JP2001259887A - Flux granulating material for flux cored wire and method for manufacturing the same as well as flux cored wire - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a flux granulating material for a flux cored wire having an excellent flow property and a flux cored wire uniformly packed with the flux. SOLUTION: The flux granulating material for the flux cored wire characterized in that the flux granulating material is packed into the wire and that the angle of repose thereof is <=40 deg.C and the flux cored wire formed by using such granulating material.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a novel flux granulated material for flux-cored wire and a method for producing the same. Further, the present invention relates to a novel flux-cored wire.

[0002]

2. Description of the Related Art A flux-cored wire is a wire in which a shell metal is filled with a flux, and is mainly used for welding or brazing.

[0003] Generally, a flux-cored wire is supplied with flux into a concave portion formed by bending a strip-shaped metal plate into a cylindrical shape, and is formed into a tubular shape by winding the flux inside while bending the same, and further expanding the wire. It is manufactured by wire processing. Alternatively, it can be manufactured by filling a tubular body produced in advance with vibrating flux. In these cases, the supply of the flux is performed via a hopper, a belt conveyor, a vibration feeder, or the like.

[0004] However, due to the poor flowability of the flux, the amount of supplied flux is not constant,
An excess or deficiency occurs in the flux filling rate in the produced flux-cored wire. In some cases, the flux particles may cause bridging in the hopper, resulting in a flux filling defect without any flux being supplied.
As described above, the conventional flux-cored wire has a large variation in the flux filling rate, and in particular, insufficient flux or a defect is a major cause of poor welding or poor brazing of the joint metal. On the other hand, if the filling amount of the flux is too large, the wire is broken in the drawing step by the drawing die after filling, resulting in a decrease in yield and, consequently, a reduction in manufacturing efficiency.

[0005] In this regard, a non-destructive inspection method of a flux-cored wire has been proposed in order to detect excess or deficiency of flux filling. However, even if an excess or deficiency location can be found, the location must be eventually removed, and the problem of yield has not been solved.

[0006]

As described above, a flux that provides a flux-cored wire having good flowability and excellent filling properties has not yet been developed.

Accordingly, an object of the present invention is to provide a flux granulated material for a flux-cored wire which is particularly excellent in fluidity. Another object of the present invention is to provide a flux-cored wire in which the flux is uniformly filled.

[0008]

Means for Solving the Problems As a result of intensive studies, the present inventor has found that a specific flux granulated material exhibits an excellent effect for a flux-cored wire,
Finally, the present invention has been completed.

That is, the present invention relates to the following flux granules for a flux-cored wire and a method for producing the same. 1. A flux-granulated material for a flux-cored wire, wherein the flux-granulated material to be filled in a wire has an angle of repose of 40 degrees or less. 2. Flux granulation for a flux-cored wire, characterized by granulating a mixture obtained by adding and mixing 7.5 to 40 parts by weight of water and 0 to 2.2 parts by weight of an organic binder with respect to 100 parts by weight of a flux. How to make the body. 3. A flux-filled wire, wherein the flux is filled with a granulated flux, and the variation of the flux filling rate is 1 or less in standard deviation.

[0010]

BEST MODE FOR CARRYING OUT THE INVENTION Flux granulated body for flux-cored wire The flux granulated body for flux-cored wire of the present invention is a flux granulated body filled in a wire, and is characterized in that the angle of repose is 40 degrees or less.

The type (material) of the flux is particularly restricted.
It is not limited, and any known flux can be applied.
Can be For example, joining iron, stainless steel, etc.
For arc welding, silver, copper, aluminum
Fluxes for brazing to join
It is. Particularly, in the present invention, potassium aluminum fluora
Id flux (KAlF_Four, K_TwoAlF_Five, K_ThreeAlF
₆Etc.), cesium aluminum fluoride-based flux
(CsAlF_Four, Cs_TwoAlF_Five, Cs_ThreeAlF ₆And so on
Can be suitably used. These fluxes are one kind
Alternatively, two or more kinds can be used.

The flux granules of the present invention have an angle of repose of 40 degrees or less, preferably 35 degrees or less. Angle of repose is 4
When it exceeds 0 degrees, the fluidity when filling the wire is reduced, and a desired flux-cored wire may not be obtained.

