CN116140769A - 3D plasma spray welding repair method for continuous casting sectional roller and spray welding powder used by same - Google Patents

3D plasma spray welding repair method for continuous casting sectional roller and spray welding powder used by same Download PDF

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Publication number
CN116140769A
CN116140769A CN202310049005.2A CN202310049005A CN116140769A CN 116140769 A CN116140769 A CN 116140769A CN 202310049005 A CN202310049005 A CN 202310049005A CN 116140769 A CN116140769 A CN 116140769A
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spray welding
continuous casting
welding
roll
casting sectional
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孟征兵
周超洋
刘晓
昌盛
陈元钰
李宇翔
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Guilin University of Technology
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Guilin University of Technology
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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
    • B23K10/00—Welding or cutting by means of a plasma
    • B23K10/02—Plasma welding
    • B23K10/027—Welding for purposes other than joining, e.g. build-up welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24—Selection of soldering or welding materials proper
    • B23K35/30—Selection of soldering or welding materials proper with the principal constituent melting at less than 1550 degrees C
    • B23K35/3053—Fe as the principal constituent
    • B23K35/308—Fe as the principal constituent with Cr as next major constituent
    • B23K35/3086—Fe as the principal constituent with Cr as next major constituent containing Ni or Mn
    • 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

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Coating By Spraying Or Casting (AREA)

Abstract

The invention discloses a 3D plasma spray welding repair method for continuous casting sectional rolls and spray welding powder used by the same. The spray welding method comprises the following steps: machining the invalid continuous casting sectional roll, setting 3D plasma spray welding parameters of the continuous casting sectional roll, performing 3D plasma spray welding operation and performing postweld heat treatment. The chemical components of the powder are as follows in mass percent: c=0.42-0.48%, si=2.0-3.0%, mn=0.5-1.0%, cr=3.5-4.5%, mo=0.20-0.30%, ni=0.10-0.30%, w=5.2-6.2%, v=0.9-1.0%, b=1.0-1.3%, the balance being iron and unavoidable impurity elements; the particle size of the powder is 200-300 meshes. The spray welding layer formed by the invention has fine and dense structure, high uniformity and high hardness; and the spray welding layer has good rapid cooling and rapid heating resistance. The invention can effectively prolong the service life of the repaired continuous casting sectional roll by more than 50 percent compared with the traditional sectional roll repaired by a build-up welding mode.

