CN110270690B - 一种Fe-Mn-Cu粉芯丝材及其电弧增材加工工艺 - Google Patents

一种Fe-Mn-Cu粉芯丝材及其电弧增材加工工艺 Download PDF

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CN110270690B
CN110270690B CN201910555616.8A CN201910555616A CN110270690B CN 110270690 B CN110270690 B CN 110270690B CN 201910555616 A CN201910555616 A CN 201910555616A CN 110270690 B CN110270690 B CN 110270690B
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core wire
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雷卫宁
薛冰
陈世鑫
张文杰
李小平
张扬
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Kangshuo Shanxi Low Stress Manufacturing System Technology Research Institute Co ltd
Xiamen Water Village Network Intellectual Property Service Co ltd
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Abstract

本发明涉及一种Fe‑Mn‑Cu粉芯丝材及其电弧增材加工工艺，Fe‑Mn‑Cu粉芯丝材由低碳钢带和Fe‑Mn‑Cu粉芯组成；将本发明制备的Fe‑Mn‑Cu粉芯丝材对破损的碳钢基板进行电弧增材加工，加工后修复了破损的碳钢基板，再制造修复的焊道能有效提高碳钢基板的硬度、致密度和抗拉强度，使修复后的碳钢基体性能要求符合再次应用。本发明主要用于针对工作现场或野外环境下及时、高效地对急用装备等关键零部件进行快速修复与再制造。

