CN117139923A - Manufacturing process of non-copper-plated solid welding wire - Google Patents
Manufacturing process of non-copper-plated solid welding wire Download PDFInfo
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- CN117139923A CN117139923A CN202310758571.0A CN202310758571A CN117139923A CN 117139923 A CN117139923 A CN 117139923A CN 202310758571 A CN202310758571 A CN 202310758571A CN 117139923 A CN117139923 A CN 117139923A
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- 238000003466 welding Methods 0.000 title claims abstract description 67
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 21
- 239000007787 solid Substances 0.000 title claims abstract description 16
- 238000000576 coating method Methods 0.000 claims abstract description 22
- 239000011248 coating agent Substances 0.000 claims abstract description 21
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 claims abstract description 21
- 238000001035 drying Methods 0.000 claims abstract description 20
- 238000004140 cleaning Methods 0.000 claims abstract description 19
- 238000000034 method Methods 0.000 claims abstract description 14
- 230000018044 dehydration Effects 0.000 claims abstract description 3
- 238000006297 dehydration reaction Methods 0.000 claims abstract description 3
- 239000010949 copper Substances 0.000 claims description 23
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 22
- 229910052802 copper Inorganic materials 0.000 claims description 22
- 239000000843 powder Substances 0.000 claims description 19
- 230000003449 preventive effect Effects 0.000 claims description 11
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 claims description 10
- 230000006835 compression Effects 0.000 claims description 10
- 238000007906 compression Methods 0.000 claims description 10
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 8
- 239000013527 degreasing agent Substances 0.000 claims description 7
- 238000005237 degreasing agent Methods 0.000 claims description 7
- 230000001050 lubricating effect Effects 0.000 claims description 6
- 238000005406 washing Methods 0.000 claims description 6
- 229910052582 BN Inorganic materials 0.000 claims description 5
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 claims description 5
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 5
- 239000011149 active material Substances 0.000 claims description 5
- 229910021389 graphene Inorganic materials 0.000 claims description 5
- -1 polytetrafluoroethylene Polymers 0.000 claims description 5
- 229920001343 polytetrafluoroethylene Polymers 0.000 claims description 5
- 239000004810 polytetrafluoroethylene Substances 0.000 claims description 5
- 239000004408 titanium dioxide Substances 0.000 claims description 5
- ITRNXVSDJBHYNJ-UHFFFAOYSA-N tungsten disulfide Chemical compound S=[W]=S ITRNXVSDJBHYNJ-UHFFFAOYSA-N 0.000 claims description 5
- 229910000831 Steel Inorganic materials 0.000 claims description 4
- 238000001816 cooling Methods 0.000 claims description 4
- 239000010959 steel Substances 0.000 claims description 4
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical group [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 claims description 2
- 229910052791 calcium Inorganic materials 0.000 claims description 2
- 239000011575 calcium Substances 0.000 claims description 2
- 238000005238 degreasing Methods 0.000 claims description 2
- 239000012153 distilled water Substances 0.000 claims description 2
- 238000005485 electric heating Methods 0.000 claims description 2
- 239000012535 impurity Substances 0.000 claims description 2
- 230000006698 induction Effects 0.000 claims description 2
- 238000009991 scouring Methods 0.000 claims description 2
- 238000005108 dry cleaning Methods 0.000 claims 1
- 238000005299 abrasion Methods 0.000 abstract description 6
- 239000000779 smoke Substances 0.000 abstract description 5
- 230000006378 damage Effects 0.000 abstract description 4
- 239000000428 dust Substances 0.000 abstract description 3
- 238000010891 electric arc Methods 0.000 abstract description 3
- 239000013543 active substance Substances 0.000 abstract description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 8
- 239000010410 layer Substances 0.000 description 8
- 239000003921 oil Substances 0.000 description 8
- 238000007747 plating Methods 0.000 description 5
- 230000035553 feeding performance Effects 0.000 description 4
- 229910052742 iron Inorganic materials 0.000 description 4
- 239000000243 solution Substances 0.000 description 4
- 239000007864 aqueous solution Substances 0.000 description 3
- 239000002253 acid Substances 0.000 description 2
- 239000003513 alkali Substances 0.000 description 2
- 230000007797 corrosion Effects 0.000 description 2
- 238000005260 corrosion Methods 0.000 description 2
- 230000001627 detrimental effect Effects 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 239000002360 explosive Substances 0.000 description 2
- 239000010687 lubricating oil Substances 0.000 description 2
- 238000005461 lubrication Methods 0.000 description 2
- 230000002265 prevention Effects 0.000 description 2
- 239000007921 spray Substances 0.000 description 2
