Flux cored wire, welding method using the same, and method for manufacturing the same

Abstract

The invention relates to a flux-cored wire (10) for a welding method, comprising: a tubular wire sheath (11); a wire core (12) consisting of flux powder, which is surrounded by the tubular wire sheath (11), wherein the wire sheath (11) and the wire core (12) have such a composition that a melt consisting of CuSn12Ni2 is produced during welding.

Description

Technical Field

[0001] The present invention relates to a flux core wire (sometimes also referred to as a flux core wire) for use in a welding method. The present invention further relates to a welding method using the flux core wire and a method for producing the flux core wire. Background Art

[0002] In welding methods known from practice, welding wires are used, which can be embodied as so-called solid wires or so-called flux-cored wires. Accordingly, for example, a flux-cored wire for welding methods and a method and a device for producing a flux-cored wire are known from DE 10 2006 048 028 B3.

[0003] Until now, it has been difficult to repair or construct functional layers made of CuSn12Ni2 or to repair or construct existing solid material components or machine elements made of CuSn12Ni2 by means of welding methods. The reason for this is that no suitable welding wire is currently known. Summary of the invention

[0004] Starting from this, the invention is based on the object of creating a novel flux-cored wire for a welding method, a welding method using a flux-cored wire, and a method for producing a flux-cored wire.

[0005] This object is achieved by a flux-cored wire according to claim 1. The flux-cored wire has a tubular wire sheath and a wire core of flux powder which is surrounded by the tubular wire sheath, wherein the wire sheath and the wire core have such a composition that a melt of CuSn12Ni2 is produced during welding.

[0006] The invention proposes a flux-cored wire for a welding method, wherein the wire sheath and the wire core have such a composition that a melt consisting of a CuSn12Ni2 alloy is formed during welding. As a result, a functional layer consisting of a CuSn12Ni2 alloy can be repaired and also formed by means of a welding method, i.e. on all known base materials, in particular on base materials or C10, C15, 16MnCr5, 42CrMo4, S355, GJL-300, GJS-400, etc.

[0007] According to another refinement of the present invention, the tubular wire sheath has the following composition: Cu in a content of at least 95% by mass, with the remainder being S and / or Fe and / or Si and / or Pb and / or Zn and / or Sb and / or Al and / or O and / or Mn and / or Ag and / or Bi as trace elements.

[0008] The wire core and thus the flux powder preferably have the following composition: a content of 50 to 80% by mass of Cu, a content of 19.99 to 40% by mass of N, a content of 0.01 to 10% by mass of Ni.

[0009] Sheath wires and wire cores with the composition defined above are particularly preferred in order to provide a melt consisting of CuSn12Ni2 during welding and thus repair or construct functional layers consisting of CuSn12Ni2 or a CuSn12Ni2 alloy or repair or construct solid material components as machine elements.

[0010] According to another development of the invention, the tubular wire sheath has an outer diameter of 0.8 to 2 mm and a thickness of 0.05 to 0.7 mm. The flux powder of the wire core preferably has a grain size of up to 250 μm, preferably between 0.01 and 250 μm. Such flux core wires are particularly suitable for welding and are therefore preferred.

[0011] Preferably, the content of wire sheath in the flux cored wire is 60±20% by mass and / or the content of wire core in the flux cored wire is 40±20% by mass. These ratios of wire sheath to wire core are particularly preferred during welding.

[0012] A welding method using a flux cored wire is defined in claim 11 and a method for producing the flux cored wire is defined in claim 12 . BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Preferred further developments of the invention are apparent from the dependent claims and the following description. Without being restricted to the drawings, exemplary embodiments of the invention are explained in detail with reference to the drawings. Among them:

[0014] Figure 1 A cross section through a flux cored wire according to the invention is shown. DETAILED DESCRIPTION

[0015] The invention relates to the repair or construction of functional layers or the repair or construction of solid material components as machine elements consisting of a CuSn12Ni2 alloy by means of a welding method, namely to a flux-cored wire for such a welding method, a welding method using the flux-cored wire and a method for producing the flux-cored wire.

[0016] Figure 1 A cross section through a flux-cored wire 10 for use in a welding method is schematically shown, wherein the flux-cored wire 10 comprises a tubular wire sheath 11 and a wire core 12 consisting of flux powder.

[0017] The wire core 12 consisting of flux powder is surrounded by a tubular wire sheath 11 .

[0018] The wire sheath 11 and the wire core 12 of the flux-cored wire 10 have such a composition that a melt consisting of CuSn12Ni2 or a CuSn12Ni2 alloy is achieved during welding.

[0019] This makes it advantageously possible to repair or build up functional layers consisting of a CuSn12Ni2 alloy, ie on all possible base materials.

[0020] The tubular wire sheath 11 preferably has the following composition:

[0021] At least 95% by mass of Cu,

[0022] The rest S and / or Fe and / or Si and / or Pb and / or Zn and / or Sb and / or Al and / or O and / or Mn and / or Ag and / or Bi serve as trace elements.

