CN104057186B - 一种特高压输电钢管塔q690高强钢钢管的焊接方法 - Google Patents
一种特高压输电钢管塔q690高强钢钢管的焊接方法 Download PDFInfo
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Abstract
本发明公开了一种特高压输电钢管塔Q690高强钢钢管的焊接方法,采用屈服强度Q690的低合金高强度钢板,厚度8~16mm,弯曲成具有纵缝的初成形钢管,开无钝边V形坡口,坡口角度50°-70°,间隙1-5mm;层间温度控制在150-250℃;采用单面双丝TIG焊打底焊接,ER110S-G实芯焊丝;填充焊采用CO2自动焊,ER80-G气体保护用实芯焊丝;盖面焊采用自动MAG焊;环境温度≥20℃时,不需焊后热处理;环境温度<20℃时,焊后保温缓冷。本发明通过合理的焊接方式和焊接材料的选择,提高了Q690钢焊缝的韧性和质量,同时提高了焊接的效率。
Description
技术领域
本发明涉及一种特高压输电钢管塔Q690高强钢钢管的焊接方法,属于钢铁材料焊接技术领域。
背景技术
在电网建设中,采用Q690钢管塔可有效降低塔重,对于大负荷线路工程,主材采用Q690钢管代替Q345普通钢管时,塔身可节省钢材30%~45%,整塔减轻13%~22%;同时可减小杆塔根开,压缩线路走廊宽度,减少拆迁、植被破坏和林木砍伐,有利于节约资源和环境保护,具有显著的经济效益和社会效益。
但受设计方法、生产及加工工艺等技术难题的影响,Q690钢管塔的推广应用仍存在一些困难。在特高压钢管塔的生产过程中,焊接是Q690钢加工技术的一个主要方面,但Q690属于低合金高强钢,在焊接过程中,热影响区容易形成淬火组织—马氏体,使近缝区的硬度提高,塑性下降,导致焊后发生裂纹、层状撕裂,因此必须对Q690钢的焊接工艺进行试验研究,通过合理的焊接材料选择和采用正确的焊接工艺参数,才能避免裂纹的产生。
《Q690钢管塔试验及工程应用》一书中,通过对8mm厚钢板对接接头的性能评定过程中,全埋弧焊三层三道单面焊以及双面焊的拉伸、弯曲性能均合格,但其冲击性能一直是重点和难点。主要原因是,埋弧焊打底热输入较大,使得晶粒粗化较严重,从而导致了接头的韧性差。研究发现,由于埋弧焊的热输入较大,焊丝强度不达标、清根不彻底等原因导致裂纹和冲击韧性下降。
发明内容
针对上述现有技术中存在的不足,本发明的目的在于提供一种特高压输电钢管塔Q690高强钢钢管的焊接方法,通过合理的焊接方式和焊接材料的选择,提高了Q690钢焊缝的韧性和质量,同时提高了焊接的效率。
为实现上述目的,本发明采用如下技术方案:
一种特高压输电钢管塔Q690高强钢钢管的焊接方法,包括以下步骤:
(1)采用屈服强度Q690的低合金高强度钢板,厚度8~16mm,弯曲成具有纵缝的初成形钢管,开无钝边V形坡口,坡口角度50°~70°坡口(单边25°~35°),间隙1~5mm;
(2)当焊接环境温度为20℃以上时,不需预热;环境温度低于20℃的情况下,预热温度为60~100℃;层间温度控制在150~250℃;
(3)采用单面双丝TIG焊打底焊接,采用ER110S~G实芯焊丝;电压12~14V,电流80~100A,焊接速度10~15cm/min,热输入4.5~6.0kJ/cm;
(4)填充焊采用CO2自动焊,焊丝选用1.2mm的ER80~G气体保护用实芯焊丝,焊接电压16~17V,电流110~125A,焊接速度20~35cm/min,热输入6.0~8.0kJ/cm;
