CN116900551B - Secondary-utilization light smelting flux and preparation method and application thereof - Google Patents
Secondary-utilization light smelting flux and preparation method and application thereof Download PDFInfo
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- CN116900551B CN116900551B CN202311168077.5A CN202311168077A CN116900551B CN 116900551 B CN116900551 B CN 116900551B CN 202311168077 A CN202311168077 A CN 202311168077A CN 116900551 B CN116900551 B CN 116900551B
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- 238000000034 method Methods 0.000 claims abstract description 34
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- 229910018072 Al 2 O 3 Inorganic materials 0.000 claims abstract description 7
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- 239000001301 oxygen Substances 0.000 description 13
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- 238000002441 X-ray diffraction Methods 0.000 description 12
- 229910000679 solder Inorganic materials 0.000 description 11
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N iron oxide Inorganic materials [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 9
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- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 description 1
- 229910003849 O-Si Inorganic materials 0.000 description 1
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 description 1
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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
- B23K35/22—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
- B23K35/362—Selection of compositions of fluxes
-
- 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
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/20—Recycling
Abstract
The invention relates to the technical field of welding, in particular to a secondary-usable light smelting flux and a preparation method and application thereof. The secondary-usable light smelting flux is prepared from the following components in percentage by mass: siO (SiO) 2 37%~41%，MnO 26%~30%，MgO 11%~13%，Al 2 O 3 13%~16%，CaF 2 3% -5% of Fe 2 O 3 2% -3%. The light smelting flux can be reused, and the mechanical property of a welding seam formed after secondary welding is excellent. The invention also provides a preparation method of the light smelting flux capable of being reused, and the method has the advantages of simple operation, short process flow, suitability for mass production and the like. The invention also provides application of the secondarily-usable light smelting flux in welding, which can avoid resource and energy waste and reduce production and processing cost.
Description
Technical Field
The invention relates to the technical field of welding, in particular to a secondary-usable light smelting flux and a preparation method and application thereof.
Background
Flux is a key factor affecting submerged arc welding seam quality and is also an important consumable in the submerged arc welding process. In the welding process, the electric arc has strong thermal action and stirring action on the flux slag and the metal molten pool, so that the flux slag and the metal molten pool are promoted to undergo a severe oxidation-reduction reaction, and the mutual migration of various alloy elements between the slag and the molten pool is promoted, and the components and the structure of the welded slag are offset to a certain extent compared with that of the original flux due to the influence of the severe welding reaction and the migration and the transmission process of the alloy elements, if the welded slag is used for welding again, uncontrollable change of the metal components of a welding seam is caused, and the mechanical property of the welding seam is influenced.
The submerged arc welding flux is a disposable consumable material, and the welding slag formed after welding can only be simply treated in the modes of remelting, landfill and the like, so that mineral resources are wasted, energy consumption is increased, and environmental protection is not facilitated.
Therefore, it is important to provide a flux that can be reused.
In view of this, the present invention has been made.
Disclosure of Invention
The invention aims to provide a light smelting flux capable of being reused, so as to solve the problem that the conventional submerged arc welding flux cannot be reused. The light smelting flux can be reused, and the mechanical property of a welding seam formed after secondary welding is excellent.
The second aim of the invention is to provide a preparation method of the light smelting flux capable of being reused, which has the advantages of simple operation, short process flow, suitability for mass production and the like.
A third object of the invention is to provide the use of a secondary usable light smelting flux in welding.
In order to achieve the above object of the present invention, the following technical solutions are specifically adopted:
the invention provides a secondary-usable light smelting flux which is prepared from the following components in percentage by mass: siO (SiO) 2 37%~41%，MnO 26%~30%，MgO 11%~13%，Al 2 O 3 13%~16%，CaF 2 3% -5% of Fe 2 O 3 2%~3%。
The invention also provides a preparation method of the light smelting flux capable of being reused, which comprises the following steps:
uniformly mixing the raw materials, and smelting to obtain a molten material;
and (3) after water quenching, drying and crushing the molten material to obtain the light smelting flux capable of being reused.
The invention also provides application of the secondary light smelting flux in welding, wherein the secondary light smelting flux is subjected to first welding application to form welding slag, and the welding slag is used as flux for second welding application.
Compared with the prior art, the invention has the beneficial effects that:
the secondary-usable light smelting flux provided by the invention integrates the advantages of the glassy flux and the pumice flux through component regulation and control, realizes stable components and states of the flux in the repeated use process of two times of welding, has small flux consumption, ensures that the weld metal formed after the two times of welding has uniform components, ensures that the mechanical property of the weld meets the related standard requirements, improves the resource utilization rate through the repeated use of the flux, and reduces the production cost.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings that are needed in the description of the embodiments or the prior art will be briefly described, and it is obvious that the drawings in the description below are some embodiments of the present invention, and other drawings can be obtained according to the drawings without inventive effort for a person skilled in the art.
