CN111774692A - Large-barrel-cladding nickel-based surfacing process - Google Patents
Large-barrel-cladding nickel-based surfacing process Download PDFInfo
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- CN111774692A CN111774692A CN201910265134.9A CN201910265134A CN111774692A CN 111774692 A CN111774692 A CN 111774692A CN 201910265134 A CN201910265134 A CN 201910265134A CN 111774692 A CN111774692 A CN 111774692A
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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
- B23K9/00—Arc welding or cutting
- B23K9/04—Welding for other purposes than joining, e.g. built-up welding
- B23K9/044—Built-up welding on three-dimensional surfaces
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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
- B23K9/00—Arc welding or cutting
- B23K9/32—Accessories
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Abstract
The invention discloses a large-barrel-cladding nickel-based surfacing process, which specifically comprises the following steps: s1: welding outer tool hoops at two ends of the cylinder; s2: cleaning the inner surface of the cylinder; s3: carrying out strip surfacing on the transition layer of the cylinder by adopting a welding strip/welding flux combination of EQNiCrMo-3/NSAS3-50BS model; s4: carrying out heat treatment on the transition layer; s5: carrying out strip surfacing on the corrosion-resistant layer of the cylinder by adopting a welding strip/welding flux combination of EQNiCrMo-4/ES A-FB 2B type; s6: and carrying out 100% penetration surface detection and 100% ultrasonic detection on the corrosion-resistant layer to be qualified. By the barrel large-cladding nickel-based surfacing process, the welding deformation of the container barrel surfacing can be effectively controlled, the quality of a bonding surface between a barrel base layer and a surfacing layer is ensured, the requirements of mechanical property, chemical property and corrosion performance detection are met, and the requirements of product manufacturing and national standards are met.
Description
Technical Field
The invention relates to the field of large-cladding surfacing welding processes, in particular to a cylinder large-cladding nickel-based surfacing welding process.
Background
With the rapid development of the petrochemical engineering industry in China, more and more container devices are in service under high-pressure, high-temperature and corrosion conditions, and therefore, the requirement that a plurality of container devices have technical performance indexes such as high-temperature resistance, corrosion resistance, high-pressure resistance and the like is required. In order to reduce the manufacturing cost of the container, it is generally designed to use a strength type low alloy steel or a heat resistant low alloy steel as a base layer to ensure the compressive strength of the container, and use a non-ferrous metal such as stainless steel, nickel, copper, titanium, zirconium, etc. as a coating layer to ensure the corrosion resistance and certain strength of the container. At present, the container is mainly designed in two ways, one way is that materials of two or more materials are directly adopted for explosive welding to form an explosive composite plate as a raw material of the cylinder body for manufacturing the container, and the thickness of a single material coating is mainly 2-3 mm; the other method is to adopt a surfacing mode, and to perform surfacing cladding on a nickel, copper or stainless steel welding material on a base material for manufacturing the container, mainly aiming at the condition that the thickness of a material cladding is more than or equal to 4mm and the material cladding is not suitable for manufacturing by explosive cladding.
The nickel-based alloy has excellent resistance to pitting corrosion, crevice corrosion and stress corrosion cracking, and has excellent corrosion resistance to most corrosive media in both the oxidized and reduced states. The EQNiCrMo-4 like the surfacing welding in the patent is particularly suitable for being used in high-temperature, inorganic acid and organic acid mixed with impurities and seawater corrosion environments. The current common nickel-based surfacing welding modes mainly comprise welding rod electric arc welding, manual tungsten electrode argon arc welding, automatic tungsten electrode argon arc welding, welding wire submerged arc welding, welding strip submerged arc welding, electroslag welding and the like. The surfacing process of the shielded metal arc welding has the defects of low welding efficiency, high labor intensity of welders, poor consistency of welding quality and great damage to the health of the welders due to welding smoke; the manual argon tungsten-arc welding surfacing process also has the problems of low welding efficiency, high labor intensity and poor welding quality consistency; although the welding quality consistency of the surfacing welding process of the automatic argon tungsten-arc welding can be ensured and the labor intensity of a welder can be reduced, the problem of low cladding efficiency exists at all; the surfacing process of the welding wire submerged arc welding can solve the problems to a certain extent, but the surfacing dilution rate of the welding wire submerged arc welding is too large, and the quality and the component requirements of a joint surface are difficult to guarantee; therefore, the strip submerged arc surfacing or strip electroslag surfacing developed at present well solves the problems, but for large-cladding nickel-based surfacing, as the surfacing area is large and the thickness of the surfacing layer is large, the welding deformation of the surfacing barrel needs to be controlled, the surfacing quality is ensured, the welding efficiency is improved, and the labor intensity of welders is reduced.
