Surfacing flux-cored wire and preparation method thereof

Abstract

The invention discloses a surfacing flux-cored wire and a preparation method thereof, the surfacing flux-cored wire is composed of an outer skin and a flux core, and the flux core is composed of the following components of, by mass, 10%-30% of chromium, 0.25%-1.0% of hollow cage-shaped carbon microspheres, 12.5%-14.8% of manganese fluoride, 3.2%-5.5% of nickel, 0.2%-0.8% of molybdenum, 3%-8% of aluminum-magnesium alloy, 1%-3% of aluminum-silicon alloy, 0.01%-0.1% of rare earth and the balance iron. The surfacing flux-cored wire has the advantages of high hardness, excellent crack resistance, high-temperature stability and the like by optimizing the proportion of all the components.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of welding materials, in particular to a surfacing flux-cored wire suitable for surface repair and reinforcement of equipment under high-temperature and high-wear conditions and a preparation method thereof. The surfacing flux-cored wire is particularly suitable for wear repair of equipment such as grinding rollers and extrusion rollers in the cement, steel and thermal power industries, and can significantly improve the service life of the equipment and reduce production costs. BACKGROUND

[0002] As an important means of modern industrial equipment repair, the self-shielded flux-cored wire surfacing technology has significant advantages in improving repair efficiency, optimizing production costs and prolonging equipment life. With the increasing requirements for equipment maintenance in the cement, steel and thermal power industries, surfacing repair technology has become the preferred solution to solve the problem of key equipment wear. Surfacing with self-shielded flux-cored wire can effectively improve repair efficiency, shorten production cycle and reduce costs, and has great social and economic benefits in improving the safe life of mechanical equipment and parts. At present, a mainstream solution to the above-mentioned equipment wear problem is to use wear-resistant flux-cored wire for surfacing repair to prolong the service life of the equipment.

[0003] The surfacing flux-cored wire commonly used in the industry at present mainly adopts a high-chromium and high-carbon alloy system, which has good wear resistance, but has the following problems: (1) the surfacing layer is prone to cracking, especially in a thermal cycle condition, in an environment with a sharp temperature change, crack propagation can cause the surfacing layer to peel off and fail; (2) the impact resistance is insufficient, and the surfacing layer of the existing wire is prone to peeling off under dynamic load, which cannot meet the repair needs of impact load bearing equipment such as extrusion rollers; (3) the welding process performance is unstable, with large spatter and poor forming, which increases the subsequent processing cost and affects the welding efficiency; (4) the high-temperature hardness retention rate is low, and the hardness decreases significantly above 600℃, which cannot meet the needs of high-temperature working conditions.

[0004] In view of the above problems, it is urgent to develop a new type of surfacing flux-cored wire with high hardness, excellent crack resistance and good high-temperature stability. SUMMARY

[0005] In order to overcome the deficiencies of the prior art, one of the purposes of the present application is to provide a surfacing flux-cored wire, which solves the above-mentioned traditional technical problems through innovative alloy system design, and is particularly suitable for surface repair and reinforcement of equipment under high-temperature and high-wear conditions.

[0006] The second purpose of the present application is to provide a preparation method of the surfacing flux-cored wire.

[0007] One of the purposes of the present application is achieved by the following technical solutions: A surfacing flux-cored wire is composed of a sheath and a core, the core is composed of the following components in mass percentage: chromium 10%-30%, hollow cage carbon microspheres 0.25%-1.0%, manganese fluoride 12.5%-14.8%, nickel 3.2%-5.5%, molybdenum 0.2%-0.8%, aluminum-magnesium alloy 3%-8%, aluminum-silicon alloy 1%-3%, rare earth 0.01%-0.1%, and the rest is iron.

[0008] In the present application, the design principle is: (1) Chromium: can improve the hardness and wear resistance of the system through secondary hardening, and can also form a dense oxide film on the surface of the material, effectively resisting corrosion of oxidizing media, and the chromium content is controlled at 10%-30%; (2) Hollow cage carbon microspheres: as a nano reinforcing phase, significantly improve the hardness and high temperature stability of the surfacing layer, and the content of hollow cage carbon microspheres is controlled at 0.25%-1.0%; (3) Manganese fluoride: significantly improves the welding process performance and reduces the spatter rate, and the content of manganese fluoride is controlled at 12.5%-14.8%; (4) Nickel: can improve the corrosion resistance, plasticity and high temperature strength of the system, and the content of nickel is controlled at 3.2%-5.5%; (5) Molybdenum: improves high temperature strength and creep resistance, enhances high temperature service performance, and the content of molybdenum is controlled at 0.2%-0.8%; (6) Aluminum-magnesium alloy: improves the fluidity of the molten pool and ensures good weld formation, and the content of aluminum-magnesium alloy is controlled at 3%-8%; (7) Aluminum-silicon alloy: significantly refines the weld metal structure, improves the strength while maintaining good plasticity and toughness, and the content of aluminum-silicon alloy is controlled at 1%-3%; (8) Rare earth: as a grain refiner and refiner, refines the alloy structure, improves the processing performance of the welding wire, and the content of rare earth is controlled at 0.01%-0.1%.

