable strand anchoring material and an anchoring method, wherein the anchoring compactness of the anchoring material is not more than 95%, and is improved by 3% compared with the compactness of a traditional hot cast anchor; the retraction value of the alloy casting body after the anchorage device is jacked is not more than 5mm, the depth of the alloy poured into the steel wire bundle after the casting body is dissected can reach 3/4 of the cone section of the anchorage device, and the casting body is not provided with shrinkage cavities. The anchoring material has good fluidity, the anchoring efficiency reaches 100%, the bond length of the steel wire is improved, and favorable conditions are provided for reducing the anchoring length of the high-strength large-diameter steel wire rope strand and reducing the size of the anchor.
Description
Technical Field
The invention relates to a steel wire main cable strand anchor, in particular to an anchor tank material and an anchor tank method for an ultrahigh-strength steel wire strand.
Background
The main cable strand is the main stressed structure of the suspension bridge, and the steel wire is the basic stressed element of the main cable strand. If the suspension bridge adopts a major diameter high-strength steel wire main cable strand with the diameter phi of between 6mm and 2060MPa, the suspension bridge has the following advantages: 1) the number of the cable strands is reduced, the space used for anchoring is reduced, and the scale of the anchorage is reduced; 2) the contact area between the steel wire and the air is reduced, and the corrosion resistance of the main cable is improved; 3) the overall volume ratio of the zinc-aluminum alloy coating or the zinc coating to the plain steel wire in the main cable is reduced by about 60%, the influence of zinc-aluminum alloy, pure zinc creep and other factors on the cable clamp of the main cable is reduced, and the anti-sliding capacity of the cable clamp is improved. However, in the case of the large-diameter steel wire, since the strength is increased and the contact area between the steel wire and the casting material is reduced, the bond length (empirical value) of the bundle of steel wires has not been able to satisfy the above requirements, and thus it is necessary to increase the bond length between the large-diameter steel wire and the casting material to ensure the anchoring reliability of the strand.
Under the condition that the main cable strand body and the anchorage assembly are qualified, the anchoring reliability of the hot-cast anchor cable is determined by the anchoring material and the casting process of the hot-cast anchor.
(1) The hot cast anchor is cast by using hot melt alloy, and the cast alloy has the advantages of good mechanical property, good casting property, small creep deformation, strong adhesion or bonding strength to steel wires and lower melting point.
(2) For large-size strands with the diameter phi of 6mm-2060MPa, the anchorage is longer than that of the traditional strands, so that the cast alloy is required to have good fluidity so as to ensure that the steel wires in the anchorage are filled with the cast material as far as possible and realize the anchoring reliability.
(3) For ultra-high strength large diameter wire strands, the corresponding anchoring length is increased due to the increased strand strength, in which case the conventional casting material is a zinc-copper alloy (c: (b))The components are 98 percent of zinc and 2 percent of copper, and the casting temperature is as follows: 460 degree To 480 degree. ) When the steel wire is cast, the molten alloy does not flow to the lower half part of the steel wire and seeps into the tiny gaps among the steel wires, and the liquid alloy is quickly solidified into solid, so that the effective bond length between the steel wire bundle and the alloy is reduced, and the compactness cannot meet the requirement. If the method of increasing the fluidity of the molten alloy by increasing the casting temperature of the molten alloy is adopted, the temperature increase is limited, a large casting shrinkage hole is generated due to the temperature increase, the relative performance of the high-strength steel wire is influenced by the overhigh temperature, and the implementation difficulty is high.
Based on the above current situation, the development of an anchoring material for an ultra-high strength and large diameter steel wire main cable strand is a problem to be solved by those skilled in the art.
Disclosure of Invention
The invention aims to provide a novel zinc-based multi-element alloy hot-cast anchor anchoring material, which ensures the strength and the fluidity of a casting material, ensures that the casting material flows rapidly within a limited time, fully flows into the gaps of steel wire bundles in a high-strength cable anchor and is fully fused with the steel wire bundles, and realizes the reliable anchoring of a main steel wire cable with ultrahigh strength and large diameter.
The technical scheme adopted by the invention for solving the problems is as follows: the main steel wire cable strand anchoring material has anchoring compactness not higher than 95% and 3% higher than that of traditional hot cast anchor; the retraction value of the alloy casting body after the anchorage device is jacked is not more than 5mm, the depth of the alloy poured into the steel wire bundle after the casting body is dissected can reach 3/4 of the cone section of the anchorage device, and the casting body is not provided with shrinkage cavities.
