JP2016215235A - Sputter adhesion preventive - Google Patents

Abstract

PROBLEM TO BE SOLVED: To maintain response to sputter grains with no need to peel a coating film off a welding target metal member even under a welding condition of high heat input because a conventional sputter adhesion preventive has no ability to maintain a performance necessary for preventing the deposition of sputter grains and for softly depositing them on a coating film under a condition that welding is repeated at high heat input is repeated, and to secure mutually contradicted performances of maintenance and ease of peeling because a coating film is requested of easily being peeled off.SOLUTION: A sputter adhesion preventive of this invention is configured by mixture agitation with a mixture liquid added to a mixture powder prepared by mixing a substrate powder consisting of a calcium carbonate powder with an additive consisting of a mixture powder of a metal or a molding target metal with the same kind of metal oxide or with the same kind of metal oxide as the same kind of metal powder.SELECTED DRAWING: Figure 3

Description

The present invention relates to a spatter adhesion preventive agent for the purpose of preventing and softening particulate spatter generated and scattered during welding work of metal structures and the like on the surface of a metal material to be welded.

Welding is an indispensable technique for joining metal structures, particularly large metal structures, etc., but spattering of particulate molten metal particles (hereinafter referred to as spatter) occurs during welding operations such as arc welding. It is scattered around the weld line of the metal member to be welded and welded onto the surface of the metal member to be welded. These spatters fall on the surface of the metal member to be welded in the state of being cooled and solidified by the surrounding air in the course of being scattered as molten or incandescent sparks that scatter in the atmosphere, without being sufficiently cooled Those that fall on the surface of the metal member to be welded in an unsolidified state (a state of being melted or a semi-molten state) are mixed.
It is known that removal methods other than scraping off with a chisel are difficult to remove spatter particles when spatter particles with a size of approximately 1.2 mm or more generated by welding of metal structures are deposited. However, the welding force of the sputtered particles on the surface of the metal member to be welded depends on the depth of penetration into the metal member to be welded and the welding area. When the penetration depth is deep, when the spatter particles are completely removed by welding, a flat chisel is used to cut off and further beautify the appearance. Although there is a difference depending on the choice of tool and how to apply force, if the penetration depth is shallow or if the welding area is small even if the penetration is deep, removal is possible by hitting the bottom of the grain with a dedicated hand tool Some are in state.

  The sputtered particles that have fallen on the surface of the metal member to be welded in a molten state without being sufficiently cooled have a sufficient amount of heat to melt and weld the surface of the metal member to be welded. Is in a state close to room temperature except in the vicinity of the part melted by welding. When the high-heat-rate sputtered particles scattered and fallen reach the surface of the metal member to be welded, the contact portions are instantly melted and welded to the surface of the metal member to be welded. Then, the sputtered particles that have been deprived of heat and cooled by the metal member to be welded are left as welded particles on the surface of the metal member to be welded.

  Sputtered particles that fall near the weld line and are welded and solidified on the surface of the metal member to be welded will cause poor smoothness of the coated surface when the product is coated, and the finished appearance will be deteriorated in the case of plating. It becomes defective. Deterioration of surface properties caused by these welded sputtered grains often becomes a defect that needs to be corrected.

  There are various states in which the sputtered particles are welded, and a welding state similar to complete welding and an incomplete soft welding state are mixed. To remove sputtered grains that have been completely welded and solidified and have a large welded area, for example, the blade edge of a flat chisel is placed on the bottom of each welded and solidified sputtered grain, and the flat chisel is struck with a hammer to remove it. Work is required. (Fig. 4) After removing the adhered sputtered particles, removal marks remain on the surface of the metal member to be welded, and the appearance of the metal structure after welding is often impaired, and the removal marks are larger above the surface. If it appears or if the appearance is poor, a repair work is required to smooth it.

  In normal operation, spatter particles having a small welding area in a completely welded state can be removed with a light force by using a manual tool even if they are soft welding sputter particles or complete welding. The current method of removing sputtered particles deposited in a completely welded state is to use a keel rod with a flat blade and a long (60 to 80 cm) handle of a special tool and a thickened cutting edge with a width of about 6 cm. Is removed from the technique of striking strongly.

  The removal and cleaning of the sputtered particles deposited on the welded metal member performed after the end of such welding work is often difficult to mechanize because the shape of the assembled metal structure is often large and complex. I have to rely on manual work. The removal and cleaning of sputtered particles is a process that requires a great deal of labor in the welding operation, and it takes a lot of time to do so.

  In order to solve this problem, the object is to prevent spatter particles from welding to the surface of the metal member to be welded by applying a coating material to the peripheral portion adjacent to the welded portion of the metal member to be welded prior to the welding operation. Various spatter adhesion preventing agents have been proposed.

  For example, the spatter adhesion preventing agent described in Patent Documents 1 and 2 is of a lacquer type, and is applied to the surface around the welded portion of the metal member to be welded in advance by a spray or the like before the welding operation and dried. It acts as a barrier against the sputtered particles that form and fly to prevent the sputtered particles from welding to the welded metal member. Many spatter adhesion preventing agents currently used have been proposed as a lacquer type.

  Lacquer-type spatter adhesion preventive agents are prone to thermal degradation (for example, thermal evaporation) under high-temperature welding heat environment. difficult. With a coating film formed by a single coating, it is difficult to maintain the effect of preventing spatter adhesion until a plurality of welding processes with a large current are completed. Therefore, a considerable amount of sputtered particles falling on the surface around the welded portion of the welded metal member are welded to the welded metal member, and the welded metal member as welded sputtered particles that cannot be easily removed at the end of the welding process. There is a drawback that it remains on the surface.

  Conventional lacquer-type spatter adhesion preventives (Patent Documents 1 and 2) are liquids, and are formed into a film on the surface of the peripheral part adjacent to the weld line of the metal member to be welded using a sprayer or a brush prior to the welding operation. A spatter adhesion preventing film is formed by applying and drying. The liquid lacquer type spatter adhesion preventing agent is advantageous in that it is easy to apply, but it is very difficult to apply a thick coating because of its high fluidity. Depending on the welding mode (welding posture such as whether the welding surface is upward or inclined), it is difficult to form a coating film having a desired thickness because the fluidity of the coating material is high.

