CN115351457A - Multi-section welding flux, self-preheating multi-section electroless welding rod and preparation method thereof - Google Patents
Multi-section welding flux, self-preheating multi-section electroless welding rod and preparation method thereof Download PDFInfo
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
- B23K35/02—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape
- B23K35/0255—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape for use in welding
- B23K35/0261—Rods, electrodes, wires
- B23K35/0266—Rods, electrodes, wires flux-cored
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
- B23K35/02—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape
- B23K35/0255—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape for use in welding
- B23K35/0261—Rods, electrodes, wires
- B23K35/0283—Rods, electrodes, wires multi-cored; multiple
-
- 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
- B23K35/28—Selection of soldering or welding materials proper with the principal constituent melting at less than 950 degrees C
- B23K35/286—Al as the principal constituent
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
- B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
- B23K35/36—Selection of non-metallic compositions, e.g. coatings, fluxes; Selection of soldering or welding materials, conjoint with selection of non-metallic compositions, both selections being of interest
- B23K35/3601—Selection of non-metallic compositions, e.g. coatings, fluxes; Selection of soldering or welding materials, conjoint with selection of non-metallic compositions, both selections being of interest with inorganic compounds as principal constituents
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
- B23K35/40—Making wire or rods for soldering or welding
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Inorganic Chemistry (AREA)
- Nonmetallic Welding Materials (AREA)
Abstract
The invention relates to a multi-section welding flux and a self-preheating multi-section electroless welding rod and a preparation method thereof, wherein the welding flux comprises a preheating section explosive column, a high-heat section explosive column and a low-heat section explosive column, and the preheating section explosive column comprises 16-18% of Al, 40-44% of CuO and MnO 2 15‑20％、CaF 2 5 percent, the high-heat section grain comprises 20 to 25 percent of Al, 60 to 65 percent of CuO, 3 percent of Ni and SiO 2 4.5 percent, nano-scale W powder 2 percent and CaF 2 3 percent of CaO, 2.5 percent of CaO, 18 to 20 percent of Al, 60 to 62 percent of CuO, 3 percent of Ni and SiO in each component of the low-heat-section grain 2 4.5 percent, nano-scale W powder 2 percent and CaF 2 5% and CaO 5.5%. In the invention, the preheating section explosive column is utilized at the beginning of weldingThe welding starting position is heated to the ideal welding temperature before, and a preheating process is not needed to be added, so that cold joint is avoided.
Description
Technical Field
The invention relates to the technical field of special welding, in particular to a multi-section welding flux, a self-preheating multi-section electroless welding rod and a preparation method thereof.
Background
When the water pipe and the air pipe of the machine and the family which are operated in the field work and run are used, parts such as structural parts, box bodies, pipelines and the like are inevitably damaged and failed, such as cracks, pore running, overflow, dripping, leakage and the like, and the normal use of the machine is seriously influenced.
Welding is a process for connecting two or more kinds of materials of the same kind or different kinds into a whole by combining and diffusing atoms or molecules, and is an important means for civil use, engineering machinery and military equipment and manufacturing, rush repair and emergency maintenance and installation. The traditional welding mode mainly adopts electric welding, gas welding and other modes, but the shielded metal arc welding needs a welding power supply capable of outputting more than kilowatt power and a heavy electric welding machine; gas welding requires high-pressure special equipment for storing combustible gases such as oxygen, acetylene and the like, so that safety cannot be guaranteed, and operators also need to be trained specially; the traditional adhesive has long curing time and can not meet the use requirement of field emergency. The flexible, flexible and efficient expansion of the emergency welding and first-aid repair task under the conditions of field, field operations, power failure, rain and snow weather and the like is greatly limited.
In addition, the traditional emergency maintenance method cannot be applied under extreme special conditions that energy sources are inconvenient to supply, such as high altitude, underground, underwater and the like. Meanwhile, in emergency rescue and disaster relief such as earthquake, fire and the like, and fire breaking and dismantling, a cutting and welding tool which does not need any external energy and equipment and is convenient to use is urgently needed. Therefore, it is necessary to develop a new welding technique with high speed, high efficiency and energy saving to overcome the shortcomings of the conventional welding technique.
