Cobalt Overlay Repair Welding With Dilution Ratio Control
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Solution Overview
Problem
In overlay welding of cobalt-based alloys, the dilution ratio is difficult to control during repair welding as the base material does not melt, leading to potential cracking due to age hardening, and existing methods fail to maintain the specified dilution range.
Innovation Solution
An overlay welding method that generates an arc between a welding torch and the overlay welded portion, forming a melt pool and simultaneously inserting a similar-composition welding material and a cobalt-based alloy welding material into the pool to control the dilution ratio, ensuring the base material components dissolve appropriately.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If repair welding is performed on a cobalt-based alloy overlay welded portion using conventional methods, then the welding process can be completed, but the dilution ratio becomes difficult to control and may fall outside the specified range, leading to cracking
Solution Approach 1:
The invention changes the compositional parameters of the welding material by adding specific elements (Fe: 3-15 mass%, Ni: 2-10 mass%, Cr: 5-20 mass%) to the cobalt-based alloy welding material. This parameter adjustment ensures that when the welding material melts and mixes with the base material in the melt pool, the resulting dilution ratio falls within the specified range, preventing cracking while maintaining manufacturing precision
Solution Approach 2:
The invention creates a composite welding material system that combines cobalt-based alloy with additional elements (Fe, Ni, Cr) to form a multi-component welding material. This composite material structure allows for controlled interaction with the base material during welding, achieving both crack suppression and precise dilution ratio control through the synergistic effect of multiple elements
2Ease of repair
If the base material is not directly melted during repair welding of cobalt-based alloy, then the overlay welded portion can be repaired, but the dilution ratio is reduced and cannot be controlled within the specified range
Solution Approach 1:
The invention adjusts the compositional parameters of the welding material to compensate for the lack of base material melting. By adding specific amounts of Fe, Ni, and Cr elements to the cobalt-based alloy welding material, the invention ensures that the dilution ratio achieved through partial mixing in the melt pool falls within the specified range, maintaining manufacturing precision while preserving repairability
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method effectively suppresses the reduction in dilution ratio during repair welding, preventing cracking and maintaining the specified range, thereby enhancing the wear resistance and durability of the repair welded portion.
Implementation Method 1
generating an arc between a welding torch and the overlay welded portion, forming a melt pool by melting a surface of the overlay welded portion with the arc
Data Source
AI summary
A method of performing overlay welding on a member including a steel material and an overlay welded portion made of a cobalt-based alloy and formed on the steel material, the method including generating an arc between a welding torch and the overlay welded portion, forming a melt pool by melting a surface of the overlay welded portion with the arc, and simultaneously inserting a similar-composition welding material having a composition similar to the steel material and a cobalt-based alloy welding material made of a cobalt-based alloy into the melt pool.