  In addition, this type of lacquer-type spatter adhesion preventive agent has the effect of preventing spatter welding in welding with a small amount of heat input, but it is applied in multi-layer welding operations in which the same part is repeatedly welded several times. The thermal deterioration (mainly evaporation) of the film proceeds remarkably, and it is difficult to maintain the effect of preventing spatter welding until all welding operations are completed. Therefore, in multi-layer welding, the welding operation is temporarily interrupted each time the effect of preventing the adhesion of the coating film decreases by a certain level or more, and after waiting for the welding site to fall to a temperature at which the spattering agent can be applied, the spatter adhesion The inhibitor must be reapplied and further welding operations must be resumed.

  Therefore, in multi-layer welding, the welding operation is accomplished by repeating the coating film re-forming operation intermittently a plurality of times. Waiting for temperature drop (standby) for re-forming the coating film for preventing spatter adhesion and re-forming the coating film intermittently repeated multiple times significantly reduce the work efficiency of welding work and increase the welding cost. It has become.

According to this type of lacquer-type anti-spattering agent coating film, the number of sputtered particles deposited on the surface of the metal member to be welded is reduced at the beginning of the welding operation, but the coating film is thermally deteriorated over time. The number of particles penetrating and welding to the surface of the metal member to be welded increases. In removing spatter particles and cleaning work, since the adhesion force of many sputter particles is strong, it is necessary to perform a work of peeling and removing with a special tool such as a flat chisel. The work of peeling off and removing spatter particles necessary for finishing the welded product is a time-consuming and hard manual work, and this work is one of the major factors hindering the reduction of welding costs. Also, there is a cleaning type spatter adhesion preventive agent developed mainly for the purpose of welding stainless steel metal structures. The coating film of this type of cleaning-type spatter adhesion inhibitor is made on the assumption that it is removed by cleaning or blasting with water or solvent after welding is completed, including spatter particles and dirt generated by welding. . When the coating film is dried, it becomes a film having a hardness that does not allow the spatter to penetrate, and is a coating material that has the ability to isolate the sputtered particles from the surface of the metal member to be welded. In order to remove the coating film, there is a drawback that it is necessary to install cleaning and water washing equipment and blast equipment which require a large equipment cost, and it is rarely applied to a large metal structure.

  When nondestructive inspection is performed on a welded part of a metal member to be welded, the removal and cleaning of spatter particles at the inspection part is an indispensable act as a preparation for inspection. In addition to the inspection time, it takes time to remove spatter particles and clean the work before inspection, which hinders this time and makes it difficult to reduce the inspection time, making it difficult to reduce welding inspection costs. .

Japanese Patent Laid-Open No. 07-088685 JP-A-10-305390 JP 2009-113073 A

  The problem of the conventional product to be solved by the present invention is that the coating film does not have the ability to maintain the performance required for preventing spattering of the spatter particles and soft welding under the welding conditions repeated at a high heat input. Is a point. Therefore, even under welding conditions with a high heat input, the coating film must maintain the response to spatter particles without peeling from the welded metal member, and the coating film can be easily peeled off during the cleaning and removal process. Therefore, it is necessary to ensure contradictory performances in which maintainability and releasability conflict.

  The spatter welding inhibitor of the present invention forms a coating film by coating on the metal surface around the welded portion of the metal member to be welded, and spatter particles scattered on the surface around the welded portion of the metal member to be welded by welding work. For preventing welding and softening. The most important feature of the coating material is the addition of a base metal powder made of calcium carbonate powder and a metal powder of the same type as the metal member to be welded or a mixed metal powder in which the metal powder and the metal oxide are mixed. This is to obtain a mixed liquid agent (coating material) having a viscosity that can be applied by adding a mixed liquid to a mixed powder made by mixing at a desired ratio and stirring and mixing.

The mixing weight ratio of the additives used for the spatter adhesion preventing agent is 5% or more and 90% or less. (Preferably 10% or more and 90% or less.)
The additive is a metal powder of the same type as the metal member to be welded, which has a higher coefficient of thermal expansion than the calcium carbonate powder, or a mixed metal powder in which the metal powder and the metal oxide are mixed.

  The main component of the mixed solution is water, and the mixed solution is used by mixing water-soluble volatile liquid (for example, alcohols) with water. The purpose of mixing is to promote the phenomenon that the water-soluble volatile liquid adheres (bonds) the fine calcium carbonate powder particles mixed with the mixed solution and the metal powder particles of the additive to improve the water permeability. This is because there is an effect of promoting the natural evaporation of water and shortening the drying time.

  The coating film based on calcium carbonate powder applied to the surface of the metal member to be welded has the ability to retain without thermal degradation until the end of the welding operation. Due to the heat shrinkage, the adhesion force to the coated surface increases and causes a phenomenon that it is difficult to peel off. According to the present invention, the thermal expansion and contraction force of the metal powder of the additive acts in a direction to suppress an increase in the force of the coating film adhering to the surface of the metal member to be welded. The coating film in which is suppressed from the inside is maintained as a coating film having the same degree of softness as when it was applied. This effect does not change the ability to prevent spattering and soft welding of the sputtered grains, which is a necessary performance of the coating film. Further, the heat curing of the coating film on the contact surface between the coating film and the metal member to be welded is suppressed by the action of the thermal expansion and contraction force of the metal powder, and maintains a state where it can be easily peeled off.

  As a result of possessing the two contradictory performances of adhesion and delamination as described above, the coating film of the anti-sputtering adhesion agent of the present invention has good retention and delamination, and has anti-spattering performance and soft welding performance. It became an excellent coating material. These effects significantly improve the efficiency of the removal work during cleaning, greatly shorten the finishing process, and greatly reduce the work cost required for welding cleaning.

  The spatter welding inhibitor of the present invention can be prepared by a simple mixing operation using a mixed powder of a base material and additive material and a mixed solution immediately before performing a welding operation, so that it can be prepared in the required amount. Therefore, the consumption of the spatter adhesion preventing agent can be kept to the minimum necessary, and it is economical without waste.

  Further, the mixed solution of the spatter welding inhibitor of the present invention does not contain a component that accelerates the curing of the dried coating film. However, when the coating material is left for a long period of time, the curing proceeds due to the evaporation of moisture over time. However, if the remaining spatter anti-adhesive agent remains unused and stored as it is, it will be naturally dried by natural drying. Since the powder is encased in calcium carbonate powder (the additive powder is not exposed), the additive does not significantly harden due to oxidation, so add the powder mixture or liquid mixture and re-stir. As a result, the coating material returns to a reusable state. Therefore, while continuing welding work on a daily basis, even if there is residual spatter welding inhibitor, it can be used by replenishing the mixed powder or liquid mixture and re-stirring before starting use. There is no need to discard the coating material and there is very little waste.