The chemical components of the material comprise one of the following formulas in percentage by mass:
one of the formulas is as follows: 5.0-6.0% of Al, 1.2-1.6% of Cu, 0-0.005% of Mg and the balance of zinc, wherein the casting temperature is as follows: 430 ℃ to 450 ℃;
the second formula is as follows: 2.0-5.0% of Al (not including 5.0%), 1.6-2.0% of Cu (not including 1.6%), 0.001-0.005% of Mg0.001-0.2% of rare earth element, and the balance of Zn, wherein the magnesium element and the rare earth element in the formula can be added simultaneously or selectively, and the casting temperature is as follows: 440 ℃ to 460 ℃;
the third formula is as follows: 0.1-0.5% of Al, 1.8-2.2% of Cu, 0.001-0.10% of rare earth elements and the balance of zinc, wherein the casting temperature is as follows: 445 ℃ to 465 ℃.
Preferably, in the second formula, the rare earth element and Mg can be added simultaneously or selectively.
Preferably, according to the size of the anchorage device, Bi can be added into chemical components of the anchorage device to improve the fluidity of the alloy, the addition amount of Bi is 0-0.1%, the addition of Bi in zinc liquid can obviously reduce the surface tension of a zinc bath, so that the fluidity of the zinc bath is further improved, but the addition amount of Bi is not high enough, the cost is increased, the expansion phenomenon can influence the compactness during solidification, and the micro-pores of the anchoring material are easily caused, so the content of Bi cannot exceed 0.1%, and the addition amount is reduced as much as possible on the premise of meeting the fluidity.
Preferably, the rare earth elements are La and Ce, the performance is stable, and the rare earth elements have good compatibility with zinc base.
Furthermore, the elements are not added independently, but are added in the form of alloy, and the raw materials are selected from Zn-Cu alloy, Zn-Al alloy, Mg and rare earth elements which are selectively added in the forms of Zn-Al10% -Mg-rare earth, Zn-Al15% -Mg-rare earth and Zn-Al30% -Mg-rare earth alloy ingots according to the fluidity condition of the alloy in actual production.
Further, the Zn-Al alloy may be selected from one or more of Zn-Al10%, Zn-Al15% and Zn-Al30% depending on Al content.
The chemical composition of the present application is further illustrated in the following principle:
the hot cast anchor is made of zinc base alloy. Zinc, when unalloyed, is a softer metal having greater strength and hardness values than tin and lead, but less than aluminum and copper. Some other alloy elements are required to be added into zinc to improve the comprehensive performance of the zinc, for example, the zinc-aluminum alloy added with the aluminum element has the characteristics of low melting point, less melting energy consumption, good fluidity and the like, and is very suitable for forming and processing by adopting the modern die-casting technology. The rare earth elements can obviously refine the dendritic crystal and improve the tensile strength and the hardness of the alloy. The proper amount of rare earth elements has the functions of fine grains and impurity removal, and can effectively improve the comprehensive mechanical property of the alloy. The effects of the respective alloying elements are as follows.
1) Effect of aluminum
Al is a main alloy element of the zinc-aluminum alloy, is closely related to microstructure, fluidity, mechanical property and corrosion resistance of the alloy, can obviously improve the fluidity of the alloy, improve the casting property of the alloy and improve the casting and filling capacity of the alloy, can effectively refine crystal grains, generate solid solution strengthening and improve the comprehensive mechanical property of the alloy, and can improve the alloy structure and the strength and the mechanical property of an alloy ingot. The better the fluidity of the zinc-aluminum alloy is, the shrinkage cavities generated in the solidification process are more easily fed, the probability of generated hot cracks is reduced, the tendency of forming cold shut on the surface of a casting is reduced, and the method is very important for obtaining a compact and high-quality casting. Therefore, aluminum element is added into the anchor pouring material, casting body crystal grains can be refined, casting body strength is improved, meanwhile, the fluidity of the pouring alloy is improved due to the addition of the aluminum element, alloy melt can flow to the lower half portion of the steel wires when the pouring material is poured, the alloy melt can fully penetrate into small gaps among the steel wires, and anchoring reliability is improved.
2) Action of copper
In the zinc-based alloy, copper is one of the main strengthening elements in the alloy, and the function of the copper is mainly expressed in the following aspects: firstly, solid solution strengthening; second, formation of intermetallic compounds (CuZn 4): thirdly, the eutectoid transformation speed is slowed down. The copper can be dissolved in the aluminum-rich phase and the zinc-rich phase, so that the alloy generates solid solution strengthening, the tensile strength and the hardness of the alloy are improved, and the intercrystalline corrosion resistance and the high-temperature creep property of the alloy can also be improved. However, since copper can inhibit the eutectoid transformation of zinc-aluminum alloy, the eutectoid transformation is difficult to be fully performed during the cooling process of the casting, so that the excessive copper can cause the size of the alloy casting to be unstable.
