WO2003028944A1 - Connexion electrique en acier/aluminium formee par soudage et son procede de production - Google Patents

Connexion electrique en acier/aluminium formee par soudage et son procede de production Download PDF

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Publication number
WO2003028944A1
WO2003028944A1 PCT/US2002/029248 US0229248W WO03028944A1 WO 2003028944 A1 WO2003028944 A1 WO 2003028944A1 US 0229248 W US0229248 W US 0229248W WO 03028944 A1 WO03028944 A1 WO 03028944A1
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WO
WIPO (PCT)
Prior art keywords
aluminum
set forth
steel
weld
mold
Prior art date
Application number
PCT/US2002/029248
Other languages
English (en)
Inventor
Harrie Van Den Nieuwelaar
Ashriel Mohammed
Paul J. Hollingsworth
Original Assignee
Erico International Corporation
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Erico International Corporation filed Critical Erico International Corporation
Publication of WO2003028944A1 publication Critical patent/WO2003028944A1/fr

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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
    • B23K23/00—Alumino-thermic welding
    • 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
    • B23K35/34—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material comprising compounds which yield metals when heated
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/58—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation characterised by the form or material of the contacting members
    • H01R4/62—Connections between conductors of different materials; Connections between or with aluminium or steel-core aluminium conductors
    • H01R4/625—Soldered or welded connections
    • 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
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/18—Dissimilar materials
    • B23K2103/20—Ferrous alloys and aluminium or alloys thereof

