Preparation method of flexible welding wire of brittle aluminum-silicon-copper brazing filler metal
Technical Field
The invention relates to a preparation method of a flexible welding wire of a brittle aluminum-silicon-copper brazing filler metal.
Background
The aluminum alloy has wide application in industrial production and social life, and the important function of the aluminum alloy in modern industrial materials cannot be replaced due to small specific gravity, good electric conductivity and thermal conductivity, good castability, plasticity and mechanical processing performance. The manufacturing of parts by using 3-series and 6-series high-strength aluminum alloys to replace the original copper structural parts has become the development direction of the manufacturing industry all over the world. But the problems associated with welding copper-aluminum components are increasing.
At present, a copper-aluminum component is mostly connected by brazing by using a zinc-aluminum brazing filler metal, an aluminum-silicon brazing filler metal or an aluminum-silicon-copper brazing filler metal, but the copper-aluminum component has some defects. When the zinc-aluminum brazing filler metal is used for welding a copper-aluminum component, electrochemical corrosion is easy to occur at the position of a welding joint, and the service life is short; the melting point of the aluminum-silicon brazing filler metal is high, the solidus temperature is 577 ℃, the liquidus temperature is above 600 ℃, the melting point is very close to that of 3-series and 6-series high-strength aluminum alloys, and the aluminum-silicon brazing filler metal is easy to overburn during brazing; the aluminum-silicon-copper brazing filler metal welded joint has good corrosion resistance, but the brazing filler metal is brittle and has poor processability, the brazing filler metal is difficult to process into a disc-shaped welding wire or a welding ring, and the requirements of continuous automation and high-efficiency brazing cannot be met.
Disclosure of Invention
The invention provides a preparation method of a flexible welding wire of a brittle aluminum-silicon-copper brazing filler metal, which can overcome the technical defect that the conventional aluminum-silicon-copper brazing filler metal is difficult to process into the welding wire due to high brittleness.
In order to achieve the purpose, the invention provides the following technical scheme that the preparation method of the flexible welding wire of the brittle aluminum-silicon-copper brazing filler metal is characterized in that a flexible material aluminum-silicon alloy sheath wraps a mixed powder, and the mixed powder is formed by mixing a brittle material aluminum-silicon-copper powder and an aluminum brazing flux powder.
Preferably, the aluminum-silicon-copper powder comprises 15-30% of copper, 3-7% of silicon, 0-3% of nickel and the balance of aluminum.
Preferably, the aluminum brazing flux powder consists of potassium fluoroaluminate powder and cesium fluoroaluminate powder.
Preferably, the mixed powder is prepared by fully mixing 10 to 100 weight percent of brittle material aluminum-silicon-copper powder and 0 to 90 weight percent of aluminum-brazing flux powder.
Preferably, the components of the aluminum-silicon alloy sheath are more than or equal to 4.5 percent and less than or equal to 13.0 percent of silicon, less than or equal to 5.0 percent of copper, less than or equal to 2.0 percent of magnesium, less than or equal to 3.0 percent of zinc, less than or equal to 0.8 percent of iron, less than or equal to 0.15 percent of manganese, less than or equal to 0.2 percent of titanium, less than or equal to 0.15 percent of chromium, less than or equal to 0..
Preferably, the content of the aluminum-silicon alloy sheath ranges from 20% to 80%, and the content of the mixed powder ranges from 20% to 80%.
Preferably, the preparation method comprises the following steps:
(1) preparing aluminum-silicon-copper powder from 15-30% of copper, 3-7% of silicon, 0-3% of nickel and the balance of aluminum by a vacuum melting and gas atomization method;
(2) mixing aluminum-silicon-copper powder and aluminum brazing filler metal powder according to a weight ratio, and then putting the mixture into a double-planet stirrer for fully stirring to obtain mixed powder;
(3) the aluminum-silicon brazing filler metal is subjected to smelting, extruding, rolling and slitting to obtain an aluminum-silicon brazing filler metal strip;
(4) putting the aluminum-silicon brazing filler metal strip into a welding wire forming machine, sequentially passing through each roller, finally rolling into a tubular welding wire and taking the tubular welding wire into a winding machine;
(5) in the welding wire forming process, adding the mixed powder obtained in the step (2) through a powder adding device, and rolling to obtain a flexible tubular flux-cored wire;
(6) the flexible welding wire can be drawn to different sizes by a drawing and reducing method through a wire drawing machine.