  The spatter welding preventive agent of the present invention is a mixed powder having a desired ratio in the welding work site where the properties of the metal member to be welded, the spreadability according to the coating form or the welding form, and the viscosity of the coating material creating the coating film thickness The workability is good because it can be easily adjusted according to the amount of liquid mixture.

  Alcohols used in calcium carbonate powder as a base material constituting the spatter adhesion preventive agent of the present invention, metal powder as an additive or a mixed powder with the metal oxide, and a mixed liquid are easily obtained and managed. Therefore, it is possible to provide an inexpensive spatter adhesion preventing agent, which contributes to a reduction in cost required at the production site.

  Although the cleaning operation for removing the sputtered particles after the welding operation is a simple operation, it is difficult to automate the processing because it is difficult to remove the sputtered particles that are strongly welded to the narrow portion. Since the spatter adhesion preventive agent of the present invention makes the removal and cleaning work of such spatter particles simple and light, the present invention opens the way to automation of the sputter removal / cleaning work.

It is sectional drawing explaining the brush painting operation | work of a spatter adhesion inhibitor in the case of the butt-butt welding of this invention. It is a schematic diagram of the coating film dried after the painting operation. It is sectional drawing explaining the scattering condition of the weld grain in the case of a lathe butt welding. FIG. 5 is a cross-sectional view for explaining a situation in which the bottom of a welded grain is hit and cleaned by a flat chisel of a conventional method in the case of a butt butt welding. FIG. 5 is a cross-sectional view for explaining a situation in which soft welding particles or small-diameter welding particles are scraped off with a spatula-like tool used manually in the case of a butt butt welding. It is a photograph of a brush and a brush used in the demonstration test. It is the enlarged photograph of the calcium carbonate powder of a base material, and the metal powder of an additive, the enlarged photograph of a coating film, and the further enlarged photograph. It is a photograph of the 1st example in a measurement frame before cleaning after completion of welding and after level 3 cleaning removal. It is a photograph of the 2nd example in a measurement frame before cleaning after completion of welding and after level 3 cleaning removal. It is a photograph of the 3rd example in a measurement frame before cleaning after completion of welding, and after level 3 cleaning removal.

It is a photograph of the preparation work of the arrangement | positioning of the test body in the confirmation test, and the brush attached to the traveling cart. It is the cleaning level 1 and 3 external appearance comparison photograph in a commercial item 200,300,500 degreeC. It is the cleaning level 1 and 3 external appearance comparison photograph in base material 100% 200,300,500 degreeC. It is the cleaning level 1 and 3 external appearance comparison photograph in 200% of base materials 95,200,300,500 degreeC. It is the cleaning level 3 external appearance comparison photograph in 90% of base materials, and 25% of base materials 200,300, degreeC.

(Decision process of base powder used in invention)
In order to solve the above problems, the inventor of the present application is superior in heat resistance even under severe welding conditions and has an effect of preventing spatter welding over a long period of time. We conducted research to find a spatter adhesion preventive agent that can be maintained continuously without being deteriorated by heat and has good releasability during cleaning and removal.

  As a result of searching for the main material of the spatter adhesion preventing agent having a high spatter adhesion preventing effect, among various inorganic substances, inorganic salts such as calcium carbonate, other inorganic compounds, ceramics, and mixtures thereof are effective. It became clear.

  In particular, when water is added to a material composed mainly of calcium carbonate powder and applied as a coating material to a metal member to be welded, the film formed by spontaneous evaporation of moisture (coating film) is extremely effective in preventing spatter welding. It has been found that it becomes a high heat insulating film and is particularly effective as a main material for the spatter welding inhibitor.

Although the temperature of the molten pool of metal produced by electric arc welding exceeds 1600 ° C, the carbonate component of calcium carbonate powder is around 800 ° C even if calcium carbonate powder is mixed into the molten pool of molten metal. Vaporizes and becomes harmless carbon dioxide. Since the calcium component is slag as oxide and floats on the surface of the molten metal and is discharged out of the molten metal, it does not adversely affect the strength and surface properties of the welded metal after welding. Calcium carbonate is also excellent in terms of safety (harmless to the human body and the environment) and prevents spatter adhesion from the viewpoints of spatter adhesion prevention effect, economic efficiency, safety, etc., which are required as spatter adhesion preventive agents. It is an optimal material as the main material of the agent.
(Problems when using only calcium carbonate powder)
Substance that has the property that the hardness of the coating film gradually increases due to evaporation of the liquid, environmental temperature and time, etc. when water is added to the calcium carbonate powder to apply it to the surface of the metal member to be welded with an appropriate thickness. It is. When the heat input from the outside increases and the temperature of the metal member to be welded rises, the coating film shrinks while increasing in hardness from the heat input direction, and seizure to the metal member to be welded on the heat source side (the adhesion force strengthens and is removed. Is difficult).

  It is very difficult to peel off and remove the coating film of calcium carbonate powder baked on the surface of the metal member to be welded due to the influence of welding heat, and it may require water washing or blasting to remove the peeling. Many. When calcium carbonate powder is used alone to form a spatter adhesion prevention film, the spatter adhesion prevention effect is sufficiently satisfied, but for large metal structures, it is stripped by washing or blasting from the cost perspective. It is extremely difficult to carry out as a constant work.

(Answer to a question)
In order to solve the above problems, the inventor of the present application is excellent in applicability (water retention, spreadability and adhesion) of the mortar applied to the wall surface and the like, and the working posture with respect to the property and shape of the application surface ( Regardless of whether the coating surface is downward, upward, or inclined, the presence of aggregate of the desired diameter makes it possible to form a coating layer with a desired uniform thickness without spraying moisture onto the surface. The selection of the additive (aggregate) to be used began.

  As a result of searching for an additive having a good affinity with calcium carbonate powder from various substances, calcium carbonate powder is used to increase the coating film thickness and ensure applicability (water retention, spreadability and adhesion). The inventors have found that it is effective to use a metal powder having a particle size sufficiently larger than that of the body (base material) as an additive.

