A vacuum seamless flux-cored welding wire and its filling process

Abstract

The present invention provides a vacuum-evacuated seamless flux-cored welding wire and a filling process thereof. The vacuum-evacuated seamless flux-cored welding wire comprises a seamless welding wire sheath and a welding wire core. The seamless welding wire sheath is a hollow structure with open ends and is integrally formed. The welding wire core is filled into the hollow portion of the seamless welding wire sheath by vacuum evacuation. The welding wire core comprises the following components, measured in parts by weight: 30-35 parts of rutile, 12-16 parts of ferrosilicon powder, 4-6 parts of nickel powder, 5-8 parts of ferromanganese alloy, 2-4 parts of chromium powder, 3-6 parts of dolomite, 2-3 parts of fluorite, 0.5-1 part of niobium powder, and 1-2 parts of titanium-boron alloy. The seamless welding wire sheath of the present invention can effectively block external air and moisture, making the welding wire core resistant to moisture, ensuring reliable use and long-term storage of the flux-cored welding wire in various environments, effectively improving the consistency and reliability of welding quality, and reducing production costs and maintenance difficulties.

Description

Technical Field

[0001] The invention relates to the technical field of welding materials, in particular to a vacuum seamless flux-cored welding wire and a filling process thereof. Background Art

[0002] With the continuous development of modern industry, the requirements for welding quality and efficiency are getting higher and higher. In many fields, such as aerospace, automobile manufacturing, shipbuilding, building structures, etc., welded structures need to have higher strength, better toughness and corrosion resistance to meet the requirements of use in complex working conditions and harsh environments. Traditional flux-cored welding wire is usually made by wrapping powder with steel strip, that is, the prepared steel strip is first passed through a forming device to form a U-shaped groove, and then a special filling device is used to fill the prepared powder into the U-shaped steel strip. After the powder is filled, another set of rollers is used to close the opening of the U-shaped steel strip, so that the powder is completely wrapped inside the steel strip. However, this production method still has the following defects:

[0003] First, because the U-shaped steel strip is closed by another set of rollers after the powder is filled, the bond between the steel strip and the powder is not completely tight, with some gaps and pores existing. This makes the welding wire susceptible to environmental influences such as moisture and oxygen during storage and transportation, causing changes in the chemical composition of the flux core, thereby affecting weld quality. Second, the inability to ensure uniform powder filling during the powder filling process can lead to arc instability and poor weld formation. Furthermore, the production process of traditional flux-cored welding wire is relatively complex and costly, and the welding process can generate a large amount of welding fume and spatter, which has certain impacts on the environment and the health of operators. Summary of the Invention

[0004] The present invention aims to provide a vacuum seamless flux-cored welding wire and a filling process thereof, which effectively solves the technical problems of traditional welding wire flux core being easily affected by moisture and having uneven composition.

[0005] In order to solve the above technical problems, the present invention provides a first aspect, which provides a vacuum seamless flux-cored welding wire, including a seamless welding wire sheath and a welding wire core, the seamless welding wire sheath is a hollow structure with openings at both ends and formed as one piece; the welding wire core is filled in the hollow part of the seamless welding wire sheath by vacuuming; the welding wire core includes the following components and the weight proportions of each component are: 30~35 parts of rutile, 12~16 parts of ferrosilicon powder, 4~6 parts of nickel powder, 5~8 parts of manganese iron alloy, 2~4 parts of chromium powder, 3~6 parts of dolomite, 2~3 parts of fluorite, 0.5~1 part of niobium powder, and 1~2 parts of titanium boron alloy.

[0006] Preferably, the particle size of the welding wire core is 60-200 mesh.

[0007] Preferably, the outer sheath of the seamless welding wire is made of any one or more materials selected from copper, silver, and nickel.

[0008] In a second aspect, the present invention further provides a filling process for the vacuum seamless flux-cored welding wire as described in the first aspect, comprising the following steps:

[0009] Mixing the raw materials of various components of the welding wire core with the liquid additive to obtain a mud-like core blank;

[0010] The mud-like core blank is heated and melted to obtain a molten core;

[0011] Take the pre-prepared seamless welding wire sheath, and connect the vacuum equipment to one end of the seamless welding wire sheath for vacuum treatment;

[0012] Pour the molten flux core into the hollow part of the seamless welding wire outer skin while keeping the vacuum equipment running until the molten flux core fills the hollow part of the seamless welding wire outer skin to obtain a welding wire blank;

[0013] The welding wire blank is placed in a vacuum environment for cooling treatment, so that the molten core is solidified inside the hollow welding wire to obtain a vacuum seamless flux-cored welding wire.

[0014] Preferably, the raw materials of the various components of the welding wire core are mixed with the liquid additive to obtain a mud-like core blank, which specifically includes the following sub-steps:

[0015] The raw materials of the welding wire core components are mixed with an appropriate amount of water in the following proportions: 30-35 parts of rutile, 12-16 parts of ferrosilicon powder, 4-6 parts of nickel powder, 5-8 parts of ferromanganese alloy, 2-4 parts of chromium powder, 3-6 parts of dolomite, 2-3 parts of fluorite, 0.5-1 part of niobium powder, and 1-2 parts of titanium-boron alloy. The mixture is placed in a vacuum stirring device and stirred until it becomes a mud-like material to obtain a bubble-free mud-like core blank.