[0009] In summary, by optimizing the proportion of each component, the welding wire has the advantages of high hardness, excellent crack resistance and high temperature stability.

[0010] Further, the performance requirements of hollow cage carbon microspheres are: diameter 50-100nm, specific surface area 200-400m 2 / g, pore size distribution 2-10nm. Preferably, the hollow cage carbon microspheres are HCS-W50.

[0011] Further, the mass ratio of aluminum and magnesium in the aluminum-magnesium alloy is (85-95):(5-15).

[0012] Further, the mass ratio of aluminum and silicon in the aluminum-silicon alloy is (70-95):(5-30).

[0013] Further, the rare earth is one or more of cerium, yttrium, lanthanum, neodymium, and gadolinium.

[0014] Further, the filling rate of the core is 35 wt% - 50 wt%.

[0015] Further, the sheath is a steel strip, preferably, the steel strip is a stainless steel 430 steel strip.

[0016] The second object of the present application is achieved by the following technical solution: A preparation method of a surfacing flux-cored wire, comprising the following preparation steps: S1: proportioning, pre-melting by an induction melting process to obtain an ingot; S2: remelting the ingot and preparing a flux-cored powder by a vacuum atomization powder preparation device; The above flux-cored powder has a sphericity of more than 80% and an oxygen content of less than 220 ppm.

[0017] S3: placing the sheath on a tape placing machine of a flux-cored wire forming machine, rolling the sheath into a U-shaped groove by the forming machine, then adding the flux-cored powder into the U-shaped groove, controlling the filling rate of the flux-cored powder to be 35 wt% - 50 wt%, rolling and closing the U-shaped groove by the forming machine, and drawing it to a diameter of 2-6 mm to obtain the flux-cored wire.

[0018] Further, in step S1, the pre-melting step by the induction melting process is: first melting iron and manganese fluoride under a protective atmosphere, then adding the remaining materials in a secondary feeding manner, completely melting and stirring uniformly, and then pouring into an ingot; In step S2, the specific steps are: controlling the temperature of the metal liquid to be 900-1200℃, using high-purity nitrogen with a purity of 99.999% as the nitrogen gas, controlling the nitrogen gas pressure to be 2.9-3.3 MPa, using a tight coupling limited circular ring structure for the nozzle, and under the high-speed jet flow and cooling of the nitrogen gas, the metal liquid is dispersed into fine liquid mist and quickly solidified into powder, and the powder falls into the receiving barrel in the conical cylinder without contacting air in the whole process.

[0019] Compared with the prior art, the present application has the following beneficial effects: 1. The surfacing flux-cored wire of the present application has high hardness, excellent crack resistance, and high temperature stability by optimizing the proportioning of each component.

[0020] 2. The surfacing flux-cored wire of the present application has the following specific advantages: (1) Hollow cage-like carbon microspheres as nano-enhancing phase significantly improve the hardness and high-temperature stability of the surfacing layer; (2) Aluminum magnesium / silicon alloy combination optimizes the deoxidization and grain boundary strengthening of the molten pool, and reduces the crack sensitivity; (3) Rare earth elements refine the grain, improve the uniformity of carbide distribution; (4) Manganese fluoride improves the welding process performance and reduces the spatter rate; (5) Adopting vacuum atomization powder and precision drawing process to ensure the uniformity of the core composition and the size accuracy of the welding wire. DETAILED DESCRIPTION

[0021] The present application provides a kind of surfacing flux-cored wire and preparation method thereof, by innovative alloy system design and precision preparation process, the deficiencies of prior art are solved.

[0022] 1, technical scheme The welding wire is composed of a sheath and a core. The core adopts a multi-element composite reinforcement system, and the specific composition is as follows: components in mass percentage: ‌Chromium (Cr): 10%-30%, forms hard carbide, provides basic hardness; for example: 10%, 12%, 15%, 18%, 20%, 22%, 25%, 28%, 30%, etc.

[0023] ‌Hollow cage-like carbon microspheres: 0.25%-1.0%, nanometer reinforcing phase, improves high temperature stability; for example: 0.25%, 0.28%, 0.3%, 0.35%, 0.4%, 0.45%, 0.5%, 0.55%, 0.6%, 0.65%, 0.7%, 0.75%, 0.8%, 0.85%, 0.9%, 0.95%, 1.0%, etc.

[0024] ‌Manganese fluoride (MnF2): 12.5%-14.8%, improves welding process performance; for example: 12.5%, 12.8%, 13%, 13.2%, 13.5%, 13.8%, 14%, 14.2%, 14.5%, 14.8%, etc.

[0025] ‌Nickel (Ni): 3.2%-5.5%, improves corrosion resistance and high temperature strength; for example: 3.2%, 3.5%, 3.8%, 4%, 4.2%, 4.5%, 4.8%, 5%, 5.2%, 5.5%, etc.

