CN114905222A - Method for welding and repairing parting surface pressure stack abrasion of aluminum alloy die-casting die - Google Patents
Method for welding and repairing parting surface pressure stack abrasion of aluminum alloy die-casting die Download PDFInfo
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- CN114905222A CN114905222A CN202210377387.7A CN202210377387A CN114905222A CN 114905222 A CN114905222 A CN 114905222A CN 202210377387 A CN202210377387 A CN 202210377387A CN 114905222 A CN114905222 A CN 114905222A
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- 238000003466 welding Methods 0.000 title claims abstract description 179
- 238000004512 die casting Methods 0.000 title claims abstract description 59
- 238000000034 method Methods 0.000 title claims abstract description 54
- 238000005299 abrasion Methods 0.000 title claims abstract description 44
- 229910000838 Al alloy Inorganic materials 0.000 title claims abstract description 16
- 238000003754 machining Methods 0.000 claims abstract description 33
- 238000013461 design Methods 0.000 claims abstract description 31
- 230000008439 repair process Effects 0.000 claims abstract description 30
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- 229910000831 Steel Inorganic materials 0.000 claims description 25
- 239000010959 steel Substances 0.000 claims description 25
- 239000000463 material Substances 0.000 claims description 17
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- 238000003825 pressing Methods 0.000 claims description 10
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- 229910045601 alloy Inorganic materials 0.000 claims description 8
- 239000000956 alloy Substances 0.000 claims description 8
- 239000011572 manganese Substances 0.000 claims description 8
- 229910052750 molybdenum Inorganic materials 0.000 claims description 8
- 239000011733 molybdenum Substances 0.000 claims description 8
- 239000011248 coating agent Substances 0.000 claims description 7
- 238000000576 coating method Methods 0.000 claims description 7
- 238000007789 sealing Methods 0.000 claims description 7
- 238000013021 overheating Methods 0.000 claims description 6
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims description 5
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims description 5
- 229910052804 chromium Inorganic materials 0.000 claims description 5
- 238000004140 cleaning Methods 0.000 claims description 5
- 229910052710 silicon Inorganic materials 0.000 claims description 5
- 239000010703 silicon Substances 0.000 claims description 5
- LEONUFNNVUYDNQ-UHFFFAOYSA-N vanadium atom Chemical compound [V] LEONUFNNVUYDNQ-UHFFFAOYSA-N 0.000 claims description 5
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 4
- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 claims description 4
- 229910052799 carbon Inorganic materials 0.000 claims description 4
- 238000001125 extrusion Methods 0.000 claims description 4
- 239000007789 gas Substances 0.000 claims description 4
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- 239000000843 powder Substances 0.000 claims description 4
- 239000011229 interlayer Substances 0.000 claims description 3
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- 229910006411 Si—Si Inorganic materials 0.000 description 1
- 238000003723 Smelting Methods 0.000 description 1
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- IADRPEYPEFONML-UHFFFAOYSA-N [Ce].[W] Chemical compound [Ce].[W] IADRPEYPEFONML-UHFFFAOYSA-N 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P6/00—Restoring or reconditioning objects
-
- 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
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Physics & Mathematics (AREA)
- Plasma & Fusion (AREA)
- Mounting, Exchange, And Manufacturing Of Dies (AREA)
- Molds, Cores, And Manufacturing Methods Thereof (AREA)
Abstract
The invention relates to a method for repairing the die-casting die parting surface pressure stack abrasion welding of aluminum alloy; in the middle temperature area of the die, the parting surface of the die is 0.15mm higher than the original design surface after machining; in the high-temperature area of the die, the parting surface of the die is 0.25mm higher than the original design surface after machining; the parting surfaces of the die after machining at the corners of the two sides of the sliding block, the corner area of the high-temperature area and the parting surface of the die are 0.3mm higher than the original design surface; when the parting surface of the die is a stepped parting surface, the three stepped parting surface surfaces related to the stepped parting surface have loss of 0.15mm, 0.30mm and 0.50mm in different degrees, and when the parting surface is worn to be 0.15mm, the machining allowance is 0 by the design reference and then the thickness of 0.10mm is added; when the abrasion of the parting surface is 0.30mm, the thickness of 0.15mm is added according to the design standard of 0; when the abrasion of the parting surface is 0.50mm, the thickness of 0.25mm is added by taking the design reference as 0; the method has the advantages that the die tool does not need to be disassembled, the cost is low, the die does not need to be subjected to heat treatment after welding repair, the repair period is short, and a good repair effect can be obtained by gantry milling after welding.
Description
Technical Field
The invention belongs to the technical field of parting surface processes of die-casting molds, and particularly relates to a method for repairing wear of a parting surface press pile of an aluminum alloy die-casting mold by welding.
Background
In the production process of the die-casting mold, the parting surface is repeatedly pressed and sealed at the working condition of 200-240 ℃, so that the phenomenon of surface pressure stack and defect abrasion is generated, high-pressure alloy overflows outwards through the parting surface in the production of the mold (commonly called as material escape) to ensure the pressure maintaining failure of a pressure chamber, the internal quality of a casting cannot be guaranteed, various forms of waste products are generated, and the early scrapping of the severe mold cannot be repaired.
