JP2006088257A - Method of welding and repairing gear box of rolling stock - Google Patents
Method of welding and repairing gear box of rolling stock Download PDFInfo
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- 238000003466 welding Methods 0.000 title claims abstract description 47
- 238000000034 method Methods 0.000 title claims abstract description 21
- 238000005096 rolling process Methods 0.000 title abstract 4
- 229910001141 Ductile iron Inorganic materials 0.000 claims abstract description 23
- 239000000463 material Substances 0.000 claims abstract description 23
- 238000001816 cooling Methods 0.000 claims abstract description 10
- 238000010438 heat treatment Methods 0.000 claims description 21
- 230000008439 repair process Effects 0.000 claims description 13
- 238000005266 casting Methods 0.000 claims description 7
- 230000007547 defect Effects 0.000 claims description 5
- 230000000694 effects Effects 0.000 abstract description 6
- 229910001208 Crucible steel Inorganic materials 0.000 abstract description 4
- 238000005336 cracking Methods 0.000 abstract description 3
- 238000013016 damping Methods 0.000 abstract description 3
- 239000010953 base metal Substances 0.000 abstract 1
- 230000015556 catabolic process Effects 0.000 abstract 1
- 230000002950 deficient Effects 0.000 abstract 1
- 238000006731 degradation reaction Methods 0.000 abstract 1
- 239000000126 substance Substances 0.000 description 6
- 229910045601 alloy Inorganic materials 0.000 description 4
- 239000000956 alloy Substances 0.000 description 4
- 239000000203 mixture Substances 0.000 description 4
- 238000002474 experimental method Methods 0.000 description 3
- 239000007789 gas Substances 0.000 description 3
- LNSPFAOULBTYBI-UHFFFAOYSA-N [O].C#C Chemical group [O].C#C LNSPFAOULBTYBI-UHFFFAOYSA-N 0.000 description 2
- 230000008859 change Effects 0.000 description 2
- 230000009467 reduction Effects 0.000 description 2
- 230000001629 suppression Effects 0.000 description 2
- 229910001018 Cast iron Inorganic materials 0.000 description 1
- 230000008901 benefit Effects 0.000 description 1
- 238000004021 metal welding Methods 0.000 description 1
- 239000000523 sample Substances 0.000 description 1
- 238000009864 tensile test Methods 0.000 description 1
- 230000009466 transformation Effects 0.000 description 1
- 239000013585 weight reducing agent Substances 0.000 description 1
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Abstract
Description
本発明は、鉄道車両用として用いる歯車箱を球状黒鉛鋳鉄で製作する場合に、鋳造欠陥が発生した部分を溶接補修する方法に関するものである。 The present invention relates to a method for welding repair of a portion where a casting defect has occurred when a gear box used for a railway vehicle is manufactured from spheroidal graphite cast iron.
鉄道車両用歯車箱は、一般には鋳造によって製作されるが、比較的大型であるので軽量化の要求から、全体的に薄肉となされている。また、形状が複雑であることから、その断面厚みの変化が大きい。したがって、鉄道車両用歯車箱は、必要とする硬さや引っ張り強さなどの機械的性質を考慮して、従来は主に鋳鋼により製作していた。 The railway vehicle gear box is generally manufactured by casting, but is relatively thin, so that it is generally thin due to the demand for weight reduction. Moreover, since the shape is complicated, the change in the cross-sectional thickness is large. Therefore, the gear box for a railway vehicle has been conventionally manufactured mainly from cast steel in consideration of mechanical properties such as required hardness and tensile strength.
ところで、最近の鉄道車両は、高速化に伴って振動の抑制が大きな課題となっているが、この振動抑制の要求は歯車箱においても例外ではない。 By the way, in recent railway vehicles, suppression of vibration has become a major issue as the speed increases, but this requirement for suppression of vibration is no exception in the gearbox.
