WO2017154120A1 - フラックス入りワイヤ、溶接継手の製造方法、及び溶接継手 - Google Patents
フラックス入りワイヤ、溶接継手の製造方法、及び溶接継手 Download PDFInfo
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- WO2017154120A1 WO2017154120A1 PCT/JP2016/057242 JP2016057242W WO2017154120A1 WO 2017154120 A1 WO2017154120 A1 WO 2017154120A1 JP 2016057242 W JP2016057242 W JP 2016057242W WO 2017154120 A1 WO2017154120 A1 WO 2017154120A1
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- B23K9/00—Arc welding or cutting
- B23K9/16—Arc welding or cutting making use of shielding gas
- B23K9/164—Arc welding or cutting making use of shielding gas making use of a moving fluid
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- 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
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- 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
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- 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
- B23K35/3073—Fe as the principal constituent with Mn as next major constituent
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- B23K35/3603—Halide salts
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- B23K35/36—Selection of non-metallic compositions, e.g. coatings, fluxes; Selection of soldering or welding materials, conjoint with selection of non-metallic compositions, both selections being of interest
- B23K35/362—Selection of compositions of fluxes
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- B23K35/365—Selection of non-metallic compositions of coating materials either alone or conjoint with selection of soldering or welding materials
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- 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
- B23K35/36—Selection of non-metallic compositions, e.g. coatings, fluxes; Selection of soldering or welding materials, conjoint with selection of non-metallic compositions, both selections being of interest
- B23K35/368—Selection of non-metallic compositions of core materials either alone or conjoint with selection of soldering or welding materials
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- B23K9/00—Arc welding or cutting
- B23K9/235—Preliminary treatment
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- C22C38/00—Ferrous alloys, e.g. steel alloys
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Definitions
- the present invention relates to a flux-cored wire, a method for manufacturing a welded joint, and a welded joint.
- the present invention is used for welding high-strength steels having a tensile strength of 780 MPa or more, can omit the preheating work for preventing low temperature cracking, or can reduce the preheating temperature during the preheating work.
- the present invention relates to a flux-cored wire that can obtain a weld metal that is excellent in resistance and can suppress generation of spatter.
- Patent Documents 1 to 4 are intended for welding mainly on a steel sheet having a strength level at which weld cracking does not cause a problem, and cold cracking of a weld metal has not been studied at all.
- Patent Document 5 in the flux-cored wire for 490 to 780 MPa class high-strength steel, the amount of V is optimized and the cold cracking resistance is improved by occluding V with diffusible hydrogen.
- a wire having a welding crack stop preheating temperature of 50 ° C. or lower is proposed, although it is a 780 MPa class wire.
- weld metal needs to have higher toughness, but Patent Document 5 does not particularly examine the toughness of the weld metal.
- Patent Literature 6 As a technique that greatly improves the above-mentioned prior art, when welding high strength steel having a tensile strength of 780 MPa or more, a wire that does not require preheating or has low temperature crack resistance even when the preheating temperature is low is disclosed in Patent Literature 6.
- gas shielded arc welding it is desired to use 100% CO 2 gas at low cost as the shielding gas, but Patent Document 6 does not show an example using 100% CO 2 gas.
- Patent Documents 7 to 9 contain CaF 2 and other fluorides and oxides, the ratio of the fluoride and oxide contents is within a predetermined range, and the Ceq content is within a predetermined range.
- a pulse gas shielded arc welding method using a flux-cored wire limited to 2 is disclosed. According to Patent Documents 7 to 9, it is possible to obtain a weld metal having excellent elongation at break while suppressing the occurrence of ductility-reducing cracking when welding ultra-high strength steel having a tensile strength of 950 MPa or more.
- Patent Document 10 contains one or more compounds selected from the group consisting of oxides containing one or more alkali metals, fluorides, and carbonates, and the specific surface area is within a predetermined range.
- a controlled metal flux-cored wire for gas shielded arc welding is disclosed. According to Patent Document 10, a flux-cored wire having excellent penetration properties and good mechanical properties and welding workability of a weld metal is provided.
- Patent Document 11 contains TiO 2 , alkali metal fluoride, and PTFE, and the ratio of the content of alkali metal fluoride to the content of PTFE is controlled within a predetermined range.
- a flux-cored wire for gas shielded arc welding whose content is limited to a predetermined amount or less is disclosed. According to Patent Document 11, a flux-cored wire that prevents diffusible hydrogen from entering a weld during arc welding, has excellent moisture absorption resistance, and exhibits good welding workability is provided.
- Patent Document 12 includes Ti oxide, Si oxide, Al oxide, Na compound and K compound, and metal fluoride, and the apparent density and average particle diameter of Al oxide are controlled within a predetermined range.
- a flux-cored wire for gas shielded arc welding for weathering steel is disclosed. According to Patent Document 12, when welding weatherproof steel, a flux-cored wire is provided in which welding workability in all-position welding is good, and a weld metal excellent in strength and toughness is obtained.
- Patent Document 13 discloses a flux-cored wire for gas shield arc welding that contains a metal fluoride and TiO 2 and whose Mg content and Al content are controlled within a range defined by a predetermined mathematical formula. According to Patent Document 13, a flux-cored wire is provided in which a weld with good welding workability and excellent low-temperature toughness is obtained.
- Patent Document 14 shows a flux-cored wire for a 490 to 780 MPa class high-tensile steel in which V is contained in the outer skin or flux. According to Patent Document 14, a flux-cored wire with improved cold crack resistance of a weld metal is provided.
- Patent Document 15 includes a metal fluoride, a neutral oxide or a basic oxide, one or two of Al and Mg, a deoxidizer, and a binder, and includes C, Si, and A flux-cored wire for gas shielded arc welding in which the Mn content is within a predetermined range is disclosed. According to Patent Document 15, a flux-cored wire that can provide a weld metal that is excellent in welding workability and that has good low-temperature toughness is provided.
- Patent Document 16 includes TiO 2 , SiO 2 , ZrO 2 , Al 2 O 3 , and fluoride, the content of which is controlled within a range defined by a predetermined mathematical formula, and the amount of hydrogen is a predetermined amount or less.
- a high-strength steel gas shielded arc-welded flux-cored wire is disclosed. According to Patent Document 16, a flux-cored wire that provides a weld metal having excellent welding workability and excellent mechanical properties is provided.
- the flux cored wires disclosed in Patent Documents 7 to 9 are required to contain a large amount of CaF 2 . Since CaF 2 increases the amount of spatter, the flux-cored wires disclosed in Patent Documents 7 to 9 deteriorate the welding workability.
- the flux-cored wire described in Patent Document 10 is a metal wire in which the flux does not contain a slag forming agent.
- the weld slag obtained by the slag forming agent has the effect of removing impurities from the molten pool, the effect of adjusting the bead width and bead wave to improve the appearance of the weld metal, and the effect of preventing the oxidation and nitridation of the weld metal immediately after solidification
- the wire disclosed in Patent Document 10 the effect of these welding slags cannot be obtained.
- Patent Document 11 does not disclose a method for sufficiently reducing the amount of diffusible hydrogen in a weld metal.
- the diffusible hydrogen of the weld metal obtained using the example of the flux-cored wire disclosed in Patent Document 11 is at least 1.9 ml / 100 g.
- the diffusible hydrogen content of the weld metal is 1.9 ml / 100 g or more, it is difficult to omit preheating or lower the preheating temperature without causing cold cracking.
- no consideration is given to the amount of sputtering when 100% CO 2 gas is used as the shielding gas, and no means for reducing the amount of sputtering is disclosed.
- Patent Document 12 does not disclose means for improving the cold cracking resistance of the weld metal.
- the amount of fluoride disclosed in Patent Document 12 is not sufficient to reduce the diffusible hydrogen of the weld metal.
- the flux-cored wires disclosed in Patent Documents 13 and 14 are required to contain a large amount of CaF 2 . Since CaF 2 increases the amount of spatter, the flux-cored wire disclosed in Patent Document 13 reduces welding workability.
- the flux-cored wire disclosed in Patent Document 15 is a filler material for low-strength steel that is less prone to cold cracking, and has not been studied to improve cold cracking resistance. No means for improving is disclosed.
- the flux cored wire disclosed in Patent Document 16 requires a large amount of TiO 2 . Therefore, when the flux-cored wire disclosed in Patent Document 16 is subjected to welding using CO 2 100% gas as a shielding gas, the toughness of the resulting weld metal is impaired.
- the present invention provides a method for manufacturing a welded joint, which can omit the preheating work for preventing cold cracking or can reduce the preheating temperature during the preheating work and can greatly reduce the amount of spatter generated. The purpose is to provide.
- an object of the present invention is to provide a welded joint having high strength and high toughness.
- the gist of the present invention is as follows.
- Flux-cored wire includes a steel sheath, and a flux filled in the steel outer skin, the flux, a fluoride, CaF 2, MgF 2,
- the total mass of the flux-cored wire of the fluoride is one or more selected from the group consisting of Na 3 AlF 6 , LiF, NaF, K 2 ZrF 6 , BaF 2 , and K 2 SiF 6
- the above-mentioned fluoride having a total value ⁇ in terms of F with respect to the above is 0.21% or more, and an oxide, which is Fe oxide, Ba oxide, Na oxide, Ti oxide, Si oxide, Zr oxide Including one or more selected from the group consisting of Mg oxide, Al oxide, Mn oxide, and K oxide, excluding CaO, and in mass% with respect to the total mass of the flux-cored wire Including the oxide
- the total value of the content of the oxide in which the total amount ⁇ is 0.30% or more and less than 3.50% and the mass percentage of the flux-core
- the content of the CaO in the flux is 0% or more and less than 0.20% by mass% with respect to the total mass of the flux-cored wire, and the content of iron powder in the flux is the flux-cored wire. Is 0% or more and less than 10.0% by mass% with respect to the total mass, the X value calculated using Equation 1 is 5.0% or less, and the content of the CaF 2 is that of the flux-cored wire.
- the content of the Ti oxide is the less than 0.10% to 2.50% in percentage by weight relative to the total weight of the flux-cored wire, the MgCO 3 ,
- the total content of Na 2 CO 3 and LiCO 3 is 0 to 3.00% by mass% with respect to the total mass of the flux-cored wire, and the fluoride, the oxide, the CaO,
- the chemical components excluding the carbonate and the iron powder are in mass% with respect to the total mass of the flux-cored wire, C: 0.003 to 0.200%, Si: 0.20 to 1.50%, Mn : 1.00 to 3.50%, ⁇ g: 0.10% or less, P: 0.020% or less, S: 0.020% or less, Al: 0.001 to 0.300%, Ni: 0.50 ⁇ 4.00%, Mo: 0.10 2.00%, Cu: 0 to 0.50%, Cr: 0 to 1.50%, Nb: 0 to 0.10%, V: 0 to 0.40%, Ti
- the element symbol with [] is the symbol of the flux-cored wire of the element corresponding to each element symbol included in the chemical component excluding the fluoride, the oxide, the CaO, the carbonate, and the iron powder.
- the content with respect to the total mass is expressed in unit mass%.
- the chemical component excluding the fluoride, the oxide, the CaO, the carbonate, and the iron powder is a mass relative to the total mass of the flux-cored wire.
- the total content of the carbonate is 0.30% by mass% with respect to the total mass of the flux-cored wire. or less super 3.50%, the MgCO 3, wherein Na 2 CO 3, and the total content of the LiCO 3 is 0.30 to 3.00% by mass% relative to the total weight of the flux-cored wire It may be.
- the ⁇ may be 0.50% or more.
- the X value may be 4.5% or less.
- the content of the Ti oxide is 0.10 to 1 in mass% with respect to the total mass of the flux-cored wire. It may be 80%.
- the content of the CaF 2 is 0.20% or less in terms of mass% with respect to the total mass of the flux-cored wire. There may be.
- ⁇ / ⁇ may be 0.10 to 4.00.
- Flux-cored wire according to any one of - (9), to the sum of the content by mass% relative to the total weight of the flux-cored wire of the fluoride, the Na 3 AlF 6 and the ratio of the total content by mass% relative to the total weight of the flux-cored wire of the NaF may be 0.50 or more.
- the flux-cored wire according to any one of the above (1) to (10) has a tensile strength of a weld metal when gas-shielded arc welding is performed using the flux-cored wire, according to Japanese Industrial Standard JIS. It may be 690 MPa or more and less than 1500 MPa in the tensile test of the weld metal specified in Z3111-2005.
- the steel outer skin may have a seamless shape.
- the flux cored wire according to any one of (1) to (11) may have a shape in which the steel outer skin has a slit-like gap.
- the flux-cored wire according to any one of (1) to (13) may further include perfluoropolyether oil applied to a surface of the flux-cored wire.
- a method for manufacturing a welded joint according to another aspect of the present invention includes a step of performing gas shield arc welding of a steel material using the flux-cored wire according to any one of (1) to (14) above. Prepare.
- the steel material is a steel plate having a plate thickness of 12 mm or less and Pcm of 0.36% or less, a plate thickness of more than 12 mm and 25 mm or less, and Pcm of 0.1.
- a welded joint according to another aspect of the present invention is obtained by the method for manufacturing a welded joint according to (15) or (16).
- a flux cored wire includes a steel outer sheath and a flux filled in the steel outer sheath, and is defined in JIS Z 3118 using the flux cored wire.
- the amount of diffusible hydrogen in the weld metal obtained by welding under the specified conditions is 1.0 ml / 100 g or less, and using the flux-cored wire, the wire polarity is positive, the current value is 270 A, and the voltage value is 29 to Weight per spatter welding time generated when DC gas shielded arc welding is performed under the conditions of 32 V, welding speed of 30 cm / min, shield gas type of CO 2 100% gas, and shield gas flow rate of 25 L / min. However, it is 5.0 g / min or less.
- a flux cored wire according to another aspect of the present invention includes a steel outer sheath and a flux filled in the steel outer sheath, and the flux cored wire is based on a total mass of the flux cored wire.
- the content of Ti oxide is 0.10 to 2.50% by mass and contains Ni: 0.5 to 4.00%.
- the diffusible hydrogen content of the weld metal obtained by direct current gas shielded arc welding under the specified conditions is 1.0 ml / 100 g or less, and using the flux-cored wire, the wire polarity is positive, the current value is 270 A, DC under the conditions that the voltage value is 29 to 32 V, the welding speed is 30 cm / min, the shielding gas type is 100% CO 2 gas, and the shielding gas flow rate is 25 L / min.
- the weight per welding time of spatter generated when gas shield arc welding is performed is 5.0 g / min or less.
- the flux-cored wire according to the above aspect of the present invention and the welding method according to the present invention a high-strength and high-toughness weld zone can be obtained, and the amount of spatter generated during welding can be greatly reduced. It is possible to omit preheating for preventing cracking or to reduce the preheating temperature during preheating work.
- the welded joint according to the present invention includes a weld portion having high strength and high toughness.
