CN110170769B - 一种含稀土、碳钢芯的不锈钢焊条及制备方法 - Google Patents
一种含稀土、碳钢芯的不锈钢焊条及制备方法 Download PDFInfo
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Abstract
本发明公开了一种含稀土、碳钢芯的不锈钢焊条及制备方法，包括药皮和焊芯，所述焊芯由所述药皮所包覆；所述药皮包括以下组分，以质量百分比计各组分分别为：大理石6～12％，萤石3～8％，钛白粉1～3％，金红石10～20％，云母1～3％，普通钾长石3～6％，电解锰3～6％，微碳铬铁20～30％，金属铬25～35％，镍粉8～12％，氟化稀土0.5～1.5％，稀土硅铁1～3％，钙溶剂0.5～1.5％，纯碱0.5～1.0％，海藻酸钠0.5～1.0％。本发明将焊条设计为合金化药皮配合专用碳钢焊芯的方式，有效解决了大直径焊条在超大电流条件下焊接时焊芯易发红、药皮易脱落的问题，同时具有耐氧化、耐硫化、耐腐蚀和抗裂的性能。
Description
技术领域
本发明涉及焊接材料领域，特别是一种含稀土、碳钢芯的不锈钢焊条及制备方法。
背景技术
镁及镁合金是21世纪最具前景的轻金属，广泛应用于汽车零部件、航空航天、电子、精密机械、军事等各个行业。由于镁及其合金在众多领域的拓展，从20世纪90年代起，在全球范围内，镁的用量已连续10年保持年增长率大于 20％，镁的生产量日益增加，镁生产技术得到广泛发展。生产金属镁的方法主要有热还原法和电解法，发达国家80％以上的金属镁是通过电解法生产的，我国主要使用热还原法-皮江法生产镁，约95％的原镁是通过皮江法生产的。皮江法生产工艺简单，产品质量高，生产过程不产生有毒气体，投资成本低，建厂快，中国丰富的白云石资源和相对廉价的劳动力是皮江法在中国发展的潜在优势。
随着中国炼镁业的急速发展，皮江法炼镁工艺获得广泛应用，金属镁还原罐的大量使用，促进了与之匹配的不锈钢专用焊条的研发与生产。近年来金属镁还原罐生产厂家为了提高生产效率，多采用粗直径、超电流焊接工艺，如采用Φ4.0mm焊条时焊接电流200-250A以上，或者采用Φ5.0mm焊条时焊接电流为250-300A以上等工艺制备方式，但由此传统工艺方式同时也带来了不锈钢焊条药皮温升开裂的问题。目前，市售的用传统工艺方法所制得的优质焊条均经受不了超大电流的考验，当焊至焊条长度的1/2－1/3时，药皮容易脱落，直接影响焊接质量和焊接效率；另一方面也使焊条的有效利用率急剧下降，焊条的利用率不到65％，进而使得镁罐的生产成本明显上升。故研发新一代耐电流、药皮不易脱落的适应超大电流焊接的金属镁还原罐专用焊条迫在眉睫。
发明内容
本发明的目的在于，提供一种含稀土、碳钢芯的不锈钢焊条及制备方法，用于解决现有技术所制备的焊条无法经受超大电流的问题。
为解决上述技术问题，本发明提供的第一解决方案为：一种含稀土、碳钢芯的不锈钢焊条包括药皮和焊芯，焊芯由药皮所包覆；药皮包括以下组分，以质量百分比计各组分分别为：大理石6～12％，萤石3～8％，钛白粉1～3％，金红石10～20％，云母1～3％，普通钾长石3～6％，电解锰3～6％，微碳铬铁20～30％，金属铬25～35％，镍粉8～12％，氟化稀土0.5～1.5％，稀土硅铁1～3％，钙溶剂 0.5～1.5％，纯碱0.5～1.0％，海藻酸钠0.5～1.0％。
优选的，焊芯包括以下组分，以质量百分比计各组分分别为：Mn： 0.35～0.60％，C≤0.10％，Si≤0.03％，S≤0.03％，P≤0.03％，Cr≤0.20％，Ni ≤0.30％，Cu≤0.20％，其余为Fe。
优选的，含稀土、碳钢芯的不锈钢焊条为CHE407焊条。
优选的，含稀土、碳钢芯的不锈钢焊条应用于对金属镁还原罐的焊接。
为解决上述技术问题，本发明提供的第二解决方案为：一种含稀土、碳钢芯的不锈钢焊条制备方法步骤具体为：将钾钠水玻璃混合液加入药皮原料中，搅拌均匀后制得药皮混合液；将药皮混合液涂布焊芯表面，烘干后制成含稀土、碳钢芯的不锈钢焊条；含稀土、碳钢芯的不锈钢焊条为前述第一解决方案中任一含稀土、碳钢芯的不锈钢焊条。
