CN115351457B - Multi-section welding flux, self-preheating multi-section non-welding electrode and preparation method thereof - Google Patents
Multi-section welding flux, self-preheating multi-section non-welding electrode and preparation method thereof Download PDFInfo
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Classifications
-
- 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
Landscapes
- 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, a self-preheating multi-section electroless welding rod and a preparation method thereof, wherein the welding flux comprises a preheating section grain, a high-heat section grain and a low-heat section grain, and each component in the preheating section grain is Al 16-18%, cuO 40-44% and MnO 2 15‑20％、CaF 2 5, each component in the high-heat section grain is composed of 20-25% of Al, 60-65% of CuO, 3% of Ni and SiO 2 4.5%, nano-scale W powder 2% and CaF 2 3 percent of CaO 2.5 percent, and each component in the low-heat section grain is composed of 18 to 20 percent of Al, 60 to 62 percent of CuO, 3 percent of Ni and SiO 2 4.5%, nano-scale W powder 2% and CaF 2 5% and 5.5% of CaO. In the invention, the preheating section grain is utilized to heat the welding starting position to the ideal welding temperature before the welding starts, and an additional preheating process is not needed, so that the 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 non-welding electrode and a preparation method thereof.
Background
The damage and faults of parts such as cracks, pore running, impersonation, dripping, leakage and the like of field operation, running machinery, household water pipe and air pipe in use structural members, boxes, pipelines and the like are unavoidable, and the normal use of the machinery is seriously affected.
Welding is a process of integrating two or more kinds of same or different materials through combination and diffusion between atoms or molecules, and is an important means for civil, engineering machinery and military equipment, manufacturing, rush repair and emergency maintenance and installation. The traditional welding mode mainly adopts electric welding, gas welding and other modes, but the welding rod arc welding needs a welding power source capable of outputting more than kilowatts of power and a heavy electric welding machine; the gas welding requires high-pressure special equipment for storing combustible gases such as oxygen, acetylene and the like, the safety cannot be ensured, and an operator also has to be specially trained; the traditional adhesive curing time is long, and the use requirement of field emergency can not be met. The emergency welding repair task is flexibly, flexibly and efficiently unfolded under the conditions of the field, field operations, power failure, rain and snow weather and the like.
In addition, under the extreme special conditions that energy sources such as high altitude, underground, underwater and the like are inconvenient to supply, the traditional emergency maintenance method cannot be performed. Meanwhile, in the rescue and relief work of earthquakes, fires and the like, the cutting and welding tool which does not need any external energy and equipment and is convenient to use is also urgently needed. Therefore, it is very necessary to develop a novel welding technology with the advantages of rapidness, high efficiency and energy saving and to make up for the defects of the traditional welding technology.
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 areas according to the propagation degree of combustion waves: the reacted zone, the combustion zone, the preheating zone and the unreacted zone are spontaneously and continuously carried out from top to bottom, the reaction speed of the whole reaction system is very high, the reaction can be completed in a short time ranging from a few seconds to tens of seconds, and a large amount of heat is released in a short timeThe reaction system reaches a very high temperature (the highest temperature can reach about 5000 ℃). The addition of combustion controlling and metallurgical components to self-propagating systems can be used to prepare electroless electrodes, for example, using thermite welding principles in patent CN20080227057. X to heat up high thermite (CuO powder, cu) 2 O powder, niO powder and 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, then are formed in a paper cylinder, and other components are added to form a thermic welding rod; the patent CN201310557331.0 proposes a self-propagating aluminum welding flux and welding rod, the welding 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 treatment, shaping, packaging and the like of the welding flux, the rosin powder and the paraffin powder, and the main structure of the welding rod comprises four parts of a grain, a firing line, a handle and a grain-coated aluminum cylinder.
The above patents all realize better welding performance through the optimization of the formula, but all do not consider the problem of uneven heating of a welding base metal in actual welding, namely, the base metal is in a normal temperature state when a self-propagating welding rod is ignited to start welding, so that a longer heating time is required to reach the melting point of the base metal to realize welding. In the subsequent stage of welding, the base metal is in a similar preheating and high temperature state, and the welding rod only needs to stay for a short time to finish welding. If the whole welding line is expected to achieve a good fusion effect, the strip conveying speed is required to be continuously changed in the welding process, and high requirements are provided for the operation technology of constructors; secondly, the self-propagating welding is different from the traditional welding, a large amount of high-melting-point impurities can be generated in the combustion process, and if the strip conveying speed is too slow in the initial stage of welding, the impurities can be deposited on the surface to influence heat conduction to a base metal. In actual operation, the inconsistent welding quality of each part of the welding line is one of the main reasons for restricting the whole welding effect.
