WO2021073628A1 - Cladding welding method applied to hydraulic support column - Google Patents

Cladding welding method applied to hydraulic support column Download PDF

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Publication number
WO2021073628A1
WO2021073628A1 PCT/CN2020/121728 CN2020121728W WO2021073628A1 WO 2021073628 A1 WO2021073628 A1 WO 2021073628A1 CN 2020121728 W CN2020121728 W CN 2020121728W WO 2021073628 A1 WO2021073628 A1 WO 2021073628A1
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alloy tube
workpiece
hydraulic support
welding method
method applied
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PCT/CN2020/121728
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French (fr)
Chinese (zh)
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樊宇
王利栋
张军
刘轶
李永超
刘乙霖
安泽
张李祥
陈正
徐杰
张平
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中国矿业大学
大同煤矿集团有限责任公司
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Publication of WO2021073628A1 publication Critical patent/WO2021073628A1/en

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P6/00—Restoring or reconditioning objects
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E30/00—Energy generation of nuclear origin
    • Y02E30/30—Nuclear fission reactors

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  • the invention relates to the field of welding, in particular to a cladding welding method applied to a hydraulic support column.
  • the mainstream technology of the surface repair process of the hydraulic support column can be roughly divided into two generations.
  • the first generation is electroplating chromium technology
  • the coating obtained by this technology can play a mechanical protection role, but the coating is thin, and it is prone to defects such as micro-cracks and pores.
  • electrochemical corrosion will occur, causing the coating to bubbling, peeling or even falling off, thereby destroying the entire sealing ring and causing the column to fail.
  • the second generation is laser cladding technology, and the column performance after this technology is better than the first generation technology.
  • the alloy powder of the second representative surface repair technology has a long production cycle and high cost, and defects such as micro-cracks, pores, and residual stress may also occur during the cladding process.
  • the powder causes the increase of floating particles in the air, which endangers the health of the operators.
  • the technical problem to be solved by the present invention is to overcome the defects of the prior art and provide a cladding welding method applied to a hydraulic support column.
  • the present invention provides a cladding welding method applied to a hydraulic support column, which includes the following steps:
  • Inlay melting squeeze the alloy tube to make the alloy tube fit the workpiece, reduce the diameter and fuse, until a fusion boundary is formed between the alloy tube and the workpiece, and the inlay melting is completed;
  • step 1) the outer circle of the workpiece is first controlled, the taper of the outer circle is 0-0.03mm and the dimensional tolerance is 0-0.05mm, and then the alloy tube is sleeved.
  • step 2) the fusion step is: heating the entire outer surface of the alloy tube to 400-500°C, then applying pressure from one end of the alloy tube to 40-45 MPa, and gradually applying pressure until the other side of the alloy tube At one end, the fusion is completed.
  • step 2) the fusion step is: start heating the entire outer surface of one end of the alloy tube to 400-500°C, while applying pressure to 40-45MPa, and gradually implement the above operations to the other end until the alloy tube At the other end, the fusion is completed.
  • step 5 Reshape: reshape the seal welds at both ends to remove welding traces.
  • step 6 surface hardening: nitriding the surface of the workpiece; the parameters are: the temperature is 380-400°C, the nitriding is 3 to 4 hours, and the heat preservation is 5 to 6 hours;
  • step 7) Polishing: polishing the outer circle of the workpiece, and the polishing time is 15-20 minutes.
  • step 5 the welding traces are removed and the outside diameter deviation required by the drawing size is within the range of 0.065 to 0.185 mm.
  • the diameter reduction step is: extruding the alloy tube with a diameter reduction die to make the alloy tube thinner and longer, and the wall thickness is reduced, so that the thickness of the alloy tube is less than the thickness of the workpiece by 0.2-0.3 mm.
  • step 6 a glow plasma nitriding furnace is used to perform nitriding treatment on the surface of the workpiece.
  • stainless steel pipes are mostly used for alloy pipes.
  • the clad welding technology replaces the electroplating solution (chromium electroplating technology) and alloy powder (laser cladding technology) with stainless steel pipes as the wear-resistant and corrosion-resistant materials on the surface of the column, and plastic deformation is generated by cold extrusion to make the stainless steel pipe It is organically integrated with the carbon steel at the base level.
  • the coating layer used in the coating welding process is stainless steel. Since no chemicals are used in the whole production process, no pollutants (such as electroplating wastewater, acid mist exhaust gas, particulate suspended matter, etc.) will be generated, and it is completely non-human. It is also very environmentally friendly, with extremely low energy consumption, short production process, high efficiency, and conforms to the social development theme of green production. It is advanced in the industry across the country, improving the manufacturing technology level of the column while reducing the manufacturing cost, in line with market and industry needs, and has long-term economic and social benefits for the mining support industry.
  • Figure 1 is the process flow chart of cladding welding
  • Figure 2 is a comparison diagram of the microhardness of coatings under different processes
  • Figure 3 is a comparison diagram of the amount of wear and relative wear rate of coatings under different processes
  • Figure 4 is a comparison chart of corrosion weight loss and corrosion rate of coatings under different processes.
  • This implementation method adopts three technologies of electroplating chromium, laser cladding, and cladding welding to form the pillar surface protective layer (coating), and test its hardness, wear resistance, corrosion resistance and other performance.
  • 27SiMn steel as the experimental base material.
  • 27SiMn has high strength and wear resistance, high hardenability, medium cold deformation plasticity, good cutting performance, and acceptable welding performance.
  • 15mm ⁇ 15mm ⁇ 10mm size squares are used to prepare hardness samples: use 80#, 200#, 400#, 600#, 800#, 1000#, 1200#, 1500#, 2000# metallographic sandpaper to grind with plating layer in turn Attention should be paid to ensure uniform force to minimize damage; then use a metallographic polishing machine to polish the mirror surface, clean the surface with absolute ethanol and dry it, immediately use 4% nitric acid alcohol (volume fraction) as a chemical etchant to corrode the mirror surface, when observing After the surface begins to darken, rinse off the surface corrosive with absolute ethanol, and dry it to make a hardness sample.