(5)盖面焊采用自动MAG焊(80%Ar+20%CO2),焊接材料选用ER80~G焊丝和SJ101焊剂,焊接电压23~26V,焊接电流200~250A,焊接速度30~50cm/min,热输入7~9kJ/cm;
(6)环境温度为20℃以上时,不需焊后热处理;环境温度低于20℃的情况下,焊后采用石棉覆盖焊接接头位置,保温缓冷。
步骤(1)中,坡口角度优选为60°,间隙优选为3mm;
本发明的有益效果在于:
(1)本发明针对Q690的低合金高强度焊接中的问题,通过双丝TIG焊打底焊接与CO2自动焊填充,盖面焊采用自动MAG焊(80%Ar+20%CO2)相结合的方法有效提高了Q690钢焊缝的韧性和质量,采用自动化焊接填充和盖面焊接同时提高了生产效率,有利Q690在特高压钢管塔中的推广应用。
(2)依据《焊接接头冲击试验方法》(GB/T2650-2008)和《金属材料夏比摆锤冲击试验方法》(GB/T229-2007)对本发明的焊接试件进行检测,结合实际板厚,采用对接接头焊接试板,冲击试样的缺口面平行于试板表面,冲击试验取样的试件形状及尺寸如图1所示。结果显示焊接接头的冲击韧性较好,而且焊接方法简单,具有很强的实用性。
附图说明
图1为对接接头夏比V形缺口冲击试件形状及尺寸;其中,RL:焊缝中心线;a:分别选取0,1,2;t:板厚为8mm时选7.5,其它板厚则选8;b:试块与表面距离,大于0.2mm。
图2为本发明所采用的三层四道焊道分布;其中,1为打底焊,2为填充焊道,3为盖面焊道。
具体实施方式
结合实施例对本发明作进一步的说明,应该说明的是,下述说明仅是为了解释本发明,并不对其内容进行限定。
实施例1:
厚度为8mm的屈服强度Q690的低合金高强度钢板对接焊。
(1)焊接设备及焊接材料
打底焊采用WSM-200脉冲氩弧焊机,CO2填充焊焊接设备选用动态性良好的NB-350二氧化碳逆变式焊机,盖面焊采用DC1000自动埋弧焊机。单面双丝TIG焊采用1.2mmER110S~G实芯焊丝,CO2自动焊采用1.2mm的ER80~G气体保护用实芯焊丝,自动MAG焊采用ER80~G焊丝和SJ101焊剂;焊前去除焊丝表面的油、锈等脏物。
(2)焊前准备
对屈服强度Q690的低合金高强度钢板,厚度8mm,弯曲成具有纵缝的初成形钢管,开无钝边V形坡口,坡口角度50°坡口(单边25°),间隙3mm;将坡口及坡口两侧接头处15mm范围内的锈蚀、油垢等清理干净,直至露出金属光泽。
(3)焊接工艺及参数
1)在焊接环境温度不低于20℃不预热的条件下施焊,采用单面双丝TIG焊打底焊接,采用ER110S~G实芯焊丝,焊丝直径为1.2mm;电压13V,电流90A,焊接速度12cm/min,热输入5.0kJ/cm;
2)填充焊采用CO2自动焊,焊丝选用1.2mm的ER80~G气体保护用实芯焊丝,焊接电压16V,电流120A,焊接速度30cm/min,热输入7.0kJ/cm;
3)盖面焊采用自动MAG焊(80%Ar+20%CO2),焊接材料选用ER80~G焊丝,焊丝直径为1.6mm,和SJ101焊剂,焊接电压25V,焊接电流230A,焊接速度40cm/min,热输入8kJ/cm;
4)焊后不需热处理。
实施例2:
厚度为12mm的屈服强度Q690的低合金高强度钢板对接焊。
(1)焊接设备及焊接材料
打底焊采用WSM-200脉冲氩弧焊机,CO2填充焊焊接设备选用动态性良好的NB-350二氧化碳逆变式焊机,盖面焊采用DC1000自动埋弧焊机。单面双丝TIG焊采用1.2mmER110S~G实芯焊丝,CO2自动焊采用1.2mm的ER80~G气体保护用实芯焊丝,自动MAG焊采用ER80~G焊丝和SJ101焊剂;焊前去除焊丝表面的油、锈等脏物。