FIG. 1 is a SEM comparison of the flux prepared in example 1 and the flux prepared in comparative example 3; wherein FIG. 1 (a) is an SEM image of the flux prepared in example 1, and FIG. 1 (b) is an SEM image of the flux prepared in comparative example 3;
FIG. 2 is a physical drawing and XRD pattern of the flux prepared in example 1 of the present invention and the slag obtained after one welding; wherein fig. 2 (a) is a flux material object diagram of example 1, fig. 2 (b) is a slag material object diagram of example 1, and fig. 2 (c) is an XRD pattern of the flux and slag of example 1;
FIG. 3 is a physical drawing and XRD pattern of the flux prepared in example 2 of the present invention and the slag obtained after one welding; wherein, fig. 3 (a) is a solder flux physical diagram of example 2, fig. 3 (b) is a solder slag physical diagram of example 2, and fig. 3 (c) is an XRD diagram of solder flux and solder slag of example 2;
FIG. 4 is a physical drawing and XRD pattern of the flux prepared in example 3 of the present invention and the slag obtained after one welding; wherein fig. 4 (a) is a flux material object diagram of example 3, fig. 4 (b) is a slag material object diagram of example 3, and fig. 4 (c) is an XRD pattern of the flux and slag of example 3;
FIG. 5 is a physical drawing and XRD pattern of the flux prepared in example 4 of the present invention and the slag obtained after one welding; wherein, fig. 5 (a) is a solder flux physical diagram of example 4, fig. 5 (b) is a solder slag physical diagram of example 4, and fig. 5 (c) is an XRD diagram of solder flux and solder slag of example 4;
FIG. 6 is a physical drawing and XRD pattern of the flux prepared in comparative example 1 of the present invention and the slag obtained after one welding; wherein, fig. 6 (a) is a comparative example 1 flux material object diagram, fig. 6 (b) is a comparative example 1 slag material object diagram, and fig. 6 (c) is a comparative example 1 flux and slag XRD pattern;
FIG. 7 is a physical drawing and XRD pattern of the flux prepared in comparative example 2 of the present invention and the slag obtained after one welding; wherein, FIG. 7 (a) is a comparative example 2 flux material object diagram, FIG. 7 (b) is a comparative example 2 slag material object diagram, and FIG. 7 (c) is a comparative example 2 flux and slag XRD diagram;
FIG. 8 is a physical drawing and XRD pattern of the flux prepared in comparative example 3 of the present invention and the slag obtained after one welding; wherein, FIG. 8 (a) is a comparative example 3 flux material object diagram, FIG. 8 (b) is a comparative example 3 slag material object diagram, and FIG. 8 (c) is a comparative example 3 flux and slag XRD diagram;
FIG. 9 is a physical view and XRD pattern of the flux prepared in comparative example 4 of the present invention and the slag obtained after one welding; wherein, fig. 9 (a) is a comparative example 4 flux material object diagram, fig. 9 (b) is a comparative example 4 slag material object diagram, and fig. 9 (c) is a comparative example 4 flux and slag XRD pattern;
FIG. 10 is a top view and a cross-sectional view of a weld obtained by primary welding and secondary welding of the flux prepared in example 1 of the present invention; wherein, fig. 10 (a) is a top view and a cross-sectional view of a weld obtained by first welding the flux of example 1, and fig. 10 (b) is a top view and a cross-sectional view of a weld obtained by second welding the flux of example 1;
FIG. 11 is a top view and a cross-sectional view of a weld obtained by primary welding and secondary welding of the flux prepared in example 2 of the present invention; wherein, fig. 11 (a) is a top view and a cross-sectional view of a weld obtained by first welding the flux of example 2, and fig. 11 (b) is a top view and a cross-sectional view of a weld obtained by second welding the flux of example 2;
FIG. 12 is a top view and a cross-sectional view of a weld obtained by primary welding and secondary welding of the flux prepared in example 3 of the present invention; wherein, fig. 12 (a) is a top view and a cross-sectional view of a weld obtained by first welding the flux of example 3, and fig. 12 (b) is a top view and a cross-sectional view of a weld obtained by second welding the flux of example 3;
FIG. 13 is a top view and a cross-sectional view of a weld obtained by primary welding and secondary welding of the flux prepared in example 4 of the present invention; wherein, fig. 13 (a) is a top view and a cross-sectional view of a weld obtained by first welding the flux of example 4, and fig. 13 (b) is a top view and a cross-sectional view of a weld obtained by second welding the flux of example 4;
FIG. 14 is a top view and a cross-sectional view of a weld obtained by primary welding and secondary welding of the flux obtained in comparative example 1 of the present invention; wherein, fig. 14 (a) is a top view and a cross-sectional view of a weld obtained by the first welding of the flux of comparative example 1, and fig. 14 (b) is a top view and a cross-sectional view of a weld obtained by the second welding of the flux of comparative example 1;
FIG. 15 is a top view and a cross-sectional view of a weld obtained by primary welding and secondary welding of the flux obtained in comparative example 2 of the present invention; wherein, fig. 15 (a) is a top view and a cross-sectional view of a weld obtained by the first welding of the flux of comparative example 2, and fig. 15 (b) is a top view and a cross-sectional view of a weld obtained by the second welding of the flux of comparative example 2;
FIG. 16 is a top view and a cross-sectional view of a weld obtained by primary welding and secondary welding of the flux obtained in comparative example 3 of the present invention; wherein, fig. 16 (a) is a top view and a cross-sectional view of a weld obtained by the first welding of the flux of comparative example 3, and fig. 16 (b) is a top view and a cross-sectional view of a weld obtained by the second welding of the flux of comparative example 3;
FIG. 17 is a top view and a cross-sectional view of a weld obtained by primary welding and secondary welding of the flux obtained in comparative example 4 of the present invention; wherein, fig. 17 (a) is a top view and a cross-sectional view of a weld obtained by the first welding of the flux of comparative example 4, and fig. 17 (b) is a top view and a cross-sectional view of a weld obtained by the second welding of the flux of comparative example 4;