- the method for manufacturing a flux-cored wire and a welded joint according to the present invention can be applied to any steel material, but it is difficult to apply a normal flux-cored wire and a method for manufacturing a welded joint. When applied to welding, it has a particularly remarkable effect.
- the present invention can omit the preheating work for preventing the cold cracking or can reduce the preheating temperature in the preheating work. Furthermore, the manufacturing method of the flux-cored wire and the welded joint according to the present invention can be combined with any shielding gas, but is combined with 100% CO 2 gas which is difficult to combine with the normal manufacturing method of the flux-cored wire and the welded joint. In this case, the present invention can significantly reduce the amount of spatter generated even in this case, which has a particularly remarkable effect.
- the factors that cause cold cracking in the HAZ during welding are the hardness of the HAZ, the amount of diffusible hydrogen in the weld metal, and the like.
- the present inventors have studied various methods for reliably suppressing cold cracking in HAZ. As a result of the study, it has been clarified that if the amount of diffusible hydrogen in the weld metal is sufficiently lowered to suppress hydrogen penetration into the HAZ, cold cracking in the HAZ can be suppressed even when the hardness of the HAZ is extremely high. .
- the present inventors have repeatedly studied using a flux-cored wire in which the types and blending ratios of the flux components are variously changed.
- the present inventors have suppressed the amount of diffusible hydrogen in the weld metal to less than 1.0 ml / 100 g when the total value of F conversion values of the fluoride content is within a specific range, and the resistance to resistance. It has been found that the cold cracking property is greatly improved.
- the inventors have also found that the amount of diffusible hydrogen can be further reduced by including carbonate in the flux and limiting the CaO content and the Mg content.
- the fluoride contained in the flux sometimes increases the amount of spatter.
- the shielding gas to the welding is 100% CO 2 gas, when applying the flux-cored wire containing a large amount of fluoride, there is the amount of spatter is very large.
- the present inventors In order to suppress the amount of sputtering, the present inventors have repeatedly studied using flux wires in which the types of fluoride contained in the flux are different. As a result, the present inventors have a good correlation between the F-converted value of the fluoride content and the amount of diffusible hydrogen in the weld metal immediately after welding, and using the following formula: It has been found that there is a good correlation between the calculated sputter generation index X and the sputter generation amount.
- the fluoride contained in the flux is designed so that the F-converted value of the fluoride contained in the flux is as large as possible and the X value calculated from the fluoride contained in the flux is as small as possible. If the type and the mixing ratio of the metal are determined, the amount of diffusible hydrogen in the weld metal immediately after welding is less than 1.0 ml / 100 g, and the flux is contained so as not to impair the workability of welding in which the shielding gas is 100% CO 2 gas. A wire can be provided. The present inventors have also found that limiting the content of CaF 2 in the fluoride is also necessary for reducing the amount of spatter generated.
- the present invention has been made as a result of the above examination.
- the flux cored wire according to the present embodiment will be described.
- the flux cored wire according to the present embodiment includes a steel outer shell and a flux filled in the steel outer shell.
- the flux of the flux-cored wire according to this embodiment includes fluoride and an oxide excluding CaO, and preferably further includes carbonate.
- the flux of the flux-cored wire according to the present embodiment may further include CaO and iron powder, but CaO and iron powder are not necessary for solving the problem of the flux-cored wire according to the present embodiment. is there.
- CaO comes into contact with the atmosphere, it changes to CaOH, which is a compound containing hydrogen, and increases the amount of diffusible hydrogen in the weld metal.
- % means “mass% with respect to the total mass of the flux-cored wire” unless otherwise specified.
- the flux of the flux-cored wire includes a total of 0.21% or more fluoride in terms of F with respect to the total mass of the flux-cored wire.
- the F converted value with respect to the total mass of the flux-cored wire indicates the amount of fluorine (F) contained in the fluoride in the flux-cored wire in terms of mass% with respect to the total mass of the flux-cored wire.
- the fluoride of the flux-cored wire is a group consisting of CaF 2 , MgF 2 , Na 3 AlF 6 , LiF, NaF, K 2 ZrF 6 , BaF 2 , and K 2 SiF 6.
- the chemical formula enclosed in parentheses is the content of the fluoride according to each chemical formula in mass% with respect to the total mass of the flux-cored wire.
- F converted value with respect to the total mass of the flux-cored wire may be referred to as “F converted value”.
- the symbol “ ⁇ ” is defined as the sum of F converted values of fluoride with respect to the total mass of the flux-cored wire.
- the above-mentioned F-converted coefficient of each fluoride is calculated from the atomic weight and number of fluorine contained in each fluoride and the chemical formula amount of each fluoride.
- the fluoride in the flux has the function of reducing the amount of diffusible hydrogen in the weld metal and significantly improving the cold crack resistance of the weld metal.
- the reason for this is not clear, but it is presumed that F and hydrogen (H) in the fluoride are combined during welding to form hydrogen fluoride (HF), and this HF is released out of the weld metal.
- the total F converted value of the fluoride content in the flux is less than 0.21%, the diffusible hydrogen content of the weld metal may not be less than 1.0 ml / 100 g.
- the cold cracking resistance may be insufficient. Therefore, the flux of the flux-cored wire according to this embodiment is required to contain 0.21% or more of fluoride in terms of F.
- the lower limit of the total amount of fluoride in terms of F is 0.25%, 0.30%, 0.35%, 0.40%, 0.45 %, 0.50%, 0.60%, 0.65%, 0.70%, 0.80%, or 0.90%.
- the upper limit of the total amount of F converted values is 2.00%, 1.70%, 1.50%, 1.30%. 1.10%, 1.00%, 0.90%, 0.80%, 0.70%, 0.60%, 0.50%, or 0.40%.
- the fluoride content is excessive, the amount of spatter during welding increases.
- the F converted value of fluoride can be selected so that the sputter generation index X falls within the range described below.
- the fluoride of the flux-cored wire according to the present embodiment is one selected from the group consisting of CaF 2 , MgF 2 , Na 3 AlF 6 , LiF, NaF, K 2 ZrF 6 , BaF 2 , and K 2 SiF 6. Or it is 2 or more types.
- Ca, Mg, Li, Na, K, Zr, Ba, Si, and Al generated by ionization of these fluorides act as deoxidizing elements that combine with oxygen to reduce the amount of oxygen in the weld metal. .
- the present inventors examined a method for increasing the F-converted value as much as possible and reducing the amount of sputtering to within an allowable range. As a result, the present inventors have found that the influence of fluoride on the amount of sputtering varies depending on the type of fluoride. As a result of further studies, the present inventors have found that there is a good correlation between the spatter generation index X (X value) calculated by the following formula and the spatter amount.
- the present inventors set the upper limit value of the X value of the flux-cored wire according to this embodiment to 5.0%.
- the upper limit of the X value is 4.5%.
- the upper limit of the X value is 4.0%, 3.5%, 3.0%, 2.5%, 2.0%, 1.8%, 1.6%, It may be 1.4%, 1.2%, or 1.0%.
- the minimum value of the X values that can satisfy the definition of the F converted value may be set as the lower limit value of the X values.
- the X value is minimized when the total F converted value is the lowest value (0.21%) and the fluoride is composed only of MgF 2 .
- the lower limit of the X value is 0.40%, 0.60%, 0.80%, 1.00%, 1.20%, 1.40%, It may be 1.60% or 1.80%.
- CaF 2 is a fluoride that tends to increase the amount of sputtering. Even if the X value of the fluoride is 2.0% or less, the inventors of the present invention generate a large amount of spatter when CaF 2 of 0.50% or more by mass% with respect to the total mass of the flux-cored wire is generated. It has been found that welding workability is deteriorated. The present inventors are described below experiments which knowledge was obtained regarding the content of CaF 2. Various flux wires having different CaF 2 contents and having an X value within the above specified range are subjected to welding under the same conditions as when the graph of FIG.
- the amount of spatter generated per minute with a diameter of 1.5 mm or more was determined by the method.
- spatters having a diameter of 1.5 mm or more were screened from spatters generated during welding, and the total weight of sputters having a diameter of 1.5 mm or more was measured.
- the relationship between the content of CaF 2 and the amount of spatter generated with a diameter of 1.5 mm or more per minute obtained by this experiment is shown in the graph of FIG. From this graph, it was found that when the CaF 2 content is 0.5% or more, the amount of spatter generated increases.
- the CaF 2 content of the flux-cored wire according to this embodiment is determined to be less than 0.50%.
- Preferred upper limit of the content of CaF 2 is 0.20%. If necessary, the CaF 2 content may be less than 0.10%, less than 0.06%, less than 0.04%, or less than 0.02%.
- the total content of unit mass% of Na 3 AlF 6 and NaF with respect to the total mass of the wire is 50% or more of the total content of unit mass% with respect to the total mass of the wire of fluoride.
- the ratio of the total content of unit mass% of Na 3 AlF 6 and NaF with respect to the total mass of the wire to the total content of unit mass% of the total mass of the wire of the fluoride is referred to as Na 3 AlF 6 + NaF ratio. .
- the Na 3 AlF 6 + NaF ratio is preferably 50% or more. If necessary, the Na 3 AlF 6 + NaF ratio may be 60% or more, 80% or more, 90% or more, or 100%.
- the total content of unit mass% of Na 3 AlF 6 , NaF, and MgF 2 having a coefficient of 1 in the calculation formula of the spatter generation index X is based on the total mass of the wire, the percentage of the total amount of unit mass% with respect to total mass of the wire fluoride (Na 3 AlF 6 + NaF + MgF 2 ratio), more than 50%, 60%, 80% or more may be 90% or 100%.
- the flux of the flux-cored wire according to the present embodiment contains 0.30% or more and less than 3.50% of oxides in total.
- the type of this oxide is a group consisting of Fe oxide, Ba oxide, Na oxide, Ti oxide, Si oxide, Zr oxide, Mg oxide, Al oxide, Mn oxide, and K oxide. 1 type or 2 types or more selected from, except CaO.
- the total content of oxides excluding CaO in mass% with respect to the total mass of the flux-cored wire is defined as “ ⁇ ”.
- “oxide excluding CaO” may be simply referred to as “oxide”.
- Oxides other than CaO have the effect of maintaining a good weld bead shape.
- the total content of oxides excluding CaO is less than 0.30%, the shape of the weld bead may be deteriorated.
- the lower limit of the total amount of oxides excluding CaO may be 0.40%, 0.50%, 0.60%, or 0.70%.
- ⁇ is 3.50% or more, the toughness of the weld metal may be lowered.
- the upper limit of the total amount ⁇ is set to 3.00%, 2.50%, 2.25%, 2.00%, 1.75%, 1.50%, 1.25%. 1.00%, 0.90%, 0.80%, or 0.70%.
- the type of oxide excluding CaO is not particularly limited.
- ⁇ is Fe oxide, Ba oxide, Na oxide, Ti oxide, Si oxide, Zr oxide, Mg oxide, Al oxide, Mn oxide, and K oxide.
- the oxide contained in the binder used for granulation of the flux is also regarded as the total content.
- Ti oxide contributes to the improvement of the weld bead shape. Even when the total content of oxides excluding CaO is 0.30% or more and less than 3.50%, when the Ti oxide contained in the oxides excluding CaO is less than 0.10%, the weld bead shape May get worse. Therefore, the lower limit value of the Ti oxide content needs to be 0.10%. In order to obtain a better weld bead shape by using Ti oxide as an arc stabilizer, the lower limit of the content of Ti oxide is 0.15%, 0.20%, 0.25%,. It may be 30%, 0.40%, or 0.45%.
- the upper limit value of the Ti oxide content needs to be less than 2.50%.
- the upper limit of the Ti oxide content is 2.40%, 2.20%, 2.00%, 1.80%, 1.50%, 1.25%. 1.00%, 0.90%, 0.80%, 0.70%, 0.60%, or 0.50%.
- the ratio of ⁇ to ⁇ (that is, ⁇ / ⁇ ) is set to 0.10 to 4.00 so that the amount of diffusible hydrogen in the weld metal is less than 1.0 ml / 100 g. It is preferable that When ⁇ / ⁇ is 0.10 or more, the amount of diffusible hydrogen in the weld metal can be more preferably reduced. If necessary, the lower limit value of ⁇ / ⁇ may be set to 0.20, 0.30, 0.50, or 0.70. When ⁇ / ⁇ exceeds 4.00, welding fume and slag are excessively generated, and welding workability may be reduced.
- ⁇ / ⁇ is less than 0.10 or more than 4.00.
- a preferred lower limit of the ratio of ⁇ to ⁇ is 0.20.
- a preferable upper limit of the ratio of ⁇ to ⁇ is 3.8, 3.50, 3.00, 2.50, 2.00, or 1.50.
- Total content in mass% with respect to the total mass of the flux-cored wire of carbonate 0 to 3.50%)
- Total content in mass% with respect to the total mass of one or more flux-cored wires of MgCO 3 , Na 2 CO 3 , and LiCO 3 0 to 3.00%
- the flux of the flux cored wire according to the present embodiment does not need to contain carbonate. Therefore, in the flux cored wire according to the present embodiment, the lower limit value of the carbonate content is 0%.
- the flux of the flux-cored wire may include carbonate.
- the preferable lower limit of the total content of carbonate is more than 0.30%.
- the total lower limit of the carbonate content may be 0.50%, 1.00%, or 1.50%.
- the upper limit of the total carbonate content is set to 3.00%, 2.50%, 2.00%, 1.50%, 1.00%, 0.50%, 0 .10%, 0.04%, 0.02%, or 0.01%.
- Types of carbonate contained in the flux of the flux cored wire according to the present embodiment MgCO 3, Na 2 CO 3 , LiCO 3, CaCO 3, K 2 CO 3, BaCO 3, FeCO 3, and consists of MnCO 3 Although it is preferable that 1 type or 2 or more types selected from a group is included, it is not limited to this. As long as the carbonate content is within the above range, the type and composition of the carbonate are not limited.
- the total content of one or more of MgCO 3 , Na 2 CO 3 , and LiCO 3 contained in the carbonate described above needs to be 0 to 3.00%. Even the total content of the carbonate was 0 ⁇ 3.50%, MgCO 3, Na 2 CO 3, and the sum of one or more content LiCO 3 is 3 contained carbonate. If it exceeds 00%, the weld bead tends to sag, so that the welding workability is deteriorated. In order to suppress sag of the weld bead, the upper limit of the total carbonate content may be 2.70%, 2.50%, or 2.00%.
- CaO may be contained in the flux of the flux cored wire according to the present embodiment.
- the content of CaO in the flux needs to be less than 0.20%. Since CaO changes to CaOH which is a compound containing hydrogen, it increases the diffusible hydrogen of the weld metal and impairs the cold crack resistance of the weld metal.
- a preferable upper limit of the content of CaO is 0.18%, 0.10%, 0.05%, 0.02%, or 0.01%. Since it is preferable not to include CaO, the lower limit of the content of CaO is 0%. Since CaO may be contained in the normal flux material by 0.20% or more as an impurity, it is necessary to select a material that does not contain CaO when manufacturing the flux-cored wire according to the present embodiment. .