- 238000004381 surface treatment Methods 0.000 description 2
- 206010018910 Haemolysis Diseases 0.000 description 1
- FAPWRFPIFSIZLT-UHFFFAOYSA-M Sodium chloride Chemical compound [Na+].[Cl-] FAPWRFPIFSIZLT-UHFFFAOYSA-M 0.000 description 1
- 230000002159 abnormal effect Effects 0.000 description 1
- 230000001154 acute effect Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 238000004210 cathodic protection Methods 0.000 description 1
- 239000011247 coating layer Substances 0.000 description 1
- 230000000052 comparative effect Effects 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000000280 densification Methods 0.000 description 1
- 238000001514 detection method Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 239000003517 fume Substances 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 230000008588 hemolysis Effects 0.000 description 1
- 210000003734 kidney Anatomy 0.000 description 1
- 210000004185 liver Anatomy 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 239000003595 mist Substances 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
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- 150000003839 salts Chemical class 0.000 description 1
- 239000004576 sand Substances 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 230000000087 stabilizing effect Effects 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
- 208000011580 syndromic disease Diseases 0.000 description 1
- 238000004804 winding Methods 0.000 description 1
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
- B23K35/40—Making wire or rods for soldering or 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
- B23K35/02—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
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Nonmetallic Welding Materials (AREA)
Abstract
The invention belongs to the technical field of automatic welding wire production, and discloses a manufacturing process of a non-copper-plated solid welding wire. The non-copper-plated solid welding wire is obtained through five steps of wire rod pretreatment, wire rod drawing, post-treatment cleaning, dehydration drying and active substance coating. The invention solves four technical problems of abrasion, conductivity, rust resistance and wire feeding property of the contact tip of the copper-free welding wire, and the obtained welding wire has good welding manufacturability; stable electric arc, less splashing, less smoke dust, less abrasion of the contact tip and excellent rust resistance. Compared with the prior art, the method has the advantages of less pollution to the environment, no harm to personnel and low cost.
Description
Technical Field
The invention belongs to the technical field of automatic welding wire production, and relates to a manufacturing process of a non-copper-plated solid welding wire.
Background
At present, solid welding wires used in China are usually plated with copper, namely, a copper layer is plated on the surface of the solid welding wires to achieve the effects of rust prevention, lubrication, conductivity and the like on the surface of the solid welding wires, but the copper-plated welding wires also have certain problems, mainly:
1. environmental protection problem in production
The production process of the solid welding wire has great pollution to the environment, the main pollution source to the environment is copper plating solution, and then the use of various chemicals such as acid and alkali and various acid and alkali mist and the like.
2. Pollution during use
Copper is a detrimental element to the weld, and too much copper is detrimental to weld quality. In addition, most of copper fumes are formed during welding of the copper layer; the excessive copper-containing smoke dust inhaled by a welder can cause metal copper smoke heat acute syndrome, and hemolysis, liver and kidney damage and direct damage to the welder body occur.
3. Quality problems of copper plated solid wire itself
1) Copper layer peeling problem
During the use of the welding wire, due to the extrusion of the straightening wheel and the long-time friction with the wire feeding hose, part of copper plating layers are stripped from the substrate, and during the welding process, a large amount of copper scraps are accumulated in the wire feeding hose to cause the blockage of the wire feeding hose, so that the stability of wire feeding is affected.
2) Rust prevention problem
Copper is cathodic protection against iron and must be dense and nonporous to achieve corrosion. Through detection, the thickness of the copper plating layer of the welding wire with phi of 1.2mm is only 0.20-0.5 mu m, which is far smaller than 5 mu m meeting the requirement of densification; therefore, the copper plating layer which is not very dense cannot protect the internal iron-based welding wire, but accelerates the corrosion of the iron-based welding wire in a corrosive medium.
3) Large welding spatter and poor weld formation
The welding spatter is reflected particularly obviously when the binding force between the copper plating layer and the iron-based layer is poor and the surface quality is poor; this is due to the unstable welding parameters caused by the wire quality problem.
