A carbon steel pipe butt welding metal powder core welding wire gas shielded welding process method

Abstract

The present application relates to carbon steel pipe butt metal powder core welding wire gas shielded welding process technical field, and disclose a kind of carbon steel pipe butt metal powder core welding wire gas shielded welding process method, comprising the following steps:1) metal powder core welding wire chemical composition;2) the preparation of metal powder core welding wire;3) metal powder core welding wire performance test;4) metal powder core welding wire welding basic parameter;5) metal powder core welding wire gas shielded welding method.By because manufacturing and chemical composition influence, metal core welding wire compared with solid core welding wire, with higher current density, also with higher deposition rate under the same current condition, in all welding material, core wire and metal powder core welding wire have highest deposition rate, for 1.2mm core wire and metal core welding wire deposition rate can reach 5.4-6.4kg / h, the deposition rate of solid core gas shielded welding wire with same diameter is 3.6-4.5kg / h, usually experience data shows that when the deposition rate of metal core welding wire reaches 4.1kg / h or higher, compared with solid core welding wire, more cost saving.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of carbon steel pipe butt metal powder core welding wire gas shielded welding process, in particular to a carbon steel pipe butt metal powder core welding wire gas shielded welding process. BACKGROUND

[0002] The carbon steel pipe butt weld is a large number of welding seams in shipbuilding products. The conventional process method is to use argon arc welding for backing and CO2 gas shielded welding for filling and covering. Although the root welding quality is easy to guarantee, the welding efficiency is too low, the operation skill of welder is required to be high, and the cost of argon and welding material is also high. Under the background of the development of the shipbuilding industry, a welding method with high welding efficiency and strong process applicability needs to be developed to further liberate labor and productivity and improve production efficiency.

[0003] Metal powder type flux cored wire has been widely used due to its excellent welding process performance, comprehensive mechanical properties and high welding efficiency. Today, the product structure of shipbuilding enterprises is fully transformed, and the technical quality requirements of high value-added engineering projects are increasing, which prompts us to continuously develop and find new welding materials that match them.

[0004] Metal powder core is similar in structure to flux cored wire, but it is used like solid core welding wire. The metal powder core welding wire is composed of a thin steel belt wrapped with powder. The powder wrapped in the steel belt is almost all alloy powder, and there is no slag former. Therefore, in terms of performance, it has the advantages of both solid core welding wire with less welding slag and flux cored wire with high deposition rate and good welding process. SUMMARY

[0005] (I) Technical problems solved

[0006] In view of the shortcomings of the prior art, the present application provides a carbon steel pipe butt metal powder core welding wire gas shielded welding process, which has the advantages of both solid core welding wire with less welding slag and flux cored wire with high deposition rate and good welding process. The conventional process method of using argon arc welding for backing and CO2 gas shielded welding for filling and covering has the problems of low welding efficiency, high requirement for welder's operation skill, and high cost of argon and welding material.

[0007] (II) Technical solutions

[0008] To achieve the above-mentioned purpose, the present application provides the following technical solutions: a carbon steel pipe butt metal powder core welding wire gas shielded welding process, comprising the following steps:

[0009] 1) Chemical composition of metal powder core welding wire;

[0010] 2) Preparation of metal powder core welding wire;

[0011] 3) Performance test of metal cored wire;

[0012] 4) Basic parameters of metal cored wire welding;

[0013] 5) Metal cored wire gas shielded welding method;

[0014] Preferably, the chemical composition of the metal cored wire is GCL-70M, the size of which is 1.2mm, and the chemical composition ratio is as follows: C, Si, Mn, P, S, Cr, Mo, Ni, Cu and V, and the standard is respectively: Max.0.12, Max.0.90, Max.1.75, Max.0.03, Max.0.20, Max.0.30, Max.0.50, Max.0.50, Max.0308, and the percentage of deposited metal is respectively: 0.058, 0.60, 1.37, 0.06, 0.013, 0.01, 0.01, 0.01, 0.01, 0.001.