Disclosure of Invention
Aiming at the problems, a multi-section welding flux, a self-preheating multi-section non-welding electrode and a preparation method thereof are provided, so that the self-preheating function of the welding electrode is utilized to ensure that the strip 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 first aspect of the invention provides a multi-section welding flux, which has the characteristics that the flux sequentially comprises a preheating section flux, a high-heat section flux and a low-heat section flux from top to bottom, wherein the preheating section flux comprises the components of 16-18% of Al, 40-44% of CuO and 40-44% of MnO in percentage by mass 2 15-20％、CaF 2 5, each component in the high-heat section grain is composed of 20-25% of Al, 60-65% of CuO, 3% of Ni and SiO 2 4.5%, nano-scale W powder 2% and CaF 2 3 percent of CaO 2.5 percent, and each component in the low-heat section grain is composed of 18 to 20 percent of Al, 60 to 62 percent of CuO, 3 percent of Ni and SiO 2 4.5%, nano-scale W powder 2% and CaF 2 5％、CaO 5.5％。
A second aspect of the present invention provides a self-preheating multi-segment no-electrode consisting of a flux tube, a flux, a primer cap, a clamping end, and a sleeve, the flux being carried in the flux tube, one end of the flux tube being connected to the clamping end, the other end of the flux tube being plugged into the primer cap for packaging, the flux tube and primer cap being carried in the sleeve with one end closed, the self-preheating multi-segment flux of claim 1 being characterized in that the flux is a self-preheating multi-segment flux.
The multi-section electroless welding rod has the characteristic that the medicine tube is made of paper roll or thin-wall stainless steel.
The multi-section non-welding rod has the characteristics that the ignition cap is manufactured by uniformly mixing thermite welding ignition powder and a binder, pressing and forming the mixture into a cylinder with the height of 3-5mm, and inserting firework leads.
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 the length of the medicine tube.
The third aspect of the present invention provides a method for preparing the multi-segment type electroless welding rod, which has the following characteristics:
1) Weighing the materials according to the mass percentage, and mixing in a powder mixer to obtain the welding flux;
2) Sequentially filling welding flux into a medicine tube sealed with a clamping end plug, and continuously compacting to sequentially prepare a low-heat section medicine column, a high-heat section medicine column and a preheating section medicine column, wherein the medicine filling is stopped at a position 4-6mm away from the medicine tube end;
3) A igniting cap is plugged into the port of the powder tube, so that the igniting cap is ensured to be in close contact with the welding powder;
4) And (5) filling the medicine tube into the sleeve, and thus completing the manufacture of the welding rod.
The beneficial effect of above-mentioned scheme is:
1) According to the invention, the preheating section grain is utilized to heat the welding starting position to the ideal welding temperature before the actual welding starts, so that the cold joint caused by insufficient temperature and insufficient melting of the parent metal is avoided;
2) According to the invention, the welding agent is divided into a high-heat section grain and a low-heat section grain according to the change rule of the temperature of the base metal in actual construction, so that high heat is released when the temperature of the base metal is lower, and correspondingly low heat is released when the temperature of the base metal is higher, thereby ensuring the temperature required by welding and avoiding overheating ablation of the base metal; therefore, when in use, the workers can carry out strip welding at a uniform speed so as to greatly reduce the operation difficulty, and simultaneously, the welding inclination angle and the welding height do not need to be changed in the welding process, and the workers can weld with little training;
3) The welding rod provided by the invention adopts various strengthening mechanisms, and the tensile strength after welding can reach 410Mpa, which is close to the level of manual arc welding;
4) The welding rod provided by the invention can be used for welding low-carbon steel and low-alloy steel and also can be used for rapidly cutting a sheet 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 splash or locally spray explosion due to overheating;
6) The welding electrode does not need external electricity, gas and other preheating processes when in welding, thereby realizing energy saving and simultaneously meeting the use requirements of rapid welding and cutting.
7) The welding product of the non-welding rod provided by the invention is common molten metal such as molten copper, and can be quickly solidified after welding, and no pollution is discharged.
Drawings
FIG. 1 is a schematic view of the structure of an electroless electrode provided in an embodiment of the present invention.
In the accompanying drawings: 1. a medicine tube; 2. a flux; 3. a primer cap; 4. a clamping end; 5. a sleeve.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
It should be noted that, without conflict, the embodiments of the present invention and features of the embodiments may be combined with each other.
The invention is further described below with reference to the drawings and specific examples, which are not intended to be limiting.
A multi-section type non-welding electrode consists of a medicine tube 1, a welding flux 2, a igniting cap 3, a clamping end 4 and a sleeve 5, wherein the welding flux 2 is loaded in the medicine tube 1, one end of the medicine tube 1 is connected with the clamping end 4, the other end of the medicine tube 1 is plugged into the igniting cap 3 for packaging, and the medicine tube 1 and the igniting cap 3 are loaded into the sleeve 5 with one end closed.