(2)焊前准备
对屈服强度Q690的低合金高强度钢板,厚度12mm,弯曲成具有纵缝的初成形钢管,开无钝边V形坡口,坡口角度60°坡口(单边30°),间隙1mm;将坡口及坡口两侧接头处15mm范围内的锈蚀、油垢等清理干净,直至露出金属光泽。
(3)焊接工艺及参数:
1)焊接环境温度为15℃,预热温度为60℃,层间温度控制在150~250℃;
2)采用单面双丝TIG焊打底焊接,采用ER110S~G实芯焊丝;电压12V,电流80A,焊接速度10cm/min,热输入4.5kJ/cm;
3)填充焊采用CO2自动焊,焊丝选用1.2mm的ER80~G气体保护用实芯焊丝,焊接电压17V,电流110A,焊接速度20cm/min,热输入6.0kJ/cm;
4)盖面焊采用自动MAG焊(80%Ar+20%CO2),焊接材料选用ER80~G焊丝和SJ101焊剂,焊接电压23V,焊接电流200A,焊接速度30cm/min,热输入7kJ/cm;
5)焊后采用石棉覆盖焊接接头位置,保温缓冷。
实施例3:
厚度为16mm的屈服强度Q690的低合金高强度钢板对接焊。
(1)焊接设备及焊接材料
打底焊采用WSM-200脉冲氩弧焊机,CO2填充焊焊接设备选用动态性良好的NB-350二氧化碳逆变式焊机,盖面焊采用DC1000自动埋弧焊机。单面双丝TIG焊采用1.2mmER110S~G实芯焊丝,CO2自动焊采用1.2mm的ER80~G气体保护用实芯焊丝,自动MAG焊采用ER80~G焊丝和SJ101焊剂;焊前去除焊丝表面的油、锈等脏物。
(2)焊前准备
对屈服强度Q690的低合金高强度钢板,厚度16mm,弯曲成具有纵缝的初成形钢管,开无钝边V形坡口,坡口角度70°坡口(单边35°),间隙5mm;将坡口及坡口两侧接头处15mm范围内的锈蚀、油垢等清理干净,直至露出金属光泽。
(3)焊接工艺及参数:
1)焊接环境温度为15℃,预热温度为100℃,层间温度控制在150~250℃;
2)采用单面双丝TIG焊打底焊接,采用ER110S~G实芯焊丝;电压14V,电流100A,焊接速度15cm/min,热输入6.0kJ/cm;
3)填充焊采用CO2自动焊,焊丝选用1.2mm的ER80~G气体保护用实芯焊丝,焊接电压17V,电流125A,焊接速度35cm/min,热输入8.0kJ/cm;
4)盖面焊采用自动MAG焊(80%Ar+20%CO2),焊接材料选用ER80~G焊丝和SJ101焊剂,焊接电压26V,焊接电流250A,焊接速度50cm/min,热输入9kJ/cm;
5)焊后采用石棉覆盖焊接接头位置,保温缓冷。
实施例4:
冲击韧性试验:
(1)试样制备:从实施例1~3的焊接接头处取样,加工成10mm×10mm×55mm的试样,通过电化学腐蚀显示出接头的热影响区,然后加工成标准的冲击试样。
(2)试验方法:按照GB/T2650-2008《焊接接头冲击试验方法》对实施例的对接接头进行焊接接头冲击试验;按照GB/T229-2007《金属材料夏比摆锤冲击试验方法》进行韧性测试。
(3)试验结果见下表。
试样 | 尺寸/mm | 试验温度/℃ | 冲击吸收功Akv/J |
实施例1 | 10mm×10mm×55mm | -20 | 118.5 |
实施例2 | 10mm×10mm×55mm | -20 | 110.8 |
实施例3 | 10mm×10mm×55mm | -20 | 97.7 |
上述虽然对本发明的具体实施方式进行了描述,但并非对本发明保护范围的限制,所属领域技术人员应该明白,在本发明的技术方案的基础上,本领域技术人员不需要付出创造性劳动即可做出的各种修改或变形仍在本发明的保护范围以内。