[0015] Preferably, the preparation of the metal cored wire is to mix each component according to the proportion, place it on the steel outer skin, roll it into a wire, and draw it to reduce the diameter to obtain the metal cored wire. The metal cored wire is similar in structure to flux cored wire, but it is like solid core wire in use. The metal cored wire is composed of a thin steel strip wrapped with a powder, and the powder wrapped in the steel strip is almost all alloy powder without slagging agent. Therefore, in terms of performance, it has the advantages of both solid core wire with less slag and flux cored wire with high deposition rate and good welding process.

[0016] Preferably, the performance test of the metal cored wire includes the following steps:

[0017] S1, base material: carbon steel pipe Grade 410, size D168X7mm;

[0018] S2, welding material: Kunshan Jingqun GCL-70M φ1.2mm metal cored wire;

[0019] S3, welding equipment: welding power supply EWM Phoenix 451plus, pipe-pipe automatic welding machine;

[0020] S4, shielding gas: 80% Ar+20% CO2;

[0021] S5, welding position: pipe rolling flat butt joint (1G position);

[0022] S6, welding effect: small welding spatter, good forming, bright weld forming when using large current cover welding, smooth droplet.

[0023] Preferably, the metal cored wire welding basic parameters are divided into mechanical properties and welding parameters, wherein the mechanical properties include: yield strength 445 Min, tensile strength 552 Min, elongation 28 Min, radiographic testing 1 level, and in addition, the test temperature in impact test is -30°C, and the absorbed energy is 82J.

[0024] Preferably, the welding parameters include: welding bead 1, welding method GMAW, welding material diameter φ1.2mm, current type and polarity DCEP, welding current 115-135A, arc voltage 19-21V, welding speed 15-33cm / min, heat input 7.47-12.45KJ / min, and gas flow 15-25l / min.

[0025] Preferably, the metal cored wire gas shielded welding method includes the following steps: preparation, cleaning and arranging the working site before welding, ensuring that the working environment is dry, ventilated and safe, and at the same time, selecting appropriate welding equipment and auxiliary tools according to the requirements of the welding material, ensuring that the operation performance and safety performance meet the specification requirements, selecting appropriate gas and electrode according to the test parameters, the commonly used gas is carbon dioxide, argon, etc., and the electrode is metal cored wire, cleaning and preheating the workpiece to ensure that the workpiece surface is free of oil stains, rust and other impurities, so as to improve the welding quality and efficiency, adjusting the equipment parameters, including current, voltage, wire feeding speed, etc., which need to be adjusted according to the workpiece thickness, material type and other factors.

[0026] Preferably, the selected metal cored wire is inserted into the welding gun, and the wire feeder is connected to the welding equipment, and the welding step is: lighting the spark and adjusting the distance, the spark is lit on the workpiece, and the spark is stabilized at the appropriate position by adjusting the distance, the wire feeding is started and the welding is carried out, the uniform and continuous welding operation is carried out by controlling the wire feeding speed and the position of the handheld welding gun, and the welding quality is observed, the quality of the weld is observed at all times during the welding process to ensure uniform and firm welding, and in order to obtain all the potential advantages of using metal cored wire, preferably, full-automatic or robot equipment is adopted, and a power supply with pulse function is configured to enhance the process performance of the metal cored wire.

[0027] Another technical problem to be solved by the present application is to provide a carbon steel pipe butt joint metal cored wire gas shielded welding process method, comprising the following steps:

[0028] 1) Chemical composition of metal cored wire;

[0029] 2) Preparation of metal cored wire;

[0030] 3) Performance test of metal cored wire;

[0031] 4) Metal cored wire welding basic parameters;

[0032] 5) Metal cored wire gas shielded welding method

[0033] (III) ADVANTAGEOUS EFFECTS

[0034] Compared with the prior art, the present application provides a carbon steel pipe butt metal cored wire gas shielded welding process method, which has the following advantageous effects:

[0035] 1. The carbon steel pipe butt metal cored wire gas shielded welding process method has a higher current density than solid core welding wire due to manufacturing and chemical composition effects, and also has a higher deposition rate under the same current conditions. Among all welding materials, cored wire and metal cored wire have the highest deposition rate. The deposition rate of 1.2 mm cored wire and metal cored wire can reach 5.4-6.4 kg / h, and the deposition rate of solid core gas shielded welding wire of the same diameter is 3.6-4.5 kg / h. According to experience, when the deposition rate of metal cored wire reaches 4.1 kg / h or higher, it is more cost-effective than solid core welding wire. Metal cored wire has similar low slag and less spatter characteristics as solid core welding wire. Like solid core welding wire, metal cored wire also has almost no slag forming components when welding wire is filled, and only a small amount of silicide is present on the surface of the weld, which makes it unnecessary to clean the slag for multi-layer and multi-pass welding. Metal cored wire has arc stabilizers that improve arc stability and reduce spatter.

[0036] 2. The carbon steel pipe butt metal cored wire gas shielded welding process method has the characteristic that the slag of cored wire covers the surface of the deposited metal, and its deposition efficiency is generally 84%-89%, while the deposition efficiency of solid core welding wire is generally 95%-98%. Under the conditions of spray transfer and high argon mixed gas protection, the deposition efficiency of metal cored wire is generally within the range of 92%-98%. Changes in transfer form and protective gas will affect the deposition efficiency. If metal cored wire uses short circuit transfer and high content CO2 protective gas, the spatter amount will increase (especially large particle spatter), resulting in a decrease in deposition efficiency. Spray transfer is the best transfer form to improve wetting and reduce spatter. To obtain spray transfer, high argon mixed gas is needed as protective gas. In order to obtain all the potential advantages of metal cored wire, full-automatic or robotic equipment is preferred, and a power source with pulse function is configured to enhance the process performance of metal cored wire. BRIEF DESCRIPTION OF DRAWINGS

[0037] Figure 1 Cross-sectional view of the metal cored wire (right) and solid core welding wire proposed by the present application;

[0038] Figure 2 Process category comparison diagram proposed by the present application;

[0039] Figure 3A pipe butt welding process comparison schematic diagram is provided for the present application;

[0040] Figure 4 A metal cored welding wire process performance test schematic diagram is provided for the present application;

[0041] Figure 5 A metal cored welding wire pipe butt welding process approval test schematic diagram is provided for the present application. DETAILED DESCRIPTION

[0042] The technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor fall within the scope of protection of the present application.

[0043] Embodiment one:

[0044] A carbon steel pipe butt metal cored welding wire gas shielded welding process method, comprising the following steps:

[0045] 1) Metal cored welding wire chemical composition, the metal cored welding wire chemical composition, the name of the metal cored welding wire is GCL-70M, the size is 1.2mm, wherein the chemical composition accounts for: components C, Si, Mn, P, S, Cr, Mo, Ni, Cu and V, wherein the standards are respectively: Max. 0.12, Max. 0.90, Max. 1.75, Max. 0.03, Max. 0.20, Max. 0.30, Max. 0.50, Max. 0.50, Max. 0308, wherein the percentage of deposited metal is respectively: 0.058, 0.60, 1.37, 0.06, 0.013, 0.01, 0.01, 0.01, 0.01, 0.001.

[0046] 2) Preparation of metal cored welding wire, after mixing each component according to the proportion, placing it on the steel outer skin, winding into wire, and drawing and reducing the diameter, the metal cored welding wire is obtained, the metal cored welding wire is similar in structure to the flux cored welding wire, but in use it is like solid core welding wire, the metal cored welding wire is composed of thin steel belt wrapped with powder, and the powder wrapped in the steel belt is almost all alloy powder without slagging agent, so in use performance, it has the advantages of less welding slag of solid core welding wire, and high deposition rate of slag type flux cored welding wire, good welding process and other advantages.

[0047] 3) Metal cored welding wire performance test, the metal cored welding wire performance test comprises the following steps:

[0048] S1, base material: carbon steel pipe Grade 410, size D168X7mm;

[0049] S2, welding material: Kunshan Jingqun GCL-70M φ1.2mm metal cored wire;

[0050] S3, welding equipment: welding power EWM Phoenix 451plus, pipe-pipe automatic welding machine;

[0051] S4, shielding gas: 80%Ar+20%CO2;

[0052] S5, welding position: pipe rolling flat butt joint (1G position);

[0053] S6, welding effect: small welding spatter, good forming, when using large current cover welding, the weld forming is bright, and the droplet is smooth.