3) Effect of magnesium
Magnesium has a low solubility in pure zinc, but even a trace amount of magnesium can perform the functions of solid solution strengthening, and strength and hardness improvement. Meanwhile, the magnesium can prevent intergranular corrosion and delay eutectoid transformation of the zinc-aluminum alloy. The magnesium content of the zinc-aluminum alloy is low, and the excessively high magnesium content can reduce the plasticity and creep strength of the alloy. For the hot cast anchor pouring casting material for the main steel wire cable strand with ultrahigh strength and large diameter, the content of magnesium is controlled to be below 0.005 percent.
4) Action of rare earth elements
The rare earth elements have strong absorption and combination ability with hydrogen and nitrogen at higher temperature, so the rare earth elements are used as additives of steel and nonferrous metal alloys, can remove impurities such as hydrogen, helium and the like, purify metal bath and improve the flow property of metal in a molten state; on the other hand, rare earth easily reacts with O and S to form stable oxides and sulfides, and the particles can serve as a substrate for heterogeneous nucleation and can inhibit grain growth during solidification, thereby playing a role in refining the alloy structure. In the process of anchor filling of the main cable strand of the main cable of the suspension bridge, ladles and the like continuously enter and exit in molten zinc liquid, so that part of zinc is inevitably oxidized into zinc oxide, and impurities are also inevitably brought in. After rare earth elements are added into a zinc bath, partial rare earth quickly carries out a displacement reaction with zinc oxide to form rare earth oxide which is suspended on the surface of zinc liquid, so that zinc on the surface of the zinc liquid is prevented from being oxidized by contacting with air, the oxidation loss of the zinc is reduced, and about 1/4 is reduced (the effect is particularly the most prominent effect of La and Ce).
Most importantly, the viscosity of the purified zinc bath is reduced, so that the flow speed of zinc liquid among the steel wire bundles after the zinc liquid is discharged is increased, the zinc liquid flows rapidly in the irrigation process, the steel wire bundle gaps in the anchorage device can be filled as far as possible within a limited time, the effective bond length of the high-strength steel wire cable strand is increased, the anchor irrigation porosity is reduced, and the anchoring reliability is improved. Based on the reasons, a small amount of rare earth is added into the casting alloy of the hot-cast anchor, so that the anchoring reliability of the cable strand can be improved, the loss of the casting alloy is greatly reduced, and the cost of the casting alloy of the anchor is reduced. However, since the atomic radius of rare earth is much larger than that of zinc, and the rare earth has very low solubility in the plating solution, it is easy to gather and float on the surface of the alloy melt. For the hot cast anchor pouring casting material for the ultrahigh-strength and large-diameter steel wire main cable strand, the rare earth content is controlled to be below 0.1 percent, particularly below 0.1 percent.
The invention also aims to provide an anchor pouring method of the main cable strand of the ultrahigh-strength large-diameter steel wire, which comprises the following steps of (1) putting an alloy ingot smelted according to the formula into a heating furnace for melting to form an alloy melt: according to theoretical calculation, Zn-Cu2%, Zn-Al10%, Zn-Al15% and Zn-Al30% alloy ingots are matched according to a certain proportion, put into a heating furnace, heated, melted and fully stirred; mg and rare earth elements are selectively added in the form of Zn-Al10% -Mg-rare earth, Zn-Al15% -Mg-rare earth and Zn-Al30% -Mg-rare earth alloy ingots according to the fluidity condition of the alloy in actual production; measuring whether each element in the molten liquid meets the design requirement after stirring, if not, finely adjusting the alloy components by adding related alloy ingots until the components of the molten liquid meet the related requirements;
(2) mounting an anchorage device on a strand, separating steel wires in the anchorage device to form a broom shape (a conical divergent shape), heading a part of the steel wires, wherein the diameter of the heading is not less than 1.4 times of the diameter of the steel wires, the height of the heading is not less than the diameter of the steel wires, and a wire separating plate with the thickness of 1.5-3 mm can be selected to ensure uniform wire separation of the strand;
(3) adopting high-temperature resistant materials to perform leak stoppage and sealing on the bottom of the anchorage device, and preheating a ladle so that the temperature of the ladle is not lower than half of the temperature of the alloy molten liquid;
(4) pouring casting, wherein the anchorage device is knocked during pouring casting, gas in the alloy melt is discharged, gas is prevented from being introduced during pouring casting, and the compactness of the alloy is improved;
(5) after the alloy is poured and cast, a shrinkage hole is formed, so that not only the strength but also the appearance are influenced, therefore, the filling is required, and the alloy in the shrinkage hole is selected to reach the initial setting state;
(6) and cooling the casting alloy, cooling to below 80 ℃, and detaching the anchorage device from the anchor pouring frame for jacking.
Compared with the prior art, the invention has the advantages that:
1) the anchoring compactness of the anchor of the ultrahigh-strength large-diameter steel wire rope strand with the diameter of more than 127-6mm-2060MPa reaches more than 95 percent, and is improved by 3 percent compared with the compactness of the traditional hot cast anchor.
