CN111590236A - 一种贝氏体钢电弧焊用焊条 - Google Patents

一种贝氏体钢电弧焊用焊条 Download PDF

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CN111590236A
CN111590236A CN201911170775.2A CN201911170775A CN111590236A CN 111590236 A CN111590236 A CN 111590236A CN 201911170775 A CN201911170775 A CN 201911170775A CN 111590236 A CN111590236 A CN 111590236A
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bainite steel
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张绵胜
张志勇
张志强
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BEIJING TEYE INDUSTRIAL AND TRADE CORP
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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
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24—Selection of soldering or welding materials proper
    • B23K35/30—Selection of soldering or welding materials proper with the principal constituent melting at less than 1550 degrees C
    • 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
    • B23K35/24—Selection of soldering or welding materials proper
    • B23K35/30—Selection of soldering or welding materials proper with the principal constituent melting at less than 1550 degrees C
    • B23K35/3053—Fe as the principal constituent
    • 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
    • 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
    • B23K35/22—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
    • B23K35/362—Selection of compositions of fluxes

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  • Chemical & Material Sciences (AREA)
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Abstract

本发明公开了一种贝氏体钢电弧焊用焊条，由焊芯和表面的药皮组成，所述焊芯由与待焊的贝氏体钢轨拉成的焊棒，所述药皮按组份的重量百分含量计，主要含有：Al2O3 0.8‑1.8，CaO 46.0‑56.0，Cl 0.02‑0.04，Cr2O3 0.02‑0.04，F 9.0‑14.0，Fe2O3 3.0‑6.0，K2O 2.5‑4.3，MgO 1.0‑2.0，MnO 1.0‑1.5，Na2O 4.1‑4.5，Nb2O5 0.038‑0.05，SiO2 13.9‑15.0，SrO 0.01‑0.03，TiO2 3.0‑9.0和ZrO 0.02‑0.08。这种焊条用于修补贝氏体钢轨及道岔，焊接后与母材硬度和耐磨性相当，可以有效提高产品使用寿命。