The cause of the problem:
1. the design of a die-casting mold has insufficient parting area, and the design of a main pouring gate of a pouring system deviates from a certain side, so that the unilateral heat of the mold is too large, namely the mold has insufficient closure, and the liquid alloy enters a pressure chamber and has uncontrollable liquidity and overflows outwards, namely the material escaping phenomenon is generated;
2. the heat treatment of the die does not reach the specified hardness HRC 44-48 degrees, and the surface coating treatment is unqualified. The hardness of the surface coating of the die-casting mould (such as nitriding, oxidation, PVD and the like) requires HRC 56-60 degrees;
3. the projection area of the mold is insufficient, the mold is pressed by small equipment, or the equipment fails, so that the mold locking force is insufficient to work blindly;
4. unreasonable technological parameters, such as: excessive pressure, excessive speed and unreasonable water circulation result in the overhigh local working temperature of the die, and the alloy can escape outwards in the pressure chamber.
Alloy adhesion is on the die joint when escaping the material because of above problem appears, will appear the die joint and be pressed the problem of piling continuing to work repeatedly, if continue to appear repeatedly that the large tracts of land escapes the material phenomenon, the mould will appear at last unable production and lead to the mould to scrap.
The repair method adopted at home and abroad is as follows:
1. and (3) welding the local small range of the surface of the small-area wear, manually polishing the welded part by using a pneumatic tool, repairing the welded part by referring to the datum plane of the parting surface, and performing online production. (so that the repair of facets is typically no more than 30mm by 30 mm);
2. the wear of the parting surface of the die with medium and large areas is generally processed by reducing the surface of the die by 10-15mm, the technology is very complex, a set of new die needs to be machined and heat treated again, the cost is extremely high, the period is too long, and the produced first batch of castings can be produced after marking and verifying the qualified dimension again and are not paid out;
3. the mould is directly scrapped.
Patent document No. CN106825492A discloses a method for grinding parting surfaces of die casting molds;
patent document No. CN106925940A discloses a welding repair process for an extrusion die;
patent document No. CN104233289A discloses a method for repairing a mold by using a high-wear-resistance laser cladding material;
the three searched patents have very low relevance with the method, and no die-casting die parting surface welding repair technology exists at home and abroad at present.
Disclosure of Invention
The invention aims to solve the key problem of die-casting material escape caused by long-term abrasion in the production of the conventional die-casting die, provides a method for repairing the die-casting surface pressure stack abrasion of an aluminum alloy die-casting die, and relates to a novel process for repairing the die-casting surface abrasion through manual argon arc welding, which can be used for repairing the die-casting surfaces of various die-casting dies.
It is noted that, herein, relational terms such as first and second, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Also, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.
In order to solve the technical problems, the invention is realized by adopting the following technical scheme:
a method for repairing the die-casting die-parting surface stack abrasion by welding is characterized by comprising the following steps:
in the middle temperature area of the die, the welding surface is processed by a gantry mill after welding, and the parting surface of the die is 0.15mm higher than the original design surface after machining;
in the high-temperature area of the die, the welding surface is processed by a gantry mill after welding, and the parting surface of the die after machining is 0.25mm higher than the original design surface;
furthermore, for some positions with too serious abrasion, the parting surface of the die after machining is 0.3mm higher than the original design surface; such as: the two sides of the sliding block, the corner area of the high-temperature area and the corner position of the parting surface of the die. The pretension thickness can be increased in advance.
The mould has three or more parting planes with different heights, which is called a stepped sealing parting plane, and the welding heights are different due to different losses on the three parting planes with different heights.
The amount of weld seam that is reserved on the surface of the die after machining (i.e., the height of the die parting surface after machining is higher than the dimension of the original design surface) is also different.
The purpose of reserving a certain height after machining is to reserve pre-tightening force for subsequent production of the die, because the die-casting die works at 650 ℃, the operation of the parting surface of the die is about 160 ℃ on average, the excessive height of the parting surface can be flattened under the repeated die-closing pressure of the die-casting machine, and the hardness and the sealing performance reach the optimal state at 800 die times.
Further, when the parting surface of the mold is a stepped parting surface, the three stepped parting surface surfaces related to the stepped parting surface have loss in different degrees of 0.15mm, 0.30mm and 0.50mm respectively, and different reserved heights are selected for the three surfaces to determine the machining allowance;
when the wear of the parting surface is 0.15mm, the principle of repairing the defect surface is that the machining allowance is 0 based on the design standard, and then the thickness of 0.10mm is added;
when the wear of the parting surface is 0.30mm, the repair principle of the defect surface is that the thickness of 0.15mm is added with the design reference of 0;
when the parting surface is worn to be 0.50mm, the principle of repairing the defect surface is that the thickness of 0.25mm is added according to the design standard of 0.