  As a result of searching for a material that does not affect the metal performance even if the metal powder of the additive material is mixed into the welded metal member in the molten pool and alloyed, it is the same kind as the welded metal member in an easily available material. It was found that there was a metal powder.

  When a mixed solution is added to calcium carbonate powder (base material) and metal powder (additive), mixed and stirred and uniformly dispersed on the surface of the metal member to be welded and dried, the surface properties of the coated surface Regardless of the shape, coating orientation, etc., a uniform thick coating film with high retention is easily formed on the surface of the metal member to be welded, and the coating film after drying is soft with a thickness that contains minute voids on average. A coating film appeared.

  Since the metal powder as an additive has a higher coefficient of thermal expansion than the calcium carbonate powder as a base material, the metal powder particles repeatedly expand and contract due to changes in the heat input temperature due to the welding operation. As a result, the mutual bonding of the particles of the calcium carbonate powder as the base material and the physical (mechanical) binding force with the metal powder (additive) and the surface of the metal member to be welded are weakened. As a result, the releasability from the surface of the metal member to be welded during cleaning after the end of the welding operation was significantly improved.

  The mixed solution used for mixing and stirring calcium carbonate powder (base material) and metal powder (additive) is an industrial alcohol (evaporation that is easy to obtain and spontaneously evaporates if left after coating film is formed) A mixture of Acera and water.

  The spreadability and the film thickness adjustment of the spatter adhesion preventing coating material can be easily performed by selecting the mixing ratio of the mixed powder to be used and adjusting the addition amount of the mixed liquid.

  Adjustment of the addition amount of the liquid mixture is set empirically so that the spreadability of the coating material and the intended coating thickness can be ensured according to the surface properties of the metal member to be welded, the coating posture during coating, and the like.

If the particle size of the metal powder is not less than about 100 times the average particle size of calcium carbonate powder (enlarged photo of calcium carbonate powder in Fig. 7), the specific gravity in the paint storage box before painting Preliminary application tests revealed that the coating process was difficult due to the difference that the precipitate settled in a short time and did not ride on the coating brush. Therefore, the additive material to be used for the spatter adhesion preventing agent of the present invention is a powder containing a mixture of metal powder having various maximum particle diameters of about 400 μm or less and an oxide powder thereof (see FIG. 7). Use the one obtained by classifying the enlarged photograph of the inner metal powder within the desired particle size range.
(Thermal phenomenon of coating film)
This coating material for preventing spatter adhesion can form a coating film having a preferable film thickness by one coating, and becomes a soft coating film including voids after drying. The impact relaxation force of the soft coating film absorbs the impact energy of the spatter that comes and deposits, and the heat absorption power of the additive absorbs the heat retained by the sputtered particles, so the sputtered particles penetrate the coating film and reach the bottom surface. To reach up to. In other words, most of the sputtered particles that have come in are retained on the surface of the coating film or in the coating film without penetrating the coating film on the surface of the metal member to be welded. Even if some of the sputtered particles pass through the coating film, the temperature is lowered due to the heat absorbing power of the additive, so that the sputtered particles are deposited on the surface of the metal member to be welded in the form of soft welded particles.

  By adding the additive metal powder to the calcium carbonate powder that is the base material, when heated from the bottom surface of the coating film, the adhesion force is increased by the physical action of the expansion and contraction force due to heat from the bottom surface side. The reduced metal powder particles repeat expansion by welding heat from the bottom surface and contraction by natural cooling from the upper layer within a short time, and as a result, the gap between the calcium carbonate powder particles and the metal powder particles is reduced. Since it changes physically, it can be avoided that the adhesive force with the metal member to be welded is loosened on the bottom side of the film and the seizure state is brought about. The bonding state (hardness) of the upper layer of the coating film is maintained on the surface of the metal member to be welded with a soft film that has the same finger marks as the coated film when applied and dried. Is done.

  When the sputtered particles reach the surface of the metal member to be welded and penetrate the coating film, the sputtered particles consume a considerable amount of kinetic energy due to physical resistance. In addition, even after the sputtered particles have entered the coating film, the surface temperature decreases instantaneously due to the vaporization action of calcium carbonate and the heat absorption action of the metal powder non-particles of the additive, resulting in inwelding or penetration. However, the welding force decreases and soft welding occurs due to temperature drop due to various phenomena. Even when the particle diameter of the deposited sputter is large and the temperature drop of the retained heat is less than the desired amount, the peelability is remarkably improved by reducing the weld area due to the temperature drop due to various phenomena.

The spatter adhesion preventing coating material of the present invention exists between the calcium carbonate powder that is the material of the coating film and the metal member to be welded even in an environment where high heat input is repeated due to the above-described thermal phenomenon. The adhesive force (bonding) is always maintained in a state where peeling is possible with a desired force.
(Coating film performance)
The dry soft coating film creates the effect of preventing spattering of particles and soft welding by changing the space between particles under the influence of physical fluctuations due to heat. The force is directed to maintain or increase the state at the time of application. Even if the sputtered particles penetrate the coating film, the force created by these physical fluctuations due to heat becomes the source of the ability to greatly change the welded state. Produced welding performance.

Regardless of welding conditions, the coating film remains soft and is held on the surface of the metal member to be welded, and the coating film is always kept in a peelable state with the desired force. This is an important factor indicating the high performance of the spatter adhesion preventing coating material of the present invention.
(Demonstration test method)
Hereinafter, although the form which implements the verification test of the sputter | spatter adhesion inhibitor of this invention is demonstrated, these embodiment is not intending limiting the content of this invention.

  In the demonstration test, a mixed powder was prepared by mixing the calcium carbonate powder, which is the base material, with the metal powder of the additive at various mixing ratios, and the mixed solution was added to this and mixed and stirred to prevent spatter adhesion. It was prepared as a coating material for the demonstration test.

  As the mixed solution used in this demonstration test, an aqueous solution in which 20% of industrial alcohol which is a water-soluble volatile liquid is added to water is used.

  FIG. 1 is a cross-sectional view of a butt butt welding of welded metal members A and B, and a coating film is formed by applying a coating material of the spatter adhesion inhibitor of the present invention along a welded portion on the welded metal member. It explains the state of being. A mixed solution is added to the mixed powder of the calcium carbonate powder of the base material and the metal powder of the additive, and the coating material in which both powders are uniformly dispersed and mixed together is used as the welded portion D of the welded metal members A and B. The coating film 1 is formed by coating on the end face of the member extending along the line and dried.

