CN102528325A - Welding material for quickly welding and repairing defects of large-sized QT500-7 nodular cast iron parts and method - Google Patents

Welding material for quickly welding and repairing defects of large-sized QT500-7 nodular cast iron parts and method Download PDF

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CN102528325A
CN102528325A CN2012100060253A CN201210006025A CN102528325A CN 102528325 A CN102528325 A CN 102528325A CN 2012100060253 A CN2012100060253 A CN 2012100060253A CN 201210006025 A CN201210006025 A CN 201210006025A CN 102528325 A CN102528325 A CN 102528325A
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welding
welding material
groove
defective
iron casting
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翟秋亚
徐锦锋
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Xian University of Technology
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Xian University of Technology
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Abstract

The invention discloses a welding material for quickly welding and repairing defects of large-sized QT500-7 nodular cast iron parts, comprising powder components including, by weight percent, from 30 to 35% of Fe2O3, from 25 to 30% of Al, from 1.4 to 1.6% of Na2CO3, from 4 to 6% of Na2B4O7, from 4 to 6% of CaF2, from 5 to 8% of CaO, from 0.5 to 1.5% of SiO2, from 5.0 to 7.0% of graphite, from 4.0 to 5.0% of 75Si-Fe, from 1.0 to 2.0% of 75Mn-Fe, from 0.5 to 2% of Ni, from 0.1 to 0.3% of Bi, from 1.0 to 2.0% of 60Si-Ca, from 0.3 to 0.8% of RE-Mg and from 7 to 10% of Q14 pig iron which are uniformly mixed. The total weight percent of the powder components is 100%. The invention further discloses a method for quickly welding and repairing the defects of the large-sized QT500-7 nodular cast iron parts by the aid of the welding material. By the aid of the material and the method, the QT500-7 nodular cast iron parts can be quickly welded and repaired at room temperature, probability of chills and cracks can be effectively, and ingredients, structures and colors of weld joints are basically consistent to those of the nodular cast iron parts.

Description

Rapid welding is repaired the welding material and the method for large-scale QT500-7 nodular iron casting defective
Technical field
The invention belongs to ironcasting and save field of engineering technology; Relate to a kind of rapid welding and repair the welding material of large-scale QT500-7 nodular iron casting defective, the invention still further relates to and utilize this kind welding material rapid welding to repair the method for large-scale QT500-7 nodular iron casting defective.
Background technology
The casting process complex process, the nodular iron casting defective is unavoidable, because the intrinsic coagulating property of cast iron very easily produces soldering district spoken parts in traditional operas and crackle in welding process.And it is higher such as the defective probability of nodular iron castings such as bed piece, large gear and wind-powered electricity generation device; And the added value of REPAIR WELDING is bigger; It is that enterprise spends more money on energy-conservation important behave that the defective nodular iron casting is implemented to save reparation, helps environmental protection and practices thrift earth resource.
The method of at present, nodular iron casting being carried out the high-quality reparation is the hot weldering of gas welding and electric arc.It is easy to operate that these two kinds of methods are used for the middle-size and small-size nodular iron casting of soldering, and effect is fine.But if then can be big because of adding (in advance) hot difficulty for large-scale ductile iron spare, gas welding can't realize the fusion welding; The arc welding cooling rate is excessive, the weld zone poor processability.Especially for the defective greatly of large-scale ductile iron spare, can cause excessive nodular iron casting distortion or the appearance cracking of causing of weld zone stress easily because of the excessive input of welding process heat, the welding difficulty is bigger.Owing to added anti-graphited nodularization element, weld zone spoken parts in traditional operas, crackle are inclined to bigger in the spheroidal graphite cast-iron production.The REPAIR WELDING nodular iron casting requires higher than spheroidal graphite cast-iron, difficulty is bigger.To this, manufacturing enterprise often seems at a loss what to do for the big defective on the important machined surface of nodular iron casting, can only scrap.The dismemberent of large-scale discard and shattering process need spend a large amount of energy; The production again of nodular iron casting needs melting again, and this is in consumes energy, and exhaust gas discharged and slag have also caused secondary pollution to environment, does not also comprise the waste of labour and time cost in the middle of this.Therefore, to be used for rapid welding restorative procedure and the welding material thereof of large-scale QT500-7 nodular iron casting defective very necessary in research and development.