The traditional Chinese medicine tube 1 is made of paper roll or thin-wall stainless steel (the wall thickness is lower than 0.3 mm) and the diameter is 12-22mm (parameters can be adjusted according to the thickness of the parent metal to be welded); the ignition cap 3 is prepared by uniformly mixing thermite welding ignition powder and a binder, pressing and forming the mixture into a cylinder with the height of 3-5mm, and inserting firework leads; the inner diameter of the sleeve 5 is 1-2mm larger than the outer diameter of the medicine tube 1, and the length of the sleeve 5 is 3-4mm longer than the length of the medicine tube 1, so that the sleeve 5 is sleeved outside the medicine tube 1 for protection in the storage and transportation process of welding rods, and when the welding rods are used, the sleeve 5 is drawn out and reversely sleeved on one side of the clamping end, and can be used as a welding handle.
The welding flux 2 sequentially comprises a preheating section grain, a high-heat section grain and a low-heat section grain from top to bottom, wherein the preheating section grain comprises the components of 16-18% of Al, 42-44% of CuO and 42-44% of MnO in percentage by mass 2 15-20％、CaF 2 5, each component in the high-heat section grain is composed of 20-25% of Al, 60-65% of CuO, 3% of Ni and SiO 2 4.5%, nano-scale W powder 2% and CaF 2 3 percent of CaO 2.5 percent, and each component in the low-heat section grain is Al 20-25 percent, cuO 60-65 percent, ni 3 percent and SiO 2 4.5%, nano-scale W powder 2% and CaF 2 5％、CaO 5.5％。
The length of the preheating section grain in the invention can be 2-5cm (also can be adjusted according to the thickness of the welding parent metal), wherein the mass ratio of Al+CuO is 60% (Al and CuO are mixed according to the stoichiometric ratio), and Al+MnO is as follows 2 The mass ratio is 35 percent (Al, mnO) 2 The mixture ratio is stoichiometric ratio). Al+CuO is the reaction with 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 a reaction with the maximum gas yield in the aluminothermic reaction, and the gas yield reaches 0.8136mol/100g, so that the method can be used for increasing the injection force of combustion flame, thereby blowing impurities generated in the reaction away from the surface of the base material, and completing preheating on the premise that no impurity accumulation is formed on the surface of the base material; caF (CaF) 2 Can be used as slag former and can react with Al generated by the above two reactions 2 O 3 The impurities form a light and low melting eutectic and remain liquid for a long period of time, leaving the weld base material under the flame spray.
The high heat section is used for finishing the welding of the front third of the welding seam, at the moment, the welding parent metal is heated by the grain of the preheating section, but the distance from the melting temperature is still large, so that the welding flux of the grain of the high heat section needs to have large heat release quantity, and the welding flux comprises 20-25% of Al, 60-65% of CuO, 3% of Ni and SiO 2 4.5%, nano-scale W powder 2% and CaF 2 3% and 2.5% of CaO, wherein the mass ratio of Al to CuO is 85% (Al and CuO are mixed according to stoichiometric ratio). Al+CuO is used for exothermic reaction to melt the base metal, and meanwhile, the reaction product Cu can be infinitely mutually dissolved with steel and forms a welding seam together with the melted base metal after being cooled; whileSiO 2 、CaF 2 CaO is a slag former and can react with Al generated by the reaction 2 O 3 The impurities form light eutectic substances with low melting point, and the eutectic substances remain liquid 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 nanoscale W powder makes use of the characteristic of the ultra-high melting point of W to enable the W powder to serve as an uneven nucleation point in the welding seam solidification process, so that the refined crystal grains generate a second-phase strengthening effect to improve the mechanical property of the welding seam; the Ni powder can be mutually fused with weld metal to play a solid solution strengthening role, so that the mechanical property of the weld is further improved.
The low-heat section explosive column is used for finishing the welding of two thirds after the welding line, and the welding parent metal is heated by the preheating section and the high-heat section and approaches the melting temperature, so that the temperature of the welding agent needs to be properly reduced to avoid overheating, and the low-heat section comprises Al 20-25%, cuO 60-65%, ni 3% and SiO 2 4.5%, nano-scale W powder 2% and CaF 2 5% and 5.5% of CaO, wherein the mass ratio of Al to CuO is 80% (Al and CuO are mixed according to stoichiometric ratio). The actions of the components are consistent with those of the high heat section, but the welding parent metal is fully heated when the welding rod burns to the low heat section, so that the welding can be finished without too high heat, and the proportion of the exothermic component Al and CuO is further reduced, so that the parent metal is prevented from being ablated due to overheating.