2) The retraction value of the alloy casting body after being jacked is not more than 5mm, the depth of the alloy poured into the steel wire bundle after the casting body is dissected can reach 3/4 of the anchor device conical section, and the casting body is not provided with shrinkage cavities.
3) The casting temperature is 10 to 20 ℃ lower than that of the traditional hot casting anchor, the energy is saved, and the influence of overhigh casting temperature on the performance of the high-strength steel wire is avoided.
4) For the ultrahigh-strength large-diameter steel wire rope strand with the diameter of more than 127-6mm-2060MPa, the anchoring efficiency reaches more than 100 percent, namely, the alloy casting body does not crack or break under the nominal breaking load of the rope strand, and the steel wire is not pulled out.
5) On the basis of improving the effective bond length of alloy and high strength steel wire above, for reducing high strength major diameter steel wire rope strand anchor length, reduce the ground tackle size and provide the advantage, under the prerequisite that reaches the same bond length promptly, the anchor length that this application was reserved compares and adopts the required anchor length of reserving of other anchor materials shorter, and then can reduce the size of ground tackle.
Drawings
FIG. 1 is a schematic illustration of a main cable strand prepared prior to anchor placement in an embodiment of the invention;
FIG. 2 is a schematic structural view of an upset head wire in an embodiment of the invention;
FIG. 3 is a schematic structural view of an end face of a filament separating plate according to an embodiment of the present invention;
FIG. 4 is a schematic view of the main cable strand after the anchor is grouted.
1 heading steel wire, 2 wire separating plates, 3 main cable steel wires and 4 main cable strands.
Detailed Description
The invention is described in further detail below with reference to the accompanying examples.
Example 1
The embodiment relates to an anchoring material for anchoring the end part of an ultrahigh-strength large-diameter steel wire main cable strand with the pressure of more than 6mm-2060MPa, which comprises the chemical components of 3.5 percent of Al, 1.8 percent of Cu, 0.002 percent of Mg and 0.005 percent of rare earth element by mass percent, and the casting temperature is controlled within the range of 440 ℃ to 460 ℃. The rare earth element is selected from La and Ce.
The method for grouting the main steel wire cable strand into the anchor comprises the following steps
(1) Putting the alloy ingot smelted according to the formula into a heating furnace for melting to form alloy melt: according to theoretical calculation, Zn-Cu2%, Zn-Al10%, Zn-Al15% and Zn-Al30% alloy ingots are matched according to a certain proportion, put into a heating furnace, heated, melted and fully stirred; mg and rare earth elements are selectively added in the form of Zn-Al10% -Mg-rare earth, Zn-Al15% -Mg-rare earth and Zn-Al30% -Mg-rare earth alloy ingots according to the fluidity condition of the alloy in actual production; measuring whether each element in the molten liquid meets the design requirement after stirring, if not, finely adjusting the alloy components by adding related alloy ingots until the components of the molten liquid meet the related requirements;
(2) mounting an anchorage device on a strand, separating steel wires in the anchorage device to form a broom shape, dispersing the steel wires of the strand, selectively heading part of the steel wires, wherein the diameter of the heading is not less than 1.4 times of the diameter of the steel wires, the height of the heading is not less than the diameter of the steel wires, using a wire separating plate with the thickness of 1.5mm to ensure uniform wire separation of the strand, arranging an exhaust channel on the wire separating plate to ensure the exhaust of gas in the casting process, and avoiding the gas from entering an anchoring material to form a shrinkage cavity;
(3) adopting high-temperature resistant materials to perform leak stoppage and sealing on the bottom of the anchorage device, and preheating a ladle so that the temperature of the ladle is not lower than half of the temperature of the alloy melt, wherein the casting temperature of the alloy melt is 440-460 ℃;
(4) pouring casting, wherein the anchorage device is knocked by a wooden hammer in pouring casting, gas in the alloy melt is discharged, gas is prevented from being introduced in the process of pouring casting, and the compactness of the alloy is improved;
(5) forming a shrinkage hole after the alloy is poured and cast, and therefore performing filling, wherein the alloy in the shrinkage hole is selected to reach an initial setting state when filling is performed;
(6) and cooling the casting alloy, cooling to below 80 ℃, and detaching the anchorage device from the anchor pouring frame for jacking.
The implementation effect is as follows: the operation is repeated for more than 10 times, the anchoring efficiency reaches 100 percent, the anchoring compactness reaches more than 95 percent, the retraction value of the alloy casting body after jacking is below 5mm, the depth of the alloy poured into the steel wire bundle reaches 3/4 of the anchor device cone section after the casting body is dissected, and no shrinkage cavity is formed on the casting body (for the traditional anchoring material, the fluidity is poor, in order to reach the bond length required by design, the longer reserved anchoring length is needed to realize that the depth of the casting body poured into the anchor device accounts for the smaller proportion of the length of the anchor device cone section, even if the method is realized reluctantly, the casting body is looser and the compactness is insufficient).