Disclosure of Invention
The invention aims to provide a large-barrel-cladding nickel-based surfacing process, which specifically comprises the following steps:
s1: welding outer tool hoops at two ends of the cylinder;
s2: cleaning the inner surface of the barrel, carrying out 100% magnetic powder detection on the cleaned surface, horizontally placing the barrel qualified for detection on a roller frame, adjusting the position of a surfacing welding head and the barrel, keeping the welding direction on the same axis with the barrel, and preheating the barrel to be surfaced;
s3: carrying out strip surfacing on a transition layer of the cylinder by adopting a welding strip/welding flux combination of EQNiCrMo-3/NSAS3-50BS model, wherein the surfacing mode is carried out according to a longitudinal straight path, and the welding strip/welding flux combination is alternately and symmetrically pressed in different areas in the circumferential direction, the thickness of the transition layer is about 4mm, the number of surfacing layers is 1, the width of the pressed path is 8-10mm, and the size of the welding strip is 60 multiplied by 0.5 mm;
s4: carrying out heat treatment on the transition layer, and carrying out 100% penetration surface detection and 100% ultrasonic bonding degree detection on the transition layer before and after the heat treatment to obtain qualified results;
s5: carrying out strip surfacing on the corrosion-resistant layer of the cylinder by adopting a welding strip/welding flux combination of EQNiCrMo-4/ES A-FB 2B type, wherein the surfacing mode is the same as S3, the welding strip/welding flux combination is staggered with a transition layer welding bead, the surfacing thickness of the corrosion-resistant layer is about 8mm, the number of surfacing layers is 2, the width of the pressing bead is 8-10mm, and the size of the welding strip is 60 multiplied by 0.5 mm;
s6: and carrying out 100% penetration surface detection and 100% ultrasonic detection on the corrosion-resistant layer to be qualified.
Preferably, the outer tool hoop in the S1 is made of Q345R low alloy steel, the thickness is 30-70mm, and the length from the two ends of the cylinder is 100-300 mm.
Preferably, the preheating of the cylinder to be subjected to surfacing welding in S2 adopts a flame heating mode, and the preheating temperature is more than or equal to 80 ℃; the detection should meet the requirements of NB/T47013-2015.
Preferably, the welding parameters of the transition layer overlaying welding in S3 are as follows: current I: 700-800A, voltage U: 24-28V, speed V: 12-18cm/min, temperature between layers: 80-200 ℃; and (3) alternately and symmetrically pressing the tracks for surfacing in different areas in the circumferential direction, increasing and decreasing according to the rule according to the diameter size of the cylinder, performing 4-track surfacing in each area, and finally keeping the weld bead at the lowest point of the cylinder when each weld bead is subjected to surfacing by rotating the cylinder, wherein the weld bead at the joint of each area is not more than 4.
Preferably, the heat treatment process parameters of the transition layer in S4 are as follows: controlling the temperature rise speed of more than 400 ℃ to be 55 ℃/h and less than or equal to VHThe temperature is less than or equal to 98 ℃/h, the heat preservation temperature is 620 +/-10 ℃, and the heat preservation time is 2.1+0.1h, the cooling speed of more than 400 ℃ is 55 ℃/h and is less than or equal to VC125 ℃/h or less, and the detection meets the requirement of NB/T47013-2015.