Example 1
In this example, two stainless steel plates 70mm×70mm×5mm were butt welded with the above-mentioned electroless welding rod, and the welding parameters were: the welding dip angle is about 70 degrees, the welding height is about 5mm, and the welding speed is 7-9mm/s;
during welding, the two steel plates are completely melted in the passing area of the welding rod and are fully fused, so that a metallurgical bonding effect is formed. The width of the welding seam is about 10mm, and no obvious defect is generated after the surface slag is removed.
Tests show that the tensile strength after welding in the embodiment 1 can reach 410MPa, which is close to the level of manual arc welding.
Example 2
In this example, two 80mm×80mm×5mm Q235 steel plates were butt welded with the above-described electroless electrode, and the welding parameters were: the welding dip angle is about 60 degrees, the welding height is about 6mm, and the welding speed is 7-9mm/s;
during welding, the two steel plates are completely melted in the passing area of the welding rod and are fully fused with the welding flux to form a metallurgical bonding effect, the width of the welding seam is about 10mm, and no obvious defect is generated after the surface layer welding slag is removed.
The welding rod provided by the invention adopts various strengthening mechanisms, and the tensile strength after welding can reach 410Mpa, which is close to the level of manual arc welding;
the welding rod provided by the invention can be used for welding low-carbon steel and low-alloy steel and also can be used for rapidly cutting a sheet with the thickness of less than 3 mm.
Example 3
In this example, the above-mentioned electroless electrode was used to melt-cut a Q235 steel sheet of 80mm×80mm×3mm, and the cutting parameters were: the dip 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 passing region of the welding rod, and huge heat penetrates through the whole steel plate to divide the steel plate into two parts, and the melting width is about 10 mm.
The foregoing is merely illustrative of the preferred embodiments of the present invention and is not intended to limit the embodiments and scope of the present invention, and it should be appreciated by those skilled in the art that equivalent substitutions and obvious variations may be made using the description and illustrations of the present invention, and are intended to be included in the scope of the present invention.
Claims (6)
1. A multi-section welding flux is characterized by sequentially comprising a preheating section grain, a high-heat section grain and a low-heat section grain from top to bottom, wherein the preheating section grain comprises Al+CuO60% and Al+MnO in percentage by mass 2 35%、CaF 2 5, reacting part of Al in the preheating section grain with CuO according to the stoichiometric ratio, and reacting part of Al with MnO according to the stoichiometric ratio 2 Reacting, wherein the CuO accounts for 42-44% of the grain in the preheating section, and MnO is contained in the grain 2 The proportion is 15-20%; the components in the Gao Reduan grain are 20-25% of Al and 20-25% of CuO60-65%、Ni 3%、SiO 2 4.5%, nano-scale W powder 2% and CaF 2 3 percent of CaO 2.5 percent, wherein each component in the low-heat section grain is composed of 18 to 20 percent of Al, 60 to 62 percent of CuO, 3 percent of Ni and SiO 2 4.5%, nano-scale W powder 2% and CaF 2 5%、CaO 5.5%。
2. The utility model provides a do not have welding rod from preheating's multistage formula, comprises pencil, welding flux, igniting cap, clamping end, sleeve pipe, the welding flux load in the pencil, the one end of pencil with the clamping end is connected, another of pencil is packed into igniting cap encapsulates, the pencil with igniting cap packs into one end confined sleeve pipe in, its characterized in that, the welding flux is the multistage formula welding flux in claim 1.
3. The multi-segment electroless electrode of claim 2 wherein the cartridge is made of paper roll or thin-walled stainless steel.
4. The multi-segment electroless welding rod of claim 2 wherein said primer cap is made by mixing thermite welding primer powder with binder, press forming into a cylinder of 3-5 a mm a height, and inserting a firework lead.
5. The multi-segment electroless electrode of claim 2, wherein the inner diameter of the sleeve is 1-2mm greater than the outer diameter of the cartridge, and the length of the sleeve is 3-4mm longer than the length of the cartridge.
6. The method for preparing the multi-section electroless welding rod as claimed in claim 2 to 5, comprising the steps of:
1) Weighing the materials according to the mass percentage, and mixing in a powder mixer to obtain the welding flux;
2) Sequentially filling welding flux into a medicine tube sealed with a clamping end plug, and continuously compacting to sequentially prepare a low-heat section medicine column, a high-heat section medicine column and a preheating section medicine column, wherein the medicine filling is stopped at a position 4-6mm away from the medicine tube end;
3) A igniting cap is plugged into the port of the medicine tube, so that the igniting cap is ensured to be in close contact with the welding medicine;
4) And (5) loading the medicine tube into a sleeve, and thus, completing the manufacture of the welding rod.
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