US3175074A - Electric arc welding - Google Patents

Electric arc welding Download PDF

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Publication number
US3175074A
US3175074A US228037A US22803762A US3175074A US 3175074 A US3175074 A US 3175074A US 228037 A US228037 A US 228037A US 22803762 A US22803762 A US 22803762A US 3175074 A US3175074 A US 3175074A
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Prior art keywords
percent
carbon
tube
rail
deposit
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Expired - Lifetime
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US228037A
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English (en)
Inventor
Russel P Culbertson
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Union Carbide Corp
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Union Carbide Corp
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Filing date
Publication date
Application filed by Union Carbide Corp filed Critical Union Carbide Corp
Priority to US228037A priority Critical patent/US3175074A/en
Priority to BE638005D priority patent/BE638005A/fr
Priority to GB38375/63A priority patent/GB1021297A/en
Priority to FR949262A priority patent/FR1376785A/fr
Priority to DEU10179A priority patent/DE1232291B/de
Priority to AT795863A priority patent/AT244706B/de
Application granted granted Critical
Publication of US3175074A publication Critical patent/US3175074A/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01B—PERMANENT WAY; PERMANENT-WAY TOOLS; MACHINES FOR MAKING RAILWAYS OF ALL KINDS
    • E01B31/00—Working rails, sleepers, baseplates, or the like, in or on the line; Machines, tools, or auxiliary devices specially designed therefor
    • E01B31/02—Working rail or other metal track components on the spot
    • E01B31/18—Reconditioning or repairing worn or damaged parts on the spot, e.g. applying inlays, building-up rails by welding; Heating or cooling of parts on the spot, e.g. for reducing joint gaps, for hardening rails
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/02—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape
    • B23K35/0255—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape for use in welding
    • B23K35/0261—Rods, electrodes, wires
    • B23K35/0266—Rods, electrodes, wires flux-cored
    • 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
    • B23K35/30—Selection of soldering or welding materials proper with the principal constituent melting at less than 1550 degrees C
    • B23K35/3053—Fe as the principal constituent
    • B23K35/308—Fe as the principal constituent with Cr as next major constituent
    • 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
    • B23K9/00—Arc welding or cutting
    • B23K9/0026—Arc welding or cutting specially adapted for particular articles or work
    • 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
    • B23K2101/00—Articles made by soldering, welding or cutting
    • B23K2101/26—Railway- or like rails