In the flux granules of the present invention, the granules having a particle size of usually 45 to 500 μm account for at least 80% by weight, preferably 90% by weight of the whole. By using granules having such a particle size, more excellent fluidity can be obtained. The particle size may be used as it is, for example, when the prepared granulated product already satisfies the particle size, or may be adjusted by a known classification method as needed. If the prepared granules do not satisfy the particle size, for example, particles smaller than 45 μm and / or 5
Particles larger than 00 μm may be cut with a screen or the like to adjust the particle size.

The bulk specific gravity of the flux granules of the present invention is preferably 1 g / cm ³ or more. The upper limit of the bulk density is not limited, but is usually about 2.5 g / cm ³ . By setting the bulk specific gravity to 1 g / cm ³ or more, more excellent fluidity can be obtained.

The shape of the granules of the present invention is not particularly limited as long as a predetermined angle of repose is obtained, and may be spherical, flat, irregular,
Any shape such as a polygonal shape may be used, but a spherical shape or a shape close thereto is particularly desirable.

The granules of the present invention can be prepared, for example, using a flux 100
It can be manufactured by granulating a mixture obtained by adding and mixing 7.5 to 40 parts by weight of water and 0 to 2.2 parts by weight of an organic binder with respect to parts by weight.

As the flux, various fluxes as mentioned above can be used. In particular, potassium aluminum fluoride-based flux, cesium aluminum fluoride-based flux, and the like can be preferably used.

As the organic binder, those used in known granulation techniques can be used. For example, alcohols such as methanol, ethanol and propanol,
Water-soluble polymers such as polyvinyl alcohol (PVA), celluloses such as methylcellulose, paraffin, acrylic acid and the like can be used. The organic binder is a component that can be added as needed.
Among the organic binders, polyvinyl alcohol is preferred.

In addition, other known additives (for example, a surfactant, a thickener, a flocculant, a pH adjuster, etc.) can be appropriately compounded within a range not to impair the effects of the present invention. .

In the production method of the present invention, the order of mixing these components is not particularly limited. For example, these components may be mixed simultaneously, or a mixture of water and an organic binder may be blended in the flux.

Next, the mixture is granulated. The granulation method itself may be in accordance with a known granulation method. Therefore, granulation may be performed using a known device such as a mixer, a blender, a tumbling granulator, an extrusion granulator, and a compression molding machine. In the present invention, granulation can also be performed using a spray dryer.
When granulating using a spray dryer, drying can be performed together with granulation.

After granulation, if necessary, operations such as drying, heat treatment, and classification may be appropriately performed according to known methods. For example, after the granules are first dried at a temperature of 200 ° C. or less, heat treatment is performed at 400 ° C. or less as needed, and the obtained granules are classified with a sieve or the like and adjusted to a predetermined particle size. good. Drying or heat treatment is a batch dryer,
It can be carried out by a known apparatus such as a firing furnace, a tunnel-type firing furnace, a rotary dryer, and a rotary-type firing furnace. 2. Flux-cored wire The flux-cored wire of the present invention is a wire filled with a flux granulated material, wherein the variation of the flux filling rate is 1 or less in standard deviation.

The flux granulation is not particularly limited as long as the standard deviation can be secured. In the present invention, it is particularly preferable to use the flux granules of the present invention.

The type and type of wire (size,
The cross-sectional structure) is not limited. As the material of the wire, for example, aluminum or aluminum alloy (A
l-Si, Al-Si-Zn, Al-Zn, etc.), iron, stainless steel, copper, zinc, tin, titanium, lead,
Gold, silver, or an alloy thereof can be used.

The method for producing the wire of the present invention is not particularly limited as long as the fluctuation of the flux filling rate is 1 or less in standard deviation. Preferably, the flux granules of the present invention are used as the flux. That is, besides using the flux granules of the present invention, a normal flux-cored wire manufacturing method can also be applied. In other words, according to the granules of the present invention, even if a known wire manufacturing method is applied, a wire having a standard deviation of 1 or less in the variation of the flux filling rate can be manufactured.

For example, a belt-shaped aluminum or aluminum alloy plate is bent into a U-shape, and after the flux granules of the present invention are supplied to the curved portion, the flux granules are formed into a tube so as to be wound therein. The wire of the present invention can be obtained by further drawing. Further, for example, it can also be manufactured by preparing a pipe in which a strip-shaped aluminum or aluminum alloy plate is formed into a tube in advance, and filling a flux granule through an opening at one end of the pipe.

