Single-sided welding double-sided forming gasket flux, its preparation process and application

Abstract

This invention belongs to the field of welding materials technology, specifically providing a single-sided welding double-sided forming backing flux, comprising the following raw material components by mass percentage: fused magnesia: 20-40%; quartz: 25-35%; zircon sand: 8-18%; fluorite: 5-15%; ferrosilicon: 3-10%; ferrotitanium: 3-10%; ferroboron: 1-2%; α-alumina: 1-5%; manganese oxide: 1-5%; strontium oxide: 0.5-1.5%; yttrium oxide: 0.5-1%; iron powder: 3-10%; phenolic resin: 2-10%. This backing flux is suitable for double-wire or triple-wire single-sided welding double-sided forming processes, and can meet the welding requirements of 10-35mm large ship panel DH36, EH36, DH40, EH40, etc. It is suitable for high heat input and high efficiency welding, with uniform and stable weld formation, no porosity or indentation, automatic slag removal, and excellent crack resistance.

Description

Technical Field

[0001] This invention belongs to the field of welding materials technology, specifically relating to a single-sided welding double-sided forming backing flux, its preparation process, and its application. Background Technology

[0002] High-efficiency welding technology remains an effective way to improve efficiency, reduce costs, and enhance quality and economic benefits in shipbuilding. In the fabrication of large planar sections, the most widely used method for flat plate welding is the FCB (Fluorescent Blanket) method with multi-wire single-sided welding and double-sided forming. This process solves the problem of difficult reverse-side welding of large flat plates, enabling assembly line operations, significantly shortening the modern shipbuilding cycle, and substantially improving efficiency. Although there is some domestic research on related materials, problems such as poor back-side forming stability, welding residue indentation, poor slag removal performance, and welding cracks still exist, hindering large-scale application. Summary of the Invention

[0003] The purpose of this invention is to overcome the problems of poor back-side forming stability, welding residue indentation, poor slag removal performance and welding cracks in the prior art.

[0004] Therefore, the present invention provides a single-sided welding double-sided forming backing flux, comprising the following raw material components by mass percentage: fused magnesia: 20-40%; quartz: 25-35%; zircon sand: 8-18%; fluorite: 5-15%; ferrosilicon: 3-10%; ferrotitanium: 3-10%; ferroboron: 1-2%; α-alumina: 1-5%; manganese oxide: 1-5%; strontium oxide: 0.5-1.5%; yttrium oxide: 0.5-1%; iron powder: 3-10%; phenolic resin: 2-10%.

[0005] Specifically, the aforementioned phenolic resin includes thermosetting phenolic resin and thermoplastic phenolic resin; the mass ratio of the thermosetting phenolic resin to the thermoplastic phenolic resin is 1:1 to 1:3.

[0006] Specifically, the particle size of the aforementioned backing flux is above 80 mesh.

[0007] Specifically, the alkalinity of the aforementioned backing flux is between 0.8 and 1.0.

[0008] Specifically, the S and P content in the above-mentioned backing flux is controlled below 0.025%.

[0009] The present invention also provides a preparation process for the above-mentioned single-sided welding double-sided forming backing flux, comprising the following steps:

[0010] (1) Prepare raw materials according to proportion, mix mineral raw materials except phenolic resin, add water glass to mineral raw materials, wet stir and then sieve, dry and then sieve again, and sinter to make basic flux.

[0011] (2) The base flux is heated in a rotary heating cylinder. Phenolic resin is blown into the rotary heating cylinder in the form of powder spraying until a resin film is evenly distributed on the surface of the base flux. Then, heating is stopped, the flux is cooled and sieved to obtain a single-sided welding double-sided forming pad flux.

[0012] Specifically, in step (1) above, the water glass includes lithium water glass and sodium water glass in a mass ratio of 1:3 to 3:4; the amount of water glass added is 12-20% based on the mass of mineral raw materials.

[0013] Specifically, in step (1) above, the basic flux is prepared by drying at 150-200℃ for 2 hours, sieving, and sintering at 850-900℃.

[0014] Specifically, in step (2) above, the blowing speed of the phenolic resin is 180-250 g / s.

