超窄间隙焊接焊剂带的制作工艺及焊接接头性能
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摘要
利用焊剂带约束电弧可以很好地解决超窄间隙焊接中容易出现的问题，焊剂带可有效约束电弧，阻止电弧攀升，同时使电弧对侧壁及坡口底部集中加热，使其完全熔合。由于超窄间隙焊接方法坡口较窄，因此对焊剂带的厚度要求较高；所以要使电弧能够受到很好的约束，焊剂带必须足够致密。本文针对原有焊剂带致密度不足的问题，研制出新的焊剂带，并通过焊剂带约束电弧超窄间隙焊接的方法对工件进行焊接，最后对焊接接头进行组织与性能的分析。
首先在课题组前期实验基础上，开发出新的焊剂带制作方法，设计出新的焊剂带制作模具。该模具主要具备以下特点：①模具小巧轻便，便于拆卸存放；②利用硅胶带与模具基座上的梯度达到压紧金属丝网的目的；③巧妙地借用发泡橡胶的弹性变形能力，使两侧用于控制焊剂量的黑橡胶迅速恢复到原来的位置，保证了焊剂带的厚度与致密度的一致。
利用满足要求的焊剂带以及专门开发的焊枪进行焊接，可获得稳定的焊接过程和良好的焊缝成型。试验采用直径为φ1.6mm的H08Mn2Si焊丝，焊件分别为14.5mm厚的X60管线钢板和6mm厚的430不锈钢板，焊接接头需要单道多层焊接来完成，焊前分析各种影响因素，得到每道焊的焊接工艺参数。两种钢材的焊接线能量均很低，分别在0.6KJ/mm和0.45KJ/mm左右；其热影响区宽度分别在1.0mm和0.65mm左右。
对两种钢的接头组织与性能进行研究分析发现，X60管线钢的热影响区组织晶粒细小，粗晶区晶粒长大并不严重；焊缝硬度高于母材，软化区非常窄，大大降低了对焊缝强度及韧性的不利因素，且与传统焊接方法焊接接头相比较，其硬度值要高出65%左右。焊缝具有高于母材的拉伸强度，且低温冲击韧性良好。430不锈钢粗晶区组织晶粒较为粗大，但由于其热影响区很窄，对整个接头的不良影响并不是特别大。在拉伸时，所选用的试样均在母材处断裂，由此也可证明接头的强度相对于母材并没有降低，反而有一定程度的提升。
Use of flux strips to constrict arc can well solve the easily occurred problems ofultranarrow gap welding,. The flux strips can effectively restrain arc, ptevent the arcgoing up along the sidewall, make the arc heat on the side wall and groove bottomcentralized, and get the full fusion. With a relatively narrow grove in the ultranarrowgap welding, the thickness requirements of flux strips is high. And the flux strips mustbe sufficiently dense. Aiming at the problem of flux strip density, the paper developednew flux strips, welded workpieces by ultranarrow gap welding with constrained arcby flux strips, and analysed organization and performance of the welded joints at last.
First, the new production mold of flux strips is designed and developed toimprove the production method, based on the pre-test. The mold mainly have thefollowing characteristics:①The mold is small and portable, so that it’s convenient toremove and storage;②To press the wire mesh，the silicone band is used and gradientsare made on the mold base;③Using elastic deformation ability of foam rubber, theboth sides of black rubber used to control the flux amount can quickly return tooriginal position, which ensure the consistency of strips thickness and density.
To weld with the flux strips which meet the requirements and the speciallydeveloped torch, it can obtain the stable welding process and good weld forming. Thetest uses H08Mn2Si wire of diameter of1.6mm,and weldments are14.5mm thick X60pipeline steel plate and6mm thick430stainless steel plate. Welded joints needmulti-layer and single-pass ultra-narrow gap welding experiments to complete. Beforewelding,various factors must be analysised to get the welding parameters of everypass welding. Both of two kinds steel have very low energy input, and are respectivelyabout0.6KJ/mm and0.45KJ/mm. And the widths of heat-affected zones are about1.0mm and0.65mm respectively.
To analysis the welded joints microstrure and properties of two kinds of steel, it’sfound that HAZ of X60pipeline steel has microstructure of fine grains, and the grains’growth of coarse grain zone is not serious. Weld hardness is higher than that of thebase metal, and the softening zone is very narrow, which will reduce unfavorablefactors on the weld strength and toughness. And the hardness increases65%or so,compared with that of adopting SAW. The weld has higher tensile strength than basemetal, and excellent low-temperature impact toughness. The grains of430stainless steel coarse grain zone are relatively coarse, but because of its very low HAZ, theadverse effect of which on the joint will not be too much. And when steching, theselected samples fractured all in the base metal. This also can be proved that thestreghth of the joint was notreduced comparede with that of base metal, but had acertain degree of improve.