  • nitric acid alcohol volume fraction
  • Use sandpaper 80#, 200#, 400#, 800#, 1000#, 1500#
  • sandpaper 80#, 200#, 400#, 800#, 1000#, 1500#
  • a square of 10 ⁇ 20 ⁇ 1mm size is used to prepare corrosion samples, remove rust, and then smooth the surfaces, clean the surfaces with alcohol, and dry them to make corrosion samples.
  • the 27SiMn steel plate was subjected to laser cladding treatment.
  • the cladding material is Ni25, and the cladding thickness is 2mm.
  • the equipment uses a LASERTEL 4kW high-power semiconductor laser with a wavelength of 980nm and a spot size of 12 ⁇ 3mm. Then the steel plate is cut by wire cutting, and the cutting size is consistent with the subsequent sample preparation plan and the chromium-plated sample, so as to obtain the hardness sample, wear sample and corrosion sample of the laser cladding process.
  • a 27SiMn cylindrical barrel with an outer diameter of 100mm, an inner diameter of 90mm, and a height of 195mm is covered and welded.
  • a 304 stainless steel plate with a thickness of 1mm is selected for the cladding layer. The stainless steel plate is made into a tube to make the inner diameter of the stainless steel tube larger than the outer diameter of the cylinder. path.
  • the cladding welding method includes the following steps:
  • Shape modification use a lathe to modify the sealing and welding at both ends, remove welding traces and meet the drawing size requirements, and the outer diameter deviation is within the range of 0.065 ⁇ 0.185mm to meet the requirements of assembly and appearance;
  • Polishing Use the polishing center to polish the outer circle of the cylinder.
  • the polishing time is 15-20min to improve the surface finish of the workpiece.
  • the steel plate is cut by wire cutting, and the cutting size and subsequent sample preparation plan are the same as the chromium-plated samples, so as to obtain the hardness samples, wear samples and corrosion samples of the cladding welding process. Subsequently, hardness test, wear resistance test and corrosion resistance test were carried out for each process sample.
  • the method of cladding welding technology is compared with chromium electroplating and laser cladding.
  • the electroplated chromium coating has the highest microhardness, reaching 676.3HV, the laser cladding coating has the lowest microhardness, and the coating welding coating has the microhardness between the two.
  • the surface of the electroplated chromium coating has the highest microhardness, which is mainly due to the extremely high hardness of the hydrated chromium oxide formed on the surface of the coating during the production process of the electroplating chromium process, so that the coating exhibits a higher surface microhardness.
  • the surface microhardness of the laser cladding coating is extremely low, only 292.9HV, which is less than half of the hardness of the electroplated chrome coating.
  • the laser cladding process can obtain a fine cladding layer structure and help improve the strength and hardness of the coating, the effect of this fine-grained strengthening is limited, and the carbon content in Ni25 alloy powder is relatively low, about 0.1%.
  • the carbon content of the base material 27SiMn is also low.
  • the low carbon content limits the formation of carbides, and carbides usually exist as hard phases in the material, which have a greater impact on the strength and hardness of the material than the small melt.
  • the fine-grain strengthening effect brought by the coating structure is much greater, so the microhardness of the final coating is generally low.
  • such a low-hardness coating The layer obviously cannot meet the long-term high-pressure work, and it is prone to failure.
  • the surface microhardness of the cladding welding coating is not high, 498.9HV, which is about 0.74 times that of the electroplated chromium coating, but it is 1.71 times that of the laser cladding layer.
  • the main reason is that the carbon content of 304 stainless steel is about 0.06. %, has a stable austenite structure, its strength and hardness are limited by the carbon content, and both show a low state, but compared with the too few carbide hard phases in the laser cladding coating, it has Advantages, so the surface microhardness is not high, but not too low, which fully meets the hardness requirements of the column in use.
  • the wear amount and relative wear rate of the laser cladding coating are 0.09207g and 0.00647 respectively, both of which are the highest values, which means that the wear resistance of this kind of coating is the worst.
  • the wear amount and relative wear rate of the electroplated chromium coating are 0.02873g and 0.00202, respectively, which are only 0.31 times that of the laser cladding coating. It exhibits extremely high wear resistance, mainly due to the surface microscopy of the electroplated chromium coating.
  • the hardness is 676.3HV, and the high hardness of the coating ensures high wear resistance to a large extent.
  • the wear volume and relative wear rate of the cladding welding coating are 0.03862g and 0.00271, respectively, which are about 0.42 times that of the laser cladding coating and 1.34 times that of the electroplated chromium coating, showing good wear resistance.
  • the too low hardness and wear resistance of the laser cladding coating cannot meet the long-term work and premature failure when faced with various downhole wear.
  • the excellent performance of the electroplated coating in terms of hardness and wear resistance is completely acceptable. It meets the requirements of long-term work in underground wells with extremely harsh working conditions for the hydraulic support column, but the hardness and wear resistance of the column surface are not as high as possible.
  • the good performance of the cladding welding coating in this respect can also meet the hydraulic pressure The work requirements of the support column.
  • the corrosion resistance of electroplated chromium coating is the worst, with a corrosion rate of 3.69 ⁇ 10 -3 mm/a; while the laser cladding coating has the worst corrosion resistance.
  • the corrosion rate is 0.59 ⁇ 10 -3 mm/a, which is 0.16 times that of electroplated chromium coating; the corrosion rate of weld coating is 0.45 ⁇ 10 -3 mm/a, which is only 0.12 times that of electroplated chromium coating.
  • Overlay welding shows very excellent corrosion resistance. Due to the particularity of the processing process, the outer surface of the molding is even completely free of defects such as pores and microcracks.
  • the equipment investment of the chromium electroplating process is not high, the raw material cost and cost are also low, and the economic benefits are good; while the equipment of the laser cladding process is expensive, which is 3% of the chromium electroplating process. ⁇ 4 times, the raw material cost is even more than twice that of the chromium electroplating process, and the cost is more than ten times that of the chromium electroplating process, and the economic benefit is relatively low. In contrast, the cladding welding process has the lowest equipment investment, and the raw material cost and cost are also extremely low. Excellent economic benefits.