Summary of the invention
The object of the present invention is to provide a kind of rapid welding to repair the welding material of large-scale QT500-7 nodular iron casting defective, solved the reluctant difficult problem of nodular iron casting defective under the prior art.
Another object of the present invention is to, provide a kind of and utilize above-mentioned welding material welding material rapid welding to repair the method for large-scale QT500-7 nodular iron casting defective.
The technical scheme that the present invention adopts is, a kind of rapid welding is repaired the welding material of large-scale QT500-7 nodular iron casting defective, evenly mixed by weight percentage by the powder of following component and forms:
Fe 2O 330%-35%, Al 25%-30%, Na 2CO 31.4%-1.6%, Na 2B 4O 74%-6%, CaF 24%-6%, CaO 5%-8%, SiO 20.5%-1.5%, graphite 5.0%-7.0%, 75Si-Fe4.0%-5.0%, 75Mn-Fe 1.0-2.0%, Ni 0.5%-2%, Bi 0.1%-0.3%, 60Si-Ca1.0%-2.0%, RE-Mg 0.3%-0.8%, Q14 pig iron 7%-10%, gross weight is 100%.
Another technical scheme that the present invention adopts is, a kind of method of utilizing above-mentioned welding material rapid welding to repair large-scale QT500-7 nodular iron casting defective, according to the following steps practical implementation:
Step 1, the rejected region of defective nodular iron casting is implemented polishing, process groove;
Step 2, along the moulding of groove upper limb periphery, use molding sand or cement to build dykes and dams along defective groove upper periphery, the upper limb of dykes and dams need leave the lead-ingroove of igniter fuse;
Step 3, be packed into groove after the welding material for preparing mixed and dykes and dams are inner, imbed compacting behind the igniter fuse, fill up, press gland at last in the above;
Step 4, light igniter fuse, make exothermic mixture generation exothermic reaction in the welding material, all components in the welding material is all melted, the iron liquid density that the fusing back is produced is higher than slag and sinks in the groove, and slag come-up and iron liquid generation layering;
Step 5, sprinkle wood powder and perlitic mixture, the deposited metal slow cooling is solidified obtain comprising the weld zone metal of slag and excess metal layer in the weld zone;
After step 6, district to be welded are cooled to be lower than 200 ± 10 ℃, remove gland, destroy the moulding dykes and dams, expose the weld zone;
Step 7, use machine-tooled method and remove slag and the metal level that the weld zone exceeds the nodular iron casting surface portion, form smooth soldering zone.
The invention has the beneficial effects as follows; Being suitable for rapid welding, to repair the trade mark be the welding material that the large-scale ductile iron defective of QT500-7 is used; Welding at room temperature can reduce spoken parts in traditional operas and crackle effectively and be inclined to, and weld seam composition of weld line, tissue, color and luster are consistent with the nodular iron casting body; The weld seam composition be organized as typical ferrite-pearlite spheroidal graphite cast-iron tissue; Weld strength with hardness and nodular iron casting body basically identical; The weld seam crack resistance strengthens, can process; The only 2-5 minute duration of welding.
Description of drawings
Fig. 1 is the position shape figure to be welded after adopting the inventive method to the polishing of nodular iron casting defective;
Fig. 2 adopts the inventive method with molding sand or cement dykes and dams moulding figure to be built on defective top;
Fig. 3 is the welding welding powder filling sketch map before that adopts the inventive method;
Fig. 4 is the postwelding weld zone structure chart that adopts the inventive method;
Fig. 5 is the nodular iron casting weld zone structure chart after the machined of employing the inventive method.
Wherein, 1. nodular iron casting, 2. dykes and dams, 3. gland, 4. welding material, 5. igniter fuse, 6. deposited metal, 7. weld zone metal, 8. groove.
The specific embodiment
Below in conjunction with the accompanying drawing and the specific embodiment the present invention is elaborated.