[0015] Compared with the prior art, the present invention has the following advantages and beneficial effects:

[0016] The single-sided welding double-sided forming backing flux provided by this invention improves the melting point of the welding slag through a suitable ratio of MgO-CaO-Al2O3-SiO2-ZrO2 combination and the carbonization and cross-linking effect of resin, thereby increasing the arc penetration energy of the backing flux during high-heat welding. By controlling the appropriate loose packing density and particle size ratio, the uniformity and stability of the backing flux formation are improved. Even at an online energy of 200KJ / cm, it still has good slag shell formation, no molten iron leakage, uniform and consistent weld bead formation, and good stability. By adding SrO to form a thin film on the inner surface of the welding slag, due to the large difference in its coefficient of linear expansion with the base material, the welding slag can automatically fall off without residue, eliminating the need for manual cleaning and saving cleaning time and costs. By controlling the appropriate addition of trace elements such as Y, Ti, and B in the weld to improve the stability of acicular ferrite in the weld under ultra-high heat input conditions, the low-temperature impact toughness and crack resistance are improved, solving the problem of similar products having to lengthen the arc initiation and termination plates due to excessively long arc termination cracks.

[0017] When used with submerged arc welding wire, it can meet the requirements of single-wire, double-wire, or triple-wire high heat input single-sided welding with double-sided forming. It has a tensile strength of over 550MPa, a yield strength of over 420MPa, a yield strength of over 150J at -20℃, and over 90J at -40℃. Its comprehensive performance meets the welding requirements of classification societies for 2Y, 3Y, and 4Y grade steel plates. It can meet the welding requirements of 10-35mm large ship panel welds of DH36, EH36, DH40, and EH40, etc., suitable for high heat input high efficiency welding, producing uniform and stable weld formation, no porosity or indentation, automatic slag removal, and excellent crack resistance.

[0018] The present invention will now be described in further detail with reference to the accompanying drawings. Attached Figure Description

[0019] Figure 1 This is an actual case of the three-wire FCB method for forming the backing flux in Embodiment 3 of the present invention.

[0020] Figure 2 This is a real-world example of flux removal from the three-wire FCB method in Embodiment 3 of the present invention. Detailed Implementation

[0021] The technical solutions of the present invention will be clearly and completely described below with reference to embodiments. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Although representative embodiments of the present invention have been described in detail, those skilled in the art will understand that various modifications and changes can be made to the present invention without departing from the scope of the present invention. Therefore, the scope of the present invention should not be limited to the embodiments, but should be defined by the appended claims and their equivalents.

[0022] This invention provides a single-sided welding double-sided forming backing flux, comprising the following raw material components by mass percentage: fused magnesia: 20-40%; quartz: 25-35%; zircon sand: 8-18%; fluorite: 5-15%; ferrosilicon: 3-10%; ferrotitanium: 3-10%; ferroboron: 1-2%; α-alumina: 1-5%; manganese oxide: 1-5%; strontium oxide: 0.5-1.5%; yttrium oxide: 0.5-1%; iron powder: 3-10%; and thermosetting phenolic resin + thermoplastic phenolic resin in a mass ratio of 1:1-1:3: 2-10%.

[0023] The preferred composition, by weight percentage, includes the following raw material components: fused magnesia: 25%; quartz: 26%; zircon sand: 12%; fluorite: 7%; ferrosilicon: 5%; ferrotitanium: 7%; ferroboron: 1%; α-alumina: 3%; manganese oxide: 3%; strontium oxide: 1%; yttrium oxide: 0.5%; iron powder: 6.5%; thermosetting phenolic resin + thermoplastic phenolic resin: 3%.

[0024] All raw materials for the backing flux have a mesh size of 80 mesh or higher to ensure the absence of large particles. The preferred particle size is 16-60 mesh, with the mass percentages of 16-24 mesh, 24-40 mesh, and 40-60 mesh being 30%, 45%, and 25%, respectively. The alkalinity of the backing flux is controlled between 0.8 and 1.0, and the S and P content is controlled below 0.025%.

[0025] The present invention also provides a preparation process for the above-mentioned single-sided welding double-sided forming backing flux, comprising the following steps:

[0026] (1) Prepare raw materials according to the proportion. Mix the mineral raw materials except phenolic resin by shaking the powder in a rotating drum for 30 minutes. Add 12-20% water glass to the mineral raw materials by weight (excluding resin), stir wet for 10-15 minutes, pass through a vibrating screen and sieve through a 16-mesh sieve, dry at 150-200℃ for 2 hours, pass through a 16-mesh sieve again, and finally sinter at 850-900℃ to make the basic flux. The water glass includes lithium water glass and sodium water glass with a mass ratio of 1:3-3:4.