Further, when the abrasion degree of the die is light, and the average abrasion loss is minus 0.15mm, two layers need to be welded, and the welding height is 2.0 mm;
when the abrasion degree of the die is moderate, the average abrasion loss is minus 0.3mm, three layers are welded, and the welding height is 3.5 mm; the welding thickness of each layer is controlled to be about 1 mm;
in the overheating area of the die, when the abrasion is serious, the abrasion loss is minus 0.5mm, four layers need to be welded, and the welding height is 5 mm; the welding thickness of each layer is controlled to be about 1 mm;
further, after the welding machine for the parting surfaces of the dies is added, the die is on-line matched and repaired by the process comprising the following steps of: coating red powder on the surface of a static mold, repeatedly closing the mold, pressing color, manually grinding, and removing local hard spots; after the repair is finished, the mold is produced for about 800 times on line, the final work hardening effect is achieved by repeatedly closing the mold at the high temperature of 160-200 ℃ and extruding, welding and repairing the surface, and the local overheating area of 0.1mm is reduced to 0.2mm by repeatedly extruding the surface of the mold.
Further, the die repairing means: after the die parting surface is machined, the die is subjected to surface embossing trimming and fine machining on a die closing machine or a die casting machine, the die is trimmed by taking the fixed die parting surface as a reference, and the machining is manual trimming and repairing.
Further, the method for checking the defect of the parting surface of the die comprises the following steps;
step one, cleaning up the alloy adhered to the movable die and the static die of the die on line,
step two, coating uniform red lead powder on the surface of the static mold,
step three, starting a die casting machine to close the die, opening the die after the die is tightly pressed and kept for 3 seconds, observing whether the parting surface on the side of the movable die is red and attached or not, and indicating that the parting surface of the die is abraded and has a gap;
manually pressing a plasticine ball at the loss part of the parting surface of the movable mold, closing the mold, pressing for 3 seconds, opening the mold, measuring the flattening thickness of the plasticine through a caliper, determining the loss amount of the mold, and recording the loss thickness of each loss surface;
and (3) inserting the die off line, opening the die, dividing the area to be welded by using a marking pen, marking the loss size of each welding area by using numbers, and preparing for subsequent welding work.
Further, cleaning up the welding part before welding;
selecting a welding wire: the welding wire is consistent with the mould material or the performance of the welding wire is higher than that of the mould material;
and (3) selecting the flow of welding argon: the gas volume flow is generally 5-12L/min;
electrode connection method selection: direct current is connected positively;
selecting welding current: 140A-160A.
Further, the steel wire grade for hot-working die has the following components:
h13 steel composition: 4Cr5MoSi1V 1;
8407 Steel composition: 0.38 of die steel carbon (C), 5.3 of chromium (Cr), 0.4 of manganese (Mn), 1.3 of Molybdenum (MO), 1.0 of silicon (Si) and 0.9 of vanadium (V).
1.2344 Steel composition: c: 0,37-0, 43; si:0, 90-1, 2; mn: 0,30-0, 50; cr: 3,00-3, 60; mo:1, 20-1, 60; v:0, 90-1, 10; s: max.0,030; p: max.0,030;
SKD61 steel composition: 0.8 to 1.2 of Si; mn is less than or equal to 0.50; 4.50-5.50 parts of Cr; 1.00-1.50% of Mo; v is 0.8 to 1.2; s is 0.03;
the hardness of the argon arc welding wire with the steel grade of the above 4 hot-working dies after annealing is about HRC24 degree, but when the welding process is applied, the hardness after welding can reach about HRC42 degree, so that the die can be directly put into production without adopting a heat treatment process after welding.
Selecting ERNi-1 pure nickel welding wires for welding the first layer;
the steel welding wire for the hot-working die is used after the second time;
weld hardnessThe degree is generally about HRC40 degrees, and the welding wire is selected as follows:
or
A diameter of the wire.
Further, during manual argon arc welding under the wire, a multilayer hammering method is adopted to effectively remove 60% -70% of welding stress, interlayer hammering is adopted during overlaying, so that a welding seam generates grain slippage, grain dislocation, plastic deformation and effective stress release, 10% -20% of residual stress is eliminated after machining, and finally after hot die production on the wire, the residual stress is eliminated through medium and low temperature extrusion, and a processing and hardening free sealing surface is generated.
Compared with the prior art, the invention has the beneficial effects that:
the invention does not need to dismantle the die tooling, directly welds on the lining die, does not need to dismantle the lining die, has low cost, is convenient and quick, does not need heat treatment after welding repair, has short repair period, can obtain good repair effect by gantry milling after welding, has the advantages that the die does not deform and completely meets the requirements of the production process, and the welding repair process can be repeatedly applied, and can prolong the service life of the die by more than 2 times.
