CN113523647A - Preparation method and system of copper alloy welding wire and sealing structure - Google Patents
Preparation method and system of copper alloy welding wire and sealing structure Download PDFInfo
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- CN113523647A CN113523647A CN202110873475.1A CN202110873475A CN113523647A CN 113523647 A CN113523647 A CN 113523647A CN 202110873475 A CN202110873475 A CN 202110873475A CN 113523647 A CN113523647 A CN 113523647A
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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
- B23K35/302—Cu 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
- 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
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- 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
- B23K9/095—Monitoring or automatic control of welding parameters
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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
- B23K9/16—Arc welding or cutting making use of shielding gas
- B23K9/173—Arc welding or cutting making use of shielding gas and of a consumable electrode
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- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
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- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
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- B33—ADDITIVE MANUFACTURING TECHNOLOGY
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- B33Y10/00—Processes of additive manufacturing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
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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
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/02—Iron or ferrous alloys
- B23K2103/06—Cast-iron alloys
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Abstract
The invention relates to the technical field of gate valve processing, in particular to a method and a system for preparing a copper alloy sealing structure. The method comprises the steps of cleaning the sealing surface of a valve core of a gray cast iron base metal; the welding machine welds the copper alloy welding wire on the surface of the valve core sealing layer in a build-up mode, and an additive layer is formed on the surface of the valve core sealing layer; and turning the additive layer to meet the specified size of the valve core sealing structure. Aiming at the technical problems of low processing efficiency, poor assembling effect and high copper material consumption of the copper alloy sealing ring, the invention utilizes the additive manufacturing technology, greatly simplifies the process for preparing the valve core sealing layer of the gate valve taking gray cast iron as a base material, obviously reduces the workload of turning scraps and the consumption of copper alloy, has less cutting scraps, does not need to manually assemble the valve core and the copper alloy sealing piece, and improves the degree of automation operation.
Description
Technical Field
The invention relates to the technical field of gate valve processing, in particular to a preparation method and a system of a copper alloy welding wire and a sealing structure.
Background
Gate valves are used in large numbers in industrial, urban and domestic pipelines, of which grey cast iron gate valves account for a large share among various valve types due to their advantages of corrosion resistance, ease of casting and low price. In order to reliably open and close the valve, a copper alloy sealing ring with the brand number of H Pb59-1 is assembled on the sealing surface of the valve body and the valve core. The copper alloy sealing ring of the valve core is machined and assembled, a seat for installing the copper alloy sealing ring is generally machined on a sealing surface of the valve core in the prior art, then the copper alloy is machined into the sealing ring, and the copper alloy ring is pressed into the installing seat of the valve core by interference fit to form a part integrated with the valve core. The process has the advantages of large turning workload and copper alloy consumption, more cutting waste, manual assembly of the valve core and the copper alloy sealing piece, and the copper alloy sealing piece is easily corroded and influenced by processing precision in the use process of the gate valve, so that the copper alloy sealing piece fails in interference fit and falls off. The technology of manually brazing tin-containing bronze on the sealing surface of the valve core by adopting oxygen-acetylene can meet the requirement of bonding strength, but the manual brazing process needs to add borax auxiliary agent, the environment is severe, the brazed valve core needs to be kept warm and the temperature is strictly controlled to be reduced, the production efficiency is low, the brazing quality is obviously related to the skill of a welder, the quality consistency has problems, and the large-scale popularization and application are difficult. CN201410683604.0 provides a surfacing process for a sealing surface of a valve, which is a process for preparing additive layers such as stellite on a steel base material by surfacing, and belongs to the conventional technology.
Disclosure of Invention
1. Technical problem to be solved by the invention
The invention provides a method and a system for preparing a copper alloy welding wire and a sealing structure, aiming at the technical problems that the existing electric arc welding technology and the copper alloy welding wire can not prepare a copper alloy additive layer meeting the requirement of bonding strength on the surface of a gray cast iron base metal.
2. Technical scheme
In order to solve the problems, the technical scheme provided by the invention is as follows:
a copper alloy welding wire is composed of the following components: zn: 30-35%, Al: 1.5-3%, Ni: 0.5-1%, Si: 1.5-3% and the balance of Cu.