このような中、歯車箱の材質として、従来から使用されている鋳鋼に比べて振動減衰効果が期待できる球状黒鉛鋳鉄を用いることが検討されている。 Under such circumstances, it has been studied to use spheroidal graphite cast iron, which can be expected to have a vibration damping effect as compared with conventionally used cast steel, as the material of the gear box.
しかしながら、歯車箱は、前述のように薄肉で断面厚みの変化が大きいので、鋳造欠陥が生じやすく、溶接補修が必要となる場合がある。一方、球状黒鉛鋳鉄は一般に溶接施工が難しいので、球状黒鉛鋳鉄を用いて歯車箱を製作するには、この溶接補修の問題を解決する必要がある。 However, since the gear box is thin and has a large change in cross-sectional thickness as described above, casting defects are likely to occur, and welding repair may be required. On the other hand, since spheroidal graphite cast iron is generally difficult to weld, in order to produce a gear box using spheroidal graphite cast iron, it is necessary to solve this welding repair problem.
通常、球状黒鉛鋳鉄の溶接には、Ｎｉ系合金棒あるいは鋳鉄製の共材棒が用いられる。Ｎｉ系合金棒を用いた場合には、溶接部が母材に対して異質となる。また、一般にアーク溶接が用いられる関係で溶接時の温度が上がり過ぎて、熱影響部が硬くなりすぎることから、靱性の低下や溶接割れが発生しやすいという問題がある。 Usually, Ni-based alloy rods or cast iron co-material rods are used for welding spheroidal graphite cast iron. When a Ni-based alloy rod is used, the welded portion is different from the base material. Further, since arc welding is generally used, the temperature at the time of welding rises too much and the heat-affected zone becomes too hard, so that there is a problem that toughness is reduced and weld cracking is likely to occur.
このような溶接により硬化した部分を軟化させ硬度を均一化させるためには、溶接後に変態点以上の温度で熱処理を施すことが有効であるが、基地がフェライト化することにより母材の強度が低下するという問題がある。 In order to soften the part hardened by such welding and make the hardness uniform, it is effective to perform heat treatment at a temperature equal to or higher than the transformation point after welding. There is a problem of lowering.
一方、共材棒を用いた場合は、溶接部に母材と異質な部分が形成されることはない。しかしながら、やはり母材部に比べて溶接部およびその周辺が固くなり、母材に比べて靱性が低下する。
このように、球状黒鉛鋳鉄を溶接施工することは現実的には困難であった。
On the other hand, when the common bar is used, a portion different from the base material is not formed in the welded portion. However, the welded portion and its periphery are hardened as compared with the base material portion, and the toughness is reduced as compared with the base material.
Thus, it was practically difficult to weld spheroidal graphite cast iron.
これらのＮｉ系合金棒と共材棒を使用して溶接した場合の、溶接後における硬さを調査した結果を下記表１に示す。下記表１は下記表２に示す化学成分の母材および共材棒と、下記表３に示す化学成分のＮｉ棒を用いて実験した結果である。 The results of investigating the hardness after welding in the case of welding using these Ni-based alloy bars and common bar are shown in Table 1 below. Table 1 below shows the results of experiments using the base material and the common bar of chemical components shown in Table 2 below and the Ni rod of chemical components shown in Table 3 below.
そこで、球状黒鉛鋳鉄を、割れなどが発生することなく良好に溶接するための手段として、２５０℃程度の比較的低い予熱温度で溶接できる共金系溶接材料を用いることが開示されている。但し、この場合は、エネルギー投入密度の高いＴＩＧ溶接（アーク溶接）法によって溶接することが望ましいと記載されている。
しかしながら、この特許文献１に開示された技術は、低温で予熱し、かつ、アーク溶接を採用していることにより、硬さが不均一になるという問題があり、また、靱性が低下して本来球状黒鉛鋳鉄が有する機械的性質を満足しないことが予想される。 However, the technique disclosed in Patent Document 1 has a problem that the hardness becomes non-uniform due to preheating at a low temperature and the use of arc welding, and the toughness is reduced. It is expected that the mechanical properties of spheroidal graphite cast iron are not satisfied.