Description

3D plasma spray welding repair method for continuous casting sectional roller and spray welding powder used by same
Technical Field
The invention relates to the technical field of steel material processing, in particular to a method for repairing a continuous casting sectional roll by adopting powder formed by Cr, mo, ni, W, V, B and other elements through a 3D plasma spray welding process.
Background
In the process from the formation of initial blank shell by molten steel from the meniscus of the crystallizer of the continuous casting machine to the final complete solidification and formation, the sectional rollers of the fan-shaped section bear various stresses such as bulging force of casting blank, alternating thermal stress of continuous casting secondary cooling water spraying and high-temperature casting blank contact heating, friction force between casting blank and rollers and the like. The severe working environment easily causes the failure of the sectional roller, the sectional roller is generally repaired by adopting a stainless steel welding rod surfacing process after the failure, and the repaired sectional roller can generate tiny netlike thermal fatigue cracks along the lap joint of a surfacing welding line in the use process. When the thermal cracking exceeds a certain quantity and scale, the outer skin of the build-up layer of the continuous casting sectional roll can be directly fallen off, so that the quality and the production efficiency of a product are affected, and the production accident is caused by heavy weight. Therefore, the new process for greatly prolonging the service life of the continuous casting sectional roll can shorten the time for stopping production and replacing the sector section of the continuous casting machine and improve the economic benefit of steel enterprises.
The plasma spray welding can select alloy powder according to the specific requirements of repairing workpieces, the powder and the base material are metallurgically melted in the spray welding process, so that the bonding strength of a spray welding layer and the base material is high, the heat affected zone of the base material and the residual stress after welding are small, parts with surface failure can be quickly repaired, and the 3D spray welding control software can realize the precise control of the shape of the spray welding layer, so that the technology has great economic and social values, and also has certain research and application. Han Jingwei et al prepared a compact and complete mixed welding layer of fusion welding and brazing on a gray cast iron substrate under the condition of cold atmospheric environment by using ultra-low carbon low iron chromium-free nickel-based powder as a spray welding material, and recovered the mechanical size and function of the mating surface of a compression ring of a diesel engine cylinder cover. Sun Bo et al used a hot forging punch as a prototype, and prepared a layer of iron-based alloy spray welding layer on the cylindrical surface of the H13 steel bar by adopting a plasma spray welding process, wherein the hardness of the iron-based spray welding layer is about 730HV, and is obviously higher than that of the matrix H13 steel.
At present, the repair of the parts by adopting the plasma spray welding process is concentrated at the abrasion positions of the valve and the die, and no report is found on the repair of the continuous casting sectional roll. The yield of steel products in China is more than 10 hundred million tons continuously for 8 years, wherein the proportion of the steel products produced by a continuous casting process is more than 96 percent, and the method has the characteristics of plasma spray welding repair, replaces the existing build-up welding repair process for the failed continuous casting sectional roller, greatly prolongs the service life of the continuous casting sectional roller and has wide development space.
The self-made iron-based powder composed of Cr, mo, ni, W, V, B and other elements is used for repairing the continuous casting sectional roll on the 3D plasma spray welding equipment with different welding parameters, and the metallurgical structure, the phase composition, the distribution of elements in the phase and the distribution of the hardness from the heat affected zone to the near surface of the spray welding layer of the repaired sectional roll are analyzed and researched, so that various technological parameters and the self-made iron-based powder formula for greatly prolonging the service life of the continuous casting sectional roll can be obtained.
Disclosure of Invention
One of the purposes of the invention is to develop a novel 3D spray welding process which combines self-made container
Cr, mo, ni, W, V, B, the service life of the continuous casting sectional roll can be greatly prolonged, the time for stopping production and replacing the sector section of the continuous casting machine is shortened, and the economic benefit of iron and steel enterprises is improved.
Another object of the invention is to provide an iron-based powder which is composed of Cr, mo, ni, W, V, B and other elements and can adapt to the use condition of the continuous casting sectional roll and the corresponding spray welding parameters.