[0016] Preferably, the raw materials of the various components of the welding wire core are mixed with the liquid additive to obtain a mud-like core blank, which specifically includes the following sub-steps:

[0017] Place the weighed raw materials of each component of the welding wire core in a vacuum stirring device and stir at a stirring speed of 50-100 rpm for 3-5 minutes to obtain a preliminarily uniform mixed raw material;

[0018] Take 20% to 30% of the total mass of the mixed raw materials and slowly add water to the mixed raw materials. Stir while adding water. Continue stirring for 2 to 3 minutes after the water is added, and stir at a stirring speed of 150 to 200 rpm for 10 to 15 minutes to obtain a uniformly mixed and bubble-free muddy core blank.

[0019] Preferably, the pre-prepared seamless welding wire sheath specifically includes the following sub-steps:

[0020] One or more materials of copper, silver, and nickel prepared in advance are melted and cast to obtain a rod-shaped blank;

[0021] The rod-shaped blank is placed in a heating furnace for preheating, and the preheated rod-shaped blank is perforated to obtain a first welding wire sheath blank having a hollow structure;

[0022] The first welding wire sheath blank is subjected to a first drawing and reducing operation to obtain a second welding wire sheath blank;

[0023] annealing the second welding wire sheath stock to obtain a third welding wire sheath stock;

[0024] The third welding wire sheath blank is subjected to a second drawing and diameter reduction to obtain a fourth welding wire sheath blank;

[0025] The fourth welding wire sheath blank is cleaned and polished to obtain a seamless welding wire sheath.

[0026] Preferably, after one or more materials of copper, silver and nickel prepared in advance are melted and cast, they are cooled and turned to obtain a rod-shaped outer skin blank without oxide scale.

[0027] Preferably, in the step of placing the rod-shaped outer skin blank in a heating furnace for preheating, the temperature is raised to 500-700° C. at a heating rate of 5-10° C. / min and kept warm for 15-30 minutes.

[0028] Preferably, the second welding wire outer sheath blank is subjected to annealing treatment, which specifically includes the following sub-steps:

[0029] After cleaning the second welding wire sheath blank, the temperature in the annealing furnace is increased to 400-700°C at a heating rate of 5-10°C / min, kept at this temperature for 1-3 hours, and then cooled to room temperature in the furnace to obtain the third welding wire sheath blank.

[0030] The technical solution provided by the present invention has the following advantages compared with the prior art:

[0031] The vacuum-evacuated seamless flux-cored welding wire provided by the present invention features an integrally formed hollow structure, and the flux core is vacuum-evacuated within the seamless wire sheath. The seamless wire sheath effectively blocks external air and moisture, making the flux core impervious to moisture. This ensures reliable use and long-term storage of the vacuum-evacuated seamless flux-cored welding wire in various environments, effectively improving the consistency and reliability of welding quality, and reducing production costs and maintenance difficulties. This effectively addresses technical issues such as the vulnerability of conventional flux cores to moisture and uneven composition, significantly improving the quality and stability of the weld. Furthermore, by using the aforementioned raw materials in the flux core material, the vacuum-evacuated seamless flux-cored welding wire can exert excellent metallurgical effects during the welding process. For example, rutile contributes to arc stabilization and slag formation, ferrosilicon powder provides deoxidation, and nickel powder, ferromanganese alloy, and chromium powder enhance the strength, toughness, and corrosion resistance of the weld. This results in a stable arc, minimal spatter, and easy slag removal during welding, significantly improving welding efficiency and quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] In order to more clearly illustrate the technical solutions of the prior art and the embodiments of the present application, the following briefly introduces the drawings required for use in the description of the prior art and the embodiments of the present application. Obviously, the drawings described below are only some embodiments recorded in this application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without any creative work.

[0033] Figure 1 The figure is a flow chart of a filling process of a vacuum seamless flux-cored welding wire according to an embodiment of the present invention.

[0034] Figure 2 This is a flow chart for preparing the seamless welding wire sheath in an embodiment of the present invention. DETAILED DESCRIPTION

[0035] In order to better understand the purpose, structure and function of the present invention, the following is a further detailed description of a vacuum seamless flux-cored welding wire and its filling process provided by the present invention in conjunction with the accompanying drawings, so that those skilled in the art can better understand the present invention and implement it, but the examples given are not intended to limit the present invention.

[0036] The present invention provides a vacuum-evacuated seamless flux-cored welding wire comprising a seamless wire sheath and a flux core. The seamless wire sheath is an integrally formed hollow structure with open ends. The flux core is filled into the hollow portion of the seamless wire sheath by vacuum evacuation. The flux core comprises the following components, with the weight percentages of each component being: 30-35 parts rutile, 12-16 parts ferrosilicon powder, 4-6 parts nickel powder, 5-8 parts ferromanganese alloy, 2-4 parts chromium powder, 3-6 parts dolomite, 2-3 parts fluorite, 0.5-1 part niobium powder, and 1-2 parts titanium-boron alloy. The flux core has a mesh size of 60-200 mesh. The seamless wire sheath is made of any one or more of copper, silver, and nickel.