优选的，钾钠水玻璃混合液为药皮原料总质量的25％，且钾钠水玻璃混合液中钾钠比为2:1。
本发明的有益效果是：区别于现有技术的情况，本发明将焊条设计为合金化药皮配合专用碳钢焊芯的方式，有效解决了大直径焊条在超大电流条件下焊接时焊芯易发红、药皮易脱落的问题，同时具有耐氧化、耐硫化、耐腐蚀和抗裂的性能。
具体实施方式
下面将结合本发明实施例，对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，均属于本发明保护的范围。
本发明中含稀土、碳钢芯的不锈钢焊条包括药皮和焊芯，焊芯由药皮所包覆；药皮包括以下组分，以质量百分比计各组分分别为：大理石6～12％，萤石 3～8％，钛白粉1～3％，金红石10～20％，云母1～3％，普通钾长石3～6％，电解锰3～6％，微碳铬铁20～30％，金属铬25～35％，镍粉8～12％，氟化稀土0.5～1.5％，稀土硅铁1～3％，钙溶剂0.5～1.5％，纯碱0.5～1.0％，海藻酸钠0.5～1.0％；焊芯包括以下组分，以质量百分比计各组分分别为：Mn：0.35～0.60％，C≤0.10％， Si≤0.03％，S≤0.03％，P≤0.03％，Cr≤0.20％，Ni≤0.30％，Cu≤0.20％，其余为Fe，且上述焊芯中的各个组分质量百分比均大于零；含稀土、碳钢芯的不锈钢焊条为CHE407焊条，且含该稀土、碳钢芯的不锈钢焊条应用于对金属镁还原罐的焊接。
关于本发明中含稀土、碳钢芯的不锈钢焊条制备方法，其制备工艺如下：按上述药皮组分配比混合配制成药皮原料，加入占药皮原料总质量25％的钾钠水玻璃混合液，其中钾钠水玻璃混合液的钾钠比为2:1，其目的在于促进原料的固化，搅拌均匀后制得药皮混合液；将药皮混合液涂布焊芯表面，烘干后制成含稀土、碳钢芯的不锈钢焊条，本实施方式中，以上述焊芯组分配比的焊芯为 H08A专用碳钢焊芯，药皮混合液涂布焊芯表面其外径为8.60mm，先自然晾干 24小时，再经烘干机烘干定型，制成直径4.0X450mm规格的含稀土、碳钢芯的不锈钢焊条，且焊条型号与前述一致。
实施例1
以表1中药皮的组分和质量百分比配制药皮原料，加入占药皮原料总质量 25％的钾钠水玻璃混合液，其中钾钠水玻璃混合液的钾钠比为2:1，搅拌均匀后制得药皮混合液，然后将搅拌好的药皮混合液通过油压机在H08A专用不锈钢焊芯上涂压，焊条经24小时自然晾干，然后进入烘干机烘烤定型，最后经过检验包装，制成4.0X450mm规格的不锈钢焊条。
表1
| 原材料名称 | 质量百分比 | 原材料名称 | 质量百分比 |
| 大理石 | 7％ | 镍粉 | 8％ |
| 萤石 | 4％ | 氟化稀土 | 1.0％ |
| 钛白粉 | 1％ | 稀土硅铁 | 2.0％ |
| 金红石 | 1％ | 钙溶剂 | 1.0％ |
| 云母 | 1％ | 纯碱 | 0.5％ |
| 普通钾长石 | 4％ | 海藻酸钠 | 0.5％ |
| 电解锰 | 4％ | ||
| 微碳铬铁 | 24％ | ||
| 金属铬 | 30％ |
将上述制备好的不锈钢焊条进行焊接工作，其中，焊接电流230A，焊接电压26～35V，进行多次测试，得到的焊后熔敷金属成分百分比范围和取样值，如表2所示，表明熔敷金属中含有微量的稀土元素；同时对熔敷金属进行机械性能测试，如表3所示，表明熔敷金属具有较高的抗拉强度，稳定性好，不易发生拉伸形变；通过实际使用表明，该不锈钢焊条焊接后金属镁还原罐的使用周期可达83天，较现有技术焊条焊接后的还原罐相比，使用周期更长。
表2
| 熔敷金属成分 | C | Mn | Si | Cr | Ni | Mo | P | S | Cu | Re |
| 范围(％) | 0.05～0.20 | 1.0～3.0 | ≤1.0 | 25.0～28.0 | 7.5～10.0 | ≤0.75 | ≤0.030 | ≤0.030 | ≤0.75 | ≤0.001 |