Example 2
The embodiment relates to an anchoring material for anchoring the end part of an ultrahigh-strength large-diameter steel wire main cable strand with the pressure of more than 60mm-2060MPa, which comprises the following chemical components in percentage by mass of 0.4% of Al, 2.0% of Cu, 0.08% of rare earth elements and the balance of zinc, wherein the casting temperature is as follows: 445 deg.C to 465 deg.C, rare earth element selected from La and Ce.
The method for grouting the main steel wire cable strand into the anchor comprises the following steps
(1) Putting the alloy ingot smelted according to the formula into a heating furnace for melting to form alloy melt: according to theoretical calculation, Zn-Cu2%, Zn-Al10%, Zn-Al15% and Zn-Al30% alloy ingots are matched according to a certain proportion, put into a heating furnace, heated, melted and fully stirred; the rare earth elements are selectively added in the forms of Zn-Al10% -rare earth, Zn-Al15% -rare earth and Zn-Al30% -rare earth alloy ingots according to the fluidity condition of the alloy in actual production; and measuring whether each element in the molten liquid meets the design requirement after stirring, and if not, finely adjusting the alloy components by adding related alloy ingots until the molten liquid components meet the related requirements.
(2) Install the ground tackle on the strand, with the steel wire in the ground tackle separately form "broom" form, let the strand steel wire be the dispersion form, can choose to carry out the upset with some steel wires, the upset diameter is not less than 1.4 times of steel wire diameter, the upset height is not less than the steel wire diameter, use the branch silk board that thickness is 3.2mm, guarantee that the strand divides the silk even, set up exhaust passage on the branch silk board, guarantee the gaseous exhaust of casting in-process, avoid gaseous formation shrinkage cavity in getting into the anchor material.
(3) And (3) adopting high-temperature resistant materials to perform leak stoppage and sealing on the bottom of the anchorage device, and preheating the ladle to ensure that the temperature of the ladle is not lower than half of the temperature of the alloy melt, and the casting temperature of the alloy melt is 445-465 ℃.
(4) Pouring casting, beating the anchorage device with a rubber hammer in pouring casting, discharging gas in the alloy melt, preventing gas from being introduced in the pouring casting process, and improving the compactness of the alloy.
(5) And (4) forming a shrinkage hole after the alloy is poured and cast, and performing filling under the condition that the alloy in the shrinkage hole reaches the initial setting, wherein the filling operation is the same as the step 4.
(6) And cooling the casting alloy, cooling to below 80 ℃, and detaching the anchorage device from the anchor pouring frame for jacking.
The implementation effect is as follows: the operation is repeated for more than 10 times, the anchoring efficiency reaches 100%, the anchoring filling compactness reaches more than 95%, the retraction value of the alloy casting body after jacking is within the range of 3-5 mm, the depth of the alloy poured into the steel wire bundle reaches 3/4 of the anchor device cone section after the casting body is dissected, no shrinkage cavity is formed on the casting body, and the design requirement is met.
Example 3
The embodiment relates to an anchoring material for anchoring the end part of a main cable strand of an ultrahigh-strength large-diameter steel wire with the pressure of more than 100mm-2060MPa, which comprises the following chemical components in percentage by mass of 5.5% of Al, 1.4% of Cu, 0.005% of Mg, 0.001% of Bi0, and the balance of zinc, wherein the casting temperature is as follows: 430 ℃ to 450 ℃.
The method for grouting the main steel wire cable strand into the anchor comprises the following steps
(1) Putting the alloy ingot smelted according to the formula into a heating furnace for melting to form alloy melt: according to theoretical calculation, Zn-Cu2%, Zn-Al10%, Zn-Al15% and Zn-Al30% alloy ingots are matched according to a certain proportion, put into a heating furnace, heated, melted and fully stirred; mg is selectively added in the form of Zn-Al10% -Mg, Zn-Al15% -Mg and Zn-Al30% -Mg alloy ingots; bi is selectively added in the form of Zn-Al10% -Bi, Zn-Al15% -Bi and Zn-Al30% -Bi alloy ingots; and measuring whether each element in the molten liquid meets the design requirement after stirring, and if not, finely adjusting the alloy components by adding related alloy ingots until the molten liquid components meet the related requirements.
(2) Install the ground tackle on the strand, with the steel wire in the ground tackle separately form "broom" form, let the strand steel wire be the dispersion form, can choose to carry out the upset with some steel wires, the upset diameter is not less than 1.4 times of steel wire diameter, the upset height is not less than the steel wire diameter, use the branch silk board that thickness is 3.2mm, guarantee that the strand divides the silk even, set up exhaust passage on the branch silk board, guarantee the gaseous exhaust of casting in-process, avoid gaseous formation shrinkage cavity in getting into the anchor material.