Self-propagating welding techniques and electroless electrodes based on self-propagating reactions have been developed in this context. After the self-propagating system is ignited, the self-propagating system is divided into four regions according to the propagating degree of combustion waves: the reaction is spontaneously and continuously carried out from top to bottom in the reacted zone, the combustion zone, the preheating zone and the unreacted zone, the reaction speed of the whole reaction system is very high, the reaction can be completed within a short time of several seconds to ten seconds generally, and a large amount of heat is released in the reaction to ensure that the reaction system reaches a very high temperature (the highest temperature can reach about 5000 ℃) within a short time. The electroless electrode can be prepared by adding combustion controlling components and metallurgical components to a self-propagating system, for example, in patent CN200810227057.X thermite welding basic principle is used to mix thermite (CuO powder, cu powder) 2 O powder, niO powder, fe 2 O 3 Powder and Al powder), slag former (B) 2 O 3 Powder, siO 2 Powder, caO powder and CaF 2 Powder), alloying agents (Fe powder, mn powder and Si powder) are uniformly mixed by a ball mill according to a certain proportion and then are formed in a paper cylinder, and other parts are mounted to form a hot agent welding rod; the patent CN201310557331.0 provides a self-propagating aluminum flux and a welding rod, the flux is composed of common gypsum powder, aluminum powder, copper powder, tin powder, zinc powder, silicon powder, calcium fluoride powder, sodium fluosilicate powder, scandium powder, yttrium powder and silver powder, the welding rod is prepared by the steps of dehydration, mixing, pressure processing, densification processing, shaping, packaging and the like of the flux, the rosin powder and the paraffin powder, and the main structure of the welding rod comprises four parts of a powder column, a ignition wire, a handle and a thin aluminum cylinder coated outside the powder column.
The above patents all realize better welding performance through optimization of the formula, but do not consider the problem that the welding base material is heated unevenly in actual welding, that is, the base material is in a normal temperature state when the self-propagating welding rod is ignited to start welding, so that a longer heating time is needed to reach the melting point of the base material to realize welding. In the subsequent welding stage, the base metal is in the similar preheating and high temperature state, and the welding rod only needs to stay for a short time to complete the welding. If the whole welding line is expected to achieve a better fusion effect, the bar conveying speed is required to be changed ceaselessly in the welding process, and higher requirements are imposed on the operation technology of constructors; secondly, self-propagating welding is different from traditional welding, can produce the impurity of a large amount of high melting point in the combustion process, if at welding initial stage fortune strip speed slow excessively, can make impurity deposit on the surface, influence the heat conduction on the base metal. In actual operation, the welding quality of each part of the welding line is inconsistent, which is one of the main reasons for restricting the overall welding effect.
Disclosure of Invention
In view of the above problems, a multi-section welding flux, a self-preheating multi-section electroless welding rod and a preparation method thereof are provided, so that the self-preheating function of the welding rod is utilized to ensure that the rod conveying speed is not required to be changed in the welding process, thereby improving the welding quality.
The specific technical scheme is as follows:
the invention provides a multi-section welding flux which is characterized by comprising 16-18% of Al, 40-44% of CuO and 40-44% of MnO in percentage by mass of a preheating section flux, a high-heat section flux and a low-heat section flux from top to bottom in sequence 2 15-20％、CaF 2 5 percent, the high-heat section grain comprises 20 to 25 percent of Al, 60 to 65 percent of CuO, 3 percent of Ni and SiO 2 4.5 percent, nano-scale W powder 2 percent and CaF 2 3 percent of CaO, 2.5 percent of CaO, 18 to 20 percent of Al, 60 to 62 percent of CuO, 3 percent of Ni and SiO in each component of the low-heat-section grain 2 4.5 percent, nano-scale W powder 2 percent and CaF 2 5％、CaO 5.5％。
In a second aspect of the present invention, there is provided a self-preheating, multi-stage electroless welding rod comprising a flux tube, flux, a primer cap, a holding end, and a sleeve, the flux being contained in the flux tube, one end of the flux tube being connected to the holding end, the other end of the flux tube being plugged into the primer cap for encapsulation, the flux tube and the primer cap being contained in the sleeve which is closed at one end, characterized in that the flux is the self-preheating, multi-stage flux of claim 1.
The multi-section electroless welding rod also has the characteristic that the medicine tube is made of paper rolls or thin-wall stainless steel.