The flux-cored wire of the present invention can be used in the same manner as a known flux-cored wire. For example, the wire may be brought into contact with the joining portion, and the portion may be heated and melted by a known heating method such as torch heating or furnace heating, and then solidified. The heating temperature, heating atmosphere, and the like may be appropriately set according to the type of the flux to be used, the type and size of the material to be joined, and the like.

The materials (materials to be joined) to which the wax of the present invention can be applied are not particularly limited, and aluminum-based materials, iron-based materials (including stainless steel, etc.), copper-based materials, zinc-based materials, tin-based materials, Examples include a titanium-based material, a lead-based material, a gold-based material, and a silver-based material. These include alloys of the respective metals. Further, the materials to be joined may be the same material or different materials.

In addition, the wire of the present invention can be formed into a form according to a construction site as required when used. For example, in joining a tubular member, by processing the wire into a ring shape in advance, the wire can be easily applied to the tubular member, and workability and workability can be improved. In the case of a ring shape, the ends of the wires may or may not be joined.

[0030]

The flux granules of the present invention have excellent fluidity and are therefore uniformly filled in a wire.
As a result, it is possible to easily and reliably provide a flux-cored wire free from uneven filling. In particular, it is also possible to provide a flux-cored wire in which the variation of the flux filling rate is 1 or less in standard deviation.

Further, the granulated product of the present invention can be smoothly supplied to the wire main body, and can contribute to the productivity of flux-cored wire, cost reduction, and the like.

The flux-cored wire of the present invention can be used for various brazing or welding applications.
For example, it can be suitably used in fields such as automobiles, shipbuilding, and construction / construction that require joining of various mechanical parts and structural parts, such as assembling of radiators, air conditioners, radiators, heat exchangers, and the like.

[0033]

EXAMPLES Examples and comparative examples are shown below to further clarify the features of the present invention. However, the present invention is not limited to these examples. In addition, the measuring method of each physical property value was performed by the following method. (1) Bulk density of flux granules Measured according to JIS-K0061 “Method for measuring specific gravity of chemical products”. (2) Angle of repose of flux granules The apparatus “ABD powder property measuring device” (manufactured by Tsutsui Rikagaku Kikai) shown in FIG. 1 was used. Specifically, after the flux granules were put into a hopper, the hopper was vibrated with a vibrating rod, and the granules were shaken from a funnel through a 500 μm sieve onto a disk-shaped sample table (diameter 60 mm), Make a pile of granules until the entire table is covered. Then, as shown in FIG. 2, a rod of an angle measuring device is applied from the edge of the sample table to the apex of the peak of the granulated body, and an angle formed between the sample table and the rod is examined. The same test is performed three times for one granule,
The arithmetic mean of three angles was defined as the angle of repose. (3) Particle Size of Flux Granulated Material Measured according to JIS-K0069-66 “Testing method for sieve residue of chemical products”. (4) Standard deviation indicating variation in the filling rate of the flux-cored wire Cut the prepared flux-cored wire by about 20 m. The cut wire is cut by 20 cm, and a total of 100 samples are taken. The weight (a) of each sample is measured. Next, the weight (b) after removing the flux in each sample is measured. The filling factor is determined for each sample by the following equation (1). An average value of 100 filling rates is determined.

Filling rate (%) = {(ab) / a} × 100 (1) Next, a standard deviation is calculated by the following equation (2).

Standard deviation = (Σ (Xi−X) ² ) / (n−1)) ^1/2 (2) (where Xi is a filling rate of an arbitrary sample, X is an average value of the filling rate, n Indicates the number of samples (that is, n = 100). Production Example 1 As a flux, a potassium aluminum fluoride-based flux for brazing aluminum (bulk specific gravity: 0.1).
6 g / cm ³ , angle of repose 55 degrees) and cesium aluminum fluoride based flux (bulk specific gravity 1.3 g / cm)
³ , angle of repose of 50 degrees).

Each flux was mixed with water and polyvinyl alcohol at the ratios (parts by weight) shown in Table 1 and uniformly mixed by a mixer. After sufficiently drying the mixture at 110 ° C., it was heat-treated at 400 ° C. to obtain a granulated body. The granules were classified with a 500 μm sieve and a 45 μm sieve, and the granules No. having a particle size of about 45 to 500 μm. 1-1 to 1-8 were obtained. The yield (% by weight), the bulk specific gravity, and the angle of repose of each granule were measured for a particle size of 45 to 500 μm. Table 1 also shows the results.