Definitions

  • the invention provides a cored-wire electrode for semiautomatic electric arc welding, especially building up worn rail ends in situ, without the need for any shielding gas stream, in which the core-material is a powder-blend of -30 screen size metal powder and free carbon in an amorphous state, the particles of which approach the molecular by virtue of the grinding which takes place with the metal powder in the mixing-blending process which also uniformly distributes and disburses such carbon throughout the core.
  • the welding operation is simpler, cheaper, and may be done by even inexperienced welders.
  • the weldments are superior in that they withstand battering in severe railroad service for a much longer time than was possible according to the prior art even in the cases of CO and argon stream are shielding.
  • This invention provides novel filled tube rod or wire electrodes, preferably in the form of coils which are applied by the open-arc process.
  • the electrode is preferably made according to the method of Stoody Patent No. 1,629,- 748, dated May 24, 1927.
  • One of the outstanding advantages of the open-arc process is the elimination of any need for an inert gas supply and attendant equipment. This feature is especially desirable for welding and hardsurfacing operations that are performed away from the shops, for example, field maintenance of railway track members.
  • the tube electrode filler usually contains an organic powder (wood or other vegetable products) or an inorganic powder such as siderite (FeCo or limestone (calcium carbonate). Such powders are consumed and/ or Sublimated by the heat of the arc, thereby providing an effective gaseous envelope (primarily CO and CO to protect the arc stream and the deposit puddle.
  • Tube electrodes that contain the above-mentioned organic and inorganic filler materials, which provide a protective gaseous envelope in open-arc processes, are used for many applications in industry.
  • deposits made from prior materials often vary widely in composition and physical and mechanical properties.
  • the railroad industry has preferred that right-of-way rail welding and surfacing be performed by inert-gas-shielded methods. Such methods assure more uniform deposits of the highest degree of quality and dependability, thus minimizing rail failures.
  • the primary object of this invention is to provide an improved composition for filler tube rods or coils.
  • Another important object is to provide .a welding or surfacing electrode suitable for application on railway right-of-way track members by the open-arc process.
  • Another object is to provide an improved tube rod or coil that will consistently produce deposits of the highest degree of quality and dependability.
  • Still another object is to provide an improved semi automatic arc Welding process.
  • a novel hard-facing tube rod consisting of a mild steel sheath and a filler material that is powderb lended, preferably according to Fischer Patent No. 2,514,126, dated July 4, 1950.
  • a filler material that is powderb lended, preferably according to Fischer Patent No. 2,514,126, dated July 4, 1950.
  • Such material comprises in weight-percent, about 23 percent chromium, 3 percent combined carbon, and 2 percent tree carbon, the particle size of which approaches the molecular, 0.80 percent silicon, 2.75 percent manganese, 2 percent molybdenum, .70 percent aluminum, 1 percent titanium, and the balance iron and incidental impurities together with less than 1 percent of an active fiuxing agent.
  • the ratio of sheath to filler material should be about 70 to 30 by weight.
  • the fused deposit of the tube rod consists of 4 to 7 percent chromium, .5 to 1.2'percent carbon, .5 to 1.25 percent manganese, .4 to 1.2 percent molybdenum, .5 percent maximum silicon, up to .1 percent aluminum, up to .25 percent titanium, and the balance iron and incidental impurities, with traces if any, of the fluxing agent.
  • Proper blending of the filler materials is an improvide impact strength, wear resistance, and hardness.
  • chromium, manganese and molybdenum may each vary in content, as shown in Table 2, it is preferred that their total content in the deposit should be not less than about 6 percent. Silicon may be present as an impurity up to about 0.5 percent.
  • Aluminum and titanium may be present as residual elements up to about .1 and .25 percent, respectively, in the deposit; however, these elements are usually lost during the hard-facing operation.
  • the aluminum-titanium compound in the filler serves as a deoxidizing and flexing agent.
  • Potassium titana-te is present in the tiller also as a fluxing agent.
  • Carbon is essential in the deposit alloy principally as a carbide former to provide hardness, wear resistance, and strength.
  • the balance of the deposit alloy is iron and the usual impurities associated with this class of alloys; i.e. phosphorus, sulphur and the like. These impurities should be kept at a very low content, consistent with the requirements of railroad mainline specifications.
  • the filled tube rods may be flash coated with copper to improve electrical contact, inhibit rust and to act as a lubricant for feeding mechanism.
  • the mild steel strip is copper coated before it is fashioned as the tube sheath.
  • FIG. 1 is a wiring diagram illustrating suitable means for carrying out the invention; Amount A t L In: 8 FIG. 2 is an enlarged cross-sectional view of the tube Added POP Material $235 rod, and cent by Weight Size FIG. 3 is a fragmentary plan view of a rail joint. As shown in FIG.
  • sheath material is the common SAE 1010 steel. Silicon, 0.0; to 0.09 percent.
  • Chromium is present in the iron-base alloy deposit as o 200 H g,; ff ⁇ -? ffi i, a carbide former to rovide stren th and hardness.
  • Man- PotasSium Titanflte 200m@S11- P g ganese and molybdenum are present in the deposit to TABLE 3 Range of Compositions, in w/o Filler Material Rail Deposit Preferred Broad Optimum Preferred Broad Optimum gr( combined) bined) Fe (tree) Best results are obtained when two percent by weight of amorphous carbon is blended into the filler powder as free carbon. Free carbon in the filler mixture stabilizes the arc, thereby promoting a steady burn-oil rate.
  • the amorphous carbon tends to stabilize the arc.
  • the stabilized arc provides a more uniform control of the fusion of the weld deposit, and especially the depth of penetration at a lower amperage. (Heretofore, high amperages had to be used to make up losses due to unstable arc performance.)
  • the burn-01f rate refers to the rate of consumption of the tube-rod during the depositing operation.
