CN111774757A - Self-lubricating wear-resistant flux-cored wire containing nickel-coated graphite component and welding method thereof - Google Patents
Self-lubricating wear-resistant flux-cored wire containing nickel-coated graphite component and welding method thereof Download PDFInfo
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- CN111774757A CN111774757A CN202010535613.0A CN202010535613A CN111774757A CN 111774757 A CN111774757 A CN 111774757A CN 202010535613 A CN202010535613 A CN 202010535613A CN 111774757 A CN111774757 A CN 111774757A
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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
- B23K35/02—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape
- B23K35/0255—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape for use in welding
- B23K35/0261—Rods, electrodes, wires
- B23K35/0266—Rods, electrodes, wires flux-cored
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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
- B23K35/3053—Fe as the principal constituent
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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
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Abstract
The invention belongs to the field of welding materials, and particularly relates to a self-lubricating wear-resistant flux-cored wire containing nickel-containing graphite components and a welding method thereof; the nickel-containing graphite component self-lubricating wear-resistant flux-cored wire comprises a flux core and a carbon steel belt used for wrapping the flux core; wherein the medicine core comprises the following components in percentage by mass: 18-22% of ferrochrome; 7-9% of ferroboron; 3-5% of ferrosilicon, 3-5% of ferromanganese, 0.4-0.6% of metallic aluminum, 2-3% of rare earth elements, 3-5% of nickel-coated graphite and the balance of iron. The wear-resistant surfacing layer prepared by the flux-cored wire containing the nickel-coated graphite powder by using a double constant current source non-molten drop arc hot wire GTAW surfacing method has a self-lubricating function.
Description
Technical Field
The invention belongs to the field of welding materials, and particularly relates to a self-lubricating wear-resistant flux-cored wire containing nickel-containing graphite components and a welding method thereof.
Background
The friction heat generated by the relative motion of the friction and wear parts can increase the temperature of the friction surface, the working environment of the friction parts is worse by adopting liquid lubrication, and the solid lubrication is widely applied to the wear-resisting field in recent years due to the good stability of the solid lubrication in the high-temperature working environment. Graphite solid lubricants have received attention from researchers because of their excellent lubricating properties.
The wear-resistant layer containing the solid lubricating material is prepared on the surface of the original workpiece by adopting a surface technology, so that a lubricating film with low shear strength can be formed between the friction pairs, the friction and wear resistance of the working layer can be improved, the friction coefficient can be reduced, the service life of the workpiece is further prolonged, and the raw materials and the production time are greatly saved.
Surfacing is a surface technology for preparing a wear-resistant layer, which is widely adopted at present, and the difficulty of preparing the wear-resistant layer of the solid lubricating material is caused by how to transfer easily burnt graphite phases into a surfacing layer during surfacing. In order to ensure the efficiency and quality of surfacing, the surfacing process requires high deposition rate of a welding wire and low heat input of a base metal in the surfacing implementation process, which is contradictory to the characteristics of the traditional welding method, namely the high deposition rate of the welding wire and the high heat input of the base metal. The welding current for realizing the high deposition rate of the welding wire is increased, the burning loss of graphite phase and alloy elements is serious, the waste loss of the alloy elements also causes the pollution of air environment, and the wear resistance of the overlaying layer is influenced.
Disclosure of Invention
The invention aims to provide a self-lubricating wear-resistant flux-cored wire containing nickel-containing graphite components and a welding method thereof.
In order to achieve the purpose, the invention adopts the following technical scheme:
a self-lubricating wear-resistant flux-cored wire containing a nickel-containing graphite component comprises a flux core and a carbon steel belt used for wrapping the flux core; wherein the medicine core comprises the following components in percentage by mass: 18-22% of ferrochrome; 7-9% of ferroboron; 3-5% of ferrosilicon, 3-5% of ferromanganese, 0.4-0.6% of metallic aluminum, 2-3% of rare earth elements, 3-5% of nickel-coated graphite and the balance of iron.