- iron powder may be included in the flux of the flux-cored wire according to the present embodiment.
- Iron powder may be included as necessary for adjusting the filling rate of the flux in the flux-cored wire or for improving the welding efficiency.
- oxygen attached to the surface layer of the iron powder may increase the oxygen content of the weld metal and reduce toughness. Therefore, in the flux cored wire according to the present embodiment, the iron powder content needs to be less than 10.0%.
- a preferable upper limit of the iron powder content is 8%, 6%, 4%, 2%, or 1%.
- the lower limit value of the iron powder content is 0%.
- the iron powder is mainly composed of non-oxidized Fe, and the Fe oxide is composed mainly of iron oxide such as hematite, limonite, and magnetite. Both can be discriminated using a known component analyzer such as EPMA.
- the flux according to the present embodiment may include components other than the above-described fluorides, oxides other than CaO, CaO, carbonates, and iron powder.
- a chemical component of a weld metal, which will be described later, and an alloy component for controlling Ceq are included in the flux in a state that is not fluoride, oxide, or carbonate (for example, a state of metal powder or alloy powder). Also good.
- % means “mass% with respect to the total mass of the flux-cored wire”.
- the chemical components described below may be included in the steel outer shell, may be included in the flux as metal powder or alloy powder as described above, or included in the plating on the outer surface of the steel outer shell. May be. Fluoride, oxides other than CaO, CaO, and carbonate are discharged out of the weld metal mainly as slag during welding, and elements contained in the state of metal or alloy are mainly dissolved in the weld metal.
- the chemical component of the flux-cored wire excluding fluoride, oxides other than CaO, CaO, carbonate, and iron powder may be simply referred to as “the chemical component of the flux-cored wire”.
- the upper limit of the C content is set to 0.200%.
- the upper limit of C content is set to 0.100%, 0.090%, 0.08%, or 0.070%. Since the C content in the wire is difficult to be less than 0.003% due to steelmaking restrictions when manufacturing the outer skin material, this is the lower limit. If necessary, the lower limit of the C content may be 0.010%, 0.020%, 0.030%, 0.040%, 0.050%, or 0.060%.
- Si 0.20-1.50%
- Si is a deoxidizing element and has a function of increasing the cleanliness of the weld metal by reducing the amount of oxygen in the weld metal and improving the toughness of the weld metal.
- the lower limit of the Si content needs to be 0.20%.
- the toughness of the weld metal may be deteriorated. Therefore, 1.50% is made the upper limit of the Si content.
- the lower limit of the Si content may be set to 0.25%, 0.30%, or 0.35%.
- the upper limit of the Si content may be 0.80%, 0.70%, or 0.60%.
- Mn increases the cleanliness of the weld metal by reducing the amount of oxygen in the weld metal, thereby improving the toughness of the weld metal.
- the lower limit of the Mn content needs to be 1.00%.
- the lower limit of the Mn content may be 1.01%, 1.20%, 1.40%, or 1.60%.
- the upper limit of the Mn content may be 2.60%, 2.40%, 2.20%, or 2.00%.
- Mg 0.10% or less
- the upper limit of the Mg content of the flux-cored wire according to the present embodiment is 0.10%, and it is preferable that the content is lower.
- the present inventors have found that Mg in the flux-cored wire increases the amount of diffusible hydrogen in the weld metal even if the amount is very small.
- the present inventors need to make Mg content of the chemical component of the flux-cored wire according to the present embodiment 0.10% or less, 0.08% or less, 0.07 % Or less, 0.05%, 0.03% or less, or 0.01% or less.
- the amount of TiO 2 is small, the effect of increasing the amount of diffusible hydrogen due to Mg becomes significant.
- the lower limit of the Mg content of the chemical component of the flux-cored wire is 0%.
- Mg has the effect of reducing the oxygen in the weld metal and improving the toughness of the weld metal. Therefore, the Mg content of the chemical component of the flux-cored wire may be 0.05% or more.
- P is an impurity element, and when it is excessively present in the weld metal, it may reduce both the toughness and ductility of the weld metal, so it is preferable to reduce the P content as much as possible.
- the P content is set to 0.020% or less.
- the P content is preferably 0.017%, 0.015%, 0.012%, or 0.010% or less. There is no need to limit the lower limit of P.
- the lower limit of the P content may be 0%.
- S is also an impurity element, and when it is excessively present in the weld metal, the toughness of the weld metal may be deteriorated. Therefore, the S content is preferably reduced as much as possible.
- the P content is set to 0.020% or less.
- the S content is preferably 0.017%, 0.015%, 0.012% or 0.010% or less. There is no need to limit the lower limit of S.
- the lower limit of the S content may be 0%.
- Al is a deoxidizing element and, like Si, reduces the amount of oxygen in the weld metal, increases the cleanliness of the weld metal, and improves the toughness of the weld metal.
- the lower limit of the Al content it is necessary to set the lower limit of the Al content to 0.001%.
- Al when Al is contained exceeding 0.300%, Al may form a nitride and an oxide, and may reduce the toughness of the weld metal. Therefore, 0.300% is made the upper limit of the Al content.
- the lower limit of the Al content may be 0.0015%, 0.002%, 0.003%, or 0.004%.
- the upper limit of the Al content may be 0.275%, 0.250%, or 0.200%.
- Ni 0.50-4.00%
- Ni is the only element that can improve the toughness of the weld metal regardless of the structure and components of the weld metal by solid solution toughening (the effect of increasing the toughness by solid solution).
- Ni is an effective element for increasing the toughness of a high strength weld metal having a tensile strength of 780 MPa or more.
- the lower limit of the Ni content needs to be 0.50%. The higher the Ni content, the more advantageous in improving toughness.
- 4.00% is made the upper limit of the Ni content.
- the lower limit of the Ni content may be set to 0.80%, 1.00%, 1.50%, 2.00% or 2.20%.
- the upper limit of the Ni content may be 3.30%, 3.10%, 2.90%, or 2.70%.
- Mo 0.10 to 2.00%
- Mo is a hardenability improving element. Furthermore, Mo is an element that forms fine carbides and increases tensile strength by precipitation strengthening. In addition, Mo has an effect of suppressing a decrease in strength when the weld metal is reheated by a subsequent pass during multi-layer welding, and suppressing deterioration of toughness. Since large plates use thick plates, in this case, welding is performed by multi-layer welding. In multi-layer welding, the weld metal formed in the previous pass is subjected to reheating from the subsequent weld pass, so that the weld metal formed in the previous pass is softened.
- the structure of the weld metal is mainly bainite, so that the degree of softening becomes large, and thus the strength of the weld metal can be secured stably. difficult. Furthermore, since the cementite of the weld metal becomes coarse due to the reheating, the toughness of the weld metal also deteriorates. Mo forms fine carbides in the weld metal when reheated by multi-layer welding, thereby suppressing a decrease in the strength of the weld metal and further suppressing the coarsening of cementite. It has the effect of suppressing toughness degradation.
- the lower limit of the Mo content needs to be 0.10%.
- the Mo content exceeds 2.00%, the precipitates become coarse and the toughness of the weld metal may deteriorate, so the upper limit of the Mo content is 2.00%.
- the lower limit of the Mo content may be 0.20%, 0.30%, or 0.50%.
- the upper limit of Mo may be 0.90%, 0.80%, or 0.70%.
- the flux-cored wire according to the present embodiment further includes Cu, Cr, V, Ti, Nb, B as an alloy component or a deoxidizing component, depending on the strength level of the steel sheet to be welded or the required toughness of the weld metal.
- Bi can be contained as selective elements.
- the content of the essential element in the flux-cored wire is within the above specified range regardless of whether or not the selected element is contained, the flux-cored wire is regarded as the flux-cored wire according to the present embodiment. . Therefore, the lower limit of the contents of Cu, Cr, V, Ti, Nb, B, and Bi is 0%.
- Cu can improve the strength and toughness of the weld metal.
- the lower limit of the Cu content is 0%, but in order to sufficiently obtain these effects, the lower limit of the Cu content may be 0.10%.
- the upper limit of the Cu content when Cu is contained in the flux-cored wire is 0.50%.
- the lower limit of the Cu content may be set to 0.15% or 0.20% in order to surely obtain the effect of containing Cu and to prevent a decrease in toughness.
- the upper limit of the Cu content may be 0.40% or 0.30%.
- the steel outer surface of the flux-cored wire may be included in the flux as a simple substance or an alloy.
- Cu plating also has the effect of improving rust prevention, electrical conductivity, and chip wear resistance. Therefore, the content of Cu in the flux-cored wire, in addition to the amount of Cu contained in either or both of the steel outer sheath and the flux, in addition to copper plating on the flux-cored wire surface, The amount of Cu contained in the copper plating is also included.
- Cr 0 to 1.50%
- the lower limit of the Cr content is 0%, but in order to obtain the effect, the lower limit of the Cr content may be 0.10%.
- the upper limit of the Cr content when Cr is contained is 1.50%. In order to further suppress the deterioration of toughness due to Cr, the upper limit of Cr may be 1.00%, 0.75%, 0.50, or 0.25%.
- V increases the hardenability of the weld metal and is therefore an effective element for increasing the strength of the weld metal.
- the lower limit of V content is 0%, but in order to obtain the effect, the lower limit of V content may be 0.01%.
- the upper limit of the V content when V is contained is 0.40%. In order to reliably obtain the effect of the V content and prevent toughness deterioration due to the excessive content of V, the upper limit of the V content is set to 0.30%, 0.20%, 0.10%, or 0.05%. Also good.
- Ti is an effective element as a deoxidizing element and has an effect of reducing the amount of oxygen in the weld metal. Ti also has the effect of fixing the solid solution N of the weld metal and mitigating the adverse effect of the solid solution N on the toughness.
- the lower limit of the Ti content is 0%, but in order to exert these effects, the lower limit of the Ti content may be 0.01%. However, if the Ti content in the flux-cored wire exceeds 0.30% and is excessive, there is a possibility that toughness deterioration due to the formation of coarse oxides and toughness deterioration due to excessive precipitation strengthening may occur in the weld metal. growing.
- the upper limit of the Ti content is 0.30%.
- the lower limit of the Ti content may be 0.015%, 0.02%, or 0.04%.
- the upper limit of Ti may be set to 0.20%, 0.10%, or 0.05% in order to further suppress toughness deterioration due to Ti.
- Nb 0-0.10% Since Nb forms fine carbides in the weld metal, Nb is an effective element for securing the tensile strength of the weld metal by precipitation strengthening.
- the lower limit of the Nb content is 0%, but in order to obtain these effects, the lower limit of the Nb content may be 0.01%.
- containing Nb exceeding 0.10% is not preferable because Nb excessively contained in the weld metal may form coarse precipitates and deteriorate the toughness of the weld metal.
- the upper limit of Nb content in the case of containing Nb shall be 0.10%.
- the lower limit of the Nb content may be 0.015% or 0.02%.
- the upper limit of Nb may be set to 0.05%, 0.04%, or 0.03%.
- B contained in a proper amount in the weld metal is combined with solute N to form BN, thereby reducing the adverse effect of solute N on toughness.
- B also has the effect of increasing the hardenability of the weld metal and contributing to strength improvement.
- the lower limit of the B content is 0%, but in order to obtain these effects, the lower limit of the B content in the flux-cored wire may be 0.0001%.
- B in the weld metal becomes excessive, coarse B compounds such as BN and Fe 23 (C, B) 6 are formed, and the toughness is reversed. This is not preferable because the possibility of deterioration is increased.
- the upper limit of the B content when B is contained is 0.0100%.
- the lower limit of the B content may be 0.0003% or 0.0010%.
- the upper limit of B may be 0.0080%, 0.0060%, or 0.0040%.
- Bi 0 to 0.0100% Since Bi is not an essential component, the lower limit of the Bi content of the chemical component of the flux-cored wire is 0%. On the other hand, Bi is an element that improves the slag peelability. For this reason, it is good also considering Bi content of the chemical component of a flux cored wire as 0.0010% or more. When the Bi content of the chemical component of the flux cored wire exceeds 0.0100%, solidification cracking is likely to occur in the weld metal, so the upper limit of the Bi content of the chemical component of the flux cored wire is 0.0100%. is there. The upper limit of the Bi content of the chemical component of the flux-cored wire is preferably 0.0080%.
- one or two of Ca and REM are optionally added within the following range. It can be contained. However, regardless of the presence or absence of Ca and REM, if the content of the essential elements in the flux-cored wire is within the above specified range, the flux-cored wire is regarded as the flux-cored wire according to this embodiment. It is. Therefore, the lower limit of the content of Ca and REM is 0%.
- Ca and REM both contribute to improving the toughness of the weld metal by changing the structure of the sulfide and reducing the size of the sulfide and oxide in the weld metal.
- the lower limit of Ca content and REM content is 0%, but in order to obtain the effect, the lower limit value of Ca content may be 0.01%, and the lower limit value of REM content is 0.0002%. Also good.
- the lower limit value of Ca content may be 0.01%, and the lower limit value of REM content is 0.0002%.
- sulfides and oxides are coarsened and the toughness of the weld metal is deteriorated.
- the upper limit value of Ca content is 0.50%, and the upper limit value of REM content is 0.0100%.
- the lower limit of the Ca content may be 0.03%, and the lower limit of the REM content may be 0.0003%.
- the upper limit of Ca may be set to 0.45%, 0.40%, 0.35%, or 0.30%, and the upper limit of REM is set to 0.0090%,. It may be 0080%, 0.0070%, or 0.0060%.
- the flux-cored wire according to the present embodiment contains each element as described above as an alloy component or a deoxidizing component. Further, in order to ensure the tensile strength of the weld metal, the carbon equivalent Ceq defined by the Japan Welding Association (WES) defined by the following formula is 0.45 to 1.20% by mass. It is necessary to further control the contents of Si, Mn, Ni, Cr, Mo, and V.
- WES Japan Welding Association
- the element symbols enclosed in parentheses are the elements corresponding to the respective element symbols included in the chemical components of the flux-cored wire excluding fluoride, oxides other than CaO, CaO, carbonates, and iron powder. Is a content in unit mass% with respect to the total mass of the flux-cored wire.
- Ceq (Ceq of the flux-cored wire) calculated from the chemical components of the flux-cored wire of this embodiment is included in the flux-cored wire in the state of fluoride, oxide excluding CaO, CaO, or carbonate. It is calculated without considering the content of the element. Most of the elements contained in the flux-cored wire in the state of fluoride, oxides other than CaO, CaO, or carbonate are discharged outside the weld metal as slag during welding. Does not substantially affect the suitability.
- the Ceq value of the flux-cored wire When the Ceq value of the flux-cored wire is high, the weld metal is hardened so that the tensile strength of the weld metal is improved, but the toughness of the weld metal is lowered.
- One of the purposes of the flux-cored wire according to the present embodiment is to obtain a weld metal having a tensile strength of 690 MPa or more. When this Ceq value is less than 0.45%, a tensile strength of 690 MPa or more is obtained. A weld metal having strength cannot be obtained. On the other hand, when the value of Ceq exceeds 1.20%, the tensile strength of the weld metal becomes excessive, and the toughness of the weld metal decreases.