A preparation method of a copper alloy sealing structure comprises the following steps: cleaning the sealing surface of the valve core; the welding machine welds the copper alloy welding wire on the sealing surface of the valve core in a build-up mode, and an additive layer is formed on the sealing surface of the valve core; and turning the additive layer to meet the specified size of the valve core sealing structure.
Optionally, the additive layer thickness is not less than 3 mm.
Optionally, the copper alloy welding wire has a diameter of 0.8-2 mm.
A preparation system of a copper alloy sealing structure comprises a controller, a welding machine and a manipulator, wherein the manipulator and the welding machine are connected with the controller.
Optionally, the controller controls an output voltage, an output current, a weld build-up speed, and a wire draw-back frequency of the welder.
Optionally, the welder is an argon arc consumable electrode welder.
Optionally, the surfacing speed of the welding machine is 8.0-8.5 cm3/min。
Optionally, the controller controls the output current of the welder not to exceed 125A.
Optionally, the controller controls the copper alloy wire to be recycled if the actual output current of the welder is higher than the highest output working current of the welder.
3. Advantageous effects
Compared with the prior art, the technical scheme provided by the invention has the following beneficial effects:
(1) the copper alloy welding wire provided by the invention is directly prepared on the surface of the valve core by combining with the digital control of the welding machine controller, the controller controls the voltage and the current to reasonably output parameters such as deflagration of molten drops of the welding wire, greatly reduces the temperature rise of a base metal in the preparation process of the additive layer, reduces the thermal stress caused by the great change of the temperature, improves the bonding strength of the additive layer and the base metal, does not need heat preservation after the additive layer is absolutely finished, and is convenient for further processing.
(2) Compared with the prior art, the preparation method and the system of the copper alloy sealing structure provided by the invention utilize the additive manufacturing technology, and solve the problem that the bonding strength is influenced by the thermal stress generated by the overhigh heat quantity in the surfacing process; the limited copper alloy welding wire material can uniformly disperse the gas released from the base metal in the additive layer, thereby improving the bonding strength of the base metal and the additive layer and improving the corrosion resistance of the additive layer. Therefore, on the premise of meeting the bonding strength of the additive layer and the base metal, the preparation process of the valve core sealing layer of the gate valve is greatly simplified, and the gate valve has the advantages of short process flow, less turning scrap and waste, less copper alloy consumption and low energy consumption; the operation environment is obviously improved, and the valve core and the copper alloy sealing piece do not need to be assembled manually.
Drawings
Fig. 1 is a schematic view of the valve core structure proposed in examples 1 to 4 and comparative examples 1 to 4 of the present invention.
Fig. 2 is a phase diagram of the additive layer and gray cast iron matrix proposed in examples 2-4 of the present invention.
Fig. 3 is a gold phase diagram of the inventive comparative examples 1-3, in which the additive layer was bonded to a gray cast iron matrix.
FIG. 4 is a metallographic photograph of the surface of a mother body after an additive layer is detached from the mother body through a bonding strength test in example 2 of the present invention.
Detailed Description
For a further understanding of the present invention, reference will now be made in detail to the embodiments illustrated in the drawings.
The present application will be described in further detail with reference to the following drawings and examples. It is to be understood that the specific embodiments described herein are merely illustrative of the relevant invention and not restrictive of the invention. It should be noted that, for convenience of description, only the portions related to the present invention are shown in the drawings. The terms first, second, and the like in the present invention are provided for convenience of describing the technical solution of the present invention, and have no specific limiting effect, but are all generic terms, and do not limit the technical solution of the present invention. It should be noted that the embodiments and features of the embodiments in the present application may be combined with each other without conflict. In the description of the present invention, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc., indicate orientations or positional relationships based on the orientations or positional relationships shown in the drawings, and are only for convenience of description and simplicity of description, but do not indicate or imply that the device or element being referred to must have a particular orientation, be constructed and operated in a particular orientation, and thus, should not be construed as limiting the present invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance. Unless expressly stated or limited otherwise, the terms "mounted," "connected," and "connected" are intended to be inclusive and mean, for example, that they may be fixedly connected, detachably connected, or integrally connected; can be mechanically or electrically connected; they may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meanings of the above terms in the present invention can be understood in specific cases to those skilled in the art. The technical solutions in the same embodiment and the technical solutions in different embodiments can be arranged and combined to form a new technical solution without contradiction or conflict, and the technical solutions are within the scope of the present invention.