首先在课题组前期实验基础上，开发出新的焊剂带制作方法，设计出新的焊剂带制作模具。该模具主要具备以下特点：①模具小巧轻便，便于拆卸存放；②利用硅胶带与模具基座上的梯度达到压紧金属丝网的目的；③巧妙地借用发泡橡胶的弹性变形能力，使两侧用于控制焊剂量的黑橡胶迅速恢复到原来的位置，保证了焊剂带的厚度与致密度的一致。
利用满足要求的焊剂带以及专门开发的焊枪进行焊接，可获得稳定的焊接过程和良好的焊缝成型。试验采用直径为φ1.6mm的H08Mn2Si焊丝，焊件分别为14.5mm厚的X60管线钢板和6mm厚的430不锈钢板，焊接接头需要单道多层焊接来完成，焊前分析各种影响因素，得到每道焊的焊接工艺参数。两种钢材的焊接线能量均很低，分别在0.6KJ/mm和0.45KJ/mm左右；其热影响区宽度分别在1.0mm和0.65mm左右。
对两种钢的接头组织与性能进行研究分析发现，X60管线钢的热影响区组织晶粒细小，粗晶区晶粒长大并不严重；焊缝硬度高于母材，软化区非常窄，大大降低了对焊缝强度及韧性的不利因素，且与传统焊接方法焊接接头相比较，其硬度值要高出65%左右。焊缝具有高于母材的拉伸强度，且低温冲击韧性良好。430不锈钢粗晶区组织晶粒较为粗大，但由于其热影响区很窄，对整个接头的不良影响并不是特别大。在拉伸时，所选用的试样均在母材处断裂，由此也可证明接头的强度相对于母材并没有降低，反而有一定程度的提升。
Use of flux strips to constrict arc can well solve the easily occurred problems ofultranarrow gap welding,. The flux strips can effectively restrain arc, ptevent the arcgoing up along the sidewall, make the arc heat on the side wall and groove bottomcentralized, and get the full fusion. With a relatively narrow grove in the ultranarrowgap welding, the thickness requirements of flux strips is high. And the flux strips mustbe sufficiently dense. Aiming at the problem of flux strip density, the paper developednew flux strips, welded workpieces by ultranarrow gap welding with constrained arcby flux strips, and analysed organization and performance of the welded joints at last.
First, the new production mold of flux strips is designed and developed toimprove the production method, based on the pre-test. The mold mainly have thefollowing characteristics:①The mold is small and portable, so that it’s convenient toremove and storage;②To press the wire mesh，the silicone band is used and gradientsare made on the mold base;③Using elastic deformation ability of foam rubber, theboth sides of black rubber used to control the flux amount can quickly return tooriginal position, which ensure the consistency of strips thickness and density.
To weld with the flux strips which meet the requirements and the speciallydeveloped torch, it can obtain the stable welding process and good weld forming. Thetest uses H08Mn2Si wire of diameter of1.6mm,and weldments are14.5mm thick X60pipeline steel plate and6mm thick430stainless steel plate. Welded joints needmulti-layer and single-pass ultra-narrow gap welding experiments to complete. Beforewelding,various factors must be analysised to get the welding parameters of everypass welding. Both of two kinds steel have very low energy input, and are respectivelyabout0.6KJ/mm and0.45KJ/mm. And the widths of heat-affected zones are about1.0mm and0.65mm respectively.
To analysis the welded joints microstrure and properties of two kinds of steel, it’sfound that HAZ of X60pipeline steel has microstructure of fine grains, and the grains’growth of coarse grain zone is not serious. Weld hardness is higher than that of thebase metal, and the softening zone is very narrow, which will reduce unfavorablefactors on the weld strength and toughness. And the hardness increases65%or so,compared with that of adopting SAW. The weld has higher tensile strength than basemetal, and excellent low-temperature impact toughness. The grains of430stainless steel coarse grain zone are relatively coarse, but because of its very low HAZ, theadverse effect of which on the joint will not be too much. And when steching, theselected samples fractured all in the base metal. This also can be proved that thestreghth of the joint was notreduced comparede with that of base metal, but had acertain degree of improve.
引文
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[3] Terumi N, Kazuo H, Chiaki S. Development of Ultra-Narrow Gap GMA WeldingProcess. In:Recent Technology of Welding in Vessel and Pipe,2000, II1-II6
[4]张富巨，罗传红，等.超窄间隙超低线能量熔化极气保护自动弧焊方法与设备.中国专利.01138322.4,2001-12-20
[5]周昀，包晔峰等.高效单丝窄间隙活性气体保护焊接方法.中国专利.03129629.7,2003-07-03
[6]胡存银,张富巨.窄间隙焊接的技术与经济特性分析.焊接技术，2001，30(2)：47-48
[7] Masysumiya Z, Kawahara M, Yakao M, et al. Development of orbital narrow-gapGTA welding equipment andapplication to main steam pipes of boilers. Technicalcommission on welding processes, SW-1645-85,1985
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[9] A.Matsunawa, BEng, Meng, et al. Arc behaviour, plate melting, and pressurebalance of the molten pool in narrow grooves. In: International ConferenceProceeding. London,1979:301-310
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