CN109093280B - 一种焊接SA516 Gr.70碳钢板的碳钢焊条及制备方法 - Google Patents
一种焊接SA516 Gr.70碳钢板的碳钢焊条及制备方法 Download PDFInfo
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- CDBYLPFSWZWCQE-UHFFFAOYSA-L Sodium Carbonate Chemical compound [Na+].[Na+].[O-]C([O-])=O CDBYLPFSWZWCQE-UHFFFAOYSA-L 0.000 claims abstract description 5
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- WPBNNNQJVZRUHP-UHFFFAOYSA-L manganese(2+);methyl n-[[2-(methoxycarbonylcarbamothioylamino)phenyl]carbamothioyl]carbamate;n-[2-(sulfidocarbothioylamino)ethyl]carbamodithioate Chemical compound [Mn+2].[S-]C(=S)NCCNC([S-])=S.COC(=O)NC(=S)NC1=CC=CC=C1NC(=S)NC(=O)OC WPBNNNQJVZRUHP-UHFFFAOYSA-L 0.000 claims abstract description 3
- 229910052751 metal Inorganic materials 0.000 claims description 17
- 239000002184 metal Substances 0.000 claims description 17
- 239000011572 manganese Substances 0.000 claims description 14
- 229910052748 manganese Inorganic materials 0.000 claims description 9
- 239000000126 substance Substances 0.000 claims description 8
- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 claims description 6
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- 235000019353 potassium silicate Nutrition 0.000 claims description 4
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- KWYUFKZDYYNOTN-UHFFFAOYSA-M Potassium hydroxide Chemical group [OH-].[K+] KWYUFKZDYYNOTN-UHFFFAOYSA-M 0.000 claims 1
- 235000010216 calcium carbonate Nutrition 0.000 claims 1
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- 239000010959 steel Substances 0.000 description 2
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- RWSOTUBLDIXVET-UHFFFAOYSA-N Dihydrogen sulfide Chemical compound S RWSOTUBLDIXVET-UHFFFAOYSA-N 0.000 description 1
- 229910006295 Si—Mo Inorganic materials 0.000 description 1
- 229910010413 TiO 2 Inorganic materials 0.000 description 1
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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
- B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
- B23K35/02—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape
- B23K35/0255—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape for use in welding
- B23K35/0261—Rods, electrodes, wires
- B23K35/0266—Rods, electrodes, wires flux-cored
-
- 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
- B23K35/3601—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 with inorganic compounds as principal constituents