(3) And (3) adopting high-temperature resistant materials to perform leak stoppage and sealing on the bottom of the anchorage device, and preheating the ladle to ensure that the temperature of the ladle is not lower than half of the temperature of the alloy melt, and the casting temperature of the alloy melt is 445-465 ℃.
(4) Pouring casting, beating the anchorage device with a rubber hammer in pouring casting, discharging gas in the alloy melt, preventing gas from being introduced in the pouring casting process, and improving the compactness of the alloy.
(5) And (4) forming a shrinkage hole after the alloy is poured and cast, and performing filling under the condition that the alloy in the shrinkage hole reaches the initial setting, wherein the filling operation is the same as the step 4.
(6) And cooling the casting alloy, cooling to below 80 ℃, and detaching the anchorage device from the anchor pouring frame for jacking.
The implementation effect is as follows: repeating the operation for more than 10 times, wherein the anchoring efficiency reaches 100 percent, the anchoring filling compactness reaches more than 95 percent, the retraction value of the alloy casting body after jacking is within 5mm, the depth of the alloy poured into the steel wire bundle reaches 3/4 of the anchor device cone section after the casting body is dissected, no shrinkage cavity is formed on the casting body, and the design requirement is met.
Comparative example 1
The anchoring material is designed for anchoring the end part of the main cable strand of the steel wire with the ultrahigh strength and the large diameter of more than 60mm-2060MPa, and comprises the chemical components of 0.3 percent of Al, 1.8 percent of Cu and rare earth elements in percentage by mass0.2～ 0.25％The balance of zinc, and the casting temperature: 445 deg.C to 465 deg.C, rare earth element selected from La and Ce.
The operation procedure of the anchor grouting method is exactly the same as that of example 2.
The implementation effect is as follows: repeating the operation for more than 5 times, wherein the rare earth element fluctuates in the range every time, the anchoring efficiency reaches 100%, the anchoring compactness reaches 95% only four times, the retraction value of the alloy casting body after jacking is within 5mm, the ratio of the depth of the alloy poured into the steel wire bundle after the casting body is dissected to the total length of the anchor cone section is 0.6-0.7, and the casting body occasionally has a shrinkage hole.
That is, when the content of the rare earth element added is too high, the fluidity is rather deteriorated, because the rare earth element has low solubility in the matrix, and once the content is too high, the rare earth aggregates and floats on the surface of the alloy solution, the reactivity is rather reduced, the zinc oxide cannot be reduced in time, the purification effect is poor, the viscosity of the zinc bath is high, and the flow speed of the zinc bath between the steel wire bundles after the zinc bath is discharged is slow.
Comparative example 2
The anchoring material is designed for anchoring the end part of the main cable strand of the ultrahigh-strength large-diameter steel wire with the diameter of more than 6mm-2060MPa, and comprises the chemical components of 3.0 percent of Al, 2.0 percent of Cu, 0.007 percent of Mg and 0.005 percent of rare earth element in percentage by mass, and the casting temperature is controlled within the range of 440 ℃ to 460 ℃. The rare earth element is selected from La and Ce.
The operation procedure of the anchor grouting method is exactly the same as that of example 1.
The implementation effect is as follows: the anchoring compactness reaches 95%, the retraction value of the alloy casting body after jacking is within 5mm, the depth of the alloy poured into the steel wire bundle reaches 3/4 of the anchor cone section after the casting body is dissected, no shrinkage cavity is formed on the casting body, and the alloy casting body is cracked and partially crushed under the nominal breaking load of the cable strand.
When the addition content of Mg is too high, the too high magnesium can reduce the plasticity of the alloy, is easy to break and crack, and cannot adapt to the anchor filling of the main cable strand with high strength and ultrahigh strength.
In addition to the above embodiments, the present invention also includes other embodiments, and any technical solutions formed by equivalent transformation or equivalent replacement should fall within the scope of the claims of the present invention.
