KR100415984B1 - Preparing Method of Iron Thermit Welding Material with Mill Scale - Google Patents
Preparing Method of Iron Thermit Welding Material with Mill Scale Download PDFInfo
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- KR100415984B1 KR100415984B1 KR10-2001-0020925A KR20010020925A KR100415984B1 KR 100415984 B1 KR100415984 B1 KR 100415984B1 KR 20010020925 A KR20010020925 A KR 20010020925A KR 100415984 B1 KR100415984 B1 KR 100415984B1
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- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 title claims abstract description 82
- 238000003466 welding Methods 0.000 title claims abstract description 45
- 229910052742 iron Inorganic materials 0.000 title claims abstract description 37
- 239000000463 material Substances 0.000 title claims abstract description 35
- 238000000034 method Methods 0.000 title claims abstract description 29
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims abstract description 39
- 229910052751 metal Inorganic materials 0.000 claims abstract description 35
- 239000002184 metal Substances 0.000 claims abstract description 35
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 claims abstract description 30
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims abstract description 27
- 229910052760 oxygen Inorganic materials 0.000 claims abstract description 27
- 239000001301 oxygen Substances 0.000 claims abstract description 27
- 238000004519 manufacturing process Methods 0.000 claims abstract description 26
- 239000002245 particle Substances 0.000 claims abstract description 26
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 22
- 239000003832 thermite Substances 0.000 claims abstract description 22
- DALUDRGQOYMVLD-UHFFFAOYSA-N iron manganese Chemical compound [Mn].[Fe] DALUDRGQOYMVLD-UHFFFAOYSA-N 0.000 claims abstract description 20
- 239000000654 additive Substances 0.000 claims abstract description 15
- 239000002994 raw material Substances 0.000 claims abstract description 7
- 229910010271 silicon carbide Inorganic materials 0.000 claims description 11
- 230000000996 additive effect Effects 0.000 claims description 9
- 238000002156 mixing Methods 0.000 claims description 6
- 239000000356 contaminant Substances 0.000 claims description 4
- 239000003921 oil Substances 0.000 claims description 3
- 239000000843 powder Substances 0.000 claims description 2
- 238000002203 pretreatment Methods 0.000 claims 1
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N Iron oxide Chemical compound [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 abstract description 50
- 238000006243 chemical reaction Methods 0.000 abstract description 29
- 241000256602 Isoptera Species 0.000 abstract description 14
- 229910000616 Ferromanganese Inorganic materials 0.000 abstract description 11
- 229910000831 Steel Inorganic materials 0.000 abstract description 11
- 239000010959 steel Substances 0.000 abstract description 11
- 239000000203 mixture Substances 0.000 abstract description 9
- 230000003647 oxidation Effects 0.000 abstract description 6
- 238000007254 oxidation reaction Methods 0.000 abstract description 6
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 abstract description 5
- 239000006227 byproduct Substances 0.000 abstract description 5
- 229910052739 hydrogen Inorganic materials 0.000 abstract description 5
- 239000001257 hydrogen Substances 0.000 abstract description 5
- 238000011946 reduction process Methods 0.000 abstract description 4
- 238000004064 recycling Methods 0.000 abstract description 3
- 238000004448 titration Methods 0.000 abstract 1
- 239000011148 porous material Substances 0.000 description 14
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 10
- 229910052799 carbon Inorganic materials 0.000 description 10
- 239000011572 manganese Substances 0.000 description 10
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 8
- 239000010703 silicon Substances 0.000 description 8
- 229910052710 silicon Inorganic materials 0.000 description 8
- 239000000126 substance Substances 0.000 description 8
- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 description 5
- 229910052748 manganese Inorganic materials 0.000 description 5
- 238000011084 recovery Methods 0.000 description 5
- 230000007423 decrease Effects 0.000 description 4
- 230000020169 heat generation Effects 0.000 description 4
- 230000000694 effects Effects 0.000 description 3
- 239000007789 gas Substances 0.000 description 3
- 229910018072 Al 2 O 3 Inorganic materials 0.000 description 2
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 description 2
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 2
- 239000004927 clay Substances 0.000 description 2
- 238000010276 construction Methods 0.000 description 2
- 238000007796 conventional method Methods 0.000 description 2
- 239000010949 copper Substances 0.000 description 2
- 229910052698 phosphorus Inorganic materials 0.000 description 2
- 239000011574 phosphorus Substances 0.000 description 2
- 239000000047 product Substances 0.000 description 2
- 238000005245 sintering Methods 0.000 description 2
- 229910052717 sulfur Inorganic materials 0.000 description 2
- 239000011593 sulfur Substances 0.000 description 2
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 230000001276 controlling effect Effects 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 238000002788 crimping Methods 0.000 description 1
- 230000003009 desulfurizing effect Effects 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 238000000227 grinding Methods 0.000 description 1
- 238000005304 joining Methods 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 230000002265 prevention Effects 0.000 description 1
- 238000006479 redox reaction Methods 0.000 description 1
- 230000001105 regulatory effect Effects 0.000 description 1
- 239000002893 slag Substances 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
- B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
- B23K35/24—Selection of soldering or welding materials proper
-
- B22F1/0003—
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Processing Of Solid Wastes (AREA)
Abstract
본 발명은 밀스케일(mill scale)을 사용한 철 테르미트 용접소재 제조방법에 관한 것으로, 밀스케일과 알루미늄 분말 그리고 미량 첨가제인 금속철, 망간철(ferro-manganese) 및 실리콘카바이드(SiC) 등을 적정 입도로 분급·조절한 다음, 테르미트 반응시 발열량을 고려하여 알루미늄과 밀스케일중 산소와의 몰비(MAl/MO)를 조절하고 미량 첨가제 등을 적정량 첨가해 균질하게 혼합하는 밀스케일을 사용한 철 테르미트 용접소재 제조방법에 관한 것이다.The present invention relates to a method for manufacturing an iron thermite welding material using a mill scale, titration of mill scale and aluminum powder and trace additives such as metal iron, ferro-manganese and silicon carbide (SiC), etc. After classifying and controlling the particle size, mill scale is used to adjust the molar ratio (M Al / M O ) between aluminum and oxygen in the mill scale in consideration of the calorific value during the termite reaction, and to add a small amount of additives and mix it homogeneously. The present invention relates to an iron thermite welding material manufacturing method.