[0054] 4) metal cored wire welding basic parameters, the metal cored wire welding basic parameters are divided into mechanical properties and welding parameters, wherein the mechanical properties include: yield strength 445Min, tensile strength 552Min, elongation 28Min, ray detection 1 level, in addition, the test temperature in impact test is-30°C, and the absorption energy is 82J, the welding parameters include: welding 1, the welding method is GMAW, the welding material diameter is φ1.2mm, the current type and polarity is DCEP, the welding current is 125A, the arc voltage is 20V, the welding speed is 15.1cm / min, the heat input is 9.96KJ / min, and the gas flow is 15-25l / min.

[0055] 5) Metal cored wire gas shielded welding method, the metal cored wire gas shielded welding method, preparation, before welding, the working place needs to be cleaned and arranged, ensure that the working environment is dry, ventilated and safe, at the same time, the appropriate welding equipment and auxiliary tools should be selected according to the requirements of the welding material, ensure that its operating performance and safety performance meet the specification requirements, select appropriate gas and electrode according to test parameters, commonly used gas is carbon dioxide, argon and other gas, electrode selects metal cored wire, clean and preheat workpiece, ensure that the workpiece surface is free of oil, rust and other impurities, to improve the welding quality and efficiency, adjust the equipment parameters, including current, voltage, wire feeding speed and other parameters, these parameters need to be adjusted according to the thickness of workpiece, material type and other factors, the selected metal cored wire is inserted into the welding gun, and the wire feeder is connected with the welding equipment, the welding step is: light up the spark and adjust the distance, the spark is on the workpiece, and the spark is stabilized in the appropriate position by adjusting the distance, start wire feeding and welding, through controlling wire feeding speed and holding welding gun position, uniform and continuous welding operation is carried out, observe the welding quality, the quality of the weld seam should be observed at all times during the welding process, to ensure uniform and firm welding, in order to obtain the full potential of the use of metal cored wire, preferably using full automatic or robot equipment, configure power supply with pulse function, to enhance the process performance of metal cored wire.

[0056] The beneficial effects of the present invention are: firstly, the metal cored wire has higher current density compared with solid wire due to the manufacturing and chemical composition, and has higher deposition rate under the same current condition, among all welding materials, the flux cored wire and the metal cored wire have the highest deposition rate, the deposition rate of 1.2mm flux cored wire and metal cored wire can reach 5.4-6.4kg / h, and the deposition rate of solid wire with the same diameter is 3.6-4.5kg / h, and the experience data shows that when the deposition rate of the metal cored wire reaches 4.1kg / h or higher, it is more cost-effective than the solid wire, the metal cored wire has similar low slag and less spatter characteristics as the solid wire, just like the solid wire, the metal cored wire also has little slag forming components when the wire is filled, and there is only a small amount of silicide on the surface of the weld, which makes it unnecessary to clean the slag for multi-layer and multi-pass welding, the metal cored wire has arc stabilizer, which improves the arc stability and reduces the spatter, then through the characteristics of the flux cored wire that the slag covers the surface of the deposited metal, the deposition efficiency of the flux cored wire is generally 84%-89%, the deposition efficiency of the solid wire is generally 95%-98%, under the conditions of selecting spray transition and high argon mixed gas protection, the deposition efficiency of the metal cored wire is generally in the range of 92%-98%, the change of transition form and protection gas will affect the deposition efficiency, if the metal cored wire adopts short circuit transition and high content of CO2 protection gas, the spatter amount will increase (especially large particle spatter), which will lead to the decrease of deposition efficiency, spray transition is the best transition form to improve wetting and reduce spatter, in order to obtain spray transition, high argon mixed gas is needed as protection gas, in order to obtain all the potential advantages of using metal cored wire, full-automatic or robot equipment is preferred, and a power source with pulse function is configured to enhance the process performance of the metal cored wire.