  The dried coating film has a cross-sectional state as shown in the schematic diagram of the dried coating film in FIG. 2, and the calcium carbonate powder particles and the metal powder particles are three-dimensionally and averagely dispersed at a predetermined mixing ratio, and the mixed solution is dried. As a result of the generation of voids between the applied particles that have disappeared by evaporation due to the above, a soft coating film of the mixed powder is formed on the surface of the metal member to be welded.

A total of 14 types of coating materials prepared with 11 types of mixing ratios and 2 types of products coated with a commercially available spatter adhesion inhibitor and 1 type of raw material are prepared and a demonstration test is carried out. The base powder used was a calcium carbonate (CaCO ₃ ) powder (Maruo calcium) having an average particle size of approximately 2.7 μm and a maximum particle size of 55 μm and an average bulk density of approximately 0.6 g / cm ³ . (Fig. 7 enlargement photo of calcium carbonate) Additive for enlargement of calcium carbonate is a mixed powder obtained by classifying a mixed powder of metal powder for construction and its oxide powder into a range of approximately 40 to 250 µm (average) The bulk density of 2.01 g / cm) is used, and the additive material which is a mixed powder of the base material powder and the product of the present invention is prepared at the mixing ratio (base material powder: additive material) shown in Table 1, and the mixed solution is prepared. In addition, 11 types of coating materials of test body numbers 02 to 13 were produced by mixing and stirring and applied to the test body.

  Of the 14 types in total, a total of 3 types including a substrate and 2 types of commercial products were subjected to the same test as a reference example for comparative evaluation. They are MA-100 manufactured by Warner Chemical Co., Ltd. (commercial product / test body number 01) and Clin Sputter ES-55 manufactured by Taiho Kouzai Co., Ltd. (commercial product test body number 08) as well-known spatter adhesion preventing agents. In addition, 100% calcium carbonate (test body number 02) and a case where no spatter adhesion preventing agent is used (base material / test body number 14).

  The spatter particle welding inhibitor described in the following Table 1 determines the mixing ratio (base powder: additive) in consideration of the coating property and performance on the surface of the metal member to be welded, In addition, what was mixed and stirred is applied to each specimen (SM490A) as an application material.

  The metal plate for welding test (SN490A / JFE) used for comparative evaluation of the spatter adhesion preventing effect of the spatter adhesion preventing coating material of the present invention is divided into the groove side metal plate A and the non-groove side. Two sets of metal plates B were used as one set, and six sets (12 sheets) corresponding to three welding forms were prepared. The test metal plate has a total length of 500 mm (70 mm width x 7 pieces + total length of 5 mm at the end portion), and 7 types of test specimens, which are one-half of 14 types of welds per set of test metal plates. Are arranged side by side.

  In each welding form, along the welded part on the metal plate member, which is the base material to be welded (see FIG. 1), the coating film is 70 mm wide by mixing ratio (with extra length of 5 mm at both ends) for welding tests. Apply to the metal plates in order. For three types of welding, namely, butt butt welding, T butt butt welding and T butt fillet welding, a quantity measurement area of 50 mm x 50 mm deposited particles was secured on the center line of 70 mm width of each specimen. .

  A welding line in which seven types are continuously juxtaposed on one sheet is defined as one welding line, and welding shown in Table 2 is performed with a predetermined number of passes.

  As the welding material, a wire diameter of 1.2 mm made of carbon dioxide welding wire MG-55 (Kobe Metal) is used.

  As shown in Table 2, the welding method depends on the welding mode, and manual carbon dioxide semi-automatic welding is used for fillet welding with a small number of welding passes. Uses a welding machine manufactured by Kobe Steel to prevent uneven welding conditions.

  In the pre-measurement process, the coating film was removed without contact with a light air blow without using any cleaning tool. The cleaning removal method for removing sputtered particles is carried out at the cleaning level set in three stages 1 to 3 shown in Table 3, and the quantity measurement of sputtered particles remaining on the welded specimen is as follows. The number of residual sputtered grains in a measurement frame having an area of 50 mm × 50 mm arranged on each specimen was counted.

For cleaning at cleaning level 1, a universal brush (manufactured by Kowa Co., Ltd.) with a bristles length of 70 mm is used, and a designated area in the vicinity of the welded portion of the base metal sheet member to be welded (coating film adjacent to the welded portion having a total length of 500 mm) The brush is manually reciprocated three times with a light force enough to sweep dust, and the unwelded sputtered particles remaining on the surface or coating film are removed by cleaning. (The brushes and brushes used for cleaning levels 1 to 3 are shown in FIG. 6.)
Cleaning level 2 cleaning is performed on soft weld spatter that was not removed by cleaning level 1 cleaning, using an iron-type nylon brush (150 x 75 mm Cainz Co., Ltd., made in China) with a hair tip length of 28 mm. Then, the coating film is reciprocated three times in the same manner as described above, and the coating film and the soft welding spatter remaining after the cleaning of the cleaning level 1 are cleaned and removed.

In the cleaning at the cleaning level 3, the remaining coating film and the soft welding spatter remaining without being removed by the cleaning at the cleaning levels 1 and 2 were removed by cleaning. The brush used for cleaning level 3 is made of brass brush that is not used because it is too soft for practical use. (Brush tip length: 25 mm, manufactured by SK11) 3 is reciprocated three times in the same manner as described above to remove and clean the coating film and welding spatter.
(Degree of removal targeted by each cleaning level)
Cleaning level 1 simply removes unwelded spatter particles left on the coating film or remains in the coating film, and level 2 bites into the coating film to the extent that it can be removed by rubbing by hand. The target is removal of unwelded sputtered particles and finely welded particles.

The product when entering the cleaning and removing operation at the actual site is in a state where the spatter adhesion preventing material of the coating film is still applied, and the welded state of the sputtered particles is level 3. Therefore, level 3 is a state in which only sputtered particles having a welding force that can be removed by light rubbing with a thin, flat, spatula-shaped light tool used in the manual operation in the final process of this demonstration test remain. The goal is to be.
(Application to low heat input welding)
Table 3 is for evaluating the spatter adhesion prevention performance and the degree of soft welding in fillet welding of low heat input welding with a small number of welding passes. It is carried out in order to confirm that the spatter adhesion preventing agent of the present invention has the ability to prevent or softly weld large sputtered particles generated in fillet welding of low heat input welding.