The powder reference surfacing welding electrode for spray welding is prepared by combining working conditions of a sectional roller and spray welding process parameters, and comprises the following chemical components in percentage by weight: c=0.42-0.48%, si=2.0-3.0%, mn=0.5-1.0%, cr=3.5-4.5%, mo=0.20-0.30%, ni=0.10-0.30%, w=5.2-6.2%, v=0.9-1.0%, b=1.0-1.3%, the balance being iron and unavoidable impurity elements.
The design principle of the 3D plasma spray welding repair method of the continuous casting sectional roll is as follows:
preparing powder for spray welding: with reference to the components of welding rods for surfacing and hot-working die steel, because Mo is unfavorable for the formation of martensitic structure, the content of Mo is reduced on the basis, W element is added, the action of W is similar to that of Mo, the heat resistance and tempering stability of a welding layer can be obviously improved, and meanwhile, W belongs to strong carbide and is soluble in Fe with Mo 23 C 6 Forming multiple composite carbide (Fe, cr, mo, W, V) with Cr and V 23 C 6 The strong carbide is dissolved in the weak carbide, so that the stability of the weak carbide can be improved, the critical temperature of the carbide dissolved in a matrix is improved, the aggregation growth speed after precipitation is slowed down, and the weak carbide can be used as a heat-resistant phase of a spray welding layer; the added B is used for improving the fluidity of a molten pool, increasing the wettability between powder and a base material, and forming boride, so that the wear resistance of the spray welding layer is improved, but the tempering brittleness of the spray welding layer is improved due to the fact that more B is contained; the addition of a small amount of Ni can increase the amount of retained austenite, improve the toughness of the weld layer and increase the hardenability.
According to the microstructure, phase composition, microhardness and formation mechanism of the spray welding layer, proper spray welding process parameters such as welding current, welding gun swing speed, welding gun swing amplitude, welding gun distance, roll body rotation angular speed, roll body advancing speed, pilot arc voltage, powder feeding speed, protection argon flow, ion argon flow, powder feeding argon flow and the like are researched and determined, so that the fine and dense structure and high uniformity degree of the spray welding layer are ensured, the base material and the spray welding layer are metallurgically bonded, the hardness of the spray welding layer is high, and the uniform hardness deviation is small.
Based on the design principle, the method provided by the invention comprises the following steps:
s1, machining a failure continuous casting sectional roll;
rough turning is firstly carried out on the surface of the failed continuous casting sectional roll to remove defective parts, and then finish turning is carried out on the surface of the failed continuous casting sectional roll to form a base material layer of the continuous casting sectional roll; after the surface of the base material layer is subjected to the dirt cleaning treatment, the roller body is loaded on a direct current motor fixture;
s2, parameter setting before spray welding of continuous casting sectional rolls
Setting welding current of 150-170A, welding gun swing speed of 80-90 times per minute, welding gun swing amplitude of 8-10mm, welding gun distance roller distance of 10-13mm, roller rotating angular speed of 0.8-1.0rad/s, roller advancing speed of 3-5mm/s, pilot arc voltage of 40-50V, powder feeding speed of 30-40g/s, protective air flow of 6-8L/min, ion air flow of 4-6L/min, powder feeding air flow of 16-20L/min and other spray welding process parameters through 3D programming; because the roller body is cylindrical, the welding gun is kept stationary during spray welding, and the clamping device table driven by the direct current motor drives the roller body to rotate and advance at the speed of 0.85-0.95rad/s and 3.5-4.5mm/s, so that the overlapping amount of the adjacent spray welding layers is ensured to be moderate;
s3, preheating a roller body before spray welding
Preheating the surface of the base material layer by using oxyacetylene flame before welding, wherein the preheating time is more than 10min, and starting spray welding after the temperature exceeds 250 ℃;
s4, spray welding operation
The spray welding adopts a mode of two layers of welding, the thickness of each layer of the spray welding is controlled to be 2-6mm, and the total thickness of a spray welding layer formed by the two layers of the spray welding is 5-10mm;
s5, post-welding machining
After the 3D spray welding repair of the continuous casting sectional roll is finished, a lathe is used for lathe processing of a spray welding layer, and then surface cleaning treatment is carried out;
s6, annealing heat treatment
After the sewage disposal treatment, a box-type annealing furnace is adopted for annealing heat treatment.
As a modification, the rough turning is performed to a thickness of 2mm in the step S1.
In a modification, in the step S1, the material of the base material layer is 42CrMo.
In the step S4, the thickness of each layer of spray welding is 4mm, and the total thickness of the spray welding layer is 8mm.