FIG. 18 is a typical structure diagram of the impact fracture of the weld metal obtained by the primary welding and the secondary welding of the flux prepared in example 1 of the present invention; wherein, fig. 18 (a) is a typical structure diagram of a weld metal impact fracture obtained by the primary welding of example 1, and fig. 18 (b) is a typical structure diagram of a weld metal impact fracture obtained by the secondary welding of example 1;
FIG. 19 is a typical structure diagram of the impact fracture of the weld metal obtained by the primary welding and the secondary welding of the flux prepared in example 2 of the present invention; wherein, fig. 19 (a) is a typical structure diagram of the weld metal impact fracture obtained by the primary welding of example 2, and fig. 19 (b) is a typical structure diagram of the weld metal impact fracture obtained by the secondary welding of example 2;
FIG. 20 is a typical structure diagram of the impact fracture of the weld metal obtained by the primary welding and the secondary welding of the flux prepared in the embodiment 3 of the present invention; wherein, fig. 20 (a) is a typical structure diagram of a weld metal impact fracture obtained by the primary welding of example 3, and fig. 20 (b) is a typical structure diagram of a weld metal impact fracture obtained by the secondary welding of example 3;
FIG. 21 is a typical structure diagram of the impact fracture of the weld metal obtained by the primary welding and the secondary welding of the flux prepared in example 4 of the present invention; wherein, fig. 21 (a) is a typical structure diagram of a weld metal impact fracture obtained by the primary welding of example 4, and fig. 21 (b) is a typical structure diagram of a weld metal impact fracture obtained by the secondary welding of example 4;
FIG. 22 is a typical structure diagram of the impact fracture of the weld metal obtained by the primary welding and the secondary welding of the flux prepared in comparative example 1 according to the present invention; wherein, FIG. 22 (a) is a typical structure diagram of a weld metal impact fracture obtained by the first welding of comparative example 1, and FIG. 22 (b) is a typical structure diagram of a weld metal impact fracture obtained by the second welding of comparative example 1;
FIG. 23 is a typical structure diagram of the impact fracture of the weld metal obtained by the primary welding and the secondary welding of the flux prepared in comparative example 2 according to the present invention; wherein, FIG. 23 (a) is a typical structure diagram of a weld metal impact fracture obtained by the first welding of comparative example 2, and FIG. 23 (b) is a typical structure diagram of a weld metal impact fracture obtained by the second welding of comparative example 2;
FIG. 24 is a typical structure diagram of a weld metal impact fracture obtained by primary welding and secondary welding of the flux prepared in comparative example 3 according to the present invention, wherein FIG. 24 (a) is a typical structure diagram of a weld metal impact fracture obtained by primary welding of comparative example 3, and FIG. 24 (b) is a typical structure diagram of a weld metal impact fracture obtained by secondary welding of comparative example 3;
fig. 25 is a typical structure diagram of a weld metal impact fracture obtained by primary welding and secondary welding of the flux prepared in comparative example 4 according to the present invention, wherein fig. 25 (a) is a typical structure diagram of a weld metal impact fracture obtained by primary welding of comparative example 4, and fig. 25 (b) is a typical structure diagram of a weld metal impact fracture obtained by secondary welding of comparative example 4.
Detailed Description
The technical solution of the present invention will be clearly and completely described below with reference to the accompanying drawings and detailed description, but it will be understood by those skilled in the art that the examples described below are some, but not all, examples of the present invention, and are intended to be illustrative of the present invention only and should not be construed as limiting the scope of the present invention. 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. The specific conditions are not noted in the examples and are carried out according to conventional conditions or conditions recommended by the manufacturer. The reagents or apparatus used were conventional products commercially available without the manufacturer's attention.
In a first aspect, the invention provides a secondary-usable light smelting flux, which is prepared from the following components in percentage by mass: siO (SiO) 2 37%~41%，MnO 26%~30%，MgO 11%~13%，Al 2 O 3 13%~16%，CaF 2 3% -5% of Fe 2 O 3 2%~3%。
Among the above components, siO 2 Including, but not limited to, any one of the point values or range values between any two of 37.5%, 38%, 38.5%, 39%, 39.5%, 40%, 40.5% by mass; mnO includes, but is not limited to, any one of the point values or any two of 26.5%, 27%, 27.5%, 28%, 28.5%, 29%, 29.5% by massA range value in between; mgO includes, but is not limited to, a point value of any one of 11.5%, 12%, 12.5% or a range value between any two in mass percent; al (Al) 2 O 3 Including, but not limited to, any one of a point value of 13.5%, 14%, 14.5%, 15%, 15.5% or a range value therebetween in mass percent; caF (CaF) 2 Including, but not limited to, any one of 3.5%, 4%, 4.5% point values or range values therebetween in mass percent; fe (Fe) 2 O 3 Including, but not limited to, any one of the point values of 2.3%, 2.5%, 2.8% or a range between any two by mass percent.
The composition and structural state of the flux are key factors affecting the welding process and metallurgical performance of the flux and are key points affecting whether the flux can be reused or not. The vitreous flux has even element component distribution, the slag shell is easy to keep amorphous state after welding, the stability of the original flux component and state can be maintained, and the vitreous flux has great recycling potential. However, the vitreous flux structure is very dense, and has a large bulk specific gravity, usually 1.1g/cm 3 ~1.8g/cm 3 This results in a larger consumption of flux during the soldering process, which is detrimental to resource saving.
The pumice flux has a foam structure, has a small bulk specific gravity, and is generally 0.7g/cm 3 ~1.0g/cm 3 The consumption of the welding process is 20-30% less than that of the vitreous flux. However, the pumice flux is prone to a crystallization state due to component design, and a slag shell formed after welding is extremely easy to form a crystal structure in disordered distribution in the process of rapid heating and slow cooling, so that the element is locally enriched, and the uniformity of the element components of the flux and the stability of the flux property cannot be ensured.