In summary, copper-free welding wires will eventually replace copper-plated welding wires. However, there are four technical difficulties with copper-free welding wires: firstly, the contact tip wears out; secondly, conductivity; thirdly, rust resistance; fourthly, wire feeding performance. In order to solve the technical problems, the excellent coating and surface treatment mode not only can play roles in reducing the abrasion of the contact tip, improving rust resistance and lubrication, but also can play roles in improving wire feeding performance, stabilizing electric arc and reducing welding spatter.
The invention patent with application number 201410311395.7 discloses a production line and a production process of a copper-free welding wire, wherein the production process comprises paying-off, abrasive belt, drawing deformation, mechanical cleaning and a post-treatment device of the welding wire. The main disadvantages are: 1) The process adopts lubricating oil during finish drawing, and 360-degree winding and polishing are carried out on yarns after drawing, so that the lubricating oil on the surface of the welding wire cannot be completely cleaned by the method, and smoke and splashing of the welding wire can be increased. 2) The process uses yarns to coat mixed active substances after cleaning, and the uniformity of a sand line coating layer is not guaranteed in the coating process due to different states of components in a solvent, so that the stability of the welding process is affected, and the problems of sudden increase of splashing, abnormal abrasion of a contact tip and the like are caused.
Thus, excellent coating and surface treatment are key control points for copper-free processes.
Disclosure of Invention
Aiming at the defects in the prior art, the invention provides a manufacturing process of a non-copper-plated solid welding wire, which solves the four technical problems of abrasion, conductivity, rust resistance and wire feeding performance of a conductive nozzle of the non-copper-plated welding wire.
The present invention achieves the above technical object by the following means.
A process for manufacturing a non-copper plated solid wire, comprising the steps of:
(1) Wire rod pretreatment: the wire rod is sequentially subjected to paying-off, shelling, abrasive belt and rough drawing deformation to obtain a semi-finished welding wire;
(2) Wire rod drawing: carrying out finish drawing deformation on the semi-finished welding wire through a polycrystalline die and matching with lubricating powder;
(3) Post-treatment cleaning: after finish drawing, a dry wiping box is arranged, and online high-pressure cleaning is performed to wipe the surface of the welding wire and degreasing is performed by a high-pressure solution, so that impurities on the surface of the welding wire are removed;
(4) Dehydrating and drying: carrying out dehydration operation on the welding wire treated in the step (3) by utilizing high-frequency drying, and ensuring clean and dry surface;
(5) Active material coating: and (3) sequentially coating active powder and rust preventive oil on the surface of the welding wire.
Further, in the step (1), the compression ratio of the rough drawing deformation is controlled to be 35% -70%, and the drawing speed is controlled to be: 2-8m/s.
Further, in the step (2), the lubricating powder adopts calcium-based lubricating powder; the compression ratio of the finish drawing deformation is controlled as follows: 25% -75%, and the drawing speed is controlled to be 6-15m/s.
Further, in the step (3), a scouring pad is selected to be placed in the dry wiping box to replace a steel wire ball so as to prevent the surface of the welding wire from being scratched and influence the wire feeding performance.
Further, in the step (3), the high-pressure cleaning is performed by adopting a mode of 5 high-pressure water washes, wherein an alkaline degreasing agent is arranged in the second water washing tank, and the pH value of the alkaline degreasing agent is controlled to be 9-12; the cleaning solution used in other washing tanks is distilled water; the cleaning pressure is 2-7 Mpa.
Further, in the step (4), during high-frequency drying, a drying box adopts a high-frequency induction electric heating mode, and the drying temperature is 90-120 ℃; and cooling the steel wire by adopting an air cooling machine for the dried workpiece, and removing a water film remained on the surface of the steel wire after washing.
Further, in the step (5), the active powder comprises the following components in parts by weight: 10-30 parts of graphene, 10-20 parts of polytetrafluoroethylene, 20-30 parts of tungsten disulfide, 15-25 parts of boron nitride and 15-25 parts of titanium dioxide. When in use, the active powder components are uniformly mixed and dried and then coated on the surface of the welding wire. The powder coating amount is achieved by controlling the drawing speed: 10-50 g/ton.
In the step (5), the rust preventive oil is PROTEC-WLS04, and the flow rate is controlled to be 4-13ml/s when the rust preventive oil is added.