Example 1
With reference to fig. 1-4, the present embodiment provides a copper alloy welding wire, which is composed of the following components: zn: 30-35%, Al: 1.5-3%, Ni: 0.5-1%, Si: 1.5-3% and the balance of Cu. Analysis and research show that Al can improve the corrosion resistance of the additive layer by manufacturing the additive layer on the sealing surface of the gray cast iron parent valve core; ni can not only improve the corrosion resistance of the additive layer, but also obviously improve the bonding strength of the additive layer and the gray cast iron parent valve core; si can improve the corrosion resistance of the additive layer, improve the fluidity of the alloy melt and reduce the defects of the additive layer; zn can reduce the melting point of the alloy, reduce the energy input by surfacing, and avoid the phenomenon that the combination strength of the parent body and the additive layer is influenced by the thermal stress aggregation caused by overhigh temperature of the valve core of the grey cast iron parent body, namely the combination strength of the valve core and the additive layer is reduced. In the surfacing process, all the components have a synergistic effect, so that gas released from the valve core can be uniformly dispersed in the additive layer far away from the valve core, and the bonding strength of the additive layer and the valve core is further improved.
The embodiment also provides a preparation method of the copper alloy sealing structure, which comprises the following steps: cleaning the sealing surface of the valve core; the welding machine is controlled by the controller to weld the copper alloy welding wire on the sealing surface of the valve core through the manipulator, and an additive layer is formed on the sealing surface of the valve core; the additive layer is turned to conform to the specified dimensions of the cartridge seal structure 10.
The preparation method of the copper alloy sealing structure is suitable for the valve core made of gray cast iron, and the copper alloy additive layer can be prepared on the sealing surface of the valve core by the method.
Compared with the conventional copper alloy sealing piece processing method, the preparation method of the copper alloy sealing structure can save about two thirds of copper alloy materials. The consumption of copper alloy is reduced, the processing cost is saved, the additive layer 10 is directly formed on the surface of the valve core in a surfacing mode, a copper alloy sealing piece does not need to be assembled manually, the process is greatly simplified, and the operation environment is improved.
The valve core and the copper alloy sealing additive layer are combined in a welding mode, so that compared with an assembly type copper alloy sealing element, the valve core and the valve core are combined more firmly and integrally, a leakage point does not exist, the sealing performance and the corrosion resistance of the sealing structure of the valve core are structurally enhanced, the service life of the whole valve core is prolonged, and the service life of the gate valve is further prolonged. In addition, in the embodiment, the copper alloy welding wire is used for forming the sealing additive layer, so that the sealing additive layer is more wear-resistant and has a longer service life compared with a brass material.
As an optional implementation manner of this embodiment, the thickness of the additive layer is not less than 3 mm. In order to ensure the using effect of the sealing additive layer, the thickness of the additive layer is not less than 3mm so as to ensure that the surface of the processed additive layer is free of defects.
As an optional implementation mode of the embodiment, the diameter of the copper alloy welding wire is 0.8-2 mm. When the copper alloy welding wire is specifically applied, the diameter of the copper alloy welding wire can be 0.8mm, 1.1mm, 1.3mm, 2mm and other numerical values by combining with the use of a welding system, and tests show that the diameter of the welding wire is 1.2mm, so that the smoothness of wire feeding can be kept, the surfacing welding speed is reasonable, and the failure rate of a welding machine is low. When the diameter of the copper alloy welding wire is too large, the smoothness of wire feeding in the preparation process of the additive layer is not facilitated, the wire clamping phenomenon is easily caused, the fault rate of a welding machine can be increased, or the power consumed by equipment is increased, the preparation efficiency is reduced, and the yield is influenced.