즉, 밀스케일을 철산화물 원료로 사용함으로써 별도로 철산화물을 제조하기 위한 산화 및 수소환원 공정과 재분쇄 공정을 생략할 수 있어 공정이 간편하고 공정비용이 저렴하며, 특히 제철소에서 부산물로 산출되는 밀스케일을 사용하여 제조원가를 상당히 낮출 수 있고 또 효율적인 자원재활용이 가능한 환경친화적인 특징이 있다.In other words, by using mill scale as an iron oxide raw material, the oxidation and hydrogen reduction process and the regrinding process for separately manufacturing iron oxide can be omitted, so the process is simple and the process cost is low. In particular, the mill produced as a by-product of steel mill The scale makes it possible to reduce manufacturing costs considerably and has an environmentally friendly feature that allows efficient resource recycling.
Description
본 발명은 알루미늄과 철산화물을 혼합하여 철구조물이나 레일 등을 용접하는 용접소재의 제조방법에 관한 것으로, 보다 상세하게는 철산화물로 밀스케일(mill scale)을 사용하여 별도의 열을 가하지 않고 알루미늄의 산화열에 의해 철산화물이 용해되어 철재 간에 용접이 이루어지는 밀스케일(mill scale)을 사용한 철 테르미트 용접소재의 제조방법에 관한 것이다.The present invention relates to a method of manufacturing a welding material for welding a steel structure or a rail by mixing aluminum and iron oxide, and more particularly, aluminum without iron using a mill scale as iron oxide The present invention relates to a method for producing an iron thermite welded material using a mill scale in which iron oxide is dissolved by heat of oxidation and welding is performed between steel materials.
일반적으로 건물의 전파방지 또는 누전시 안전장치로 시행되는 접지를 위한 전기적 연결 그리고 전철의 궤도 신호연결용에는 압착법이 이용되어 왔으며 철 구조물의 연결 및 레일간의 연결에는 가스용접이나 아크용접이 주로 시행되어 왔으나, 이들 방법들은 시공이 불편하고 작업성이 떨어짐과 동시에 경제적으로 비효율적인 것으로 나타나고 있으며, 특히 가스용접이나 아크용접의 경우 용접시 용가재(Filler Metal)를 용융하기 위해서 약 900℃ 내지 1000℃ 이상의 열원을 가해주어야 하는 시공상의 문제점이 제기되어 왔다. 이에 따라 최근에는 전기배선이나 철재 간의 용접을 테르미트 용접법으로 대체함으로써 작업능률과 접합성능을 향상시키고 있으며, 용접시 자체의 반응열을 이용하여 에너지 절감효과를 크게 기하고 있다.In general, the crimping method has been used for the electrical connection for grounding, which is implemented as a safety device in the event of earthquake prevention or leakage of the building, and for the rail signal connection of the train, and gas welding or arc welding is mainly used for the connection of the steel structure and the rail. However, these methods have been found to be inconvenient in construction, inferior in workability and economically inefficient, and especially in the case of gas welding or arc welding, in order to melt filler metal during welding, it is about 900 ° C to 1000 ° C or more. Construction problems that have to be applied to the heat source has been raised. Accordingly, in recent years, the work efficiency and the joining performance are improved by replacing the electric wiring or welding between steel by the termite welding method, and the energy saving effect is greatly increased by using the reaction heat of the welding.
테르미트 용접은 철산화물과 금속 알루미늄을 적정비로 혼합하여 가열시키면 자체의 산화환원반응이 일어나 알루미늄은 산화물의 슬래그(slag)로 그리고 철산화물은 환원된 용탕이 되어 철재 간의 용접이 이루어지게 된다. 즉, 철산화물과 알루미늄의 산화반응에 대한 열역학적 반응식은 다음과 같이 표시할 수 있다.Thermite welding mixes iron oxide and metal aluminum at an appropriate ratio and heats them to produce a redox reaction, so that aluminum is a slag of oxide and iron oxide is a reduced molten metal to weld between steel materials. That is, the thermodynamic reaction equation for the oxidation of iron oxide and aluminum can be expressed as follows.