Preferably, the above brittle aluminum-silicon-copper brazing filler metal can adjust the brazing performance of the welding wire by adjusting the ratio of aluminum-silicon-copper powder to aluminum brazing filler metal powder in the aluminum-silicon alloy sheath and the mixed powder.
The invention has the beneficial effects that: the method solves the problem of poor processing and forming performance of the aluminum-silicon-copper brazing filler metal due to large brittleness of the aluminum-silicon-copper brazing filler metal, prepares the flexible aluminum-silicon-copper brazing filler metal welding wire, meets the requirements of subsequent wire coiling or ring manufacturing processing, and is suitable for the requirements of continuous automation and high-efficiency brazing. The aluminum-silicon-copper flexible welding wire produced by the forming method can be directly used for welding a copper-aluminum component without adding an aluminum brazing flux, a welding joint has good corrosion resistance, long service life and good processability, and can be further processed into a disc-shaped welding wire or a welding ring to realize continuous automatic welding; the brazing performance of the welding wire can be adjusted by adjusting the proportion of the aluminum-silicon-copper powder to the aluminum brazing flux powder in the aluminum-silicon alloy sheath and the mixed powder, and the method is simple and convenient, low in cost and high in efficiency.
Detailed Description
The present invention will be further described below.
Example 1
1. The aluminum-silicon-copper brazing filler metal with the components of 26.0 to 27.0 percent of copper, 4.5 to 5.5 percent of silicon and the balance of aluminum is prepared into aluminum-silicon-copper powder with the granularity of-120 meshes by a vacuum melting and gas atomization method.
2. Weighing aluminum-silicon-copper powder and aluminum brazing filler metal powder according to the weight ratio of 3:1, and fully stirring the weighed aluminum-silicon-copper powder and aluminum brazing filler metal powder in a double-planet stirrer to obtain mixed powder with the aluminum-silicon-copper powder content of 75%.
3. The aluminum-silicon brazing filler metal with the components of 11.0-13.0 percent of silicon and the balance of aluminum is obtained into the aluminum-silicon brazing filler metal strip with the thickness of 0.20mm and the width of 10.0mm by smelting, extruding, rolling and slitting.
4. The tubular flux-cored wire is prepared by a steel belt method, an aluminum-silicon brazing filler metal strip is placed into a welding wire forming machine, sequentially passes through each roller, is finally rolled into the tubular welding wire and is collected into a winding machine.
5. And (3) in the welding wire forming process, adding the mixed powder obtained in the step (2) through a powder adding device, controlling the adding weight of the mixed powder to be about 80% of the total weight of the welding wire, and rolling to obtain the flexible tubular flux-cored welding wire with the diameter phi of 3.2mm, wherein the aluminum-silicon-copper powder in the welding wire accounts for 60%, the aluminum-silicon brazing filler metal sheath accounts for 20%, and the aluminum brazing filler metal powder accounts for 20%.
6. By the drawing and reducing method, the flexible welding wire can be drawn to the required size of phi 3.0mm and smaller by a drawing machine.
Example 2
1. The aluminum-silicon-copper brazing filler metal with the components of 26.0 to 27.0 percent of copper, 4.5 to 5.5 percent of silicon and the balance of aluminum is prepared into aluminum-silicon-copper powder with the granularity of-120 meshes by a vacuum melting and gas atomization method.