As a modification, the lathe processing in step S5 includes the steps of:
carrying out finish turning or rough turning and then finish turning treatment, so that the total thickness of the finally obtained spray welding layer is between 4 and 6 mm.
As improvement, the annealing temperature of the annealing treatment in the step S6 is 450-500 ℃, and the heat preservation is carried out for 4 hours along with furnace cooling so as to eliminate the welding residual stress in the spray welding layer.
The invention has the advantages that:
the 3D plasma spray welding repair method of the continuous casting sectional roll has the advantages that the structure of a spray welding layer is fine and uniform, a base material and the spray welding layer are in metallurgical bonding, the main phase of the spray welding layer is alpha-Fe, and a hard phase is mainly (Fe, cr, W, V and Mo) precipitated among alpha-Fe crystals 7 C 3 、(Fe,Cr,W,V,Mo) 23 C 6 Carbide particles, wherein the spray welding layer grains are mainly equiaxed crystals, and part of precipitated carbide is distributed in residual austenite among crystals, so that the carbide particles have high hardness and good uniformity, the average hardness is more than 580HV, and the hardness deviation is less than 30HV.
According to the 3D plasma spray welding repair method for the continuous casting sectional roll, laboratory cold-hot alternating simulation experiments show that the spray welding repair layer has good rapid cooling and rapid heating resistance. In the working environment of the continuous casting sectional roll (the surface temperature of a continuous casting blank clamped by the continuous casting sectional roll is up to more than 800 ℃ and is subjected to rapid cooling by continuous casting secondary cooling water spraying), the thermal stability of a spray welding layer in a cold-hot alternating environment is good, a test sample is quickly put into water after being heated to 800 ℃ in a muffle furnace, and the hardness is reduced by not more than 20HV after the test sample is circulated back and forth for 100 times.
Compared with other surfacing repaired segmented rollers which are opposite to the same part of the same continuous casting machine, the 3D plasma spray welding repair method for the continuous casting segmented roller has the advantages that the service life is prolonged by more than 50%, the average steel passing amount of the surfacing repaired segmented roller is 40 ten thousand tons according to statistics, and the average steel passing amount of the continuous casting segmented roller repaired by 3D plasma spray welding is more than 60 ten thousand tons.
Drawings
FIG. 1 is a drawing of a 3D spray welding repair process of a continuous casting sectional roll (a) before repair; (b) after spray welding; (c) after heat treatment and machining.
Fig. 2 is a diagram of EDS elemental analysis for the weld overlay.
Fig. 3 is a microstructure of the solder mask after thermal stability test.
Detailed Description
For the purpose of making the objects, technical solutions and advantages of the embodiments of the present invention more apparent, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention, and it is apparent that the described embodiments are some embodiments of the present invention, but not all embodiments of the present invention. The components of the embodiments of the present invention generally described and illustrated in the figures herein may be arranged and designed in a wide variety of different configurations.
Example 1
The chemical composition of the powder for spray welding prepared in this example is as follows in wt%:
c=0.45%, si=2.3%, mn=0.62%, cr=3.95%, mo=0.25%, ni=0.19%, w=5.9%, v=0.93%, b=1.1%, the balance being iron and unavoidable impurity elements; the particle size of the powder is 200-300 meshes.
The method for repairing the continuous casting sectional roll by 3D plasma spray welding provided by the embodiment comprises the following steps:
s1, machining a failure continuous casting sectional roll:
selecting a sectional roller (with the diameter of 240mm, see the roller close to the upper surface in fig. 1 (a)) for peeling off the surface part of the lower line of a slab continuous casting machine in a certain steel mill 2150mm, roughly turning an original surfacing layer to about 2mm thick by using a lathe for the selected continuous casting sectional roller before spray welding, finely turning a parent metal layer (made of 42 CrMo) of the sectional roller after the defect part is completely removed, and carrying out dirt removal treatment on the surface of the parent metal layer, and loading a roller body on a direct current motor fixture.
S2, setting parameters before spray welding of continuous casting sectional rolls:
through 3D software programming, welding current of 160A, welding gun swing speed of 85 times/min, welding gun swing amplitude of 9mm, welding gun distance roller distance of 11mm, roller rotation angular speed of 0.9rad/s, roller advancing speed of 4mm/s, arc maintaining voltage of 45V, powder feeding speed of 35g/s, protective air flow of 7L/min, ion air flow of 5L/min, powder feeding air flow of 18L/min and other spraying process parameters are set, and as the roller is cylindrical, the welding gun is kept stationary during spraying, a clamping table driven by a direct current motor drives the roller to rotate and advance at speeds of 0.90rad/s and 4.0mm/s, so that the splicing amount of adjacent spraying layers is ensured to be moderate.