Drawings
The invention is further described with reference to the accompanying drawings in which:
FIG. 1 is a schematic diagram of a repairing case of a parting surface of a medium-large die-casting die tooling;
FIG. 2 is a schematic view of the welding thickness in a side view of three stepped parting surfaces of a die casting mold;
FIG. 3 is a schematic diagram of the mold on three stepped parting surfaces, after machining, adding dimension and thickness on the original design basis;
FIG. 4 is a top view of the mold showing the three stepped parting surfaces and the weld locations;
FIG. 5 is a shape diagram of a die-casting mold with a stepped parting surface after a movable mold and a fixed mold are closed;
FIG. 6 is a flow chart of a method for repairing the die-casting die parting surface stack abrasion by welding.
Detailed Description
In order to make the implementation objects, technical solutions and advantages of the present invention clearer, the technical solutions in the embodiments of the present invention will be described in more detail below with reference to the accompanying drawings in the embodiments of the present invention. In the drawings, the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The described embodiments are only some, but not all embodiments of the invention. The embodiments described below with reference to the drawings are illustrative and intended to be illustrative of the invention and are not to be construed as limiting the invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention. Embodiments of the present invention will be described in detail below with reference to the accompanying drawings.
In the description of the present invention, it is to be understood that the terms "center", "longitudinal", "lateral", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate orientations or positional relationships based on those shown in the drawings, and are used merely for convenience in describing the present invention and for simplifying the description, and 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 therefore, should not be taken as limiting the scope of the present invention.
The invention is described in detail below with reference to the attached drawing figures:
the technology is subjected to a plurality of research and development tests in dies produced on 2200T die casting machines and 2800T die casting machines, and good experimental effects are obtained. Particularly, the process is adopted on a medium-large die-casting die, the technical effect is obvious, the repaired die is produced on line again, the effect of processing and hardening the surface of the die steel can be achieved generally within 600-800 die times, and the working period can be generally within 2-3 ten thousand die times (namely the complete angle of the surface of the parting surface of the die is good) after welding repair when the die is the hardest. If the welding parting surface is abraded again after a period, the welding repairing process can be used repeatedly after secondary and repeated repairing. Compared with the prior art scheme shown in figure 1, the method is originated in the technology for repairing the parting surface of the die in the same industry at home and abroad, and the method is shown in figure 6 and is a flow chart of the repairing method.
The invention creates the detailed explanation of the technical scheme:
firstly, the die is on line, after the alloy adhered to the movable die and the static die of the die is cleaned, the surface of the static die is coated with uniform red powder, the die casting machine is started to close the die, the die is opened after the die is pressed and kept for 3S, whether the parting surface on the side of the movable die is red and adhered or not is observed, and no adhesion or light coloring is caused, so that the parting surface of the die is worn and has a gap.
And secondly, manually pressing a plasticine ball at the loss part of the parting surface of the movable mold, closing the mold, pressing for 3S, opening the mold, measuring the flattening thickness of the plasticine through a caliper, determining the loss amount of the mold, and recording the loss thickness of each loss surface. And (4) inserting the die off line, opening the die, and dividing the area to be welded by using a marking pen.
Welding and repairing the surface of the parting surface of the mold:
(1) cleaning up the welding part before welding;
(2) selecting a welding wire: consistent with the mold material, or selecting a wire with higher performance than the mold material.
The chemical composition of the welding wire is also the same as that of steel grade with the same grade, and the chemical composition is the same as that of the welding wire with the same grade as long as the grade is the same, so that the performance of the welding wire is almost the same in use, and die-casting molds made of steel grades selected by manufacturers internationally are different, so that the welding wire is preferably selected to be the same as the materials of molds for welding, such as: when the material of the die-casting die is 8407 steel, an argon arc welding wire of 8407 is preferably selected. The chemical elements of each wire are different but the major components are roughly equivalent. The first layer of welding must select ERNi-1 pure nickel welding wire, and welding can select other welding wires after the second (when selecting the welding wire, it will coincide with the mould brand, as long as the welding wire brand is the same, can carry on the multilayer welding), pay attention to: the ERNi-1 pure nickel welding wire can be used for the first layer of welding to be used as backing welding, and other layers can not be used and can only be used once.
Mechanical properties: the hardness of the annealed wire was HRC24 degrees in Rockwell hardness.
H13 steel chemical composition: 4 (chromium Cr)5 (molybdenum Mo) (Si1 silicon) (V1 vanadium).
Note: 245-205 degrees HB (HB represents Brinell hardness), but in the industry, the hardness of a mold is generally HRC Rockwell hardness, and the two hardnesses need to be converted or looked up in a table to be identical, for example: the Brinell hardness 245HB is obtained by table lookup and is approximately equal to the Rockwell hardness HRC24 degrees, so that the hardness is conveniently changed into the HRC Rockwell hardness uniformly here.
HRC Rockwell hardness, HB Brinell hardness and HV Vickers hardness are all industrial common hardness, and HB Brinell hardness and HV Vickers hardness are generally adopted in most laboratories, because the two hardness values are finer and more accurate than the fine values.
8407 Steel composition: 0.38 of die steel carbon (C), 5.3 of chromium (Cr), 0.4 of manganese (Mn), 1.3 of Molybdenum (MO), 1.0 of silicon (Si) and 0.9 of vanadium (V).