The beneficial effects of the invention are as follows:
(1) According to the invention, after drawing deformation, a dry wiping box and two high-pressure water washes are added, so that the surface cleaning of the welding wire is ensured.
(2) The post-treatment adopts a mechanical wiping mode to sequentially coat active powder and rust preventive oil on the surface of the welding wire. The rust resistance and the welding performance of the copper-plated welding wire are ensured by strictly controlling the oil quantity of the powder.
(3) The welding wire obtained by the invention has good welding manufacturability; the electric arc is stable, the splashing is small, the smoke dust is less, and the abrasion of the contact tip is less. Also has excellent rust resistance.
(4) Compared with the prior art, the invention has the advantages of little pollution to the environment, no harm to personnel and low cost.
Drawings
FIG. 1 is a schematic diagram of the process flow of the present invention.
Detailed Description
The invention will be further described with reference to the drawings and the specific embodiments, but the scope of the invention is not limited thereto.
Example 1
A method for preparing a non-copper plated solid wire, comprising the steps of:
step one, wire rod pretreatment: and (3) paying off, peeling, sanding belt, dry wiping, boron-coating and drying and rough drawing and deforming the wire rod with the diameter of phi 6.5mm to obtain the semi-finished welding wire with the diameter of phi 3.2. The compression ratio was 50.8% and the drawing speed was 6m/s.
Step two, wire rod drawing: (1) the finish draw compression ratio is 62.5%; (2) drawing speed of 8m/s
Step three, post-treatment cleaning: (1) the PH value of the alkaline degreasing agent aqueous solution is 10; (2) the cleaning pressure is 5Mpa;
step four, dehydrating and drying: (1) the high-frequency drying temperature is 105 ℃;
step five, active material coating: (1) the powder coating amount is controlled at 10 g/ton; (2) the flow rate of the rust preventive oil adding device is controlled at 5ml/min;
the coating comprises the following components: 10% of graphene, 15% of polytetrafluoroethylene, 30% of tungsten disulfide, 20% of boron nitride and 25% of titanium dioxide
Example 2
A method for preparing a non-copper plated solid wire, comprising the steps of:
step one, wire rod pretreatment: and (3) paying off, peeling, sanding belt, dry wiping, boron-coating and drying and rough drawing and deforming the wire rod with the diameter of 5.5mm to obtain the semi-finished welding wire with the diameter of 3.2. The compression ratio was 41.8% and the drawing speed was 7m/s.
Step two, wire rod drawing: (1) the finish draw compression ratio is 62.5%; (2) drawing speed of 10m/s
Step three, post-treatment cleaning: (1) the PH value of the alkaline degreasing agent aqueous solution is 11; (2) the cleaning pressure is 7Mpa;
step four, dehydrating and drying: (1) the high-frequency drying temperature is 110 ℃;
step five, active material coating: (1) the powder coating amount is controlled at 10 g/ton; (2) the flow rate of the rust preventive oil adding device is controlled at 7ml/min, and the coating comprises the following components: 20% of graphene, 20% of polytetrafluoroethylene, 20% of tungsten disulfide, 20% of boron nitride and 20% of titanium dioxide
Example 3
A method for preparing a non-copper plated solid wire, comprising the steps of:
step one, wire rod pretreatment: and (3) paying off, peeling, sanding belt, dry wiping, boron-coating and drying and rough drawing and deforming the wire rod with the diameter of 5.5mm to obtain the semi-finished welding wire with the diameter of 3.2. The compression ratio was 41.8% and the drawing speed was 7m/s.