I. 3FeO + 2Al → Al2O3+3Fe + 783.95KJI. 3FeO + 2Al → Al 2 O 3 + 3Fe + 783.95KJ
II. Fe2O3+ 2Al → Al2O3+ 2Fe + 760.48KJII. Fe 2 O 3 + 2Al → Al 2 O 3 + 2Fe + 760.48KJ
III. 3Fe3O4+ 8Al → 4Al2O3+9Fe + 3013.86KJIII. 3Fe 3 O 4 + 8Al → 4Al 2 O 3 + 9Fe + 3013.86KJ
상기 반응식에서와 같이 철산화물이 알루미늄에 의해 환원되면 강력한 발열반응이 일어나 열용량의 이론적 온도가 FeO에 의한 테르미트 반응시에는 2500℃ 정도이고, Fe2O3에 의한 테르미트 반응의 경우는 2960℃ 정도로 철 용탕의 유지가 용이하여 철재 간의 용접이 이루어진다.When iron oxide is reduced by aluminum as in the above reaction formula, a strong exothermic reaction occurs, and the theoretical temperature of the heat capacity is about 2500 ° C. when the thermite reaction by FeO is performed, and in the case of the termite reaction by Fe 2 O 3 , 2960 ° C. It is easy to maintain the molten iron to the extent that welding between the steel is made.
테르미트 용접재의 제조에 있어 철산화물의 입도가 너무 작으면 혼합이 어려울 뿐만 아니라 용접효율이 떨어지는데 입도가 미세할 경우에는 반응은 격렬하게 일어나나 일부 미반응 입자들은 비산되어 반응용기로부터 분출하게 되며, 반대로 입도가 너무 조대하면 반응이 억제되어 미반응 입자들이 철생성물중에 혼입하게 된다. 또 알루미늄이 부족하게 되면 발열량이 감소하거나 철산화물에 의해 공급된 과잉의 산소가 다른 원소나 반응용기 자체와 반응하게 되어 용접효율이 떨어지게 된다. 지금까지 실용화되고 있는 철테르미트 용접소재의 제조방법은 여러 문헌[J. of Metal, 24(1972) 제30페이지; Metal Handbook, 6(1983) 제692페이지; Welding News, 35(1985) 제1페이지]에 소개되어 있다.If the particle size of iron oxide is too small in the manufacture of thermite welding material, not only is it difficult to mix, but also the welding efficiency is low. On the contrary, if the particle size is too coarse, the reaction is suppressed and unreacted particles are incorporated in the iron product. In addition, when aluminum is insufficient, the amount of heat generated decreases or excess oxygen supplied by iron oxide reacts with other elements or the reaction vessel itself, thereby reducing the welding efficiency. The manufacturing method of the iron-termit welding material which has been put to practical use until now is various literature [J. of Metals, 24 (1972) page 30; Metal Handbook, 6 (1983) page 692; Welding News, 35 (1985), page 1).
상기한 종래의 제조방법은 테르미트 용접재의 주원료로 철산화물을 제조함에 있어서 철분말을 600℃∼700℃ 정도의 고온에서 산화시켜 산소함량을 조절하기 때문에 공정이 복잡해짐은 물론 제조비용이 높아지는 문제점이 있으며, 특히 철분말의 산화시 소결현상이 일어나 철산화물의 입자가 조대해지기 때문에 이를 다시 분쇄해 주어야 하는 단점이 있다.In the conventional manufacturing method described above, the iron powder is oxidized at a high temperature of about 600 ° C. to 700 ° C. to adjust the oxygen content in manufacturing iron oxide as the main raw material of the thermite welding material, thereby complicating the process and increasing the manufacturing cost. In particular, since the sintering phenomenon occurs when the iron powder is oxidized, the particles of iron oxide become coarse, so there is a disadvantage in that they must be crushed again.
한편 철산화물로 직접 산화철 분말을 사용하는 경우에도 산소함량이 부족하면 발열량이 감소하여 양호한 용접이 곤란해지고, 반대로 산소함량이 많은 경우에는 과잉의 산소가 다른 원소와 반응하여 용접특성이 저하되므로 산화철 분말을 수소환원에 의해 산소함량을 적절히 조절해 주어야 하며 이때도 소결현상에 의해 산화철 입자가 조대해지므로 다시 분쇄해 주어야 하는 문제점이 있다.On the other hand, even when iron oxide powder is directly used as iron oxide, when oxygen content is insufficient, heat generation decreases, making it difficult to weld. Conversely, when oxygen content is large, excess oxygen reacts with other elements to reduce welding characteristics. The oxygen content should be properly adjusted by hydrogen reduction, and in this case, iron oxide particles are coarsened due to the sintering phenomenon.
따라서 본 발명은 이러한 종래 기술의 문제점을 감안하여 안출된 것으로, 산화 또는 수소환원 공정과 재분쇄 공정이 수반되는 종래의 테르미트 용접소재 제조방법이 갖는 공정상의 복잡함과 공정비가 높은 단점을 해소할 수 있는 밀스케일(mill scale)을 사용한 철 테르미트 용접소재 제조방법을 제공하는데 그 목적이 있다.Accordingly, the present invention has been made in view of the problems of the prior art, and can solve the disadvantages of the process complexity and high process cost of the conventional thermite welding material manufacturing method involving the oxidation or hydrogen reduction process and the regrinding process. An object of the present invention is to provide a method for manufacturing an iron thermite welded material using a mill scale.
또한 본 발명은 제철소에서 부산물로 산출되는 밀스케일(mill scale)을 철산화물의 원료로 사용함으로써 제조원가를 낮출 수 있고 효율적인 자원재활용이 가능한 철 테르미트 용접소재 제조방법을 제공하는 데에도 그 목적이 있다.In addition, an object of the present invention is to provide a method for manufacturing an iron-termit welded material which can reduce manufacturing cost and efficiently recycle resources by using mill scale calculated as a by-product of ironworks as a raw material of iron oxide. .