Claims (5)
1. An anchor grouting method for main steel wire cable strands with ultrahigh strength and large diameter is characterized by comprising the following steps: comprises the following steps
(1) Putting the alloy ingot smelted according to the formula into a heating furnace for melting to form alloy melt: according to theoretical calculation, Zn-Cu2%, Zn-Al10%, Zn-Al15% and Zn-Al30% alloy ingots are matched according to a certain proportion, put into a heating furnace, heated, melted and fully stirred; mg and rare earth elements are selectively added in the form of Zn-Al10% -Mg-rare earth, Zn-Al15% -Mg-rare earth and Zn-Al30% -Mg-rare earth alloy ingots according to the fluidity condition of the alloy in actual production; measuring whether each element in the molten liquid meets the design requirement after stirring, and if not, adding related alloy ingots to carry out fine adjustment on the alloy components until the components of the molten liquid meet the related requirements;
(2) mounting an anchorage device on a strand, separating steel wires in the anchorage device to form a broom shape, namely a conical divergence shape, heading a part of the steel wires, wherein the diameter of the heading is not less than 1.4 times of the diameter of the steel wires, the height of the heading is not less than the diameter of the steel wires, selecting a wire separating plate with the thickness of 1.5-3 mm, ensuring uniform wire separation of the strand, arranging an exhaust channel on the wire separating plate, ensuring gas exhaust in the casting process, and avoiding the formation of shrinkage cavities;
(3) adopting high-temperature resistant materials to perform leak stoppage and sealing on the bottom of the anchorage device, and preheating a ladle so that the temperature of the ladle is not lower than half of the temperature of the alloy molten liquid;
(4) pouring casting, wherein the anchorage device is knocked during pouring casting, gas in the alloy melt is discharged, gas is prevented from being introduced during pouring casting, and the compactness of the alloy is improved;
(5) after the alloy is poured and cast, a shrinkage hole is formed, so that not only the strength but also the appearance are influenced, therefore, the filling is required, and the alloy in the shrinkage hole is selected to reach the initial setting state;
(6) cooling the casting alloy, and after cooling to below 80 ℃, detaching the anchorage device from the anchor pouring frame for jacking;
one of the formulas of the alloy melt in the step 1 is as follows: 5.0-6.0% of Al, 1.2-1.6% of Cu, 0-0.005% of Mg and the balance of zinc, wherein the casting temperature is as follows: 430 ℃ to 450 ℃;
the second formula is as follows: 2.0-5.0% of Al, 1.6-2.0% of Cu, 0.001-0.005% of Mg, 0.001-0.2% of rare earth elements and the balance of zinc, wherein the casting temperature is as follows: 440 ℃ to 460 ℃;
the third formula is as follows: 0.1-0.5% of Al, 1.8-2.2% of Cu, 0.001-0.10% of rare earth elements and the balance of zinc, wherein the casting temperature is as follows: 445 ℃ to 465 ℃.
2. The method for grouting the main cable strand of the ultra-high strength large-diameter steel wire cable according to claim 1, wherein: the rare earth elements are La and Ce.
3. The method for grouting the main cable strand of the ultra-high strength large-diameter steel wire cable according to claim 1, wherein: the raw materials are selected from Zn-Cu alloy, Zn-Al alloy, Mg and rare earth elements, and are selectively added in the forms of Zn-Al10% -Mg-rare earth, Zn-Al15% -Mg-rare earth and Zn-Al30% -Mg-rare earth alloy ingots according to the fluidity condition of the alloy in actual production.
4. The method for grouting the main cable strand of the ultra-high strength large-diameter steel wire cable according to claim 3, wherein: the Zn-Al alloy is selected from one or more of Zn-Al10%, Zn-Al15% and Zn-Al30% according to different Al contents.
5. The method for grouting the main cable strand of the ultra-high strength large-diameter steel wire cable according to claim 1, wherein: the anchor filling compactness reaches over 95 percent and is improved by 3 percent compared with the traditional hot cast anchor device; the retraction value of the alloy casting body after the anchorage device is jacked is not more than 5mm, the depth of the alloy poured into the steel wire bundle after the casting body is dissected can reach 3/4 of the cone section of the anchorage device, and no shrinkage cavity is formed in the casting body.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201810438786.3A CN108546847B (en) | 2018-05-09 | 2018-05-09 | Ultrahigh-strength large-diameter steel wire main cable strand anchoring material and anchoring method |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201810438786.3A CN108546847B (en) | 2018-05-09 | 2018-05-09 | Ultrahigh-strength large-diameter steel wire main cable strand anchoring material and anchoring method |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN108546847A CN108546847A (en) | 2018-09-18 |
| CN108546847B true CN108546847B (en) | 2020-03-10 |
Family
ID=63494494