[0026] ‌Molybdenum (Mo): 0.2%-0.8%, enhances creep resistance; 0.20%, 0.22%, 0.25%, 0.30%, 0.35%, 0.4%, 0.45%, 0.5%, 0.55%, 0.6%, 0.65%, 0.7%, 0.75%, 0.8%, etc.

[0027] Aluminum magnesium alloy: 3%-8%, improve the fluidity of the molten pool; for example: 3.0%, 3.2%, 3.5%, 3.8%, 4%, 4.2%, 4.5%, 4.8%, 5%, 5.2%, 5.5%, 5.8%, 6%, 6.2%, 6.5%, 6.8%, 7%, 7.2%, 7.5%, 7.8%, 8%, etc.

[0028] Aluminum silicon alloy: 1%-3%, refine the weld structure; for example: 1.0%, 1.2%, 1.5%, 1.8%, 2.0%, 2.2%, 2.5%, 2.8%, 3.0%, etc.

[0029] Rare earth elements: 0.01%-0.1%, grain refiner; for example: 0.01%, 0.02%, 0.03%, 0.04%, 0.05%, 0.06%, 0.07%, 0.08%, 0.09%, 0.1%, etc.

[0030] Iron (Fe): the balance.

[0031] 2. Mechanism of action of each component 2.1 Main alloying elements (1) Chromium element: Improve the hardness and wear resistance of the system through secondary hardening; Form a dense Cr2O3 oxide film on the surface of the material to resist corrosion by oxidizing media; Form M7C3 carbide with carbon to further improve the hardness of the system; The content is controlled at 10%-30%, too low and the hardness is insufficient, too high and the brittleness increases.

[0032] (2) Hollow cage-like carbon microspheres: The unique hollow structure (diameter 50-100nm) can effectively hinder dislocation movement; High specific surface area (200-400m 2 / g) enhances the bonding force with the matrix; Stable at high temperature, inhibit the coarsening of carbide; The preferred HCS-W50 model has the best reinforcing effect.

[0033] (3) Manganese fluoride: Reduce the surface tension of the droplets and reduce spatter (spatter rate <1%); As a deoxidizer, reduce porosity defects; Form low-melting silicates with silicon to improve slag flowability; 2.2 Auxiliary alloying elements (1) Nickel element: Expand the gamma phase zone, improve plasticity and toughness; Forming Ni3Al ordered phase at high temperature, enhancing high temperature strength; Improving corrosion resistance, especially in acidic environment; ‌(2) Molybdenum element: Solid solution strengthening matrix, improving high temperature strength; Forming Mo2C carbide, enhancing creep resistance; Inhibiting σ phase precipitation, reducing the tendency of embrittlement; ‌(3) Aluminum magnesium alloy: Magnesium vapor generates stirring effect, improving molten pool fluidity; Aluminum as a strong deoxidizer, reducing oxide inclusions; The optimal Al:Mg mass ratio is (85-95):(5-15); ‌(4) Aluminum silicon alloy: Silicon promotes eutectic reaction, refining solidification structure; Forming fine and dispersed silicide, improving strength; The optimal Al:Si mass ratio is (70-95):(5-30); ‌(5) Rare earth elements: Rare earth elements such as cerium (Ce) and yttrium (Y) purify grain boundaries; Changing the morphology of inclusions, reducing stress concentration; Promoting uniform distribution of carbides, inhibiting the formation of network carbides.

[0034] In summary, by optimizing the allocation ratio of each component, the welding wire has the advantages of high hardness, excellent crack resistance and high temperature stability.

[0035] 3. Preparation process The preparation method of the present application comprises the following key steps: ‌(1) batching and pre-melting: First, melt iron and manganese fluoride under a protective atmosphere, then add the remaining materials in a secondary feeding manner, completely melt and stir uniformly, and then pour into ingots; In this step, a step-by-step feeding strategy is adopted: first melt iron and manganese fluoride, then add other components; melt under a protective atmosphere (nitrogen) to prevent element oxidation loss; induction melting ensures composition uniformity.

[0036] ‌(2) vacuum atomization powdering: The vacuum atomization powder making equipment is used to remelt the ingot and make the flux-cored powder, wherein the temperature of the metal liquid is controlled to be 900-1200 ℃, the high-purity nitrogen gas with a purity of 99.999% is used, the nitrogen gas pressure is 2.9-3.3 MPa, the nozzle adopts a tight coupling limiting ring structure, under the high-speed jet and cooling of the nitrogen gas, the metal liquid is dispersed into fine liquid mist and rapidly solidified into powder, and the powder falls into the receiving barrel in the conical cylinder without contacting air in the whole process.

[0037] In the above step, the temperature of the metal liquid is accurately controlled to be 900-1200 ℃, the high-purity nitrogen gas with a purity of 99.999% is used, the pressure is 2.9-3.3 MPa, the tight coupling limiting ring nozzle is adopted, the sphericity of the powder is ensured to be greater than 80%, the whole process is operated in an oxygen-free manner, and the oxygen content is less than 220 ppm.