상기한 목적을 달성하기 위하여, 본 발명에 따르면, 철 테르미트 용접소재를 제조함에 있어서, 원료물질로서, 밀스케일(mill scale)과 알루미늄 분말 그리고 미량 첨가제인 금속철, 망간철 및 실리콘카바이드를 분급하여 밀 스케일의 입도가 14메쉬(mesh)∼100메쉬(mesh), 알루미늄 분말의 입도가 30메쉬(mesh)∼100메쉬(mesh), 금속철과 망간철의 입도가 14메쉬(mesh) 이상, 실리콘카바이드의 입도는 30메쉬(mesh)∼50메쉬(mesh)가 되도록 입도를 조절하는 단계; 및 상기 알루미늄 분말과 밀 스케일중의 산소와의 몰비(MAl/MO)가 0.6∼0.7이 되도록 혼합하고, 상기 밀 스케일과 알루미늄 분말 및 미량 첨가제를 혼합하는 단계를 포함하는 것을 특징으로 하는 밀 스케일을 사용한 철 테르미트 용접소재 제조방법이 제공된다.In order to achieve the above object, according to the present invention, in the manufacture of the iron thermite welded material, as a raw material, mill scale and aluminum powder and the trace additive metal iron, manganese iron and silicon carbide classification The grain size of the mill scale is 14 mesh to 100 mesh, the aluminum powder is 30 mesh to 100 mesh, the metal iron and manganese iron are 14 mesh or more, Controlling the particle size of the silicon carbide to be 30 mesh to 50 mesh; And mixing the aluminum powder with the oxygen in the mill scale so that the molar ratio (M Al / M O ) is 0.6 to 0.7, and mixing the mill scale with the aluminum powder and a trace additive. Provided is a method for manufacturing an iron thermite welded material using a scale.
상기한 철산화물로 사용된 밀스케일(mill scale)에는 기름과 오염물질이 묻어 있어 테르미트 반응시 가스가 많이 발생되어 기포 생성과 같은 용접특성에 악영향을 미치므로 400℃ 부근에서 10분 정도 배소하여 오염물질을 제거해 주어야 하며, 밀스케일(mill scale)중 산소는 25중량% 정도 함유되어 있다.The mill scale used as the iron oxide has oil and contaminants, and gas is generated during the termite reaction, which adversely affects welding characteristics such as bubble formation. Contaminants must be removed and oxygen contains about 25% by weight of oxygen on the mill scale.
상기와 같이 몰비 조절단계에서 금속철의 첨가량은 용접재 총량의 4중량%∼6중량%인 것을 특징으로 하고, 상기 몰비 조절단계에서 망간철(ferro-manganese)의 첨가량은 용접재 총량의 2중량%∼3중량%인 것을 특징으로 하고, 상기 몰비 조절단계에서 실리콘카바이드(SiC)의 첨가량은 용접재 총량의 1.4중량%∼1.6중량%인 것을 특징으로 한다.As described above, the addition amount of the metal iron in the molar ratio adjustment step is characterized in that 4% by weight to 6% by weight of the total amount of the welding material, the addition amount of ferro-manganese in the molar ratio adjustment step is 2 weight of the total amount of the welding material. It is characterized in that the% to 3% by weight, the addition amount of silicon carbide (SiC) in the molar ratio adjustment step is characterized in that 1.4% to 1.6% by weight of the total amount of the welding material.
본 발명에 따라 철산화물로 밀스케일(mill scale)을 사용하여 철 테르미트 용접소재를 제조하는 바람직한 과정은 밀스케일(mill scale)과 알루미늄 분말 그리고 금속철, 망간철(ferro-manganese) 및 실리콘카바이드(SiC)를 적정 입도로 조절하고, 테르미트 반응시 발생되는 열량을 고려하여 알루미늄과 밀스케일(mill scale)중 산소와의 몰비(MAl/MO)조절과 함께 미량 첨가제로 금속철, 망간철(ferro-manganese) 및 실리콘카바이드(SiC)의 첨가량을 적절하게 조절하는 과정으로 이루어진다.According to the present invention, a preferred process for producing an iron-termit welded material using mill scale with iron oxide is mill scale and aluminum powder and metal iron, ferro-manganese and silicon carbide. (SiC) is adjusted to an appropriate particle size, and considering the amount of heat generated during the thermite reaction, it controls the molar ratio (M Al / M O ) of aluminum and oxygen in the mill scale and metal iron, manganese as a trace additive It consists of a process of properly adjusting the addition amount of iron (ferro-manganese) and silicon carbide (SiC).
본 발명에 의하면 상기한 입도 조절단계에서 밀스케일(mill scale)이나 알루미늄 분말의 입자가 지나치게 미세할 경우에는 균질한 혼합이 어려울 뿐만 아니라 반응이 격렬하게 일어나 일부 미반응 입자들은 비산되어 용접효율이 떨어지게 되고, 반대로 입자들이 너무 조대하면 반응이 억제되어 미반응 입자들이 테르미트 반응 후 금속생성물중에 혼입하게 되므로, 밀스케일(mill scale)은 체(sieve)로 분급하여 입도를 14메쉬(mesh)∼100메쉬(mesh)로 조절하고, 알루미늄 분말은 30메쉬(mesh)∼100메쉬(mesh)로 조절하는 것이 좋다. 그리고 금속철은 입도가 14메쉬(mesh) 이상으로 조절하며, 망간철(ferro-manganese)은 롤 크러셔(Roll Crusher)로 분쇄하여 입도를 14메쉬(mesh) 이상으로 조절하고, 실리콘카바이드(SiC)는 입도를 30메쉬(mesh)∼50메쉬(mesh)로 조절하는 것이 좋다.According to the present invention, when the particles of the mill scale or the aluminum powder are too fine in the particle size adjusting step, not only homogeneous mixing is difficult but also the reaction takes place violently, so that some unreacted particles are scattered and the welding efficiency is reduced. On the contrary, if the particles are too coarse, the reaction is suppressed and the unreacted particles are mixed in the metal product after the termite reaction, so the mill scale is classified into a sieve and the particle size is 14 mesh to 100 The mesh is adjusted, and the aluminum powder is preferably adjusted to 30 mesh (mesh) to 100 mesh (mesh). And the metal iron to adjust the particle size to 14 mesh (mesh) or more, the ferro-manganese is crushed by a roll crusher (Roll Crusher) to adjust the particle size to 14 mesh (mesh) or more, silicon carbide (SiC) It is good to adjust the particle size to 30 mesh (mesh) to 50 mesh (mesh).