Preferably, the welding parameters of the corrosion-resistant layer surfacing welding in S5 are as follows: current I: 800-: 26-30V, speed V: 15-21cm/min, temperature between layers: 5-120 ℃; the surfacing mode is the same as the requirement in S4.
Preferably, the detection in S6 should meet the requirements of NB/T47013-2015.
Compared with the prior art, the invention has the beneficial effects that: the surfacing cladding efficiency of a large-area surfacing manufactured container can be improved, the surfacing labor intensity of a welder is reduced, the manufacturing period of a product is shortened, and the welding quality is more stable in the welding process. And through a barrel large-cladding nickel-based surfacing process method, the welding deformation of the container barrel surfacing can be effectively controlled, the quality of a bonding surface between a barrel base layer and a surfacing layer is ensured, the requirements of mechanical, chemical and corrosion performance detection are met, and the requirements of product manufacturing and national standards are met.
Drawings
FIG. 1 is a schematic view showing the preheating and surfacing directions of a cylinder;
FIG. 2 is a schematic view of a large cladding weld overlay joint;
FIG. 3 is a schematic view of a weld bead build-up sequence of each region of the cylinder;
FIG. 4 is a schematic diagram of the position distribution and sequence of the circumferential bead welding area of the cylinder;
FIG. 5 is a graph of a post-weld heat treatment process for a transition layer.
In the figure: 1, a cylinder body; 2, preheating a flame tool; 3, an outer tool hoop; 4, a transition layer; 5 corrosion resistant layer.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is further described in detail with reference to the following embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.
Example 1
A large-cladding nickel-based surfacing process for a cylinder mainly comprises a cylinder 1, a flame preheating tool 2, an outer tool hoop 3, a transition layer 4 and an anti-corrosion layer 5. The method specifically comprises the following steps and key technologies:
(1) respectively welding outer tool hoops at the positions, at the two ends of the cylinder 1, of which the lengths are 100-300mm away from the two ends of the cylinder, wherein the materials are Q345R or other low alloy steel, and the thickness is 30-70 mm;
(2) cleaning the inner surface of the barrel body 1, grinding, polishing, brushing and cleaning to remove harmful impurities which affect the surfacing quality, such as rust, oil stain, dust and the like on the inner surface of the barrel body, detecting 100% of magnetic powder (MT) on the inner surface of the cleaned barrel body 1 according to the requirement of NB/T47013-2015, horizontally placing the barrel body 1 on a roller frame after the detection is qualified, adjusting the directions of a surfacing machine head and the barrel body 1, keeping the welding direction and the barrel body 1 on the same axis, and preheating the barrel body 1 to be surfaced; preheating is carried out by adopting a flame preheating tool 2, 4 rows of flame heating pipes are additionally arranged below the cylinder body as shown in figure 1 and are symmetrically distributed according to two sides of the lowest point of the cylinder body 1, and the cylinder body 1 synchronously rotates along with the roller carrier in the heating process. So that the cylinder body 1 is uniformly heated in the circumferential direction. The preheating temperature is detected in the heating process, and the preheating temperature of the cylinder body 1 is ensured to be more than or equal to 80 ℃.