  • the stabilized arc promotes a uniform rate of deposition, and therefore, the process is less complicated and may be performed by semior even unskilled operators. Further, the uniformly high quality of the deposit renders it suitable for railroad right-of-way maintenance.
  • Lampblack is especially eifective as the amorphous carbon addition, especially when blended, so that its form approaches molecular size, with the other powdered ingredients of the filler.
  • the exact mechanism underlying criticality of lampblack in the composition is not clearly understood. It is tentatively proposed that the amorphous carbon, when added in the form of lampblack, is combined with oxygen in the heat of the arc, thereby providing a C envelope to protect the deposit puddle.
  • Equivalents of lampblack may be deposit products of the flame resulting from the incomplete combustion of carbonaceous materials or gases. These may include flame deposits of acetylene, natural or producers gas, petroleum products and the like. It is believed that the amorphous structure of such soot deposits combines more readily with oxygen to form the CO envelope. Further, the amorphous carbon is consumed during the hard-facing operation, and does not deleteriously altect the carbon content of the deposited alloy. Experiments show that, when crystalline carbon alone is used as the free carbon in the tube rod in open-arc operations, the carbon behaves erratically in the puddle and yields an alloy with an unpredictable carbon content.
  • crystalline carbon may be added to the tube-rod filler powder along with the amorphous carbon, in sufiicient quantities to obtain a predictable carbon content in the deposit. This constitutes a further improvement in the art.
  • the amorphous carbon is not readily wetted by the molten metal and, therefore, is less likely to be incorporated into the composition of the deposit alloy.
  • the amorphous carbon will tend to float on the puddle because of its lower specific gravity.
  • a comparison of the properties of the two forms of carbon is given in Table 4.
  • EXAMPLE I A mixture of filler material for a hard-facing tube rod was prepared in accordance with the preferred composition as shown in Table 2. After blending the mixture for about one hour in a twin-shell type of blender, the material was processed into a %4ll'lCl1 diameter rod. The proportion by weight of the S.A.E. 1010 steel sheath to filler material was 70 to 30. The method of preparing various sizes of tube-rod (for example, /1eto -inch diameter), while maintaining an established sheath-tofiller ratio is well known in the art.
  • the tube rod was prepared in the form of a coil with a flash coating of copper for the reasons mentioned above.
  • Methods of flash plating the mild steel sheath material are well known in the art.
  • the copper plating is very thin (less than 1 mil) and is probably vaporized and/ or oxidized in the heat of the arc.
  • the residual copper content, if any, is only in trace quantities and does not adversely affect the deposit quality.
  • the tube-rod was Open-arc deposited on a plate of SAE 1020 steel with a welding current of 275 amperes and 30 volts (direct current-reverse polarity). To obtain a smooth deposit, the weld beads were overlapped approximately 25 percent. Three layers were deposited; the entire deposit was then cold-work hardened by peening. Hardness values for each layer and the work-hardened deposit are shown in Table 5.
  • compositions were prepared to check the eproducibility of the tube-rod.
  • the compositions are identified as Heat No. 7 and Heat No. 36.
  • Each heat was prepared into a number of coils. Hardness values of deposits from random coils are shown in Table 5.
  • Alloy A Several miles of mainline track of an eastern railroad was designated as a testing site where Alloy A was deposited on worn rail ends by the open-arc process. The deposits are continually inspected and evaluated to determine the wear and endurance characteristics under actual conditions of use in mainline track.
  • An arc welding tube rod filler material composed of a --30 screen size powder-blend of the following ingredients, by weight:
  • An arc welding tube rod filler material composed of a --30 screen size powder-blend of the following ingredients, by weight:
  • An arc Welding tube rod consisting of a mild steel sheath containing a core of filler material as defined by claim 2, in which the proportion by Weight of the steel sheath to filler material is of the order of 70 to 30.
  • Method of hard facing Work composed of steel, which comprises energizing an electric Welding are between the end of tube rod as defined by claim 4, and such Work with a source of direct current at reverse polarity in circuit therewith, and feeding said tube rod toward such are to obtain a smooth fused deposit of alloy from the tube rod that is welded to the Work, consisting of a -30 screen size powder-blended mixture, of 4 to 7 percent chromium, .5 to 1.2 percent carbon, about half of which is in an amorphous form having an almost molecular particle size, .5 to 1.25 percent manganese, .4 to 1.2 percent molybdenum, .5 percent maximum silicon, up to .1 percent aluminum, up to .25 percent titanium, and the balance iron and incidental impurities, with traces, if any, of the fiuxing agent.
  • a hard-facing tube rod consisting of a mild steel sheath and a -30 screen size powder blend of filler mate rial comprising, in weight-percent, about 23 percent chronium, 3 percent combined carbon and 2 percent free carbon, 0.80 percent silicon, 2.75 percent manganese, 2 percent molybdenum, .70 percent aluminum, 1 percent titanium, and the balance iron and incidental impurities together with less than 1 percent of an active fiuxing agent, in which the ratio of sheath to filler material is about 70 to 30 'by Weight, and said free carbon in an amorphous state is uniformly powder-blended with the other ingredients of the filler material so that the particles of free carbon in such blend approach molecular particle size.
  • a Work-in-circuit Welding tube rod filler material containing a -30 screen size powder-blend of chromium, manganese, molygdenum, silicon, and a fluxing agent said powder-blend comprising of, by weight, about 50 percent iron powder and about 2 percent free carbon, wherein such free carbon is in an amorphous state; and incidental unavoidable impurities normally found in articles of this class; said free canbon having a particle size that approaches the molecular.
  • An arc welding electrode consisting of a wire provided with a core composed of the material set forth in claim 7.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Nonmetallic Welding Materials (AREA)
  • Arc Welding In General (AREA)
US228037A 1962-10-03 1962-10-03 Electric arc welding Expired - Lifetime US3175074A (en)