S3, preheating a roller body before spray welding:
preheating the surface of the base material layer by oxyacetylene flame before welding to prevent the welding crack of the spray welding layer caused by excessive thermal stress in the spray welding process, wherein the preheating time is 12min, and when the temperature reaches 250 ℃, the spray welding is started.
S4, spray welding operation:
the spray welding adopts a two-layer welding mode, the thickness increase of each layer after spray welding is controlled to be about 4mm, and the obtained continuous casting sectional roll is a spray welding layer with the thickness of about 8mm.
S5, post-welding machining
Rough turning the spray welding layer for 2mm, finish turning for 1mm, and finally obtaining the spray welding layer with the thickness of about 5mm
S6, annealing heat treatment:
and (3) carrying out surface cleaning treatment on the continuous casting sectional roll repaired in the step (S5), then adopting a box-type annealing furnace for annealing heat treatment, wherein the annealing temperature is 500 ℃, and carrying out furnace cooling after heat preservation for 4 hours, so as to eliminate welding residual stress in a welding spraying layer.
Example 2
The chemical composition of the powder for spray welding prepared in this example is as follows in wt%:
c=0.43%, si=2.5%, mn=0.60%, cr=3.85%, mo=0.26%, ni=0.22%, w=5.6%, v=0.96%, b=1.2%, the balance being iron and unavoidable impurity elements; the particle size of the powder is 200-300 meshes.
The method for repairing the continuous casting sectional roll by 3D plasma spray welding provided by the embodiment comprises the following steps:
s1, machining a failure continuous casting sectional roll:
selecting a sectional roller (with the diameter of 260mm, see a roller below in fig. 1 (a)) for stripping off the surface part of the lower line of a slab continuous casting machine of a certain steel mill 2150mm, roughly turning an original surfacing layer to about 2mm thick by using a lathe for the selected continuous casting sectional roller before spray welding, finely turning a parent material layer (made of 42 CrMo) of the sectional roller after the defect part is completely removed, and carrying out dirt removal treatment on the surface of the parent material layer, and then loading a roller body on a direct current motor fixture.
S2, setting parameters before spray welding of continuous casting sectional rolls:
through 3D software programming, welding current of 165A, 90 times/min welding gun swing speed, 9mm welding gun swing amplitude, 11mm welding gun distance, 0.9rad/s roller rotating angular speed, 4.2mm/s roller advancing speed, 48V arc maintaining voltage, 36g/s powder feeding speed, 7L/min protection air flow, 5.5L/min ion air flow, 19L/min powder feeding air flow and other spraying process parameters are set, and as the roller body is cylindrical, the welding gun keeps static during spraying, a fixture table driven by a direct current motor drives the roller body to rotate forward at a speed of 0.88rad/s and 4.2mm/s, so that the lapping amount of adjacent spraying layers is ensured to be moderate.
S3, preheating a roller body before spray welding:
and preheating the surface of the base material layer by oxyacetylene flame before welding to prevent the occurrence of welding cracks of a spray welding layer caused by excessive thermal stress in the spray welding process, wherein the preheating time is 15min, and the spray welding is started after the preheating temperature reaches 300 ℃.
S4, spray welding treatment:
and during spray welding, a two-layer welding mode is adopted, the thickness increase after each layer of spray welding is controlled to be about 4mm, and the obtained continuous casting sectional roll base material is a spray welding layer with the thickness of about 8mm.
S5, post-welding machining
And (3) roughly turning the spray welding layer for 2mm, finely turning the spray welding layer for 1mm, and finally obtaining the spray welding layer with the thickness of about 5mm.
S6, annealing heat treatment:
and (3) carrying out surface cleaning treatment on the continuous casting sectional roll repaired in the step (S5), then adopting a box-type annealing furnace for annealing heat treatment, wherein the annealing temperature is 480 ℃, and carrying out furnace cooling after heat preservation for 4 hours, so as to eliminate welding residual stress in a welding spraying layer.
The above description of the specific embodiments of the present invention is given by way of example only, and the present invention is not equivalent to the above-described specific embodiments. Any equivalent modifications and substitutions for the present invention will occur to those skilled in the art, and are also within the scope of the present invention. Accordingly, equivalent changes and modifications to the disclosed embodiments are intended to be included within the scope of the present invention.