The medicine core comprises the following components in percentage by mass: 20% of ferrochrome; 8% of ferroboron; 4% of ferrosilicon, 4% of ferromanganese, 0.5% of metallic aluminum, 2.5% of rare earth elements, 4% of nickel-coated graphite and the balance of iron.
The 80-mesh passing rate of the flux core powder particles is 100 percent.
The filling rate of the medicinal powder is 23-27%.
The diameter of the wear-resistant welding wire is 1.6 mm.
The application also comprises a welding method of the self-lubricating wear-resistant flux-cored wire containing the nickel-coated graphite component, which is used and has the following technological parameters: welding voltage: 22-26V; main arc current: 120A; auxiliary arc current: 120-240A; wire feeding speed: 2.2-2.6 m/min; welding speed: 3-4 mm/s; distance between the tungsten electrode and the workpiece: 7-8 mm; distance between tungsten electrode and welding wire: 2-3 mm; flow rate of shielding gas: 15L/min. Because the surfacing welding of the welding system can realize high deposition rate of welding wires and low heat input of base materials, the surfacing welding layer contains graphite solid lubricant for transition of the welding wires, the friction coefficient is reduced along with the prolonging of the abrasion time, and the surfacing welding layer has the self-lubricating function.
The self-lubricating overlaying layer of the Fe-Cr-B wear-resistant matrix is prepared by the self-designed flux-cored wire containing the nickel-coated graphite powder by utilizing the self-built double constant-current source non-molten-drop arc hot wire GTAW welding system.
During welding, a point-to-point auxiliary arc is formed between the end of the welding wire and a tungsten electrode to preheat the welding wire, the deposition rate of the welding wire is adjusted by adjusting the energy of the auxiliary arc, and the heat of the auxiliary arc is concentrated on the welding wire, so that the deposition rate can be improved without increasing the energy of the main arc, the relationship between the energy of the main arc and the wire feeding speed is decoupled, and the coupling relationship that the energy of the main arc is required to be increased when the deposition rate is increased in the traditional welding method is broken through.
During welding, the molten drop transition mode adopts non-molten drop transition, namely, a welding wire is directly inserted into a molten pool, the wire feeding speed and the welding wire melting keep dynamic balance, a front welding wire core before entering the molten pool is completely wrapped by a carbon steel strip and is not exposed in electric arc, meanwhile, the welding wire is not overheated, the burning loss of graphite phase and alloy can be reduced to a great extent, and the heat input of base metal is further reduced.
The filling rate of the welding wire is 23-27%, the filling rate cannot be too high, otherwise, the carbon steel belt is too thin, the welding wire is easy to damage when the auxiliary electric arc preheats the welding wire, welding spatters are generated, and the powder is easy to burn when exposed in the electric arc. On the other hand, because the welding method effectively protects the alloy elements of the flux core, the flux core can meet the requirement of the content of the alloy elements of the overlaying layer without excessively high filling rate.
The designed flux-cored wire adopts nickel-coated graphite powder as a solid lubricant, and nickel can protect the burning loss of graphite so as to improve the transition coefficient of the graphite and improve the combination of the graphite and a metal matrix.
The double-constant-current-source non-molten-drop arc hot wire GTAW welding method can realize low heat input of the base metal and high deposition rate of the welding wire, thereby realizing low dilution rate of the base metal and ensuring the alloy content of the surfacing layer. The structure of the surfacing layer is a typical Fe-Cr-B series wear-resistant matrix, is a hypoeutectic structure, and has dendritic crystal martensite and eutectic boride, and the hardness of a welding seam is more than 57 HRC. The black nickel-coated graphite phase particles are uniformly distributed at the dendrite crystal boundary.
The method is characterized in that a double-constant-current-source non-droplet electric arc hot wire GTAW surfacing technology is utilized to prepare a surfacing layer of a Fe-Cr-B wear-resistant matrix by adopting a flux-cored wire containing nickel-coated graphite powder, the wear-resistant surfacing layer contains a graphite solid lubricant, and when a friction wear experiment is carried out on the wear-resistant surfacing layer, the friction coefficient is reduced along with the extension of the wear time, which indicates that the surfacing layer containing the graphite solid lubricant has a self-lubricating function when being worn.