| 取样值(％) | 0.090 | 1.80 | 0.78 | 26.80 | 8.20 | 0.17 | 0.018 | 0.010 | 0.15 | 0.001 |
表3
基于本发明采用的方案，经过多次试用试验表明，主成分为27％Cr-8％Ni 的含稀土、碳钢芯的不锈钢焊条，采用直流电源进行全位置焊接时，熔敷金属中含微量稀土元素，较之现有炼镁还原罐所使用的焊接材料具有更好的耐氧化、耐硫化、耐腐蚀性能和抗裂性能；同时本发明焊条的焊接工艺性能优良，超大电流焊接中焊条药皮强度好，不易发红开裂，不易脱落，在深窄坡口中熔渣流动性好，脱渣容易。
本发明中含稀土、碳钢芯的不锈钢焊条所具有的优势及相关机理如下：1) 以合金化药皮与H08A专用碳钢焊芯相配合的方式制备得到上述含稀土、碳钢芯的不锈钢焊条，将药皮合金化使其在超大电流条件下更加稳定，不会因电流过大而导致药皮脱落，从而解决粗大直径焊条超大电流焊接时焊芯易发红、药皮易脱落的问题。2)药皮原料中引入微量稀土元素，通过稀土硅铁和氟化稀土复合加入，配合适量还原的电弧气氛，能够确保稀土过渡；适量稀土的加入可使不锈钢焊缝金属具有更好的耐氧化、耐硫化、耐腐蚀性能和抗裂性能，使本发明与现有技术相比，成本降低且耐氧化、耐硫化、耐腐蚀性能提高。3)在药皮原料中添加稀土氧化物，使其熔敷金属在含硫气氛下的抗高温硫化腐蚀性能有明显提高，其作用机理在于，稀土元素富集在晶界发生反应，生成硫化物，减少交替腐蚀的速度；同时，富含稀土夹杂物在晶界的析出也可起到钉扎作用，防止膜层的脱落和阻碍腐蚀通道的形成，提高抗高温硫化腐蚀性能。
区别于现有技术的情况，本发明将焊条设计为合金化药皮配合专用碳钢焊芯的方式，有效解决了大直径焊条在超大电流条件下焊接时焊芯易发红、药皮易脱落的问题，同时具有耐氧化、耐硫化、耐腐蚀和抗裂的性能。
以上所述实施例仅表达了本发明的实施方式，其描述较为具体和详细，但并不能因此而理解为对发明专利范围的限制。应当指出的是，对于本领域的普通技术人员来说，在不脱离本发明构思的前提下，还可以做出若干变形和改进，这些都属于本发明的保护范围。因此，本发明专利的保护范围应以所附权利要求为准。
Claims (5)
1.一种含稀土、碳钢芯的不锈钢焊条，其特征在于，包括药皮和焊芯，所述焊芯由所述药皮所包覆；
所述药皮包括以下组分，以质量百分比计各组分分别为：大理石6～12％，萤石3～8％，钛白粉1～3％，金红石10～20％，云母1～3％，普通钾长石3～6％，电解锰3～6％，微碳铬铁20～30％，金属铬25～35％，镍粉8～12％，氟化稀土0.5～1.5％，稀土硅铁1～3％，钙溶剂0.5～1.5％，纯碱0.5～1.0％，海藻酸钠0.5～1.0％；
所述含稀土、碳钢芯的不锈钢焊条应用于对金属镁还原罐的焊接。
2.根据权利要求1所述的含稀土、碳钢芯的不锈钢焊条及制备方法，其特征在于，所述焊芯包括以下组分，以质量百分比计各组分分别为：Mn：0.35～0.60％，C≤0.10％，Si≤0.03％，S≤0.03％，P≤0.03％，Cr≤0.20％，Ni≤0.30％，Cu≤0.20％，其余为Fe。
3.根据权利要求1所述的含稀土、碳钢芯的不锈钢焊条，其特征在于，所述含稀土、碳钢芯的不锈钢焊条为CHE407焊条。
4.一种含稀土、碳钢芯的不锈钢焊条制备方法，其特征在于，步骤具体为：
将钾钠水玻璃混合液加入药皮原料中，搅拌均匀后制得药皮混合液；
将所述药皮混合液涂布焊芯表面，烘干后制成含稀土、碳钢芯的不锈钢焊条；
所述含稀土、碳钢芯的不锈钢焊条为权利要求1～3中任一所述含稀土、碳钢芯的不锈钢焊条。
5.根据权利要求4所述的含稀土、碳钢芯的不锈钢焊条制备方法，其特征在于，所述钾钠水玻璃混合液为所述药皮原料总质量的25％，且所述钾钠水玻璃混合液中钾钠比为2:1。
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