堆芯焊料中的放热添加物对自保护药芯焊弧焊接过程中电弧稳定性和微观结构的影响

Crystals Pub Date : 2024-03-31 DOI:10.3390/cryst14040335
V. Lozynskyi, Bohdan Trembach, Egidijus Katinas, Kostiantyn Sadovyi, M. Krbaťa, Oleksii Balenko, Ihor Krasnoshapka, Olena Rebrova, Sergey Knyazev, Oleksii Kabatskyi, Hanna Kniazieva, L. Ropyak
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引用次数: 0

摘要

在能源危机的条件下,提高焊接和堆焊工艺的能源效率和生产率是一个重要问题。文章论证了在药芯焊丝电弧焊工艺的芯材填料中加入放热添加剂作为相对廉价的附加热源的观点,从而降低了熔化填料时的能耗,并提高了熔敷率。混合设计(MD)被选为优化电流和电压平均值以及电弧稳定性参数(取决于焊芯填料成分)的设计方法。本文研究了在 FCAW S 工艺中引入放热添加剂 (EA) 以及 CuO/C 和 CuO/Al 比例对电弧稳定性的影响。使用示波器确定了表征电弧稳定性的参数,并根据获得的示波器分析了药芯弧焊过程中的电弧电压和焊接电流信号。结果表明,有多种方法可用于评估电弧稳定性,这些方法可分为两类:图形方法(电流和电压循环图、带有频率直方图的箱形图、绘制在电流和电压循环图上的椭圆参数)和统计方法(焊接电流和电弧电压的标准变异和变异系数)。本文根据焊芯填料的成分对电弧稳定性进行了综合评估。结果表明,药芯焊丝电极的平均放热添加量为 EA = 26.5-28.58 wt.%,碳含量高(CuO/C = 3.75 的低值),其电流参数最为稳定。相反,在使用药芯焊丝电极进行硬面堆焊时,电弧稳定性(CV(U) 和 Std(U))值最低,该电极的 CuO/Al 比高达 ≥ 4.5,芯部填料中的放热添加物含量低于平均 EA < 29 wt.%。建立了焊接电流和电弧电压的平均值、标准偏差和变异系数数学模型。结果表明,响应面预测模型具有良好的准确性和预测能力。所建立的数学模型表明,放热添加剂(CuO/Al)成分中氧化剂与还原剂的比例对所研究的焊接电流和电弧电压特性影响最大。焊芯填料(EA)中放热混合物的比例仅影响平均焊接电流(Iaw)和平均电弧电压(Uaw)。通过 CuO/C 比率表示的石墨含量对焊接电流参数和电弧电压变化系数(CV(U))有显著影响。选择了两个焊接参数进行优化:平均焊接电流 (Iaw) 和电弧电压标准偏差 (std(U))。在焊芯填料中使用放热添加剂 CuO-Al 时,CuO/Al = 3.6-3.9、CuO/C = 3.5-4.26、EA 平均含量为 29-38 wt.%,电弧稳定性最佳。CuO/Al 和 CuO/C 比率对电弧电压参数的重大影响也可以通过它们对焊接电弧元素成分(铜、氧化铜 (CuO) 和 Al2O3)的影响来解释。这种反应越完全,电弧等离子体中易气化的铜(Cu)含量就越高,从而提高电弧的稳定性。研究了铁芯填料成分对 Fe-Cr-Cu-Ti 合金体系熔敷金属微观结构的影响。
本文章由计算机程序翻译,如有差异,请以英文原文为准。
Effect of Exothermic Additions in Core Filler on Arc Stability and Microstructure during Self-Shielded, Flux-Cored Arc Welding
In the conditions of an energy crisis, an important issue is the increase in energy efficiency and productivity of welding and hardfacing processes. The article substantiates the perspective of using exothermic additives introduced into core filler for flux-cored wire arc welding processes as a relatively cheap additional heat source, reducing energy consumption when melting filler materials, and increasing the deposition rate. The mixture design (MD) was selected as the design method to optimize the average values of current and voltage, as well as arc stability parameters depending on core filler composition. This article studies the influence of the introduction of exothermic addition (EA), as well as the ratios CuO/C and CuO/Al on arc stability for the FCAW S process. Parameters characterizing arc stability were determined using an oscillograph, and from the obtained oscillograms, an analysis was conducted on arc voltage and welding current signals during flux-cored arc welding. It was determined that various methods can be used to evaluate arc stability, which can be divided into two groups: graphical (current and voltage cyclograms, box plots with frequency histograms, ellipse parameters plotted on current, and voltage cyclograms) and statistical (standard variation and coefficients of variation for welding current and arc voltage). In this paper, a comprehensive evaluation of arc stability depending on the composition of the cored wire filler was carried out. It was determined that the most stable current parameters were observed for the flux-cored wire electrode with an average exothermic addition content at the level of EA = 26.5–28.58 wt.% and a high carbon content (low values of CuO/C = 3.75). Conversely, the lowest values of arc stability (CV(U) and Std(U)) were observed during hardfacing with a flux-cored wire electrode with a high CuO/Al ratio ≥ 4.5 and a content of exothermic addition in the core filler below the average EA < 29 wt.%. Mathematical models of mean values, standard deviation, coefficient of variation for welding current, and arc voltage were developed. The results indicated that the response surface prediction models had good accuracy and prediction ability. The developed mathematical models showed that the ratio of oxidizing agent to reducing agent in the composition of exothermic addition (CuO/Al) had the greatest influence on the welding current and arc voltage characteristics under investigation. The percentage of exothermic mixture in the core filler (EA) only affected the average welding current (Iaw) and the average arc voltage (Uaw). The graphite content expressed through the CuO/C ratio had a significant impact on welding current parameters as well as the coefficient of variation of arc voltage (CV(U)). Two welding parameters were selected for optimization: the mean welding current (Iaw) and the standard deviation of arc voltage (Std(U)). The best arc stability when using exothermic addition CuO-Al in the core filler was observed at CuO/Al = 3.6–3.9, CuO/C = 3.5–4.26, and at an average EA content of 29–38 wt.%. The significant influence of the CuO/Al and CuO/C ratios on arc voltage parameters can also be explained by their impact on the elemental composition of the welding arc (copper, cupric oxide (CuO), and Al2O3). The more complete this reaction, the higher the amount of easily vaporized copper (Cu) in the arc plasma, enhancing arc stability. The influence of core filler composition on the microstructure of deposited metal of the Fe-Cr-Cu-Ti alloy system was investigated.
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