The multi-section type electroless welding rod is also characterized in that the ignition cap is prepared by mixing thermite welding ignition powder and a binder uniformly, pressing and forming the mixture into a cylinder with the height of 3-5mm, and inserting a firework lead.
The multi-section electroless welding rod has the characteristics that the inner diameter of the sleeve is 1-2mm larger than the outer diameter of the medicine tube, and the length of the sleeve is 3-4mm longer than that of the medicine tube.
The third aspect of the present invention is to provide a method for preparing the above multi-section electroless welding rod, having the characteristics that it comprises the steps of:
1) Weighing the materials according to the mass percent, and mixing the materials in a powder mixer to obtain the welding flux;
2) Sequentially filling the welding flux into a powder tube closed by a clamping end plug, continuously compacting to sequentially prepare a low-heat-section powder column, a high-heat-section powder column and a preheating-section powder column, and stopping charging at a position 4-6mm away from the end opening of the powder tube;
3) A fire cap is plugged into the end opening of the explosive tube to ensure that the fire cap is tightly contacted with the welding flux;
4) And (5) filling the explosive tube into a sleeve to finish the manufacture of the welding rod.
The beneficial effect of above-mentioned scheme is:
1) In the invention, the preheating section explosive column is utilized to heat the welding starting position to the ideal welding temperature before the actual welding is started, so as to avoid cold joint caused by insufficient temperature and insufficient melting of the base metal;
2) According to the invention, the welding flux is divided into a high-heat section flux column and a low-heat section flux column according to the change rule of the base metal temperature in actual construction, so that high heat is emitted when the base metal temperature is lower, and low heat is emitted when the base metal temperature is higher correspondingly, thus the welding temperature is ensured, and the overheating ablation of the base metal is avoided; therefore, when in use, workers can carry out welding at a uniform speed so as to greatly reduce the operation difficulty, meanwhile, the welding inclination angle and the welding height do not need to be changed in the welding process, and the workers can carry out welding by training slightly;
3) The welding rod provided by the invention applies a plurality of strengthening mechanisms, and the tensile strength after welding can reach 410Mpa, which is close to the level of manual electric arc welding;
4) The welding rod provided by the invention can be used for welding low-carbon steel and low-alloy steel and quickly cutting a thin plate with the thickness of less than 3 mm;
5) The welding rod provided by the invention has uniform heat and stable combustion in the welding and cutting process, and can not generate splashing or local explosion phenomenon due to overheating;
6) The non-electric welding rod provided by the invention does not need preheating processes such as external power and gas during welding, realizes energy conservation, and meets the use requirements of rapid welding and cutting.
7) The welding product of the electroless welding rod provided by the invention is metal liquid such as common copper water and the like, can be rapidly solidified after welding, and has no pollution discharge.
Drawings
FIG. 1 is a schematic view of a structure of an electroless welding electrode provided in an embodiment of the present invention.
In the drawings: 1. a medicine tube; 2. welding flux; 3. a fire cap; 4. a clamping end; 5. a sleeve.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. 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.
It should be noted that the embodiments and features of the embodiments of the present invention may be combined with each other without conflict.
The invention is further described with reference to the following drawings and specific examples, which are not intended to be limiting.
A multi-section electroless welding rod comprises a flux tube 1, a welding flux 2, a firing cap 3, a clamping end 4 and a sleeve 5, wherein the welding flux 2 is loaded in the flux tube 1, one end of the flux tube 1 is connected with the clamping end 4, the other end of the flux tube 1 is plugged into the firing cap 3 for packaging, and the flux tube 1 and the firing cap 3 are loaded into the sleeve 5 with one end closed.
The traditional Chinese medicine tube 1 is made of paper rolls or thin-wall stainless steel (the wall thickness is less than 0.3 mm), and the diameter is 12-22mm (parameters can be adjusted according to the thickness of a base material to be welded); the ignition cap 3 is prepared by mixing thermite welding ignition powder and a binder uniformly, pressing and forming into a cylinder with the height of 3-5mm, and inserting a firework lead; the inner diameter of the sleeve 5 is 1-2mm larger than the outer diameter of the explosive tube 1, the length of the sleeve 5 is 3-4mm longer than the length of the explosive tube 1, so that the sleeve 5 is sleeved outside the explosive tube 1 to play a role in protection in the storage and transportation process of welding rods, and when the welding rods are used, the sleeve 5 is pulled out and reversely sleeved on one side of the clamping end to be used as a welding handle.