- the range of Ceq is set to 0.45 to 1.20%.
- the lower limit of Ceq is 0.48%, 0.50%, 0.52%, 0.55%, 0.58%, or 0.
- the upper limit of Ceq may be 1.15%, 1.10%, 1.05%, 1.00%, 0.95%, 0.90%, 0.85%, or 0. It may be 80%.
- the present inventors have found that the chemical component of the flux-cored wire according to this embodiment preferably satisfies the following formula. ([Mg] + 10 ⁇ [Al]) ⁇ 0.45 [Mg] and [Al] are unit mass% of the content of Mg and Al contained in the chemical components excluding the fluoride of the flux-cored wire, the oxide excluding CaO, and the carbonate with respect to the total mass of the flux-cored wire. It is shown by.
- the present inventors have a relationship between the amount of Mg and Al contained in the chemical component of the flux-cored wire and the amount of diffusible hydrogen in the weld metal, particularly when the welding atmosphere is hot and humid.
- the above is the reason for limiting the content of each element contained in the chemical component of the flux-cored wire according to the present embodiment, but the other remaining components are Fe and impurities.
- the Fe component includes Fe in the steel outer shell, iron powder added in the flux, and Fe in the alloy component.
- the shape of the flux cored wire which concerns on this embodiment is demonstrated.
- 7A to 7C show cut surfaces of the flux-cored wire.
- Fig. 7A shows a flux-cored wire made by welding the edge surfaces
- Fig. 7B shows a flux-cored wire made by butt-edge joining
- Fig. 7C shows a flux-cored wire made by caulking the edge surfaces.
- the flux-cored wire includes a wire having no slit-like gap in the steel outer shell as shown in FIG. 7A, and a wire having a slit-like gap 6 in the steel outer shell as shown in FIGS. 7B and 7C. And can be broadly divided.
- any cross-sectional structure can be adopted.
- the diameter of the flux-cored wire according to this embodiment is not particularly defined, but is, for example, ⁇ 1.0 to ⁇ 2.0 mm.
- the diameter of a general flux cored wire is ⁇ 1.2 to ⁇ 1.6 mm.
- the filling rate of the flux-cored wire according to the present embodiment is not particularly limited as long as the above-described conditions are satisfied.
- the lower limit of the general filling rate of the flux-cored wire according to the present embodiment is 10% or 12%.
- the upper limit value of the general filling rate of the flux-cored wire according to the present embodiment is 20% or 17%.
- the flux-cored wire according to the present embodiment may further include a lubricating oil applied to the wire surface.
- a lubricating oil applied to the wire surface is perfluoropolyethylene. Oils that do not contain hydrogen, such as ether (PFPE), are preferred.
- the flux-cored wire according to the present embodiment may further include plating formed on the wire surface. In this case, the lubricant is applied to the plating surface.
- the amount of hydrogen contained in the flux-cored wire according to this embodiment is not particularly specified. This is because the amount of hydrogen in the flux-cored wire varies between manufacture and use. However, it is preferably 12 ppm or less with respect to the total mass of the flux-cored wire at the stage immediately after production. The amount of hydrogen in the flux-cored wire may increase due to moisture entering the flux-cored wire during storage of the flux-cored wire. Therefore, when the period from wire manufacture to wire use is long, it is desirable to prevent moisture from entering by the above-mentioned means.
- the flux cored wire according to the present embodiment can be manufactured by a normal flux cored wire manufacturing method. Below, an example of a manufacturing method is demonstrated.
- a method of manufacturing a flux-cored wire having a seamless shape includes a step of preparing a flux, a step of forming a U-shaped open pipe by forming a steel strip in a longitudinal direction while feeding a steel strip, and an opening of the open pipe After completing the process of supplying flux into the open pipe, the process of butt welding the opposing edge surfaces of the opening of the open pipe, the process of drawing the seamless pipe, and the middle of the drawing process or after the drawing process And a step of annealing the flux-cored wire.
- the flux is prepared so that the amount of fluoride in the flux-cored wire, the chemical component, the amount of oxide excluding CaO, the amount of CaO, the amount of carbonate, and the like are within the predetermined ranges described above.
- the flux filling rate determined by the width and thickness of the steel strip, which is the material of the steel outer sheath, and the flux filling amount is also the fluoride content of the flux-cored wire, the oxide amount excluding CaO, the CaO amount, It should be noted that the amount of carbonate and chemical composition are affected.
- the butt welding is performed by electric seam welding, laser welding, TIG welding, or the like.
- a flux cored wire is annealed.
- the hydrogen content of the flux-cored wire is 12 ppm or less, it is necessary that the annealing temperature is 650 to 900 ° C. and the annealing time is 4 hours or more.
- the manufacturing method of the flux-cored wire having the slit-shaped gap is not the step of butt welding the end of the open tube to obtain a seamless tube, but forming the open tube and butting the end of the open tube Except for having a step of obtaining a tube with a gap, it is the same as the method of manufacturing a flux-cored wire having a seamless shape.
- the manufacturing method of the flux-cored wire having the slit-shaped gap may further include a step of caulking the end portion of the opened open tube. In a method for manufacturing a flux-cored wire having a slit-like gap, a tube having a slit-like gap is drawn.
- a cross section of a wire without slit-like gaps made by butt seam welding looks like FIG. 7A. In this cross section, no weld marks are observed unless polished and etched. Therefore, a wire having a steel outer butt seam welded may be referred to as seamless as described above. For example, “New Edition: Introduction to Welding and Joining Technology” edited by the Japan Welding Society (2008); In 111, such a wire is described as a seamless type wire.
- FIG. 7B shows an example of a flux-cored wire that has not been welded after the edge surfaces are butted
- FIG. 7C shows an example of crimping after the edge surfaces are butted. Even if the gap between the steel outer sheaths of the flux-cored wire shown in FIGS. 7B and 7C is brazed, a flux-cored wire having no slit-like gap can be obtained.
- the tensile strength of the deposited metal when the gas shielded arc welding is performed using the flux-cored wire described above is 690 to 1500 MPa, which is almost the same level as that of the high-strength steel having a tensile strength of 780 MPa or more. This is because if the tensile strength of the weld metal is less than 690 MPa, the strength of the welded joint cannot be secured to 780 MPa. In other words, if the tensile strength of the weld metal is 690 MPa or more, the strength of the welded joint can be secured to 780 MPa. If necessary, the lower limit of the tensile strength of the weld metal may be 780 MPa.
- the toughness of the weld metal tends to deteriorate.
- the upper limit of the tensile strength of the weld metal may be limited to 1100 MPa, 1050 MPa, 1000 MPa, 950 MPa, or 900 MPa.
- deposited metal indicates a metal that has moved from a filler metal (flux-cored wire) to a welded portion.
- the tensile strength of the weld metal can be determined by conducting a tensile test of the weld metal specified in Japanese Industrial Standard JIS Z3111-2005. Further, the Charpy absorbed energy (average value of three pieces) at ⁇ 40 ° C. of the weld metal may be 47 J or more.
- the flux-cored wire of the present embodiment described above can be applied to welding of all kinds of steel materials, and is particularly suitable for use in gas shield arc welding of high-strength steel sheets having a tensile strength of 780 MPa or more. ing.
- a weld metal having a diffusible hydrogen content of 1.0 ml / 100 g or less is obtained, and the occurrence of cold cracks in the weld metal is suppressed.
- the flux-cored wire according to this embodiment does not crack cold cracking even if the preheating work is omitted or the preheating temperature is lowered during the preheating work. Can be prevented.
- the amount of diffusible hydrogen in the present embodiment is the amount of diffusible hydrogen measured by a method based on JIS Z 3118: 2007 “Method for Measuring Hydrogen Amount of Steel Weld”.
- Pcm (%) of steel materials says the value calculated by the following formula
- Pcm (C) + (Si) / 30 + (Mn) / 20 + (Cu) / 20 + (Ni) / 60 + (Cr) / 20 + (Mo) / 15 + (V) / 10 + 5 ⁇ (B)
- each element enclosed in the parenthesis contained in the said formula shows content (mass%) of each element contained in steel materials.
- the content of elements not contained in the steel material is regarded as 0% by mass.
- the method for manufacturing a welded joint according to the present embodiment includes a step of performing gas shield arc welding of a steel material using the flux-cored wire according to the present embodiment described above.
- the base material which is a material to be welded is not particularly limited, it is mainly a steel material having a tensile strength of 780 MPa or more. Since it is not hindered to weld a steel material having a tensile strength higher than that of the weld metal, there is no need to particularly limit the upper limit of the tensile strength of the steel material.
- the upper limit of the tensile strength of the steel material may be limited to 1100 MPa, 1050 MPa, 1000 MPa, 940 MPa, or 900 MPa.
- the plate thickness of the steel material is not particularly limited, but since the plate thickness of a general steel material is 3 to 100 mm, it may be limited to this plate thickness.
- two base materials that are high-strength steel are set at welding positions so as to form a gap therebetween, and gas shielded arc welding is performed using the flux-cored wire according to the present embodiment.
- gas shielded arc welding is performed using the flux-cored wire according to the present embodiment.
- a weld metal is formed on the base material by performing multi-layer welding by gas shield arc welding using a flux-cored wire that meets the above-described conditions.
- the purpose can be achieved.
- the method of gas shield arc welding is not particularly limited, and a commonly used method can be adopted.
- the shielding gas in addition to 100% CO 2 gas, a mixed gas of Ar gas and 3 to 20 vol% CO 2 gas can be used.
- the flux cored wire according to this embodiment does not increase the amount of sputtering even when used in combination with 100 vol% CO 2 gas.
- welding conditions such as current and voltage can also be used as usual.
- the steel material is a steel plate with a plate thickness of 12 mm or less and Pcm of 0.36% or less, a steel plate with a plate thickness of more than 12 mm and 25 mm or less and Pcm of 0.33% or less, a plate thickness of more than 25 mm and 40 mm or less and Pcm.
- a steel plate having a thickness of 0.31% or less Is one selected from the group consisting of a steel plate having a thickness of 0.31% or less, and a steel plate having a thickness of more than 40 mm and not more than 100 mm and a Pcm of 0.29% or less.
- the temperature of the steel material is less than 5 ° C, it is preferable to perform gas shield arc welding after preheating the steel material temperature to 5 ° C or higher.
- the welded joint according to the present embodiment is obtained by the welding method according to the present embodiment described above. Since the weld joint according to this embodiment is manufactured using the welding wire according to this embodiment in which the amount of Ceq, oxygen amount, and slag forming agent is preferably controlled, it has high strength and high toughness, and diffusion. A weld metal having a good bead shape and a hydrogen content of 1.0 ml / 100 g or less is provided. The shape of the weld joint is determined according to the application and the like, and is not particularly limited.
- the weld joint according to the present embodiment can be a weld joint that forms a groove, such as a normal butt joint, a corner joint, or a T joint. Therefore, the shape of the steel plate to be welded in the method for manufacturing a welded joint according to the present embodiment is not limited as long as at least the part forming the welded joint is plate-like, and the whole may not be a plate. Is included.
- the welded joint according to the present embodiment is not limited to the one constituted by a plurality of steel plates, and may be a butt weld joint obtained by forming a single steel plate into a predetermined shape such as a tubular shape.
- a flux-cored wire includes a steel outer sheath and a flux filled in the steel outer sheath, and the conditions defined in JIS Z 3118 are used using the flux-cored wire.
- the diffusible hydrogen content of the weld metal obtained by direct current gas shielded arc welding is 1.0 ml / 100 g or less, and using the flux-cored wire, the wire polarity is positive, the current value is 270 A, and the voltage value is 29.
- a flux cored wire according to another aspect of the present invention includes a steel outer sheath and a flux filled in the steel outer sheath, and the flux cored wire is in mass% with respect to the total mass of the flux cored wire.
- the content of Ti oxide is 0.10 to 2.50% by mass and includes Ni: 0.5 to 4.00% and is specified in JIS Z 3118 using the flux-cored wire.
- the diffusible hydrogen content of the weld metal obtained by direct current gas shielded arc welding under conditions is 1.0 ml / 100 g or less, and using the flux-cored wire, the wire polarity is positive, the current value is 270 A, and the voltage value is DC gas seal under the conditions of 29 to 32 V, welding speed of 30 cm / min, shielding gas type of CO 2 100% gas, and shielding gas flow rate of 25 L / min.
- the weight per welding time of spatter generated when the arc arc welding is performed is 5.0 g / min or less.
- the polarity of the wire may be either plus or minus since the influence on the diffusible hydrogen amount and spatter generation amount of the weld metal is negligible, and is preferably plus.
- the wire side is plus, the posture is downward, the current value is 270 A, the voltage value is 30 V, the welding speed is 30 cm / min, the shielding gas type is 100% CO 2 gas, and the shielding gas flow rate is 25 l / min.
- the amount of diffusible hydrogen in the weld metal can be reliably reduced to 1.0 ml / 100 g or less.
- the flux cored wire according to the present embodiment can obtain a welded portion having excellent low temperature cracking resistance, and can greatly reduce the amount of spatter generated during welding.
- the preheating operation for preventing low temperature cracking is omitted or the preheating temperature during the preheating operation is reduced. be able to.
- the amount of spatter generated can be reduced even if the shielding gas is 100% CO 2 gas.
- the conditions in the examples are one example of conditions used for confirming the feasibility and effects of the present invention, and the present invention is based on this one example of conditions. It is not limited.
- the present invention can adopt various conditions as long as the object of the present invention is achieved without departing from the gist of the present invention.
- a step of preparing a flux a step of forming a U-shaped open tube by forming a steel strip in a longitudinal direction while feeding a steel strip, a step of supplying a flux into the open tube through an opening of the open tube, and an open tube
- the flux-cored wire is annealed at an annealing temperature of 650 to 900 ° C. at the end of the butt welding of the facing edge surfaces of the openings, the step of drawing the seamless pipe, the middle of the drawing step, or the completion of the drawing step.
- a flux-cored wire having a seamless shape with a wire diameter of ⁇ 1.2 mm was prepared by a manufacturing method including a step of annealing for 4 hours or more.
- a flux-cored wire having a slit-like gap and having a wire diameter of ⁇ 1.2 mm was produced by the same production method as that of a flux-cored wire having a seamless shape.
- a part of the tube was a slit-like tube with no slit-like gap welded, and a wire with a wire diameter of ⁇ 1.2 mm was prototyped by drawing it.
- Tables 1A to 2B show the compositions of the slag components of the prototype flux cored wires
- Tables 3A to 4B show the compositions of the alloy components.
- the balance of the whole wire is Fe and impurities.
- the units of “fluoride”, “oxide”, “carbonate”, “CaO”, “iron powder” and “chemical components excluding fluoride, oxide, CaO, carbonate, and iron powder” in the table are fluxes. It is the mass% with respect to the total mass of a cored wire. “F conversion value total”, “X value”, “oxide total”, “ ⁇ / ⁇ ”, and “Ceq” are calculated based on the above-mentioned values.