Definitions

  • This invention relates generally as indicated to a welded steel/aluminum electrical connection and method, and more particularly to an exothermic welding apparatus and method for welding a variety of steel and aluminum electrical conductors, which steel parts may be in the form of steel collector bars or yokes, rectangular-in-section or round, and which aluminum parts may be solids, braids, flexible bar, laminations, strip, cable and the like.
  • Exothermic welding has become recognized as a preferred way to form top quality high ampacity, low resistance electrical connections.
  • Exothermic welded connections are generally immune to thermal conditions which can cause mechanical and compression joints to become loose or corrode. They are recognized for their durability and longevity. The process fuses together the parts or conductors to provide a molecular bond, with a current carrying capacity usually equal to that of the conductor. Such connections are widely used in grounding systems enabling the system to operate as a continuous conductor with lower resistivity.
  • CADWELD ® exothermic weld compositions and the high ampacity electrical connections utilize reusable molds such as those made of graphite or high temperature refractory materials and also sold under the trademark CADWELD ® .
  • the aluminum compositions and power connections are sold under the trademarks A-22TM and A-99TM, also trademarks of ERICO.
  • the reusable molds are two or more part molds usually opened and closed and held together by toggle clamps.
  • the mold parts have faces which abut at a parting plane in which are formed recesses forming the various cavities and passages when the parts are clamped together.
  • the mold parts form a weld chamber, which usually includes a riser which may be the enlarged lower end of a tap hole passage which extends from the top of the mold to the weld chamber.
  • the parts to be welded enter the weld chamber through passages which extend from outside the mold to the chamber. Such passages usually extend horizontally.
  • a crucible normally sits on top of the assembled mold parts.
  • the crucible includes a chamber holding the exothermic material on top of a fusible disk.
  • a sprue or tap hole below the disk communicates with the top of the mold through the riser.
  • the exothermic reaction may be comprised of a reaction between aluminum (Al) and a metal oxide wherein the metal oxide is reduced providing a filler metal, i.e., the source of the filler metal is the oxide on reduction.
  • U.S. Patent No. 3, 020,61 0 to Rejdak disk loses a method of welding aluminum (Al) and other metals, such as steel and provides a listing of various reactions which can be utilized to provide reaction products which may be utilized to provide a weldment.
  • This Rejdak patent along with prior patents 2,870,498 and 2,831 ,760, diskloses the bonding of steel and stainless steel to aluminum using an exothermic material having substantial amounts of tin oxide. However, the parts are dipped in molten tin so the cast weld metal will braze thereto.
  • Other aluminum welding compositions and processes may be seen in prior U.S. patents 5,062,903 to Brosnan, et al., 5, 1 71 ,378 to Kovarik, et al., and 5,490,888 to Assel, et al.
  • ferric oxide mixtures have been used to join steel- to-steel, rail welding being a common application.
  • such mixture is disklosed in Leuthy, et al. U.S. patents 3,234,603 and 3,255,498, both relating to the formation of the high tensile strength rebar splices using molten metal cast into a sleeve.
  • the splice and process is also sold under the CADWELD ® trademark.
  • CADWELD ® is a registered trademark of ERICO International Corporation. The mixture however, is not designed to fuse the bar ends but simply create a cast in place locking key.
  • Ferric oxide mixtures are also seen in prior U.S. patent 4, 104,093.
  • the composition is used with a refractory filler for repairing ingot mold base plates.
  • fusion welding of steel to aluminum which parts are widely found in electric furnaces, smelters, anode connections and other electrolytic processes, to form a high tensile strength low resistance electrical connection has not been economically successful, resulting in more expensive or more complex and costly techniques and mostly less practical techniques, such as mechanical connections, friction welding, or explosive or roll cladding, usually in combination with MIG or TIG welding. These are expensive techniques, and do not have the low cost or reliability of exothermic welding.
  • a method and apparatus for forming in-situ a welded fused electrical connection between a steel bar conductor part and an aluminum conductor part such as a solid, a braid, cable, laminate, or other flexible uses a ferric oxide, aluminum and flux composition which when ignited, forms a molten metal which fuses to the steel part but melts the aluminum part which then, when the weld cools, recrystallizes and anneals the adjacent unmelted aluminum to form an adequately strong molecularly bonded electrical connection.
  • the connection is an improvement over other forms of connections.
  • the weld metal forming the weld nugget by the process is primarily molten iron which welds to the steel but which melts the aluminum so that the nugget is on one side iron and on the other side aluminum with a substantial and very irregular Fe-AI intermetallics zone therebetween.
  • the aluminum part as it enters the mold may be sleeved in steel to prevent excess melting of the aluminum and provide containment for the molten aluminum.
  • the nugget is welded to about 60 - 80% or more of the steel face exposed while the entire end of the aluminum part is fused, recrystallized and annealed adjacent the melted part. The process requires no external energy, and may be accomplished in short order without shutting down the line.
  • Figure 1 is a fragmentary side elevation of apparatus for forming a steel-aluminum weld connection welding a round steel collector bar to an aluminum laminated flexible;
  • Figure 2 is a vertical section through the flexible as seen from the line 2-2 of Figure 1 ;
  • Figure 3 is a vertical section through the collector bar as seen from the line 3-3 of Figure 1 ;
  • Figure 4 is fragmentary view of a steel sleeve positioned around the aluminum flexible as it enters the mold.
  • Figure 5 is a vertical section taken from the line 5-5 of Figure 4 showing the L-shape components of the sleeve;
  • Figure 6 is a vertical section of the mold assembly of Figure 1 ;
  • Figure 7 is a view of the assembly from the left hand side of Figure 6;
