相关申请的交叉引用：本申请要求2009年6月5日递交的美国专利申请序列号12/478,849以及2012年12月10日递交的美国专利申请序列号13/709,684的优先权，所述两个申请都通过引用被完全并入本文。CROSS REFERENCE TO RELATED APPLICATIONS: This application claims priority to U.S. Patent Application Serial No. 12/478,849, filed June 5, 2009, and U.S. Patent Application Serial No. 13/709,684, filed December 10, 2012, both of which Both applications are fully incorporated herein by reference.
发明的技术领域technical field of invention
提供焊接丝焊条和方法用于提高的焊缝性能。更特别地，提供并入这样的材料的焊接丝焊条和方法，所述材料在被包含在金属套的芯之内的芯材料的颗粒上具有至少一层金属性包覆物(metallic coating)。再更特别地，提供根据权利要求1的前序部分(preamble)的焊接丝电极，以及根据权利要求12的前序部分的堆焊(hard surfacing)金属工件的方法。Welding wire electrodes and methods are provided for improved weld performance. More particularly, welding wire electrodes and methods incorporating materials having at least one layer of metallic coating on particles of core material contained within a core of a metal sheath are provided. Still more particularly, a welding wire electrode according to the preamble of claim 1 , and a method of hard surfacing a metal workpiece according to the preamble of claim 12 are provided.
发明背景Background of the invention
多年来，常规的焊条以及制造这样的焊条的方法已经是可获得的。然而，虽然在焊接过程期间，这样的常规的焊条和方法多少排除氮和氧进入焊缝，但是其不足以将氮和氧从焊接电弧等离子体(weld arc plasma)排除。Conventional electrodes and methods of making such electrodes have been available for many years. However, while such conventional electrodes and methods somewhat exclude nitrogen and oxygen from entering the weld during the welding process, they do not adequately exclude nitrogen and oxygen from the weld arc plasma.
在焊剂芯弧焊工艺(FCAW)中，被包含在金属套的芯之内的芯材料(包括焊剂化合物和合金化(alloying)化合物)在焊接过程期间受到电弧中的高温反应和氧化反应的影响。最终，这些反应对芯材料和被沉积的焊缝金属的性质造成有害的改变。In the flux cored arc welding process (FCAW), the core material (including flux compounds and alloying compounds) contained within the core of the metal sheath is subjected to high temperature reactions and oxidation reactions in the arc during the welding process . Ultimately, these reactions cause detrimental changes to the properties of the core material and deposited weld metal.
发明内容Contents of the invention
根据一个实施方案，提供焊接丝焊条。所述焊接丝焊条包括金属套以及芯材料，所述金属套包括芯，所述芯材料被包含在所述金属套的所述芯之内，其中所述芯材料包括至少一种金属合金化化合物的颗粒，其中所述颗粒中的每个具有外表面，并且其中至少一层金属性包覆物被沉积到每个颗粒的所述外表面上，以形成金属性包覆的颗粒。According to one embodiment, a welding wire electrode is provided. The welding wire electrode includes a metal sheath including a core and a core material contained within the core of the metal sheath, wherein the core material includes at least one metal alloying compound wherein each of the particles has an outer surface, and wherein at least one layer of metallic coating is deposited on the outer surface of each particle to form metallic coated particles.
根据另一个实施方案，提供一种堆焊金属工件的方法，所述方法包括以下步骤：提供金属工件，制备包括多个颗粒的颗粒状金属合金化化合物，其中所述多个颗粒中的每个具有外表面，并且其中将至少一层金属性包覆物沉积到每个颗粒的所述外表面上以形成金属性包覆的颗粒，制备包括所述金属性包覆的颗粒的芯材料，通过将所述芯材料放置到金属套中来形成有芯丝焊条，将所述有芯丝焊条朝所述工件输送，以及采取焊接手段以创建焊接熔池并且将所述有芯丝焊条传递到所述焊接熔池中，其中所述有芯丝焊条的至少一部分被熔化，并且所述金属性包覆的颗粒被沉积到所述焊接熔池中。According to another embodiment, there is provided a method of overlaying a metal workpiece, the method comprising the steps of: providing a metal workpiece, preparing a particulate metal alloying compound comprising a plurality of particles, wherein each of the plurality of particles having an outer surface, and wherein at least one layer of metallic coating is deposited onto said outer surface of each particle to form a metallic coated particle, preparing a core material comprising said metallic coated particle by placing the core material into a metal sheath to form a cored electrode, conveying the cored electrode toward the workpiece, and performing welding to create a weld puddle and deliver the cored electrode to the The weld puddle wherein at least a portion of the cored wire electrode is melted and the metallically coated particles are deposited into the weld puddle.