[0038] ‌(3) Welding wire forming The outer skin is placed on the tape placing machine of the flux-cored wire forming machine, the outer skin steel strip is rolled into a U-shaped groove through the forming machine, then the flux-cored powder is added into the U-shaped groove, the filling rate of the flux-cored powder is controlled to be 35 wt%-50 wt%, the U-shaped groove is closed through the forming machine and is drawn to a diameter of 2-6 mm to obtain the flux-cored wire.

[0039] In this step, the steel strip is rolled into a U-shaped groove, the filling rate is 35-50 wt%, and the precision drawing is to a diameter of 2-6 mm, the dimensional tolerance is ±0.05 mm, and the online monitoring system ensures the quality consistency.

[0040] In the above step, the vacuum atomization powder making and precision drawing processes are adopted to ensure the uniformity of the flux core composition and the dimensional accuracy of the welding wire.

[0041] In the following, the present application is further described in combination with specific embodiments, and it should be noted that the following described embodiments or technical features can be combined in any manner to form new embodiments without conflict. In the following embodiments, the hollow cage-like carbon microspheres are HCS-W50, the performance of which is a diameter of 50 nm, a specific surface area of 350 m 2 / g, a pore size distribution of 5 nm, and the steel strip is a stainless steel 430 steel strip.

[0042] Example 1 A surfacing flux-cored wire is composed of an outer skin and a flux core, and the flux core is composed of components with the following mass percentages: chromium 10%, hollow cage-like carbon microspheres 0.5%, manganese fluoride 13.5%, nickel 4.5%, molybdenum 0.5%, aluminum-magnesium alloy 5% (Al:Mg=90:10), aluminum-silicon alloy 2% (Al:Si=80:20), cerium 0.06%, and the rest is iron.

[0043] The preparation steps are as follows: S1: proportioning, first smelting iron and manganese fluoride under the protection of nitrogen atmosphere, then adding the remaining materials in the form of secondary feeding, completely melting and stirring evenly, and then pouring into ingots; S2: using a vacuum atomization powder production device to remelt the ingots and produce the flux-cored powder; wherein the temperature of the metal liquid is controlled to be 900-1200℃, high-purity nitrogen gas with a purity of 99.999% is used, the nitrogen gas pressure is 2.9~3.3MPa, the nozzle adopts a tight coupling limited ring structure, under the high-speed jet and cooling of nitrogen gas, the metal liquid is dispersed into fine liquid mist and rapidly solidified into powder, and the powder falls into the receiving barrel in the conical cylinder without contacting air throughout the process; S3: placing the sheath on the tape machine of the flux-cored wire forming machine, rolling the sheath steel strip into a U-shaped groove through the forming machine, then adding the flux-cored powder into the U-shaped groove, controlling the filling rate of the flux-cored powder to be 40 wt%, then rolling and closing the U-shaped groove through the forming machine, and drawing it to a diameter of 5mm to obtain the flux-cored wire.

[0044] Example 2 A surfacing flux-cored wire composed of a sheath and a core, the core is composed of the following components in mass percentage: chromium 20%, hollow cage-like carbon microspheres 0.5%, manganese fluoride 13.5%, nickel 4.8%, molybdenum 0.6%, aluminum-magnesium alloy 6% (Al:Mg=85:15), aluminum-silicon alloy 2.5% (Al:Si=85:15), lanthanum 0.06%, and the rest is iron.

[0045] The preparation steps are: S1: proportioning, first smelting iron and manganese fluoride under the protection of nitrogen atmosphere, then adding the remaining materials in the form of secondary feeding, completely melting and stirring evenly, and then pouring into ingots; S2: using a vacuum atomization powder production device to remelt the ingots and produce the flux-cored powder; wherein the temperature of the metal liquid is controlled to be 900-1200℃, high-purity nitrogen gas with a purity of 99.999% is used, the nitrogen gas pressure is 2.9~3.3MPa, the nozzle adopts a tight coupling limited ring structure, under the high-speed jet and cooling of nitrogen gas, the metal liquid is dispersed into fine liquid mist and rapidly solidified into powder, and the powder falls into the receiving barrel in the conical cylinder without contacting air throughout the process; S3: placing the sheath on the tape machine of the flux-cored wire forming machine, rolling the sheath steel strip into a U-shaped groove through the forming machine, then adding the flux-cored powder into the U-shaped groove, controlling the filling rate of the flux-cored powder to be 40 wt%, then rolling and closing the U-shaped groove through the forming machine, and drawing it to a diameter of 5mm to obtain the flux-cored wire.

[0046] Example 3 A surfacing flux-cored wire, which is composed of a sheath and a core, the core is composed of the following components in mass percentage: chromium 30%, hollow cage carbon microspheres 0.5%, manganese fluoride 13.5%, nickel 5.2%, molybdenum 0.7%, aluminum-magnesium alloy 7% (Al:Mg=85:15), aluminum-silicon alloy 3% (Al:Si=90:10), cerium 0.04%, yttrium 0.04%, and the rest is iron.