(3) According to the area division mode in the attached figure 4, firstly, a 270-degree area of a cylinder body 1 is rotated to the lowest point along with a roller frame, surfacing welding of a transition layer 4 is carried out in the 270-degree area, surfacing welding passes are 4, as shown in the attached figure 3, the sequence of surfacing welding of 4 passes is carried out according to the steps of firstly → secondly → thirdly → fourthly, and it is noted that when surfacing welding of each pass is carried out, the position of the corresponding welding pass needs to be rotated to the lowest point for surfacing welding, so that surfacing welding is in a flat position; after the 270-degree area surfacing is completed, the cylinder body 1 is rotated to turn the 90-degree area to the horizontal position for surfacing of the transition layer 4, and the sequence and the mode of the 4-layer surfacing in the 90-degree area are the same as those in the 270-degree area. According to the method, the build-up welding areas are divided in sequence according to the size of the cylinder 1, the order of dividing the build-up welding areas is 270 ° → 90 ° → 0 ° → 180 ° → 45 ° → 225 ° → 135 ° → 315 ° → … …, and if the diameter of the cylinder 1 becomes large, the division is continued as described above until the transition layer 4 is fully stacked in the entire circumferential direction of the cylinder 1. It should be noted that, the final lap joint opening of each area exists in the circumferential divided area overlaying welding, and the welding path at the lap joint opening is less than or equal to 4; the surfacing welding of each region and pass of the transition layer 4 is performed along the longitudinal straight path of the cylinder 1, the circumferential directions of the regions are alternately symmetrical, the passes are sequentially pressed in sequence, and the surfacing welding process parameters of the transition layer 4 are as shown in table 1.
TABLE 1 transition layer build-up welding process
(4) Performing heat treatment on the transition layer 4 according to figure 5, and controlling the temperature rise speed of more than 400 ℃ to be 55 ℃/h to be less than or equal to VHThe temperature is less than or equal to 98 ℃/h, the heat preservation temperature is 620 +/-10 ℃, and the heat preservation time is 2.1+0.1h, the cooling speed of more than 400 ℃ is 55 ℃/h and is less than or equal to VCLess than or equal to 125 ℃/h; after the heat treatment is finished, carrying out 100% Penetration (PT) surface detection and 100% Ultrasonic (UT) bonding degree detection on the transition layer 4 according to the requirement of NB/T47013-2015;
(5) and after the heat treatment of the transition layer 4 is finished and the detection is qualified, performing surfacing welding on the corrosion-resistant layer 5. The corrosion resistant layer had a total of 2 layers, each 4 mm. The specific surfacing step and the mode are the same as (3), firstly, according to the mode of area division in the attached figure 4, firstly, the 270-degree area of the cylinder body 1 is rotated to the lowest point along with the roller frame, surfacing of the transition layer 5 is carried out in the 270-degree area, the surfacing welding passes are 4, as shown in the attached figure 3, the 4-pass surfacing sequence is carried out according to the sequence of (i) → (iii) → r, and it is noted that the welding pass of the corrosion-resistant layer 5 at the moment should be staggered from the welding pass of the transition layer 4 in the attached figure 3 by half the welding pass width, as shown in the attached figure 2. Similarly, when each bead is built up, the position of the corresponding bead needs to be turned to the lowest point for building up, and the building up is ensured to be in a flat position; after the 270-degree area surfacing is completed, the cylinder body 1 is rotated to turn the 90-degree area to the horizontal position for surfacing of the corrosion-resistant layer 5, and the sequence and the mode of 4-layer surfacing in the 90-degree area are the same as those in the 270-degree area. According to this method, the build-up welding regions are divided in order according to the size of the cylinder 1, the order of dividing the build-up welding regions is 270 ° → 90 ° → 0 ° → 180 ° → 45 ° → 225 ° → 135 ° → 315 ° → … …, and if the diameter of the cylinder 1 becomes large, the division is continued as described above until the entire circumferential direction of the cylinder 1 is filled with the corrosion-resistant layer 5. It should be noted that, the final lap joint opening of each area exists in the circumferential divided area overlaying welding, and the welding path at the lap joint opening is less than or equal to 4; the surfacing welding of each area and each pass of the anti-corrosion layer 5 is carried out along the longitudinal straight channel of the cylinder 1, the circumferential directions of the areas are alternately symmetrical, the passes are sequentially pressed in sequence, and the surfacing welding process parameters of the anti-corrosion layer 5 are as shown in the table 2. And after one circle of surfacing welding of the circumferential corrosion-resistant layer of the cylinder is finished, repeating the steps to perform surfacing welding of a second circle of corrosion-resistant layer until the thickness of the corrosion-resistant layer required by the pattern is achieved.