1.2344 Steel composition: c (carbon): 0,37-0, 43; si (silicon): 0,90-1, 2; mn (manganese): 0,30-0, 50; cr (chromium): 3,00-3, 60; mo (molybdenum): 1,20-1, 60; v (vanadium): 0,90-1, 10; s (sulfur): 0,030, respectively; p: (phosphorus) 0,030;
SKD61 steel composition: 0.8-1.2 parts of (Si-Si); (Mn: less than or equal to 0.50);
(Cr-Cr) 4.50-5.50; (Mo-Mo) 1.00-1.50; (V) 0.8 to 1.2; (S-S) 0.03 (P-P) 0.03;
the first layer is required to be made of ERNi-1 pure nickel welding wires, the chemical components of the welding wires are pure nickel, and the second layer is made of other welding wires which are used after the second time;
the first layer uses ERNi-1 pure nickel welding wire, because the pure nickel welding wire is soft, the welding stress is not easy to generate, and the pure nickel welding wire has the excellent property of connecting the upper layer and the lower layer excessively, the red heat strength is good at 800 degrees, the strength is lower because the pure nickel welding wire is soft, the strength of the parting surface of the die is improved by other grades of welding wire, and other welding wires can be used from the second layer to the n layers. 1.2344 is selected after the second layer, because (1) the welding wire and the die have the same mechanical property and can meet the use requirement of the die after being welded due to the same mark, and (2) the mechanical property: the hardness of the annealed wire, rockwell HRC24 degrees, refers to the hardness of the wire, but when we weld with this hard wire on the die, the underlying metal is rapidly solidified as the wire melts and dissolves. The hardness of the die can reach about HRC40 degrees (because the welding process is a metal smelting process, the metal is changed from a solid state to a liquid state, and the rapid change from the liquid state to the solid state is equivalent to a quenching process, the reason is that the surface of the parting surface of the die after welding is hard.
The hardness of the welding seam is generally about HRC40 degrees, and the diameter of the welding wire is selected
It is preferable.
(3) And (3) selecting the flow of welding argon: the gas volume flow rate is generally 5 to 12L/min (min).
The diameter D of the nozzle is 2D + 4; after the diameter of the nozzle is selected, adjusting the flow of argon to realize the gas protection effect; the tungsten electrode is generally 2.0 or 2.4mm in diameter, and a cerium tungsten electrode is generally selected. D represents the inner diameter of the nozzle, D represents the diameter of the tungsten electrode, 2 represents the calculation multiple, and 4 represents the coefficient
Such as: when the parting surface of the welding mould is welded according to experience, the welding current is selected from 140A to 160A, so that the welding arc with larger heating value can be selected
The tungsten electrode of (1).
Introducing a formula: D2D (tungsten electrode) +4
And D is 2 x 2.4 (tungsten electrode) +4 is 8.8mm, the nozzle is selected as long as the diameter is larger than the calculation result, the No. 6 ceramic welding nozzle for argon arc welding is selected, and the inner diameter of the No. 6 welding nozzle is 10mm, so that the welding requirement can be met.
(4) Electrode connection method selection: DCEN is direct current positive connection (i.e. the positive output electrode of the workpiece welding machine is positive connection, and the same is true for the inverter type pulse argon arc welding machine).
(5) Selecting welding current: the larger the selected current is, the larger the welding stress is, and the most reasonable is 140A-160A;
when manual argon arc welding is adopted, H13 steel welding wires are generally selected to weld and repair the defect part with the thickness of 2mm-5mm, and machining is carried out according to the defect of the parting surface to ensure that no welding defect exists.
Whether manual welding or automatic machine welding is adopted, welding wires can be selected as long as the grade of the welding wires is the same as that of a mould material, and other welding wires can be selected if the welding wires do not have the same grade, such as: the die is H13 steel welding wire or H8407, 1.2344.
If the die-casting die is a stepped parting surface, and when the three parting surfaces with different heights are worn in different degrees, the welding layer number can be selected according to the wear degree, namely the welding thickness. Refer to fig. 2 and 3.
Three layers are welded in the same place, also known as build-up welding or as multilayer welding.
Referring to fig. 3 and 4, in fig. 3, the abrasion degree of the die is relatively light, which is-0.15 mm (negative) on average, and two layers are welded, and the height is about 2.0 mm; (the thickness of the two layers is thinner, and each layer is controlled to be about 1 mm)
Secondly, the abrasion degree of the die is neutral, the average is-0.3 mm (negative), two layers are welded, and the welding height is about 3.5 mm;
thirdly, in a mold overheating area, the abrasion is minus 0.5mm (minus), four layers are required to be welded if the abrasion is serious, and the height of a welding line is controlled to be 5 mm;
FIG. 4 is a top view of the mold (i) and (ii) showing three stepped parting surfaces and welding positions; fig. 5 is a shape diagram of the die-casting mould with the step-shaped parting surface after the movable mould and the fixed mould are closed.