[0047] The preparation steps are: S1: ingredients are proportioned, iron and manganese fluoride are smelted under a protective atmosphere of nitrogen, then the remaining materials are added in a two-time feeding manner, after complete melting and uniform stirring, the ingot is poured; S2: the ingot is remelted and the core powder is made by using a vacuum atomization powder making equipment; wherein, the temperature of the metal liquid is controlled to be 900-1200℃, high-purity nitrogen with a purity of 99.999% is used, the nitrogen pressure is 2.9~3.3MPa, the nozzle adopts a tight coupling limited ring structure, under the high-speed jet and cooling of nitrogen, the metal liquid is dispersed into fine liquid mist and rapidly solidified into powder, the powder falls into the receiving barrel in the conical cylinder without contacting air in the whole process; S3: the sheath is placed on the tape machine of the flux-cored wire forming machine, the sheath steel belt is rolled into a U-shaped groove by the forming machine, then the core powder is added into the U-shaped groove, the filling rate of the core powder is controlled to be 40 wt%, the U-shaped groove is closed by rolling through the forming machine, and is drawn to a diameter of 5mm, to obtain the flux-cored wire.

[0048] Example 4 A surfacing flux-cored wire, which is composed of a sheath and a core, the core is composed of the following components in mass percentage: chromium 25%, hollow cage carbon microspheres 0.25%, manganese fluoride 13.5%, nickel 4.5%, molybdenum 0.5%, aluminum-magnesium alloy 5% (Al:Mg=90:10), aluminum-silicon alloy 2% (Al:Si=80:20), cerium 0.06%, and the rest is iron.

[0049] The preparation steps are: S1: ingredients are proportioned, iron and manganese fluoride are smelted under a protective atmosphere of nitrogen, then the remaining materials are added in a two-time feeding manner, after complete melting and uniform stirring, the ingot is poured; S2: the ingot is remelted and the core powder is made by using a vacuum atomization powder making equipment; wherein, the temperature of the metal liquid is controlled to be 900-1200℃, high-purity nitrogen with a purity of 99.999% is used, the nitrogen pressure is 2.9~3.3MPa, the nozzle adopts a tight coupling limited ring structure, under the high-speed jet and cooling of nitrogen, the metal liquid is dispersed into fine liquid mist and rapidly solidified into powder, the powder falls into the receiving barrel in the conical cylinder without contacting air in the whole process; S3: placing the sheath on the tape feeder of the flux-cored wire forming machine, rolling the sheath steel strip into a U-shaped groove by the forming machine, then adding the flux powder into the U-shaped groove, controlling the filling rate of the flux powder to be 40 wt%, rolling and closing the U-shaped groove by the forming machine, and drawing it to a diameter of 5 mm to obtain the flux-cored wire.

[0050] Example 5 A surfacing flux-cored wire composed of a sheath and a flux, the flux being composed of the following components in mass percentage: chromium 25%, hollow cage-shaped carbon microspheres 0.5%, manganese fluoride 13.5%, nickel 4.5%, molybdenum 0.5%, aluminum-magnesium alloy 5% (Al:Mg=90:10), aluminum-silicon alloy 2% (Al:Si=80:20), cerium 0.06%, and the rest being iron.

[0051] The preparation steps are as follows: S1: proportioning, first smelting iron and manganese fluoride under a protective atmosphere of nitrogen, then adding the remaining materials in a two-time feeding manner, completely melting and stirring uniformly, and then pouring into an ingot; S2: remelting the ingot and preparing the flux powder by using a vacuum atomization powder preparation device; wherein the metal liquid temperature is controlled to be 900-1200℃, high-purity nitrogen with a purity of 99.999% is used, the nitrogen pressure is 2.9~3.3MPa, the nozzle adopts a tight coupling limiting ring structure, under the high-speed jet and cooling of nitrogen, the metal liquid is dispersed into fine liquid mist and rapidly solidified into powder, and the powder falls into the receiving barrel in the conical cylinder without contacting air in the whole process; S3: placing the sheath on the tape feeder of the flux-cored wire forming machine, rolling the sheath steel strip into a U-shaped groove by the forming machine, then adding the flux powder into the U-shaped groove, controlling the filling rate of the flux powder to be 40 wt%, rolling and closing the U-shaped groove by the forming machine, and drawing it to a diameter of 5 mm to obtain the flux-cored wire.

[0052] Example 6 A surfacing flux-cored wire composed of a sheath and a flux, the flux being composed of the following components in mass percentage: chromium 25%, hollow cage-shaped carbon microspheres 1.0%, manganese fluoride 13.5%, nickel 4.5%, molybdenum 0.5%, aluminum-magnesium alloy 5% (Al:Mg=90:10), aluminum-silicon alloy 2% (Al:Si=80:20), cerium 0.06%, and the rest being iron.