[0037] The functions of each component in the welding wire core are as follows:

[0038] Rutile: Builds slag to protect the weld, stabilize the arc, and reduce spatter. During the welding process, rutile forms slag that coats the weld surface, protecting the weld. The slag prevents harmful gases in the air, such as oxygen and nitrogen, from reacting with the molten metal, reducing oxidation and nitridation of the weld metal. It also improves weld formation and creates a smoother surface. If its content is too low, it may not fully cover the weld, allowing gas intrusion; if its content is too high, it may result in excessive slag, affecting welding performance and weld appearance. The rutile content in the welding wire core of the present invention is 30 to 35 parts by weight. For example, the rutile content in the welding wire core can be any value within the range of 30 to 35 parts by weight, such as 30 parts, 32.5 parts, or 35 parts. This ensures sufficient slag to effectively protect the weld while preventing excessive slag from affecting welding performance and appearance. Furthermore, the slag achieves a good balance between coverage and fluidity, improving weld quality.

[0039] Ferrosilicon powder: acts as a deoxidizer. During the welding process, ferrosilicon can react with oxygen in the weld, removing oxygen from the weld metal, thereby improving the quality of the weld. At the same time, silicon can dissolve in the weld metal, playing a role of solid solution strengthening and improving the strength of the weld metal. If its content is too little, the deoxidation effect is not obvious; if the content is too much, it may cause the silicon content in the weld metal to be too high, making the weld metal brittle. The weight proportion of ferrosilicon powder in the welding wire core of the present invention is 12 to 16 parts. For example, the weight proportion of ferrosilicon powder in the welding wire core can be any value within the range of 12 to 16 parts, such as 12 parts, 14 parts, or 16 parts. While effectively performing the deoxidation operation, it can provide an appropriate amount of silicon to strengthen the weld, ensure that the oxygen content in the weld metal is controlled at a low level, and will not make the weld brittle due to excessive silicon content, which helps to maintain good mechanical properties of the weld.

[0040] Nickel powder: used to improve the toughness and crack resistance of weld metal. Nickel can refine the grains of weld metal, improve the microstructure of weld metal, and better resist the generation and expansion of cracks when subjected to external forces. If its content is too little, the improvement effect on toughness and crack resistance will not be obvious; too much content may increase costs and may have an adverse effect on other properties. The weight proportion of nickel powder in the welding wire core of the present invention is 4 to 6 parts. For example, the weight proportion of nickel powder in the welding wire core can be any value within the range of 4 to 6 parts, such as 4 parts, 5 parts, or 6 parts. It can effectively play the role of refining grains and improving toughness, and can effectively improve the microstructure of weld metal, making it more crack-resistant when subjected to external forces, without increasing excessive costs or having an adverse effect on other properties due to excessive nickel content.

[0041] Ferromanganese alloy: Serves as a deoxidizer and alloying agent. As a deoxidizer, ferromanganese alloy reacts with oxygen in the weld, reducing the oxygen content in the weld metal. As an alloying agent, manganese improves the strength and toughness of the weld metal. Manganese forms a solid solution with iron, strengthening the weld metal matrix while also improving the weld metal's workability. If its content is too low, the deoxidation and strengthening effects are insufficient; if its content is too high, the manganese content in the weld metal may be too high, affecting other weld metal properties, such as corrosion resistance. The weight percentage of ferromanganese alloy in the welding wire core of the present invention is 5 to 8 parts. For example, the weight percentage of ferromanganese alloy in the welding wire core can be any value within the range of 5 to 8 parts, such as 5 parts, 6.5 parts, or 8 parts. This ensures a good deoxidation effect while more effectively improving the strength and toughness of the weld metal. Manganese can better utilize the matrix-strengthening effect of forming a solid solution with iron, while preventing the manganese content in the weld metal from being too high, which could affect other properties, such as corrosion resistance.

[0042] Chromium powder: used to improve the corrosion resistance of weld metal. Chromium can form a dense oxide film on the surface of weld metal, preventing external corrosive media from contacting the weld metal, thereby improving the corrosion resistance of the weld metal. At the same time, chromium can also improve the strength and hardness of the weld metal. If its content is too low, the corrosion resistance and strengthening effects are not obvious; too high a content may increase the brittleness of the weld metal. The weight proportion of chromium powder in the welding wire core of the present invention is 2 to 4 parts. For example, the weight proportion of chromium powder in the welding wire core can be any value within the range of 2 to 4 parts, such as 2 parts, 3 parts, or 4 parts. It can form an effective dense oxide film on the surface of the weld metal, improve the corrosion resistance of the weld metal, and moderately improve the strength and hardness of the weld metal. While ensuring corrosion resistance and strengthening effects, it can avoid the increase in weld metal brittleness due to excessive chromium content.

[0043] Dolomite: plays the role of slag formation and arc stabilization. Dolomite can improve the performance of the slag, making it easier for the slag to cover the weld surface, and can adjust the stability of the welding arc, making the welding process smoother. If its content is too little, the improvement effect on the slag performance and arc stability will be poor; too much content may affect other properties of the slag, such as fluidity. The weight proportion of dolomite in the welding wire core of the present invention is 3 to 6 parts. For example, the weight proportion of dolomite in the welding wire core can be any value within the range of 3 to 6 parts, such as 3 parts, 4.5 parts, 6 parts, etc. It can effectively play the dual role of slag formation and arc stabilization, can well improve the slag performance, make it easier to cover the weld surface, and can better adjust the stability of the welding arc, making the welding process smoother.