  • the chromium electroplating process has higher economic benefits, but it will produce electroplating wastewater and various acid mist exhaust gas, which will seriously pollute the environment; the equipment investment and cost of the laser cladding process are both high, and it will also increase the suspended particulates in the air. , Causing serious air pollution; while the equipment investment of the coating welding process is low, the cost is low, and it shows excellent economic benefits, and no chemical products are used in the production process, such as electroplating wastewater, acid mist exhaust gas, and particulate suspended solids.
  • the production is completely harmless to the human body and very friendly to the environment. It conforms to the social development theme of green production, reduces the manufacturing cost while improving the manufacturing technology level of the column, and meets the needs of the market and the industry. It has long-term economic and social benefits for the mining support industry. It is predicted that the cladding welding process will gradually replace Chrome plating and laser cladding technology have become the development trend of future hydraulic support column remanufacturing technology.

Abstract

A cladding welding method applied to a hydraulic support column, comprising the following steps: manufacturing: sleeving an alloy tube onto a workpiece so as to cover the whole workpiece; inlaying and fusing: squeezing the alloy tube, so that the alloy tube is attached to the workpiece, and performing diameter reduction and fusion until a fusion boundary is generated between the alloy tube and the workpiece, thereby completing inlaying and fusing; cutting: removing redundant alloy tube at two ends; and sealing and welding: sealing and welding two ends of the alloy tube. In the cladding welding method, an alloy tube replaces electroplating solution and alloy powder to serve as wear-resistant and corrosion-resistant materials on the surface of the column, and plastic deformation is generated by cold extrusion, so that the alloy tube and a base layer carbon steel are organically fused into a whole. In the whole production process, no chemical product is used, and thus no pollutant is produced, being completely harmless to the human body, being also very friendly to the environmental, having very low energy consumption, having a short production flow and high efficiency, and complying with the social development theme of green production.

Description

一种应用于液压支架立柱的包覆焊方法Cladding welding method applied to hydraulic support column 技术领域Technical field
本发明涉及焊接领域，尤其是一种应用于液压支架立柱的包覆焊方法。The invention relates to the field of welding, in particular to a cladding welding method applied to a hydraulic support column.
背景技术Background technique
液压支架立柱的表面修复工艺的主流技术大致可以分为两代。第一代为电镀铬技术，该技术得到的镀层可起到机械保护作用，但镀层较薄，易产生微裂纹和孔隙等缺陷。在使用过程中，这样的微裂纹或孔隙一旦穿透立柱表面的镀层，就会形成电化学腐蚀，造成镀层鼓泡、起皮甚至脱落，从而破坏整个密封圈，导致立柱失效。The mainstream technology of the surface repair process of the hydraulic support column can be roughly divided into two generations. The first generation is electroplating chromium technology, the coating obtained by this technology can play a mechanical protection role, but the coating is thin, and it is prone to defects such as micro-cracks and pores. During use, once such micro-cracks or pores penetrate the coating on the surface of the column, electrochemical corrosion will occur, causing the coating to bubbling, peeling or even falling off, thereby destroying the entire sealing ring and causing the column to fail.
第二代为激光熔覆技术，经此技术处理后的立柱性能要优于第一代的技术。但是，第二代表面修复技术的合金粉末制作的周期较长且成本较高，且在熔覆的过程中也会产生微裂纹、气孔以及残余应力等缺陷。生产过程中，粉末导致空气中的浮颗粒物增多，危害操作工人的身体健康。The second generation is laser cladding technology, and the column performance after this technology is better than the first generation technology. However, the alloy powder of the second representative surface repair technology has a long production cycle and high cost, and defects such as micro-cracks, pores, and residual stress may also occur during the cladding process. During the production process, the powder causes the increase of floating particles in the air, which endangers the health of the operators.
发明内容Summary of the invention
本发明所要解决的技术问题在于克服现有技术缺陷，提供一种应用于液压支架立柱的包覆焊方法。The technical problem to be solved by the present invention is to overcome the defects of the prior art and provide a cladding welding method applied to a hydraulic support column.
为了解决上述技术问题，本发明一种提供应用于液压支架立柱的包覆焊方法，包括以下步骤：In order to solve the above technical problems, the present invention provides a cladding welding method applied to a hydraulic support column, which includes the following steps:
1)制作：将合金管套在工件上，覆盖整个工件；1) Production: The alloy tube is sleeved on the workpiece to cover the entire workpiece;
2)镶熔：对合金管进行挤压，使合金管与工件贴合，进行缩径、熔合，直至合金管和工件之间产生熔合结界，完成镶熔；2) Inlay melting: squeeze the alloy tube to make the alloy tube fit the workpiece, reduce the diameter and fuse, until a fusion boundary is formed between the alloy tube and the workpiece, and the inlay melting is completed;
3)裁剪：去掉两端多余的合金管；3) Cutting: Remove the excess alloy tube at both ends;
4)封焊：对合金管两端进行封焊。4) Sealing and welding: sealing and welding both ends of the alloy pipe.
作为改进，在步骤1)中，先对工件车外圆，控制外圆的锥度0～0.03mm和尺寸公差0～0.05mm，然后再套入合金管中。As an improvement, in step 1), the outer circle of the workpiece is first controlled, the taper of the outer circle is 0-0.03mm and the dimensional tolerance is 0-0.05mm, and then the alloy tube is sleeved.
作为改进，在步骤2)中，熔合的步骤为：将合金管的整个外表面加热至400～500℃，然后从合金管的一端开始施加压力至40～45MPa，逐步施压直至合金管的另一端，完成熔合。As an improvement, in step 2), the fusion step is: heating the entire outer surface of the alloy tube to 400-500°C, then applying pressure from one end of the alloy tube to 40-45 MPa, and gradually applying pressure until the other side of the alloy tube At one end, the fusion is completed.
作为改进，在步骤2)中，熔合的步骤为：将合金管的一端的整个外表面开始加热至400～500℃、同时施加压力至40～45MPa，逐步向另一端实施上述操作，直至合金管的另一端，完成熔合。As an improvement, in step 2), the fusion step is: start heating the entire outer surface of one end of the alloy tube to 400-500°C, while applying pressure to 40-45MPa, and gradually implement the above operations to the other end until the alloy tube At the other end, the fusion is completed.
