A non-copper plated electrolytic coated welding wire and a method of making the same
By coating the welding wire substrate with an electrolytic coating, the problems of wear on the contact tip and welding spatter in copper-free welding wires have been solved, thereby improving the stability and safety of the welding wire and promoting the widespread application of copper-free welding wires.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- WUHAN TEMO WELDING CONSUMABLES CO LTD
- Filing Date
- 2024-01-25
- Publication Date
- 2026-07-21
AI Technical Summary
Existing copper-free welding wires suffer from severe wear of the conductive tip during use, resulting in significant welding spatter and health hazards, thus limiting their widespread application.
The copper-free electrolytically coated welding wire consists of a welding wire substrate and an electrolytic coating applied to its surface. The electrolytic coating is composed of citric acid, inorganic alkali, polytetrafluoroethylene, nano-titanium dioxide, acrylic copolymer, and sodium octyl sulfate. It is formed through an electrolytic coating process and a die-reducing oiling process, which improves the stability and rust prevention performance of the welding wire.
It significantly reduces the wear rate of the contact tip, reduces welding spatter, improves wire feeding performance, ensures that the welding wire does not rust within 50 days, and enhances welding stability and health and safety.
Smart Images
Figure BDA0004681506110000061 
Figure BDA0004681506110000071
Abstract
Description
Technical Field
[0001] This invention belongs to the field of welding materials technology, specifically relating to a copper-free electrolytic coating welding wire and its preparation method. Background Technology
[0002] With the rapid development and promotion of welding automation, copper-free solid welding wire, as a new generation of gas-shielded solid welding wire, has been widely used in industries such as shipbuilding, marine engineering, rail transportation, engineering and mining machinery, and bridges. Currently, most gas-shielded solid welding wires used domestically and internationally are copper-plated. Copper-plated welding wires have many drawbacks in their production, storage, transportation, and use. The copper plating process during production severely pollutes the environment, and the copper plating solution is extremely harmful to personnel. Moreover, when welding copper-plated welding wires, their process performance and weld formation are poor, and they are prone to clogging the contact tip during welding. In addition, under the high temperature of the electric arc, the copper plating layer on the surface of the welding wire evaporates, resulting in welding fumes containing toxic copper ions, which seriously damages the physical and mental health of welding operators.
[0003] To avoid the problems associated with copper-plated welding wire, welding researchers have developed copper-free welding wire. Compared with traditional copper-plated welding wire, it has advantages such as strong rust resistance, stable arc, less spatter, good wire feeding, and less toxic and polluting fumes. However, the biggest problem with existing copper-free welding wire is the severe wear of the contact tip during use, which makes its promotion very difficult. Some related companies are actively working on this aspect. Summary of the Invention
[0004] The purpose of this invention is to provide a copper-free electrolytic coating welding wire, which can at least solve some of the defects existing in the prior art.
[0005] To achieve the above objectives, the present invention adopts the following technical solution:
[0006] A copper-free electrolytically coated welding wire includes a welding wire substrate and an electrolytic coating applied to the surface of the welding wire substrate. The electrolytic coating comprises the following components by mass percentage: 30-41% citric acid, 43-50% inorganic alkali, 5-12% polytetrafluoroethylene, 0.5-1.3% nano-titanium dioxide, 7-13% acrylic copolymer, and 1-3% sodium octyl sulfate.
[0007] Furthermore, the welding wire base is a Φ5.5mm wire rod, which is a finished welding wire formed by diameter reduction drawing through 10 to 16 sets of dies, and the diameter of the finished welding wire is Φ1.0 to Φ1.6mm.
[0008] Furthermore, the inorganic base is potassium carbonate.
[0009] Furthermore, the electrolytic coating comprises the following components by mass percentage: citric acid 31-40%, inorganic alkali 43-48%, polytetrafluoroethylene 6-11%, nano titanium dioxide 0.8-1%, acrylic copolymer 8-10%, and sodium octyl sulfate 1.2-2%.
[0010] Furthermore, the surface of the electrolytic coating is coated with an oil layer.
[0011] In addition, the present invention also provides a method for preparing a copper-free electrolytically coated welding wire, comprising the following steps:
[0012] S1. Dissolve each component of the electrolytic coating in water according to the designed dosage, stir evenly to form an electrolytic coating solution;
[0013] S2. The welding wire substrate is coated with an electrolytic coating on its surface through an electrolytic coating process in an electrolytic coating solution.