Description

一种Fe-Mn-Cu粉芯丝材及其电弧增材加工工艺
技术领域
本发明涉及金属表面加工技术领域，具体涉及一种Fe-Mn-Cu粉芯丝材及其电弧增材加工工艺。
背景技术
丝材－电弧增材制造(WAAM)是以电弧为热源，以氩气等惰性气体作保护气，通过填充焊丝逐层沉积堆敷，从而获得近净成形的制造技术。WAAM是一种快速、低成本制造技术，适用于航空、航海、能源等领域复杂构件大尺寸、小批量制造。
常见的电弧熔覆丝材主要为Fe基和Ni基两大类。电弧熔覆粉芯丝材由金属外皮和粉芯两部分组成，因而同时具备丝材和粉末的优点,拓宽了焊丝材料的成分和种类范围,满足了对焊丝多功能化、多元化和高性能化的要求。近来金属粉芯丝材在电弧熔覆领域有了突飞猛进的发展,国内外已经开发了多种耐磨、耐腐蚀电弧熔覆粉芯丝材，广泛应用于电力、石油、化工、汽车制造等工业领域。因此,采用粉芯丝材电弧熔覆基体已成为该技术发展趋势。
然而目前市场上的电弧熔覆粉芯丝材种类较为单一，针对适用碳钢类型的粉芯丝材更为稀缺，在应用于修复碳钢的机械工作中，修复后的熔覆层或焊道极易出现气孔、裂纹等缺陷，且硬度、致密度和抗拉强度等力学性能均达不到所要求的修复标准。
发明内容
为了解决目前碳钢类型基板再修复粉芯丝材的缺失问题，而提供一种Fe-Mn-Cu粉芯丝材及其电弧增材加工工艺。本发明工艺可有效提高基体与焊道的致密度，改善修复的基体表面硬度和抗拉强度。
本发明通过以下技术方案实现：
一种Fe-Mn-Cu粉芯丝材，由低碳钢带和Fe-Mn-Cu粉芯组成；
所述Fe-Mn-Cu粉芯丝材的制备方法为：
(1)Fe-Mn-Cu粉芯的制备：将Fe、Mn和Cu粉末过筛筛选成相同颗粒度，混合均匀，进行第一次球磨，第一次球磨冷却后，加入溶剂，再进行第二次球磨，干燥；将干燥后的Fe、Mn和Cu粉末在氩气保护下进行真空烧结制得所述Fe-Mn-Cu粉芯；
(2)Fe-Mn-Cu粉芯丝材的制备：将所述Fe-Mn-Cu粉芯置于送粉器中，将低碳钢带经过多道轧制工序后，形成凹槽，将Fe-Mn-Cu粉芯送入凹槽内再进行轧制，多次轧制后Fe-Mn-Cu粉芯被低碳钢带包裹，再经过多道连续拔丝最后制得Fe-Mn-Cu粉芯丝材。
进一步地，步骤(1)中Fe、Mn和Cu粉末分别按照2:1:1的摩尔比混合均匀。
进一步地，步骤(1)中所述溶剂为甘油、石蜡、煤油中的一种或几种。
进一步地，步骤(1)中所述第一次球磨的时间为1～2h，所述第二次球磨的时间为1h。
进一步地，步骤(1)中所述真空烧结的工艺参数为：烧结温度为1220～1280℃,升温速率为10℃/min，保温时间为4～5h，烧结压力为10～30Mpa。
进一步地，步骤(2)中所述凹槽为U型槽形状。
进一步地，步骤(2)中所述Fe-Mn-Cu粉芯丝材经过多道连续拔丝后直径小于1.2mm，所述低碳钢带厚度为0.2mm。
上述Fe-Mn-Cu粉芯丝材的电弧增材加工工艺，包括如下步骤：对需要电弧增材加工的碳钢基板进行表面氧化层、脱碳层及其他杂物的除杂处理；然后预热碳钢基板，在电压为15～18V、电流为160～200A、Fe-Mn-Cu粉芯丝材送丝速度为130～190cm/min、氩气气体流量为15L/min的条件下进行电弧增材加工。
进一步地，所述预热碳钢基板的温度为80～100℃。
有益技术效果：本发明涉及Fe-Mn-Cu粉芯丝材电弧增材加工工艺，将本发明制备的Fe-Mn-Cu粉芯丝材对碳钢基板进行电弧增材加工，加工后在碳钢上制得具有较高致密度的焊道，能有效提高碳钢硬度和抗拉强度，使修复的碳钢基体性能要求符合再次应用。本发明主要用于针对工作现场或野外环境下及时、高效地对急用装备等关键零部件进行快速修复与再制造。
附图说明
图1为碳钢基板及其与Fe-Mn-Cu粉芯丝材电弧增材加工后产生的焊道的抗拉强度对比图。
具体实施方式
以下结合附图及具体实施例进一步描述本发明，但不限制本发明范围。
实施例1
一种Fe-Mn-Cu粉芯丝材，由低碳钢带和Fe-Mn-Cu粉芯组成，所述丝材直径为1.2mm，所述低碳钢带厚度为0.2mm；
(1)Fe-Mn-Cu粉芯的制备：将Fe、Mn和Cu粉末过筛筛选成相同颗粒度，Fe、Mn和Cu粉末分别按照摩尔分数比例2:1:1混合均匀，进行1的第一次球磨，第一次球磨冷却后，加入甘油和石蜡，再进行1h第二次球磨，干燥；将干燥后的Fe、Mn和Cu粉末在氩气保护下进行真空烧结，工艺参数为：烧结温度为1220℃,升温速率为10℃/min，保温时间为4h，烧结压力为10Mpa，最后制得所述Fe-Mn-Cu粉芯；