[0053] The preparation steps are as follows: S1: proportioning, first smelting iron and manganese fluoride under a protective atmosphere of nitrogen, then adding the remaining materials in a two-time feeding manner, completely melting and stirring uniformly, and then pouring into an ingot; S2: The vacuum atomization powder preparation equipment is used to remelt the ingot and prepare the flux-cored powder; wherein, the temperature of the metal liquid is controlled to be 900-1200℃, the high-purity nitrogen gas with a purity of 99.999% is used, the nitrogen gas pressure is 2.9-3.3MPa, the nozzle adopts a tight coupling limited ring structure, under the high-speed jet and cooling of the nitrogen gas, the metal liquid is dispersed into fine liquid mist and rapidly solidified into powder, and the powder falls into the receiving barrel in the conical cylinder without contacting the air in the whole process; S3: The outer skin is placed on the tape machine of the flux-cored wire forming machine, the outer skin steel belt is rolled into a U-shaped groove through the forming machine, then the flux-cored powder is added into the U-shaped groove, the filling rate of the flux-cored powder is controlled to be 40 wt%, then the U-shaped groove is rolled and closed through the forming machine, and it is drawn to a diameter of 5mm to obtain the flux-cored wire.

[0054] Comparative Example 1 Different from Example 1, Comparative Example 1 does not contain hollow cage-shaped carbon microspheres, and other aspects are the same as Example 1.

[0055] Specifically, the surfacing flux-cored wire is composed of an outer skin and a core, and the core is composed of components with the following mass percentages: chromium 10%, manganese fluoride 13.5%, nickel 4.5%, molybdenum 0.5%, aluminum-magnesium alloy 5% (Al:Mg=90:10), aluminum-silicon alloy 2% (Al:Si=80:20), cerium 0.06%, and the rest is iron.

[0056] The preparation steps are as follows: S1: The ingredients are proportioned according to the ratio, the iron and manganese fluoride are first melted under a protective atmosphere of nitrogen gas, then the remaining materials are added in a secondary feeding manner, and after complete melting and uniform stirring, the molten metal is poured into an ingot; S2: The vacuum atomization powder preparation equipment is used to remelt the ingot and prepare the flux-cored powder; wherein, the temperature of the metal liquid is controlled to be 900-1200℃, the high-purity nitrogen gas with a purity of 99.999% is used, the nitrogen gas pressure is 2.9-3.3MPa, the nozzle adopts a tight coupling limited ring structure, under the high-speed jet and cooling of the nitrogen gas, the metal liquid is dispersed into fine liquid mist and rapidly solidified into powder, and the powder falls into the receiving barrel in the conical cylinder without contacting the air in the whole process; S3: The outer skin is placed on the tape machine of the flux-cored wire forming machine, the outer skin steel belt is rolled into a U-shaped groove through the forming machine, then the flux-cored powder is added into the U-shaped groove, the filling rate of the flux-cored powder is controlled to be 40 wt%, then the U-shaped groove is rolled and closed through the forming machine, and it is drawn to a diameter of 5mm to obtain the flux-cored wire.

[0057] Comparative Example 2 Different from Example 1, Comparative Example 2 does not contain rare earth (cerium), and other aspects are the same as Example 1.

[0058] Specifically, the surfacing flux-cored wire is composed of a sheath and a core, and the core is composed of components with the following mass percentages: chromium 10%, hollow cage carbon microspheres 0.5%, manganese fluoride 13.5%, nickel 4.5%, molybdenum 0.5%, aluminum-magnesium alloy 5% (Al:Mg=90:10), aluminum-silicon alloy 2% (Al:Si=80:20), and the rest is iron.

[0059] The preparation steps are as follows: S1: ingredients are proportioned, iron and manganese fluoride are smelted under a protective atmosphere of nitrogen, then the remaining materials are added in a two-time feeding manner, and after complete melting and uniform stirring, the molten metal is poured into an ingot; S2: the ingot is remelted and the core powder is prepared by using a vacuum atomization powder preparation device; wherein the temperature of the molten metal is controlled at 900-1200°C, high-purity nitrogen with a purity of 99.999% is used, the nitrogen pressure is 2.9-3.3 MPa, the nozzle adopts a tightly coupled limiting ring structure, under the high-speed jet flow and cooling of nitrogen, the molten metal is dispersed into fine liquid mist and rapidly solidified into powder, and the powder falls into a collection barrel in a conical cylinder without contacting air throughout the process; S3: the sheath is placed on a tape placement machine of a flux-cored wire forming machine, the sheath steel strip is rolled into a U-shaped groove by the forming machine, then the core powder is added into the U-shaped groove, the filling rate of the core powder is controlled at 40 wt%, the U-shaped groove is then rolled and closed by the forming machine, and is drawn to a diameter of 5 mm to obtain the flux-cored wire.

[0060] Comparative Example 3 Different from Example 1, Comparative Example 3 does not contain aluminum-silicon alloy, and other components are the same as those in Example 1.

[0061] The surfacing flux-cored wire is composed of a sheath and a core, and the core is composed of components with the following mass percentages: chromium 10%, hollow cage carbon microspheres 0.5%, manganese fluoride 13.5%, nickel 4.5%, molybdenum 0.5%, aluminum-magnesium alloy 5% (Al:Mg=90:10), cerium 0.06%, and the rest is iron.