TABLE 2 surfacing welding process for corrosion-resistant layer
(6) After the corrosion resistant layer is built up, the corrosion resistant layer is subjected to 100% Penetration (PT) surface detection and 100% Ultrasonic (UT) detection according to the requirements of NB/T47013-2015.
The method for carrying out large cladding nickel-based surfacing on the cylinder has the following beneficial effects:
(1) the cylinder test plate of the embodiment is respectively sampled from the positions 2mm, 3mm and 5.5mm above the transition layer for chemical analysis, the detailed chemical component detection values are shown in table 3, the result is qualified, and the relevant standards and design requirements are met.
TABLE 3 chemical composition test of corrosion resistant layer
(2) The corrosion resistance test of the cylinder test plate of the embodiment according to ASTM G28A shows that the corrosion rate of the test sample is less than 12mm/a, and the ratio of the corrosion rate of the test sample to the corrosion rate of the test sample in the state of solution treatment in the laboratory is less than 1.5, thereby meeting the relevant standards and design requirements.
(3) The entire surfacing layer and the base layer of the cylinder test plate are sampled and subjected to macroscopic metallographic analysis and detection, no defects such as air holes, slag inclusion, incomplete fusion and the like are found, no cracks under the layer are found under observation under a magnifying lens of 10 times, and the surfacing layer and the bonding surface are qualified in quality.
(4) The bending performance of the whole surfacing layer of the cylinder test plate and the base layer of the cylinder is detected, and the detection structure shows that no crack is generated after the tests of the large side bending sample, the small side bending sample and the standard side bending sample of the surfacing, so that the requirements of the standard on the surfacing quality are met.
(5) The ovality of the cylinder body is detected after surfacing welding of the cylinder body, the measurement result shows that the ovality of the cylinder body is less than or equal to 4mm, the deformation control is good, and the standard and the manufacturing requirement are met.
(6) To the barrel build-up welding of this embodiment, welding efficiency improves greatly, has shortened the manufacturing cycle of product.
(7) In the cylinder surfacing process of the embodiment, a welder does not enter the cylinder to perform surfacing operation, so that the labor intensity of the welder is reduced.
The above description is only for the preferred embodiment of the present invention, but the scope of the present invention is not limited thereto, and any person skilled in the art should be considered to be within the technical scope of the present invention, and the technical solutions and the inventive concepts thereof according to the present invention should be equivalent or changed within the scope of the present invention.
Claims (7)
1. The large-barrel-cladding nickel-based surfacing process is characterized by comprising the following steps:
s1: welding outer tool hoops at two ends of the cylinder;
s2: cleaning the inner surface of the barrel, carrying out 100% magnetic powder detection on the cleaned surface, horizontally placing the barrel qualified for detection on a roller frame, adjusting the position of a surfacing welding head and the barrel, keeping the welding direction on the same axis with the barrel, and preheating the barrel to be surfaced;
s3: carrying out strip surfacing on a transition layer of the cylinder by adopting a welding strip/welding flux combination of EQNiCrMo-3/NSAS3-50BS model, wherein the surfacing mode is carried out according to a longitudinal straight path, and the welding strip/welding flux combination is alternately and symmetrically pressed in different areas in the circumferential direction, the thickness of the transition layer is about 4mm, the number of surfacing layers is 1, the width of the pressed path is 8-10mm, and the size of the welding strip is 60 multiplied by 0.5 mm;
s4: carrying out heat treatment on the transition layer, and carrying out 100% penetration surface detection and 100% ultrasonic bonding degree detection on the transition layer before and after the heat treatment to obtain qualified results;
s5: carrying out strip surfacing on the corrosion-resistant layer of the cylinder by adopting a welding strip/welding flux combination of EQNiCrMo-4/ES A-FB 2B type, wherein the surfacing mode is the same as S3, the welding strip/welding flux combination is staggered with a transition layer welding bead, the surfacing thickness of the corrosion-resistant layer is about 8mm, the number of surfacing layers is 2, the width of the pressing bead is 8-10mm, and the size of the welding strip is 60 multiplied by 0.5 mm;
s6: and carrying out 100% penetration surface detection and 100% ultrasonic detection on the corrosion-resistant layer to be qualified.