本発明が解決しようとする問題点は、従来の球状黒鉛鋳鉄の溶接補修方法では、硬さが不均一になり、また、溶接部およびその近傍の靱性が低下して本来球状黒鉛鋳鉄が有する機械的性質を満足しなくなるので、球状黒鉛鋳鉄によって鉄道車両用歯車箱を製作していなかったという点である。 The problem to be solved by the present invention is that the conventional spheroidal graphite cast iron welding repair method has non-uniform hardness, and the toughness of the welded part and its vicinity is reduced, so that the machine inherently possessed by spheroidal graphite cast iron In this case, the railway vehicle gearbox was not made of spheroidal graphite cast iron.
本発明の鉄道車両用歯車箱の溶接補修方法は、
溶接による割れが生じず、溶接部の硬さの均一化が図れ、かつ、母材の強度低下が生じることがないようにするため、
球状黒鉛鋳鉄からなる鉄道車両用歯車箱を溶接補修する方法であって、
前記歯車箱の鋳造欠陥部分を共材系の溶接棒を用いてガス溶接した後、
８９０℃以上の温度に加熱して一定時間保持した後、７５０℃〜８２０℃まで炉冷して当該温度で１時間以上保持し、
その後、空冷することを最も主要な特徴としている。
The method for welding repair of a railway vehicle gear box according to the present invention,
In order to prevent cracks due to welding, to make the hardness of the welded portion uniform, and to prevent the strength of the base material from being reduced,
A method for welding and repairing a railway vehicle gearbox made of spheroidal graphite cast iron,
After gas welding the casting defect portion of the gear box using a joint material welding rod,
After heating to a temperature of 890 ° C. or higher and holding for a certain time, the furnace is cooled to 750 ° C. to 820 ° C. and held at that temperature for 1 hour or longer,
After that, air cooling is the main feature.
前記本発明の鉄道車両用歯車箱の溶接補修方法において、球状黒鉛鋳鉄からなる鉄道車両用歯車箱の補修箇所の溶接を、Ｎｉ系合金棒を使用せずに共材系の溶接棒を使用するのは、Ｎｉ系溶接棒を使用する場合には、前述のように一般にアーク溶接が用いられる関係で溶接時の温度が高くなり過ぎて、溶接部およびその周辺が硬くなりすぎ、また、溶接部に母材と異質な部分が形成されるからである。 In the welding repair method for a railway vehicle gear box according to the present invention, welding of a repaired portion of a railway vehicle gear box made of spheroidal graphite cast iron is used without using a Ni-based alloy rod. When using a Ni-based welding rod, arc welding is generally used as described above, so the temperature during welding becomes too high, the welded part and its surroundings become too hard, and the welded part This is because a portion different from the base material is formed.
また、前記本発明の鉄道車両用歯車箱の溶接補修方法において、２段階の熱処理を行うのは、従来の１段階の熱処理だけでは、溶接部の均一化と母材の強度低下抑制を両立することができない、すなわち、溶接部の均一化は図れるものの、炉冷の場合には母材の強度低下は避けられず、一方、空冷の場合には溶接部およびその周辺が硬くなりすぎるからである。 Further, in the welding repair method for a railway vehicle gearbox according to the present invention, the two-stage heat treatment performs both the uniformization of the welded portion and the strength reduction of the base material only by the conventional one-stage heat treatment. This is because the welded portion can be made uniform, but in the case of furnace cooling, the strength of the base material is inevitably reduced, while in the case of air cooling, the welded portion and its surroundings become too hard. .