[0023] Preferably, the Cu content in the tubular wire sheath 11 is at least 96% by mass, preferably at least 97% by mass, particularly preferably at least 99% by mass or even at least 99.8% by mass.

[0024] The content of the corresponding trace elements (which represent alloying elements) in the wire sheath 11 is in each case a maximum of 2% by mass, preferably in each case a maximum of 1% by mass, preferably in each case a maximum of 0.5% by mass, particularly preferably in each case a maximum of 0.1% by mass.

[0025] The sum of Cu and the or each trace element obviously totals 100% by mass of the wire sheath 11. Thus, when the wire sheath 11 comprises 97% by mass of Cu, the sum of all trace elements is 3% by mass. When the wire sheath 11 comprises 99% by mass of Cu, the sum of all trace elements is 1% by mass. When the wire sheath 11 comprises 99.8% by mass of Cu, the total of all trace elements is 0.2% by mass. Mass percentage is also referred to as weight percentage.

[0026] The tubular wire sheath 11 has an outer diameter of 0.8 to 2 mm and a thickness of 0.05 to 0.7 mm.

[0027] Preferably, the tubular wire sheath 11 has an outer diameter of 1.2 mm to 1.6 mm and a thickness of 0.1 mm to 0.4 mm.

[0028] The thickness and outer diameter of the wire sheath 11 are preferably selected so that the content of the wire sheath 11 in the flux cored wire 10 is 60±20% by mass. Accordingly, the content of the wire core 12 in the flux cored wire 10 is 40±20% by mass.

[0029] The wire core 12 of the flux-cored wire 10 consisting of flux powder and thus the flux powder have the following composition:

[0030] 50% to 80% by mass of Cu,

[0031] Sn content of 19.99% to 40% by mass,

[0032] The content of Ni is 0.01 mass % to 10 mass %.

[0033] Preferably, the flux powder has the following composition:

[0034] 60% to 73% by mass of Cu,

[0035] Sn content of 25% to 32% by mass,

[0036] The content of Ni is 2% to 8% by mass.

[0037] The flux powder of the wire core 12 may contain S and / or Fe and / or Si and / or Pb and / or Zn and / or Sb and / or Al and / or O and / or Ag and / or Bi as trace elements or alloying elements in addition to Cu, Sn and Ni.

[0038] The content of each trace element in the flux powder of the wire core 12 is in each case a maximum of 2% by mass, preferably in each case a maximum of 1% by mass, preferably a maximum of 0.5% by mass, particularly preferably a maximum of 0.1% by mass.

[0039] In the flux powder of the wire core 12 , the total amount of Cu, Sn, and Ni is 100% by mass, and the mass content of any trace elements that may be present can be understood as a super addition to Cu, Sn, and Ni.

[0040] Preferably, the total amount of all trace elements present in the flux powder in addition to Cu, Sn and Ni is maximum 5% by mass, preferably maximum 3% by mass, particularly preferably maximum 2% by mass or even maximum 1% by mass.

[0041] The flux powder of the wire core 12 is preferably ideally a spherical flux powder that does not form any lumps during melting. The powder particles of the flux powder are solid and preferably do not have any cavities.

[0042] The flux powder of the wire core 12 may have a grain size of up to 250 μm, wherein the flux powder of the wire core 12 may include powder grains with different grain sizes between 0.01 μm and 250 μm. Within this grain size range, the flux powder may have a grain size distribution.

[0043] The flux powder of the wire core 12 of the flux-cored wire 10 is preferably a main alloy composed of the above-mentioned elements, which is produced, for example, by gas atomization.

[0044] The flux cored wire 10 is preferably wound on a coil and may be unwound from the coil during welding.

[0045] In a specific exemplary embodiment, the following applies to the flux cored wire 10:

[0046] The outer diameter of the wire sheath is 1.2 or 1.6 mm

[0047] The thickness of the wire sheath is 0.1 or 0.3 mm

[0048] The Cu content of the wire sheath is 99.8% by mass.

[0049] The remaining trace elements in the wire sheath total 0.2% by mass

[0050] The Cu content of the flux powder is 65% by mass

[0051] Sn content of flux powder 30% by mass

[0052] The Ni content of the flux powder is 5% by mass.

[0053] In addition, a maximum of 2.5% by mass of trace elements may be added to the flux powder.

[0054] In a specific exemplary embodiment of a flux cored wire, the flux powder of the wire core 12 has a grain size between 0.01 and 250 μm.

[0055] The grain size distribution is preferably as follows:

[0056] 10% powder particles with a grain size between 0.01 and 44.99 µm

[0057] 85% of powder particles with a grain size between 45 and 200 µm

[0058] 5% of powder particles with a grain size between 200.01 and 250 µm.

[0059] The invention further relates to a welding method using the above-described flux-cored wire, namely for repairing or for constructing a functional layer consisting of a CuSn12Ni2 alloy or for repairing or constructing a solid material component as a machine element consisting of a CuSn12Ni2 alloy.