Rapid welding of the present invention is repaired the welding material of large-scale QT500-7 nodular iron casting defective, is evenly mixed by weight percentage by the powder of following component and forms: Fe 2O 330%-35%, Al 25%-30%, Na 2CO 31.4%-1.6%, Na 2B 4O 74%-6%, CaF 24%-6%, CaO 5%-8%, SiO 20.5%-1.5%, graphite 5.0%-7.0%, 75Si-Fe 4.0%-5.0%, 75Mn-Fe 1.0-2.0%, Ni0.5%-2%, Bi 0.1%-0.3%, 60Si-Ca 1.0%-2.0%, RE-Mg 0.3%-0.8%, Q14 pig iron 7%-10%, gross weight is 100%.
Above-mentioned welding material of the present invention comprises tetrameric powder constituent according to its function:
First is exothermic mixture (or claiming thermite), comprises Fe 2O 3And Al, after heat-producing chemical reaction takes place for both, both provided Welding Metallurgy needed heat, product Fe can be used as main deposited metal again and forms weld seam, Al 2O 3Get into slag, also can participate in the slag making reaction in the molten bath.
Second portion is a slag former, comprises Na 2CO 3, Na 2B 4O 7, CaF 2, CaO and SiO 2Na wherein 2B 4O 7And CaF 2Have the diluent effect concurrently, can be used to regulate viscosity coefficient of dross; CaF 2And SiO 2Also have dehydrogenation and the prevention welding cold cracking effect.
Third part is deoxidation, desulfurizing agent, comprises Al, 60Si-Ca, 75Mn-Fe, CaO and RE-Mg etc.
The 4th part is an alloying constituent, to QT500-7 nodular iron casting composition and performance requirement, selects for use the different-alloy powder as welding filling material, with obtain with the weld zone metal that is complementary of the foundry goods tissue of being repaired and performance.Comprise components such as graphite, the pig iron, 75 ferrosilicon, 60 silico-calciums, 75 ferromanganese.Both can form weld metal after the fusing, have alloying action again.Add an amount of nickel, the bismuth metal also has the crystal grain thinning effect, helps improving weld properties.
Exothermic mixture and slag former in the welding material component of the present invention have versatility, are the REPAIR WELDING needs of QT500-7 nodular iron casting and be directed against the trade mark, and alloying constituent all has corresponding diversity aspect kind and the content.
In welding material composition of the present invention, each component and content limit reason and are respectively:
In order to make that welding process is able to carry out, added a large amount of Fe 2O 3With the Al powder as exothermic mixture.The energy that reaction produces not only can be kept proceeding of exothermic reaction, and can also be enough to melt various metal powder materials, and makes the mother metal local melting, forms weld seam jointly, reaches the purpose of welding.
In order to make welding slag assemble, float and separate with deposited metal, prevention weld metal slag inclusion has added Na 2CO 3, Na 2B 4O 7, CaF 2With CaO as slag former and diluent.For reducing the weld porosity that high-temperature oxydation caused of weld zone metal, Fe 2O 3Addition is too much unsuitable.
In order to make weld metal obtain the magnesium iron tissue of ferrite+pearlite matrix, prevent that weld seam and fusion area from producing spoken parts in traditional operas, guarantee the machining property in welding (benefit) district, phosphorus content and silicon content are all higher in the powder; Moreover, for the mechanical performance of improving weld seam and promote graphitization, add minor N i and Al; In order to purify weld metal, reduce the influence of objectionable impurities elements such as S, H, also added Al, 60Si-Ca, 75Mn-Fe, CaO and RE-Mg etc.; For crystal grain thinning, promotion graphite forming core and growth fast, also added micro-Bi element.
Exothermic mixture and slag former in the welding material of the present invention have versatility; REPAIR WELDING to different grade nodular cast iron spares needs; The difference of welding material is that alloying constituent is aspect kind and content; Through regulating alloying constituent composition and content thereof, can satisfy the REPAIR WELDING requirement of different grade nodular cast iron spares.