[0044] Fluorite: As a flux, it can reduce the melting point and viscosity of the slag. During the welding process, fluorite can make the slag flow more easily and cover the weld surface. It also helps to separate the weld metal from the slag, thereby improving the quality of the weld. If its content is too little, the fluxing effect is not obvious; too much content may cause the slag to be too thin, affecting the protective effect of the slag on the weld. The weight proportion of fluorite in the welding wire core of the present invention is 2 to 3 parts. For example, the weight proportion of fluorite in the welding wire core can be any value within the range of 2 to 3 parts, such as 2 parts, 2.5 parts, 3 parts, etc., which can effectively reduce the melting point and viscosity of the slag, so that it can play a good fluxing role, make the slag more flowable, and cover the weld. It also helps to separate the weld metal from the slag, thereby ensuring the quality of the weld.

[0045] Niobium powder: plays a role in refining grains. During the solidification process of the weld metal, niobium can prevent the growth of grains, making the grains of the weld metal finer, thereby improving the strength and toughness of the weld metal. If its content is too little, the effect on grain refinement is not obvious; too much content may cause the balance of other elements to be destroyed, affecting the performance of the weld metal. The weight proportion of niobium powder in the welding wire core of the present invention is 0.5 to 1 part. For example, the weight proportion of niobium powder in the welding wire core can be any value within the range of 0.5 to 1 part, such as 0.5 part, 0.75 part, 1 part, etc., which can effectively refine the grains of the weld metal, improve the strength and toughness of the weld metal, and better play the role of niobium in preventing grain growth without destroying the balance of other elements.

[0046] Titanium-boron alloy: acts as a grain refiner. Titanium and boron can act as heterogeneous nuclei during the solidification process of the weld metal, promoting grain refinement. Titanium can also react with harmful elements such as nitrogen in the weld, reducing their impact on weld quality. Boron can enhance the hardenability of the weld metal and improve its performance to a certain extent. If its content is too low, the grain refinement and weld purification effects will be inadequate; if its content is too high, the weld metal may contain excessively high levels of titanium and boron, adversely affecting other properties of the weld metal. The titanium-boron alloy in the welding wire core of the present invention contains 1 to 2 parts by weight. For example, the titanium-boron alloy in the welding wire core can contain any value within the range of 1 to 2 parts by weight. This effectively enhances grain refinement and removes harmful elements, effectively utilizing titanium and boron as heterogeneous nuclei to promote grain refinement and titanium's ability to react with harmful elements, while avoiding the adverse effects of excessive titanium and boron content in the weld metal on other properties.

[0047] The vacuum-evacuated seamless flux-cored welding wire provided by the present invention features an integrally formed hollow structure, and the flux core is vacuum-evacuated within the seamless wire sheath. The seamless wire sheath effectively blocks external air and moisture, making the flux core impervious to moisture. This ensures reliable use and long-term storage of the vacuum-evacuated seamless flux-cored welding wire in various environments, effectively improving the consistency and reliability of welding quality, and reducing production costs and maintenance difficulties. This effectively addresses technical issues such as the vulnerability of conventional flux cores to moisture and uneven composition, significantly improving the quality and stability of the weld. Furthermore, by using the aforementioned raw materials in the flux core material, the vacuum-evacuated seamless flux-cored welding wire can exert excellent metallurgical effects during the welding process. For example, rutile contributes to arc stabilization and slag formation, ferrosilicon powder provides deoxidation, and nickel powder, ferromanganese alloy, and chromium powder enhance the strength, toughness, and corrosion resistance of the weld. This results in a stable arc, minimal spatter, and easy slag removal during welding, significantly improving welding efficiency and quality.

[0048] See also Figure 1 As shown, the present invention provides a filling process for vacuum seamless flux-cored welding wire, comprising the following steps:

[0049] Step S1: Mix the raw materials of the welding wire core components with the liquid additive to obtain a slurry core blank. This step specifically includes the following sub-steps:

[0050] The raw materials for the welding wire core are mixed with an appropriate amount of water in the following proportions: 30-35 parts rutile, 12-16 parts ferrosilicon powder, 4-6 parts nickel powder, 5-8 parts ferromanganese alloy, 2-4 parts chromium powder, 3-6 parts dolomite, 2-3 parts fluorite, 0.5-1 part niobium powder, and 1-2 parts titanium-boron alloy. The mixture is then stirred in a vacuum stirring device until it forms a slurry, yielding a bubble-free slurry core stock. Furthermore, the following sub-steps are specifically included:

[0051] Place the weighed raw materials of each component of the welding wire core in a vacuum stirring device and stir at a stirring speed of 50-100 rpm for 3-5 minutes to obtain a preliminarily uniform mixed raw material;

[0052] Take 20% to 30% of the total mass of the mixed raw materials and slowly add water to the mixed raw materials. Stir while adding water. Continue stirring for 2 to 3 minutes after the water is added, and stir at a stirring speed of 150 to 200 rpm for 10 to 15 minutes to obtain a uniformly mixed and bubble-free muddy core blank.

[0053] Specifically, this step is to mix the raw materials of the various components of the welding wire core with an appropriate amount of water and stir them into a mud under a vacuum environment. This not only allows the various raw materials to fully contact and achieve uniform mixing, but also removes bubbles generated during the stirring process. When the mud-like core blank is heated and melted in step S2, it prevents bubbles from gathering or bursting, resulting in an uneven internal structure of the molten core.