Priority Applications (6)

Application Number Priority Date Filing Date Title
US228037A US3175074A (en) 1962-10-03 1962-10-03 Electric arc welding
BE638005D BE638005A (OSRAM) 1962-10-03 1963-09-30
GB38375/63A GB1021297A (en) 1962-10-03 1963-09-30 Improvements in or relating to arc welding
FR949262A FR1376785A (fr) 1962-10-03 1963-10-01 électrodes pour soudure à l'arc électrique
DEU10179A DE1232291B (de) 1962-10-03 1963-10-03 Seelen-Elektrode fuer das Lichtbogenschweissen von Stahl
AT795863A AT244706B (de) 1962-10-03 1963-10-03 Lichtbogen-Schweißelektrode

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US228037A US3175074A (en) 1962-10-03 1962-10-03 Electric arc welding

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US3175074A true US3175074A (en) 1965-03-23

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US228037A Expired - Lifetime US3175074A (en) 1962-10-03 1962-10-03 Electric arc welding

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US (1) US3175074A (OSRAM)
AT (1) AT244706B (OSRAM)
BE (1) BE638005A (OSRAM)
DE (1) DE1232291B (OSRAM)
FR (1) FR1376785A (OSRAM)
GB (1) GB1021297A (OSRAM)

Cited By (14)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3253120A (en) * 1963-08-19 1966-05-24 Hobart Brothers Co Welding electrodes
US3303323A (en) * 1963-08-19 1967-02-07 Hobart Brothers Co Welding electrodes
US3342626A (en) * 1963-10-02 1967-09-19 Avco Corp Flame spray metallizing
US3365565A (en) * 1964-07-20 1968-01-23 Hobert Brothers Company Welding electrodes
US3420980A (en) * 1966-07-22 1969-01-07 Union Carbide Corp Method and material for hard-surfacing
US3534390A (en) * 1968-04-29 1970-10-13 Stoody Co Welding wire
US4129773A (en) * 1975-09-12 1978-12-12 Abex Corporation Consumable guide tube assembly
US4134196A (en) * 1975-07-25 1979-01-16 Hitachi Cable Ltd. Method of production of a wire-shaped composite addition material
US4143211A (en) * 1974-05-01 1979-03-06 Nippon Steel Corporation Continuous casting addition material
JPS62282800A (ja) * 1986-05-30 1987-12-08 Daido Steel Co Ltd ガスシ−ルドア−ク溶接用ワイヤ
WO1997018921A1 (de) * 1995-11-23 1997-05-29 Jinpo Pluls A.S. Verfahren zur aufschweissung der schienen
US20130233839A1 (en) * 2012-03-12 2013-09-12 Hobart Brothers Company Systems and methods for welding electrodes
US20140021188A1 (en) * 2012-07-19 2014-01-23 Lincoln Global, Inc. Hot-wire consumable to provide weld with increased wear resistance
JP2015518427A (ja) * 2012-04-17 2015-07-02 ホバート ブラザーズ カンパニー 溶接電極用のシステムおよび方法