The secondary-usable light smelting flux provided by the invention comprises SiO 2 、MnO、MgO、Al 2 O 3 、CaF 2 And Fe (Fe) 2 O 3 Six components and specific proportion, comprehensively considers the balance control of slag and molten pool oxygen potential and the evolution of flux-slag components in the welding process, and can combine the advantages of glass-shaped flux and pumice-shaped flux to ensure that the flux has an amorphous state and a foam loose structure. The flux has stable component state, and is suitable forThe welding machine can be used for large heat input welding, can be directly reused, and has the advantages of small bulk specific gravity, low welding consumption, good arc stability, excellent slag removal performance, uniform obtained welding seam components, and the like, and the mechanical properties meet the requirements.
The secondary-usable light smelting flux provided by the invention adopts SiO with specific proportion 2 And Al 2 O 3 It can be ensured that the flux remains in a nearly completely amorphous state in two soldering applications; by adding MgO dispersed flux structure, the amorphous state of the material is light; by adding Fe in a specific content 2 O 3 The accumulation of FeO in the slag is effectively suppressed, thereby avoiding the sudden increase of the oxygen content of the welding seam and the performance deterioration of the welding seam during the secondary application of the welding flux, which are not mentioned in the prior art.
Higher content of SiO 2 The method can promote the formation of amorphous flux and amorphous welding slag, thereby ensuring the stability of the component property of the flux, but simultaneously increasing the oxygenation capacity of the flux, resulting in overhigh oxygen content of the welding seam and deterioration of the mechanical property of the welding seam. And Al is 2 O 3 Can be added to the welding agent SiO 2 The structure is modified to form an Al-O-Si composite structure, thereby inhibiting SiO 2 The oxygen increasing capability of the welding line solves the problem of the decline of the mechanical property of the welding line, and simultaneously maintains the amorphous forming capability of the welding flux. And, proper amount of MgO can be added to fill gaps of large-diameter Mg in a flux network structure 2+ The structure density is reduced on the basis of maintaining the original integral configuration, and the purpose of lightening the welding flux is achieved.
The accumulation of FeO in slag during the reuse of flux can increase the oxygen supply capacity of flux, and the invention adds proper amount of Fe 2 O 3 By means of the reducing atmosphere in the welding arc droplet area, feO with certain content is formed in the interface between flux slag and molten metal pool in advance, so that the formation of FeO and the migration and diffusion of FeO to the welding slag are weakened.
Specifically, siO 2 The crystallization capability is weak, is an important amorphous formation control component, can stabilize electric arc, has high current carrying capability, participates in slag formation, ensures good slag removal of welding flux, but has the advantages of low cost, low cost and low costThe oxygen supply capability is stronger, and excessive addition can lead to the too high oxygen content of the welding seam, and the mechanical property of the welding seam is deteriorated. SiO (SiO) 2 The flux has the functions of forming a network in the flux slag structure, can form a silicate network structure at high temperature, and improves the slag removing performance of the flux through phase change stress generated by multiple crystal form changes in the cooling process. In the present invention, siO 2 The mass percentage content of the solder is 37% -41%, so that the amorphous state is kept in the primary welding and secondary welding application to ensure the stable component state, and meanwhile, the good fluidity of the solder is ensured, and the deterioration of the components and performance of the solder during secondary use is avoided.
MnO has good conductivity and thus certain arc stability, can effectively inhibit burning loss of Mn element in weld metal in the welding process, ensures mechanical property of the weld, can assist in regulating and controlling fluidity of welding flux and reducing tendency of generating hydrogen pores, but MnO also has strong oxygenation capacity and can simultaneously react with Fe 2 O 3 Promote each other and improve the reactivity. In the invention, the mass percentage content of MnO is 26% -30%, so that the stability of the mechanical property of the welding seam and the welding process can be ensured.
The main function of MgO is to depolymerize Mg by network 2+ The flux is dispersed into a flux melt structure, so that the water quenched flux has the foam structure characteristic, the flux is light, meanwhile, the flux acts as a slag former, the fluidity of flux slag can be regulated, and the rust resistance is enhanced. In the invention, the mass percentage content of MgO is 11% -13%, so that the foam structure characteristics and amorphous glass state can be simultaneously considered, the bulk specific gravity of the welding flux is small, and the welding consumption is small.
Al 2 O 3 Is a stable amphoteric oxide, has weak oxygen supply capability, can regulate and control the structure of the flux, weakens the oxygen supply capability of the flux, serves as a vitreous slag-forming material, can improve the melt viscosity of the flux, and can deteriorate the flux fluidity when excessively added. In the present invention, al 2 O 3 The mass percentage content of the alloy is 13% -16%, and the consumption can ensure excellent mechanical properties of welding seams, ensure fluidity of welding flux and avoid air holes and pits on the surfaces of the welding seams.
CaF 2 The flux has the advantages that the flux can assist in regulating and controlling the metal oxygen content of the welding line, and simultaneously, the flux slag fluidity is regulated, so that the flux has a certain effect on inhibiting the formation of hydrogen holes, but the component has strong crystallization capability and is easy to volatilize and lose in the welding process. In the present invention, caF 2 The mass percentage content of the alloy is 3% -5%, the consumption can adjust the fluidity of flux slag, inhibit the volatilization reaction of the flux slag so as to keep good recoverability of the flux, and improve the arc stability.
Fe 2 O 3 Is a key control component for realizing secondary utilization of the welding flux, is used for regulating and controlling the Fe-O balance between flux slag and a metal molten pool in the welding process and inhibiting FeO accumulation in the welding slag, thereby weakening the strengthening effect of the welding flux on the oxygenation capacity of the secondary utilization of the welding flux. In the present invention, fe 2 O 3 The mass percentage content of the alloy is 2% -3%, so that on one hand, the alloy can ensure that the alloy can inhibit the accumulation of FeO in welding slag; on the other hand, the weld joint can be ensured to have excellent mechanical properties.