상기와 같이 입도 조절단계 후 알루미늄 분말과 밀스케일(mill scale) 그리고 미량 첨가제인 금속철, 망간철(ferro-manganese) 및 실리콘카바이드(SiC)를 브이 믹서(V-Mixer)를 사용해 균질하게 혼합하여 알루미늄과 밀스케일(mill scale)중 산소와의 몰비(MAl/MO)를 조절한다.After the particle size adjusting step as described above, the aluminum powder, mill scale and trace additives of metal iron, ferro-manganese and silicon carbide (SiC) are mixed homogeneously using a V-Mixer. Adjust the molar ratio (M Al / M O ) between aluminum and oxygen on mill scale.
상기한 몰비 조절단계에서 미량 첨가제인 금속철은 순간적으로 진행되는 테르미트 반응을 제어하기 위해서 첨가하는데, 이 경우 용탕이 냉각되는 효과를 갖게 되어 열량이 감소하고 이로 인해 용탕의 온도가 낮아지게 되므로 금속철의 첨가량은 4중량%∼6중량% 정도로 조절하는 것이 좋다.In the molar ratio adjustment step, the metal additive as a trace additive is added to control the termit reaction that proceeds instantaneously. In this case, the molten metal has an effect of cooling, so that the amount of heat decreases and the temperature of the molten metal decreases. The amount of iron added is preferably adjusted to about 4% by weight to 6% by weight.
한편 망간철(ferro-manganese)은 철구조물이나 레일 등의 기계적 강도를 유지하기 위한 경화원소로 첨가되며 또 탈황제로도 작용하는데, 테르미트 반응시 산소와 반응하여 발열량이 필요 이상으로 많아져 용접효율을 저하시키므로 망간철의 첨가량은 2중량%∼3중량% 정도로 조절한다.Ferro-manganese, on the other hand, is added as a hardening element to maintain the mechanical strength of iron structures and rails, and also acts as a desulfurizing agent. The amount of manganese iron added is adjusted to about 2% by weight to 3% by weight because it lowers.
이와 함께 철구조물이나 특히 레일의 경우 한국산업규격(KS B-8106)에 탄소함량이 0.6-0.75중량% 정도로 정해져 있어 용접부위의 탄소함량을 조절해 주기 위한 공급원으로 실리콘카바이드(SiC)를 첨가하게 되는데, 실리콘카바이드(SiC)중 실리콘(Si)의 일부가 테르미트 반응시 산소와 반응하여 상대적으로 알루미늄의 양이 많아지는 결과를 초래하게 되어 발열량이 필요 이상으로 많아지고 이로 인해 용접부위의 표면이 불량해지는 것과 함께 내부에 조대한 기공이 생기게 되므로 실리콘카바이드(SiC)의 첨가량은 1.4중량%∼1.6중량%로 조절한다.In addition, in the case of steel structures and especially rails, the carbon content is set at 0.6-0.75% by weight in Korean Industrial Standard (KS B-8106), so that silicon carbide (SiC) should be added as a source to control the carbon content of the welded part. Part of the silicon (Si) in the silicon carbide (SiC) reacts with oxygen during the thermite reaction, resulting in a relatively large amount of aluminum, resulting in a higher heat generation than necessary, resulting in a surface of the weld site In addition to the poor pores are formed inside the silicon carbide (SiC) addition amount is adjusted to 1.4% by weight to 1.6% by weight.
그리고 상기한 알루미늄과 밀스케일(mill scale)중 산소와의 몰비(MAl/MO) 조절단계에서 알루미늄의 양이 너무 적으면 용탕의 열량이 충분히 유지되지 않기 때문에 용탕이 응고되기 전에 기포가 제거될 시간이 별로 없어 철시편에 기공이 약간 존재하게 되며, 반대로 알루미늄의 양이 상당히 많아지게 되면 발열량이 급격히 증가하여 용탕이 끓으면서 철시편의 표면이 매우 거칠게 되고 내부에 매우 큰 기공이 존재하게 되므로 금속철과 망간철(ferro-manganese) 그리고 실리콘카바이드(SiC)의 첨가량을 고려하여 알루미늄과 산소와의 몰비(MAl/MO)는 0.6∼0.7로 조절하며, 더욱 바람직하게는 0.65가 좋다.And if the amount of aluminum is too small in the molar ratio (M Al / M O ) of the aluminum and oxygen in the mill scale, the heat of the molten metal is not maintained sufficiently, so bubbles are removed before the molten metal is solidified. Because there is not much time to be present, there will be some pores in the iron specimen. On the contrary, if the amount of aluminum is considerably increased, the calorific value will increase rapidly and the surface of the iron specimen will become very rough as the molten metal boils, and very large pores will exist inside the metal. In consideration of the addition amount of iron, ferro-manganese and silicon carbide (SiC), the molar ratio (M Al / M O ) between aluminum and oxygen is adjusted to 0.6 to 0.7, more preferably 0.65.