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6375895B1 (en) * 2000-06-14 2002-04-23 Att Technology, Ltd. Hardfacing alloy, methods, and products
US7361411B2 (en) 2003-04-21 2008-04-22 Att Technology, Ltd. Hardfacing alloy, methods, and products
WO2012080435A1 (en) 2010-12-15 2012-06-21 Land Rover Wading vehicle water level display

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1629748A (en) * 1926-01-28 1927-05-24 Stoody Co Method of making welding rods and the resulting product
US1704978A (en) * 1920-12-06 1929-03-12 Rail Welding And Bonding Compa Welding stick
US1745267A (en) * 1926-05-22 1930-01-28 Hollup Corp Coating for welding rods
US1942364A (en) * 1926-06-01 1934-01-02 Una Welding & Bending Company Welding electrode
US3029165A (en) * 1960-08-26 1962-04-10 Int Nickel Co Malleable-cored hard surfacing welding electrode

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CH171637A (de) * 1933-04-08 1934-09-15 Kokay Jolan Fessel.

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1704978A (en) * 1920-12-06 1929-03-12 Rail Welding And Bonding Compa Welding stick
US1629748A (en) * 1926-01-28 1927-05-24 Stoody Co Method of making welding rods and the resulting product
US1745267A (en) * 1926-05-22 1930-01-28 Hollup Corp Coating for welding rods
US1942364A (en) * 1926-06-01 1934-01-02 Una Welding & Bending Company Welding electrode
US3029165A (en) * 1960-08-26 1962-04-10 Int Nickel Co Malleable-cored hard surfacing welding electrode

Cited By (20)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3253120A (en) * 1963-08-19 1966-05-24 Hobart Brothers Co Welding electrodes
US3303323A (en) * 1963-08-19 1967-02-07 Hobart Brothers Co Welding electrodes
US3342626A (en) * 1963-10-02 1967-09-19 Avco Corp Flame spray metallizing
US3365565A (en) * 1964-07-20 1968-01-23 Hobert Brothers Company Welding electrodes
US3420980A (en) * 1966-07-22 1969-01-07 Union Carbide Corp Method and material for hard-surfacing
US3534390A (en) * 1968-04-29 1970-10-13 Stoody Co Welding wire
US4143211A (en) * 1974-05-01 1979-03-06 Nippon Steel Corporation Continuous casting addition material
US4134196A (en) * 1975-07-25 1979-01-16 Hitachi Cable Ltd. Method of production of a wire-shaped composite addition material
US4129773A (en) * 1975-09-12 1978-12-12 Abex Corporation Consumable guide tube assembly
JPS62282800A (ja) * 1986-05-30 1987-12-08 Daido Steel Co Ltd ガスシ−ルドア−ク溶接用ワイヤ
WO1997018921A1 (de) * 1995-11-23 1997-05-29 Jinpo Pluls A.S. Verfahren zur aufschweissung der schienen
US20130233839A1 (en) * 2012-03-12 2013-09-12 Hobart Brothers Company Systems and methods for welding electrodes
WO2013138175A3 (en) * 2012-03-12 2013-11-21 Hobart Brothers Company A welding wire electrode, a welding method and a welding system
CN104144765A (zh) * 2012-03-12 2014-11-12 霍伯特兄弟公司 用于焊接电极的系统和方法
JP2015514584A (ja) * 2012-03-12 2015-05-21 ホバート ブラザーズ カンパニー 溶接電極用のシステムおよび方法
US9950394B2 (en) * 2012-03-12 2018-04-24 Hobart Brothers Company Systems and methods for welding electrodes
JP2015518427A (ja) * 2012-04-17 2015-07-02 ホバート ブラザーズ カンパニー 溶接電極用のシステムおよび方法
US9707643B2 (en) 2012-04-17 2017-07-18 Hobart Brothers Company Systems and methods for welding electrodes
US11130203B2 (en) 2012-04-17 2021-09-28 Hobart Brothers Llc Systems and methods for welding electrodes
US20140021188A1 (en) * 2012-07-19 2014-01-23 Lincoln Global, Inc. Hot-wire consumable to provide weld with increased wear resistance

Also Published As

Publication number Publication date
FR1376785A (fr) 1964-10-31
DE1232291B (de) 1967-01-12
BE638005A (OSRAM) 1964-01-16
GB1021297A (en) 1966-03-02
AT244706B (de) 1966-01-25

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