Sputtering according to the degree of difficulty in removing welding spatter remaining after cleaning level 3 cleaning, in other words, the mixing ratio of the mixed powder, which is the main component of the spatter adhesion inhibitor The degree of performance of adhesion prevention and soft welding was evaluated. The criteria for evaluation judgment are as follows, and the evaluation results are shown by the used cleaning tool and the work evaluation at level 3 in Tables 4, 5, and 6.
× Spatter remained that could not be removed by hitting with a conventional dedicated tool.

(Conventional level)
□ Welding particles that cannot be removed by cleaning a lightweight tool (such as a light spatula such as a skin plow) or a metal brush that are used without being blown are occasionally scattered. It was possible to clean and remove with a light work of hitting the bottom of the sputtered grains lightly. (Practical range is good)
△ All spatters and coating materials were removed by lightly rubbing with a light tool or metal hanging cleaning. (Within the range desired by the developer)
○ All spatters and coatings were removed at cleaning levels 1 to 3

(Progress of confirmation test evaluation)
The numerical difference between level 2 and level 3 where the difference in cleaning power is small was not significant except for F14. Looking at the results of Level 3 in F14, the slight difference in the removal power between Level 1 and Level 2 has affected the value of Level 2. The value of Level 3 is generally reasonable compared to the others. Yes.
The number of grains before cleaning is that after a considerable amount of fine sputtered particles left on the surface of the soft coating film that could not even enter the surface of the coating film were blown away by air blow of the cleaning level 1 pretreatment. It is clear from the numerical values of the specimen numbers 01 to 14 before cleaning that they are numerical values. Looking at the range of specimen numbers 09 to 12 where the coating material was applied in the manner of the present invention, the number of particles in the welded state before cleaning at the cleaning level 1 is large, but the sputtered particles softly welded as a result of the cleaning level 3 You can see that the number of grains.

  Even with light force-removal cleaning with level 1 brushes, the amount of sputtered particles attached was very small when the calcium carbonate content was 50% or more, and lightly plunged into the surface of the coating film before cleaning within a range of 25% to 50%. A considerable amount of sputter particles were removed. In the butt-type butt welding and the T-type butt welding, approximately 40 to 70% of spatter particles were removed at the cleaning level 1, and 100 to 50% were removed in the fillet welding. The softness held by the surface of the coating film serves as an ability to receive the sputtered particles as a cushion, and this is a factor for extracting the effect of preventing the sputtered particles from penetrating.

In level 3 spatter removal cleaning, when the mixture ratio of calcium carbonate is in the range of 5% to 90%, even if the remaining adhering spatter remains on the surface of the base metal to be welded, wes alone in the final process or a lightweight tool All the sputtered particles could be removed by using a metal brush together. (F01 in FIG. 8 and F10 in FIG. 10 are used as reference figures.)
When the mixing ratio of calcium carbonate is 10%, the amount of spattered particles of level 3 is large, but since it is softly welded, the welding situation of sputtered particles is greatly improved from the practical point of cleaning removal work. 3 and later are referred to as the final process of the verification test, but in practice, the state evaluation before the cleaning removal work is referred to as good.

  When the calcium carbonate content was 95%, all residual spatter was removed by level 3 removal cleaning. In fillet welding, a small number of weld spatter particles were observed, but they could be easily removed by using a lightweight tool. In addition, since a nearly transparent white calcium carbonate burnt-out trace is visible on the metal member to be welded, it was removed using a true cast brush in this demonstration test (special case during testing).

When the calcium carbonate content is 5% and 0%, the amount of spatter deposited on the residual spatter increases to the level of a conventional commercial product. However, since the sputtered particles are softly welded at the actual cleaning level, most of the remaining sputtered particles Et al. Could be removed by using a lightweight tool, but a part of the remaining sputtered grains needed to be removed by smashing a flat chisel with a hammer. (F13 in FIG. 10 is used as a reference diagram.)
In the case where the calcium carbonate blending ratio is 5%, the hardness of the coating film kept by heating decreases when the calcium carbonate blending ratio is reduced to a certain level or more. It turned out to turn into a trend. Even if the coating film is made with the additive metal powder, there is almost no adhesion between the iron powder particles. The amount of decrease in the passage speed is small. It is presumed that the sputtered particles pass away at a high speed due to the influence of speed and adhesion, and the amount of heat taken away by the metal powder is reduced, reaching the surface of the metal member to be welded and welding without progressing soft welding. it can. Some of the above-mentioned sputtered particles had to be removed by smashing the flat chisel with a hammer. The reason was that the calcium carbonate content was reduced by more than a certain level. It can be said that the number of sputtered grains reaching the surface of the metal member to be welded is not increased.

The prevention of welding and the effect in multi-layer welding showed a great effect by the coating film of the spatter adhesion preventive agent of the present invention for both high heat input and low heat input welding. It is clear that if the compounding ratio of calcium carbonate is 10% or more, a stable spatter adhesion preventing effect is exhibited in both high heat input and low heat input welding. When the mixture ratio of calcium carbonate for low heat input welding was 10%, there were adhering sputtered particles remaining after the level 3 spatter removal cleaning, but these were because of the soft-welded sputtered particles. In actual work sites, it was confirmed that there was no problem even if this was applied to field work because it could be easily removed by wiping with waste cloth or using auxiliary light tools including metal brushes. (F13 in FIG. 10 is used as a reference diagram.)
(Consideration of demonstration experiment)
From the verification results, the following has been clarified regarding the spatter adhesion preventing effect of the spatter adhesion preventive agent of the present invention.

  The coating film of the anti-spattering agent applied to the base metal to be welded and formed by drying adheres to the surface of the metal powder of the additive having no adhesion on the surface while the calcium carbonate powder non-particles are wrapped. The holding power on the surface of the weld base metal is sufficiently maintained.

  A gap formed by drying is interposed between the additive particles and the calcium carbonate powder non-particles inside the coating film applied to the welded base metal surface. Therefore, the force that the coating film adheres to the welded base metal through the calcium carbonate powder non-particles is greater when the metal powder particles are included than when the additive metal powder particles are not included. Since the calcium carbonate powder non-particles per unit volume to be reduced is reduced, the peelability at the time of cleaning is greatly improved as compared with a coating film formed only with calcium carbonate powder.