이와 같이 제조된 용접소재를 사용하여 테르미트 용접반응을 행하면 발열량이 적절하여 용접시편의 내부에 기공이 존재하지 않으며, 화학조성도 레일 규격(KS B-8106)에 나타난 화학조성 범위에 속하고 있다.When thermite welding reaction is performed using the welding material manufactured as described above, the amount of heat generated is appropriate, so that no pores exist in the welding specimen, and the chemical composition is also within the chemical composition range indicated in the rail standard (KS B-8106). .
상기 본 발명으로 밀스케일(mill scale)을 사용하여 철 테르미트 용접소재를 제조하는 경우, 종래의 테르미트 용접소재 제조방법에 비해 철산화물을 제조하기 위한 산화 및 수소환원 공정과 재분쇄 공정을 생략할 수 있어 공정이 간편하고 공정비용이 저렴하며, 용접성능이 우수한 장점이 있다. 또한 본 발명은 제철소에서 부산물로 산출되는 밀스케일(mill scale)을 철산화물의 원료로 사용함으로써 제조원가를 상당히 낮출 수 있고, 효율적인 자원재활용이 가능한 환경친화적인 특징이 있다.When the iron thermite welded material is manufactured by using the mill scale according to the present invention, the oxidation and hydrogen reduction process and the regrinding process for manufacturing iron oxide are omitted in comparison with the conventional method of manufacturing thermite welded material. It can be a simple process, low process cost, and has excellent welding performance. In addition, the present invention can significantly reduce the manufacturing cost by using a mill scale (calculated as a by-product from the steel mill) as a raw material of iron oxide, it has an environmentally friendly feature that enables efficient resource recycling.
이하에 상기한 본 발명의 바람직한 실시예를 참고하여 더욱 상세하게 설명한다.Hereinafter, with reference to the preferred embodiment of the present invention described above in more detail.
(실시예 1)(Example 1)
테르미트 용접소재중 철산화물은 제철소에서 부산물로 산출되는 밀스케일(mill scale)로 기름이나 오염물질 등을 제거하기 위해 400℃에서 10분간 배소하여 사용하였으며, 밀스케일(mill scale)과 금속철, 망간철((ferro-manganese) 및 실리콘카바이드(SiC)의 화학조성을 표1에 나타내었다.Iron oxide in the thermite welding material is a mill scale produced as a by-product of the steel mill, and roasted at 400 ° C. for 10 minutes to remove oil or contaminants. Mill scale, metal iron, Table 1 shows the chemical composition of ferro-manganese and silicon carbide (SiC).
표 1에서 보는 바와 같이 밀스케일(mill scale)중에는 철(Fe)가 73.2 중량% 그리고 산소가 25중량% 함유되어 있고, 이외에 망간(Mn), 실리콘(Si) 및 구리(Cu)가 미량 함유되어 있으며 탄소(C)가 0.083중량% 함유되어 있다. 그리고 미량 첨가제인 금속철에는 망간(Mn), 실리콘(Si) 및 탄소(C)가 소량 함유되어 있으며, 망간철(ferro-manganese)에는 망간(Mn)이 74중량%, 철(Fe)이 23.6중량% 함유되어 있고, 실리콘카바이드(SiC)에는 실리콘(Si)이 66.4중량% 및 탄소(C)가 29중량% 정도 함유되어 있다.As shown in Table 1, the mill scale contains 73.2% by weight of iron (Fe) and 25% by weight of oxygen, and also contains a small amount of manganese (Mn), silicon (Si), and copper (Cu). It contains 0.083% by weight of carbon (C). The trace additive metal iron contains a small amount of manganese (Mn), silicon (Si) and carbon (C), and ferro-manganese contains 74% by weight of manganese (Mn) and iron (Fe) of 23.6. By weight%, silicon carbide (SiC) contains about 66.4% by weight of silicon (Si) and about 29% by weight of carbon (C).
상기한 각 첨가제들을 체(sieve)로 분급하여 밀스케일(mill scale)과 알루미늄 분말의 입도는 각각 14메쉬(mesh)∼100메쉬(mesh)와 30메쉬(mesh)∼100메쉬(mesh)로 조절하며, 금속철과 망간철(ferro-manganese)의 입도는 14메쉬(mesh) 이상으로 조절하고, 실리콘카바이드(SiC)는 입도를 30메쉬(mesh)∼50메쉬(mesh)로 조절한다. 상기에서 입도 조절된 첨가제들 중 금속철은 용접재 총량의 4중량%, 망간철은 용접재 총량의 2중량% 그리고 실리콘카바이드는 1.4중량% 정도 첨가하고, 알루미늄 분말과 밀스케일중 산소와의 몰비(MAl/MO)는 0.5, 0.6, 0.7 및 0.8로 변화시켜면서 브이 믹서(V-mixer)를 사용하여 균질하게 혼합한 다음 테르미트 반응을 시행하였으며, 그 결과를 표 2에 나타내었다.The additives are classified into sieves to adjust the grain size of the mill scale and the aluminum powder to 14 mesh to 100 mesh and 30 mesh to 100 mesh, respectively. In addition, the particle size of the metal iron and ferro-manganese is adjusted to more than 14 mesh (mesh), silicon carbide (SiC) is adjusted to 30 mesh (mesh) to 50 mesh (mesh). Among the particle size-adjusted additives, metal iron is added 4% by weight of the total welding material, manganese iron is added by 2% by weight of the total welding material and about 1.4% by weight of silicon carbide, and the molar ratio of aluminum powder and oxygen in the mill scale. (M Al / M O ) was changed to 0.5, 0.6, 0.7 and 0.8, homogeneously mixed using a V-mixer, and then subjected to the Termit reaction. The results are shown in Table 2.