Description

一种贝氏体钢电弧焊用焊条
技术领域
本发明涉及一种电弧焊用的焊条，具体来说是一种用于贝氏体钢轨焊接用的焊条。
背景技术
道岔是轨道线路结构三大薄弱环节之一，道岔的辙叉，由于有有害空间又是道岔的薄弱环节，是轨道结构的薄弱环节。使用过程中受机车的碾压、冲击所产生的病害，主要是磨耗和裂纹，整治方法是打磨和焊补。特别是磨损缺肉和裂纹打磨后必须焊补，方能正常使用。
辙叉的焊修是电焊为主，要求极为严格，在焊肉材质上要求机械性能和辙叉同材质、同性能。然而，焊补的操作环境与钢轨的生产环境和条件完全不同，若想达到焊肉的材质与性能与母材一致，有相当的难度，对于不同的母材，必须开发专用的焊条。
北京特冶工贸有限公司作为辙叉的专业研究和生产企业，与包钢合作开发了贝氏体钢组合辙叉，是一种马贝复相组织的贝氏体钢，辙叉寿命提高了2-3倍，但同样也出现磨损、压溃、微细裂纹常见的病害，因此需要电焊修补。然而，市场并没有针对这种钢轨的电弧焊焊条，因此在铁道科学研究院金化所、钢铁研究院焊接所的支持和指导下，开始研究贝氏体钢焊条，经过多年的研究、试验和验证，在京山、京广、京沪等主要干线取得焊修成功，得到本发明。
发明内容
本发明的目的在于，提供一种用于贝氏体钢焊接的电弧焊用焊条。
本发明的贝氏体钢电弧焊用焊条，由焊芯和表面的药皮组成，所述焊芯采用与焊接贝氏体钢同材质。药皮在焊接中起着极为重要的作用，好的药皮能够起到避免由于氧和氮的侵入造成的焊缝气孔、夹渣或裂纹，补充合金元素，并稳定电弧作用。本发明是针对贝氏体钢轨研发，没有现成的药皮可以直接采用和借鉴，经过反复试验，得到的合适的药皮按组份的重量百分含量计，主要含有：Al2O3 0.8-1.8，CaO 46.0-56.0，Cl 0.02-0.04，Cr2O30.02-0.04，F 9.0-14.0，Fe2O3 3.0-6.0，K2O 2.5-4.3，MgO 1.0-2.0，MnO 1.0-1.5，Na2O4.1-4.5，Nb2O5 0.038-0.05，SiO2 13.9-15.0，SrO 0.01-0.03，TiO2 3.0-9.0和ZrO 0.02-0.08。
进一步地，药皮还可以添加有NiO 0.01-0.02，或者添加有CuO 0.01-0.02和/或ZnO 0.02-0.04，以改善焊接质量。
特冶的辙叉用钢为U20Mn2SiCrNiMo，化学成份及其重量百分含量为：C 0.16-0.25，Si 0.70-1.20，Mn 1.60-2.45，Ni 0-0.7，Cr 0.6-1.2，Mo 0.15-0.6，P≤0.022，S≤0.015，其余为Fe，金相组织为贝氏体。为保证成份的一致，本发明的焊芯采用由钢轨切割后拔成的焊条棒。
本发明的这种电弧焊用焊条，焊接贝氏体钢轨、道岔，满足贝氏体钢辙叉、尖轨、钢轨的使用要求，通过焊修、焊补可延长部件使用寿命显著提高，焊修后轨料的刚性、硬度及耐磨性等技术指标能够满足铁路要求，焊修后质量稳定。
具体实施方式
下面结合具体实施例对本发明做进一步说明，以助于理解本发明的内容。
实施例1对U20Mn2SiCrNiMo贝氏体钢辙叉的焊补
U20Mn2SiCrNiMo贝氏体钢辙叉Rm为1280MPa，Rp0.2为1000MPa，A≥9％，Z为14.7％，常温ak为68.7J，热处理状态为热轧空冷，显微组织为贝氏体。
电焊条，直径3.2mm，焊芯采用U20Mn2SiCrNiMo钢轨轧制成棒材，药皮成份(wt％)为Al2O3 1.0，CaO 50.0，Cl 0.03，Cr2O3 0.03，F 13.0，Fe2O3 4.0，K2O 3.8，MgO 1.5，MnO1.25，Na2O 4.2，Nb2O5 0.04，SiO2 14.28，SrO 0.02，TiO2 6.8和ZrO 0.05。
焊接电压24V，焊接电流120A，焊接速度3mm/s，层间温度120℃。
电焊条熔敷金属化学成份：Si 1.5-2.5，Mn 1.5-2.5，Cr 0.6-2.0，Ni 0.5-1.0，Mo0.36，Al 0.004，S 0.003，P 0.019。
熔敷金属力学性能：Rm为1260MPa，Rp0.2为953MPa，A8％，Z为12％，常温ak为64J，无气孔、夹渣和裂纹，焊接质量良好，金相组织未见明显马氏体。
分别对焊缝层表面及钢轨母材进行布氏硬度实验，结果见表1
表1布氏硬度试验结果
Figure BDA0002288659760000021
Figure BDA0002288659760000031
堆焊层材料硬度均高于母材。
实施例2U20Mn2SiCrNiMo钢轨辙叉现场顶面焊补
焊条：为保证成份的一致，本发明的焊芯采用由U20Mn2SiCrNiMo钢轨切割后拔成的焊条棒。药皮成份为Al2O3 0.88，CaO 55.08，Cl 0.027，Cr2O3 0.025，F 9.13，Fe2O3 5.86，K2O 4.08，MgO 1.04，MnO 1.28，Na2O 4.28，Nb2O5 0.046，SiO2 14.59，SrO 0.026，TiO2 3.4和ZrO 0.062，CuO 0.017，Nd2O3 0.068，P2O5 0.011，SO3 0.081。
大秦线上行大同段湖东站15#岔号12349号辙叉75kg-1 2#心直翼轨压溃掉块，施焊长度直翼轨410*37*7mm，心轨210mm深5mm，2013年7月18日焊接，焊接后该部位寿命与翼轨同寿命。
实施例3对U20Mn2SiCrNiMo贝氏体钢辙叉的焊补
焊芯采用U20Mn2SiCrNiMo贝氏体钢轨轧制成棒材，药皮成份为Al2O3 1.68，CaO48.5，Cl 0.037，Cr2O3 0.32，F 13.24，Fe2O3 3.39，K2O 2.6，MgO 1.72，MnO 1.1，Na2O 4.38，Nb2O5 0.041，SiO2 14.05，SrO 0.014，TiO2 8.51，ZnO 0.031，ZrO 0.03，MoO3 0.20，P0.0096，S 0.15。
U20Mn2SiCrNiMo贝氏体钢轨辙叉机械性能为：Rm为1280MPa，A≥10％，Rp0.2≥1000MPa，断后伸长率Z≥12％，室温冲击功ak≥70J,踏面硬度360-430HBW，热处理状态为热轧空冷，显微组织为贝氏体和马氏体复相组织。
焊接电压：24V，焊接电流：120A，焊接速度3mm/s，层间温度120℃。
焊接后的熔敷金属力学性能为：Rm 1210MPa，Rp0.2 980MPa，A 9.0％，Z 11.6％，ak 65J，硬度445HBW，无气孔、夹渣和裂纹。

Claims (3)

1.一种贝氏体钢电弧焊用焊条，由焊芯和表面的药皮组成，所述焊芯由与待焊的贝氏体钢轨拉成的焊棒，所述药皮按组份的重量百分含量计，主要含有：Al2O3 0.8-1.8，CaO46.0-56.0，Cl 0.02-0.04，Cr2O3 0.02-0.04，F 9.0-14.0，Fe2O33.0-6.0，K2O 2.5-4.3，MgO1.0-2.0，MnO 1.0-1.5，Na2O 4.1-4.5，Nb2O5 0.038-0.05，SiO2 13.9-15.0，SrO 0.01-0.03，TiO2 3.0-9.0和ZrO 0.02-0.08。
2.如权利要求1所述的贝氏体钢电弧焊用焊条，其特征在于：药皮还添加有NiO 0.01-0.02，或者添加有CuO 0.01-0.02和/或ZnO 0.02-0.04。
3.如权利1或2所述的贝氏体钢电弧焊用焊条，其特征在于：所述贝氏体钢轨为U20Mn2SiCrNiMo，化学成份及其重量百分含量为：C 0.16-0.25，Si
0.70-1.20，Mn 1.60-2.45，Ni 0-0.7，Cr 0.6-1.2，Mo 0.15-0.6，P≤0.022，S≤0.015，其余为Fe，金相组织为贝氏体组织。
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