-
- 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
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Inorganic Chemistry (AREA)
- Nonmetallic Welding Materials (AREA)
Abstract
本发明涉及焊条及其制备方法技术领域,更具体的说是一种焊接SA516Gr.70碳钢板的碳钢焊条及其制备方法,包括焊芯、药皮和粘结剂,药皮中物料成分为药粉,药粉与焊条重量比为35‑45:100,药粉与粘结剂的重量比为100∶20‑30,其余为焊芯;其中药皮中各成分以及重量百分比含量分别为:金红石粉3~8%、大理石粉25~40%、萤石粉15~30%、电解锰3~5%、喷雾硅铁2~8%、钼铁0.2~1.0%、还原铁粉20~30%、石墨0.1~0.4%、CMC 0.2~0.8%、纯碱0.3~1.0%。本发明的优点是:电弧稳定性,熔池流动性好,熔渣渣壳覆盖均匀;脱渣容易;焊缝成型平整。
Description
技术领域
本发明涉及焊条及其制备方法技术领域,具体的说是一种焊接SA516 Gr.70碳钢板的碳钢焊条及制备方法。
背景技术
SA516 Gr.70完全满足高含量硫和氢的油气体的需要,降低硫和氢的腐蚀、减少设备的检修、增加设备的使用寿命。该钢板抗冲击性能好、温度形变小、焊接性能好、抗疲劳性能好,防层状撒裂性能好、微合金化、高纯净度、低碳当量以及抗硫氢能力强。SA516 Gr.70广泛应用于石油、化工、电站、锅炉等行业,用于制作反应器、换热器、分离器、球罐、煤气罐、液化气罐、核能反应堆压力壳、锅炉汽包、液化石油气瓶、水电站高压水管、水轮涡壳等设备及构件。
目前国内能生产SA516 Gr.70碳钢板对应焊接材料E7018-1,但是能同时满足焊态及595~620℃×24h热处理态熔敷金属力学性能一致、且C含量≤0.100wt%、Mn含量0.40~1.40wt%的E7018-1焊条很少,且普遍存在焊条飞溅大或脱渣差等现象。
因此,现有技术还有待发展。
发明内容
本发明的目的是针对现有技术存在的缺陷,研究开发一种SA516 Gr.70碳钢板焊接用碳钢焊条,达到在满足GB/T 5117、AWS A5.1/A5.1M以及NF EN ISO 2560标准所要求的熔敷金属成分及熔敷金属力学性能的基础上,实现同时满足焊态及595~620℃×24h热处理态熔敷金属力学性能一致、且C含量≤0.100wt%、Mn含量0.40~1.40wt%,焊接时熔渣流动性好、电弧稳定、熔渣覆盖均匀、飞溅小、脱渣性优良、焊缝光亮、成型美观、焊道高度和焊缝浸润角适中以及全方位操作性能好等目的。采用高碱度的碱性铁粉型渣系药皮,同时调整为Mn-Si-Mo合金体系,对药皮中各组分的比例进行合理化调整,并保证焊条焊接工艺性能优良。
为达到上述目的,本发明采用如下技术方案:
本发明提供一种焊接SA516 Gr.70碳钢板的碳钢焊条,包括焊芯、药皮和粘结剂,其特征在于,所述药皮中的物料成分为药粉,所述药粉与焊条重量比为35-45∶100,药粉与粘结剂的重量比为100:20-30,其余为焊芯;其中药皮中各成分以及重量百分比含量分别为:金红石粉3~8%、大理石粉25~40%、萤石粉15~30%、电解锰3~5%、喷雾硅铁2~8%、钼铁0.2~1.0%、还原铁粉20~30%、石墨0.1~0.4%、CMC 0.2~0.8%、纯碱0.3~1.0%。
进一步的,所述药粉中的金红石粉中TiO2含量≥92wt%,大理石粉CaCO3含量≥96wt%,萤石粉中CaF2含量≥96wt%,电解锰中Mn含量≥99.5wt%,喷雾硅铁中Si含量:40~48wt%,钼铁中Mo含量≥55wt%。
进一步的,所述粘结剂为钾钠水玻璃,其波美浓度为42.5°~43.5°。
进一步的,焊条焊接后熔敷金属化学成分的重量百分比含量分别为:C≤0.100%、Mn:0.40-1.40%、Si≤0.75%、S≤0.020%、P≤0.015%、Cr≤0.15%、Ni≤0.25%、Mo≤0.30%、V≤0.04%、Cu≤0.25%、Mn+Cr+Ni+Mo+V≤1.75%、余量的Fe以及不可避免的杂质。
一种焊接SA516 Gr.70碳钢板的碳钢焊条的制备方法,其特征在于,包括以下步骤:
(1)将所述药皮中各成分的药粉按比例混合均匀;
(2)加入药粉总成分重20-30%的钾钠水玻璃粘结剂,波美浓度为42.5°~43.5°,搅拌混合均匀;然后送入压条机内将其裹覆于焊芯上;
(3)再依次经低温烘焙和高温烘焙,即成;
进一步的,其特征在于,步骤(3)中低温烘焙的温度为80-120℃,低温烘焙时间为1.5-2小时,高温烘焙的温度为360-380℃,高温烘焙时间为1-2小时。
本发明的有益效果是:1、配方比例合理,具有良好的焊接工艺性能:电弧稳定性,熔池流动性好,熔渣渣壳覆盖均匀;脱渣容易;焊缝成型平整,并具有良好的焊缝抗裂性。2、本发明焊条焊后熔敷金属的化学成分纯度较高,性能稳定优越,完全符合国家标准GB/T5117、美国标准AWS A5.1/A5.1M以及欧洲标准NF EN ISO 2560的要求。3、本发明焊条的焊缝具有优良的强韧性匹配,并且能保持焊态及595~620℃×24h热处理态熔敷金属力学性能一致、且熔敷金属化学成分范围较窄,C含量≤0.100wt%、Mn含量0.40~1.40wt%。4、本发明焊条不仅可用SA516 Gr.70碳钢板焊接,同样也可用于其他相同强度等级碳钢板的焊接。
具体实施方式