作为改进，还包括步骤5)：修形：对两端封焊处进行修形，去掉焊接痕迹。As an improvement, it also includes step 5): Reshape: reshape the seal welds at both ends to remove welding traces.
作为改进，还包括步骤6)：表面硬化：对工件表面进行氮化处理；参数为：温度为380～400℃，氮化3～4小时，保温5～6小时；As an improvement, it also includes step 6): surface hardening: nitriding the surface of the workpiece; the parameters are: the temperature is 380-400°C, the nitriding is 3 to 4 hours, and the heat preservation is 5 to 6 hours;
作为改进，还包括步骤7)：抛光：对工件外圆进行抛光，抛光时间为15～20min。As an improvement, it also includes step 7): Polishing: polishing the outer circle of the workpiece, and the polishing time is 15-20 minutes.
作为改进，在步骤5)中，去掉焊接痕迹并达到图纸尺寸要求外径偏差在0.065～0.185mm范围内。As an improvement, in step 5), the welding traces are removed and the outside diameter deviation required by the drawing size is within the range of 0.065 to 0.185 mm.
作为改进，在步骤2)中，缩径的步骤为：用缩径模具挤压合金管，使合金管变细变长，壁厚减薄，使合金管厚度小于工件厚度0.2～0.3mm。As an improvement, in step 2), the diameter reduction step is: extruding the alloy tube with a diameter reduction die to make the alloy tube thinner and longer, and the wall thickness is reduced, so that the thickness of the alloy tube is less than the thickness of the workpiece by 0.2-0.3 mm.
作为改进，在步骤6)中，采用辉光等离子氮化炉对工件表面进行氮化处理。As an improvement, in step 6), a glow plasma nitriding furnace is used to perform nitriding treatment on the surface of the workpiece.
实践中合金管多采用不锈钢管。In practice, stainless steel pipes are mostly used for alloy pipes.
本发明的有益效果在于：包覆焊技术以不锈钢管替代电镀液(电镀铬技术)和合金粉末(激光熔覆技术)作为立柱表面耐磨耐蚀材料，通过冷挤压产生塑性变形使不锈钢管与基层碳钢有机融合成一体。包覆焊工艺所用的包覆层为不锈钢，在生产全过程中由于没有使用任何化学制品，因此不会产生任何污染物(如电镀废水、酸雾废气、颗粒悬浮物等)，对人体完全无害，对环境也十分友好，且能耗极低，生产流程短，效率高，符合绿色生产的社会发展主题。在全国同行业内具有超前性，提升立柱的制造技术水平同时降低制造成本，符合市场和行业需求，对矿用支架行业拥有长期的经济效益和社会效益。The beneficial effects of the present invention are: the clad welding technology replaces the electroplating solution (chromium electroplating technology) and alloy powder (laser cladding technology) with stainless steel pipes as the wear-resistant and corrosion-resistant materials on the surface of the column, and plastic deformation is generated by cold extrusion to make the stainless steel pipe It is organically integrated with the carbon steel at the base level. The coating layer used in the coating welding process is stainless steel. Since no chemicals are used in the whole production process, no pollutants (such as electroplating wastewater, acid mist exhaust gas, particulate suspended matter, etc.) will be generated, and it is completely non-human. It is also very environmentally friendly, with extremely low energy consumption, short production process, high efficiency, and conforms to the social development theme of green production. It is advanced in the industry across the country, improving the manufacturing technology level of the column while reducing the manufacturing cost, in line with market and industry needs, and has long-term economic and social benefits for the mining support industry.
附图说明Description of the drawings
图1为包覆焊工艺流程图；Figure 1 is the process flow chart of cladding welding;
图2为不同工艺下的涂层的显微硬度对比图；Figure 2 is a comparison diagram of the microhardness of coatings under different processes;
图3为不同工艺下的涂层的磨损量和相对磨损速率对比图；Figure 3 is a comparison diagram of the amount of wear and relative wear rate of coatings under different processes;
图4为不同工艺下的涂层的腐蚀失重和腐蚀速率对比图。Figure 4 is a comparison chart of corrosion weight loss and corrosion rate of coatings under different processes.
具体实施方式Detailed ways
下面将结合附图对本发明作详细说明。The present invention will be described in detail below in conjunction with the accompanying drawings.
本实施方法采用电镀铬、激光熔覆、包覆焊三种技术来形成立柱表面防护层(涂层)，并对其的硬度、耐磨性、耐腐蚀性等使用性能进行测验。This implementation method adopts three technologies of electroplating chromium, laser cladding, and cladding welding to form the pillar surface protective layer (coating), and test its hardness, wear resistance, corrosion resistance and other performance.
选择27SiMn钢作为实验基材。27SiMn具有较高的强度和耐磨性，淬透性高，冷变形塑性中等，切削加工性能良好，焊接性能尚可。Choose 27SiMn steel as the experimental base material. 27SiMn has high strength and wear resistance, high hardenability, medium cold deformation plasticity, good cutting performance, and acceptable welding performance.