- JIS G3106 SM490A with a plate thickness of 20 mm as a base material, butting with a root gap of 16 mm and a groove angle of 20 °, and using a backing metal of the steel plate, 100% CO 2 gas (welding Gas flow: 25 L / min), welding was performed under welding conditions of a welding current of 270 A, a welding voltage of 30 V, and a welding speed of 30 cm / min.
- the groove surface of the base material and the surface of the backing metal were subjected to buttering with two or more layers and a height of 3 mm or more using a flux-cored wire to be tested. In all weldings, the welding current was DC and the wire polarity was positive.
- PFPE oil was apply
- PFPE was not apply
- a mixed gas of 20% CO 2 and 80% Ar is used as the shielding gas under the above-described welding conditions. 100% CO 2 gas was used.
- the flux-cored wires 24, 32, 73, 81 are flux-cored wires having slit-like gaps formed by caulking the outer skin to form the wires, and the other flux-cored wires are seamless wires in which the slit-like gaps are welded. there were.
- FIG. 8 is a diagram showing the sampling position of the test piece.
- the backing metal 2 is placed on the steel plate 1 and welded to form a weld bead 3, and a 2 mm V notch Charpy impact test piece 4 and a round bar tensile test piece. 5 was collected. Using these test pieces, mechanical property tests were performed to measure the tensile strength and Charpy absorbed energy of the weld metal.
- Tables 5 and 6 show the results of the obtained mechanical properties.
- a flux-cored wire from which a weld metal having a tensile strength of 710 MPa or more and a Charpy absorption energy of 55 J or more was obtained was regarded as acceptable for mechanical property evaluation.
- the test conditions for the Charpy impact test are as follows. Test piece shape: No. 4 Charpy test piece (2 mmV notch) Test temperature: -40 ° C
- low temperature cracking resistance test and diffusible hydrogen measurement under welding conditions of 100% CO 2 gas welding gas flow rate: 25 L / min
- welding position downward welding current 270 A
- welding voltage 30 V welding speed 30 cm / min.
- the low temperature cracking resistance test is JIS Z3158 (y-type weld cracking test method 1993) using a steel sheet having a thickness of 50 mm which is a high strength steel sheet for welded structure shown in Table 7, and JIS Z using the same steel sheet having a thickness of 25 mm.
- 3157 U-shaped weld weld cracking test
- each test was conducted without preheating under a constant atmosphere control at a temperature of 5 ° C. and a humidity of 60%. .
- the diffusible hydrogen content measurement test was carried out by a gas chromatograph method in accordance with JIS Z 3118 (Method for measuring hydrogen content of steel welds 2007) under the above-mentioned welding conditions of the low temperature cracking resistance test.
- Table 5 and Table 6 show the results of the obtained y-type weld crack test and U-type weld crack test.
- Weld metal with less than 1.0 ml / 100 g of diffusible hydrogen has no cross-section cracks (no cross-section cracks occur) in all cross sections of the test piece, even without preheating at a low temperature of 5 ° C. And extremely high cold cracking resistance was proved.
- the sputter generation amount was evaluated by the following method. First, the flux wire was subjected to welding under the following conditions. Welding gas type: 100% CO 2 gas Welding gas flow rate: 25 L / min Welding current: 270A Welding voltage 29-32V Welding speed: 30 cm / min Welding posture: Downward welding time: 60 seconds Polarity: Wire + (plus) direct current with bead-on-plate welding under the above-mentioned conditions was carried out inside a copper collection box, and was scattered in the box during welding All of the spatter and spatter adhering to the steel plate were collected, the weight of all spatter was measured, and the amount of spatter generated per unit time was calculated. A sputter generation amount of less than 5.0 g / min was determined to be acceptable. The results are shown in Tables 5 and 6.
- the weld metal obtained with the flux-cored wires 1 to 62 according to the examples of the present invention is excellent in all of tensile strength, toughness, and low-temperature cracking resistance. there were. Furthermore, the workability of welding using the flux-cored wire as an example of the present invention was good. On the other hand, since the flux-cored wires 63 to 100 as comparative examples do not satisfy the requirements defined in the present invention, the tensile strength, toughness, and cold cracking resistance of the resulting weld metal, and workability during welding are improved. At least one or more failed.
- a steel plate having a plate thickness of 12 mm with a Pcm of 0.30%, a plate thickness of 25 mm with a Pcm of 0.29%, a plate thickness of 40 mm with a Pcm of 0.28%, and a plate thickness of 100 mm with a Pcm of 0.27% is used.
- the y-type weld cracking test and the U-shaped cracking test are the same as the cold cracking test and the same welding conditions as in the cold cracking test and without preheating at a temperature of 5 ° C. and a humidity of 60%.
- a shape welding weld cracking test was conducted. As a result, in all tests, it was confirmed that there were no cracks on the surface and the cross section.
- the flux-cored wire according to the present invention has a high strength and high toughness, has an excellent cold cracking resistance, and can obtain a weld part having a good bead shape, greatly reducing the amount of spatter generated during welding. can do.
- the welding method according to the present invention can omit the preheating work for preventing cold cracking of the weld metal, or can reduce the preheating temperature during the preheating work, and can greatly reduce the amount of spatter generated. is there.
- the welded joint according to the present invention has a weld portion having high strength and high toughness and having a good bead shape.
- the preheating operation for preventing the cold cracking can be omitted or the preheating temperature in the preheating operation can be lowered.
- the shielding gas is 100% CO 2 gas, the amount of spatter generated can be reduced. Therefore, the present invention can remarkably improve the welding operation efficiency, and its value in the industry is extremely high.
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Abstract
Description
また、本発明は、低温割れを防止するための予熱作業を省略可能または予熱作業の際の予熱温度を低下させること可能であり、スパッタの発生量を大幅に低減可能である溶接継手の製造方法の提供を目的とする。
さらに本発明は、高強度且つ高靭性の溶接継手の提供を目的とする。
X=[NaF]+[MgF2]+[Na3AlF6]+1.50×([K2SiF6]+[K2ZrF6]+[LiF]+[BaF2])+3.50×([CaF2]):式1
但し、[]付化学式は、それぞれの前記化学式に対応する弗化物の前記フラックス入りワイヤの前記全質量に対する含有量を単位質量%で示す。
Ceq=[C]+[Si]/24+[Mn]/6+[Ni]/40+[Cr]/5+[Mo]/4+[V]/14:式2
但し、[]付元素記号は、前記弗化物、前記酸化物、前記CaO、前記炭酸塩、および前記鉄粉を除く前記化学成分に含まれる各前記元素記号に対応する元素の前記フラックス入りワイヤの前記全質量に対する含有量を単位質量%で表す。
(2)上記(1)に記載のフラックス入りワイヤは、前記弗化物、前記酸化物、前記CaO、前記炭酸塩、および前記鉄粉を除く化学成分が、前記フラックス入りワイヤの前記全質量に対する質量%で、Mg:0.07%以下を含有してもよい。
(3)上記(1)または(2)に記載のフラックス入りワイヤは、前記弗化物、前記酸化物、前記CaO、前記炭酸塩、および前記鉄粉を除く化学成分が、式3を満たしてもよい。
([Mg]+10×[Al])≦0.45:式3
但し、[]付元素記号は、前記弗化物、前記酸化物、前記CaO、前記炭酸塩、および前記鉄粉を除く前記化学成分に含まれる、各前記元素記号に対応する元素の、前記フラックス入りワイヤの前記全質量に対する含有量を単位質量%で示す。
(4)上記(1)~(3)のいずれか一項に記載のフラックス入りワイヤは、前記炭酸塩の含有量の合計が、前記フラックス入りワイヤの前記全質量に対する質量%で0.30%超3.50%以下であり、前記MgCO3、前記Na2CO3、及び前記LiCO3の含有量の合計が、前記フラックス入りワイヤの前記全質量に対する質量%で0.30~3.00%であってもよい。
(5)上記(1)~(4)のいずれか一項に記載のフラックス入りワイヤは、前記αが0.50%以上であってもよい。