[0027] (2) Place the base flux in a rotary heating cylinder and heat it to 200°C. Use a powder spraying method to blow phenolic resin into the rotary heating cylinder at a speed of 180-250 g / s until a resin film is evenly distributed on the surface of the base flux. Stop heating, cool it to below 50°C and remove it from the furnace. Pass it through a 16-mesh sieve and then through a 60-mesh sieve to remove fine powder, thus obtaining a single-sided welding double-sided forming pad flux.

[0028] The effect of the single-sided welding double-sided forming pad flux of the present invention will be studied through specific embodiments below.

[0029] Example 1:

[0030] This embodiment provides a single-sided welding double-sided forming backing flux, which, by mass percentage, comprises the following raw material components: fused magnesia: 30%; quartz: 29%; zircon sand: 8%; fluorite: 6%; ferrosilicon: 3%; ferrotitanium: 5%; ferroboron: 1%; α-alumina: 2%; manganese oxide: 2%; strontium oxide: 1.2%; yttrium oxide: 0.6%; iron powder: 8.2%; thermosetting phenolic resin + thermoplastic phenolic resin: 4%, with the mass ratio of the two controlled at 1:1.5.

[0031] This embodiment also provides a preparation process for the above-mentioned single-sided welding double-sided forming backing flux, including the following steps:

[0032] (1) Prepare raw materials according to proportion. Mix the mineral raw materials except phenolic resin by shaking the powder in a rotating drum for 30 minutes. Add 12% water glass to the mineral raw materials by weight, stir wet for 14 minutes, pass through a vibrating screen and 16 mesh screen, dry at 160℃ for 2 hours, pass through a 16 mesh screen again, and finally sinter at 870℃ to make the basic flux. The water glass includes lithium water glass and sodium water glass with a mass ratio of 1:3.

[0033] (2) The base flux is placed in a rotary heating shaker and heated to 200°C. Phenolic resin is blown into the rotary heating shaker in the form of powder spraying at a speed of 200 g / s until a resin film is evenly distributed on the surface of the base flux. Then, heating is stopped, and the flux is cooled to below 50°C before being taken out of the furnace. It is then passed through a 16-mesh sieve and then through a 60-mesh sieve to remove fine powder, thus obtaining a single-sided welding double-sided forming pad flux. The alkalinity of this pad flux is 0.83.

[0034] Example 2:

[0035] This embodiment provides a single-sided welding double-sided forming backing flux, which, by mass percentage, comprises the following raw material components: fused magnesia: 28%; quartz: 25%; zircon sand: 14%; fluorite: 10%; ferrosilicon: 6%; ferrotitanium: 3%; ferroboron: 1.4%; α-alumina: 1%; manganese oxide: 3%; strontium oxide: 0.7%; yttrium oxide: 0.6%; iron powder: 5.3%; thermosetting phenolic resin + thermoplastic phenolic resin: 2%, with the mass ratio of the two controlled at 1:1.2.

[0036] This embodiment also provides a preparation process for the above-mentioned single-sided welding double-sided forming backing flux, including the following steps:

[0037] (1) Prepare raw materials according to proportion. Mix the mineral raw materials except phenolic resin by shaking the powder in a rotating drum for 30 minutes. Add 14% water glass to the mineral raw materials by weight, stir wet for 15 minutes, pass through a vibrating screen and 16 mesh screen, dry at 180℃ for 2 hours, pass through a 16 mesh screen again, and finally sinter at 880℃ to make the basic flux. The water glass includes lithium water glass and sodium water glass with a mass ratio of 1:2.

[0038] (2) The base flux is placed in a rotary heating shaker and heated to 200°C. Phenolic resin is blown into the rotary heating shaker in the form of powder spraying at a speed of 200 g / s until a resin film is evenly distributed on the surface of the base flux. Then, heating is stopped, and the flux is cooled to below 50°C before being taken out of the furnace. It is then passed through a 16-mesh sieve and then through a 60-mesh sieve to remove fine powder, thus obtaining a single-sided welding double-sided forming pad flux. The alkalinity of this pad flux is 0.92.