  • Figure 8 is a section of the apparatus assembled with the parts to be welded in place and showing the crucible;
  • Figure 9 is an isometric view of similar apparatus for use with a rectangular steel collector bar
  • Figure 10 is an isometric view of a vertically split mold assembly as seen in Figure 9;
  • Figure 1 1 is a typical weld nugget section showing in somewhat idealized fashion the steel and aluminum parts; the Fe-AI intermetallics zone, the aluminum remelted zone, and the aluminum recrystallized and annealed zone.
  • FIG. 1 -3 there is illustrated a steel collector bar shown generally at 20 and an aluminum laminated flexible shown generally at 21 which are exothermically welded by the apparatus shown generally at 22.
  • the exothermic weld between the steel collector bar 20 and the aluminum flexible 21 produces a good electrical connection having sufficient mechanical strength.
  • the electrical connection between the steel and the aluminum is typical of many industrial applications involving electrolytic or electrolysis cells, electric furnaces, pot lines, smelters, such as aluminum smelters, and like heavy electrical equipment.
  • the various parts may comprise steel collector bars or yokes, anode yokes and stems, or cathode bars, for example.
  • Such connections require heavy duty, low resistence and high tensile strength electrical connections and should have a useful service life equal to that of the equipment involved.
  • the steel collector bar 20 is generally circular in cross- section although it may have a small flat 24 on the bottom as seen in Figure 3.
  • a clamp shown generally at 26 is secured around the projecting end of the collector bar.
  • the clamp comprises two generally semi-circular clamp elements 27 and 28, each of which includes almost diametrically extending ears or flanges shown at 29 and 30 for the clamp 27, and 31 , and 32 for the clamp 28.
  • the paired projecting ears or flanges are clamped together by respective nut and bolt assemblies shown generally at 33 and 34.
  • the clamp 27 includes radially projecting flanges or tabs 36 and 37, while clamp 28 includes similar tabs 38 and 39.
  • Each flange or tab is provided with a tapped hole to receive a threaded clamp rod as shown at 40, 41 , 42, and 43, respectively.
  • the lower clamp member 28 is provided with an L-shape bracket or base 45 which projects downwardly and then outwardly to support a horizontally split mold assembly shown generally at 46.
  • the mold assembly without the clamping, supporting, and other paraphernalia is shown more clearly in Figures 6, 7 and 8. Referring now additionally to such figures, it will be seen that the mold assembly 46 includes an upper mold part 48 and a lower mold part 49.
  • the refractory blocks forming the mold may be machined from graphite, or other suitable refractory material.
  • the mold parts join at a horizontal parting plane indicated at 50.
  • Each mold part has machined grooves or openings therein designed to mate with openings in the other mold part to form a sleeving passage indicated at 51 for the aluminum part, and a mold chamber shown generally at 52 communicating therewith.
  • a sprue passage shown generally at 54 is formed in the upper mold part and includes an angled slope sheet 55 terminating at the bottom in a lip or edge 56 at the upper end of the mold chamber 52.
  • the mold chamber undercuts the lip 56 to form a riser chamber 57 above the aluminum part. If slag is drawn into the mold chamber during the latter stages of exothermic process, it will form on top of the mold within the riser chamber and the lower end of the sprue passage, and may be removed after the weld is formed.
  • the weld chamber also extends below the projecting aluminum to ensure that any unreacted exothermic material which might be drawn into the weld chamber early in the welding process will flow past the end of the aluminum conductor so that at the interface between the aluminum conductor and the steel, only the desired hot metal of the correct formulation will form the principal part of the weld nugget between the aluminum and the face of the projecting steel.
  • a crucible shown generally at 60.
  • the crucible like the mold assembly may be formed of mating machined refractory blocks, and when joined they form a crucible chamber shown generally at 61 containing the exothermic material 62.
  • the lower end of the chamber is provided with a tap hole or passage 63 which communicates with the sprue passage 54 of the mold assembly.
  • the unreacted exothermic material 62 is supported on a fusable metal disk shown at 64 seated at the top of the tap hole and the bottom of the crucible chamber.
  • a layer of starting powder composition may be provided on top of the exothermic material as indicated at 65.
  • the crucible may be provided with a lid or top, not shown, and the exothermic material may be ignited with a spark gun, for example, through the open top 66. Alternatively, the exothermic material may be ignited electrically.
  • the upper and lower mold parts are provided with jackets indicated at 78 and 79 and are clamped vertically together by side tie-rods 80 and 81 .
  • Each of the rods are pivoted to the upper mold jacket as indicated at 82 and 83, respectively.
  • the distal or lower tips however are threaded and provided with nut and washer assemblies indicated at 84 and 85, each tightened against the underside of a projecting U-shape clevis as shown at 86 and 87, projecting from the lower mold part jacket.
  • the upper mold part may then quickly be clamped on the lower mold part by simply swinging the tie-rods into the receiving clevis and tightening the respective nut and washer assemblies.
  • the mold assembly also includes an L-shape bar indicated at 90 just below the entrance of the aluminum sleeving passage.
  • a clamp bracket bar 91 above the aluminum sleeving passage may be used to clamp the aluminum part in place by tightening the nut and bolt assemblies 92 and 93 clamping the aluminum part against the horizontally projecting shelf provided by the L-shape bracket 90. This assures that the end face 94 of the aluminum part is properly positioned in the mold chamber 52.
  • the end of the aluminum part in a steel sleeve shown generally at 96. It has been found that without the steel sleeve, excessive melting on the aluminum may occur.
  • the steel sleeve acts to absorb some of the heat generated by the exothermic reaction and the molten metal, contain the molten aluminum and provides an overall stronger joint.