표 2에서와 같이 알루미늄과 산소와의 몰비(MAl/MO)가 0.5일 경우에는 알루미늄 양이 작아 테르미트 반응에 의해 발생되는 발열량이 적은 관계로 기포가 전부 제거되기 전에 용탕이 빨리 응고되어 용접부내에 미세한 기공이 존재하고 있다. 그리고 몰비(MAl/MO)가 0.6 내지 0.7인 경우는 발열량이 적절하여 용접부내에 기공이 전혀 존재하지 않으나, 몰비(MAl/MO)가 0.8로 증가하면 알루미늄 양이 상대적으로 많아 발열량이 크게 증가하여 용접시편의 표면이 불량하고 내부에 조대한 기공이 존재하고 있다.As shown in Table 2, when the molar ratio (M Al / M O ) between aluminum and oxygen is 0.5, the molten metal solidifies quickly before all the bubbles are removed because the amount of heat generated by the Termit reaction is small because the amount of aluminum is small. Fine pores exist in the weld. If the molar ratio (M Al / M O ) is 0.6 to 0.7, the heat generation amount is appropriate, and there are no pores in the weld. However, if the molar ratio (M Al / M O ) is increased to 0.8, the amount of aluminum is relatively high and the heat generation amount is increased. Due to the large increase, the surface of the welded specimen is poor and there are coarse pores therein.
한편 테르미트 반응후 금속철의 회수율은 92%에서 96% 정도로 몰비(MAl/MO) 변화에 따라 급격한 증가를 보이지 않으며, 조대한 기공이 생성되는 몰비(MAl/MO) 0.8에서도 금속철 회수율이 96% 정도로 나타나고 있다.On the other hand, the recovery of metal iron after the termite reaction did not increase rapidly due to the change in the molar ratio (M Al / M O ) from 92% to 96%, and the metal even at the molar ratio (M Al / M O ) 0.8 where coarse pores are formed. Iron recovery is estimated at 96%.
(실시예 2)(Example 2)
실시예 1과 동일한 방법으로 행하되, 몰비 조절단계에서 알루미늄 분말과 밀스케일중 산소와의 몰비(MAl/MO)는 0.65로 하고, 금속철은 용접재 총량의 6중량%, 망간철은 용접재 총량의 3중량% 그리고 실리콘카바이드의 첨가량은 1.0중량%, 1.4중량%, 1.6중량%, 1.8중량% 및 2.0중량%로 변화시켜면서 브이 믹서(V-Mixer)를 사용하여 균질하게 혼합한 다음 테르미트 반응을 시행하였으며, 그 결과를 표 3에 나타내었다.In the same manner as in Example 1, in the molar ratio adjustment step, the molar ratio (M Al / M O ) of aluminum powder and oxygen in the mill scale is 0.65, the metal iron is 6% by weight of the total amount of the welding material, the manganese iron is welded 3% by weight of the total amount of ash and the amount of silicon carbide added were 1.0%, 1.4%, 1.6%, 1.8% and 2.0% by weight, and then mixed homogeneously using a V-Mixer. Thermit reaction was carried out and the results are shown in Table 3.
표 3에서 보는 바와 같이, 실리콘카바이드(SiC)의 첨가량이 1.0중량%인 경우는 실리콘과 반응하는 산소 양이 적고, 이는 곧 잔류산소에 비해 상대적으로 알루미늄이 적기 때문에 발열량이 낮아 응고 후 용접부내에 미세한 기공이 존재하고 있다. 그리고 실리콘카바이드(SiC)의 첨가량이 1.4중량%에서 1.6중량%인 경우에는 실리콘과 반응하는 산소와 알루미늄과 반응하는 잔류산소 비가 적절하여 테르미트 반응후 용접부내에 기공이 나타나지 않고 있다. 그러나 실리콘카바이드(SiC)의 첨가량이 1.8중량% 이상일 때는 밀 스케일중 산소가 실리콘과 반응하는 양이 많아지게 되고 이는 잔류산소에 비해 알루미늄 양이 많아지는 결과를 초래하여 테르미트 반응시 발열량이 급격히 증가하고 용접부내에 기공이 존재하게 되며, 첨가량이 2.0중량% 정도로 더욱 증가하게 되면 용접부 내부에 조대한 기공이 존재하게 된다.As shown in Table 3, when the addition amount of silicon carbide (SiC) is 1.0% by weight, the amount of oxygen reacting with silicon is small, which is low in calorific value because the aluminum is relatively low compared to residual oxygen. Pore exists. When the amount of silicon carbide (SiC) added is 1.4% by weight to 1.6% by weight, the oxygen ratio reacting with silicon and the residual oxygen ratio reacting with aluminum are appropriate, and no pores appear in the weld after the termit reaction. However, when the addition amount of silicon carbide (SiC) is more than 1.8% by weight, the amount of oxygen reacts with silicon in the mill scale increases, which leads to an increase in the amount of aluminum compared to the residual oxygen, so that the calorific value rapidly increases during the termite reaction. The pores are present in the weld, and when the addition amount is increased to about 2.0% by weight, coarse pores are present in the weld.