[0014] Furthermore, the mass percentage of the electrolytic coating in the electrolytic coating solution is 3-7%.
[0015] Furthermore, the pH value of the electrolytic coating solution is 8-11, and the water temperature at which the electrolytic coating is dissolved is 50-80℃.
[0016] Furthermore, the electrolytic coating process conditions are: electrolytic current 5-15A, electrolytic voltage 10-20V, and electrolytic coating time of the welding wire substrate in the electrolytic coating solution 1-3s.
[0017] Furthermore, the preparation method of the copper-free electrolytic coating welding wire also includes step S3: after coating the surface of the welding wire substrate with an electrolytic coating, an oil layer is coated on the surface of the welding wire substrate by means of a die-reduction oil coating method, and the reduction amount is 0.01 to 0.03 mm.
[0018] Compared with the prior art, the beneficial effects of the present invention are as follows:
[0019] (1) The copper-free electrolytic coating welding wire provided by the present invention forms an electrolytic coating on the surface of the welding wire substrate. The electrolytic coating material contains inorganic alkali components, which can make the electrolytic coating obtain excellent stable arc effect; it contains nano titanium dioxide components, which can make the copper-free welding wire obtain excellent spatter reduction performance when used; it contains acrylic copolymer, which makes the electrolytic coating material firmly and uniformly adhered to the surface of the welding wire.
[0020] (2) The copper-free electrolytic coating welding wire provided by the present invention significantly reduces the wear of the contact tip of the existing copper-free welding wire, reduces welding spatter, and improves the wire feeding performance during the use of the welding wire. It can achieve a welding spatter rate of ≤1.0%, a contact tip wear rate of ≤0.2mg / kg, and no rust within 50 days under the conditions of 20℃ temperature and 60% relative humidity. Detailed Implementation
[0021] The technical solutions in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.
[0022] This invention provides a copper-free electrolytically coated welding wire, comprising a welding wire substrate and an electrolytic coating coated on the surface of the welding wire substrate. The electrolytic coating comprises the following components by mass percentage: citric acid 30-41%, inorganic alkali 43-50%, polytetrafluoroethylene 5-12%, nano titanium dioxide 0.5-1.3%, acrylic copolymer 7-13%, and sodium octyl sulfate 1-3%.
[0023] The welding wire base is made of Φ5.5mm wire rod, which is drawn into a finished welding wire through 10-16 sets of dies to reduce its diameter, and the diameter of the finished welding wire is Φ1.0-Φ1.6mm. In the components of the electrolytic coating, the inorganic alkali can be, but is not limited to, potassium carbonate, and the acrylic copolymer is a polymer compound formed by the polymerization of acrylic monomers; all components of the electrolytic coating can be purchased directly from the market.
[0024] Optionally, after coating the surface of the welding wire substrate with an electrolytic coating, an oil layer can be applied to the surface of the electrolytic coating to improve the rust prevention performance of the welding wire.
[0025] The performance of the copper-free electrolytic coated welding wire of the present invention will be further explained below through specific embodiments.
[0026] Example 1:
[0027] This embodiment provides a copper-free electrolytically coated welding wire, comprising a welding wire substrate and an electrolytic coating applied to the surface of the welding wire substrate. The electrolytic coating comprises the following components by mass percentage: 36% citric acid, 48% inorganic alkali, 6% polytetrafluoroethylene, 0.8% nano-titanium dioxide, 8% acrylic copolymer, and 1.2% sodium octyl sulfate. The inorganic alkali is potassium carbonate.
[0028] The preparation process of this copper-free electrolytically coated welding wire is as follows:
[0029] First, weigh out each component of the electrolytic coating according to the above design dosage, dissolve it in water, stir evenly to form an electrolytic coating solution; the mass percentage of the electrolytic coating in the electrolytic coating solution is 7%, the pH value of the electrolytic coating solution is 11, and the temperature of the electrolytic coating solution is 80℃.
[0030] Then, the Φ5.5mm wire rod is drawn into a finished welding wire with a diameter of Φ1.5mm through 10 to 16 sets of dies. The finished welding wire is then placed in the electrolytic coating solution prepared above, and an electrolytic coating layer is formed on the surface of the welding wire through an electrolytic coating process. The electrolytic coating process conditions are: electrolytic current 5 to 15A, electrolytic voltage 10 to 20V, and electrolytic coating time of 2s for the welding wire substrate in the electrolytic coating solution.