Note that:
(1) the contraction force of the weld metal and the heat affected zone metal can be counteracted by striking the weld with a hand hammer, so that the internal stress and deformation are reduced or eliminated. The hammering can also change the molecular arrangement in the metal structure, and improve the mechanical property and the corrosion resistance of the metal. The hammering force is moderate, the hammering force is sequentially arranged and knocked, and the hammering force cannot be applied to the bottom welding seam. Otherwise weld fusion zone ductile cracks can occur, rendering the weld ineffective.
(2) Aiming at different abrasion thicknesses, comprehensive consideration is needed according to the heated area, the loss degree and the area size, so the allowance left after the parting surface machine is added is also different. See fig. 2.
Such as: after welding, the gantry milling machine is used for processing a welding surface, and allowance is reserved (the allowance height is that 0.15mm is added on the design reference height of a parting surface, the thickness of 0.30mm can be increased on the basis of the original design in the vicinity of two sides of a sliding block or a high-temperature corner area, and the sealing effect of a high-temperature area of the parting surface of the die can be better improved.
The on-line matching and repairing process of the machined die comprises the following steps: and (3) coating red powder on the surface of the static mold, repeatedly closing the mold, pressing color, manually grinding and removing local hard spots. After the repair is finished, the mold is produced for about 800 times on line, the final work hardening effect is achieved by repeatedly closing the mold, extruding and welding the repaired surface at the high temperature of 160-200 ℃, and the effect of aluminum sealing can be achieved by reducing the local overheating area of 0.1mm to 0.25mm by repeatedly extruding the surface of the mold.
During manual argon arc welding under the wire, a multilayer hammering method is adopted, 60% -70% of welding stress can be effectively removed, interlayer hammering is adopted during surfacing, a welding seam can generate grain slippage, grain dislocation, plastic deformation and effective stress release, 10% -20% of residual stress can be eliminated after machining, and finally after hot die production on the wire, all residual stress can be eliminated through medium and low temperature extrusion, and a processing and hardening free sealing surface is generated. After the scheme is implemented, through batch production verification, when the die is produced on line for the first time, a small-area aluminum alloy thin skin is adhered on a local parting surface, but the material escaping phenomenon cannot occur, the production is continued after manual removal, along with the fact that the temperature of the die reaches about 200 ℃, the surface of the parting surface is under the pressure of die locking force, the yield strength of a welding surface base layer is reduced, the hard point of the parting surface is gradually flattened, a completely matched surface is formed (the surface is generally produced for 600-800 times for the first time, the final ideal matching surface can be completed), when the die is produced on line, the welding tissue of the die parting surface is more and more compact under the pressure action of a die casting machine, the surface hardness is not much different from the nitriding surface of the die, the welding surface hardness of the die-casting die parting surface is detected through a hardness tester, the average HRC44 degrees (Rockwell hardness) can be achieved, and the working requirement can be completely met.
Research and development practices prove that the repairing method can be suitable for repairing all die-casting die parting surfaces, the service life of the die can be prolonged by about 2 times, the internal quality and the size of a produced casting are detected to be qualified, faults such as block breakage, low hardness, die pressure chamber deformation and the like do not exist on the welding surface, and the repairing method has good economic benefits for repairing various die-casting die parting surfaces.
The invention is used as a die-casting mould parting surface welding repair technology, and is characterized in that a welding technology and a machining allowance of a welded surface are set, a little more thickness can be left for a mold overheating area or a position with serious abrasion according to a mold gating system and the flow and the direction of liquid alloy, so the machining allowance of each set of mold after welding needs to be acquired and determined on the actual site, but the thickness of 0.15mm or 0.30mm is generally increased on the basis of mold design, and the pretightening force of the surface of the die surface can be ensured according to the heating condition of the surface of the mold during the operation of the mold.
See FIG. 2: the die experiences differential wear on the three stepped parting surfaces of different heights. Such as: firstly, the No. position has 0.15mm abrasion, secondly, the No. position has 0.30mm abrasion, thirdly, the No. position has 0.50mm abrasion,
it is important to select different machining margins for different wear of the three planes of the die.
The principle of repairing the loss surface when the wear of the parting surface is 0.15mm is that the thickness of 0.10mm is added after the machining allowance is 0 by the design standard, because the heat of the surface is small, and the thickness of 0.10mm is added at the far end of a die-casting cavity after welding (the thickness of 0.1 is the allowance left after machining, and the aim is to increase the pretightening force of the parting surface).
When the wear of the parting surface is 0.30mm, the principle of repairing the loss surface is that the thickness of 0.15mm is added with the design standard of 0, and the surface has larger heat and is arranged at the middle section of the die-casting cavity, so that the thickness of 0.15mm can be added after the welding.
When the wear of parting surface (III) is 0.50mm, the principle of repairing the loss surface is that the thickness of 0.25mm is added to the design reference of 0, because the heat of the surface is the largest, and the heat is higher at the near end of the gate on the parting surface, the thickness of 0.25mm is added to the original design reference of the mold machining process, and a larger amount of pretightening force can be increased. See fig. 5.