The embodiment also comprises a preparation system of the copper alloy sealing structure, which comprises a controller, a welding machine and a manipulator, wherein the manipulator and the welding machine are connected with the controller.
As an alternative embodiment of the present embodiment, the controller controls the output voltage, output current, weld deposit speed, and wire withdrawal frequency of the welder.
The welding system in this embodiment can realize industrialization, the sealed material adding layer of automatic preparation case, greatly improves the machining efficiency on sealed material adding layer, and manipulator among the welding system can pile the sealed face of applying in the case with the copper alloy welding wire in the area and the shape on material adding layer as required under the control action of controllers such as PLC, singlechip, forms sealed material adding layer automatically. The controller ensures that copper alloy molten drops do not generate deflagration splashing in the material increase process by controlling parameters such as output voltage, output current, surfacing speed and the like of the welding machine, and avoids overlarge input energy.
As an optional implementation manner of the embodiment, the welding machine is an argon arc consumable electrode welding machine. The argon arc consumable electrode welding machine is provided with a controller with a digital control function, parameters such as output voltage, output current and surfacing speed in the surfacing process are controlled, and a welding wire is subjected to surfacing welding on the surface of a valve core through the control cooperation of a manipulator, the controller and the welding machine to form a material adding layer; the method has the advantages of preventing and controlling the deflagration phenomenon of welding wire molten drops, reducing the temperature of the parent valve core in the surfacing process, reducing the thermal stress caused by the large temperature change, and improving the bonding strength of the additive layer and the valve core.
As an optional implementation manner of the embodiment, the surfacing speed controlled by the welding machine controller is 8.0-8.5 cm3And/min. In the embodiment, the speed of preparing the additive layer by the copper alloy welding wire is 8.0-8.5 cm3Min, when in practical application, the speed can be set to be 8.0cm3/min、8.5cm3/min、8.4cm3A value of/min, etc.; research shows that the working efficiency is affected due to too low speed, the working speed is too high, the input energy is too high, the temperature of the gray cast iron parent body is too high, and the bonding strength of the copper alloy additive layer and the gray cast iron parent body is affected in the rapid cooling process.
In the embodiment, the controller controls the output voltage of the welding machine to be 12.3-12.5V, and in the specific welding process, the output voltage can be 12.3V, 12.4V or 12.5V and other numerical values, and researches show that the voltage in the range is suitable for configuring the copper alloy welding wire with the diameter of 1.2 mm.
In this embodiment, the controller controls the output current of the welding machine not to exceed 125A, and in the specific welding process, the output voltage can be 120A, 124A or 125A, which is too large and easily causes the welding wire molten drop to explode seriously, increases the temperature of the parent valve core, affects the bonding strength, is too low to be beneficial to the continuity of the surfacing operation, and also affects the bonding strength of the additive layer and the valve core.
The welding machine is electrified to work, under the condition of relatively constant input current and voltage of the welding machine, the copper alloy welding wire is melted into liquid drops according to a set speed, the liquid drops are also called molten drops, when the molten drops are not completely separated from the copper alloy welding wire and are dripped onto a matrix, the molten drops are separated from the copper alloy welding wire to instantly generate large current due to necking, the instantaneous current is far greater than the output current of the welding machine during normal work, the copper alloy molten drops are easy to generate burning explosion, the output current of the welding machine is suppressed by a controller at the moment, the copper alloy welding wire is quickly drawn back to be separated from the molten drops as soon as possible, and burning explosion of the molten drops is avoided.
Based on the fact that a larger impact current exists at the moment of explosion, a value close to the impact current is used as an early warning threshold value of output current of the welding machine, the highest output current value of the welding machine is equivalent to the impact current at the moment of explosion, and the value close to or lower than the highest output current value of the welding machine is used as the early warning threshold value in general situations; at least the speed generated by the molten drop is used as the drawing back frequency of the copper alloy welding wire, and the two frequencies are matched with each other, so that the burning explosion phenomenon generated by the molten drop is avoided.