(6)上記(1)~(5)のいずれか一項に記載のフラックス入りワイヤは、前記X値が4.5%以下であってもよい。
(7)上記(1)~(6)のいずれか一項に記載のフラックス入りワイヤは、前記Ti酸化物の含有量が、前記フラックス入りワイヤの前記全質量に対する質量%で0.10~1.80%であってもよい。
(8)上記(1)~(7)のいずれか一項に記載のフラックス入りワイヤは、前記CaF2の含有量が、前記フラックス入りワイヤの前記全質量に対する質量%で0.20%以下であってもよい。
(9)上記(1)~(8)のいずれか一項に記載のフラックス入りワイヤは、α/βが0.10~4.00であってもよい。
(10)上記(1)~(9)のいずれか一項に記載のフラックス入りワイヤは、前記弗化物の前記フラックス入りワイヤの前記全質量に対する質量%での含有量の合計に対する、前記Na3AlF6及び前記NaFの前記フラックス入りワイヤの前記全質量に対する質量%での含有量の合計の割合が0.50以上であってもよい。
(11)上記(1)~(10)のいずれか一項に記載のフラックス入りワイヤは、前記フラックス入りワイヤを用いてガスシールドアーク溶接したときの溶着金属の引張強さが、日本工業規格JIS Z3111-2005に規定された溶着金属の引張試験で、690MPa以上1500MPa未満となってもよい。
(12)上記(1)~(11)のいずれか一項に記載のフラックス入りワイヤは、前記鋼製外皮がシームレス形状を有してもよい。
(13)上記(1)~(11)のいずれか一項に記載のフラックス入りワイヤは、前記鋼製外皮がスリット状の隙間を有する形状であってもよい。
(14)上記(1)~(13)のいずれか一項に記載のフラックス入りワイヤは、前記フラックス入りワイヤの表面に塗布されたパーフルオロポリエーテル油をさらに備えてもよい。
(15)本発明の別の態様に係る溶接継手の製造方法は、上記(1)~(14)のいずれか一項に記載のフラックス入りワイヤを用いて、鋼材をガスシールドアーク溶接する工程を備える。
(16)上記(15)に記載の溶接継手の製造方法は、前記鋼材が、板厚が12mm以下かつPcmが0.36%以下である鋼板、板厚が12mm超25mm以下かつPcmが0.33%以下である鋼板、板厚が25mm超40mm以下かつPcmが0.31%以下である鋼板、及び板厚が40mm超100mm以下かつPcmが0.29%以下である鋼板からなる群から選択される1種であり、前記鋼材を、前記ガスシールドアーク溶接をする際、前記鋼材の温度が5℃未満の場合には予熱を省略してガスシールドアーク溶接を行ってもよい。
(17)本発明の別の態様に係る溶接継手は、上記(15)又は(16)に記載の溶接継手の製造方法によって得られる。
(18)本発明の別の態様に係るフラックス入りワイヤは、鋼製外皮と、前記鋼製外皮の内部に充填されたフラックスと、を備え、前記フラックス入りワイヤを用いて、JIS Z 3118に規定された条件で溶接することにより得られる溶接金属の拡散性水素量が1.0ml/100g以下であり、前記フラックス入りワイヤを用いて、ワイヤ極性がプラス、電流値が270A、電圧値が29~32V、溶接速度が30cm/min、シールドガス種がCO2100%ガス、及びシールドガス流量が25L/minである条件で直流ガスシールドアーク溶接を行った際に発生するスパッタの溶接時間あたりの重量が、5.0g/min以下である。
(19)本発明の別の態様に係るフラックス入りワイヤは、鋼製外皮と、前記鋼製外皮の内部に充填されたフラックスと、備え、前記フラックス入りワイヤは、前記フラックス入りワイヤの全質量に対する質量%で、Ti酸化物の含有量が質量%で0.10~2.50%であり、Ni:0.5~4.00%を含み、前記フラックス入りワイヤを用いて、JIS Z 3118に規定された条件で直流ガスシールドアーク溶接することにより得られる溶接金属の拡散性水素量が1.0ml/100g以下であり、前記フラックス入りワイヤを用いて、ワイヤ極性がプラス、電流値が270A、電圧値が29~32V、溶接速度が30cm/min、シールドガス種がCO2100%ガス、及びシールドガス流量が25L/minである条件で直流ガスシールドアーク溶接を行った際に発生するスパッタの溶接時間あたりの重量が、5.0g/min以下である。
本発明に係る溶接継手は、高強度及び高靭性の溶接部を備える。
本発明に係るフラックス入りワイヤ及び溶接継手の製造方法は、いかなる鋼材にも適用可能であるが、通常のフラックス入りワイヤ、及び溶接継手の製造方法を適用することが難しい780MPa以上の高強度鋼の溶接に適用された場合、特に著しい効果を奏する。この場合であっても、本発明は低温割れを防止するための予熱作業を省略又は予熱作業の際の予熱温度を低下させることができる。さらに、本発明に係るフラックス入りワイヤ及び溶接継手の製造方法は、いかなるシールドガスと組み合わせることができるが、通常のフラックス入りワイヤ及び溶接継手の製造方法と組み合わせることが難しい100%CO2ガスと組み合わせた場合、特に著しい効果を奏するこの場合であっても、本発明は、スパッタの発生量を著しく低減することができる。
しかし、フラックスに含まれる弗化物は、スパッタ量を増大させる場合があった。特に、シールドガスが100%CO2ガスである溶接に、弗化物を多く含有するフラックス入りワイヤを適用した場合、スパッタ量が非常に多くなることがあった。本発明者らは、スパッタ量を抑制するために、フラックスに含まれる弗化物の種類を異ならせたフラックスワイヤを用いて、検討を重ねた。
その結果、本発明者らは、弗化物の含有量のF換算値と、溶接直後の溶接金属中の拡散性水素量との間に良好な相関関係があること、及び、下記式を用いて算出されるスパッタ発生指数Xとスパッタ生成量との間に良好な相関関係があることを見いだした。
X=[NaF]+[MgF2]+[Na3AlF6]+1.50×([K2SiF6]+[K2ZrF6]+[LiF]+[BaF2])+3.5×[CaF2]
上述の式において、括弧で囲まれた化学式は、各化学式に対応する弗化物の、フラックス入りワイヤの全質量に対する単位質量%での含有量である。上述の式は、各弗化物の量を種々変化させたフラックス入りワイヤを100%CO2シールドガスの溶接に供した際に発生するスパッタ量を測定し、各弗化物量とスパッタ量との関係を重回帰分析することにより得られた。図1は、X値とスパッタ量との関係を示すグラフである。このグラフから、X値とスパッタ量との間に良好な相関関係があることがわかる。従って、フラックス中に含まれる弗化物のF換算値を可能な限り大きくし、且つフラックス中に含まれる弗化物から算出されるX値を可能な限り小さくするように、フラックス中に含まれる弗化物の種類及び配合比を決定すれば、溶接直後の溶接金属中の拡散性水素量を1.0ml/100g未満とし、且つシールドガスが100%CO2ガスである溶接の作業性を損なわないフラックス入りワイヤを提供することができる。
また、本発明者らは、弗化物のうちCaF2の含有量を制限することも、スパッタ発生量の低減のために必要とされることを見出した。
本実施形態に係るフラックス入りワイヤのフラックスは、フラックス入りワイヤの全質量に対するF換算値で合計0.21%以上の弗化物を含む。フラックス入りワイヤの全質量に対するF換算値とは、フラックス入りワイヤ中の弗化物に含まれる弗素(F)の量を、フラックス入りワイヤの全質量に対する質量%で示すものである。後述されるように、本実施形態に係るフラックス入りワイヤの弗化物は、CaF2、MgF2、Na3AlF6、LiF、NaF、K2ZrF6、BaF2、及びK2SiF6からなる群から選択される1種以上であり、フラックス入りワイヤの全質量に対するF換算値の合計は、以下の数式によって求められる。
(F換算値の合計)=0.487×[CaF2]+0.610×[MgF2]+0.732×[LiF]+0.452×[NaF]+0.402×[K2ZrF6]+0.217×[BaF2]+0.517×[K2SiF6]+0.543×[Na3AlF6
上述の式において、括弧で囲まれた化学式は、各化学式に係る弗化物の、フラックス入りワイヤの全質量に対する質量%での含有量である。以下、「フラックス入りワイヤの全質量に対するF換算値」を「F換算値」と記載する場合がある。また、記号「α」を、フラックス入りワイヤの全質量に対する弗化物のF換算値の合計と定義する。
なお、上記の各弗化物のF換算値の係数は、各弗化物に含まれる弗素の原子量及び個数と、各弗化物の化学式量とから算出したものである。例えば、CaF2のF換算値の係数0.487は、弗素原子量19.00を2倍した値をCaF2の化学式量78.08で徐すことで得られた値である(つまり、19.00×2/78.08=0.487)。
フラックス中の弗化物は、溶接金属の拡散性水素量を低減させて、溶接金属の耐低温割れ性を顕著に向上させる働きを有する。この理由は明らかではないが、弗化物中のFと水素(H)とが溶接中に結合して弗化水素(HF)となり、このHFが溶接金属外に放出されるからであると推測される。しかしながら、フラックス中の弗化物量のF換算値合計が0.21%未満である場合、溶接金属の拡散性水素量を1.0ml/100g未満とすることができない場合があるので、溶接金属の耐低温割れ性が不十分になるおそれがある。従って、本実施形態に係るフラックス入りワイヤのフラックスは、F換算値で0.21%以上の弗化物を含むことが必要とされる。溶接金属の拡散性水素量をより低減するために、弗化物のF換算値での合計量の下限を0.25%、0.30%、0.35%、0.40%、0.45%、0.50%、0.60%、0.65%、0.70%、0.80%、又は0.90%としてもよい。一方、拡散性水素量の低減よりスパッタ発生量の低減を優先させたい場合には、F換算値の合計量の上限を2.00%、1.70%、1.50%、1.30%、1.10%、1.00%、0.90%、0.80%、0.70%、0.60%、0.50%、又は、0.40%としても差し支えない。
ワイヤ径:1.2mm
溶接ガス種:100%CO2
ガス流量:25L/min
溶接電流:270A
溶接速度35cm/min
溶接環境温度:20℃
溶接環境湿度:60%
姿勢:下向
極性:ワイヤ+(プラス)
電流:直流
上述の実験により得られた、フラックス入りワイヤのF換算値の合計と溶接金属の拡散性水素量との関係を図2のグラフに示す。このグラフから、フラックス入りワイヤのF換算値の合計が0.21%以上である場合に、拡散性水素量が1.0ml/100g以下に低減されることがわかった。また、このグラフから、フラックス入りワイヤのF換算値の合計が0.50%以上である場合に、拡散性水素量が0.6ml/100g以下に低減されることがわかった。
本実施形態に係るフラックス入りワイヤの弗化物は、CaF2、MgF2、Na3AlF6、LiF、NaF、K2ZrF6、BaF2、及びK2SiF6からなる群から選択される1種または2種以上である。これら弗化物が電離して生じたCa、Mg、Li、Na、K、Zr、Ba、Si、およびAlは、酸素と結合して溶接金属中の酸素量を低減させる、脱酸元素として作用する。
弗化物の含有量が大きすぎる場合、溶接の際に生じるスパッタの量が過剰になり、溶接性が劣化する。本発明者らは、F換算値を可能な限り増加させ、かつスパッタ量を許容範囲内まで減少させる方法について検討を行った。その結果、本発明者らは、弗化物がスパッタ量に与える影響が弗化物の種類に応じて異なることを知見した。そして本発明者らはさらなる検討を行った結果、以下の式によって算出されるスパッタ発生指数X(X値)とスパッタ量との間に良好な相関関係があることを見いだした。
X=[NaF]+[MgF2]+[Na3AlF6]+1.50×([K2SiF6]+[K2ZrF6]+[LiF]+[BaF2])+3.50×([CaF2])
上述の式において、括弧で囲まれた化学式は、各化学式に対応する弗化物の、フラックス入りワイヤの全質量に対する単位質量%での含有量である。上述の式は、各弗化物の量を種々変化させたフラックス入りワイヤをCO2100%シールドガスの溶接に供した際に発生するスパッタ量を測定し、各弗化物量とスパッタ量との関係を重回帰分析することにより得られた。
ワイヤ径:1.2mm
溶接ガス種:100%CO2ガス
溶接ガス流量:25L/min
溶接電流:270A
溶接電圧29~32V
溶接速度:30cm/min
溶接姿勢:下向き
溶接時間:60秒
極性:ワイヤ+(プラス)
電流:直流
上述の条件での溶接を、銅製スパッタ捕集箱の内部で実施することにより、溶接中に発生したスパッタ(溶接後に銅製スパッタ捕集箱および鋼板に付着したスパッタ)を捕集し、その重量を測定した。なお、本実験では、溶接中に発生した全てのスパッタの合計重量を測定した。
上述の実験により得られた、フラックス入りワイヤのX値と、1分あたりの全てのスパッタ発生量との関係を図1のグラフに示す。このグラフから、フラックス入りワイヤのX値が5.0%以下である場合に、全てのスパッタ発生量が低減されることがわかった。この実験結果に基づいて、本発明者らは、本実施形態に係るフラックス入りワイヤのX値の上限値を5.0%と定めた。本実施形態に係るフラックス入りワイヤでは、X値が上述の条件を満たすように、弗化物の含有量及び種類を制御する必要がある。X値の好ましい上限値は4.5%である。スパッタ発生量を低減させたい場合、X値の上限値を4.0%、3.5%、3.0%、2.5%、2.0%、1.8%、1.6%、1.4%、1.2%、又は、1.0%としてもよい。
CaF2は、特にスパッタ量を増大させやすい弗化物である。本発明者らは、弗化物のX値が2.0%以下であったとしても、フラックス入りワイヤの全質量に対する質量%で0.50%以上のCaF2は、大量のスパッタを発生させ、溶接作業性を悪化させることを知見した。本発明者らがCaF2の含有量に関する知見を得た実験について以下に説明する。CaF2の含有量が異なり、X値が上述の規定範囲内である種々のフラックスワイヤを、図1のグラフを作成した際と同じ条件の溶接に供し、図1のグラフを作成した際と同じ方法で、径1.5mm以上のスパッタの1分当たりの発生量を求めた。なお、本実験では、溶接中に発生したスパッタから、径1.5mm以上のスパッタをふるい分け、1.5mm以上のスパッタの合計重量を測定した。この実験により得られた、CaF2の含有量と1分あたりの径1.5mm以上のスパッタ発生量との関係を図3のグラフに示す。このグラフから、CaF2含有量が0.5%以上である場合、スパッタ発生量が増大することがわかった。一方、このグラフから、CaF2含有量が0.2%以下である場合、径1.5mm以上のスパッタ発生量が一層減少することがわかった。従って、本実施形態に係るフラックス入りワイヤのCaF2の含有量が0.50%未満と定められる。CaF2の含有量の好ましい上限値は0.20%である。必要に応じて、CaF2の含有量を、0.10%未満、0.06%未満、0.04%未満、又は、0.02%未満としてもよい。
(CaOを除く酸化物の、フラックス入りワイヤの全質量に対する質量%での合計含有量:0.30%以上3.50%未満)
本実施形態に係るフラックス入りワイヤのフラックスは、酸化物を合計で0.30%以上3.50%未満含有する。この酸化物の種類は、Fe酸化物、Ba酸化物、Na酸化物、Ti酸化物、Si酸化物、Zr酸化物、Mg酸化物、Al酸化物、Mn酸化物、及びK酸化物からなる群から選択される1種または2種以上を含み、CaOを除く。本実施形態では、フラックス入りワイヤの全質量に対する質量%での、CaOを除く酸化物の含有量の合計を「β」と定義する。本実施形態では、「CaOを除く酸化物」を単に「酸化物」と称する場合がある。
Ti酸化物は、溶接ビード形状の改善に寄与する。CaOを除く酸化物の含有量の合計が0.30%以上3.50%未満である場合でも、CaOを除く酸化物に含まれるTi酸化物が0.10%未満である場合、溶接ビード形状が悪くなることがある。従って、Ti酸化物の含有量の下限値を0.10%とする必要がある。Ti酸化物をアーク安定剤として用いることで、さらに良好な溶接ビード形状を得るために、Ti酸化物の含有量の下限値を0.15%、0.20%、0.25%、0.30%、0.40%、又は、0.45%としてもよい。一方、Ti酸化物の含有量が2.50%以上である場合、溶接金属の靭性を低下させることがある。従って、Ti酸化物の含有量の上限値を2.50%未満とする必要がある。溶接金属の靱性のさらなる改善のために、Ti酸化物の含有量の上限値を2.40%、2.20%、2.00%、1.80%、1.50%、1.25%、1.00%、0.90%、0.80%、0.70%、0.60%、又は0.50%としてもよい。
本実施形態に係るフラックス入りワイヤでは、溶接金属中の拡散性水素量を1.0ml/100g未満とするために、βに対するαの比(即ち、α/β)を0.10~4.00とすることが好ましい。α/βが0.10以上である場合、溶接金属中の拡散性水素量をさらに好ましく減少させることができる。必要に応じて、α/βの下限値を0.20、0.30、0.50、又は、0.70としてもよい。α/βが4.00超である場合、溶接ヒューム及びスラグが過剰に生成して、溶接作業性が低下する場合がある。しかし、弗化物及び酸化物に関する上述の規定が満たされている限り、α/βが0.10未満または4.00超であっても好ましい特性が得られる。βに対するαの比の好ましい下限値は0.20である。βに対するαの比の好ましい上限値は3.8、3.50、3.00、2.50、2.00、又は、1.50である。