[0039] Example 3:

[0040] This embodiment provides a single-sided welding double-sided forming backing flux, which, by mass percentage, comprises the following raw material components: fused magnesia: 25%; quartz: 26%; zircon sand: 12%; fluorite: 7%; ferrosilicon: 5%; ferrotitanium: 7%; ferroboron: 1%; α-alumina: 3%; manganese oxide: 3%; strontium oxide: 1%; yttrium oxide: 0.5%; iron powder: 6.5%; thermosetting phenolic resin + thermoplastic phenolic resin: 3%, with the mass ratio of the two controlled at 1:1.

[0041] This embodiment also provides a preparation process for the above-mentioned single-sided welding double-sided forming backing flux, including the following steps:

[0042] (1) Prepare raw materials according to proportion. Mix the mineral raw materials except phenolic resin by shaking the powder in a rotating drum for 30 minutes. Add 16% water glass to the mineral raw materials by weight, stir wet for 13 minutes, pass through a vibrating screen and 16 mesh screen, dry at 190℃ for 2 hours, pass through a 16 mesh screen again, and finally sinter at 890℃ to make the basic flux. The water glass includes lithium water glass and sodium water glass with a mass ratio of 1:2.

[0043] (2) The base flux is placed in a rotary heating shaker and heated to 200°C. Phenolic resin is blown into the rotary heating shaker in the form of powder spraying at a speed of 200 g / s until a resin film is evenly distributed on the surface of the base flux. Then, heating is stopped, and the flux is cooled to below 50°C before being taken out of the furnace. The flux is then passed through a 16-mesh sieve and then through a 60-mesh sieve to remove fine powder, resulting in a single-sided welding double-sided forming pad flux. The alkalinity of this pad flux is 0.90.

[0044] Example 4:

[0045] This embodiment provides a single-sided welding double-sided forming backing flux, which, by mass percentage, comprises the following raw material components: fused magnesia: 22%; quartz: 30%; zircon sand: 8%; fluorite: 12%; ferrosilicon: 4%; ferrotitanium: 4%; ferroboron: 1.5%; α-alumina: 4%; manganese oxide: 2%; strontium oxide: 0.5%; yttrium oxide: 0.8%; iron powder: 8.7%; thermosetting phenolic resin + thermoplastic phenolic resin: 2.5%, with the mass ratio of the two controlled at 1:2.

[0046] This embodiment also provides a preparation process for the above-mentioned single-sided welding double-sided forming backing flux, including the following steps:

[0047] (1) Prepare raw materials according to proportion. Mix the mineral raw materials except phenolic resin by shaking the powder in a rotating drum for 30 minutes. Add 18% water glass to the mineral raw materials by weight, stir wet for 12 minutes, pass through a vibrating screen and 16 mesh screen, dry at 185℃ for 2 hours, pass through a 16 mesh screen again, and finally sinter at 870℃ to make the basic flux. The water glass includes lithium water glass and sodium water glass with a mass ratio of 2:3.

[0048] (2) The base flux is placed in a rotary heating shaker and heated to 200°C. Phenolic resin is blown into the rotary heating shaker in the form of powder spraying at a speed of 200 g / s until a resin film is evenly distributed on the surface of the base flux. Then, heating is stopped, and the flux is cooled to below 50°C before being taken out of the furnace. It is then passed through a 16-mesh sieve and then through a 60-mesh sieve to remove fine powder, thus obtaining a single-sided welding double-sided forming pad flux. The alkalinity of this pad flux is 0.96.

[0049] Example 5:

[0050] This embodiment provides a single-sided welding double-sided forming backing flux, which, by mass percentage, includes the following raw material components: fused magnesia: 21%; quartz: 26%; zircon sand: 10%; fluorite: 12%; ferrosilicon: 4%; ferrotitanium: 5%; ferroboron: 2%; α-alumina: 3%; manganese oxide: 4%; strontium oxide: 1.2%; yttrium oxide: 0.8%; iron powder: 5%; thermosetting phenolic resin + thermoplastic phenolic resin: 6%, with the mass ratio of the two controlled at 1:2.