Welding material rapid welding of the present invention is repaired the method for large-scale QT500-7 nodular iron casting defective, utilizes above-mentioned welding material to carry out, according to the following steps practical implementation:
Step 1, the rejected region of defective nodular iron casting 1 is implemented polishing, process groove 8, like Fig. 1;
Step 2, along the moulding of groove 8 upper limbs peripheries.Use molding sand or cement to build dykes and dams 2 (defective top molding body) along defective groove 8 upper periphery, in order to slagging-off and the overflow of prevention molten metal, the upper limb of dykes and dams 2 need leave the lead-ingroove of igniter fuse 5, like Fig. 2;
Step 3, filling welding material: be packed into groove shown in Figure 28 and dykes and dams 2 inside after welding material 4 mixed, tamp, fill up after imbedding igniter fuse 5, press gland 3 (refractory brick) at last in the above, like Fig. 3;
Step 4, light igniter fuse 5, make exothermic mixture generation exothermic reaction in the welding material, all components in the welding material is all melted, the iron liquid density that the fusing back is produced is higher than slag and sinks in the groove 8, and slag come-up and iron liquid generation layering;
Step 5, sprinkle wood powder and perlitic mixture, make deposited metal 6 slow cooling solidify the weld zone metal 7 that obtains comprising slag and excess metal layer in the weld zone;
After step 6, district to be welded are cooled to be lower than 200 ± 10 ℃, remove gland 3 (refractory brick), destroy moulding dykes and dams 2, expose weld zone metal 7 as shown in Figure 4;
Step 7, use machine-tooled method and remove slag and the metal level that weld zone metal 7 exceeds the nodular iron casting surface portion, it is regional to form smooth soldering as shown in Figure 5.
Technical characterictic of the present invention is the moulding dykes and dams 2 of defective groove 8 upper limbs, the filling of welding material, the introducing of igniter fuse 5 and the use of gland 3 structures; Especially welding the insulation slow cooling in later stage, is the key point that realizes that large-scale ductile iron spare defective rapid welding is repaired.
Along the moulding of defective groove 8 upper limbs build dykes and dams the time, reserve high about 3mm, the fuse groove of wide about 5mm is absolutely necessary.The offering the orientation and will be convenient to operation of this fuse groove, and wide and high-order to can not getting wrong is in case the excessive outflow of slag and molten metal in the welding process.
Rapid welding of the present invention is repaired the method for large-scale QT500-7 nodular iron casting defective; Can realize REPAIR WELDING under the room temperature of the various defectives on the nodular iron casting; Weld seam composition and tissue are corresponding with institute soldering nodular iron casting body; Performance and nodular iron casting body are complementary, and the welding zone color and luster is consistent with the nodular iron casting body; The weld seam crack resistance is strong, but machined.
Embodiment 1
At first, preparation is used for the welding material of large-scale QT500-7 nodular iron casting welding, is evenly mixed by weight percentage by the powder of following component and forms:
Fe 2O 330%, Al 27%, Na 2CO 31.6%, Na 2B 4O 76%, CaF 26%, CaO 6%, SiO 21.0%, graphite 7.0%, 75Si-Fe 5.0%, 75Mn-Fe 1.0%, Ni 0.5%, Bi 0.2%, 60Si-Ca 1.2%, RE-Mg 0.5%, the Q14 pig iron 7%, gross weight is 100%.
Then, utilize the above-mentioned welding material for preparing, according to the following steps practical implementation:
Step 1, the rejected region of defective nodular iron casting 1 is implemented polishing, process groove 8, like Fig. 1;
Step 2, along the moulding of groove 8 upper limbs peripheries.Use molding sand or cement to build dykes and dams 2 along defective groove 8 upper periphery, in order to slagging-off and the overflow of prevention molten metal, the upper limb of dykes and dams 2 need leave the lead-ingroove of igniter fuse 5, like Fig. 2;
Step 3, filling welding material: be packed into groove shown in Figure 28 and dykes and dams 2 inside after will mixing by 3 most of welding materials of forming 4, tamp, fill up after imbedding igniter fuse 5, press gland 3 at last in the above, like Fig. 3;
Step 4, light igniter fuse 5, make welding material generation exothermic reaction, all components in the welding material is all melted, the iron liquid density that the fusing back is produced is higher than slag and sinks in the groove 8, and slag come-up and iron liquid generation layering;
Step 5, sprinkle wood powder and perlitic mixture, make deposited metal 6 slow cooling solidify the weld zone metal 7 that obtains comprising slag and excess metal layer in the weld zone;
After step 6, district to be welded are cooled to be lower than 200 ℃, remove gland 3, destroy moulding dykes and dams 2, expose weld zone metal 7 as shown in Figure 4;
Step 7, use machine-tooled method and remove slag and the metal level that weld zone metal 7 exceeds the nodular iron casting surface portion, it is regional to form smooth soldering as shown in Figure 5.