Step two, wire rod drawing: (1) the finish draw compression ratio is 68.8%; (2) drawing speed of 10m/s
Step three, post-treatment cleaning: (1) the PH value of the alkaline degreasing agent aqueous solution is 12; (2) the cleaning pressure is 6Mpa;
step four, dehydrating and drying: (1) the high-frequency drying temperature is 112 ℃;
step five, active material coating: (1) the powder coating amount is controlled at 25 g/ton; (2) the flow rate of the rust preventive oil adding device is controlled at 11ml/min, and the coating comprises the following components: 30% of graphene, 10% of polytetrafluoroethylene, 20% of tungsten disulfide, 20% of boron nitride and 20% of titanium dioxide
Analysis of using effect results:
the evaluation basis of each parameter in table 1:
the mass loss rate of the contact tip is as follows: the specification is 45mm multiplied by 1.2mm, the material is Cr+Zr+Cu, an automatic welding trolley is adopted, and the current is 280A; the welding speed of the voltage 29V is 37cm/min; welding is continuously performed for 20min under the welding parameter that the flow rate of 80% Ar+20% CO2 shielding gas is 20L/min. Calculating the mass loss rate of the contact tip through a formula;
the number of explosive splashes was: at a current of 240; counting the number of explosive splashing times in 5min when welding at a welding speed of 7m/s and a voltage of 25.6
The rust resistance is: and placing each group of welding wires in a salt spray experiment machine. The spray was continued for 1 hour with a 3% NACl solution at 60℃and 80% humidity.
Table 1 shows the results of comparing the performance of the welding wire prepared according to the embodiment of the present invention with that of the comparative example.
The examples are preferred embodiments of the present invention, but the present invention is not limited to the above-described embodiments, and any obvious modifications, substitutions or variations that can be made by one skilled in the art without departing from the spirit of the present invention are within the scope of the present invention.
Claims (9)
1. A process for manufacturing a non-copper plated solid wire, comprising the steps of:
(1) Wire rod pretreatment: the wire rod is sequentially subjected to paying-off, shelling, abrasive belt and rough drawing deformation to obtain a semi-finished welding wire;
(2) Wire rod drawing: carrying out finish drawing deformation on the semi-finished welding wire through a polycrystalline die and matching with lubricating powder;
(3) Post-treatment cleaning: after finish drawing, a dry wiping box is arranged, and online high-pressure cleaning is performed to wipe the surface of the welding wire and degreasing is performed by a high-pressure solution, so that impurities on the surface of the welding wire are removed;
(4) Dehydrating and drying: carrying out dehydration operation on the welding wire treated in the step (3) by utilizing high-frequency drying, and ensuring clean and dry surface;
(5) Active material coating: and (3) sequentially coating active powder and rust preventive oil on the surface of the welding wire.
2. The manufacturing process according to claim 1, wherein in the step (1), the compression ratio of the rough drawing deformation is controlled to be 35% -70%, and the drawing speed is controlled to be: 2-8m/s.
3. The manufacturing process according to claim 1, wherein in the step (2), the lubricating powder is a calcium-based lubricating powder; the compression ratio of the finish drawing deformation is controlled as follows: 25% -75%, and the drawing speed is controlled to be 6-15m/s.
4. The process of claim 1, wherein in step (3), a scouring pad is placed in the dry cleaning tank.
5. The manufacturing process according to claim 1, wherein in the step (3), the high-pressure washing is performed by using 5 high-pressure water washes, wherein the second water washing tank is provided with an alkaline degreasing agent, and the pH value of the alkaline degreasing agent is controlled to be 9-12; the cleaning solution used in other washing tanks is distilled water; the cleaning pressure is 2-7 Mpa.
6. The manufacturing process according to claim 1, wherein in the step (4), during high-frequency drying, a high-frequency induction electric heating mode is adopted for the drying box, and the drying temperature is 90-120 ℃; and cooling the steel wire by adopting an air cooling machine for the dried workpiece.
7. The manufacturing process according to claim 1, wherein in step (5), the active powder comprises the following components in parts by weight: 10-30 parts of graphene, 10-20 parts of polytetrafluoroethylene, 20-30 parts of tungsten disulfide, 15-25 parts of boron nitride and 15-25 parts of titanium dioxide.
8. The manufacturing process according to claim 7, wherein, in use, the components of the active powder are uniformly mixed and dried and then applied to the surface of the welding wire, and the powder coating amount is achieved by controlling the drawing speed: 10-50 g/ton.
9. The manufacturing process according to claim 1, wherein in the step (5), the rust preventive oil is PROTEC-WLS04, and the flow rate of the rust preventive oil is controlled to be 4-13ml/s when the rust preventive oil is added.
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CN202310758571.0A CN117139923A (en) | 2023-06-26 | 2023-06-26 | Manufacturing process of non-copper-plated solid welding wire |
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CN202310758571.0A CN117139923A (en) | 2023-06-26 | 2023-06-26 | Manufacturing process of non-copper-plated solid welding wire |
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