[0051] This embodiment also provides a preparation process for the above-mentioned single-sided welding double-sided forming backing flux, including the following steps:

[0052] (1) Prepare raw materials according to proportion. Mix the mineral raw materials except phenolic resin by shaking the powder in a rotating drum for 30 minutes. Add 16% water glass to the mineral raw materials by weight, stir wet for 10 minutes, pass through a vibrating screen and sieve through a 16-mesh sieve, dry at 200℃ for 2 hours, pass through a 16-mesh sieve again, and finally sinter at 885℃ to make the basic flux. The water glass includes lithium water glass and sodium water glass with a mass ratio of 4:3.

[0053] (2) The base flux is placed in a rotary heating shaker and heated to 200°C. Phenolic resin is blown into the rotary heating shaker in the form of powder spraying at a speed of 200 g / s until a resin film is evenly distributed on the surface of the base flux. Then, heating is stopped, and the flux is cooled to below 50°C before being taken out of the furnace. It is then passed through a 16-mesh sieve and then through a 60-mesh sieve to remove fine powder, thus obtaining a single-sided welding double-sided forming pad flux. The alkalinity of this pad flux is 0.89.

[0054] Example 6:

[0055] This embodiment conducts a fusion metal test on the backing flux products prepared in Examples 1-5. The test uses the three-wire FCB method for welding, wherein the three wires are iron anchor TMS-50M (4.8mm) and TMS-50L (6.4mm). The welding parameters are shown in Table 1, and the mechanical properties obtained are shown in Table 2.

[0056] Table 1 Butt welding parameters for 35mm thick plates

[0057]

[0058] Table 2 Mechanical properties of butt joints with a thickness of 35mm

[0059]

[0060] The above examples are merely illustrative of the present invention and do not constitute a limitation on the scope of protection of the present invention. All designs that are the same as or similar to the present invention are within the scope of protection of the present invention.

Claims

1. A single-sided welding double-sided forming pad flux characterized by, By weight percentage, it includes the following raw material components: Fused magnesia: 20-40%; Quartz: 25-35%; Zircon sand: 8-18%; Fluorite: 5-15%; Ferrosilicon: 3-10%; Iridium ferrophosphate: 3-10%; Ferroboron: 1-2%; Alpha alumina: 1-5%; Manganese oxide: 1-5%; Strontium oxide: 0.5-1.5%; Yttrium oxide: 0.5-1%; Iron powder: 3-10%; Phenolic resin: 2-10%; the phenolic resin includes thermosetting phenolic resin and thermoplastic phenolic resin; the mass ratio of the thermosetting phenolic resin and the thermoplastic phenolic resin is 1:1-1:3; the alkalinity of the backing flux is 0.8-1.

0.

2. The single-pass double-sided forming pad flux according to claim 1, wherein: The particle size of the backing flux is above 80 mesh.

3. The preparation process of the single-sided welding double-sided forming backing flux as described in any one of claims 1-2, characterized in that, Includes the following steps: (1) Prepare raw materials according to proportion, mix mineral raw materials except phenolic resin, add water glass to mineral raw materials, wet stir and then sieve, dry and then sieve again, and sinter to make basic flux. (2) The base flux is heated in a rotary heating cylinder. Phenolic resin is blown into the rotary heating cylinder in the form of powder spraying until a resin film is evenly distributed on the surface of the base flux. Then, heating is stopped, the flux is cooled and sieved to obtain a single-sided welding double-sided forming pad flux.

4. The preparation process of the single-sided welding double-sided forming backing flux as described in claim 3, characterized in that: In step (1), the water glass includes lithium water glass and sodium water glass in a mass ratio of 1:3 to 3:4; the amount of water glass added is 12-20% based on the mass of the mineral raw materials.

5. The preparation process of the single-sided welding double-sided forming backing flux as described in claim 3, characterized in that: In step (1), the basic flux is prepared by drying at 150-200℃ for 2 hours, sieving, and sintering at 850-900℃.

6. The preparation process of the single-sided welding double-sided forming backing flux as described in claim 3, characterized in that: In step (2), the blowing speed of the phenolic resin is 180-250 g / s.

7. The application of the single-sided welding double-sided forming backing flux as described in any one of claims 1-2 in single-wire, double-wire, or triple-wire single-sided welding double-sided forming processes.

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