Specifically, in order to avoid the generation of the droplet explosion phenomenon, the welding part in the preparation method further comprises the following steps according to the real-time welding condition: if the actual output current of the welding machine reaches the early warning threshold value, that is, if the actual output current of the welding machine is higher than the highest output working current of the welding machine, 125A in the embodiment, the controller controls the copper alloy welding wire to be immediately recycled; controlling the withdrawal frequency of the copper alloy welding wire at a rate higher than the rate of droplet generation to allow the copper alloy welding wire to be withdrawn quickly, namely: after the molten drop is formed and before the molten drop is completely separated from the welding wire, the copper alloy welding wire is drawn back, the possibility of preventing the molten drop from burning and exploding is achieved, only the normal arcing phenomenon exists, and the energy input can be reduced.
A large number of practical applications show that when the bonding strength of the additive layer and the gray cast iron parent body is larger than 50MPa, the additive layer is not easy to fall off from the parent body when being knocked, collided and the like in the using process, and long-term reliable sealing of the valve core of the gate valve can be ensured, so that the bonding strength is larger than 50MPa, and the standard of the bonding strength which is accepted by the industry is formed. In the description of the embodiments of the present application, the base material valve element, and the base material valve element are all referred to as valve elements coupled to the additive layer, and the expressions are consistent in meaning so that the surfaces of the valve elements form a seal structure.
The difference of the material of the welding wire and the base metal and the high temperature of the base metal can influence the stress at the joint surface of the welding wire and the base metal, and further influence the joint strength of a final formed product; meanwhile, by using an automatic preparation method, various parameter variables in the welding process are accurately controlled, the phenomenon of molten drop burning explosion is prevented, and the high temperature generated on the base material matrix is reduced to the maximum extent. The combination of the additive layer and the gray cast iron base material valve core enables the stress at the combination interface of the additive layer and the gray cast iron base material valve core to be effectively dispersed, and further ensures that the combination strength of the additive layer and the base material meets the requirement of being higher than 50 MPa. Compared with welding modes such as manual welding, gas welding or hydrogen welding, the manufacturing method related in the embodiment can effectively guarantee the bonding strength between the valve core and the additive layer, and greatly reduces the manufacturing cost of the gate valve core sealing structure.
In any technical solution of this embodiment, the method includes controlling a welding method, setting welding parameters, limiting a size of a welding wire, and further limiting a thickness of an additive layer, for example, the thickness of the additive layer is set to 3mm, 4mm, 5mm, and the like, which satisfy any value in a range of values greater than or equal to 3mm, so as to ensure that the valve element sealing structure is completely manufactured and has a bonding strength meeting the acceptance criteria, that is, the bonding strength is greater than 50 MPa; and then can guarantee the stability and the good leakproofness of case seal structure to improve the life of gate valve.
Example 2
The embodiment provides a preparation method of a copper alloy sealing structure, which comprises the following steps:
(1) the surface of the valve core for preparing the copper alloy sealing layer is turned and flattened to eliminate impurities such as oil stains and the like on the sealing surface of the valve core, wherein the drift diameter specification of the valve core is DG 65;
(2) after the case is fixed, the manipulator is according to the area and the shape on the required increase layer of case sealing surface, automatically, apply the copper alloy welding wire build-up welding in the sealing surface of case, form 3.0 ~ 3.5mm increase layer, set the thickness on increase layer to this range value, can neutralize the build-up welding error of increase layer thickness that automatic build-up welding process brought, in the actual operation process, final fashioned increase layer thickness can be 3mm, 3.1mm, 3.2mm, numerical value such as 3.5mm, in order fully to ensure that the thickness on increase layer keeps more than 3mm, so that the bonding strength of the case seal structure who prepares the completion is greater than 50MPa, and then ensure the sealing performance and the life of gate valve. The controller in the automatic welding system ensures that the molten drops of the welding materials do not generate deflagration splashing in the material increase process by controlling parameters such as output voltage, output current, surfacing speed and the like of the welding machine, and prevents the temperature of the base metal from being overhigh;
(3) after the valve core sealing surface additive layer is prepared, the valve core is taken down, the copper alloy additive layer is processed into a plane on a turning module, and the valve core can be taken down and fixed by utilizing the matching of a manipulator and a clamp in an automatic welding system.
Alternatively, the diameter of the copper alloy wire is 1.2 mm.