そして、２段階の熱処理のうち第１の熱処理を８９０℃以上の温度で行うのは、熱処理温度が８９０℃未満の場合には、チル組織を分解することができず、溶接部およびその周辺の硬さを均一にすることができないからである。なお、この第１の熱処理温度の上限は、母材がフェライト化して母材の強度が低下しない温度であることは言うまでもない。 The first heat treatment of the two stages of heat treatment is performed at a temperature of 890 ° C. or higher because the chill structure cannot be decomposed when the heat treatment temperature is lower than 890 ° C. This is because the hardness cannot be made uniform. Needless to say, the upper limit of the first heat treatment temperature is a temperature at which the base material becomes ferritic and the strength of the base material does not decrease.
また、第２の熱処理を７５０℃〜８２０℃の温度で行うのは、７５０℃未満では母材の強度低下を抑制できず、また、８２０℃を超えると溶接部およびその周辺が硬くなりすぎるからである。 Moreover, the reason why the second heat treatment is performed at a temperature of 750 ° C. to 820 ° C. is that if the temperature is lower than 750 ° C., the strength reduction of the base material cannot be suppressed, and if it exceeds 820 ° C., the welded part and its surroundings become too hard. It is.
また、第２の熱処理における保持時間を１時間以上とするのは、発明者らの実験によれば、１時間未満であれば、第２の熱処理を実施する効果が得られないからである。
また、第２の熱処理後に空冷するのは、炉冷した場合には、母材の強度が向上しないからである。
The reason why the holding time in the second heat treatment is set to 1 hour or longer is that, according to the experiments by the inventors, if the time is less than 1 hour, the effect of performing the second heat treatment cannot be obtained.
The reason for air cooling after the second heat treatment is that the strength of the base material is not improved when the furnace is cooled.
本発明によれば、球状黒鉛鋳鉄の溶接を、溶接部の硬さの均一化を図りつつ、母材の強度低下を生じさせることなく行えるので、鉄道車両用として用いる歯車箱を、鋳鋼に比べて振動減衰効果が期待できる球状黒鉛鋳鉄で製作することができるようになるという利点を有する。 According to the present invention, spheroidal graphite cast iron can be welded without causing a decrease in the strength of the base material while making the hardness of the welded portion uniform, so that the gear box used for railway vehicles can be compared with cast steel. Thus, it has an advantage that it can be made of spheroidal graphite cast iron which can be expected to have a vibration damping effect.
以下、本発明の鉄道車両用歯車箱の溶接補修方法の最良の実施形態について説明する。
本発明の鉄道車両用歯車箱の溶接補修方法は、たとえば前記の表２に示した化学組成の母材を鋳造して製作した球状黒鉛鋳鉄製の鉄道車両用歯車箱の鋳造欠陥が生じた補修箇所を、同じく表２に示した化学組成の共材系の溶接棒を用いてたとえば酸素アセチレンガスでガス溶接するのである。
BEST MODE FOR CARRYING OUT THE INVENTION The best embodiment of the welding repair method for a railway vehicle gearbox according to the present invention will be described below.
The railway vehicle gearbox welding repair method according to the present invention is, for example, a repair in which a casting defect is produced in a spheroidal graphite cast iron gearbox produced by casting a base material having the chemical composition shown in Table 2 above. The part is gas-welded with, for example, oxygen acetylene gas using a welding rod having the same chemical composition as shown in Table 2.
そして、その後、前記補修箇所をガス溶接した歯車箱を、図１に示したように、たとえば９００℃の温度まで加熱して２時間保持した後炉冷し、７５０℃〜８２０℃の温度となったところで、その温度で１時間保持した後、空冷するのである。 Then, as shown in FIG. 1, the gear box in which the repaired portion is gas-welded is heated to a temperature of, for example, 900 ° C. and held for 2 hours, and then cooled in a furnace, resulting in a temperature of 750 ° C. to 820 ° C. By the way, after holding at that temperature for 1 hour, it is air-cooled.