Claims (5)
1.一种特高压输电钢管塔Q690高强钢钢管的焊接方法,其特征在于,包括以下步骤:
(1)采用屈服强度Q690的低合金高强度钢板,厚度8~16mm,弯曲成具有纵缝的初成形钢管,开无钝边V形坡口,坡口角度50°-70°,间隙1-5mm;
(2)当焊接环境温度为20℃以上时,不需预热;环境温度低于20℃的情况下,预热温度为60-100℃;层间温度控制在150-250℃;
(3)采用单面双丝TIG焊打底焊接,采用ER110S-G实芯焊丝;电压12-14V,电流80-100A,焊接速度10-15cm/min,热输入4.5-6.0kJ/cm;
(4)填充焊采用CO2自动焊,焊丝选用的ER80-G气体保护用实芯焊丝,焊接电压16-17V,电流110-125A,焊接速度20-35cm/min,热输入6.0-8.0kJ/cm;
(5)盖面焊采用自动MAG焊,焊接材料选用ER80-G焊丝和SJ101焊剂,焊接电压23-26V,焊接电流200-250A,焊接速度30-50cm/min,热输入7-9kJ/cm;
(6)环境温度为20℃以上时,不需焊后热处理;环境温度低于20℃的情况下,焊后在焊接接头位置保温缓冷。
2.如权利要求1所述的一种特高压输电钢管塔Q690高强钢钢管的焊接方法,其特征在于,所述步骤(1)中,坡口角度为60°,间隙为3mm。
3.如权利要求1所述的一种特高压输电钢管塔Q690高强钢钢管的焊接方法,其特征在于,所述步骤(4)中,ER80-G气体保护用实芯焊丝的直径为1.2mm。
4.如权利要求1所述的一种特高压输电钢管塔Q690高强钢钢管的焊接方法,其特征在于,所述步骤(5)中,自动MAG焊采用80%Ar和20%CO2作为保护气。
5.如权利要求1所述的一种特高压输电钢管塔Q690高强钢钢管的焊接方法,其特征在于,所述步骤(6)中,环境温度低于20℃的情况下,焊后采用石棉覆盖焊接接头位置,保温缓冷。
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CN105945389A (zh) * | 2016-05-18 | 2016-09-21 | 张家港市恒强冷却设备有限公司 | 冷却器中管板对接焊的方法 |
CN107009025B (zh) * | 2017-04-26 | 2020-01-14 | 西安交通大学 | 一种提高钼及钼合金熔焊焊缝强韧性的微合金化方法 |
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CN107584229A (zh) * | 2017-10-27 | 2018-01-16 | 湖州正德轻工机械有限公司 | 一种合金钢管焊接方法 |
CN110871312B (zh) * | 2018-08-29 | 2021-10-19 | 上海梅山钢铁股份有限公司 | 屈服强度600MPa级低合金钢板的MAG焊接方法 |
CN110449698A (zh) * | 2019-07-23 | 2019-11-15 | 安徽伟宏钢结构集团股份有限公司 | 一种6-16mm钢板焊接方法 |
CN110508926B (zh) * | 2019-09-09 | 2020-11-27 | 西安煤矿机械有限公司 | 一种激光-mig复合焊接的方法 |
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