The peelability of the coating film improves as the ratio of the additive in the mixed powder increases. However, if the calcium carbonate powder and the additive powder have an affinity for a common liquid, when the coating material is manufactured In calcium carbonate, viscosity increases and adhesion of the coating material improves. When the amount of calcium carbonate as a base material is decreased, the hardness of the surface of the dry coating film is lowered due to the influence of the volume density, and the sputtered particles easily enter the coating film. However, when the additive powder is increased, the endothermic amount of the coating film is increased, and the effect of reducing the welding force by reducing the area where the sputtered particles can be welded appears. If the ratio of the metal powder to be added exceeds 90%, even if the sputtered particles have a reduced welding area, the coating film hardness is low (soft), so the amount of penetration increases, and accordingly, welding to the metal member to be welded As the amount of powerful sputtered particles increases, the efficiency of cleaning work is reduced. (See the enlarged photo of the coating film after application and the re-enlarged photo of the coating film after application in Fig. 7.)
Therefore, by applying the spatter adhesion preventive agent of the present invention, the mixing ratio of the additive metal is in the range of 5% to 90%, preferably in the range of 10% to 80, regardless of high heat input or low heat input welding. It can be confirmed by a demonstration test that it becomes a very high and excellent spatter adhesion preventing agent if it is limited to%, and maintains a high ability to reduce the welding power of spatter particles.
(Coating film peelability confirmation test due to temperature change)
An important performance of the spatter adhesion preventive agent of the present invention is how the coating film keeps the desired spatter welding prevention and soft welding performance for a long time. In the verification test described in the previous section, it was verified that the coating film maintained the suitability for preventing spatter particles and soft welding throughout the entire welding process. However, for the coating film that was made by mixing and stirring the base material and the mixed powder with the mixed solution, the supporting literature on the bonding and separation of the powder due to the heating temperature was searched, but it was unclear, and the peelability due to temperature change This verification test was conducted to verify the transition of

In this confirmation test, calcium carbonate powder (CaCO ₃ ) powder (manufactured by Maruo Calshum Co., Ltd.) of the same base material used in the demonstration experiment regarding the spatter adhesion prevention effect, and metal powder for construction and its oxidation as additives. 7 types of coating materials and the base material 100 in which the mixed liquid was added to and mixed with the mixed powders of the mixing ratios (base material powder: additive material) shown in Table 7 in Table 7 A total of 9 types of specimens were prepared.

  As a comparative evaluation object of temperature and peelability change and seizure state, a well-known commercial product spa coat (manufactured by J International Co., Ltd.) premised on water washing and 100% calcium carbonate powder (reference) were added to the confirmation test. .

  A specimen of a metal member with one side of a 9 mm metal plate (50 × 140 · SS400) blasted (about 70 μm Rz) was heated to 200 ° C., 300 ° C., 400 ° C. and 500 ° C. and kept at the temperature for 1 hour to cool naturally. A test film for the confirmation test was prepared by applying each of the spatter adhesion preventing agents mixed in accordance with the procedure shown in Table 7 to the test body and applying it to one side of the test blasted to a roughness of about 70 μm Rz and drying it.

  For evaluation of releasability, before using the cleaning tool, etc., without using any cleaning tools, remove the non-contact dust with a light air blow, and then apply a small-sized brush (48 x 95 mm, hair tip length 30 mm, flocking material PP, manufactured by Kowa) It is fixed on an automatic traveling carriage for gas cutting (MAX-1 type, manufactured by Koike Oxygen Co., Ltd.) whose speed can be adjusted, and this carriage is placed on a surface plate (metal plate) installed horizontally at a constant speed (650 mm / min). Was reciprocated, and the coating film of the test specimen was cleaned with a brush. (FIG. 11 shows the arrangement of the test pieces and the preparatory work state of the brush attached to the automatic traveling carriage.) As the inspection level was increased, the cumulative number of reciprocations of the brush was increased to clean the coating film on the metal plate.

  The degree of adhesion strength of the coating film in each inspection stage, in other words, the difficulty of peeling was evaluated.

The evaluation categories are as follows.
× The coating film cannot be removed.
Δ: Adherence was observed on the surface.
○ Removed

(Summary of confirmation test)
The commercial product (Spacoat) contains a binder that cures when dried at 200,300 ° C, so the surface of the coating film is hard and the coating film cannot be removed. The coating film remained attached to the surface of the test specimen. The degree of hardening of the film gradually disappears from around 400 ° C, and it can be removed by rubbing with a finger at 400 and 500 ° C. It was in a state. (1) to (3) in FIG. 12 are photographs showing the above situation.

The commercially available coating film is not removed at all cleaning levels when heated to 200 ° C. and 300 ° C., and the coating film is peeled and removed manually while remaining attached to the surface of the metal plate that is the metal member to be welded. It is impossible to do. Even if there is a portion heated to 400 ° C. and 500 ° C., most of the coating film is not removed because it is only around the weld line, and the water washing operation is selected as the cleaning operation. ((3) in FIG. 12 is a photograph showing the above situation.)
Specimens with a calcium carbonate mixing ratio of 100% show a hardening phenomenon when heated at 200 to 300 ° C., and cleaning levels 1, 2 and 3 at 200 to 300 ° C. can remove only part of the surface layer of the coating film. Since the coating film remains attached to the film, the peelability is not good. At 500 ° C, the curing phenomenon tended to be alleviated in the same way as commercial products, but at 500 ° C and 400 ° C cleaning level 3, the coating film remained in a pale white color that was nearly transparent, and the cleaning level was 500 ° C and 400 ° C. There was almost no difference in the appearance of 3. ((1) to (3) in FIG. 13 are photographs showing the above situation.)
In the test specimen in which the mixing ratio of calcium carbonate was 95%, a slight light white adhesion was observed on the surface at cleaning levels 1, 2, and 3 at 200 and 300 ° C., but 500 ° C. and 400 ° C. at level 4 Then all the colors were removed. (1) to (3) in FIG. 14 are photographs showing the above situation.