Alternatively, the speed of preparing the additive layer by the copper alloy is 8.0cm3/min。
Optionally, the output voltage of the welder is 12.3V.
Optionally, the maximum output working current of the welder is set to 125A, and the controller is used for real-time matching and adjustment according to the welding condition.
Optionally, the special copper alloy welding wire in the embodiment comprises the following components in percentage by weight: zn: 30.0%, Al: 1.5%, Ni: 0.5%, Si: 1.5% and the balance of Cu.
Fig. 4 is a metallographic photograph of the surface of the base material after the additive layer of example 2 of the present invention was separated from the base material by a bonding strength test.
Example 3
The embodiment provides a preparation method of a copper alloy sealing structure, which comprises the following steps:
(1) the surface of the valve core of the gate valve with the drift diameter specification of DG50 is turned and flattened to eliminate impurities such as oil stains and the like;
(2) after the valve core is fixed, the manipulator automatically applies the copper alloy welding wire to the sealing surface of the valve core in a surfacing mode according to the area and the shape of the additive layer required by the valve core of the DG50 gate valve, and a 3.0-3.5 mm additive layer is formed. A controller in the automatic welding system ensures that the copper alloy molten drops do not generate deflagration splashing in the material increase process by controlling parameters such as power, speed and the like of a welding machine.
(3) After the valve core sealing surface additive layer is prepared, the valve core is taken down, the copper alloy additive layer is processed into a plane on a turning module, and the valve core can be taken down and fixed by utilizing the matching of a manipulator and a clamp in an automatic welding system.
Alternatively, the diameter of the copper alloy wire is 1.2 mm.
Alternatively, the additive layer was prepared at a speed of 8.5cm3/min。
Alternatively, the output voltage of the welder is 12.4V.
Optionally, the maximum output working current of the welder is set to 125A, and the controller is used for real-time matching and adjustment according to the welding condition.
Optionally, the weight percentage of the special copper alloy welding wire in the embodiment is as follows: zn: 32.5%, Al: 3.0%, Ni: 1.0%, Si: 3.0 percent, and the balance being Cu.
Example 4
The embodiment provides a preparation method of a copper alloy sealing structure, which comprises the following steps:
(1) the surface of the valve core of the gate valve with the drift diameter specification of DG50 is turned and flattened to eliminate impurities such as oil stains and the like;
(2) after the valve core is fixed, the manipulator automatically applies a copper alloy welding wire to the sealing surface of the valve core in a surfacing mode according to the area and the shape of the additive layer as required to form the additive layer with the thickness of 3.0-3.5 mm. A controller in the automatic welding system ensures that the copper alloy molten drops do not generate deflagration splashing in the material increase process by controlling parameters such as power, speed and the like of a welding machine.
(3) After the valve core sealing surface additive layer is prepared, the valve core is taken down, the copper alloy additive layer is processed into a plane on a turning module, and the valve core can be taken down and fixed by utilizing the matching of a manipulator and a clamp in an automatic welding system.
Alternatively, the diameter of the copper alloy wire is 1.2 mm.
Alternatively, the additive layer was prepared at a speed of 8.5cm3/min。
Alternatively, the output voltage of the welder is 12.5V.
Optionally, the maximum output working current of the welder is set to 125A, and the controller is used for real-time matching and adjustment according to the welding condition.
Optionally, the special copper alloy welding wire comprises the following components in percentage by weight: zn: 35.0%, Al: 3.0%, Ni: 1.0%, Si: 3.0 percent, and the balance being Cu.
Fig. 2 is a gold phase diagram of the additive layer of examples 2-4 of the present invention in combination with a gray cast iron valve insert, in which the continuous band porosity and porosity are not visible, and in which the black lines in the additive layer are detected as graphite falling out of the matrix.
Comparative example 1
The embodiment provides a preparation method of a copper alloy sealing structure, which comprises the following steps:
(1) the surface of the valve core of the gate valve with the drift diameter specification of DG50 is turned and flattened to eliminate impurities such as oil stains and the like;
(2) after the valve core is fixed, the manipulator automatically applies a copper alloy welding wire to the sealing surface of the valve core in a surfacing mode according to the area and the shape of the additive layer as required to form the additive layer with the thickness of 3.0-3.5 mm. A controller in the automatic welding system ensures that the copper alloy molten drops do not generate deflagration splashing in the material increase process by controlling parameters such as power, speed and the like of a welding machine.