[0062] The preparation steps are as follows: S1: ingredients are proportioned, iron and manganese fluoride are smelted under a protective atmosphere of nitrogen, then the remaining materials are added in a two-time feeding manner, and after complete melting and uniform stirring, the molten metal is poured into an ingot; S2: the ingot is remelted and the core powder is prepared by using a vacuum atomization powder preparation device; wherein the temperature of the molten metal is controlled at 900-1200°C, high-purity nitrogen with a purity of 99.999% is used, the nitrogen pressure is 2.9-3.3 MPa, the nozzle adopts a tightly coupled limiting ring structure, under the high-speed jet flow and cooling of nitrogen, the molten metal is dispersed into fine liquid mist and rapidly solidified into powder, and the powder falls into a collection barrel in a conical cylinder without contacting air throughout the process; S3: Place the sheath on the tape machine of the flux-cored wire forming machine, roll the sheath steel strip into a U-shaped groove through the forming machine, then add the flux powder into the U-shaped groove, control the filling rate of the flux powder to be 40 wt%, then roll and close the U-shaped groove through the forming machine, and draw it to a diameter of 5 mm to obtain the flux-cored wire.

[0063] Comparative Example 4 Different from Example 1, Comparative Example 4 does not contain manganese fluoride, and the others are the same as Example 1.

[0064] The surfacing flux-cored wire is composed of a sheath and a flux core, and the flux core is composed of components with the following mass percentages: chromium 10%, hollow cage-shaped carbon microspheres 0.5%, nickel 4.5%, molybdenum 0.5%, aluminum-magnesium alloy 5% (Al:Mg=90:10), aluminum-silicon alloy 2% (Al:Si=80:20), cerium 0.06%, and the rest is iron.

[0065] The preparation steps are as follows: S1: According to the ratio, first melt the iron under a protective atmosphere of nitrogen, then add the remaining materials in a two-step feeding manner, completely melt and stir uniformly, and then pour into an ingot; S2: Remelt the ingot and make the flux powder by using a vacuum atomization powder making equipment; wherein, the metal liquid temperature is controlled to be 900-1200℃, high-purity nitrogen with a purity of 99.999% is used, the nitrogen pressure is 2.9~3.3MPa, the nozzle adopts a tight coupling limited circular ring structure, under the high-speed jet and cooling of nitrogen, the metal liquid is dispersed into fine liquid mist and quickly solidified into powder, and the powder falls into the receiving barrel in the conical cylinder without contacting air throughout the process; S3: Place the sheath on the tape machine of the flux-cored wire forming machine, roll the sheath steel strip into a U-shaped groove through the forming machine, then add the flux powder into the U-shaped groove, control the filling rate of the flux powder to be 40 wt%, then roll and close the U-shaped groove through the forming machine, and draw it to a diameter of 5 mm to obtain the flux-cored wire.

[0066] Comparative Example 5 Different from Example 1, Comparative Example 5 is as follows: A surfacing flux-cored wire is composed of a sheath and a flux core, and the flux core is composed of components with the following mass percentages: chromium 50%, hollow cage-shaped carbon microspheres 0.5%, manganese fluoride 13.5%, nickel 4.5%, molybdenum 0.5%, aluminum-magnesium alloy 5% (Al:Mg=90:10), aluminum-silicon alloy 2% (Al:Si=80:20), cerium 0.06%, and the rest is iron.

[0067] The preparation steps are as follows: S1: proportioning, first melting and stirring completely under the protection of nitrogen atmosphere, and then pouring into ingot; S2: using vacuum atomization powder making equipment to remelt the ingot and make the flux-cored powder; wherein, the temperature of the metal liquid is controlled at 900-1200℃, high-purity nitrogen gas with a purity of 99.999% is used, the nitrogen gas pressure is 2.9~3.3MPa, the nozzle adopts a tight coupling limited ring structure, under the high-speed jet and cooling of nitrogen gas, the metal liquid is dispersed into fine liquid mist and quickly solidified into powder, and the powder falls into the receiving barrel in the conical cylinder without contacting air throughout the process; S3: placing the sheath on the tape machine of the flux-cored wire forming machine, rolling the sheath steel strip into a U-shaped groove through the forming machine, then adding the flux-cored powder into the U-shaped groove, controlling the filling rate of the flux-cored powder to be 40 wt%, then closing the U-shaped groove through the forming machine, and drawing it to a diameter of 5mm to obtain the flux-cored wire.

[0068] Comparative Example 6 Different from Example 1, Comparative Example 6 is as follows: A surfacing flux-cored wire composed of a sheath and a flux, the flux is composed of components with the following mass percentages: chromium 2%, hollow cage-like carbon microspheres 0.5%, manganese fluoride 13.5%, nickel 4.5%, molybdenum 0.5%, aluminum-magnesium alloy 5% (Al:Mg=90:10), aluminum-silicon alloy 2% (Al:Si=80:20), cerium 0.06%, and the rest is iron.