27SiMn钢的主要化学成分表The main chemical composition table of 27SiMn steel
元素element CC SiSi MnMn CrCr NiNi PP SS
含量/％content/% 0.270.27 1.201.20 1.251.25 ≤0.309≤0.309 ≤0.30≤0.30 ≤0.035≤0.035 ≤0.035≤0.035
对27SiMn钢板进行切割，分别截取15mm×15mm×10mm、19mm×10mm×10mm、10mm×20mm×1mm的方块作为基材，然后以铜锡合金作为打底层，镀层厚度为25μm，再在表面镀硬铬，厚度为35μm，镀层厚度达60μm，从而制成镀铬试样(其中10mm×20mm×1mm尺寸的方块进行所有面的镀铬处理)。15mm×15mm×10mm尺寸的方块用于制备硬度试样：依次使用80#、200#、400#、600#、800#、1000#、1200#、1500#、2000#金相砂纸磨制带镀层的一面，注意保证均匀用力，尽量减少损伤；然后使用金相抛光机抛光呈镜面，用无水乙醇清洗表面并吹干后立即使用4％硝酸酒精(体积分数)作为化学腐蚀剂腐蚀镜面，当观察到表面开始变暗后，再用无水乙醇冲洗掉表面腐蚀剂，吹干后制成硬度试样。将19mm×10mm×10mm尺寸的那一面使用砂纸(80#、200#、400#、800#、1000#、1500#)打磨平整，清洗干燥后，制成磨损试样；根据JBT7901-2001，将10×20×1mm尺寸的方块用于制备腐蚀试样，除锈，再将各表面打磨平整，用酒精清洗表面，晾干后制成腐蚀试样。Cut the 27SiMn steel plate and cut 15mm×15mm×10mm, 19mm×10mm×10mm, 10mm×20mm×1mm squares as the base material, and then use the copper-tin alloy as the base layer, the plating thickness is 25μm, and then the surface is hard-plated Chromium has a thickness of 35 μm and a plating thickness of 60 μm to make a chromium-plated sample (a square of 10mm×20mm×1mm size is subjected to chromium plating treatment on all sides). 15mm×15mm×10mm size squares are used to prepare hardness samples: use 80#, 200#, 400#, 600#, 800#, 1000#, 1200#, 1500#, 2000# metallographic sandpaper to grind with plating layer in turn Attention should be paid to ensure uniform force to minimize damage; then use a metallographic polishing machine to polish the mirror surface, clean the surface with absolute ethanol and dry it, immediately use 4% nitric acid alcohol (volume fraction) as a chemical etchant to corrode the mirror surface, when observing After the surface begins to darken, rinse off the surface corrosive with absolute ethanol, and dry it to make a hardness sample. Use sandpaper (80#, 200#, 400#, 800#, 1000#, 1500#) to smooth the side of 19mm×10mm×10mm size, clean and dry, and make abrasion samples; according to JBT7901-2001, A square of 10×20×1mm size is used to prepare corrosion samples, remove rust, and then smooth the surfaces, clean the surfaces with alcohol, and dry them to make corrosion samples.
对27SiMn钢板进行激光熔覆处理。熔覆材料选用Ni25，熔覆厚度为2mm。设备采用波长为980nm，光斑尺寸为12×3mm的LASERTEL 4kW大功率半导体激光器。然后采用线切割对钢板进行切割，切割尺寸与后续的制样方案同镀铬试样保持一致，从而获取激光熔覆工艺的硬度试样、磨损试样及腐蚀试样。The 27SiMn steel plate was subjected to laser cladding treatment. The cladding material is Ni25, and the cladding thickness is 2mm. The equipment uses a LASERTEL 4kW high-power semiconductor laser with a wavelength of 980nm and a spot size of 12×3mm. Then the steel plate is cut by wire cutting, and the cutting size is consistent with the subsequent sample preparation plan and the chromium-plated sample, so as to obtain the hardness sample, wear sample and corrosion sample of the laser cladding process.
对外径为100mm、内径为90mm，高为195mm的27SiMn圆柱筒进行包覆焊处理，包覆层选用厚度为1mm的304不锈钢板，将不锈钢板制作成管状，使不锈钢管内径大于圆柱筒的外径。A 27SiMn cylindrical barrel with an outer diameter of 100mm, an inner diameter of 90mm, and a height of 195mm is covered and welded. A 304 stainless steel plate with a thickness of 1mm is selected for the cladding layer. The stainless steel plate is made into a tube to make the inner diameter of the stainless steel tube larger than the outer diameter of the cylinder. path.
304不锈钢主要化学成分表(wt.％)304 stainless steel main chemical composition table (wt.%)
元素element CC SiSi MnMn CrCr NiNi PP SS
含量/％content/% 0.060.06 ≤1.0≤1.0 ≤2.0≤2.0 18.018.0 9.09.0 ≤0.035≤0.035 ≤0.03≤0.03
包覆焊方法包括以下步骤：The cladding welding method includes the following steps:
1)制作：对圆柱筒车外圆，控制外圆的锥度0～0.03mm和尺寸公差0～0.05mm，精准控制镶熔工序的变形量；然后再套入不锈钢管中；1) Production: For the outer circle of the cylindrical barrel car, control the taper of the outer circle 0～0.03mm and the dimensional tolerance 0～0.05mm, and accurately control the deformation of the inlay melting process; then it is sleeved into the stainless steel tube;
2)镶熔：对不锈钢管进行挤压，使不锈钢管与圆柱筒贴合，进行缩径，用缩径模具挤压不锈钢管，使不锈钢管变细变长，壁厚减薄，使不锈钢管厚度小于圆柱筒厚度0.2～0.3mm；然后对不锈钢管的一端开始加热至400℃、同时施加压力至40MPa，逐步实施上述操作至不锈钢管的另一端，完成熔合直至不锈钢管和圆柱筒之间产生熔合结界，完成镶熔，镶熔后不锈钢管与工件产生20KN左右的包覆力，使两者间形成结界界面，并紧密结合成一体，整个过程10分钟左右；然后对工件表面进行防腐处理；2) Inlay melting: squeeze the stainless steel tube, make the stainless steel tube fit the cylindrical tube, and reduce the diameter. Use the reducing die to squeeze the stainless steel tube to make the stainless steel tube thinner and longer, and the wall thickness is reduced to make the stainless steel tube The thickness is less than the thickness of the cylindrical barrel 0.2～0.3mm; then start heating one end of the stainless steel pipe to 400℃, while applying pressure to 40MPa, gradually implement the above operations to the other end of the stainless steel pipe, and complete the fusion until the stainless steel pipe and the cylindrical barrel are formed Fuse the boundary to complete the inlay fusion. After the inlay fusion, the stainless steel tube and the workpiece produce a coating force of about 20KN, so that the two form a boundary interface and are tightly integrated into one body. The whole process is about 10 minutes; then the surface of the workpiece is anticorrosive deal with;
3)裁剪：两端工艺头20～30mm，去掉两端多余的100mm的不锈钢管，为下道封焊工序作准备工作；3) Cutting: The process heads at both ends are 20-30mm, and the extra 100mm stainless steel pipes at both ends are removed to prepare for the next sealing and welding process;
4)封焊：使用精密环缝焊机对不锈钢管两端进行封焊，使圆柱筒结界具有密封性，保证圆柱筒处在高压液体介质中不会窜液；4) Sealing and welding: Use a precision circular seam welder to seal both ends of the stainless steel pipe to make the cylindrical barrel boundary airtight and ensure that the cylindrical barrel will not flow in the high-pressure liquid medium;
5)修形：使用车床对两端封焊处进行修形，去掉焊接痕迹并达到图纸尺寸要求外径偏差在0.065～0.185mm范围内，以满足装配和外观需求；5) Shape modification: use a lathe to modify the sealing and welding at both ends, remove welding traces and meet the drawing size requirements, and the outer diameter deviation is within the range of 0.065～0.185mm to meet the requirements of assembly and appearance;
6)表面硬化：使用氮化炉对圆柱筒表面进行氮化处理，氮化处理时的参数温度升至380～400℃，氮化3～4小时，保温5～6小时，提升表面硬度达到《油缸制造规程》中规定立柱活塞杆表面硬度必须达到600HV；6) Surface hardening: Use a nitriding furnace to perform nitriding treatment on the surface of the cylinder. The parameter temperature during nitriding treatment is increased to 380-400℃, nitriding for 3 to 4 hours, and heat preservation for 5 to 6 hours to increase the surface hardness to " The "Cylinder Manufacturing Regulations" stipulates that the surface hardness of the column piston rod must reach 600HV;
7)抛光：使用抛光中心对圆柱筒外圆进行抛光，抛光所需时间为15～20min，以提高工件表面光洁度。7) Polishing: Use the polishing center to polish the outer circle of the cylinder. The polishing time is 15-20min to improve the surface finish of the workpiece.