(3) After the valve core sealing surface additive layer is prepared, the valve core is taken down, the additive layer is machined into a plane on a turning module, and the valve core can be taken down and fixed by matching of a manipulator and a clamp in an automatic welding system.
Alternatively, the diameter of the copper alloy wire is 1.2 mm.
Alternatively, the additive layer was prepared at a speed of 8.5cm3/min。
Optionally, the output voltage of the welder is 12.3V.
Optionally, the maximum output working current of the welder is set to 125A, and the controller is used for real-time matching and adjustment according to the welding condition.
Optionally, the copper alloy welding wire is made of silicon bronze SG-CuSi 3.
Comparative example 2
The embodiment provides a preparation method of a copper alloy sealing structure, which comprises the following steps:
(1) the surface of the valve core of the gate valve with the drift diameter specification of DG50 is turned and flattened to eliminate impurities such as oil stains and the like;
(2) after the valve core is fixed, the manipulator automatically applies a copper alloy welding wire to the sealing surface of the valve core in a surfacing mode according to the area and the shape of the additive layer as required to form the additive layer with the thickness of 3.0-3.5 mm. The controller in the automatic welding system ensures that the copper alloy molten drops do not generate deflagration splashing in the material increase process by controlling parameters such as power, speed and the like of the welding machine;
(3) after the valve core sealing surface additive layer is prepared, the valve core is taken down, the additive layer is machined into a plane on a turning module, and the valve core can be taken down and fixed by matching of a manipulator and a clamp in an automatic welding system.
Alternatively, the diameter of the copper alloy wire is 1.2 mm.
Alternatively, the speed of preparing the additive layer by the copper alloy is 8.5cm3/min。
Optionally, the output voltage of the welder is 12.3V.
Optionally, the maximum output working current of the welder is set to 125A, and the controller is used for real-time matching and adjustment according to the welding condition.
Optionally, the copper alloy welding wire is made of silicon bronze S211.
Comparative example 3
The embodiment provides a preparation method of a copper alloy sealing structure, which comprises the following steps:
(1) the surface of the valve core of the gate valve with the drift diameter specification of DG50 is turned and flattened to eliminate impurities such as oil stains and the like;
(2) after the valve core, the manipulator automatically applies a copper alloy welding wire to the sealing surface of the valve core in a surfacing mode according to the area and the shape of the additive layer as required to form the additive layer with the thickness of 3.0-3.5 mm. The controller in the automatic welding system ensures that the copper alloy molten drops do not generate deflagration splashing in the material increase process by controlling parameters such as power, speed and the like of the welding machine;
(3) after the valve core sealing surface additive layer is prepared, the valve core is taken down, the additive layer is machined into a plane on a turning module, and the valve core can be taken down and fixed by matching of a manipulator and a clamp in an automatic welding system.
Alternatively, the diameter of the copper alloy wire is 1.2 mm.
Alternatively, the speed of preparing the additive layer by the copper alloy is 8.5cm3/min。
Alternatively, the output voltage of the welder is 12.5V.
Optionally, the highest output working current of the welding machine is set to be 125A and recorded as an output current threshold; the controller is used for real-time matching and adjustment according to the welding condition.
Optionally, the copper alloy welding wire is made of HS 221.
Fig. 3 is a gold phase diagram of the additive layer in comparison examples 1-3 according to the present invention in combination with gray cast iron, from which it is evident that band porosity and porosity are present, i.e. that the stresses are not effectively dispersed, and that there is an effect on the bond strength between the additive layer and the gray cast iron matrix. Because the additive layer and the gray cast iron are different in material, and the welding inevitably generates heat, stress is inevitably generated at the joint interface of the additive layer and the gray cast iron parent metal, and as can be seen from the comparison between fig. 2 and fig. 3, continuous strip-shaped looseness and air holes are not seen in fig. 2, which means that fig. 2 of the scheme of the invention is adopted, wherein the stress is effectively dispersed at the joint interface of the additive layer and the gray cast iron, and the joint strength of the additive layer and the parent metal is effectively ensured, namely the joint strength of the additive layer and the parent metal is ensured to be more than 50 MPa.