[0054] Step S2: taking the mud-like core blank and heating and melting it to obtain a molten core.

[0055] Specifically, this step heats the muddy flux core blank to a molten state, which not only facilitates the subsequent pouring of the flux core into the hollow part of the seamless welding wire sheath, but also the flux core in a molten state can better fill the hollow part of the seamless welding wire sheath, and after solidification, it can be tightly combined with the seamless welding wire sheath to form an integral structure, providing a stable flux core for subsequent welding work.

[0056] Step S3: Take the pre-prepared seamless welding wire sheath, and connect a vacuum device to one end of the seamless welding wire sheath for vacuum treatment.

[0057] Specifically, this step can create an oxygen-free environment for the subsequent filling of the molten core by vacuuming, ensuring that the molten core fills the seamless welding wire sheath in a pure environment, thereby improving the quality of the vacuum seamless welding wire. Figure 2 As shown, the pre-prepared seamless welding wire sheath specifically includes the following sub-steps:

[0058] Step S31: Melt and cast one or more of the pre-prepared copper, silver, and nickel materials to obtain a rod-shaped blank.

[0059] Specifically, this step involves melting and casting one or more of the previously prepared copper, silver, and nickel materials to initially shape these metal raw materials into the desired rod shape, providing the foundation for the subsequent production of the seamless welding wire sheath. After the previously prepared copper, silver, and nickel materials are melted and cast, they are cooled and turned to produce a scale-free rod-shaped sheath blank.

[0060] Step S32: placing the rod-shaped blank in a heating furnace for preheating, and performing a perforation process on the preheated rod-shaped blank to obtain a first welding wire sheath blank with a hollow structure.

[0061] Specifically, this step involves preheating the rod-shaped stock in a furnace to a suitable temperature for piercing. At the appropriate temperature, the metal exhibits improved ductility, which reduces deformation resistance during piercing, reduces energy consumption during processing, and reduces stress concentration within the material. The piercing process creates a hollow structure within the rod-shaped stock, resulting in a first welding wire sheath stock with a hollow structure. This provides a foundation for subsequent filling with wire cores, allowing the seamless wire sheath to accommodate the cores.

[0062] Step S33: performing a first drawing and reducing of the first welding wire sheath blank to obtain a second welding wire sheath blank.

[0063] Specifically, this step involves performing a first drawing and reducing process on the first welding wire sheath stock to refine its dimensions. The drawing process applies tension to the first welding wire sheath stock through the die, reducing its diameter. This improves the dimensional accuracy of the first welding wire sheath, making its diameter more uniform. It also improves its surface quality and enhances its mechanical properties, such as its strength and hardness, providing a better performance foundation for subsequent processing and use.

[0064] Step S34: annealing the second welding wire sheath blank to obtain a third welding wire sheath blank.

[0065] Specifically, this step is to eliminate the internal stress generated during the first drawing and reducing process by annealing the second welding wire sheath blank. During the drawing process, the first welding wire sheath blank will undergo work hardening due to external force, and a large amount of stress will accumulate inside. These stresses will make the material brittle and reduce its toughness and ductility. Through annealing, the crystal structure inside the material is restored and adjusted, the internal stress is eliminated, and the toughness and ductility of the second welding wire sheath blank are restored to facilitate subsequent processing steps. Among them, in the step of taking the rod-shaped sheath blank and placing it in a heating furnace for preheating, the temperature is raised to 500~700℃ at a heating rate of 5~10℃ / min, and kept warm for 15~30min.

[0066] Step S35: The third welding wire sheath blank is subjected to a second drawing and diameter reduction to obtain a fourth welding wire sheath blank.

[0067] Specifically, this step further refines the dimensions of the third welding wire sheath stock material by subjecting it to a second drawing and reducing process, thereby improving its dimensional accuracy and surface quality. The resulting third welding wire sheath stock material, after annealing, exhibits improved processability. The second drawing process allows the third welding wire sheath stock material to be sized closer to the desired dimensions of the final seamless welding wire sheath, further enhancing the mechanical properties of the final seamless welding wire sheath.

[0068] Step S36: Clean and polish the fourth welding wire sheath blank to obtain a seamless welding wire sheath.

[0069] Specifically, this step is to remove impurities, oil stains, and oxide layers attached to the surface of the fourth welding wire sheath stock during processing by cleaning and polishing the fourth welding wire sheath stock. Cleaning can use chemical solvents or physical flushing methods to ensure the cleanliness of the sheath surface. Polishing is used to make the surface of the fourth welding wire sheath stock smoother, improve its surface quality, and reduce surface roughness, so that the resulting seamless welding wire sheath is more beautiful in appearance, and can better perform its functions during subsequent combination with the welding wire core and welding process, for example, it can reduce friction between the welding wire core and the seamless welding wire sheath, making the core filling smoother, and also can reduce problems such as spatter caused by surface roughness during welding.

[0070] Step S4: pouring the molten flux into the hollow portion of the seamless welding wire sheath while keeping the vacuum equipment running until the molten flux fills the hollow portion of the seamless welding wire sheath to obtain a welding wire blank.