Compared with the prior art, the invention has the beneficial effects that:
by utilizing the characteristics of low heat input of parent metal and high deposition rate of welding wires in a double-constant-current-source non-molten-drop arc hot wire GTAW welding method, the self-designed flux-cored welding wire containing nickel-coated graphite powder is adopted for surfacing, and when a non-molten-drop transition form is adopted, graphite and alloy elements in a flux core are protected and effectively transition to a weld joint of a molten pool, so that the wear resistance of the surfacing layer is ensured. The electric arc is stable, the welding spatter is small, and the welding smoke is less.
The self-designed flux-cored wire containing nickel-coated graphite powder has a self-lubricating function, and the wear-resistant surfacing layer prepared by the double-constant-current-source non-droplet arc hot wire GTAW surfacing method has the advantages of simple structure, low cost and the like.
Description of the drawings:
FIG. 1 is a cross-sectional view of a flux cored welding wire;
FIG. 2 is a macro-topography of example and comparative weld seams;
FIG. 3 is a schematic view of the welding principle of an embodiment and a comparative example;
FIG. 4 is a diagram of a molten drop-free transition of an embodiment;
FIG. 5 is a metallographic picture of a weld overlay of examples and comparative examples;
FIG. 6 is a graph of energy spectrum analysis of black grain phase in weld.
FIG. 7 is a graph of the coefficient of friction of the weld overlay versus time for the examples and comparative examples
FIG. 8 is SEM topography of weld overlay wear for examples and comparative examples.
Detailed Description
In order to make the technical solutions of the present invention better understood by those skilled in the art, the present invention will be further described in detail with reference to the following preferred embodiments.
1. Preparing a flux-cored wire:
the powder of the medicine core layer comprises the following components in percentage by weight: 20% of ferrochrome; 8% of ferroboron; 4% of ferrosilicon, 4% of ferromanganese, 0.5% of metallic aluminum, 2.5% of rare earth elements, 4% of nickel-coated graphite and the balance of iron. The powder particle size of the flux-cored wire is 100 percent, the outer steel belt is a carbon steel belt, the filling rate of the flux core in the carbon steel belt is about 25 percent, the outer steel belt is made into a U shape, the medicinal powder is added into a U-shaped groove, the U-shaped groove is closed, and then continuous drawing and reducing are carried out to obtain the flux-cored wire with the specification diameter of 1.6mm, and the cross section of the flux-cored wire is shown in figure 1.
2. Preparing a surfacing layer:
example (b):
a self-built double-constant-current-source arc hot wire GTAW welding system is utilized, and a self-designed flux-cored wear-resistant welding wire containing nickel and graphite components is adopted to carry out surfacing on a Q235 steel plate with the thickness of 6 mm. The technological parameters are as follows: welding voltage: 22-26V; main arc current: 240A; auxiliary arc current: 120A; wire feeding speed: 2.4 m/min; welding speed: 3.5mm/s；Distance between the tungsten electrode and the workpiece: 7-8 mm; tungstenDistance between electrode and welding wire: 2-3 mm; flow rate of shielding gas: 15L/min.
Comparative example:
a traditional consumable electrode argon arc surfacing (GMAW) welding system is utilized, and a flux-cored wear-resistant welding wire containing nickel and graphite components is adopted to carry out surfacing on a Q235 steel plate with the thickness of 6 mm. Welding voltage: 22-26V; arc current: 240A; wire feeding speed: 2.0 m/min; welding speed: 3.5mm/s；Flow rate of shielding gas: 15L/min.
3. The embodiment and the comparative example relate to a macroscopic weld joint, structure and self-lubricating performance comparative analysis of a overlaying layer of a wear-resistant flux-cored wire containing a graphite component by using a double constant current source non-droplet arc hot wire GTAW (gas tungsten arc welding).