In a preferred embodiment, the reusable light smelting flux is amorphous flux. The crystal state of the secondarily used light smelting flux is amorphous.
In a preferred embodiment, the microstructure of the reusable light smelting flux is a foam-like structure, a loose structure, rather than the dense structure of conventional fluxes.
In a preferred embodiment, the secondary light smelting flux has a bulk specific gravity of 0.7g/cm 3 ~0.8g/cm 3 Including but not limited to 0.72g/cm 3 、0.74g/cm 3 、0.75g/cm 3 、0.77g/cm 3 、0.79g/cm 3 Any one of the point values or a range value between any two.
The bulk specific gravity is also referred to as bulk density or bulk specific gravity, and is the mass per unit volume measured immediately after filling a certain container with a material.
The secondary-usable light smelting flux provided by the invention has lower bulk specific gravity, so that the amount of the flux used in welding is small, and the welding cost and the production cost of welding parts are further reduced.
In a preferred embodiment, the melting temperature of the secondary-usable light smelting flux is 1202 ℃ to 1221 ℃, including but not limited to any one of 1205 ℃, 1210 ℃, 1215 ℃, 1220 ℃ or a range of values between any two.
The light smelting flux with specific chemical composition and capable of being reused has lower smelting temperature and is easy to prepare.
In a preferred embodiment, the present invention provides a reusable light smelting flux that is amorphous in crystalline state.
In a second aspect, the invention provides a method for preparing the secondarily-usable light smelting flux, which comprises the following steps:
the raw materials are weighed according to the proportion, uniformly mixed and then smelted to obtain liquid molten materials.
And (3) granulating the obtained melting stock through water quenching, and drying and crushing to obtain the secondary-usable light smelting flux.
The preparation method of the secondary-usable light smelting flux provided by the invention is simple to operate, short in flow and suitable for mass production. The smelting flux prepared by the method has the advantages of small bulk specific gravity, light weight and secondary recycling.
In a preferred embodiment, the particle size of each feedstock is 100 mesh to 300 mesh, including but not limited to a point value of any one of 150 mesh, 200 mesh, 250 mesh, or a range of values between any two.
The raw materials with the granularity range are beneficial to improving smelting efficiency and shortening smelting time.
In a preferred embodiment, the smelting temperature is 1450 ℃ to 1500 ℃, including but not limited to any one or a range of values between 1460 ℃, 1470 ℃, 1480 ℃, 1490 ℃.
The welding flux provided by the invention adopts specific components and the proportion thereof, so that the smelting temperature is low, and the energy conservation is facilitated.
The heat preservation time of smelting is 15-20 min, including but not limited to any one point value or range value between any two of 16min, 17min, 18min and 19 min.
The invention shortens smelting time, saves energy and reduces the production cost of the welding flux by controlling the granularity of each raw material.
In a preferred embodiment, the particle size of the light smelting flux crushed to be capable of being reused is 8-40 meshes.
It will be appreciated that the above-described crushing further comprises a step of sieving.
And the secondary-usable light smelting flux is crushed into the granularity, so that the welding process is stable and efficient.
In a preferred embodiment, the mixing time of the raw materials is 10 min-30 min, including but not limited to any one of 15min, 18min, 20min, 25min or a range between any two.
In a preferred embodiment, the mixing of the individual raw materials takes place in a mixer.
In a preferred embodiment, the smelting is carried out in a high temperature reburning furnace.
In a preferred embodiment, the drying after the water quenching is carried out in a forced air drying oven. More preferably, the drying temperature is 270-300 ℃ and the drying time is 1.5-2 h.
In a third aspect, the present invention provides the use of said light-weight, re-usable flux in welding, said light-weight, re-usable flux being used for a first welding operation to form slag, said slag being used as flux for a second welding operation.
The welding flux can be used for large-line energy submerged arc welding, and the fusion glassy flux has the outstanding advantages of stable component state, small bulk specific gravity of pumice flux, small consumption quality and the like, and the flux is used for large-line energy welding, so that the welding process has stable electric arc, high cladding efficiency and good deslagging performance, the metal components of the obtained welding seam are uniform, and the mechanical property of the obtained welding seam can meet the requirements of relevant standards.
The secondary-usable light smelting flux provided by the invention is used for secondary welding, the mechanical property of a welding line is not reduced, the metal components and the performance of the welding line can be kept stable, the resource and energy utilization rate can be greatly improved by repeated utilization, the resource and energy waste is avoided, and the welding cost is reduced.
In a preferred embodiment, the slag may be used alone or in any ratio with the flux for the second welding.
In a preferred embodiment, the line energy of the weld is 60kJ/cm to 70kJ/cm.
In a preferred embodiment, the slag is crushed to a particle size of 14 mesh to 40 mesh prior to the second welding.
The secondary-usable light smelting flux with specific composition provided by the invention realizes uniform and stable flux component state, but the cooling process of the welding slag in welding is different from the water quenching process of flux production, so that the density of the welding slag after the first welding is improved compared with that of the original flux. In order to keep the welding and melting process of the welding slag and the original welding flux consistent, before secondary utilization, namely secondary welding, the particle size of the welding slag can be reduced, namely, the welding slag is crushed to 14-40 meshes, so that the welding and melting process of the welding slag and the original welding flux is kept consistent, and the purpose of ensuring excellent mechanical properties of a welding seam formed by secondary welding is achieved.
In a preferred embodiment, the amount of the secondary light smelting flux used during the first welding is less than 0.7kg/m, including but not limited to a point value of any one of 0.65kg/m, 0.6kg/m, 0.55kg/m, 0.5kg/m, 0.45kg/m, 0.4kg/m, or a range value between any two. More preferably 0.62kg/m or less.