(2)Fe-Mn-Cu粉芯丝材的制备：将上述制得的Fe-Mn-Cu粉芯置于送粉器中，将低碳钢带经过至少5道轧制工序后，形成U型槽形状后，将Fe-Mn-Cu粉芯送入U型槽内再进行轧制，至少5次轧制后Fe-Mn-Cu粉芯被低碳钢带包裹，再经过至少5道连续拔丝将直径减小至1.2mm的丝材，最后制得Fe-Mn-Cu粉芯丝材。
选用20#钢的低碳钢，基板板厚20mm，在平整的基板上开一个V型坡口，坡口深度6mm，再进行本发明的一种Fe-Mn-Cu粉芯丝材电弧增材加工工艺，包括如下步骤：
(1)清理20#钢基板的V型坡口及外侧5cm范围处的杂质、污物、毛刺等，然后使用装有砂轮片的角向磨光机打磨表面10分钟，去除较厚的氧化层、脱碳层，再用240#的砂纸打磨表面至光滑，最后清洗烘干；
(2)将20#钢基板放入DHG-202型电热鼓风干燥箱预热，使20#钢基板预热至80℃，在电压为17.5V、电流为160A、Fe-Mn-Cu粉芯丝材送丝速度为140cm/min、99.99％的纯氩气保护、气体流量为15L/min的条件下进行电弧增材加工工艺；
实施例2
一种Fe-Mn-Cu粉芯丝材，由低碳钢带和Fe-Mn-Cu粉芯组成，所述丝材直径为1.2mm，所述低碳钢带厚度为0.2mm；
所述Fe-Mn-Cu粉芯丝材的制备方法为：
(1)Fe-Mn-Cu粉芯的制备：将Fe、Mn和Cu粉末过筛筛选成相同颗粒度，Fe、Mn和Cu粉末分别按照摩尔分数比例2:1:1混合均匀，进行1.5h的第一次球磨，第一次球磨冷却后，加入石蜡和煤油，再进行1h第二次球磨，干燥；将干燥后的Fe、Mn和Cu粉末在氩气保护下进行真空烧结，工艺参数为：烧结温度为1250℃,升温速率为10℃/min，保温时间为5h，烧结压力为30Mpa，最后制得所述Fe-Mn-Cu粉芯；
(2)Fe-Mn-Cu粉芯丝材的制备：将上述制备的Fe-Mn-Cu粉芯置于送粉器中，将低碳钢带经过至少5道轧制工序后，形成U型槽形状后，将Fe-Mn-Cu粉芯送入U型槽内再进行轧制，至少5次轧制后Fe-Mn-Cu粉芯被低碳钢带包裹，再经过至少5道连续拔丝将直径减小至1.2mm的丝材，最后制得Fe-Mn-Cu粉芯丝材。
选用T10钢的高碳钢，基板板厚20mm，在平整的基板上开一个V型坡口，坡口深度6mm，在进行本发明的一种Fe-Mn-Cu粉芯丝材电弧增材加工工艺，包括如下步骤：
(1)清理T10钢基板的V型坡口及外侧5cm范围处的杂质、污物、毛刺等，然后使用装有砂轮片的角向磨光机打磨表面15分钟，去除较厚的氧化层、脱碳层，再用240#的砂纸打磨表面至光滑，最后清洗烘干；
(2)将T10钢基板放入DHG-202型电热鼓风干燥箱预热，使T10钢基板预热至100℃，在电压为15.3V、电流为190A、Fe-Mn-Cu粉芯丝材送丝速度为190cm/min、99.99％的纯氩气保护、气体流量为15L/min的条件下进行电弧增材加工工艺。
对本发明实施例1和实施例2的Fe-Mn-Cu粉芯丝材电弧增材加工后产生的焊道进行切样，实施例1的焊道标记试样1，实施例2的焊道标记试样2，使用HVS-1000A型维氏硬度计对试样1和2进行显微硬度测试，载荷200g，保压时间为5s，数据见表1。
采用排水法对试样1、试样2进行致密度测试，测试方法：采用阿基米德排水法原理，利用公式(1-1)计算致密度：
Figure BDA0002106790840000041
式中，ρ水为蒸馏水密度0.9982g/cm3，ρ1为试样1或试样2的密度9.7g/cm3，m0为试样在空气中的质量，m1为试样在蒸馏水中的质量，m0和m1使用高精度电子天平测量，ρ水和ρ1使用密度仪测量。
焊道与碳钢基板的硬度和致密度数据见表1。硬度采用GB/T 4340.1-2009标准测试。
表1焊道与碳钢基板的硬度和致密度数据
Figure BDA0002106790840000051
本发明的Fe-Mn-Cu粉芯丝材经过电弧增材加工工艺，在破损的碳钢基板上经过电弧加热熔化形成熔池，使碳钢基板与Fe-Mn-Cu粉芯丝材搅拌融合，并冷却凝固在坡口处，经过电弧增材加工后形成焊道，达到对破损件的再制造修复。由表1数据可知，经再制造修复后的20#钢硬度相比于其基材本身有明显的提高，焊道的硬度较20#钢基板提高了31％，较T10钢基板提高了28％；在致密度方面也有一定程度的提升，焊道的致密度较20#钢基板提高了4％，较T10钢基板提高了约7％，能够达到对破损零件再制造修复。
对碳钢基板20#钢、T10钢和进行了Fe-Mn-Cu粉芯丝材电弧增材加工后产生焊道进行抗拉强度测试，按照GB/T 228.1-2010标准测试。抗拉强度性能对比图如图1所示，由图1可知，再制造修复后的碳钢基板的抗拉强度均大于基板本身的强度，焊道的抗拉强度较20#钢基板提高了17.2％，较T10钢基板提高了47％。

