Flux-Cored Wire Single-Layer Wear Surfacing
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Solution Overview
Problem
Existing submerged-arc welding methods for surfacing require multiple layers to achieve a wear layer with desired alloy composition and hardness, leading to increased material, energy, and time consumption, along with potential cracking issues due to deep penetration and mixing with the parent material.
Innovation Solution
The use of flux-cored wire electrodes with a higher alloy content and a magnetizable casing electrode allows for deep penetration and efficient mixing, enabling a single-layer wear layer with improved hardness and corrosion resistance by adjusting welding parameters and metal powder composition, which mimics the characteristics of a third layer in conventional multilayer welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If submerged-arc welding is used for surfacing, then welding rate and penetration are improved, but dendritic structure and cracking tendency increase
Solution Approach 1:
The patent changes the welding parameters by using flux-cored wire electrodes with specific alloy compositions (higher carbon and alloy content than conventional electrodes) and controlled welding currents to achieve a balance between penetration depth and dendritic structure formation, reducing cracking tendency while maintaining high welding rates
2Stability of the object's composition
If strip electrodes are used to reduce penetration, then mixing with parent material is reduced, but number of layers required increases
Solution Approach 1:
The patent uses flux-cored wire electrodes with specifically designed alloy compositions that contain higher proportions of alloying elements (such as chromium, nickel, molybdenum) compared to conventional electrodes. This allows achieving the desired wear layer composition in a single layer by controlling the chemical composition parameters of the filler material
Solution Approach 2:
The patent employs composite flux-cored wire electrodes that combine multiple materials within the core (metal powder, flux, alloying elements) to achieve complex alloy compositions in a single electrode, enabling single-layer surfacing with the desired properties
3Productivity
If high energy density is used for deep penetration, then welding rate is improved, but heat-affected zone and intrinsic stresses increase
Solution Approach 1:
The patent optimizes welding parameters including current density, welding speed, and electrode composition to control the thermal input. By using flux-cored wires with specific alloy content and adjusting welding parameters, the process achieves high welding rates while controlling the heat-affected zone size and reducing intrinsic stresses through parameter optimization
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 reduces material, energy, and processing time by producing a single wear layer with enhanced hardness and corrosion resistance, while avoiding dendritic seam formation and cracking, and achieves a thickness comparable to three layers in conventional methods, with a significant cost and time savings.
Implementation Method 1
welding powder is supplied to the weld pool
Implementation Method 2
a first wire electrode and at least one second wire electrode each have a welding current applied to them
Implementation Method 3
produce a common weld pool
Data Source
AI summary
A method of welding a wear layer onto a parent material, wherein a welding current is applied to a first wire electrode and to at least one second wire electrode. The first wire electrode and at least one second wire electrode are continuously fed to the parent material for producing a common weld pool. Metal powder and welding powder are fed to the weld pool. The wire electrodes are flux-cored wire electrodes, having a core and a covered electrode. The flux-cored wire electrodes have a higher alloy than a weld deposit analysis of the wear layer to be welded on the parent material. The covered electrode of the flux-cored wire electrodes includes an alloy, which has magnetization properties suitable for adhesion of the metal powder.