In a preferred embodiment, the amount of slag formed after the first weld during the second weld is <0.7kg/m, including but not limited to a point value of any one of 0.65kg/m, 0.6kg/m, 0.55kg/m, 0.5kg/m, 0.45kg/m, 0.4kg/m, or a range value therebetween.
The consumption of the secondary light smelting flux in the welding process can be achieved by using the secondary light smelting flux.
The unit kg/m refers to the mass (kg) of the flux used for welding each meter of the base material to be welded.
The secondary-usable light smelting flux provided by the invention has smaller dosage, and further reduces the welding cost.
In a preferred embodiment, the secondary light smelting flux is used in applications such as, but not limited to, welding high strength low alloy marine steels, such as, for example, welding vessels, marine platforms, oil and gas storage vessels, such as, for example, the exemplary marine steel EH 36.
Wherein the method of welding comprises high heat input welding. Welding wires used in the welding process include, but are not limited to, low carbon high manganese welding wires such as H10Mn2, H08Mn2SiA, and the like.
Embodiments of the present invention will be described in detail below with reference to examples, but it will be understood by those skilled in the art that the following examples are only for illustrating the present invention and should not be construed as limiting the scope of the present invention. The specific conditions are not noted in the examples and are carried out according to conventional conditions or conditions recommended by the manufacturer. The reagents or apparatus used were conventional products commercially available without the manufacturer's attention.
Example 1:
the preparation raw materials of the secondary-usable light smelting flux provided in this example and the amounts of the raw materials (in mass%) are shown in table 1.
The preparation method of the light smelting flux capable of being reused comprises the following steps:
(1) According to the component ingredients in table 1, all raw material components are processed into powder with the granularity of 200-300 meshes after being detected to be qualified, and the powder is weighed according to the proportion in table 1.
(2) Pouring the weighed raw materials into a mixer, stirring for 15min, and placing the mixture into a high-temperature reburning furnace for smelting and heat preservation after uniform stirring; wherein the smelting temperature is 1500 ℃, and the heat preservation time is 20min.
(3) And (3) carrying out water quenching granulation on the high-temperature molten material obtained in the step (2) to obtain a welding flux semi-finished product.
(4) Draining the semi-finished product obtained in the step (3) for 1h, and then placing the semi-finished product in a blast drying oven for drying; wherein the temperature of the drying is 300 ℃, the time is 2 hours, and the laying thickness of the semi-finished product is 40mm.
(5) And (3) crushing the dried flux semi-finished product obtained in the step (4) to a granularity range of 8-40 meshes to obtain the required light smelting flux capable of being reused.
Example 2:
the preparation raw materials of the secondary-usable light smelting flux provided in this example and the amounts of the raw materials (in mass%) are shown in table 1.
The preparation method of the light smelting flux capable of being reused comprises the following steps:
(1) According to the component ingredients in table 1, all raw material components are processed into powder with the granularity of 200-300 meshes after being detected to be qualified, and the powder is weighed according to the proportion in table 1.
(2) Pouring the weighed raw materials into a mixer, stirring for 13min, and placing the mixture into a high-temperature reburning furnace for smelting and heat preservation after uniform stirring; wherein the smelting temperature is 1470 ℃, and the heat preservation time is 18min.
(3) And (3) carrying out water quenching granulation on the high-temperature molten material obtained in the step (2) to obtain a welding flux semi-finished product.
(4) Draining the semi-finished product obtained in the step (3) for 1h, and then placing the semi-finished product in a blast drying oven for drying; wherein the temperature of the drying is 290 ℃, the time is 1.5h, and the laying thickness of the semi-finished product is 47mm.
(5) And (3) crushing the dried flux semi-finished product obtained in the step (4) to a granularity range of 8-40 meshes to obtain the required light smelting flux capable of being reused.
Example 3:
the preparation raw materials of the secondary-usable light smelting flux provided in this example and the amounts of the raw materials (in mass%) are shown in table 1.
The preparation method of the light smelting flux capable of being reused comprises the following steps:
(1) According to the component ingredients in table 1, all raw material components are processed into powder with the granularity of 250-300 meshes after being detected to be qualified, and the powder is weighed according to the proportion in table 1.
(2) Pouring the weighed raw materials into a mixer, stirring for 15min, and placing the mixture into a high-temperature reburning furnace for smelting and heat preservation after uniform stirring; wherein the smelting temperature is 1480 ℃ and the heat preservation time is 17min.
(3) And (3) carrying out water quenching granulation on the high-temperature molten material obtained in the step (2) to obtain a welding flux semi-finished product.
(4) Draining the semi-finished product obtained in the step (3) for 1h, and then placing the semi-finished product in a blast drying oven for drying; wherein the temperature of the drying is 280 ℃, the time is 2 hours, and the laying thickness of the semi-finished product is 45mm.
(5) And (3) crushing the dried flux semi-finished product obtained in the step (4) to a granularity range of 8-40 meshes to obtain the required light smelting flux capable of being reused.
Example 4:
the preparation raw materials of the secondary-usable light smelting flux provided in this example and the amounts of the raw materials (in mass%) are shown in table 1.
The preparation method of the light smelting flux capable of being reused comprises the following steps:
(1) According to the component ingredients in table 1, all raw material components are processed into powder with 100-200 meshes after being detected to be qualified, and the powder is weighed according to the proportion in table 1.
(2) Pouring the weighed raw materials into a mixer, stirring for 10min, and placing the mixture into a high-temperature reburning furnace for smelting and heat preservation after uniform stirring; wherein the smelting temperature is 1450 ℃, and the heat preservation time is 15min.