The results and analysis of the examples and comparative examples are as follows:
(1) macroscopic analysis of the cross-section of a welded joint
The macroscopic cross-section of the weld joint is shown in fig. 1 with the same total current. The dilution rates of the two welding methods are very different, the dilution rate of the GTAW technique surfacing is very low and is less than 5%, and the dilution rate of the GMAW surfacing is larger and is about 25%. It can be seen from the cross-sectional profile shape of the weld that the weld obtained by the GTAW technique is high, the left and right side surfaces of the weld are basically vertical to the base material, and the weld of the traditional GMAW surfacing welding is flat, namely, the aspect ratio is very different. When the weld joint is actually produced and applied in the overlaying process, the welding seam shape of the GTAW technology overlaying can obviously reduce the number of welding layers, and can also avoid repeated melting and solidification of overlaying metal to influence the performance of the material.
(2) Principle of welding analysis
The principle of double constant-current source no-droplet arc hot wire GTAW surfacing welding is shown in figure 3(a), when in welding, a point-to-point auxiliary arc is formed between the end of a welding wire and a tungsten electrode, the deposition rate of the welding wire can be easily adjusted by decoupling the relation between the energy of a main arc and the wire feeding speed without considering the heat input sent to the surface of a workpiece, the deposition rate can be improved without increasing the energy of the main arc, the main arc current 120A and the auxiliary arc current 120A can reach the wire feeding speed of 2.4m/min, and stable welding can be realized. Experimental results prove that the adoption of the non-molten drop arc hot wire GTAW can effectively reduce the heat input of the base metal and increase the deposition efficiency of the welding wire. The heat transfer characteristic of the coupling relation between the heat input of the base metal and the deposition rate of the welding wire is eliminated, and the requirements of the surfacing process, namely low heat input and high deposition rate, are deeply met. The conventional GMAW welding principle is shown in fig. 3(b), and during overlaying, an electric arc is burned between a welding wire and a workpiece. If the deposition rate of the welding wire is increased, the wire feeding speed is increased, so that the welding current is increased, the test current is 240A, and the wire feeding speed can only reach 2.0 m/min. The coupling relation between the current and the deposition rate causes the workpiece parent metal to absorb more arc heat, so that the dilution rate is increased, which is in contradiction with the technological requirements of high deposition rate of the welding wire and low heat input of the workpiece parent metal during surfacing.
(3) Analysis of welding wire heating
By adopting the coupled arc hot wire GTAW method, the wire feeding speed of the welding wire and the main arc current are not coupled any more, so that the wire feeding speed can be increased as required under a certain welding current, the welding wire melting can be adjusted from a molten droplet state to a molten droplet-free state, and the transition form is shown in figure 4. Under the condition of no molten drop, the auxiliary electric arc acts on the tip of the tungsten electrode and a small section of welding wire, so that the welding wire can be fully preheated, and the components of the welding wire can be prevented from being damaged due to overhigh preheating temperature. According to the characteristics, the flux-cored wire containing graphite components is subjected to surfacing by the technology, so that the graphite is not burnt by concentrated heating of electric arcs in the process of melting the graphite into a molten pool through the wire at a lower temperature as far as possible, and a graphite lubricant with a self-lubricating function in surfacing metal exists. In conventional GMAW welding, one end of the arc may intensively heat the end of the wire due to the generation of droplets, as shown in fig. 3 (b). The arc high-efficiency heating enables the molten drops at the end of the welding wire to be in an overheated state or even in a vaporized state, so that the burning loss of alloy elements in the surfacing process is serious.
(4) Weld overlay microstructure and compositional analysis
Fig. 5 (a) is a metallographic photograph of a welded joint etched by a droplet-free arc hot wire GTAW process, in which a plurality of black particles are distributed at a post-solidified dendrite grain boundary, i.e., at a eutectic. The composition analysis of the larger black particles in the weld structure is shown in FIG. 6. The percentage of carbon atoms in the black particulate material was as high as 79.87%, and it was therefore judged that the black particulate material was retained graphite. Fig. 5 (b) is a metallographic photograph of a conventional GMAW weld overlay after etching, and it can be seen that the nickel-coated graphite phase is seriously damaged by burning and has very little residual amount.