Claims (7)

1.一种Fe-Mn-Cu粉芯丝材，其特征在于，由低碳钢带和Fe-Mn-Cu粉芯组成；
所述Fe-Mn-Cu粉芯丝材的制备方法为：
(1)Fe-Mn-Cu粉芯的制备：将Fe、Mn和Cu粉末过筛筛选成相同颗粒度，Fe、Mn和Cu粉末分别按照2:1:1的摩尔比混合均匀，进行第一次球磨，第一次球磨冷却后，加入溶剂，再进行第二次球磨，干燥；将干燥后的Fe、Mn和Cu粉末在氩气保护下进行真空烧结制得所述Fe-Mn-Cu粉芯；
步骤(1)中所述溶剂为甘油、石蜡、煤油中的一种或几种；
(2)Fe-Mn-Cu粉芯丝材的制备：将所述Fe-Mn-Cu粉芯置于送粉器中，将低碳钢带经过多次轧制工序后，形成凹槽，将Fe-Mn-Cu粉芯送入凹槽内再进行轧制，多次轧制后Fe-Mn-Cu粉芯被低碳钢带包裹，再经过多道连续拔丝最后制得Fe-Mn-Cu粉芯丝材。
2.根据权利要求1所述的一种Fe-Mn-Cu粉芯丝材，其特征在于，步骤(1)中所述第一次球磨的时间为1～2h，所述第二次球磨的时间为1h。
3.根据权利要求1所述的一种Fe-Mn-Cu粉芯丝材，其特征在于，步骤(1)中所述真空烧结的工艺参数为：烧结温度为1220～1280℃,升温速率为10℃/min，保温时间为4～5h，烧结压力为10～30Mpa。
4.根据权利要求1所述的一种Fe-Mn-Cu粉芯丝材，其特征在于，步骤(2)中所述凹槽为U型槽形状。
5.根据权利要求1所述的一种Fe-Mn-Cu粉芯丝材，其特征在于，步骤(2)中所述Fe-Mn-Cu粉芯丝材经过多道连续拔丝后直径小于1.2mm，所述低碳钢带厚度为0.2mm。
6.一种根据权利要求1～5任一项所述的Fe-Mn-Cu粉芯丝材的电弧增材加工工艺，包括如下步骤：对需要电弧增材加工的碳钢基板进行表面氧化层、脱碳层及其他杂物的除杂处理；然后预热碳钢基板，在电压为15～18V、电流为160～200A、Fe-Mn-Cu粉芯丝材送丝速度为130～190cm/min、氩气气体流量为15L/min的条件下进行电弧增材加工。
7.根据权利要求6所述的一种Fe-Mn-Cu粉芯丝材的电弧增材加工工艺，其特征在于，所述预热碳钢基板的温度为80～100℃。
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