下面通过具体实施例,对本发明的技术方案作进一步具体的说明,但是本发明并不限于实施例。
实施例1~3
本发明提供一种焊接SA516 Gr.70碳钢板的碳钢焊条,选用直径为Φ4.0mm的优质H08A碳钢焊芯,其具体化学成分见表1;
表1本实施例焊条的焊芯具体化学成分对比(重量%)
C | S | Mn | Si | P | Cr | Ni | Cu | As |
0.055 | 0.008 | 0.46 | 0.01 | 0.005 | 0.01 | 0.01 | 0.01 | 0.01 |
(1)按表2所示的组分和百分比取各种配料并混合均匀;
(2)使用波美浓度为43°钾钠混合水玻璃作为粘结剂,药粉与粘结剂的重量比为100:20,搅拌混合均匀;将混合物料以及H08A碳钢焊芯送入压条机内,按常规方法将其裹覆于H08A碳钢焊芯上;
(3)依次经100摄氏度低温烘焙1.5小时和370摄氏度高温烘焙1.5小时,即制成成品碳钢焊条。
表2实施例焊条的药皮成分配比(按重量%)
进一步的,实施例1~3中焊条焊接后熔敷金属化学成分的重量百分比含量如表3所示:
表3实施例电焊条的熔敷金属化学成分(按重量%)
表4与表5为实施例1~3的电焊条熔敷金属的力学性能;
表4拉伸性能
表5冲击性能
上述实施例试验结果显示本发明的CHE508A1焊条拥有稳定的良好的强度及低温韧性,完全可以满足GB/T 5117《非合金钢及细晶粒钢焊条》中对E5018-1、AWS A5.1/A5.1M《Specification for Carbon Steel Electrodes for Shielded Metal Arc welding》中对E7018-1以及NF EN ISO 2560《welding consumables-Covered electrodes for manualmetal arc welding of non-alloy and fine grain steels-Classification》中对E 380B的要求。
本发明药皮原料中各成分的主要作用如下:
金红石粉:金红石的主要作用是稳定电弧、造渣,调整熔渣的表面张力、粘度、流动性等物理性能,改善提高脱渣性能,改善焊缝成型,减少飞溅等作用;但是太多的金红石易恶化熔敷金属机械性能及抗裂性,因此金红石在药皮中的含量为
大理石粉:主要作用是造渣、造气,稳定电弧,提高熔渣碱度,改善脱渣性能,并有较好的脱硫能力和间接脱磷效果,分解CO2保护焊缝不被氧、氮化,减少焊缝金属中的氢含量;大理石在药皮中的含量为
萤石粉:适量的萤石可以降低液态金属的表面张力,提高其流动性,使得焊缝成型美观,降低焊缝气孔敏感性,并能够降低熔敷金属的扩散氢含量。本发明的萤石含量的合适范围是
电解锰:电解锰的加入主要是向焊缝中过度锰元素,提高焊缝金属的强度和塑性,同时可以起到脱氧脱硫、加快焊接反应速度的作用;电解锰在药皮中的含量为3~5%。
喷雾硅铁:主要作用是脱氧和渗合金,喷雾硅铁在药皮中的含量为2~8%。
还原铁粉:还原铁粉可有效提高焊条熔敷效率,是高效铁粉型焊条必备的原材料,还原铁粉在药皮中的含量20~30%。
石墨:主要作用是稳弧与改善压涂,石墨在药皮中的含量为0.1~0.4%。
钼铁:主要是作为合金剂加入,提高焊缝热强性。钼铁在药皮中的加入量为0.2~1.0%。
CMC与纯碱的加入是为了改善焊条的压涂性能。
本发明即通过上述成分的有机组配成药皮,并与低S、P含量的优质碳钢焊芯配合从而实现本发明的目的。
以上所述仅为本发明的实施例,并非因此限制本发明的专利范围,凡是利用本发明说明书内容所作的等效结构或等效流程变换,或直接或间接运用在其他相关的技术领域,均同理包括在本发明的专利保护范围内。
Claims (3)
1.一种焊接SA516 Gr.70碳钢板的碳钢焊条,包括焊芯、药皮和粘结剂,其特征在于,所述药皮中的物料成分为药粉,所述药粉与焊条重量比为35-45:100,药粉与粘结剂的重量比为100:20-30,其余为焊芯;其中药皮中各成分以及重量百分比含量分别为:金红石粉3~8%、大理石粉25~40%、萤石粉15~30%、电解锰3~5%、喷雾硅铁2~8%、钼铁0.2~1.0%、还原铁粉20~30%、石墨0.1~0.4%、CMC 0.2~0.8%、纯碱0.3~1.0%;所述药粉中的金红石粉中TiO2含量≥92wt%,大理石粉中CaCO3含量≥96wt%,萤石粉中CaF2含量≥96wt%,电解锰中Mn含量≥99.5wt%,喷雾硅铁中Si含量:40~48wt%,钼铁中Mo含量≥55wt%;焊条焊接后熔敷金属化学成分的重量百分比含量分别为:C≤0.100%、Mn:0.40-1.40%、Si≤0.75%、S≤0.020%、P≤0.015%、Cr≤0.15%、Ni≤0.25%、Mo≤0.30%、V≤0.04%、Cu≤0.25%、Mn+Cr+Ni+Mo+V≤1.75%、余量的Fe以及不可避免的杂质。
2.根据权利要求1所述的一种焊接SA516 Gr.70碳钢板的碳钢焊条,其特征在于,所述粘结剂为钾钠水玻璃,其波美浓度为42.5°~43.5°。
3.一种权利要求1~2中任一项所述的碳钢焊条的制备方法,其特征在于,包括以下步骤:
(1)将所述药皮中各成分的药粉按比例混合均匀;
(2)加入药粉总成分重20-30%的钾钠水玻璃粘结剂,波美浓度为42.5°~43.5°,搅拌混合均匀;然后送入压条机内将其裹覆于焊芯上;
(3)再依次经低温烘焙和高温烘焙,即成;
步骤(3)中所述低温烘焙的温度为80-120℃,低温烘焙时间为1.5-2小时,高温烘焙的温度为360-380℃,高温烘焙时间为1-2小时。
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