[0037]

[Table 1]

Production Example 2 As the flux, the same potassium aluminum fluoride-based flux and cesium aluminum fluoride-based flux as in Production Example 1 were used.

Each of the fluxes was mixed with water in the proportions (parts by weight) shown in Table 1 and uniformly mixed by a mixer. This mixture was granulated and dried by a spray dryer. That is,
The mixture is dropped into hot air at 200 ° C., sprayed in a mist,
By evaporating the water, the granular material No. 1-9-1
-10 was obtained. The yield (% by weight), the bulk specific gravity and the angle of repose of the particles having a particle size of 45 to 500 μm were measured. Table 1 also shows the results.

Example 1 A flux-cored wire was produced using the granules produced in each production example.

The apparatus shown in FIG. 3 was used as a manufacturing apparatus. In the apparatus shown in FIG. 3, an aluminum alloy strip is wound around a reel, and the aluminum alloy (material for the wire body) that has passed through the cleaning device is bent into a U shape by a U-shaped forming roll. Next, a flux is supplied to the curved portion from a flux supply device. The flux supply device includes a hopper, a scraper, and a belt conveyor. After the flux is filled on the aluminum alloy, it is processed into a wire in a wire drawing process to form a wire.
While continuously bending the strip of the aluminum alloy, which is the material for the wire body, into a U-shape, the granulated material was continuously supplied into the belt by a belt conveyor. In this case, FIG.
As shown in the above, a flux hopper and a height-adjustable scraper were attached to the back of the belt conveyor so that the flux was supplied to the belt conveyor at a constant rate. The speed of the belt conveyor and the feeding speed of the aluminum alloy strip are constant, and the filling rate is 20%, 25%, 31% and 36%.
The height of the stripped plate was adjusted so that

The average value (average filling rate) and the standard deviation of the filling rate of the obtained wire were determined. Table 2 shows the results. Table 2 shows the potassium aluminum fluoride-based flux (KAlF-based, No. 2-12) before granulation.
The average filling rate and the standard deviation of the flux-cored wire produced in the same manner as above using cesium aluminum fluoride-based flux (CsAlF-based, No. 2-13) are also shown. In addition, No. In 2-12, a portion (filling defect) where the flux filling rate was 0% was also observed.

[0043]

[Table 2]

From the results in Table 2, it can be seen that the wire manufactured by using the granules of the present invention has a standard deviation of 1 or less, particularly 0.9 or less. An improvement in yield can also be expected.

[Brief description of the drawings]

FIG. 1 is a schematic diagram of a repose angle measuring device.

FIG. 2 is a diagram showing a method of measuring a repose angle on a sample stage of a repose angle measuring device.

FIG. 3 is a diagram showing an outline of an apparatus for manufacturing a flux-cored wire.

Claims (9)

[Claims] 1. A flux granulated material for a flux-cored wire, wherein the flux granulated material is filled in a wire and has an angle of repose of 40 degrees or less. 2. The flux granulated product according to claim 1, wherein the granulated product having a particle size of 45 to 500 μm accounts for 80% by weight or more of the whole. 3. The flux granule according to claim 1, wherein the bulk specific gravity is 1 g / cm ³ or more. 4. The flux according to claim 1, wherein the flux is at least one of a potassium aluminum fluoride-based flux and a cesium aluminum fluoride-based flux.
The flux granulated product according to any one of the above. 5. A method according to claim 1, wherein said water is 7.5 parts by weight based on 100 parts by weight of said flux.
Granulating a mixture obtained by adding and mixing 0 to 40 parts by weight and 0 to 2.2 parts by weight of an organic binder,
A method for producing a flux granulated body for a flux-cored wire. 6. A flux-filled wire filled with a flux granule, wherein the flux filling rate has a standard deviation of 1 or less in variation. 7. The flux-cored wire according to claim 6, wherein the flux granulate is the granulate according to any one of claims 1 to 4. 8. The flux-cored wire according to claim 6, which is used for welding or brazing. 9. The flux-cored wire according to claim 6, which has a ring shape.