[0069] The preparation steps are as follows: Mixing the materials uniformly to obtain mixed flux-cored powder; Placing the sheath on the tape machine of the flux-cored wire forming machine, rolling the sheath steel strip into a U-shaped groove through the forming machine, then adding the flux-cored powder into the U-shaped groove, controlling the filling rate of the flux-cored powder to be 40 wt%, then closing the U-shaped groove through the forming machine, and drawing it to a diameter of 5mm to obtain the flux-cored wire.

[0070] Performance test 1. Hardness test The Rockwell hardness tester (HRC) is used to measure the surface hardness of the surfacing layer, and the test standard is GB / T 230.1-2018. Five points of each sample are measured, and the average value is taken.

[0071] 2. High temperature hardness test The sample is heated to 600℃ and kept for 1 hour, and a special high temperature hardness tester is used to measure the hardness in a high temperature environment, wherein the hardness retention rate=(high temperature hardness / room temperature hardness) x 100%.

[0072] 3. Anti-cracking test The fishbone-shaped anti-cracking test method is used to measure the crack propagation length along the center line of the test piece, wherein, the crack length less than 15% is evaluated as excellent (no macroscopic crack), 15-30% is qualified (a small amount of micro-cracks), and more than 30% is evaluated as unqualified.

[0073] 4. Abrasion resistance test The ML-100 abrasive wear testing machine is used, the load is 50N, and the abrasive is 80 mesh quartz sand, wherein the abrasion resistance is expressed by the relative wear amount, and compared with Example 1.

[0074] 5. Welding process test The ratio of the metal particles splashed in the welding process to the total deposited metal amount is calculated by using the pulse MIG welding technology, wherein the splashing rate formula is: splashing rate = (splashing mass / melted welding core mass) x 100%.

[0075] 6. The test results are shown in Table 1.

[0076] Table 1

[0077] From the above table, it can be seen that the welding wire of the present application has the advantages of high hardness, excellent crack resistance and high temperature stability, etc. compared with the comparative example.

[0078] The above embodiments are only preferred embodiments of the present application, and cannot be used to limit the scope of protection of the present application, and any non-essential changes and substitutions made by those skilled in the art on the basis of the present application are within the scope of protection of the present application.

Claims

1. A cladding cored welding wire characterized by, The outer skin and the medicine core are composed of the following components in mass percentage: chromium 10%-30%, hollow cage carbon microspheres 0.25%-1.0%, manganese fluoride 12.5%-14.8%, nickel 3.2%-5.5%, molybdenum 0.2%-0.8%, aluminum-magnesium alloy 3%-8%, aluminum-silicon alloy 1%-3%, rare earth 0.01%-0.1%, and the rest is iron.

2. The overlay flux cored welding wire of claim 1, wherein, The hollow cage-like carbon microspheres have the following performance requirements: diameter 50-100 nm, specific surface area 200-400 m 2 / g, pore size distribution 2-10 nm.

3. The overlay flux cored welding wire of claim 2, wherein, The hollow cage carbon microspheres are HCS-W50.

4. The overlay flux cored wire of claim 1 wherein, The mass ratio of aluminum to magnesium in the aluminum-magnesium alloy is (85-95):(5-15).

5. The overlay flux cored welding wire of claim 1 wherein, The mass ratio of aluminum to silicon in the aluminum-silicon alloy is (70-95):(5-30).

6. The overlay flux cored wire of claim 1 wherein, The rare earth is one or more of cerium, yttrium, lanthanum, neodymium and gadolinium.

7. The overlay flux cored welding wire of claim 1 wherein, The filling rate of the medicine core is 35wt%-50wt%.

8. The overlay flux cored wire of claim 1 wherein, The outer skin is a steel belt.

9. A method of making a cladding flux cored wire as claimed in any one of claims 1 to 8, characterised in that, The preparation steps include: S1: proportioning, pre-melting by induction melting process to obtain ingot; S2: remelting the ingot by vacuum atomization powder making equipment to make medicine core powder; S3: placing the outer skin on the belt placing machine of the medicine core wire forming machine, rolling the outer skin steel belt into a U-shaped groove by the forming machine, then adding medicine core powder into the U-shaped groove, controlling the filling rate of the medicine core powder to be 35wt%-50wt%, then rolling and closing the U-shaped groove by the forming machine, and drawing it to a diameter of 2-6mm to obtain the medicine core wire.

10. The method of making a hardfacing flux cored welding wire of claim 9, wherein, In step S1, the pre-melting step by induction melting process is as follows: first, melt iron and manganese fluoride under a protective atmosphere, then add the remaining materials in a secondary feeding manner, completely melt and stir uniformly, and then pour into an ingot; in step S2, the specific steps are as follows: control the metal liquid temperature to be 900-1200℃, use high-purity nitrogen with a purity of 99.999%, the nitrogen pressure is 2.9~3.3MPa, and the nozzle adopts a tight coupling limited ring structure.

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