このような本発明の鉄道車両用歯車箱の溶接補修方法の効果を確認するために、前記表２に示した化学成分の球状黒鉛鋳鉄で、図２に示したような寸法の素材（高さ３０ｍｍ×幅４０ｍｍ×長さ１７０ｍｍ）の一側面中央に内径がφ１０ｍｍで深さが６ｍｍの穴を開けた試験片を製作した。 In order to confirm the effect of the welding repair method for a railway vehicle gear box according to the present invention, the material (height) of spheroidal graphite cast iron having the chemical composition shown in Table 2 has the dimensions shown in FIG. A test piece having an inner diameter of φ10 mm and a depth of 6 mm in the center of one side surface (30 mm × width 40 mm × length 170 mm) was produced.
そして、この試験片を７００℃で予熱した後、この試験片の前記穴に前記表２に示した化学成分の共材系の溶接棒（外径がφ５ｍｍ）を使用して酸素アセチレンガス溶接で肉盛を行った。その後、９００℃の温度で２時間保持した後炉冷し、第２の熱処理温度を種々変化させて１時間保持した後に空冷した場合の機械的性質を調査した。 Then, after preheating the test piece at 700 ° C., by using a joint rod of the chemical composition shown in Table 2 (outer diameter: 5 mm) in the hole of the test piece, oxygen acetylene gas welding is performed. Overlaying was performed. Then, after holding at a temperature of 900 ° C. for 2 hours, the furnace was cooled, and the mechanical properties when the second heat treatment temperature was changed variously and held for 1 hour and then cooled by air were investigated.
その結果を下記表４に示す。下記表４には球状黒鉛鋳鉄の２種（ＦＣＤ４５０）の機械的性質と、比較として、熱処理前の場合（Ｎｏ．１）と、第１の熱処理のみを行った場合（Ｎｏ．２，３）の機械的性質も合わせて示した。なお、表４の結果を得た供試材はＹ型試験片より採取した。また、引張り試験はＪＩＳ４号試験片を使用して行った。 The results are shown in Table 4 below. Table 4 below shows the mechanical properties of two types of spheroidal graphite cast iron (FCD450) and, as a comparison, the case before heat treatment (No. 1) and the case where only the first heat treatment was performed (No. 2, 3). The mechanical properties of are also shown. In addition, the sample material which obtained the result of Table 4 was extract | collected from the Y-type test piece. Moreover, the tensile test was done using the JIS4 test piece.
表４より明らかなように、従来の１段階の熱処理を実施した場合のうち、冷却を炉冷とした場合（Ｎｏ．２）は、硬さおよび引張強度が熱処理前（Ｎｏ．１）より低下し、球状黒鉛鋳鉄の代表的なＦＣＤ４５０の規格を満足しなかった。 As is clear from Table 4, when the conventional one-stage heat treatment was performed, when the cooling was furnace cooling (No. 2), the hardness and tensile strength were lower than before the heat treatment (No. 1). However, the standard FCD450 standard for spheroidal graphite cast iron was not satisfied.
また、従来の１段階の熱処理を実施した場合のうち、冷却を空冷とした場合（Ｎｏ．３）は、硬さが上昇しすぎて前記規格の上限を満足しなかった。
これらに対して２段階の熱処理を実施した場合（Ｎｏ．４〜Ｎｏ．８）では、第２の熱処理を８５０℃で行った場合（Ｎｏ．４）は硬さが前記規格の上限を満足しなかったが、７５０℃〜８２０℃で行った場合（Ｎｏ．５〜Ｎｏ．８）には、前記規格の全ての項目を満足した。
Further, among the cases where the conventional one-step heat treatment was performed, when the cooling was air cooling (No. 3), the hardness increased so much that the upper limit of the standard was not satisfied.
When two-stage heat treatment is performed on these (No. 4 to No. 8), when the second heat treatment is performed at 850 ° C. (No. 4), the hardness satisfies the upper limit of the standard. However, when it was performed at 750 ° C. to 820 ° C. (No. 5 to No. 8), all the items of the standard were satisfied.