采用线切割对钢板进行切割，切割尺寸及后的制样方案同镀铬样保持一致，从而获取包覆焊工艺的硬度试样、磨损试样及腐蚀试样。随后针对各工艺试样进行硬度测试、耐磨性测试及耐蚀性测试。将包覆焊技术的方法，与电镀铬和激光熔覆进行对比。The steel plate is cut by wire cutting, and the cutting size and subsequent sample preparation plan are the same as the chromium-plated samples, so as to obtain the hardness samples, wear samples and corrosion samples of the cladding welding process. Subsequently, hardness test, wear resistance test and corrosion resistance test were carried out for each process sample. The method of cladding welding technology is compared with chromium electroplating and laser cladding.
如图2所示，电镀铬涂层具有最高的显微硬度，达到676.3HV，激光熔覆涂层显微硬度最低，而包覆焊涂层显微硬度介于二者之间。电镀铬涂层表面的显微硬度最高，这主要是由于在电镀铬工艺的生产过程中，镀层表面反应生成的含水氧化铬硬度极高，从而使涂层表现出较高的表面显微硬度。激光熔覆涂层的表面显微硬度极低，仅为292.9HV，未达到电镀铬涂层硬度的一半。尽管激光熔覆工艺可以获得细小的熔覆层组织，有助于提高涂层的强度硬度，但是这种细晶强化效果有限，而Ni25合金粉末中含碳量较低，约为0.1％，而基体材料27SiMn的碳含量也较低，偏低的碳含量限制了碳化物的形成，而碳化物在材料中通常在作为硬质相而存在的，它对材料强度和硬度的影响比细小的熔覆层组织所带来的细晶强化效果要大得多，因而最终涂层的显微硬度呈现整体偏低的状况，然而在井下这种工况条件及其苛刻的地方，如此低硬度的涂层显然无法满足长时间的高压工作，容易出现失效的情况。而包覆焊涂层的表面显微硬度不高，为498.9HV，约为电镀铬涂层的0.74倍，但却是激光熔覆层的1.71倍，主要原因是304不锈钢含碳量约为0.06％，具有稳定的奥氏体组织，其强度和硬度受含碳量限制，均表现出不高的状态，但是相比起激光熔覆涂层中过少的碳化物硬质相，却又有所优势，因而其表面显微硬度不高，但是也不算过低，完全满足立柱在使用时对硬度的要求。As shown in Figure 2, the electroplated chromium coating has the highest microhardness, reaching 676.3HV, the laser cladding coating has the lowest microhardness, and the coating welding coating has the microhardness between the two. The surface of the electroplated chromium coating has the highest microhardness, which is mainly due to the extremely high hardness of the hydrated chromium oxide formed on the surface of the coating during the production process of the electroplating chromium process, so that the coating exhibits a higher surface microhardness. The surface microhardness of the laser cladding coating is extremely low, only 292.9HV, which is less than half of the hardness of the electroplated chrome coating. Although the laser cladding process can obtain a fine cladding layer structure and help improve the strength and hardness of the coating, the effect of this fine-grained strengthening is limited, and the carbon content in Ni25 alloy powder is relatively low, about 0.1%. The carbon content of the base material 27SiMn is also low. The low carbon content limits the formation of carbides, and carbides usually exist as hard phases in the material, which have a greater impact on the strength and hardness of the material than the small melt. The fine-grain strengthening effect brought by the coating structure is much greater, so the microhardness of the final coating is generally low. However, in such a harsh place under the working conditions of the underground, such a low-hardness coating The layer obviously cannot meet the long-term high-pressure work, and it is prone to failure. The surface microhardness of the cladding welding coating is not high, 498.9HV, which is about 0.74 times that of the electroplated chromium coating, but it is 1.71 times that of the laser cladding layer. The main reason is that the carbon content of 304 stainless steel is about 0.06. %, has a stable austenite structure, its strength and hardness are limited by the carbon content, and both show a low state, but compared with the too few carbide hard phases in the laser cladding coating, it has Advantages, so the surface microhardness is not high, but not too low, which fully meets the hardness requirements of the column in use.