Among the embodiment 1, the chemical composition (Wt%) of welding powder deposited metal is: C 3.5, and Si 2.71, and Mn 0.55, and S 0.017, and P 0.041, and basic identical with the composition of reparation QT500-7 nodular iron casting material, promptly metallographic structure is identical.The weld metal mechanical property is: tensile strength sigma bBe 520MPa, percentage elongation δ is 7.6%, and hardness HB is 220.
Embodiment 2
At first, preparation is used for the welding material of large-scale QT500-7 nodular iron casting welding, is evenly mixed by weight percentage by the powder of following component and forms:
Fe 2O 333%, Al 28%, Na 2CO 31.4%, Na 2B 4O 74%, CaF 24%, CaO 5%, SiO 20.5%, graphite 6.0%, 75Si-Fe 4.5%, 75Mn-Fe 1.5%, Ni 0.9%, Bi 0.1%, 60Si-Ca 1.5%, RE-Mg 0.6%, the Q14 pig iron 9%, gross weight is 100%.
Then, utilize the above-mentioned welding material for preparing, implement according to the concrete steps among the embodiment 1; The chemical composition (Wt%) that obtains deposited metal is: C 3.3, and Si 2.67, and Mn 0.50; S 0.018; P 0.045, and basic identical with the composition of reparation QT500-7 nodular iron casting material, promptly metallographic structure is identical.The weld metal mechanical property is: tensile strength sigma bBe 530MPa, percentage elongation δ is 6.8%, and hardness HB is 247.
Embodiment 3
At first, preparation is used for the welding material of large-scale QT500-7 nodular iron casting welding, is evenly mixed by weight percentage by the powder of following component and forms:
Fe 2O 333%, Al 28%, Na 2CO 31.5%, Na 2B 4O 74%, CaF 24%, CaO 5%, SiO 21.0%, graphite 7.0%, 75Si-Fe 5.0%, 75Mn-Fe 1.4%, Ni 1.0%, Bi 0.1%, 60Si-Ca 1.5%, RE-Mg 0.5%, the Q14 pig iron 7%, gross weight is 100%.
Then, utilize the above-mentioned welding material for preparing, implement according to the concrete steps among the embodiment 1; The chemical composition (Wt%) that obtains deposited metal is: C 3.61, and Si 2.74, and Mn 0.50; S 0.019; P 0.046, and basic identical with the composition of reparation QT500-7 nodular iron casting material, promptly metallographic structure is identical.The weld metal mechanical property is: tensile strength sigma bBe 491MPa, percentage elongation δ is 7.6%, and hardness HB is 216.
In the foregoing description, the chemical composition of welding powder deposited metal is basic identical with the composition of the nodular iron casting material of repairing, i.e. metallographic structure is basic identical, has reached the REPAIR WELDING requirement of nodular iron casting.
Embodiment 4
At first, preparation is used for the welding material of large-scale QT500-7 nodular iron casting welding, is evenly mixed by weight percentage by the powder of following component and forms:
Fe 2O 335%, Al 25%, Na 2CO 31.4%, Na 2B 4O 75%, CaF 25%, CaO 7%, SiO 20.6%, graphite 5%, 75Si-Fe 4%, 75Mn-Fe 1%, Ni 1.5%, Bi 0.2%, 60Si-Ca1.0%, RE-Mg 0.3%, the Q14 pig iron 8%, gross weight is 100%.
Then, utilize the above-mentioned welding material for preparing, implement according to the concrete steps among the embodiment 1.
Embodiment 5
At first, preparation is used for the welding material of large-scale QT500-7 nodular iron casting welding, is evenly mixed by weight percentage by the powder of following component and forms:
Fe 2O 330%, Al 26%, Na 2CO 31.5%, Na 2B 4O 74.5%, CaF 24%, CaO 8%, SiO 21.3%, graphite 5%, 75Si-Fe 4%, 75Mn-Fe 1.8%, Ni 2%, Bi 0.3%, 60Si-Ca1.8%, RE-Mg 0.8%, the Q14 pig iron 9%, gross weight is 100%.
Then, utilize the above-mentioned welding material for preparing, implement according to the concrete steps among the embodiment 1.