[0071] Specifically, this step involves pouring the molten flux into the hollow portion of the seamless wire sheath and maintaining the vacuum equipment in operation, in order to ensure that the flux fully fills the wire sheath in an oxygen-free environment. Under vacuum, the molten flux can flow smoothly into the hollow portion, preventing air from entering. At the same time, the continuous vacuum environment ensures that the molten flux is not oxidized during the filling process and can evenly fill the entire hollow portion, making the molten flux more evenly distributed within the seamless wire sheath. This, in turn, creates a tighter bond between the molten flux and the seamless wire sheath, providing a good foundation for subsequent welding work and ensuring the stability of the weld quality.

[0072] Step S5: placing the welding wire blank in a vacuum environment for cooling treatment, so that the molten flux core solidifies inside the hollow welding wire, thereby obtaining a vacuumized seamless flux-cored welding wire.

[0073] Specifically, this step involves cooling the wire stock in a vacuum environment. Firstly, this is to ensure that the molten flux core does not oxidize due to contact with air during the solidification process. Secondly, cooling in a vacuum environment prevents the formation of bubbles during the solidification process of the molten flux core. Because there is no interference from external air in a vacuum environment, the molten flux core can smoothly transform from a liquid state to a solid state, making the molten flux core more compact after solidification and more closely fitting the seamless welding wire sheath. The resulting vacuum-evacuated seamless flux-cored welding wire is of higher quality and can better perform its function during the welding process, thereby improving the quality of the weld.

[0074] The present invention is described in detail below through some specific examples. The drugs used in the following examples can be obtained through common commercial means.

[0075] Example 1

[0076] The vacuum-evacuated seamless flux-cored welding wire of this embodiment includes a seamless welding wire sheath and a welding wire core. The seamless welding wire sheath is a hollow structure with openings at both ends and is integrally formed. The welding wire core is filled in the hollow part of the seamless welding wire sheath by vacuuming. The welding wire core includes the following components and the weight proportions of each component are: 30 parts of rutile, 12 parts of ferrosilicon powder, 4 parts of nickel powder, 5 parts of manganese iron alloy, 2 parts of chromium powder, 3 parts of dolomite, 2 parts of fluorite, 0.5 parts of niobium powder, and 1 part of titanium-boron alloy.

[0077] Step 1: Place the weighed raw materials of each component of the welding wire core into a vacuum stirring device and stir them at a stirring speed of 50 rpm for 3 minutes to obtain a preliminarily uniform mixed raw material.

[0078] Step 2: In a vacuum stirring device, mix the mixed raw materials with water at a ratio of 20% of the total weight of the welding wire core, stir while adding water, continue stirring for 2 minutes after the water is added, and then stir at a stirring speed of 150 rpm for 10 minutes to obtain a uniformly mixed and bubble-free muddy core blank.

[0079] Step 3: First heat and melt the mud-like flux core blank to obtain a molten flux core, and then pour the molten flux core into the hollow part of the seamless welding wire outer skin, while keeping the vacuum equipment running until the molten flux core fills the hollow part of the seamless welding wire outer skin to obtain the welding wire blank.

[0080] Step 4: Place the welding wire blank in a vacuum environment for cooling treatment, so that the molten flux core solidifies in the outer skin of the hollow welding wire to obtain a vacuum seamless flux-cored welding wire.

[0081] Example 2

[0082] The vacuum-evacuated seamless flux-cored welding wire of this embodiment includes a seamless welding wire sheath and a welding wire core. The seamless welding wire sheath is a hollow structure with openings at both ends and formed integrally. The welding wire core is filled in the hollow part of the seamless welding wire sheath by vacuuming. The welding wire core includes the following components and the weight proportions of each component are: 32 parts of rutile, 14 parts of ferrosilicon powder, 5 parts of nickel powder, 6 parts of manganese iron alloy, 3 parts of chromium powder, 4 parts of dolomite, 2.5 parts of fluorite, 0.8 parts of niobium powder, and 1.5 parts of titanium-boron alloy.

[0083] Step 1: Place the weighed raw materials of each component of the welding wire core into a vacuum stirring device and stir them at a stirring speed of 75 rpm for 4 minutes to obtain a preliminarily uniform mixed raw material.

[0084] Step 2: In a vacuum stirring device, mix the mixed raw materials with water at a ratio of 25% of the total weight of the welding wire core, stir while adding water, continue stirring for 2.5 minutes after the water is added, and then stir at a stirring speed of 175 rpm for 12.5 minutes to obtain a uniformly mixed and bubble-free muddy core blank.

[0085] Step 3: First heat and melt the mud-like flux core blank to obtain a molten flux core, and then pour the molten flux core into the hollow part of the seamless welding wire outer skin, while keeping the vacuum equipment running until the molten flux core fills the hollow part of the seamless welding wire outer skin to obtain the welding wire blank.

[0086] Step 4: Place the welding wire blank in a vacuum environment for cooling treatment, so that the molten flux core solidifies in the outer skin of the hollow welding wire to obtain a vacuum seamless flux-cored welding wire.