When the mixing ratio of calcium carbonate was 90% or less and 25% or more, all coating films were removed at the cleaning level 3 without being affected by the heating temperature, and further beautification cleaning was unnecessary at the subsequent cleaning level. ((1) to (4) in FIG. 15 are photographs showing the above situation.)
(Consideration of confirmation test)
The peripheral part of metal welding has a wide distribution from room temperature to approximately 1000 ° C. At 200 to 300 ° C. in the initial stage of heating, the peeling state of the coating film on the surface of the base metal to be welded is affected by the mixing ratio of calcium carbonate, but the additive is 10 due to the movement (expansion / shrinkage) of the particles of the additive. Even if the coating film containing more than% is heated, the coating film can be kept as soft as when it is applied. For the above reasons, the force required for the removal operation is maintained with little influence on the temperature change. Table 9 showing the results of the confirmation test shows that a wide range of coating films with a mixing ratio of 90 to 25% of calcium carbonate are soft coating films that can be removed with a brush until the end of welding.

In metal welding, the peripheral part of the welded portion has a wide distribution from room temperature to around 1000 ° C. However, the coating film having a calcium carbonate mixing ratio of 25 to 75% in the test bodies 01 to 07 has a slight decrease in peelability when the heating temperature is in the range of 200 ° C. to 300 ° C. and the calcium carbonate mixing ratio is high. However, it is clear that the peelability of the coating film created by the present invention is less dependent on the heating temperature. When the mixing ratio of calcium carbonate was 25% or less, this confirmation test was not carried out. However, considering the results of the verification test, the mixing ratio of the additive metal should be in the range of 5% to 90%, preferably in the range. If the content is limited to 10% to 80%, it can be confirmed that an extremely high spatter adhesion preventing agent is obtained.
(Summary of verification test and confirmation test)
From the verification test and the confirmation test, it was confirmed that the peelability of the flexible soft coating film created by the spatter adhesion preventive agent of the present invention has a very good spatter adhesion prevention performance. The spatter adhesion preventive agent of the present invention is a soft and flexible coating film with little dependence on temperature, but it can achieve adhesion and peelability performance at the end of the welding operation under one welding heat input condition. The ability to hold is the effect of the present plan developed for the purpose of preventing spatter adhesion and simplifying cleaning and removal, and this performance is in line with the requirements of the field for improving efficiency in welding operations.

A Welded metal material B Welded metal material with groove C Backing metal D Welded part E Torch nozzle used for carbon dioxide gas welding F Welding grain (welded grain welded to welded base material)
DESCRIPTION OF SYMBOLS 1 Coating film 2 Sputtered grain 3 Brush for coating 4 Additive (iron powder)
5 calcium carbonate powder (base material)
6 Flat chisel 7 Hammer 8 Hand tool for spatula

A 9 mm metal plate (50x140 / SS400) with a blasted finish (about 70 μm Rz) on one side was heated to 200 ° C , 300 ° C , 400 ° C and 500 ° C and held for 1 hour to cool naturally. . A test film for the confirmation test was prepared by applying each of the spatter adhesion preventing agents mixed in accordance with the procedure shown in Table 7 to the test body and applying it to one side of the test blasted to a roughness of about 70 μm Rz and drying it.

A total of 14 types of coating materials prepared with 11 types of mixing ratios and 2 types of products coated with a commercially available spatter adhesion inhibitor and 1 type of raw material are prepared and a demonstration test is carried out. As the base material powder, calcium carbonate ( CaCO ₃ ) powder (Maruo calcium) having an average particle size of about 2.7 μm and a maximum particle size of 55 μm and an average bulk density of about 0.6 g / cm ³ was used. (Fig. 7 enlargement photo of calcium carbonate) Additive for enlargement of calcium carbonate is a mixed powder obtained by classifying a mixed powder of metal powder for construction and its oxide powder into a range of approximately 40 to 250 µm (average) The bulk density is 2.01 g / cm 3 ), and the additive material which is the mixed powder of the base material powder and the product of the present invention is prepared at the mixing ratio (base material powder: additive material) shown in Table 1, and the mixed solution Were added and mixed and stirred, and 11 types of coating materials of specimen numbers 02 to 13 were produced and applied to the specimen.

A 9 mm metal plate (50x140 · SS 400) with one side blasted (approx. 70μmRz) is heated to 200 ° C, 300 ° C, 400 ° C, and 500 ° C, and the temperature is maintained for 1 hour to cool naturally. did. A test film for the confirmation test was prepared by applying each of the spatter adhesion preventing agents mixed according to the procedure shown in Table 7 to the test body and applying it to one side of the test blasted to a roughness of about 70 μm Rz and drying it.

For evaluation of releasability, before using the cleaning tool, etc., without using any cleaning tools, remove the non-contact dust with a light air blow, and then apply a small-sized brush (48 x 95 mm, hair tip length 30 mm, flocking material PP, manufactured by Kowa) It is fixed on an automatic traveling carriage for gas cutting (MAX-1 type, manufactured by Koike Oxygen Industry Co., Ltd.) whose speed can be adjusted, and this carriage is mounted on a surface plate (metal plate) horizontally installed at a constant speed ( 650 mm / min ). Was reciprocated, and the coating film of the test specimen was cleaned with a brush. (FIG. 11 shows the arrangement of the test pieces and the preparatory work state of the brush attached to the automatic traveling carriage.) As the inspection level was increased, the cumulative number of reciprocations of the brush was increased to clean the coating film on the metal plate.

Claims (7)

A base powder containing calcium carbonate powder and an additive containing a metal powder of the same type as the metal member to be welded or a mixed metal powder in which the metal powder and the metal oxide are mixed are mixed in a desired ratio. A spatter adhesion preventive agent, wherein the mixed powder made by mixing and stirring the mixed liquid.   The spatter adhesion preventing agent according to claim 1, wherein the mixed powder obtained by mixing the base powder and the additive contains 10 to 95% by weight of the base powder. The base powder has a maximum particle size of 75 μm or less and the additive has a maximum particle size of 250 μm or less, and the thermal expansion coefficient of the additive is higher than the thermal expansion coefficient of the base powder. The spatter adhesion inhibitor according to claim 1 or 2. The spatter adhesion preventing agent according to claim 1, wherein the mixed solution is an aqueous solution of a volatile liquid. The spatter adhesion preventing agent according to claim 4, wherein the volatile liquid is an alcohol. The spatter adhesion preventive agent according to claim 1, wherein the mixed powder and the mixed liquid are stirred and mixed in the vicinity of a welding site. It is a welding method using the spatter adhesion inhibitor in any one of Claim 1 thru | or 6, Comprising: The process of apply | coating the said spatter adhesion inhibitor to the said to-be-welded structure before welding a to-be-welded structure. A welding method using a spatter adhesion inhibitor.