FIG. 5 is a shape diagram of the die-casting mold with the stepped parting surface after the movable mold and the fixed mold are closed; a shape diagram of a die-casting mould with closed movable and fixed moulds with stepped parting surfaces; the upper part is a fixed die, the lower part is a shape diagram of the closed movable die, and the first step parting surface and the second step parting surface are set according to the abrasion degree.
The method firstly determines that the parting surface of the static mould is intact, and if the static mould is locally worn and collapsed, the static mould is firstly repaired to be intact, and the repairing standard is based on the design standard and can be manually repaired. Because the water channel and the parting surface are far away from each other due to the thick fixed mold lining, the fixed mold lining has high strength and hardness and is not easy to wear and collapse, and therefore, the fixed mold lining is preferably matched and repaired by taking the fixed mold parting surface as a reference. FIG. 6 is a flow chart of the method for repairing the die stack abrasion of the parting surface of the aluminum alloy die-casting die in the invention.
The working principle of increasing the thickness of the repaired parting surface is as follows:
the hardness of the welding surface of the die after cold welding is generally about HRC40-42 degrees, the hardness of the welding metal which is close to the surface of the die after machining is generally below HRC42 degrees, the Rockwell hardness of the original die after heat treatment is HRC46-48 degrees, the difference between the Rockwell hardness and the Rockwell hardness is larger, and the hardness of the surface of the die after nitriding can reach about HRC58-60 degrees. We want to increase the hardness by pressing the metal to create the work hardening properties of the material surface. Because the temperature of the die is generally about 200-240 ℃ during the operation of the die-casting die, the surface temperature of the molded surface is generally about 160 (DEG C) during the operation of the die-casting die, and the metal surface of the die bears great compression stress during each die assembly, therefore, under the dual action of temperature and pressure, the welding metal on the surface of the parting surface can generate micro plastic deformation, that is, the crystal grain sliding occurs to cause the crystal grain dislocation tangle to elongate, or to break and fibrillate, thereby greatly improving the surface sinking deformation hardness of the parting surface, when the sinking depth of the welding surface of the parting surface of the die reaches 0.05mm0.1mm higher than the design plane, the residual stress generated in the metal is completely released when the sinking is stopped, meanwhile, due to the effect of work hardening, the surface hardness of the parting surface can be improved to HRC42-48 degrees, and the production requirement of the die can be completely met when the welding surface is the hardest.
Generally, when a welding parting surface of a mold works for 800 times in 600 times and 800 times, the surface of the welding parting surface is crushed by 0.10-0.20mm according to different mold heat and area distribution, so the reserved height of the parting surface machine is determined by actual conditions and cannot be directly given a theoretical value.
After the common medium-large die-casting die adopts the parting surface repairing technology, when the die is debugged and produced on line again, the work hardening effect can be achieved within 600-800 mould times, and when the welding layer on the parting surface of the die is the hardest, one working cycle of the die after welding repair is within 2-3 mould times (namely the integrity angle of the parting surface of the die is good). If the welding parting surface is abraded again after a period, the welding repairing process can be used for repairing for two times or more times and can be used repeatedly.
The technology is very complex, namely, a new set of new die is newly opened and machining and heat treatment are needed again, the cost is extremely high, the period is too long, and the produced first batch of castings can be put into production after the first batch of castings need to be scribed again and the size is qualified, so that the loss is not paid.
The mould parting surface welding belongs to large-area surfacing welding, a heat treatment process is required to be matched after the mould welding under normal conditions, but the risk is higher during the mould heat treatment, the mould deformation and the staggered superposition of the internal stress of the mould can occur due to the mould reheating treatment, the surface hardness of the mould is uneven, and early large-area staggered cracks occur in production to cause the mould to be scrapped, even if the problem does not exist, the operation is time-consuming, labor-consuming and high in cost, and the adoption is generally not suggested in the mould industry.
The above description is only for the purpose of illustrating the present invention and the appended claims are not to be construed as limiting the scope of the invention, which is intended to cover all modifications, equivalents and improvements that are within the spirit and scope of the invention as defined by the appended claims. And those not described in detail in this specification are well within the skill of those in the art.
Claims (10)
1. A method for repairing the die-casting die-parting surface stack abrasion by welding is characterized by comprising the following steps:
in the middle temperature area of the die, the welding surface is processed by a gantry mill after welding, and the parting surface of the die is 0.15mm higher than the original design surface after machining;
and in the high-temperature area of the die, the welding surface is processed by a gantry mill after welding, and the parting surface of the die after machining is 0.25mm higher than the original design surface.
2. The aluminum alloy die-casting die parting surface pressure stack abrasion welding repair method as claimed in claim 1, characterized in that:
for some positions with too serious abrasion, the parting surface of the die after machining is 0.3mm higher than the original design surface; the positions with too serious abrasion are positioned at the two sides of the sliding block, the corner area of the high-temperature area and the corner position of the parting surface of the die.