2. The barrel large-cladding nickel-based surfacing process according to claim 1, characterized in that: in S1, the outer tool hoop is made of Q345R low alloy steel, the thickness is 30-70mm, and the length from the two ends of the cylinder body is 100-300 mm.
3. The barrel large-cladding nickel-based surfacing process according to claim 1, characterized in that: s2, preheating the cylinder to be subjected to surfacing by adopting a flame heating mode, wherein the preheating temperature is more than or equal to 80 ℃; the detection should meet the requirements of NB/T47013-2015.
4. The barrel large-cladding nickel-based surfacing process according to claim 1, characterized in that: in S3, the surfacing welding parameters of the transition layer are as follows: current I: 700-800A, voltage U: 24-28V, speed V: 12-18cm/min, temperature between layers: 80-200 ℃; and (3) alternately and symmetrically pressing the tracks for surfacing in different areas in the circumferential direction, increasing and decreasing according to the rule according to the diameter size of the cylinder, performing 4-track surfacing in each area, and finally keeping the weld bead at the lowest point of the cylinder when each weld bead is subjected to surfacing by rotating the cylinder, wherein the weld bead at the joint of each area is not more than 4.
5. The barrel large-cladding nickel-based surfacing process according to claim 1, characterized in that: the heat treatment process parameters of the transition layer in the S4 are as follows: controlling the temperature rise speed of more than 400 ℃ to be 55 ℃/h and less than or equal to VHThe temperature is less than or equal to 98 ℃/h, the heat preservation temperature is 620 +/-10 ℃, and the heat preservation time is 2.1+0.1h, the cooling speed of more than 400 ℃ is 55 ℃/h and is less than or equal to VC125 ℃/h or less, and the detection meets the requirement of NB/T47013-2015.
6. The barrel large-cladding nickel-based surfacing process according to claim 1, characterized in that: the surfacing welding parameters of the corrosion-resistant layer in the S5 are as follows: current I: 800-: 26-30V, speed V: 15-21cm/min, temperature between layers: 5-120 ℃; the surfacing mode is the same as the requirement in S4.
7. The barrel large-cladding nickel-based surfacing process according to claim 1, characterized in that: the detection in S6 should meet the requirements of NB/T47013-2015.
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Cited By (3)
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| CN113523719A (en) * | 2021-07-10 | 2021-10-22 | 上海泽超实业有限公司 | Machining process of helical blade |
| CN114888407A (en) * | 2022-05-30 | 2022-08-12 | 太重（天津）滨海重型机械有限公司 | Technique for surfacing H2Cr13 on outer circle surface of large plunger |
| CN115283876A (en) * | 2022-09-13 | 2022-11-04 | 上海外高桥造船有限公司 | Defect processing method for crane hook shaft |
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| CN113523719A (en) * | 2021-07-10 | 2021-10-22 | 上海泽超实业有限公司 | Machining process of helical blade |
| CN114888407A (en) * | 2022-05-30 | 2022-08-12 | 太重（天津）滨海重型机械有限公司 | Technique for surfacing H2Cr13 on outer circle surface of large plunger |
| CN114888407B (en) * | 2022-05-30 | 2024-03-05 | 太重（天津）滨海重型机械有限公司 | Technological method for surfacing H2Cr13 on outer circle surface of large plunger |
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Application publication date: 20201016 |