The welding flux 2 comprises a preheating section powder column, a high-heat section powder column and a low-heat section powder column from top to bottom in sequence, wherein the preheating section powder column comprises, by mass, 16-18% of Al, 42-44% of CuO, and MnO 2 15-20％、CaF 2 5 percent, the high-heat section grain comprises 20 to 25 percent of Al, 60 to 65 percent of CuO, 3 percent of Ni and SiO 2 4.5 percent, nano-scale W powder 2 percent and CaF 2 3 percent of CaO, 2.5 percent of CaO, 20 to 25 percent of Al, 60 to 65 percent of CuO, 3 percent of Ni and SiO in each component of the low-heat-section grain 2 4.5 percent, nano-scale W powder 2 percent and CaF 2 5％、CaO 5.5％。
The length of the preheating section grain can be 2-5cm (can also be adjusted according to the thickness of a welding base metal), wherein the mass ratio of Al and CuO is 60% (Al and CuO are proportioned according to the stoichiometric ratio), and Al and MnO are added 2 35% by mass (Al, mnO) 2 In stoichiometric ratio). Al + CuO is the highest reaction temperature in the thermit reaction, and the adiabatic reaction temperature is up to 5718K, so that the task of heating the base metal can be well completed; al + MnO 2 The method is the reaction with the maximum gas production rate in the thermit reaction, and the gas production rate reaches 0.8136mol/100g, so that the method can be used for increasing the jet force of combustion flame, thereby blowing impurities generated by the reaction off the surface of a parent metal and completing preheating on the premise of not forming impurity accumulation on the surface of the parent metal; caF 2 Al capable of reacting with the above two for slag forming agent 2 O 3 The impurities form light eutectic with a low melting point, and are kept in a liquid state for a long time to be separated from the welding base metal by the flame ejection.
The high-heat section is used for completing the welding of the first one third of a welding line, the welding base metal is heated by the explosive column of the preheating section, but the distance from the melting temperature is still large, so that the explosive column welding flux of the high-heat section needs large heat release, and the components of the explosive column welding flux of the high-heat section are 20-25% of Al, 60-65% of CuO, 3% of Ni and 3% of SiO 2 4.5 percent, nano-scale W powder 2 percent and CaF 2 3 percent of CaO and 2.5 percent of CaO, wherein the mass ratio of Al and CuO is 85 percent (the Al and the CuO are proportioned according to the stoichiometric ratio). Al + CuO is used for reacting to release heat to melt a base metal, and simultaneously, a reaction product Cu of the Al + CuO can be infinitely mutually dissolved with steel and forms a welding line together with the melted base metal after being cooled; and SiO 2 、CaF 2 CaO and CaO are slag formers, and can react with Al generated by the above reaction 2 O 3 Impurities form light eutectic matters with low melting point, and the eutectic matters keep liquid state for a long time and float upwards to leave the welding line under the action of gravity, so that the welding line is purified, and the mechanical property of the welding line is improved; the addition of the nano-scale W powder utilizes the characteristic of ultra-high melting point of W to serve as an uneven nucleation point position in the process of welding line solidification, so that grains are refined to generate a second-phase strengthening effect, and the mechanical property of the welding line is improved; the Ni powder can be mutually fused with weld metal to play a role in solid solution strengthening, so that the mechanical property of the weld is further improved.
The low-heat section powder column is used for completing the welding of two thirds of the welding seam, the welding base metal is heated by the preheating section and the high-heat section and approaches to the melting temperature, so the welding flux needs to reduce the temperature properly and avoid overheating, and the low-heat section comprises 20-25% of Al, 60-65% of CuO, 3% of Ni and SiO 2 4.5 percent, nano-scale W powder 2 percent and CaF 2 5 percent of CaO and 5.5 percent of CaO, wherein the mass ratio of Al and CuO is 80 percent (the Al and the CuO are proportioned according to the stoichiometric ratio). The above components have the same action as that of the high heat section, but the welding base metal is fully heated when the welding rod burns to the low heat section, so that the welding can be completed without too high heat, and the heat release componentThe Al + CuO ratio is further reduced to avoid the ablation of the parent metal caused by overheating.