[0057] Although embodiments of the present invention have been shown and described, it is to be understood that various modifications, substitutions, replacements and changes can be made to these embodiments without departing from the principles and spirit of the present invention, and the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A carbon steel pipe butt welding metal cored gas shielded welding process method characterized by, It comprises the following steps: 1) Chemical composition of metal cored welding wire; 2) Preparation of metal cored welding wire; 3) Performance test of metal cored welding wire; 4) Basic welding parameters of metal cored welding wire; 5) Gas shielded welding method of metal cored welding wire; The chemical composition of the metal cored welding wire, the name of the metal cored welding wire is GCL-70M, the size is 1.2mm, and the chemical composition accounts for: components C, Si, Mn, P, S, Cr, Mo, Ni, Cu and V, wherein the percentage of deposited metal is: 0.058, 0.60, 1.37, 0.06, 0.013, 0.01, 0.01, 0.01, 0.01, 0.001; The preparation of the metal cored welding wire, after mixing each component according to the proportion, it is placed on the steel outer skin, rolled into a wire, and drawn to reduce the diameter, to obtain the metal cored welding wire, the metal cored welding wire is similar in structure to the flux cored welding wire, but in the use process, it is like solid core welding wire, the metal cored welding wire is composed of thin steel belt and powder, the powder wrapped in the steel belt is almost all alloy powder, without slagging agent, so in the use performance, it has the advantages of less welding slag of solid core welding wire, and high deposition rate and good welding process of slag type flux cored welding wire; The performance test of the metal cored welding wire comprises the following steps: S1, base material: carbon steel pipe Grade 410, specification D168X7mm; S2, welding material: Kunshan Jingqun GCL-70M φ1.2mm metal cored welding wire; S3, welding equipment: welding power source EWM Phoenix 451plus, pipe-pipe automatic welding machine; S4, shielding gas: 80%Ar+20%CO2; S5, welding position: pipe rolling flat butt joint (1G position); S6, welding effect: small welding spatter, good forming, when using large current cover welding, the weld forming is bright and the droplet is smooth; The basic welding parameters of the metal cored welding wire are divided into mechanical properties and welding parameters, wherein the mechanical properties include: yield strength 445Min, tensile strength 552Min, elongation 28Min, ray detection 1 level, and the test temperature in impact test is-30°C, and the absorbed energy is 82J; The welding parameters include: welding 1, welding method is GMAW, welding material diameter is φ1.2mm, current type and polarity is DCEP, welding current is 115-135A, arc voltage is 19-21V, welding speed is 15-33cm / min, heat input is 7.47-12.45KJ / min, and gas flow is 15-25l / min; The metal-cored wire gas shielded welding method, preparation, before welding, need to clean and arrange the working place, ensure the dry, ventilation and safety of the working environment, at the same time, should choose the appropriate welding equipment and auxiliary tools according to the requirements of welding materials, ensure that its operating performance and safety performance meet the specification requirements, according to the test parameters to choose the appropriate gas and electrode, commonly used gas has carbon dioxide, argon, electrode selects metal cored wire, cleaning and preheating workpiece, ensure that the workpiece surface is free of oil, rust and impurities, to improve the welding quality and efficiency, adjust the equipment parameters, including current, voltage, wire feed speed, these parameters need to be adjusted according to the thickness of workpiece, material type factor; Insert the selected metal cored wire into the welding gun, and connect the wire feeder with the welding equipment, the welding steps are: light up the spark and adjust the distance, point the spark on the workpiece, and make the spark stable at the appropriate position by adjusting the distance, start wire feeding and welding, control the wire feeding speed and the position of the handheld welding gun to carry out uniform and continuous welding operation, observe the welding quality, and observe the quality of the weld seam at all times during the welding process to ensure uniform and firm welding, in order to obtain all the potential advantages of using metal cored wire, full automatic or robot equipment is adopted, and a power supply with pulse function is configured to enhance the process performance of the metal cored wire.

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