  • the sleeve may be formed from two L-shaped members indicated at 97 and 98. The sleeve may be held in place by tape wrapped around the proximal end of the sleeve indicated at 99 and the adjacent aluminum part.
  • the sleeving passage 51 is of course dimensioned closely to accommodate the sleeve 96.
  • FIG. 9 there is illustrated a mold assembly mounted on a rectangular steel collector bar indicated at 1 10.
  • the mold assembly shown generally at 1 1 2 is held in place by a clamp assembly comprised of upper and lower clamps 1 13 and 1 14 which clamp around the projecting end of the collector bar.
  • the clamps fit the rectangular configuration of the bar and are clamped together by nut and bolt assemblies extending through the aligned openings in the laterally projecting ears seen at 1 1 5 and 1 1 6.
  • the clamps are also provided with vertically protecting tabs indicated at 1 1 7 and 1 18 accommodating threaded tie-rods which clamp the mold assembly 1 1 2 in place on the end of the collector bar.
  • a two part crucible indicated at 1 20 sits on top of the mold assembly and provides a chamber 1 21 for containing the exothermic material as illustrated more clearly in Figure 8.
  • the two parts of the crucible may be held together by suitable clamps, and like the mold assembly, the parts may be disassembled for cleaning and reuse.
  • the mold assembly shown at 1 1 2 unlike the mold assembly 46, is vertically split so that the side-by-side mold parts 1 23 and 1 24 have a vertical center parting plane indicated at 1 25. Otherwise the mold chamber and passages formed by the mold assembly are substantially as illustrated in Figures 6, 7, and 8.
  • the side-by-side molds form a sprue passage indicated at 1 26 which is formed of a slope sheet 1 27 which extends to the mold chamber 1 28.
  • the slope sheet directs the molten metal away from the aluminum and toward the steel.
  • Entering the mold chamber from the opposite side as the viewer in Figures 9 and 1 0 is the sleeving passage 1 29 for the aluminum part closely accommodating the part and its steel sleeve.
  • the rectangular face of the protecting steel collector bar closes the side of the mold chamber facing the viewer in Figures 9 and 1 0.
  • the mold assembly 1 1 2 is held to the clamp assembly by suitable tie- rods or clamp rods passing through the holes indicated at 1 30 in the projections 1 31 and 1 32 extending laterally from the side-by-side mold parts.
  • the mold assemblies illustrated may quickly be clamped to and assembled upon the projecting end face of the steel collector bar and they hold the aluminum part with its steel sleeve in proper position vis a vis the mold chamber and the end face of the steel collector bar.
  • the exothermic material When the exothermic material is ignited within the crucible, it reacts and melts the metal disk 64 to run downwardly through the sprue passage and is directed by the slope sheet toward the face of the steel to form a weld nugget bonding the steel and aluminum parts. Any slag forms on top and is later removed when the weld cools, the parts are disassembled and cleaned for reuse to form the next weld.
  • the weld takes about thirty minutes to accomplish since the parts may be quickly assembled and disassembled with a ratchet wrench, for example, and the power for the entire system does not have to be shut off as it would for MIG or TIG welding.
  • the weld nugget indicated generally at 1 40 is formed of molten iron fused as indicated at 141 to approximately sixty to ninety percent or more of the face 77 of the steel alloy collector bar. Preferably the fusion area is at least 75 or 80% of the face 77.
  • the iron weld nugget 140 is also fused to the steel sleeve as indicated at 142 and 143.
  • the weld nugget forms an intermetallic zone indicated generally at 1 44 while the zone 145 is primarily aluminum melted from the aluminum part and resolidified.
  • the zone 146 represents the part of the aluminum conductor which has been recrystallized and annealed by the weld heat.
  • the preferred intermetallic aluminum-iron alloy is FeAI and that such intermetallic zone may extend only for a distance from less than fifty (50) to about one hundred and twenty (1 20) microns between the iron and the aluminum section.
  • the intermetallic zone is extremely erose or irregular and literally meanders through the weld nugget in the zone 144 shown by the dotted lines which may be up to two millimeters wide.
  • the intermetallic zone is like a meandering river running through a relatively broad valley and the actual extent of the intermetallic zone is perhaps five to ten times or more the length of such zone.
  • the remelted zone 1 45 may be about eight (8) to twelve (1 2) millimeters wide, while the recrystallized and annealed zone 146 may be twelve (1 2) to fifteen (1 5) millimeters wide.
  • a preferred exothermic composition for forming the weld metal is a composition which will produce ninety-eight to ninety-nine percent (98-99%) or more of iron (Fe).
  • a preferred composition is iron oxide scale (primarily Fe 3 O 4 ) seventy-three point six percent (73.6%), aluminum powder twenty- two point nine percent (22.9%), and a flourspar (CaF 2 ) flux at about three point five percent (3.5%). It is important that additional materials such as silica not be included.
  • the composition should comprise about seventy to seventy-five percent (70-75%) by weight of iron oxide scale, about twenty-five to thirty percent (25-30%) aluminum, and a flux.
  • the proportions of the aluminum as the reducing agent and flux are designed to complete the reaction and form the resulting slag.
  • essentially none of the aluminum in the weld nugget derives from the exothermic composition but rather from the melted or fused aluminum part.
  • the size of the parts and the weld connections may vary.
  • the aluminum flexible may be thirty millimeters (30mm) or more thick and one hundred twenty millimeters (120mm) or more wide, while the collector bar may be one hundred thirty millimeters (130mm) or more in diameter or in rectangular dimension.
  • the amount of weld metal may vary, for example, from about two thousand grams (2000g) to about three thousand five hundred grams (3500g) .
  • Tests of electrical connections made in accordance with the present invention indicate a good low resistivity connection and, importantly, connections with sufficient tensile strength.
  • the electrical connection can be made quickly without shutting down the system and the electrical connection has a service life substantially equal to that of the components being joined.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Arc Welding In General (AREA)