[0031] Finally, after coating the surface of the welding wire with an electrolytic coating, an oil layer is applied to the surface of the welding wire by means of a die-reduction oiling method, with a reduction amount of 0.01 to 0.03 mm.
[0032] Example 2:
[0033] This embodiment provides a copper-free electrolytically coated welding wire, comprising a welding wire substrate and an electrolytic coating applied to the surface of the welding wire substrate. The electrolytic coating comprises the following components by mass percentage: 40% citric acid, 43% inorganic alkali, 8% polytetrafluoroethylene, 0.5% nano-titanium dioxide, 7% acrylic copolymer, and 1.5% sodium octyl sulfate. The inorganic alkali is potassium carbonate.
[0034] The preparation process of this copper-free electrolytically coated welding wire is as follows:
[0035] First, weigh out each component of the electrolytic coating according to the above design dosage, dissolve it in water, stir evenly to form an electrolytic coating solution; the mass percentage of the electrolytic coating in the electrolytic coating solution is 5%, the pH value of the electrolytic coating solution is 8, and the temperature of the electrolytic coating solution is 50℃.
[0036] Then, the Φ5.5mm wire rod is drawn into a finished welding wire with a diameter of Φ1.6mm through 10 to 16 sets of dies. The finished welding wire is then placed in the electrolytic coating solution prepared above, and an electrolytic coating layer is formed on the surface of the welding wire through an electrolytic coating process. The electrolytic coating process conditions are: electrolytic current 5 to 15A, electrolytic voltage 10 to 20V, and electrolytic coating time of 3s for the welding wire substrate in the electrolytic coating solution.
[0037] Finally, after coating the surface of the welding wire with an electrolytic coating, an oil layer is applied to the surface of the welding wire by means of a die-reduction oiling method, with a reduction amount of 0.01 to 0.03 mm.
[0038] Example 3:
[0039] This embodiment provides a copper-free electrolytically coated welding wire, comprising a welding wire substrate and an electrolytic coating coated on the surface of the welding wire substrate. The electrolytic coating comprises the following components by mass percentage: 31% citric acid, 45% inorganic alkali, 11% polytetrafluoroethylene, 1% nano-titanium dioxide, 10% acrylic copolymer, and 2% sodium octyl sulfate. The inorganic alkali is potassium carbonate.
[0040] The preparation process of this copper-free electrolytically coated welding wire is as follows:
[0041] First, weigh out each component of the electrolytic coating according to the above design dosage, dissolve it in water, stir evenly to form an electrolytic coating solution; the mass percentage of the electrolytic coating in the electrolytic coating solution is 5%, the pH value of the electrolytic coating solution is 9, and the temperature of the electrolytic coating solution is 60℃.
[0042] Then, the Φ5.5mm wire rod is drawn into a finished welding wire with a diameter of Φ1.0mm through 10 to 16 sets of dies for diameter reduction. The finished welding wire is then placed in the electrolytic coating solution prepared above, and an electrolytic coating layer is formed on the surface of the welding wire through an electrolytic coating process. The electrolytic coating process conditions are: electrolytic current 5 to 15A, electrolytic voltage 10 to 20V, and electrolytic coating time of 1s for the welding wire substrate in the electrolytic coating solution.
[0043] Finally, after coating the surface of the welding wire with an electrolytic coating, an oil layer is applied to the surface of the welding wire by means of a die-reduction oiling method, with a reduction amount of 0.01 to 0.03 mm.
[0044] Comparative Example 1:
[0045] This comparative example provides a copper-free electrolytic coating welding wire, whose structure and preparation method are roughly the same as those in Example 1. The difference is that the electrolytic coating of this comparative example does not contain inorganic alkali.
[0046] Comparative Example 2:
[0047] This comparative example provides a copper-free electrolytic coating welding wire, whose structure and preparation method are roughly the same as those in Example 1. The difference is that the electrolytic coating of this comparative example does not contain nano-titanium dioxide.
[0048] Comparative Example 3:
[0049] This comparative example provides a copper-free electrolytic coating welding wire, whose structure and preparation method are roughly the same as those in Example 1. The difference is that the electrolytic coating of this comparative example does not contain acrylic copolymer.