[0087] Example 3

[0088] The vacuum-evacuated seamless flux-cored welding wire of this embodiment includes a seamless welding wire sheath and a welding wire core. The seamless welding wire sheath is a hollow structure with openings at both ends and formed integrally. The welding wire core is filled in the hollow part of the seamless welding wire sheath by vacuuming. The welding wire core includes the following components and the weight proportions of each component are: 33 parts of rutile, 15 parts of ferrosilicon powder, 5.5 parts of nickel powder, 7 parts of manganese iron alloy, 3.5 parts of chromium powder, 5 parts of dolomite, 2.8 parts of fluorite, 0.9 parts of niobium powder, and 1.8 parts of titanium-boron alloy.

[0089] Step 1: Place the weighed raw materials of each component of the welding wire core into a vacuum stirring device and stir them at a stirring speed of 75 rpm for 4 minutes to obtain a preliminarily uniform mixed raw material.

[0090] Step 2: In a vacuum stirring device, mix the mixed raw materials with water at a ratio of 27% of the total weight of the welding wire core, stir while adding water, continue stirring for 2.5 minutes after the water is added, and then stir at a stirring speed of 175 rpm for 13 minutes to obtain a uniformly mixed and bubble-free muddy core blank.

[0091] Step 3: First heat and melt the mud-like flux core blank to obtain a molten flux core, and then pour the molten flux core into the hollow part of the seamless welding wire outer skin, while keeping the vacuum equipment running until the molten flux core fills the hollow part of the seamless welding wire outer skin to obtain the welding wire blank.

[0092] Step 4: Place the welding wire blank in a vacuum environment for cooling treatment, so that the molten flux core solidifies in the outer skin of the hollow welding wire to obtain a vacuum seamless flux-cored welding wire.

[0093] Example 4

[0094] The vacuum-evacuated seamless flux-cored welding wire of this embodiment includes a seamless welding wire sheath and a welding wire core. The seamless welding wire sheath is a hollow structure with openings at both ends and formed integrally. The welding wire core is filled in the hollow part of the seamless welding wire sheath by vacuuming. The welding wire core includes the following components and the weight proportions of each component are: 35 parts of rutile, 16 parts of ferrosilicon powder, 6 parts of nickel powder, 8 parts of manganese iron alloy, 4 parts of chromium powder, 6 parts of dolomite, 3 parts of fluorite, 1 part of niobium powder, and 2 parts of titanium-boron alloy.

[0095] Step 1: Place the weighed raw materials of each component of the welding wire core into a vacuum stirring device and stir them at a stirring speed of 75 rpm for 5 minutes to obtain a preliminarily uniform mixed raw material.

[0096] Step 2: In a vacuum stirring device, mix the mixed raw materials with water at a ratio of 30% of the total weight of the welding wire core, stir while adding water, continue stirring for 3 minutes after the water is added, and then stir at a stirring speed of 200 rpm for 15 minutes to obtain a uniformly mixed and bubble-free muddy core blank.

[0097] Step 3: First heat and melt the mud-like flux core blank to obtain a molten flux core, and then pour the molten flux core into the hollow part of the seamless welding wire outer skin, while keeping the vacuum equipment running until the molten flux core fills the hollow part of the seamless welding wire outer skin to obtain the welding wire blank.

[0098] Step 4: Place the welding wire blank in a vacuum environment for cooling treatment, so that the molten flux core solidifies in the outer skin of the hollow welding wire to obtain a vacuum seamless flux-cored welding wire.

[0099] Comparative Example 1

[0100] Core material components: 32 parts of rutile, 14 parts of ferrosilicon powder, 5 parts of nickel powder, 6 parts of ferromanganese alloy, 3 parts of chromium powder, 4 parts of dolomite, 2.5 parts of fluorite, 0.8 parts of niobium powder, and 1.5 parts of titanium-boron alloy.

[0101] The production method of flux-cored welding wire is as follows: the steel strip is rolled into a U-shaped groove, and then the mixed flux core is filled into the U-shaped groove; then the flux-cored welding wire is obtained by closing, reducing the diameter, drawing and winding the wire.

[0102] Comparative Example 2

[0103] Core material components: 33 parts of rutile, 15 parts of ferrosilicon powder, 5.5 parts of nickel powder, 7 parts of ferromanganese alloy, 3.5 parts of chromium powder, 5 parts of dolomite, 2.8 parts of fluorite, 0.9 parts of niobium powder, and 1.8 parts of titanium-boron alloy.

[0104] The production method of flux-cored welding wire is as follows: the steel strip is rolled into a U-shaped groove, and then the mixed flux core is filled into the U-shaped groove; then the flux-cored welding wire is obtained by closing, reducing the diameter, drawing and winding the wire.

[0105] Various welding tests were conducted on the vacuum-evacuated seamless flux-cored welding wires and flux-cored welding wires provided in Examples 1 to 4 and Comparative Examples 1 and 2 in accordance with relevant standards and specifications. The welding current was 150A to 200A, and a mixture of argon and carbon dioxide was used as the shielding gas at a gas flow rate of 10 to 15 L / min. The welding process performance is as follows:

[0106] Table 1 Mechanical properties of weld

[0107]

[0108] Table 2 Stability of welding process

[0109]

[0110] Table 3 Core stability and moisture resistance test

[0111]

[0112] The test results of Examples 1 to 3 and Comparative Examples 1 and 2 show that the vacuum seamless flux-cored welding wire provided by the present invention has a stable arc, less spatter, and easy slag removal during the welding process, has high tensile strength and yield strength, can provide a stronger bearing capacity for the welded structure, and has good moisture-proof properties.