Abstract

L'invention concerne un procédé et un appareil permettant de former une connexion électrique par fusion et soudage entre une partie de conducteur en acier (20) et une partie de conducteur en aluminium (21), laquelle peut se présenter sous la forme d'un solide, d'une tresse, d'un câble, d'une lame ou d'une autre structure souple. Ce procédé fait essentiellement appel à une composition exothermique comprenant un oxyde de fer, de l'aluminium et un fondant, et qui, une fois enflammée, forme principalement un métal ferreux fondu. Ce dernier fusionne avec la partie en acier (20) mais entraîne la fusion de la partie en aluminium (21) et, lorsque la soudure refroidit, il fusionne avec la partie en aluminium (21), recristallise et recuit l'aluminium non fondu pour constituer une connexion électrique présentant une solidité suffisante. Le noyau de soudure (140) comprend essentiellement du fer (140) ayant fusionné avec l'acier et une couche (142) intermétallique Fe-Al, ainsi que de l'aluminium refondu provenant de la partie en aluminium (21) et ayant fusionné avec l'aluminium recuit.
PCT/US2002/029248 2001-09-14 2002-09-13 Connexion electrique en acier/aluminium formee par soudage et son procede de production WO2003028944A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US32213801P 2001-09-14 2001-09-14
US60/322,138 2001-09-14

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WO2003028944A1 true WO2003028944A1 (fr) 2003-04-10

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN103286476A (zh) * 2013-05-13 2013-09-11 兰州连城铝业有限责任公司 铝电解槽立柱母线带电修复用熔剂

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5062903A (en) * 1989-09-13 1991-11-05 Erico Products, Inc, Welding process and mixture of reactants for use in such process
US5171378A (en) * 1989-09-13 1992-12-15 Erico International Corporation Aluminum welding process and mixture of reactants for use in such process
US5490888A (en) * 1993-12-06 1996-02-13 Erico International Corporation Mixture of reactants for use in welding

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5062903A (en) * 1989-09-13 1991-11-05 Erico Products, Inc, Welding process and mixture of reactants for use in such process
US5171378A (en) * 1989-09-13 1992-12-15 Erico International Corporation Aluminum welding process and mixture of reactants for use in such process
US5490888A (en) * 1993-12-06 1996-02-13 Erico International Corporation Mixture of reactants for use in welding

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN103286476A (zh) * 2013-05-13 2013-09-11 兰州连城铝业有限责任公司 铝电解槽立柱母线带电修复用熔剂

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