3. The aluminum alloy die-casting die parting surface pressure stack abrasion welding repair method as claimed in claim 2, characterized in that:
when the parting surface of the mold is a stepped parting surface, the three stepped parting surface surfaces related to the stepped parting surface have loss of 0.15mm, 0.30mm and 0.50mm in different degrees respectively, and different reserved heights are selected for the three surfaces to determine the machining allowance;
when the wear of the parting surface is 0.15mm, the principle of repairing the defect surface is that the machining allowance is 0 based on the design standard, and then the thickness of 0.10mm is added;
when the wear of the parting surface is 0.30mm, the principle of repairing the damaged surface is that the thickness of 0.15mm is added with the design reference of 0;
when the wear of the parting surface is 0.50mm, the principle of repairing the loss surface is that the thickness of 0.25mm is added with the design standard of 0.
4. The aluminum alloy die-casting die parting surface pressure stack abrasion welding repair method as claimed in claim 3, characterized in that:
when the average abrasion loss of the die is minus 0.15mm, welding two layers, wherein the welding height is 2.0 mm;
the average abrasion loss of the die is minus 0.3mm, three layers are welded, and the welding height is 3.5 mm; the welding thickness of each layer is controlled to be about 1 mm;
the abrasion loss of the die is minus 0.5mm, four layers are welded, and the welding height is 5 mm; the welding thickness of each layer is controlled to be about 1 mm.
5. The aluminum alloy die-casting die parting surface stack abrasion welding repair method as claimed in claim 4, characterized in that:
after the welding machine for the parting surface of the mold is added, the mold is on-line matched and repaired: coating red powder on the surface of a static mold, repeatedly closing the mold, pressing color, manually grinding, and removing local hard spots; after the repair is finished, the die is produced for about 800 times on line, and the local overheating area of 0.1mm is reduced to 0.2mm by repeatedly closing the die, extruding and welding the repaired surface at the high temperature of 160-200 ℃.
6. The aluminum alloy die-casting die parting surface pressure stack abrasion welding repair method as claimed in claim 5, characterized in that:
a die repairing means: after the die parting surface is machined, the die is subjected to surface impression repair fine machining on a die closing machine or a die casting machine, and the fixed die parting surface is used as a reference for repair.
7. The aluminum alloy die-casting die parting surface pressure stack abrasion welding repair method as claimed in claim 6, characterized in that:
the method for checking the loss of the parting surface of the die comprises the following steps;
firstly, cleaning up an alloy adhered to a movable die and a static die of a die on a line;
step two, coating uniform red lead powder on the surface of the static mold;
step three, starting a die casting machine to close the die, opening the die after the die is tightly pressed and kept for 3 seconds, observing whether the parting surface on the side of the movable die is red and attached or not, and indicating that the parting surface of the die is abraded and has a gap;
manually pressing a plasticine ball at the loss part of the parting surface of the movable mold, closing the mold, pressing for 3 seconds, opening the mold, measuring the flattening thickness of the plasticine through a caliper, determining the loss amount of the mold, and recording the loss thickness of each loss surface;
the mould is taken off line, the mould is opened, the areas to be welded are marked with a marker pen and the loss size of each welding zone is marked with a number.
8. The aluminum alloy die-casting die parting surface stack abrasion welding repair method as claimed in claim 7, characterized by comprising the following steps:
cleaning up the welding part before welding;
selecting a welding wire: the welding wire is consistent with the mould material or the performance of the welding wire is higher than that of the mould material;
and (3) welding argon flow selection: the gas volume flow is generally 5-12L/min;
electrode connection method selection: direct current is connected positively;
selecting welding current: 140A-160A.
9. The aluminum alloy die-casting die parting surface pressure stack abrasion welding repair method as claimed in claim 8, characterized in that:
the steel welding wire mark for the hot-working die comprises the following components:
h13 steel composition: 4Cr5MoSi1V 1;
8407 Steel composition: 0.38 of die steel carbon (C), 5.3 of chromium (Cr), 0.4 of manganese (Mn), 1.3 of Molybdenum (MO), 1.0 of silicon (Si) and 0.9 of vanadium (V).
1.2344 Steel composition: c: 0,37-0, 43; si:0, 90-1, 2; mn: 0,30-0, 50; cr: 3,00-3, 60; mo:1, 20-1, 60; v:0, 90-1, 10; s: max.0,030; p: max.0,030;
SKD61 steel composition: 0.8 to 1.2 of Si; mn is less than or equal to 0.50; 4.50-5.50 parts of Cr; 1.00-1.50% of Mo; v is 0.8 to 1.2; and S is 0.03.
10. The aluminum alloy die-casting die parting surface pressure stack abrasion welding repair method as claimed in claim 9, characterized in that:
during manual argon arc welding under the wire, a multilayer hammering method is adopted to remove 60-70% of welding stress; interlayer hammering is adopted during surfacing to release stress; after machining, 10-20% of residual stress is eliminated; and finally, after the on-line hot die is produced, residual stress is eliminated through low-and-medium-temperature extrusion, and a work-hardened free sealing surface is produced.
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