Example 1
In this embodiment, the two stainless steel plates of 70mm × 70mm × 5mm are butt-welded by using the above-mentioned electrode, and the welding parameters are as follows: the welding inclination angle is about 70 degrees, the welding height is about 5mm, and the welding speed is 7-9mm/s;
when in welding, the two steel plates are completely melted in the area where the welding rod passes through and are fully fused to form a metallurgical bonding effect. The width of the welding seam is about 10mm, and no obvious defect exists after surface welding slag is removed.
Tests show that the tensile strength of the steel plate in the example 1 after welding can reach 410MPa, and the tensile strength is close to the level of manual arc welding.
Example 2
In this embodiment, two 80mm × 80mm × 5mm Q235 steel plates are butt-welded with the above-mentioned electrode, and the welding parameters are: the welding inclination angle is about 60 degrees, the welding height is about 6mm, and the welding speed is 7-9mm/s;
when in welding, the two steel plates are completely melted in the welding rod passing through the area and fully fused with the welding flux to form a metallurgical bonding effect, the width of the welding line is about 10mm, and no obvious defect exists after surface welding slag is removed.
The welding rod provided by the invention applies a plurality of strengthening mechanisms, and the tensile strength after welding can reach 410Mpa, which is close to the level of manual electric arc welding;
the welding rod provided by the invention can be used for welding low-carbon steel and low-alloy steel and quickly cutting thin plates with the thickness of less than 3 mm.
Example 3
In this example, the non-welding electrode is used to perform the fusion cutting on the Q235 steel plate with the thickness of 80mm × 80mm × 3mm, and the cutting parameters are as follows: the inclination angle is about 80 degrees, the height of the welding rod is about 4mm, and the cutting speed is 9-10mm/s;
the steel plate is completely melted in the area where the welding rods pass through, and huge heat penetrates through the whole steel plate to divide the steel plate into two parts, wherein the melting width is about 10 mm.
While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes in form and detail may be made without departing from the spirit and scope of the invention.
Claims (6)
1. The multi-section welding flux is characterized by comprising 16-18% of Al, 40-44% of CuO and 40-44% of MnO in percentage by mass of a preheating section powder column, and a low-heat section powder column from top to bottom in sequence 2 15-20％、CaF 2 5 percent of high-heat section grain, wherein the high-heat section grain comprises 20 to 25 percent of Al, 60 to 65 percent of CuO, 3 percent of Ni and SiO 2 4.5%, nano-scale W powder 2%, caF 2 3 percent of Al, 2.5 percent of CaO, 18 to 20 percent of CuO, 60 to 62 percent of Ni 3 percent of SiO 24.5 percent of nano-scale W powder and 2 percent of CaF 2 5％、CaO 5.5％。
2. A self-preheating multi-section electroless welding rod is composed of a flux tube, a welding flux, a fire cap, a clamping end and a sleeve, wherein the welding flux is loaded in the flux tube, one end of the flux tube is connected with the clamping end, the other end of the flux tube is plugged into the fire cap for packaging, and the flux tube and the fire cap are loaded into the sleeve with one end closed, and the self-preheating multi-section welding flux is characterized in that the welding flux is the self-preheating multi-section welding flux in claim 1.
3. The multi-section electroless welding electrode of claim 2, wherein said cartridge is made of paper roll or thin-walled stainless steel.
4. The multi-segment electroless welding electrode according to claim 2, wherein the ignition cap is made by mixing and mixing thermite welding ignition powder and binder, pressing the mixture into a cylinder with a height of 3-5mm, and inserting a firework lead.
5. The multi-part electroless welding electrode according to claim 2, wherein the inner diameter of the sleeve is 1-2mm larger than the outer diameter of the charge tube, and the length of the sleeve is 3-4mm longer than the length of the charge tube.
6. The method for preparing the multi-section electroless welding electrode of claims 2-5, comprising the steps of:
1) Weighing the materials according to the mass percent, and mixing the materials in a powder mixer to obtain the welding flux;
2) Sequentially filling the welding flux into a powder tube closed by a clamping end plug, continuously compacting to sequentially prepare a low-heat-section powder column, a high-heat-section powder column and a preheating-section powder column, and stopping charging at a position 4-6mm away from the end opening of the powder tube;
3) A fire cap is plugged into the end opening of the explosive tube to ensure that the fire cap is tightly contacted with the welding flux;
4) And (4) filling the explosive tube into a sleeve to finish the manufacture of the welding rod.
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