(5) Overlay friction and wear performance:
a friction and wear comparison experiment is carried out on a surfacing layer obtained by adopting double constant-current source no-droplet arc hot wire GTAW welding and a traditional GMAW method, and the friction coefficient is shown in figure 7. The experimental result shows that when the non-droplet arc hot wire GTAW surfacing welding is adopted, the average friction coefficient of a surfacing welding test piece is about 0.65, as shown in fig. 7(a), and the friction coefficient is reduced along with the prolonging of the abrasion time, which indicates that the self-lubricating capability of the abrasion-resistant surfacing layer obtained by adopting the technology begins to show along with the proceeding of an abrasion-resistant experiment. The friction coefficient of the conventional GMAW weld test pieces was on average about 1.4, which is 2 times that of the GTAW weld, as shown in fig. 7 (b).
To further analyze the overlay frictional wear performance, the frictional wear surface was observed under a scanning electron microscope, as shown in FIG. 8. The wear surface appearance after the dry friction wear test of the overlaying layer of the two welding methods is obviously different. Fig. 8(a) shows that the wear surface is relatively fine and smooth, the grinding mark is shallow and fine, the grain of the grinding mark is not clear, and the wear surface has blackened marks, which indicates that the wear surface basically forms a graphite lubricating layer. FIG. 8(b) shows a relatively rough wear surface, dense and distinct wear marks, and a surface with a large number of hard point micro-protrusions. Therefore, the friction coefficient of the welding overlay of the GTAW welding without the molten drop arc hot wire is relatively small, and is caused by the formation of a graphite lubricating layer in the friction and wear process.
The above description is only a preferred embodiment of the present invention, and for those skilled in the art, the present invention should not be limited by the description of the present invention, which should be interpreted as a limitation.
Claims (6)
1. A self-lubricating wear-resistant flux-cored wire containing a nickel-containing graphite component is characterized by comprising a flux core and a carbon steel belt used for wrapping the flux core; wherein the medicine core comprises the following components in percentage by mass: 18-22% of ferrochrome; 7-9% of ferroboron; 3-5% of ferrosilicon, 3-5% of ferromanganese, 0.4-0.6% of metallic aluminum, 2-3% of rare earth elements, 3-5% of nickel-coated graphite and the balance of iron.
2. The nickel-containing graphite component self-lubricating abrasion-resistant flux-cored wire of claim 1, wherein the flux core comprises the following components in mass fraction: 20% of ferrochrome; 8% of ferroboron; 4% of ferrosilicon, 4% of ferromanganese, 0.5% of metallic aluminum, 2.5% of rare earth elements, 4% of nickel-coated graphite and the balance of iron.
3. The nickel-containing graphite component self-lubricating abrasion-resistant flux-cored wire as claimed in claim 1, wherein the flux core has a powder particle 80 mesh passage rate of 100%.
4. The nickel-containing graphite component self-lubricating abrasion-resistant flux-cored wire as claimed in claim 1, wherein the flux-cored filling rate is 23-27%.
5. The nickel-containing graphite component self-lubricating abrasion-resistant flux-cored wire of claim 1, wherein the diameter of the abrasion-resistant flux-cored wire is 1.6 mm.
6. A welding method of the self-lubricating wear-resistant flux-cored wire containing the nickel and graphite components, which is described in any one of claims 1 to 5, is characterized in that no-droplet arc hot wire GTAW surfacing is used, and the technological parameters are as follows: welding voltage: 22-26V; main arc current: 120A; auxiliary arc current: 120-240A; wire feeding speed: 2.2-2.6 m/min; welding speed: 3-4 mm/s; distance between the tungsten electrode and the workpiece: 7-8 mm; distance between tungsten electrode and welding wire: 2-3 mm; flow rate of shielding gas: 15L/min.
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| CN202010535613.0A CN111774757A (en) | 2020-06-12 | 2020-06-12 | Self-lubricating wear-resistant flux-cored wire containing nickel-coated graphite component and welding method thereof |
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