The inventive method had both been simplified the wlding production technology; Practiced thrift the energy again; Environmentally safe; But also can guarantee the strong graphitizability of wlding, and obtain the weld zone that is complementary with nodular iron casting body composition, tissue, performance and color and luster, realized the high-performance rapid welding reparation of the big defective of large-scale QT500-7 nodular iron casting.
In sum, material of the present invention and method are suitable for rapid welding and repair large-scale QT500-7 nodular iron casting defective, and welding at room temperature can reduce spoken parts in traditional operas and crackle tendency effectively, and the weld seam color and luster is consistent with the nodular iron casting body; The weld seam composition be organized as typical spheroidal graphite cast-iron tissue; Weld strength with hardness and nodular iron casting body basically identical; The weld seam crack resistance strengthens, can process; The only 2-5 minute duration of welding.

Claims (3)

1. a rapid welding is repaired the welding material of large-scale QT500-7 nodular iron casting defective, it is characterized in that, is evenly mixed by weight percentage by the powder of following component and forms:
Fe 2O 330%-35%, Al 25%-30%, Na 2CO 31.4%-1.6%, Na 2B 4O 74%-6%, CaF 24%-6%, CaO 5%-8%, SiO 20.5%-1.5%, graphite 5.0%-7.0%, 75Si-Fe4.0%-5.0%, 75Mn-Fe 1.0-2.0%, Ni 0.5%-2%, Bi 0.1%-0.3%, 60Si-Ca1.0%-2.0%, RE-Mg 0.3%-0.8%, Q14 pig iron 7%-10%, gross weight is 100%.
2. a method of utilizing the described welding material rapid welding of claim 1 to repair large-scale QT500-7 nodular iron casting defective is characterized in that, utilizes described component of claim 1 and content preparation welding material, again according to the following steps practical implementation:
Step 1, the rejected region of defective nodular iron casting (1) is implemented polishing, process groove (8);
Step 2, along the moulding of groove (8) upper limb periphery, use molding sand or cement to build dykes and dams (2) along defective groove (8) upper periphery, the upper limb of dykes and dams (2) need leave the lead-ingroove of igniter fuse (5);
Step 3, be packed into groove (8) and dykes and dams (2) inside after the welding material for preparing (4) mixed, tamp, fill up after imbedding igniter fuse (5), press gland (3) at last in the above;
Step 4, light igniter fuse (5); Make exothermic mixture generation exothermic reaction in the welding material (4); All components in the welding material (4) is all melted, and the iron liquid density that the fusing back is produced is higher than slag and sinks in the groove (8), and slag come-up and iron liquid generation layering;
Step 5, sprinkle wood powder and perlitic mixture, make deposited metal (6) slow cooling solidify the weld zone metal (7) that obtains comprising slag and excess metal layer in the weld zone;
After step 6, district to be welded are cooled to be lower than 200 ± 10 ℃, remove gland (3), destroy moulding dykes and dams (2), expose weld zone metal (7);
Step 7, use machine-tooled method and remove slag and the metal level that weld zone metal (7) exceeds the nodular iron casting surface portion, form smooth soldering zone.
3. method according to claim 2 is characterized in that, the high about 3mm of the fuse groove of reservation, wide about 5mm.
CN2012100060253A 2012-01-10 2012-01-10 Welding material for quickly welding and repairing defects of large-sized QT500-7 nodular cast iron parts and method Pending CN102528325A (en)

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CN106825986A (en) * 2016-12-12 2017-06-13 新疆众和股份有限公司 A kind of iron-based Thermofusion welding agent
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CN106825986A (en) * 2016-12-12 2017-06-13 新疆众和股份有限公司 A kind of iron-based Thermofusion welding agent
CN112188945A (en) * 2018-05-23 2021-01-05 西门子股份公司 Manufacture welding and maintenance welding of nodular cast iron
CN109500477A (en) * 2018-11-21 2019-03-22 中船海洋动力部件有限公司 A kind of repairing method with welding suitable for spheroidal graphite cast-iron
CN113134680A (en) * 2021-04-27 2021-07-20 合肥工业大学 Welding material and welding process for cold welding repair of casting defects of high-strength nodular cast iron castings
CN113134680B (en) * 2021-04-27 2024-05-14 合肥工业大学 Welding material and welding process for repairing casting defects of spheroidal graphite cast iron castings

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Application publication date: 20120704