(3) And (3) carrying out water quenching granulation on the high-temperature molten material obtained in the step (2) to obtain a welding flux semi-finished product.
(4) Draining the semi-finished product obtained in the step (3) for 1h, and then placing the semi-finished product in a blast drying oven for drying; wherein the temperature of the drying is 270 ℃, the time is 1.5h, and the laying thickness of the semi-finished product is 50mm.
(5) And (3) crushing the dried flux semi-finished product obtained in the step (4) to a granularity range of 8-40 meshes to obtain the required light smelting flux capable of being reused.
Comparative example 1-comparative example 4:
comparative examples 1-4 the raw materials for preparing the reusable light smelting flux provided in comparative example 1 and the amounts of the raw materials are shown in table 1.
Comparative examples 1-4 the preparation method of the reusable light smelting flux provided in example 1 was the same.
Experimental example:
the welding performance test was performed by using the smelting fluxes prepared in the above examples and comparative examples, and each flux was combined with H08Mn2 welding wire to weld a typical marine steel EH36 steel with double-wire submerged-arc welding high heat input, the flux pile height was 40mm, the heat input was 60kJ/cm, the front wire direct current was 850A/32V, the rear wire alternating current was 625A/36V, the front and rear wire spacing was 25mm, and the welding speed was 500mm/min.
After the first welding is finished, collecting the obtained welding slag, crushing and sieving the welding slag to a granularity range of 14-40 meshes, and performing secondary welding as welding flux (the parameters of the two welding are the same as the parameters). The composition of the slag collected after one welding was measured and the results are shown in table 1.
Table 1 formulation of smelting flux and slag composition measurement results.
As can be seen from Table 1, the molten flux prepared in each example has small composition changes before and after welding and has great recycling potential.
Further, bulk specific gravity, melting temperature and crystallization state of the molten fluxes prepared in the above examples and comparative examples were measured, respectively, and the test results are shown in table 2. The consumption of each flux during the first soldering is shown in table 2.
Table 2 bulk specific gravity, melting temperature, crystallization state, and consumption of each molten flux.
Further, the chemical compositions of the EH36 steel and the weld metal obtained after the primary welding and the secondary welding were measured, respectively, and the results are shown in table 3. And impact absorbing work KV at-40 ℃ is carried out on each weld metal 2 The results of the test are shown in Table 3.
Table 3 EH36 steel and weld metal composition (wt.%), -40 ℃ impact absorption work.
F5A 2-H10 Mn2 specified weld metal in the standard GB/T5293-2018 is not less than 27J in impact absorption work at minus 40 ℃.
As can be seen from tables 1 to 3: the welding seam obtained in the examples 1-4 has uniform components, no obvious element burning loss and no obvious difference in the welding seam components obtained in the two welding processes, which indicates that the welding flux can be applied to the welding of the sea steel EH36 under the condition of large line energy, the bulk specific gravity is small, the welding consumption is low, and the primary welding slag can be directly used for the secondary welding.
Comparative example 1, however, no Fe was added to the raw flux 2 O 3 The FeO accumulation is inhibited, so that the FeO content of the obtained welding slag is higher, the oxygen supply capacity of the welding flux in secondary application is too strong, and the mechanical property of the welding seam is reduced.
Comparative example 2A flux with an excess of Fe was added 2 O 3 The oxygen supply capability of the welding flux in the welding process is too strong, and meanwhile, the accumulation of FeO in welding slag cannot be effectively inhibited, so that the mechanical property of the welding seam is deteriorated.
The comparative example 3 has the advantages that the crystallization capability of the flux is enhanced by adding excessive MgO into the raw flux, element segregation occurs in the raw flux and the primary welding slag, a large amount of crystal structures are formed, the flux and the welding slag are compact in structure, the bulk specific gravity and consumption of the flux are obviously increased, the specific heat of the flux is increased, the melting volume of the flux in the welding process is excessively small, the protection effect of a welding pool is weakened, the Mn element of the welding seam is lost, the oxygen content of the welding seam is increased, the mechanical property of the welding seam metal is deteriorated, the crystallization tendency of the welding slag is obvious (see fig. 8 (c)), and the performance of the welding seam metal obtained by the second welding is further deteriorated.
Comparative example 4 addition of excessive Al to the raw flux 2 O 3 And use too low SiO 2 The flux mobility is deteriorated, the flux and the welding slag structure are compact, the bulk specific gravity and the consumption of the flux are obviously increased, the resource saving is not facilitated, meanwhile, the flux generates larger pressure on the weld metal in the welding process, the density of the formed welding slag is further increased, the molten metal flows in the cooling process in the two welding processes are greatly hindered, the mechanical properties are barely satisfactory, but the components are uneven, and the weld formability is extremely poor (see figure 9).
Further, fig. 1 is an SEM comparison of the flux prepared in example 1 and the flux prepared in comparative example 3; among them, fig. 1 (a) is an SEM image of the flux prepared in example 1, and fig. 1 (b) is an SEM image of the flux prepared in comparative example 3. As can be seen from FIG. 1, the microstructure of the flux prepared in example 1 is a foam-like loose structure, while the non-foam structure of the flux prepared in comparative example 3 is a conventional dense structure.
Similarly, SEM examination was performed on the fluxes prepared in examples 2 to 4, and each microstructure was also in a foam-like loose structure. Whereas the flux prepared in comparative example 4 is of a conventional dense structure.