以上より、本発明の鉄道車両用歯車箱の溶接補修方法によれば、溶接による割れが生じず、溶接部の硬さの均一化が図れ、かつ、母材の強度低下を生じさせることなく、球状黒鉛鋳鉄の溶接が行えることが確認できた。 As described above, according to the welding repair method for a railway vehicle gear box of the present invention, cracks due to welding do not occur, the hardness of the welded portion can be made uniform, and the strength of the base material is not reduced. It was confirmed that spheroidal graphite cast iron could be welded.
本発明は上記の例に限らず、請求項に記載された技術的思想の範疇であれば、適宜実施の形態を変更しても良いことは言うまでもない。 The present invention is not limited to the above example, and it goes without saying that the embodiments may be changed as appropriate within the scope of the technical idea described in the claims.
Claims (1)
前記歯車箱の鋳造欠陥部分を共材系の溶接棒を用いてガス溶接した後、
８９０℃以上の温度に加熱して一定時間保持した後、７５０℃〜８２０℃まで炉冷して当該温度で１時間以上保持し、
その後、空冷することを特徴とする鉄道車両用歯車箱の溶接補修方法。
A method for welding and repairing a railway vehicle gearbox made of spheroidal graphite cast iron,
After gas welding the casting defect portion of the gear box using a joint material welding rod,
After heating to a temperature of 890 ° C. or higher and holding for a certain time, the furnace is cooled to 750 ° C. to 820 ° C. and held at that temperature for 1 hour or longer,
Thereafter, the method for welding repair of a gear box for a railway vehicle is characterized by air cooling.
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Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102366859A (en) * | 2011-08-08 | 2012-03-07 | 北京天恒成工业技术有限公司 | Repair welding regeneration technology for manipulator of multifunctional furnace |
| CN108555468A (en) * | 2018-04-25 | 2018-09-21 | 安徽马钢设备检修有限公司 | A kind of online welding and restoring process of large size spur gear |
| CN109158789A (en) * | 2018-11-06 | 2019-01-08 | 本钢板材股份有限公司 | The renovation technique of questions of drive gear tooth |
| RU2686407C1 (en) * | 2017-11-24 | 2019-04-25 | Публичное акционерное общество "Транснефть" (ПАО "Транснефть") | Reservoir wall repair method |
| CN114888405A (en) * | 2022-03-31 | 2022-08-12 | 阳江核电有限公司 | Method for eliminating defects of large heat-resistant steel special-shaped welded joint of nuclear power station on line |
-
2004
- 2004-09-22 JP JP2004275274A patent/JP4416614B2/en not_active Expired - Fee Related
Cited By (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102366859A (en) * | 2011-08-08 | 2012-03-07 | 北京天恒成工业技术有限公司 | Repair welding regeneration technology for manipulator of multifunctional furnace |
| RU2686407C1 (en) * | 2017-11-24 | 2019-04-25 | Публичное акционерное общество "Транснефть" (ПАО "Транснефть") | Reservoir wall repair method |
| CN108555468A (en) * | 2018-04-25 | 2018-09-21 | 安徽马钢设备检修有限公司 | A kind of online welding and restoring process of large size spur gear |
| CN109158789A (en) * | 2018-11-06 | 2019-01-08 | 本钢板材股份有限公司 | The renovation technique of questions of drive gear tooth |
| CN114888405A (en) * | 2022-03-31 | 2022-08-12 | 阳江核电有限公司 | Method for eliminating defects of large heat-resistant steel special-shaped welded joint of nuclear power station on line |
| CN114888405B (en) * | 2022-03-31 | 2023-12-05 | 阳江核电有限公司 | Method for online eliminating defects of special-shaped welding joint of large heat-resistant steel in nuclear power station |
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|---|---|
| JP4416614B2 (en) | 2010-02-17 |
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