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN201810438786.3A Active CN108546847B (en) | 2018-05-09 | 2018-05-09 | Ultrahigh-strength large-diameter steel wire main cable strand anchoring material and anchoring method |
Country Status (1)
| Country | Link |
|---|---|
| CN (1) | CN108546847B (en) |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN114192745B (en) * | 2021-11-05 | 2023-05-26 | 江苏法尔胜缆索有限公司 | Main cable strand anchor filling method for suspension bridge |
Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP4000339B2 (en) * | 2003-08-11 | 2007-10-31 | Ｄｏｗａメタルマイン株式会社 | Zn alloy for die casting and Zn alloy die casting product |
| CN101437970A (en) * | 2006-03-31 | 2009-05-20 | 同和金属矿业有限公司 | Diecasting Zn alloy, process for production thereof, and Al master alloy for diecasting alloy |
| CN101935815A (en) * | 2010-09-01 | 2011-01-05 | 中国电力科学研究院 | Transmission line fastening piece alloy coating and preparation process thereof |
| CN102011029A (en) * | 2010-12-08 | 2011-04-13 | 宁波博威合金材料股份有限公司 | Zinc alloy for zipper tooth belt and preparation method of zipper tooth belt |
| CN105862592A (en) * | 2016-04-13 | 2016-08-17 | 江苏法尔胜缆索有限公司 | Manufacturing method of hot extrusion polyethylene zinc-aluminum alloy coating steel wire cable |
-
2018
- 2018-05-09 CN CN201810438786.3A patent/CN108546847B/en active Active
Patent Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP4000339B2 (en) * | 2003-08-11 | 2007-10-31 | Ｄｏｗａメタルマイン株式会社 | Zn alloy for die casting and Zn alloy die casting product |
| CN101437970A (en) * | 2006-03-31 | 2009-05-20 | 同和金属矿业有限公司 | Diecasting Zn alloy, process for production thereof, and Al master alloy for diecasting alloy |
| CN101935815A (en) * | 2010-09-01 | 2011-01-05 | 中国电力科学研究院 | Transmission line fastening piece alloy coating and preparation process thereof |
| CN102011029A (en) * | 2010-12-08 | 2011-04-13 | 宁波博威合金材料股份有限公司 | Zinc alloy for zipper tooth belt and preparation method of zipper tooth belt |
| CN105862592A (en) * | 2016-04-13 | 2016-08-17 | 江苏法尔胜缆索有限公司 | Manufacturing method of hot extrusion polyethylene zinc-aluminum alloy coating steel wire cable |
Also Published As
| Publication number | Publication date |
|---|---|
| CN108546847A (en) | 2018-09-18 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| RU2550063C2 (en) | Cable material based on aluminium alloy with high degree of elongation, and method for its obtaining | |
| CN100335666C (en) | High-strength cast Mg alloy containing rare-earth and preparing process thereof | |
| US9033025B2 (en) | Aluminium-copper alloy for casting | |
| WO2006016614A1 (en) | Master alloy for use in modifying copper alloy and casting method using the same | |
| CN110512051A (en) | A kind of RE alloyed method avoiding continuous casting sprue dross | |
| CN108504900A (en) | A kind of corrosion-resistant Environment-friendlyzinc zinc alloy | |
| CN108546847B (en) | Ultrahigh-strength large-diameter steel wire main cable strand anchoring material and anchoring method | |
| CN111793758A (en) | High-conductivity heat-resistant aluminum alloy monofilament for overhead conductor and preparation method thereof | |
| CN102127669A (en) | Heatproof and anticorrosion rare earth magnesium alloy with high obdurability and preparation method thereof | |
| CN113930648A (en) | Preparation method of high-zinc-aluminum alloy flat ingot | |
| CN1442501A (en) | High purity high strength aluminium alloy | |
| CN101619469B (en) | Crust-hitting hammer head for aluminum reduction cell and casting technique thereof | |
| CN115386771B (en) | Aluminum alloy material and die casting method of barrier gate transmission structural member | |
| CN110669968A (en) | Heat-resistant rare earth aluminum alloy and preparation method thereof | |
| CN114717453B (en) | High-toughness cast aluminum-silicon alloy and preparation method thereof | |
| CN109852856A (en) | A kind of high tough high-modulus metal mold gravity casting magnesium alloy and preparation method thereof | |
| CN109913739A (en) | The production technology of the high-quality Q195 continuous casting square billet of aircraft industry fastener | |
| CN113403514B (en) | High-strength cast aluminum alloy and preparation method thereof | |
| CN109161749A (en) | A kind of high intensity Mg-Sn-Zn-Al-Ce magnesium alloy and preparation method thereof | |
| CN109022918B (en) | Silicon-containing high-toughness ZZnAl4Y die-casting zinc alloy and preparation method thereof | |
| JP4096825B2 (en) | Operation method of copper smelting furnace | |
| CN111575533A (en) | Zinc-aluminum alloy round ingot, preparation method and application thereof, and zinc-aluminum alloy material | |
| CN107805737B (en) | Preparation method of dezincification-resistant lead-free low-silicon extruded arsenic brass rod | |
| CN112391572A (en) | Preparation process of Cu-Cr corrosion-resistant reinforcing steel bar | |
| JPH0814011B2 (en) | Zinc base alloy for high strength die casting |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| PB01 | Publication | ||
| PB01 | Publication | ||
| SE01 | Entry into force of request for substantive examination | ||
| SE01 | Entry into force of request for substantive examination | ||
| GR01 | Patent grant | ||
| GR01 | Patent grant |