The physical pattern of the flux prepared in example 1 and the slag obtained after one welding and the XRD results thereof are shown in FIG. 2. The physical pattern of the flux prepared in example 2 and the slag obtained after one welding and the XRD results thereof are shown in FIG. 3. The physical pattern of the flux prepared in example 3 and the slag obtained after one welding and the XRD results thereof are shown in FIG. 4. The physical pattern of the flux obtained in example 4 and the slag obtained after one welding and the XRD results thereof are shown in FIG. 5. The physical pattern of the flux prepared in comparative example 1 and the slag obtained after one welding and the XRD results thereof are shown in FIG. 6. The physical pattern of the flux prepared in comparative example 2 and the slag obtained after one welding and the XRD result thereof are shown in fig. 7. The physical pattern of the flux prepared in comparative example 3 and the slag obtained after one welding and the XRD results thereof are shown in FIG. 8. The physical pattern of the flux obtained in comparative example 4 and the slag obtained after one welding and the XRD results thereof are shown in FIG. 9.
The flux prepared in example 1 is shown in fig. 10 in top view and cross-sectional view of the weld obtained after the primary welding and the secondary welding. The flux prepared in example 2 is shown in fig. 11 in top view and cross-sectional view of the weld obtained after the primary welding and the secondary welding. The flux prepared in example 3 is shown in fig. 12 in top view and cross-sectional view of the weld obtained after the primary welding and the secondary welding. The flux prepared in example 4 was subjected to primary and secondary welding to obtain a weld with a top view and a cross-sectional view as shown in fig. 13. The flux prepared in comparative example 1 is shown in fig. 14 in top view and cross-sectional view of the weld obtained after the primary welding and the secondary welding. The flux prepared in comparative example 2 is shown in fig. 15 in top view and cross-sectional view of the weld obtained after the primary welding and the secondary welding. The flux prepared in comparative example 3 is shown in fig. 16 in top view and cross-sectional view of the weld obtained after the primary welding and the secondary welding. The flux prepared in comparative example 4 was subjected to primary welding and secondary welding to obtain a weld, and a top view and a cross-sectional view of the weld were shown in fig. 17.
A typical structure diagram of the impact fracture of the weld metal obtained after the first welding and the second welding of the flux prepared in example 1 is shown in FIG. 18. A typical microstructure of the weld metal impact fracture obtained after the primary welding and the secondary welding of the flux prepared in example 2 is shown in FIG. 19. A typical structure diagram of the impact fracture of the weld metal obtained after the first welding and the second welding of the flux prepared in example 3 is shown in FIG. 20. A typical microstructure of the weld metal impact fracture obtained after the primary welding and the secondary welding of the flux prepared in example 4 is shown in FIG. 21. A typical structure diagram of the impact fracture of the weld metal obtained after the first welding and the second welding of the flux prepared in comparative example 1 is shown in FIG. 22. A typical structure diagram of the impact fracture of the weld metal obtained after the first welding and the second welding of the flux prepared in comparative example 2 is shown in FIG. 23. A typical structure diagram of the impact fracture of the weld metal obtained after the first welding and the second welding of the flux prepared in comparative example 3 is shown in FIG. 24. A typical structure diagram of the impact fracture of the weld metal obtained after the first welding and the second welding of the flux prepared in comparative example 4 is shown in FIG. 25.
While the invention has been illustrated and described with reference to specific embodiments, it is to be understood that the above embodiments are merely illustrative of the technical aspects of the invention and not restrictive thereof; those of ordinary skill in the art will appreciate that: modifications may be made to the technical solutions described in the foregoing embodiments, or equivalents may be substituted for some or all of the technical features thereof, without departing from the spirit and scope of the present invention; such modifications and substitutions do not depart from the spirit of the corresponding technical solutions; it is therefore intended to cover in the appended claims all such alternatives and modifications as fall within the scope of the invention.
Claims (9)
1. The secondary-usable light smelting flux is characterized by being prepared from the following components in percentage by mass: siO (SiO) 2 37%~41%，MnO 26%~30%，MgO 11%~13%，Al 2 O 3 13%~16%，CaF 2 3% -5% of Fe 2 O 3 2%~3%；
The microstructure of the secondarily-usable light smelting flux is a foam structure;
the bulk specific gravity of the secondary light smelting flux is 0.7g/cm 3 ~0.8g/cm 3 ；
The melting temperature of the secondarily-usable light smelting flux is 1202-1221 ℃.
2. The light-weight, reusable flux of claim 1, wherein the light-weight, reusable flux is an amorphous flux.
3. The method for preparing the secondarily usable light smelting flux according to any one of claims 1 to 2, comprising the steps of:
uniformly mixing the raw materials, and smelting to obtain a molten material;
and (3) after water quenching, drying and crushing the molten material to obtain the light smelting flux capable of being reused.
4. The method for producing a secondarily usable light flux as claimed in claim 3, wherein the particle size of each raw material is 100 mesh to 300 mesh.
5. The method for preparing the light smelting flux capable of being reused as claimed in claim 3, wherein the smelting temperature is 1450-1500 ℃, and the smelting heat preservation time is 15-20 min.
6. The method for producing a light-weight, reusable flux according to claim 3, wherein the size of the light-weight, reusable flux is 8-40 mesh.
7. The use of a secondary light smelting flux according to any one of claims 1-2 in welding, wherein the secondary light smelting flux is applied in a first welding operation to form slag, and the slag is applied in a second welding operation as flux.
8. The use of a re-usable light smelting flux according to claim 7 in welding, characterized in that the slag is crushed to a grain size of 14-40 mesh before the second welding.
9. The use of a secondary light smelting flux according to claim 7 in welding, characterized in that the secondary light smelting flux is used in an amount <0.7kg/m during the first welding.
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| JP2023007912A (en) * | 2021-07-02 | 2023-01-19 | 日鉄溶接工業株式会社 | Melting type flux for submerged arc welding |
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