如图3所示，激光熔覆涂层的磨损量和相对磨损率分别为0.09207g、0.00647，均为 最高值，这意味着该种涂层的耐磨性能最差。而电镀铬涂层的磨损量和相对磨损率分别为0.02873g、0.00202，仅为激光熔覆涂层的0.31倍，表现出极高的耐磨性能，主要是因为电镀铬涂层的表面显微硬度为676.3HV，涂层的高硬度在很大程度上保证了高耐磨性。包覆焊涂层磨损量和相对磨损率分别为0.03862g、0.00271，约为激光熔覆涂层的0.42倍，电镀铬涂层的1.34倍，表现出不俗的耐磨性能。激光熔覆涂层过低的硬度和耐磨性在面对井下各种磨损时，无法满足长时间的工作，而过早失效；电镀涂层在硬度和耐磨性方面的优异表现，完全可以满足液压支架立柱在工况条件极其恶劣的井下长时间工作的要求，但是立柱表面的硬度和耐磨性并不是越高越好，包覆焊涂层在该方面不俗的性能同样可以满足液压支架立柱的工作需求。As shown in Figure 3, the wear amount and relative wear rate of the laser cladding coating are 0.09207g and 0.00647 respectively, both of which are the highest values, which means that the wear resistance of this kind of coating is the worst. The wear amount and relative wear rate of the electroplated chromium coating are 0.02873g and 0.00202, respectively, which are only 0.31 times that of the laser cladding coating. It exhibits extremely high wear resistance, mainly due to the surface microscopy of the electroplated chromium coating. The hardness is 676.3HV, and the high hardness of the coating ensures high wear resistance to a large extent. The wear volume and relative wear rate of the cladding welding coating are 0.03862g and 0.00271, respectively, which are about 0.42 times that of the laser cladding coating and 1.34 times that of the electroplated chromium coating, showing good wear resistance. The too low hardness and wear resistance of the laser cladding coating cannot meet the long-term work and premature failure when faced with various downhole wear. The excellent performance of the electroplated coating in terms of hardness and wear resistance is completely acceptable. It meets the requirements of long-term work in underground wells with extremely harsh working conditions for the hydraulic support column, but the hardness and wear resistance of the column surface are not as high as possible. The good performance of the cladding welding coating in this respect can also meet the hydraulic pressure The work requirements of the support column.
如图4所示，经过72h的盐酸溶液腐蚀后的各种涂层，其中电镀铬涂层的耐腐蚀性最差，腐蚀速率为3.69×10 -3mm/a；而激光熔覆涂层的腐蚀速率为0.59×10 -3mm/a，为电镀铬涂层的0.16倍；包覆焊涂层的腐蚀速率为0.45×10 -3mm/a，仅为电镀铬涂层的0.12倍，包覆焊表现出非常优异的耐腐蚀性能。包覆焊工艺由于加工过程的特殊性，成型的外表面甚至完全没有孔隙和微裂纹等缺陷，因而这两种涂层在腐蚀试验中由于溶液中的Cl -在短时间内无法通过渗入涂层的孔隙和微裂纹的方式到达基体，从而导致电化学腐蚀无法形成，只能依靠H +的腐蚀性对涂层表面进行腐蚀，因此腐蚀速率较低，表现出优异的耐腐蚀性。 As shown in Figure 4, after 72 hours of hydrochloric acid solution corrosion of various coatings, the corrosion resistance of electroplated chromium coating is the worst, with a corrosion rate of 3.69×10 -3 mm/a; while the laser cladding coating has the worst corrosion resistance. The corrosion rate is 0.59×10 -3 mm/a, which is 0.16 times that of electroplated chromium coating; the corrosion rate of weld coating is 0.45×10 -3 mm/a, which is only 0.12 times that of electroplated chromium coating. Overlay welding shows very excellent corrosion resistance. Due to the particularity of the processing process, the outer surface of the molding is even completely free of defects such as pores and microcracks. Therefore, in the corrosion test, the two coatings cannot penetrate into the coating in a short time due to the Cl-in the solution. The way of pores and microcracks reaches the substrate, which leads to the failure of electrochemical corrosion to form, and can only rely on the corrosivity of H + to corrode the coating surface, so the corrosion rate is low and it shows excellent corrosion resistance.
同时，通过对比各工艺的投入及成本对比发现，电镀铬工艺的设备投入不高，原料费和成本也较低，经济效益良好；而激光熔覆工艺的设备价格高昂，是电镀铬工艺的3～4倍，原料费甚至超过电镀铬工艺的两倍，成本达到电镀铬工艺的十倍多，经济效益偏低；反观包覆焊工艺，设备投入最低，原料费和成本也极低，表现出极佳的经济效益。At the same time, by comparing the input and cost of each process, it is found that the equipment investment of the chromium electroplating process is not high, the raw material cost and cost are also low, and the economic benefits are good; while the equipment of the laser cladding process is expensive, which is 3% of the chromium electroplating process. ～4 times, the raw material cost is even more than twice that of the chromium electroplating process, and the cost is more than ten times that of the chromium electroplating process, and the economic benefit is relatively low. In contrast, the cladding welding process has the lowest equipment investment, and the raw material cost and cost are also extremely low. Excellent economic benefits.
各工艺设备投入及成本对比Comparison of investment and cost of various process equipment
Figure PCTCN2020121728-appb-000001
Figure PCTCN2020121728-appb-000001
电镀铬工艺经济效益较高，但会产生电镀废水以及各类酸雾废气，对环境的污染十分严重；激光熔覆工艺的设备投入及成本费均偏高，还会使空气中的悬浮颗粒物增多，造成严重的空气污染；而包覆焊工艺的设备投入较低，成本低廉，表现出极优的经济效益，而且生产过程 中没有使用任何化学制品，无电镀废水、酸雾废气、颗粒悬浮物的产生，对人体完全无害，对环境也十分友好。符合绿色生产的社会发展主题，在提升立柱的制造技术水平的同时降低了制造成本，符合市场和行业需求，对矿用支架行业拥有长期的经济效益和社会效益，预测包覆焊工艺会逐渐取代电镀铬、激光熔覆工艺，成为未来液压支架立柱再制造技术的发展趋势。The chromium electroplating process has higher economic benefits, but it will produce electroplating wastewater and various acid mist exhaust gas, which will seriously pollute the environment; the equipment investment and cost of the laser cladding process are both high, and it will also increase the suspended particulates in the air. , Causing serious air pollution; while the equipment investment of the coating welding process is low, the cost is low, and it shows excellent economic benefits, and no chemical products are used in the production process, such as electroplating wastewater, acid mist exhaust gas, and particulate suspended solids. The production is completely harmless to the human body and very friendly to the environment. It conforms to the social development theme of green production, reduces the manufacturing cost while improving the manufacturing technology level of the column, and meets the needs of the market and the industry. It has long-term economic and social benefits for the mining support industry. It is predicted that the cladding welding process will gradually replace Chrome plating and laser cladding technology have become the development trend of future hydraulic support column remanufacturing technology.