[0050] Comparative Example 4:
[0051] This comparative example provides a copper-plated welding wire whose base material is the same as that of this invention. It is made of Φ5.5mm wire rod, which is drawn by reducing the diameter through 10 to 16 sets of dies, and the surface of the welding wire base material is coated with a traditional copper plating coating.
[0052] The copper-free electrolytically coated welding wires prepared in Examples 1-3 and Comparative Examples 1-3, as well as the copper-plated welding wire in Comparative Example 4, were subjected to wire feeding performance tests. The test results are shown in Table 1. The testing methods and specific procedures for wire feeding performance (welding spatter rate, contact tip wear rate, and rust prevention performance) are existing technologies and will not be described in detail here.
[0053] Table 1:
[0054]
[0055]
[0056] As shown in Table 1, the comprehensive performance of the copper-free electrolytic coated welding wire provided by this invention is as follows: welding spatter rate ≤1.0%, contact tip wear rate ≤0.2mg / kg, and no rust within 50 days under conditions of 20℃ and 60% relative humidity. Furthermore, the above data shows that compared with traditional copper-plated welding wire, the copper-free electrolytic coated welding wire of this invention exhibits less spatter, less contact tip wear, and better rust prevention. Moreover, the electrolytic coating component of this invention contains inorganic alkali components, which enable the electrolytic coating to achieve excellent arc stabilization; it contains nano-titanium dioxide components, which enable the copper-free welding wire to achieve excellent spatter reduction performance during use; and it contains acrylic copolymer, which enables the electrolytic coating material to adhere firmly and uniformly to the surface of the welding wire.
[0057] 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 copper-free electrolytic coating welding wire, characterized in that, It includes a welding wire substrate and an electrolytic coating applied to the surface of the welding wire substrate, the electrolytic coating comprising the following components by mass percentage: 30-41% citric acid, 43-50% inorganic alkali, 5-12% polytetrafluoroethylene, 0.5-1.3% nano-titanium dioxide, 7-13% acrylic copolymer, and 1-3% sodium octyl sulfate.
2. The copper-free electrolytic coating welding wire as described in claim 1, characterized in that, The welding wire base is a Φ5.5mm wire rod, which is a finished welding wire formed by reducing the diameter and drawing through 10 to 16 sets of dies, and the diameter of the finished welding wire is Φ1.0 to Φ1.6mm.
3. The copper-free electrolytic coating welding wire as described in claim 1, characterized in that, The inorganic base is potassium carbonate.
4. The copper-free electrolytic coating welding wire as described in claim 1, characterized in that, The electrolytic coating comprises the following components by mass percentage: citric acid 31-40%, inorganic alkali 43-48%, polytetrafluoroethylene 6-11%, nano titanium dioxide 0.8-1%, acrylic copolymer 8-10%, and sodium octyl sulfate 1.2-2%.
5. The copper-free electrolytic coating welding wire as described in claim 1, characterized in that, The surface of the electrolytic coating is coated with an oil layer.
6. The method for preparing copper-free electrolytically coated welding wire according to any one of claims 1 to 5, characterized in that, Includes the following steps: S1. Dissolve each component of the electrolytic coating in water according to the designed dosage, stir evenly to form an electrolytic coating solution; S2. The welding wire substrate is coated with an electrolytic coating on its surface through an electrolytic coating process in an electrolytic coating solution.
7. The method for preparing copper-free electrolytically coated welding wire as described in claim 6, characterized in that, The mass percentage of the electrolytic coating in the electrolytic coating solution is 3-7%.
8. The method for preparing copper-free electrolytically coated welding wire as described in claim 6, characterized in that, The pH value of the electrolytic coating solution is 8-11, and the water temperature at which the electrolytic coating is dissolved is 50-80℃.
9. The method for preparing copper-free electrolytically coated welding wire as described in claim 6, characterized in that, The electrolytic coating process conditions are: electrolytic current 5-15A, electrolytic voltage 10-20V, and electrolytic coating time of the welding wire substrate in the electrolytic coating solution 1-3s.
10. The method for preparing copper-free electrolytically coated welding wire as described in claim 6, characterized in that, It also includes step S3, after the electrolytic coating is applied to the surface of the welding wire substrate, an oil layer is applied to the surface of the welding wire substrate by means of a die-reduction oiling method, and the reduction amount is 0.01 to 0.03 mm.