[0060] The functional layer can be formed as a single layer or as a plurality of layers with a thickness preferably between 0.05 mm and 15 mm.

[0061] Possible welding methods used are the MIG welding method or the MAG welding method.

[0062] In particular, the functional layer to be constructed or repaired is a tribologically functional layer, for example a plain bearing layer of a plain bearing from the field of drive technology, such as wind energy (offshore / onshore), the energy industry, the automotive industry, transmission technology or machine elements from the field of sealing technology, etc. Furthermore, machine parts can be solid-state machine elements from the above-mentioned fields of application, which are constructed or repaired completely from the materials mentioned.

[0063] The invention further relates to a method for producing the above-described flux cored wire 10. Here, a metal sheet for the wire sheath 11 is first provided, which has the above-described composition. The thickness of the metal sheet is preferably between 0.05 mm and 0.7 mm. A blank for the wire sheath 11 is cut from the metal sheet. Furthermore, a flux powder for the wire core 12 is provided, in particular a flux powder with a defined grain size distribution, wherein the powder particles have the above-described composition and preferably consist of a main alloy produced, for example, by gas atomization.

[0064] After cutting the blank for the wire sheath 11, the blank for the wire sheath 11 is formed into the wire sheath 11, wherein the cavity of the wire sheath 11 is filled with flux powder, i.e. during and / or after the forming of the blank for the wire sheath 11. In this process, the wire core 12 is formed by the flux powder. After the blank is formed into the wire sheath 11, the adjacent edges of the metal sheets can be joined via a fold or a weld for forming the wire sheath 11. The flux powder of the wire core 12 is held in the wire sheath 11 via frictional engagement.

[0065] Reference numerals list

[0066] 10 Flux cored wire

[0067] 11 Wire sheath

[0068] 12 wire cores.

Claims

1. A flux cored wire for use in a welding method for repairing or building a functional layer of a sliding bearing, comprising: a wire sheath which is tubular and has a Cu content of at least 95 mass %; and A wire core consisting of flux powder surrounded by the tubular wire sheath, wherein The wire sheath and the wire core have such a composition that a melt consisting of CuSn12Ni2 occurs during welding, Wherein, the wire core and thus the flux powder comprises: 50 to 80% by mass of Cu, 19.99 to 40% by mass of Sn, and 0.01 to 10% by mass of Ni, wherein the total mass percentage of Cu, Sn and Ni is 100%; and in: The flux powder of the wire core comprises S and / or Fe and / or Si and / or Pb and / or Zn and / or Sb and / or Al and / or O and / or Mn and / or Ag and / or Bi as one or more trace elements, The content of the respective trace element as an additional addition in the flux powder of the wire core is in each case a maximum of 0.5% by mass, The content of the wire sheath in the flux core wire is 60±20% by mass, and The content of the wire core in the flux core wire is the rest.

2. The flux-cored wire according to claim 1, wherein The wire sheath comprises: The rest S and / or Fe and / or Si and / or Pb and / or Zn and / or Sb and / or Al and / or O and / or Mn and / or Ag and / or Bi serve as trace elements.

3. The flux-cored wire according to claim 2, wherein: The content of the corresponding trace elements in the wire sheath is a maximum of 0.1% by mass.

4. The flux-cored wire according to claim 2, wherein: The wire sheath comprises at least one of the following: Cu content of at least 96% by mass, A Cu content of at least 97% by mass, and The Cu content is at least 99% by mass.

5. The flux-cored wire according to claim 1, wherein The wire sheath has: 0.8 to 2 mm outer diameter and 0.05 to 0.7mm thickness.

6. The flux-cored wire according to claim 1, wherein The wire core and therefore the flux powder comprises: 60 to 73% by mass of Cu, 25 to 32% by mass of Sn, and The Ni content is 2 to 8 mass %.

7. The flux-cored wire according to claim 1, wherein The flux powder of the wire core has a grain size of up to 250 μm.

8. A welding method comprising: There is provided a flux cored wire according to claim 1, One of the MIG welding methods or the MAG welding method is carried out for repairing or forming a functional layer consisting of a CuSn12Ni2 alloy or for forming a solid material component consisting of a CuSn12Ni2 alloy as a machine element.

9. A method for manufacturing a flux cored wire according to claim 1, A method of manufacturing a wire having a tubular wire sheath and a wire core consisting of flux powder surrounded by the tubular wire sheath, wherein the tubular wire sheath and the wire core have such a composition that a melt consisting of CuSn12Ni2 occurs during welding, comprising the following steps: providing a metal plate for the wire sheath, cutting a blank for said tubular wire sheath, providing the flux powder for the wire core, forming the blank for the wire sheath into a tubular wire sheath with a cavity, and The wire core is formed by filling the cavity of the tubular wire sheath with the flux powder during and / or after the blank for the wire sheath is formed into the wire sheath.

10. The welding method according to claim 9, wherein: The functional layer is a plain bearing layer of a plain bearing.

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