Claims (9)

1. The 3D plasma spray welding repair method for the continuous casting sectional roll is characterized by comprising the following steps of:
s1, machining a failure continuous casting sectional roll;
rough turning is carried out on the failed continuous casting sectional roll to eliminate the surface defect of the roll, and then finish turning is carried out on the roll until the base material layer of the continuous casting sectional roll is obtained; after the surface of the base material layer is subjected to the dirt cleaning treatment, the roller body is loaded on a direct current motor fixture;
s2, parameter setting before spray welding of continuous casting sectional rolls
Setting welding current of 150-170A, welding gun swing speed of 80-90 times per minute, welding gun swing amplitude of 8-10mm, welding gun distance roller distance of 10-13mm, roller rotating angular speed of 0.8-1.0rad/s, roller advancing speed of 3-5mm/s, pilot arc voltage of 40-50V, powder feeding speed of 30-40g/s, protective air flow of 6-8L/min, ion air flow of 4-6L/min, powder feeding air flow of 16-20L/min and other spray welding process parameters through 3D programming;
s3, preheating a roller body before spray welding
Preheating the surface of the base material layer by using oxyacetylene flame before welding, wherein the preheating time is more than 10min, and starting spray welding after the temperature exceeds 250 ℃;
s4, spray welding operation
The spray welding adopts a mode of two layers of welding, the thickness of each layer of the spray welding is controlled to be 2-6mm, and the total thickness of a spray welding layer formed by the two layers of the spray welding is 5-10mm;
s5, post-welding machining
After the 3D spray welding repair of the continuous casting sectional roll is finished, a lathe is used for lathe processing of a spray welding layer, and then surface cleaning treatment is carried out;
s6, annealing heat treatment
After the sewage disposal treatment, a box-type annealing furnace is adopted for annealing heat treatment.
2. The method for repairing the continuous casting sectional roll by 3D plasma spray welding according to claim 1, wherein the step S1 is characterized in that the step is roughly machined to be 2mm thick.
3. The method for repairing a continuous casting sectional roll by 3D plasma spray welding according to claim 1, wherein the material of the base material layer in the step S1 is 42CrMo.
4. The method for repairing the continuous casting sectional roll by 3D plasma spray welding according to claim 1, wherein the rotation angular speed of the roll body in the step S2 is 0.85-0.95rad/S, and the running speed of the roll body is 3.5-4.5mm/S.
5. The 3D plasma spray welding repair method of the continuous casting sectional roll according to claim 1, wherein in the step S4, the thickness of each layer of the spray welding is 4mm, and the total thickness of the spray welding layers is 8mm.
6. The method for repairing the continuous casting sectional roll by 3D plasma spray welding according to claim 1, wherein the lathe processing in the step S5 comprises the following steps:
carrying out finish turning or rough turning and then finish turning treatment, so that the total thickness of the finally obtained spray welding layer is between 4 and 6 mm.
7. The 3D plasma spray welding repair method of the continuous casting sectional roll according to claim 1, wherein the annealing temperature of the annealing treatment in the step S6 is 450-500 ℃, and the annealing treatment is carried out for 4h along with furnace cooling.
8. A spray welding powder used based on the continuous casting sectional roll 3D plasma spray welding repair method of claim 1, characterized in that the powder comprises the following chemical components in percentage by mass:
C＝0.42-0.48％、Si＝2.0-3.0％、Mn＝0.5-1.0％、Cr＝3.5-4.5％、Mo＝0.20-
0.30%, ni=0.10-0.30%, w=5.2-6.2%, v=0.9-1.0%, b=1.0-1.3%, the balance being iron and unavoidable impurity elements;
the particle size of the powder is 200-300 meshes.
9. The method of manufacturing a spray welding powder according to claim 8, wherein the powder is manufactured by a water atomization process.
CN202310049005.2A 2023-02-01 2023-02-01 3D plasma spray welding repair method for continuous casting sectional roller and spray welding powder used by same Pending CN116140769A (en)

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CN116140769A true CN116140769A (en) 2023-05-23

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