以上所述仅是本发明的优选实施方式，应当指出，对于本技术领域的普通技术人员来说，在不脱离本发明原理的前提下还可以做出若干改进，这些改进也应视为本发明的保护范围。The above are only the preferred embodiments of the present invention. It should be pointed out that for those of ordinary skill in the art, several improvements can be made without departing from the principle of the present invention, and these improvements should also be regarded as the present invention. The scope of protection.

Claims (10)

  1. 一种应用于液压支架立柱的包覆焊方法，其特征在于包括以下步骤：A cladding welding method applied to a hydraulic support column, which is characterized in that it comprises the following steps:
    1)制作：将合金管套在工件上；1) Production: sleeve the alloy tube on the workpiece;
    2)镶熔：对合金管进行挤压，使合金管与工件贴合，进行缩径、熔合，直至合金管和工件之间产生熔合结界，完成镶熔；2) Inlay melting: squeeze the alloy tube to make the alloy tube fit the workpiece, reduce the diameter and fuse, until a fusion boundary is formed between the alloy tube and the workpiece, and the inlay melting is completed;
    3)裁剪：去掉两端多余的合金管；3) Cutting: Remove the excess alloy tube at both ends;
    4)封焊：对合金管两端进行封焊。4) Sealing and welding: sealing and welding both ends of the alloy pipe.
  2. 根据权利要求1所述的应用于液压支架立柱的包覆焊方法，其特征在于：在步骤1)中，先对工件车外圆，控制外圆的锥度0～0.03mm和尺寸公差0～0.05mm，然后再套入合金管中。The cladding welding method applied to the column of a hydraulic support according to claim 1, characterized in that: in step 1), the outer circle of the workpiece is firstly controlled, and the taper of the outer circle is 0～0.03mm and the dimensional tolerance is 0～0.05. mm, and then put it into the alloy tube.
  3. 根据权利要求1所述的应用于液压支架立柱的包覆焊方法，其特征在于：在步骤2)中，熔合的步骤为：将整个合金管加热至400～500℃，然后从合金管的一端开始施加压力至40～45MPa直至合金管的另一端，完成熔合。The cladding welding method applied to the column of a hydraulic support according to claim 1, characterized in that: in step 2), the fusion step is: heating the entire alloy tube to 400-500°C, and then starting from one end of the alloy tube Start to apply pressure to 40-45MPa until the other end of the alloy tube, complete fusion.
  4. 根据权利要求1所述的应用于液压支架立柱的包覆焊方法，其特征在于：在步骤2)中，熔合的步骤为：将合金管的一端加热至400～500℃、同时施加压力至40～45MPa，逐步实施上述操作至合金管的另一端，完成熔合。The cladding welding method applied to a hydraulic support column according to claim 1, wherein in step 2), the fusion step is: heating one end of the alloy tube to 400-500°C while applying pressure to 40°C. ~45MPa, gradually implement the above operations to the other end of the alloy tube to complete the fusion.
  5. 根据权利要求1所述的应用于液压支架立柱的包覆焊方法，其特征在于：还包括步骤5)：修形：对两端封焊处进行修形，去掉焊接痕迹。The cladding welding method applied to the column of a hydraulic support according to claim 1, characterized in that it further comprises step 5): shaping: shaping the sealing welds at both ends to remove welding traces.
  6. 根据权利要求5所述的应用于液压支架立柱的包覆焊方法，其特征在于：还包括步骤6)：表面硬化：对工件表面进行氮化处理；参数为：温度为380～400℃，氮化3～4小时，保温5～6小时。The cladding welding method applied to the column of a hydraulic support according to claim 5, characterized in that it further comprises step 6): surface hardening: nitriding the surface of the workpiece; the parameters are: temperature is 380-400°C, nitrogen Heat for 3 to 4 hours and keep warm for 5 to 6 hours.
  7. 根据权利要求6所述的应用于液压支架立柱的包覆焊方法，其特征在于：还包括步骤7)：抛光：对工件外圆进行抛光，抛光时间为15～20min。The cladding welding method applied to the column of the hydraulic support according to claim 6, characterized in that it further comprises step 7): polishing: polishing the outer circle of the workpiece, and the polishing time is 15-20 minutes.
  8. 根据权利要5所述的应用于液压支架立柱的包覆焊方法，其特征在于：在步骤5)中，去掉焊接痕迹并达到图纸尺寸要求外径偏差在0.065～0.185mm范围内。The cladding welding method applied to the hydraulic support column according to claim 5, characterized in that: in step 5), the welding traces are removed and the outer diameter deviation of the drawing size requirement is within the range of 0.065 to 0.185 mm.
  9. 根据权利要求1所述的应用于液压支架立柱的包覆焊方法，其特征在于：在步骤2)中，缩径的方式为：用缩径模具挤压合金管，使合金管变细变长，壁厚减薄，使合金管厚度小于工件厚度0.2～0.3mm。The cladding welding method applied to the column of a hydraulic support according to claim 1, characterized in that: in step 2), the method of reducing the diameter is: extruding the alloy tube with a diameter reduction die to make the alloy tube thinner and longer , The wall thickness is reduced, so that the thickness of the alloy tube is less than the thickness of the workpiece by 0.2 ~ 0.3mm.
  10. 根据权利要求6所述的应用于液压支架立柱的包覆焊方法，其特征在于：在步骤6)中，采用辉光等离子氮化炉对工件表面进行氮化处理。The cladding welding method applied to the column of the hydraulic support according to claim 6, characterized in that: in step 6), a glow plasma nitriding furnace is used to perform nitriding treatment on the surface of the workpiece.
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