(炭酸塩の種類:MgCO3、Na2CO3、LiCO3、CaCO3、K2CO3、BaCO3、FeCO3、及び、MnCO3からなる群から選択される1種又は2種以上を含む)
(MgCO3、Na2CO3、及びLiCO3の1種又は2種以上のフラックス入りワイヤの全質量に対する質量%での含有量の合計:0~3.00%)
本実施形態に係るフラックス入りワイヤのフラックスは、炭酸塩を含む必要がない。従って、本実施形態に係るフラックス入りワイヤにおいて、炭酸塩の含有量の下限値は0%である。しかしながら炭酸塩は、アークによって電離し、CO2ガスを発生させる。CO2ガスは、溶接雰囲気中の水素分圧を下げ、溶接金属中の拡散性水素量を低減させる。この効果を得るために、本実施形態に係るフラックス入りワイヤのフラックスは炭酸塩を含んでも良い。炭酸塩の含有量の合計の好ましい下限値は0.30%超である。溶接金属中の拡散性水素量をさらに低減するために、炭酸塩の含有量の合計の下限を0.50%、1.00%、又は、1.50%としてもよい。
本実施形態に係るフラックス入りワイヤのフラックスにCaOが含まれる場合がある。しかしながら、本実施形態に係るフラックス入りワイヤでは、フラックス中のCaOの含有量を0.20%未満にする必要がある。CaOは、水素を含む化合物であるCaOHに変化するので、溶接金属の拡散性水素を増加させ、溶接金属の耐低温割れ性を損なう。CaOの含有量の好ましい上限値は0.18%、0.10%、0.05%、0.02%、又は、0.01%である。CaOは含まれないほうが好ましいので、CaOの含有量の下限値は0%である。CaOは、通常のフラックスの材料に不純物として0.20%以上含まれるおそれがあるので、本実施形態に係るフラックス入りワイヤの製造の際には、CaOが含まれない材料を選定する必要がある。
上述の通り、本実施形態に係るフラックス入りワイヤのフラックスに鉄粉が含まれていても良い。鉄粉は、フラックス入りワイヤにおけるフラックスの充填率の調整のために、または溶着効率の向上のために必要に応じて含有させる場合がある。しかし、鉄粉の表層に付着した酸素が、溶接金属の酸素量を増加させて靭性を低下させる場合がある。したがって、本実施形態に係るフラックス入りワイヤでは、鉄粉の含有量を10.0%未満にする必要がある。鉄粉の含有量の好ましい上限値は8%、6%、4%、2%、又は、1%である。鉄粉が含まれないことが好ましいので、本実施形態に係るフラックス入りワイヤでは、鉄粉の含有量の下限値は0%である。なお、鉄粉と上述のFe酸化物とは異なるものである。鉄粉は、主に酸化されていないFeから構成されるものであり、Fe酸化物は、赤鉄鉱、褐鉄鉱、及び磁鉄鉱等の、主に酸化鉄から構成されるものである。両者は、EPMA等の公知の成分分析装置を用いて判別可能である。
フラックス入りワイヤ中のC含有量が多いほど、溶接金属中のC含有量が増加し、溶接金属の強度が高まる。しかし、Cが多くなり過ぎると、炭化物が溶接金属中に過剰に生成し、溶接金属の靭性が劣化することがある。そこで、溶接金属の靭性を確保するために、C含有量の上限を0.200%とする。また、安定して低温靭性を確保するには、C含有量の上限を、0.100%、0.090%、0.08%、又は0.070%としてもよい。ワイヤ中のC含有量は、外皮材を製造する際の製鋼上の制約から、0.003%未満とすることは難しいので、これを下限とする。必要に応じて、C含有量の下限を0.010%、0.020%、0.030%、0.040%、0.050%、又は0.060%としてもよい。
Siは、脱酸元素であり、溶接金属中の酸素量を低減して溶接金属の清浄度を高め、溶接金属の靱性を向上させる働きを有する。この効果を得るために、Si含有量の下限を0.20%とする必要がある。ただし、1.50%を超えてSiを含有させると、溶接金属の靭性を劣化させることがある従って、1.50%をSi含有量の上限とする。溶接金属中の酸素量を十分に低減させるために、Si含有量の下限を0.25%、0.30%又は0.35%としてもよい。溶接金属の靭性を安定して確保するために、Si含有量の上限を、0.80%、0.70%、又は0.60%としてもよい。
Mnは、溶接金属中の酸素量を低減させて溶接金属の清浄度を高め、これにより溶接金属の靱性を向上させる。その効果を確実に発揮するためには、Mn含有量の下限を1.00%とする必要がある。一方、3.50%を超えてMnを含有させると、溶接金属の粒界脆化感受性が増加して、溶接金属の靭性が劣化することがある。従って、3.50%をMn含有量の上限とする。より安定して溶接金属の強度を高めるためには、Mn含有量の下限を1.01%、1.20%、1.40%又は1.60%としてもよい。溶接金属の靭性をさらに向上させるために、Mn含有量の上限を2.60%、2.40%、2.20%、又は2.00%としてもよい。
本実施形態に係るフラックス入りワイヤのMg含有量は、その上限値が0.10%であり、少ない方が好ましい。本発明者らは、フラックス入りワイヤ中のMgが、たとえ微量であっても、溶接金属の拡散性水素量を増大させることを知見した。
Pは不純物元素であり、溶接金属中に過大に存在する場合、溶接金属の靭性及び延性をともに低下させることがあるので、P含有量は極力低減することが好ましい。靭性及び延性へのPの悪影響を許容できる範囲内とするために、P含有量を0.020%以下とする。溶接金属の靭性および延性の低下を確実に防ぐために、P含有量を0.017%、0.015%、0.012%又は0.010%以下とすることが好ましい。Pの下限を制限する必要はない。P含有量の下限は、0%としてもよい。
Sも不純物元素であり、溶接金属中に過大に存在する場合、溶接金属の靭性を劣化させることがあるので、S含有量は極力低減することが好ましい。靭性へのSの悪影響を許容できる範囲内とするために、P含有量を0.020%以下とする。溶接金属の靭性の劣化を確実に防ぐために、S含有量を0.017%、0.015%、0.012%又は0.010%以下とすることが好ましい。Sの下限を制限する必要はない。S含有量の下限は、0%としてもよい。
Alは脱酸元素であり、Siと同様に、溶接金属中の酸素量を低減させ、溶接金属の清浄度を高め、溶接金属の靱性を向上させる。その効果を得るために、Al含有量の下限を0.001%とすることが必要である。一方、0.300%を超えてAlを含有させると、Alが窒化物及び酸化物を形成して、溶接金属の靭性を低下させることがある。従って、0.300%をAl含有量の上限とする。また、溶接金属の靭性を向上させる効果を十分に得るためには、Al含有量の下限を0.0015%、0.002%、0.003%又は0.004%としてもよい。粗大酸化物の生成を抑制するために、Al含有量の上限を、0.275%、0.250%、又は0.200%としてもよい。
Niは、固溶靭化(固溶により靭性を高める作用)により、溶接金属の組織及び成分を問わず、溶接金属の靭性を向上させることができる唯一の元素である。特に、引張強さが780MPa以上の高強度の溶接金属の靭性を高めるために、Niは有効な元素である。必要な固溶靭化効果を得るためには、Ni含有量の下限を0.50%とする必要がある。Ni含有量が多いほど、靭性を向上させる上で有利である。しかし、含有量が4.00%を超えると、溶接金属中に島状マルテンサイトが生成し、溶接金属の靭性が劣化することがある。従って、4.00%をNi含有量の上限とする。確実にNiの靭性向上効果を得るためには、Ni含有量の下限を0.80%、1.00%、1.50%、2.00%又は2.20%としてもよい。また、溶接金属の靭性を確保するためには、Ni含有量の上限を3.30%、3.10%、2.90%又は2.70%としてもよい。
Moは、焼入性向上元素である。さらにMoは、微細炭化物を形成して、析出強化により引張強さを高める元素である。また、Moは、多層盛溶接時に、溶接金属が後続パスによる再加熱を受けた際の強度低下を抑制し、靭性の劣化も抑制する効果を持つ。大型構造物では厚板が使用されるので、この場合、溶接は多層盛溶接によって行われる。多層盛溶接では、後続の溶接パスから、その前のパスで形成された溶接金属が再加熱を受けることで、前のパスで形成された溶接金属に軟化が生じる。被溶接材(母材)が780MPa級の高強度鋼である場合、溶接金属の組織がベイナイト主体となるので、その軟化の程度が大きくなり、したがって溶接金属の強度を安定的に確保することが難しい。さらに、その再加熱によって溶接金属のセメンタイトが粗大化するので、溶接金属の靭性も劣化する。Moは、多層盛溶接で再加熱を受けた際に溶接金属内にて微細炭化物を形成し、これによって溶接金属の強度低下を抑制し、さらにセメンタイトの粗大化を抑制し、これによって溶接金属の靭性の劣化も抑制する効果を持つ。
Cuは、溶接金属の強度と靭性とを向上させることができる。Cu含有量の下限は0%とするが、それらの効果を十分に得るためには、Cu含有量の下限を0.10%としてもよい。一方、Cu含有量が0.50%を超えると、溶接金属の靭性が低下することがある。そのため、Cuをフラックス入りワイヤに含有させる場合のCu含有量の上限は0.50%とする。Cuを含有させる効果を確実に得るとともに、靭性の低下を防ぐために、Cu含有量の下限を0.15%又は0.20%としてもよい。靭性の向上のため、Cu含有量の上限を0.40%又は0.30%としてもよい。
Crは、溶接金属の焼入性を高めるので、溶接金属の高強度化に有効な元素である。Cr含有量の下限は0%とするが、その効果を得るためには、Cr含有量の下限を0.10%としてもよい。一方、Crは1.50%を超えて過剰に含有させると、溶接金属のベイナイト組織を不均一に硬化させ、靭性を劣化させることがある。従って、Crを含有させる場合のCr含有量の上限は1.50%とする。Crによる靭性の劣化をより抑制するために、Crの上限を1.00%、0.75%、0.50、又は0.25%%としてもよい。
Vは、溶接金属の焼入性を高めるので、溶接金属の高強度化に有効な元素である。V含有量の下限は0%とするが、その効果を得るためには、V含有量の下限を0.01%としてもよい。一方で、0.40%を超えて過剰にVを含有させると、炭化物が溶接金属中に析出することにより、溶接金属の硬化および靭性劣化が生じることがある。従って、Vを含有させる場合のV含有量の上限は0.40%とする。Vの含有による効果を確実に得るとともに、Vの過剰な含有による靭性劣化を防ぐために、V含有量の上限を0.30%、0.20%、0.10%、又は0.05%としてもよい。
Tiも、Alと同様に、脱酸元素として有効な元素であり、溶接金属中の酸素量を低減させる効果を有する。また、Tiは、溶接金属の固溶Nを固定して、固溶Nの靭性への悪影響を緩和する効果も有する。Ti含有量の下限は0%とするが、これら効果を発揮させるためには、Ti含有量の下限を0.01%としてもよい。ただし、フラックス入りワイヤ中のTi含有量が0.30%を超えて過剰になると、粗大な酸化物の形成に起因した靭性劣化、及び過度な析出強化による靭性劣化が溶接金属に生じる可能性が大きくなる。このため、Tiを含有させる場合のTi含有量の上限は0.30%とする。Tiの含有による効果を確実に得るために、Ti含有量の下限を0.015%、0.02%、又は0.04%としてもよい。また、Tiによる靭性劣化をより抑制するためにTiの上限を0.20%、0.10%又は0.05%としてもよい。
Nbは、溶接金属中にて微細炭化物を形成するので、析出強化による溶接金属の引張強さ確保のために有効な元素である。Nb含有量の下限は0%とするが、これらの効果を得るためには、Nb含有量の下限を0.01%としてもよい。一方、0.10%を超えてNbを含有させることは、溶接金属中に過剰に含有されたNbが粗大な析出物を形成して溶接金属の靭性を劣化させることがあるので、好ましくない。このため、Nbを含有させる場合のNb含有量の上限は0.10%とする。Nbの含有による効果を確実に得るために、Nb含有量の下限を0.015%又は0.02%としてもよい。また、Nbによる靭性劣化をより抑制するためにはNbの上限を0.05%、0.04%又は0.03%としてもよい。
溶接金属中に適正量含有されるBは、固溶Nと結びついてBNを形成して、靭性に対する固溶Nの悪影響を減じる。また、Bは、溶接金属の焼入性を高めて強度向上に寄与する効果も有する。B含有量の下限は0%とするが、これらの効果を得るためには、フラックス入りワイヤ中のB含有量下限を0.0001%としてもよい。一方、Bの含有量が0.0100%超となることは、溶接金属中のBが過剰となり、粗大なBN及びFe23(C、B)6等のB化合物が形成されて、靭性を逆に劣化させる可能性が高くなるので、好ましくない。そこで、Bを含有させる場合のB含有量の上限は0.0100%とする。Bの含有による効果を確実に得るために、B含有量の下限を0.0003%又は0.0010%としてもよい。また、Bによる靭性劣化をより抑制するためにはBの上限を0.0080%、0.0060%又は0.0040%としてもよい。
Biは必須成分ではないので、フラックス入りワイヤの化学成分のBi含有量の下限値は0%である。一方、Biは、スラグの剥離性を改善する元素である。このため、フラックス入りワイヤの化学成分のBi含有量を0.0010%以上としても良い。フラックス入りワイヤの化学成分のBi含有量が0.0100%を超える場合、溶接金属に凝固割れが発生しやすくなるので、フラックス入りワイヤの化学成分のBi含有量の上限値は0.0100%である。フラックス入りワイヤの化学成分のBi含有量の上限値は、好ましくは0.0080%である。
(REM:0~0.0100%)
Ca及びREMは、いずれも硫化物の構造を変化させ、溶接金属中での硫化物及び酸化物のサイズを微細化して、溶接金属の靭性向上に寄与する。Ca含有量及びREM含有量の下限は0%とするが、その効果を得るために、Ca含有量の下限値を0.01%としてもよく、REM含有量の下限値を0.0002%としてもよい。一方、Ca及びREMの少なくとも一方を過剰に含有すると、硫化物及び酸化物の粗大化を生じさせて、溶接金属の靭性の劣化を招く。また、Ca及びREMの少なくとも一方を過剰に含有すると、溶接ビード形状の劣化、及び溶接性の劣化の可能性も生じる。したがって、Ca及びREMの少なくとも一方を含有させる場合、Ca含有量の上限値を0.50%、REM含有量の上限値を0.0100%とする。これら元素の含有による効果を確実に得るために、Ca含有量の下限を0.03%としてもよく、REM含有量の下限を0.0003%としてもよい。溶接金属の靭性劣化防止の観点から、Caの上限を0.45%、0.40%、0.35%、又は、0.30%としてもよく、REMの上限を0.0090%、0.0080%、0.0070%、又は、0.0060%としてもよい。
本実施形態に係るフラックス入りワイヤでは、合金成分又は脱酸成分として以上のように各元素を含有する。さらに、溶接金属の引張強さを確保するために、下記式で定義される、日本溶接協会(WES)で定められた炭素当量Ceqが0.45~1.20質量%となるように、C、Si、Mn、Ni、Cr、Mo、及びVの含有量をさらに制御する必要がある。
Ceq=[C]+[Si]/24+[Mn]/6+[Ni]/40+[Cr]/5+[Mo]/4+[V]/14
上述の式において、括弧で囲まれた元素記号は、フラックス入りワイヤの、弗化物、CaOを除く酸化物、CaO、炭酸塩、および鉄粉を除く化学成分に含まれる各元素記号に対応する元素の、フラックス入りワイヤの全質量に対する単位質量%での含有量である。すなわち、本実施形態のフラックス入りワイヤの化学成分から算出されるCeq(フラックス入りワイヤのCeq)は、弗化物、CaOを除く酸化物、CaO、又は炭酸塩の状態でフラックス入りワイヤに含まれている元素の含有量を考慮せずに算出される。弗化物、CaOを除く酸化物、CaO、又は炭酸塩の状態でフラックス入りワイヤに含まれている元素の大半は、溶接の際にスラグとして溶接金属の外部に排出されるので、溶接金属の焼入性に実質的に影響しない。
([Mg]+10×[Al])≦0.45
[Mg]及び[Al]は、フラックス入りワイヤの弗化物、CaOを除く酸化物、及び炭酸塩を除く化学成分に含まれるMg及びAlの、フラックス入りワイヤの全質量に対する含有量を単位質量%で示すものである。本発明者らは、フラックス入りワイヤの化学成分に含まれるMg及びAlの量と、溶接金属中の拡散性水素量との間に関係があり、特に、溶接雰囲気が高温多湿である場合に「[Mg]+10×[Al]」の制御が拡散性水素量の低減に貢献することを知見した。さらに本発明者らは、Mg含有量及びAl含有量が異なる種々のフラックス入りワイヤから得られる溶接金属の拡散性水素量を重回帰分析することにより、「[Mg]+10×[Al]」と拡散性水素量との間に、図6に示される良好な線形関係があることを見いだした。
溶接ガス種:100%CO2