[0113] It will be understood that the present invention is described by way of some embodiments, and it will be appreciated by those skilled in the art that various changes or equivalent substitutions may be made to these features and embodiments without departing from the spirit and scope of the present invention. In addition, under the teachings of the present invention, these features and embodiments may be modified to adapt to specific circumstances and materials without departing from the spirit and scope of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed herein, and all embodiments falling within the scope of the claims of this application are intended to be protected by the present invention.

Claims

1. A vacuum seamless flux-cored welding wire, characterized in that: The invention comprises a seamless welding wire sheath and a welding wire core, wherein the seamless welding wire sheath is a hollow structure with openings at both ends and formed integrally; the welding wire core is filled in the hollow part of the seamless welding wire sheath by vacuuming; the welding wire core comprises the following components and the weight proportions of each component are respectively: 30-35 parts of rutile, 12-16 parts of ferrosilicon powder, 4-6 parts of nickel powder, 5-8 parts of manganese iron alloy, 2-4 parts of chromium powder, 3-6 parts of dolomite, 2-3 parts of fluorite, 0.5-1 part of niobium powder and 1-2 parts of titanium boron alloy.

2. The vacuum seamless flux-cored welding wire according to claim 1, characterized in that: The particle size of the welding wire core is 60-200 meshes.

3. The vacuum seamless flux-cored welding wire according to claim 1 or 2, characterized in that: The outer sheath of the seamless welding wire is made of any one or more materials selected from the group consisting of copper, silver, and nickel.

4. A filling process for the vacuum seamless flux-cored welding wire according to any one of claims 1 to 3, characterized in that: The steps include: Mixing raw materials of various components of welding wire core with water to obtain mud-like core blank; Taking the mud-like core blank and heating and melting it to obtain a molten core; Take the pre-prepared seamless welding wire sheath, and connect a vacuum device to one end of the seamless welding wire sheath for vacuum treatment; pouring the molten flux core into the hollow portion of the seamless welding wire sheath while maintaining the operation of the vacuum device until the molten flux core fills the hollow portion of the seamless welding wire sheath to obtain a welding wire blank; The welding wire blank is placed in a vacuum environment for cooling treatment, so that the molten flux core is solidified inside the hollow welding wire to obtain a vacuum seamless flux cored welding wire.

5. The filling process according to claim 4, characterized in that: The step of mixing the raw materials of the welding wire core components with water to obtain a mud-like core blank specifically includes the following sub-steps: The raw materials of the welding wire core components are mixed with an appropriate amount of water in the following proportions: 30-35 parts of rutile, 12-16 parts of ferrosilicon powder, 4-6 parts of nickel powder, 5-8 parts of ferromanganese alloy, 2-4 parts of chromium powder, 3-6 parts of dolomite, 2-3 parts of fluorite, 0.5-1 part of niobium powder, and 1-2 parts of titanium-boron alloy. The mixture is placed in a vacuum stirring device and stirred until it becomes a mud-like material to obtain a bubble-free mud-like core blank.

6. The filling process according to claim 4, characterized in that: The step of mixing the raw materials of the welding wire core components with water to obtain a mud-like core blank further includes the following sub-steps: Place the weighed raw materials of each component of the welding wire core in a vacuum stirring device and stir at a stirring speed of 50-100 rpm for 3-5 minutes to obtain a preliminarily uniform mixed raw material; Take 20% to 30% of the total mass of the mixed raw materials and slowly add water to the mixed raw materials. Stir while adding water. After the water is added, continue stirring for 2 to 3 minutes and stir at a stirring speed of 150 to 200 rpm for 10 to 15 minutes to obtain a muddy core blank that is evenly mixed and free of bubbles.

7. The filling process according to claim 4, characterized in that: The pre-prepared seamless welding wire sheath specifically includes the following sub-steps: One or more materials of copper, silver, and nickel prepared in advance are melted and cast to obtain a rod-shaped blank; The rod-shaped blank is placed in a heating furnace for preheating, and the preheated rod-shaped blank is perforated to obtain a first welding wire sheath blank having a hollow structure; Performing a first drawing and reducing of the first welding wire sheath blank to obtain a second welding wire sheath blank; annealing the second welding wire sheath blank to obtain a third welding wire sheath blank; The third welding wire sheath blank is subjected to a second drawing and diameter reduction to obtain a fourth welding wire sheath blank; The fourth welding wire sheath blank is cleaned and polished to obtain a seamless welding wire sheath.

8. The filling process according to claim 7, characterized in that: After the pre-prepared one or more materials of copper, silver and nickel are melted and cast, they are cooled and turned to obtain a rod-shaped outer skin blank without oxide scale.

9. The filling process according to claim 7, characterized in that: In the step of placing the rod-shaped outer skin blank in a heating furnace for preheating, the temperature is raised to 500-700° C. at a heating rate of 5-10° C. / min and then kept at this temperature for 15-30 minutes.

10. The filling process according to claim 7, characterized in that: The annealing of the second welding wire sheath blank specifically includes the following sub-steps: After cleaning the second welding wire sheath blank, the temperature in the annealing furnace is increased to 400-700° C. at a heating rate of 5-10° C. / min, kept at this temperature for 1-3 hours, and then cooled to room temperature in the furnace to obtain a third welding wire sheath blank.

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