이때 테르미트 반응 후 금속철 회수율은 실리콘카바이드(SiC)의 첨가량이 증가함에 따라 약간씩 증가하여 첨가량이 1.6중량%에서는 회수율이 96%로 나타나고 있으나, 실리콘카바이드(SiC) 첨가량이 2.0중량%로 높은 경우에는 급격한 발열량에 의해 입자들이 비산되어 회수율은 90% 정도로 감소하고 있다.At this time, the recovery rate of iron in the metal after the Termit reaction increased slightly as the amount of addition of silicon carbide (SiC) increased to 1.6% by weight, but the recovery was 96%, but the amount of addition of silicon carbide (SiC) was 2.0% by weight. In this case, the particles are scattered by the rapid calorific value and the recovery rate is reduced to about 90%.
한편 실리콘카바이드(SiC) 첨가량에 따른 용접부내에 탄소(C)함량을 살펴보면 테르미트 반응이 양호하게 나타나는 1.4중량% 내지 1.6중량%에서는 탄소(C)함량이 0.5중량% 및 0.65중량% 정도로 나타나 레일 규격(KS B-8106)의 화학조성 범위에 속하고 있으나, 실리콘카바이드(SiC) 첨가량이 2.0중량% 일 때는 탄소(C)함량이 0.73중량%로서 레일 규격 범위에 비해 다소 증가하고 있다.On the other hand, when looking at the carbon (C) content in the weld zone according to the amount of silicon carbide (SiC) added, the carbon (C) content is about 0.5% by weight and 0.65% by weight at 1.4% to 1.6% by weight, which shows a good termite reaction. Although it belongs to the chemical composition range of (KS B-8106), when the content of silicon carbide (SiC) is 2.0% by weight, the carbon (C) content is 0.73% by weight, which is slightly increased compared to the rail specification range.
한편, 입도 조절단계 및 몰비 조절단계에서 제조된 용접소재를 사용하여 테르미트 반응을 행한 후 회수된 용접부위의 화학조성은 표 4에서 보는 바와 같이 실리콘(Si)과 망간(Mn)이 각각 0.2중량% 및 0.72중량% 정도이고, 탄소(C)가 0.65중량%정도로 레일 규격(KS B-8106)에서 나타낸 화학조성 범위내에 속하고 있으며, 이외에 철재간 용접에서 유해원소인 인(P)과 황(S)등도 레일 규격(KS B-8106)의 규제범위(인 : 0.045중량% 이하, 황 : 0.05중량% 이하) 내에 속하고 있다.Meanwhile, as shown in Table 4, the chemical composition of the welded area after the termit reaction using the welding material manufactured in the particle size adjusting step and the molar ratio adjusting step is 0.2 weight of silicon (Si) and manganese (Mn), respectively. % And 0.72% by weight, carbon (C) of 0.65% by weight is within the chemical composition range indicated in the rail standard (KS B-8106), in addition to the harmful elements phosphorus (P) and sulfur ( S) and the like also fall within the regulated range (phosphorus: 0.045 wt% or less, sulfur: 0.05 wt% or less) of the rail standard (KS B-8106).
상기한 바와 같이 이루어진 본 발명의 방법에 의해, 밀스케일을 사용하여 철 테르미트 용접소재를 제조하는 경우, 종래의 테르미트 용접소재 제조방법에 비해 철산화물을 제조하기 위한 산화 및 수소환원 공정과 재분쇄 공정을 생략할 수 있어 공정이 간편하고 공정비용이 저렴하며, 용접성능이 우수한 효과가 있다. 특히 제철소에서 부산물로 산출되는 밀스케일(mill scale)을 철산화물의 원료로 사용함으로써 제조원가를 상당히 낮출 수 있고, 효율적인 자원재활용이 가능한 환경친화적인 효과를 제공한다.By the method of the present invention made as described above, in the case of manufacturing the iron thermite welding material using a mill scale, the oxidation and hydrogen reduction process and ash for producing iron oxide compared to the conventional method of manufacturing thermite welding material Since the grinding process can be omitted, the process is simple, the process cost is low, and the welding performance is excellent. In particular, by using the mill scale (calculated as a by-product of the steel mill) as a raw material of iron oxide, the manufacturing cost can be considerably lowered, and an environmentally friendly effect that enables efficient resource recycling is provided.
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| JPS5772792A (en) * | 1980-10-27 | 1982-05-07 | Kobe Steel Ltd | Coated electrode |
| JPS59147795A (en) * | 1983-02-15 | 1984-08-24 | Kawasaki Steel Corp | Welding method with large heat input by which welded joint having excellent toughness and bendability is obtained |
| JPS61140399A (en) * | 1984-12-12 | 1986-06-27 | Nippon Steel Corp | Coated electrode for fillet welding |
| JPS61176487A (en) * | 1985-02-01 | 1986-08-08 | Ishikawajima Harima Heavy Ind Co Ltd | Joining device of rolled stock |
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| JPS5772792A (en) * | 1980-10-27 | 1982-05-07 | Kobe Steel Ltd | Coated electrode |
| JPS59147795A (en) * | 1983-02-15 | 1984-08-24 | Kawasaki Steel Corp | Welding method with large heat input by which welded joint having excellent toughness and bendability is obtained |
| JPS61140399A (en) * | 1984-12-12 | 1986-06-27 | Nippon Steel Corp | Coated electrode for fillet welding |
| JPS61176487A (en) * | 1985-02-01 | 1986-08-08 | Ishikawajima Harima Heavy Ind Co Ltd | Joining device of rolled stock |
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