Comparative example 4
The method for preparing the valve core copper alloy sealing layer of the gate valve by adopting the brazing method comprises the following steps:
(1) the gate valve with the valve core of which the drift diameter specification is DG50 is adopted, the surface of the valve core for preparing the copper alloy sealing layer is turned to be flat, and impurities such as oil stains and the like are eliminated;
(2) manually heating the whole valve core to above 600 ℃ by using oxygen-acetylene flame, brazing a copper alloy welding wire on the surface of a sealing layer of the valve core to form a 3-4 mm additive layer, adding borax as a soldering flux during the brazing process, and placing the valve core into an incubator to be cooled at the speed of 2 ℃/min;
(3) after the valve core is cooled, processing the copper alloy additive layer into a plane by using a lathe;
optionally, the diameter of the copper alloy wire is 3.0 mm.
Optionally, the copper alloy welding wire is of grade HS 221.
The bonding strength between the additive layer and the gray cast iron base valve element in the above examples and comparative examples was measured by referring to the test method in GB/T12948-91, "sliding bearing bimetal bond strength destructive test method", and the bond strength data and the manufacturing time data were obtained as shown in table 1.
TABLE 1 comparison of bond strengths of additive layers to gray cast iron substrates for various examples and comparative examples
As can be seen from Table 1, the working efficiency of the method of the invention is obviously more than doubled compared with manual brazing; the additive layers of the examples 2, 3 and 4 have the highest bonding strength with gray cast iron, are basically consistent with those of the comparative example 1 of manual brazing, and can meet the industrial application; in comparative examples 1 to 3, the bonding strength of the additive layer and the gray cast iron is lower than 50MPa, the acceptance requirements of the industry cannot be met, and the bonding strength is obviously lower.
The present invention and its embodiments have been described above schematically, without limitation, and what is shown in the drawings is only one of the embodiments of the present invention, and the actual structure is not limited thereto. Therefore, if the person skilled in the art receives the teaching, without departing from the spirit of the invention, the person skilled in the art shall not inventively design the similar structural modes and embodiments to the technical solution, but shall fall within the scope of the invention.
Claims (10)
1. A copper alloy welding wire is characterized by comprising the following components: zn: 30-35%, Al: 1.5-3%, Ni: 0.5-1%, Si: 1.5-3% and the balance of Cu.
2. A preparation method of a copper alloy sealing structure is characterized by comprising the following steps: cleaning the sealing surface of the gray cast iron valve core; the welding machine welds the copper alloy welding wire of claim 1 on the valve core sealing surface in an overlaying mode, and an additive layer is formed on the valve core sealing surface; and turning the additive layer to meet the specified size of the valve core sealing structure.
3. The method of claim 1, wherein the additive layer thickness is not less than 3 mm.
4. The method for manufacturing a copper alloy sealing structure according to claim 1, wherein the diameter of the copper alloy welding wire is 0.8-2.0 mm.
5. The preparation system of the copper alloy sealing structure is characterized by comprising a controller, a welding machine and a manipulator, wherein the manipulator and the welding machine are connected with the controller.
6. The method of manufacturing a copper alloy sealing structure according to claim 5, wherein the controller controls an output voltage, an output current, a build-up welding speed, and a welding wire drawing back frequency of the welding machine.
7. The system for manufacturing a copper alloy sealing structure according to claim 5, wherein the welding machine is an argon arc consumable electrode welding machine.
8. The preparation system of a copper alloy seal structure according to claim 6, characterized in that the build-up welding speed of the welding machine is 8.0-8.5 cm3/min。
9. The system for preparing a copper alloy sealing structure according to claim 6, wherein the controller controls the output current of the welding machine not to exceed 125A.
10. The system of claim 9, wherein the controller controls the copper alloy wire to be drawn back if the actual output current of the welding machine is higher than the maximum output operating current of the welding machine.
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