溶接電流:270A
溶接環境温度:30℃
溶接環境湿度:80%
上述の溶接環境は、本実施形態に係るフラックス入りワイヤが属する技術分野において、いわゆる高温多湿環境であるとみなされる。上述の実験により得られた、「[Mg]+10×[Al]」と溶接金属の拡散性水素量との関係を図6のグラフに示す。このグラフから、「[Mg]+10×[Al]」が0.45%以下である場合に、溶接環境が高温多湿環境であっても、拡散性水素量がさらに低減されることがわかった。この実験結果に基づいて、本発明者らは、本実施形態に係るワイヤの化学成分が、「[Mg]+10×[Al]」が0.45%以下となるように制御されることが好ましく、0.40%以下、0.38%、または0.35%以下とされることがさらに好ましい旨を知見した。高温多湿環境で溶接を行った場合、溶接金属の拡散性水素量が高くなりやすいので、この特徴は、高温多湿環境での溶接性の改善という顕著な効果を奏する。ただし、「[Mg]+10×[Al]」が0.45%を上回っていても、Mg含有量及びAl含有量が上述された数値範囲内である限り、本実施形態に係るフラックス入りワイヤの特性は損なわれない。
図7A~図7Cに、フラックス入りワイヤの切断面を示す。図7Aに、エッジ面を突合せて溶接して作ったフラックス入りワイヤ、図7Bに、エッジ面を突合せて作ったフラックス入りワイヤ、及び、図7Cに、エッジ面をかしめて作ったフラックス入りワイヤを示す。このように、フラックス入りワイヤには、図7Aに示すように鋼製外皮にスリット状の隙間がないワイヤと、図7B、図7Cに示すように鋼製外皮がスリット状の隙間6を有するワイヤとに大別できる。本実施形態に係るフラックス入りワイヤでは、いずれの断面構造も採用することができる。しかしながら、溶接金属の低温割れを抑制するためには、スリット状の隙間がないワイヤ(シームレスワイヤ)とすることが好ましい。
Pcm=(C)+(Si)/30+(Mn)/20+(Cu)/20+(Ni)/60+(Cr)/20+(Mo)/15+(V)/10+5×(B)
なお、上記式に含まれる、括弧で囲まれた各元素は、鋼材に含まれる各元素の含有量(質量%)を示す。鋼材中に含有されない元素の含有量は0質量%とみなされる。
本実施形態に係る溶接継手の製造方法は、上述された本実施形態に係るフラックス入りワイヤを用いて、鋼材を、ガスシールドアーク溶接する工程を備える。被溶接材である母材は、特に限定されないが、主として引張強さ780MPa以上の鋼材である。溶接金属の引張強さより高い引張強さの鋼材に溶接を行うことは妨げられないので、鋼材の引張強さの上限を特に制限する必要はない。しかしながら、鋼材の引張強さの上限を、1100MPa、1050MPa、1000MPa、940MPa又は900MPaに制限してもよい。鋼材の板厚は、特に限定されないが、一般的な鋼材の板厚は、3~100mmであるので、この板厚に限定しても差し支えない。
なお、鋼材が、板厚が12mm以下かつPcmが0.36%以下である鋼板、板厚が12mm超25mm以下かつPcmが0.33%以下である鋼板、板厚が25mm超40mm以下かつPcmが0.31%以下である鋼板、及び板厚が40mm超100mm以下かつPcmが0.29%以下である鋼板からなる群から選択される1種であり、鋼材をガスシールドアーク溶接する際、鋼材の温度が5℃未満の場合、鋼材温度を5℃以上に予熱後にガスシールドアーク溶接を行うことが好ましい。鋼材の種類、及び溶接時の鋼材温度が上述の範囲内で、予熱を行わずに溶接したとしても、低温割れが必ず発生する訳ではない。溶接後にX線やUST等の非破壊検査を行って、溶接継手に割れ等がある場合には、割れた部分を補修溶接すればよい。また、鋼材の種類が上述の範囲内であるが、溶接時の鋼材の温度が5℃以上の場合、予熱を省略しても、低温割れを確実に防止できる。したがって、本実施形態に係るフラックス入りワイヤを用いることで、溶接補修を含めた溶接施工のコストを大幅に低減でき、溶接施工時間を大幅に短縮できる。
本実施形態に係る溶接継手は、上述された本実施形態に係る溶接方法によって得られる。本実施形態に係る溶接継手は、Ceq、酸素量、及びスラグ形成剤の量が好ましく制御された本実施形態に係る溶接ワイヤを用いて製造されるので、高強度及び高靱性を有し、拡散性水素量が1.0ml/100g以下であり、且つ良好なビード形状を有する溶接金属を備える。溶接継手の形状は、用途等に応じて決定され、特に限定されるものではない。本実施形態に係る溶接継手は、通常の突合せ継手、角継手、T継手など、開先を形成する溶接継手とすることができる。したがって、本実施形態に係る溶接継手の製造方法において溶接される鋼板の形状も、少なくとも溶接継手を形成する部分が板状であればよく、全体が板でなくともよく、例えば、形鋼なども含むものである。また、本実施形態に係る溶接継手は、複数の鋼板から構成されるものに限定されず、1枚の鋼板を管状などの所定の形状に成形したものの突合せ溶接継手であってもよい。
試験片形状:4号シャルピー試験片(2mmVノッチ)
試験温度:-40℃
溶接ガス種:100%CO2ガス
溶接ガス流量:25L/min
溶接電流:270A
溶接電圧29~32V
溶接速度:30cm/min
溶接姿勢:下向き
溶接時間:60秒
極性:ワイヤ+(プラス)で直流
上述の条件でのビードオンプレート溶接を、銅製の捕集箱の内部で実施することにより、溶接中に箱内に飛散したスパッタおよび鋼板に付着したスパッタの全てを回収し、全てのスパッタの重量を測定し、単位時間当たりのスパッタ発生量を算出した。そのスパッタ発生量について5.0g/min未満であるものを合格と判定した。結果を表5及び表6に示す。
2 裏当金
3 溶接ビード
4 2mmVノッチシャルピー衝撃試験片
5 丸棒引張り試験片
6 隙間
Claims (19)
- 鋼製外皮と、
前記鋼製外皮に充填されたフラックスと、
を備えるフラックス入りワイヤであって、
前記フラックスが、
弗化物であって、CaF2、MgF2、Na3AlF6、LiF、NaF、K2ZrF6、BaF2、及び、K2SiF6からなる群から選択される1種又は2種以上であり、前記弗化物の前記フラックス入りワイヤの全質量に対するF換算値の合計値αが0.21%以上である前記弗化物と、
酸化物であって、Fe酸化物、Ba酸化物、Na酸化物、Ti酸化物、Si酸化物、Zr酸化物、Mg酸化物、Al酸化物、Mn酸化物、及びK酸化物からなる群から選択される1種又は2種以上を含み、CaOを除き、前記フラックス入りワイヤの前記全質量に対する質量%での前記酸化物の含有量の合計値βが0.30%以上3.50%未満である前記酸化物と、
前記フラックス入りワイヤの前記全質量に対する質量%での含有量の合計値が0~3.50%であり、MgCO3、Na2CO3、LiCO3、CaCO3、K2CO3、BaCO3、FeCO3及びMnCO3からなる群から選択される1種又は2種以上を含む炭酸塩と、
を含み、
前記フラックス中の前記CaOの含有量が、前記フラックス入りワイヤの前記全質量に対する質量%で0%以上0.20%未満であり、
前記フラックス中の鉄粉の含有量が、前記フラックス入りワイヤの前記全質量に対する質量%で0%以上10.0%未満であり、 式1を用いて算出されるX値が5.0%以下であり、
前記CaF2の含有量が前記フラックス入りワイヤの前記全質量に対する質量%で0.50%未満であり、
前記Ti酸化物の含有量が前記フラックス入りワイヤの前記全質量に対する質量%で0.10%以上2.50%未満であり、
前記MgCO3、前記Na2CO3、及び前記LiCO3の含有量の合計値が前記フラックス入りワイヤの前記全質量に対する質量%で0~3.00%であり、
前記弗化物、前記酸化物、前記CaO、前記炭酸塩、および前記鉄粉を除く化学成分が、前記フラックス入りワイヤの前記全質量に対する質量%で、
C :0.003~0.200%、
Si:0.20~1.50%、
Mn:1.00~3.50%、
Мg:0.10%以下、
P :0.020%以下、
S :0.020%以下、
Al:0.001~0.300%、
Ni:0.50~4.00%、
Mo:0.10~2.00%、
Cu:0~0.50%、
Cr:0~1.50%、
Nb:0~0.10%、
V :0~0.40%、
Ti:0~0.30%、
B :0~0.0100%、
Bi:0~0.0100%、
Ca:0~0.50%、及び
REM:0~0.0100%を含み、
残部が鉄及び不純物からなり、
下記の式2を用いて算出されるCeqが0.45~1.20%である
ことを特徴とするフラックス入りワイヤ。
X=[NaF]+[MgF2]+[Na3AlF6]+1.50×([K2SiF6]+[K2ZrF6]+[LiF]+[BaF2])+3.50×([CaF2]):式1
但し、[]付化学式は、それぞれの前記化学式に対応する弗化物の前記フラックス入りワイヤの前記全質量に対する含有量を単位質量%で示す。
Ceq=[C]+[Si]/24+[Mn]/6+[Ni]/40+[Cr]/5+[Mo]/4+[V]/14:式2
但し、[]付元素記号は、前記弗化物、前記酸化物、前記CaO、前記炭酸塩、および前記鉄粉を除く前記化学成分に含まれる各前記元素記号に対応する元素の前記フラックス入りワイヤの前記全質量に対する含有量を単位質量%で表す。 - 前記弗化物、前記酸化物、前記CaO、前記炭酸塩、および前記鉄粉を除く化学成分が、前記フラックス入りワイヤの前記全質量に対する質量%で、
Mg:0.07%以下
を含有することを特徴とする請求項1に記載のフラックス入りワイヤ。 - 前記弗化物、前記酸化物、前記CaO、前記炭酸塩、および前記鉄粉を除く化学成分が、式3を満たすことを特徴とする請求項1または2に記載のフラックス入りワイヤ。
([Mg]+10×[Al])≦0.45:式3
但し、[]付元素記号は、前記弗化物、前記酸化物、前記CaO、前記炭酸塩、および前記鉄粉を除く前記化学成分に含まれる、各前記元素記号に対応する元素の、前記フラックス入りワイヤの前記全質量に対する含有量を単位質量%で示す。 - 前記炭酸塩の含有量の合計が、前記フラックス入りワイヤの前記全質量に対する質量%で0.30%超3.50%以下であり、
前記MgCO3、前記Na2CO3、及び前記LiCO3の含有量の合計が、前記フラックス入りワイヤの前記全質量に対する質量%で0.30~3.00%である
ことを特徴とする請求項1~3のいずれか一項に記載のフラックス入りワイヤ。 - 前記αが0.50%以上であることを特徴とする請求項1~4のいずれか一項に記載のフラックス入りワイヤ。
- 前記X値が4.5%以下であることを特徴とする請求項1~5のいずれか一項に記載のフラックス入りワイヤ。
- 前記Ti酸化物の含有量が、前記フラックス入りワイヤの前記全質量に対する質量%で0.10~1.80%であることを特徴とする請求項1~6のいずれか一項に記載のフラックス入りワイヤ。
- 前記CaF2の含有量が、前記フラックス入りワイヤの前記全質量に対する質量%で0.20%以下であることを特徴とする請求項1~7のいずれか一項に記載のフラックス入りワイヤ。
- α/βが0.10~4.00であることを特徴とする請求項1~8のいずれか一項に記載のフラックス入りワイヤ。
- 前記弗化物の前記フラックス入りワイヤの前記全質量に対する質量%での含有量の合計に対する、前記Na3AlF6及び前記NaFの前記フラックス入りワイヤの前記全質量に対する質量%での含有量の合計の割合が0.50以上である
ことを特徴とする請求項1~9のいずれか一項に記載のフラックス入りワイヤ。 - 前記フラックス入りワイヤを用いてガスシールドアーク溶接したときの溶着金属の引張強さが、日本工業規格JIS Z3111-2005に規定された溶着金属の引張試験で、690MPa以上1500MPa未満となることを特徴とする請求項1~10のいずれか一項に記載のフラックス入りワイヤ。
- 前記鋼製外皮がシームレス形状を有することを特徴とする請求項1~11のいずれか一項に記載のフラックス入りワイヤ。
- 前記鋼製外皮がスリット状の隙間を有する形状であることを特徴とする請求項1~11のいずれか一項に記載のフラックス入りワイヤ。
- 前記フラックス入りワイヤが、前記フラックス入りワイヤの表面に塗布されたパーフルオロポリエーテル油をさらに備えることを特徴とする請求項1~13のいずれか一項に記載のフラックス入りワイヤ。
- 請求項1~14のいずれか一項に記載のフラックス入りワイヤを用いて、鋼材をガスシールドアーク溶接する工程
を備える溶接継手の製造方法。 - 前記鋼材が、
板厚が12mm以下かつPcmが0.36%以下である鋼板、
板厚が12mm超25mm以下かつPcmが0.33%以下である鋼板、
板厚が25mm超40mm以下かつPcmが0.31%以下である鋼板、及び
板厚が40mm超100mm以下かつPcmが0.29%以下である鋼板
からなる群から選択される1種であり、
前記鋼材を、前記ガスシールドアーク溶接をする際、前記鋼材の温度が5℃未満の場合には前記鋼材の温度が5℃以上になるように予熱して、前記鋼材の温度が5℃以上の場合には予熱せずに、ガスシールドアーク溶接を行うことを特徴とする請求項15に記載の溶接継手の製造方法。
ここで、Pcmは、式4により算出する。
Pcm=[C]+[Si]/30+[Mn]/20+[Cu]/20+[Ni]/60+[Cr]/20+[Mo]/15+[V]/10+5×[B]:式4
但し、[]付元素記号は、前記鋼材に含まれるそれぞれの前記元素記号に対応する元素の含有量を単位質量%で表す。 - 請求項15又は16に記載の溶接継手の製造方法によって得られることを特徴とする溶接継手。
- 鋼製外皮と、前記鋼製外皮の内部に充填されたフラックスと、を備えるフラックス入りワイヤであって、
前記フラックス入りワイヤを用いて、JIS Z 3118に規定された条件で直流ガスシールドアーク溶接することにより得られる溶接金属の拡散性水素量が1.0ml/100g以下であり、
前記フラックス入りワイヤを用いて、ワイヤ極性がプラス、電流値が270A、電圧値が29~32V、溶接速度が30cm/min、シールドガス種がCO2100%ガス、及びシールドガス流量が25L/minである条件で直流ガスシールドアーク溶接を行った際に発生するスパッタの溶接時間あたりの重量が、5.0g/min以下である
ことを特徴とするフラックス入りワイヤ。 - 鋼製外皮と、
前記鋼製外皮の内部に充填されたフラックスと、
を備えるフラックス入りワイヤであって、
前記フラックス入りワイヤは、前記フラックス入りワイヤの全質量に対する質量%で、Ti酸化物の含有量が0.10~2.50%であり、Ni:0.5~4.00%を含み、
前記フラックス入りワイヤを用いて、JIS Z 3118に規定された条件で直流ガスシールドアーク溶接することにより得られる溶接金属の拡散性水素量が1.0ml/100g以下であり、
前記フラックス入りワイヤを用いて、ワイヤ極性がプラス、電流値が270A、電圧値が29~32V、溶接速度が30cm/min、シールドガス種がCO2100%ガス、及びシールドガス流量が25L/minである条件で直流ガスシールドアーク溶接を行った際に発生するスパッタの溶接時間あたりの重量が、5.0g/min以下である
ことを特徴とするフラックス入りワイヤ。
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JP2020142277A (ja) * | 2019-03-06 | 2020-09-10 | 日鉄溶接工業株式会社 | 耐候性鋼のAr−CO2混合ガスシールドアーク溶接用フラックス入りワイヤ |
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US11331742B2 (en) | 2022-05-17 |
BR112018015822A2 (ja) | 2018-12-26 |
JP6766866B2 (ja) | 2020-10-14 |
CN108698175B (zh) | 2021-01-15 |
JPWO2017154120A1 (ja) | 2018-09-13 |
BR112018015822B1 (pt) | 2021-07-13 |
CA3013886A1 (en) | 2017-09-14 |
CA3013886C (en) | 2021-05-18 |
KR102118387B1 (ko) | 2020-06-03 |
EP3427890A4 (en) | 2019-10-30 |
EP3427890A1 (en) | 2019-01-16 |
MX2018010659A (es) | 2019-01-30 |
CN108698175A (zh) | 2018-10-23 |
US20200070273A1 (en) | 2020-03-05 |
AU2016396546A1 (en) | 2018-08-23 |
KR20180108731A (ko) | 2018-10-04 |
EP3427890B1 (en) | 2021-06-02 |
AU2016396546B2 (en) | 2019-10-17 |
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