2. Weighing the aluminum-silicon-copper powder and the aluminum brazing filler metal powder according to the weight ratio of 2:1, and fully stirring the weighed materials in a double-planet stirrer to obtain mixed powder with the aluminum-silicon-copper powder content of 67%.
3. The aluminum-silicon brazing filler metal with the components of 11.0-13.0 percent of silicon and the balance of aluminum is obtained into the aluminum-silicon brazing filler metal strip with the thickness of 0.25mm and the width of 6.5mm by smelting, extruding, rolling and slitting methods.
4. The tubular flux-cored wire is prepared by a steel belt method, an aluminum-silicon brazing filler metal strip is placed into a welding wire forming machine, sequentially passes through each roller, is finally rolled into the tubular welding wire and is collected into a winding machine.
5. And (3) in the welding wire forming process, adding the mixed powder obtained in the step (2) through a powder adding device, controlling the adding weight of the mixed powder to be about 60% of the total weight of the welding wire, and rolling to obtain the flexible tubular flux-cored welding wire with the diameter phi of 2.2mm, wherein the aluminum-silicon-copper powder accounts for 40%, the aluminum-silicon brazing filler metal sheath accounts for 40%, and the aluminum brazing filler metal powder accounts for 20%.
6. By the drawing and reducing method, the flexible welding wire can be drawn to the required size of phi 2.0mm and smaller by a drawing machine.
Embodiment 3
1. The aluminum-silicon-copper brazing filler metal with the components of 26.0 to 27.0 percent of copper, 4.5 to 5.5 percent of silicon and the balance of aluminum is prepared into aluminum-silicon-copper powder with the granularity of-120 meshes by a vacuum melting and gas atomization method.
2. The aluminum-silicon brazing filler metal with the components of 11.0-13.0 percent of silicon and the balance of aluminum is obtained into the aluminum-silicon brazing filler metal strip with the thickness of 0.35mm and the width of 10.0mm by smelting, extruding, rolling and slitting methods.
3. The tubular flux-cored wire is prepared by a steel belt method, an aluminum-silicon brazing filler metal strip is placed into a welding wire forming machine, sequentially passes through each roller, is finally rolled into the tubular welding wire and is collected into a winding machine.
4. In the welding wire forming process, aluminum-silicon-copper powder is independently added through one powder feeder, aluminum-brazing flux powder is independently added through the other powder feeder, the adding weight of the aluminum-silicon-copper powder and the adding weight of the aluminum-brazing flux powder are controlled to be respectively 40% and 20% of the total weight of the welding wire, the flexible tubular flux-cored welding wire with the diameter of phi 3.2mm is obtained through rolling, the aluminum-silicon-copper powder in the welding wire accounts for 40%, the aluminum-silicon brazing filler metal sheath accounts for 40%, and the aluminum-brazing flux powder accounts for 20%.
5. By the drawing and reducing method, the flexible welding wire can be drawn to the required size of phi 3.0mm and smaller by a drawing machine.
The forming method solves the problems that the aluminum-silicon-copper brazing filler metal has poor processability and the brazing filler metal is difficult to process into a disc-shaped welding wire or a welding ring, and can realize continuous automatic and efficient welding. The aluminum-silicon-copper flexible welding wire produced by the forming method can be directly used for welding a copper-aluminum component without adding an aluminum brazing flux, a welding joint has good corrosion resistance, long service life and good processability, can be processed into a disc-shaped welding wire or a welding ring, and can realize continuous automatic welding; the brazing performance of the welding wire can be adjusted by adjusting the proportion of the aluminum-silicon-copper powder to the aluminum brazing flux powder in the aluminum-silicon alloy sheath and the mixed powder, and the method is simple and convenient, low in cost and high in efficiency.
The above description is only the preferred embodiment of the present invention, and the novel flexible welding wire can also be produced by using a steel tube method, a coiling method, etc., and it should be noted that: it will be apparent to those skilled in the art that various modifications and adaptations can be made without departing from the principles of the invention and these are intended to be within the scope of the invention.