根据又另一个实施方案，提供一种用于与热丝焊接工艺一起使用的焊接丝焊条，所述焊条包括金属套以及芯材料，所述金属套包括芯，所述芯材料被包含在所述金属套的所述芯之内，其中所述芯材料包括至少一种金属合金化化合物的颗粒，其中所述颗粒中的每个具有外表面，其中至少一层金属性包覆物通过气相沉积工艺被沉积到每个颗粒的所述外表面上，以形成金属性包覆的颗粒，并且其中所述金属性包覆的颗粒中的每个被沉积到焊接熔池中，所述焊接熔池在热丝焊接过程期间被形成。另外的实施方案在以下描述、附图和权利要求中被公开。According to yet another embodiment, there is provided a welding wire electrode for use with a hot wire welding process, the electrode comprising a metal sheath including a core, the core material contained in the Within said core of a metal sheath, wherein said core material comprises particles of at least one metal alloying compound, wherein each of said particles has an outer surface, wherein at least one metallic coating is deposited by a vapor phase deposition process is deposited onto the outer surface of each particle to form metallically coated particles, and wherein each of the metallically coated particles is deposited into a weld pool, the weld pool at are formed during the hot wire bonding process. Additional embodiments are disclosed in the following description, drawings, and claims.
附图简要描述Brief description of the drawings
虽然说明书以特别地指明并清楚地要求本发明的权利要求结束，但是认为的是所述说明书将从以下采取结合附图的方式的描述被更好地理解，在所述附图中：While the specification concludes with claims which particularly point out and distinctly claim the invention, it is believed that the specification will be better understood from the following description when taken in conjunction with the accompanying drawings in which:
图1是描绘根据本发明的一个实施方案的焊接焊条的截面图；以及Figure 1 is a cross-sectional view depicting a welding electrode according to one embodiment of the present invention; and
图2是描绘根据本发明的另一个实施方案的焊接焊条的截面图。Fig. 2 is a cross-sectional view depicting a welding electrode according to another embodiment of the present invention.
发明详细描述Detailed description of the invention
选定的实施方案在此关于图1被详细描述。图1图示说明焊接焊条10的截面。如在图1中图示说明的，焊接焊条10描绘焊剂芯焊条的实施方案，其中焊剂部分20可以基本上被金属性电极部分30围绕，并且焊剂部分20可以充当焊条10的芯。在图1中表示的配置中，焊剂部分20可以被采用来在焊接操作期间提供保护气体，以便排除氮进入焊缝金属，这可以通过在焊接操作期间将空气与焊接熔池屏蔽开来实现。这些类型的焊接焊条一般地被称为自保护焊条。自保护焊条被使用在许多不同类型的焊接操作中，比如焊剂芯弧焊(“FCAW”)。在一个实施方案中，焊剂部分可以在焊条的重量的从约5％至约50％的范围内。在另一个实施方案中，焊剂部分可以在焊条的重量的从约10％至约30％的范围内。Selected embodiments are described in detail herein with respect to FIG. 1 . FIG. 1 illustrates a cross-section of a welding electrode 10 . As illustrated in FIG. 1 , welding electrode 10 depicts an embodiment of a flux-cored electrode in which flux portion 20 may be substantially surrounded by metallic electrode portion 30 , and flux portion 20 may serve as the core of electrode 10 . In the configuration shown in FIG. 1, the flux portion 20 may be employed to provide shielding gas during the welding operation in order to exclude nitrogen from entering the weld metal, which may be accomplished by shielding the weld pool from air during the welding operation. These types of welding electrodes are generally referred to as self-shielding electrodes. Self-shielded electrodes are used in many different types of welding operations, such as flux cored arc welding ("FCAW"). In one embodiment, the flux portion may range from about 5% to about 50% by weight of the electrode. In another embodiment, the flux portion may range from about 10% to about 30% by weight of the electrode.
在焊接过程中，焊条经由形成焊剂部分的材料产生其自己的保护气体，以将氧和氮从焊接熔池的区域去除。保护气体由包含在焊剂部分中的化合物产生，所述化合物在焊接期间分解和/或汽化(vaporize)。所释放的气体使在焊接弧环境中的氮和氧的分压降低，以至于焊接熔池对氮和氧的吸收被降低。During welding, the electrode generates its own shielding gas via the material forming part of the flux to remove oxygen and nitrogen from the region of the weld puddle. The shielding gas is generated from compounds contained in the flux portion which decompose and/or vaporize during soldering. The released gases lower the partial pressure of nitrogen and oxygen in the welding arc environment so that the uptake of nitrogen and oxygen by the weld pool is reduced.
为了达到氮从焊缝金属排除，常规的自保护焊条在焊剂部分、金属性电极部分的任一部分中包含一定量的铝或者两个部分中都包含一定量的铝。铝的存在有助于将氮和氧与焊缝金属阻隔开，并且防止脆性焊缝，所述脆性焊缝在许多应用中是不符合期望的。同样地，需要焊条具有这样的组成，所述组成在焊接操作期间阻挡氮进入焊缝金属并且不结束或者不显著地妨碍焊缝金属的相转移。To achieve nitrogen exclusion from the weld metal, conventional self-shielding electrodes contain an amount of aluminum in either the flux portion, the metallic electrode portion, or both. The presence of aluminum helps to keep nitrogen and oxygen away from the weld metal and prevents brittle welds, which are undesirable in many applications. Likewise, it is desirable for the electrode to have a composition that blocks nitrogen from entering the weld metal and does not end or significantly impede the phase transfer of the weld metal during the welding operation.
在一个实施方案中，焊剂部分可以包括这样的材料，所述材料包括颗粒，其中每个颗粒包括基本上用外层包覆的基体(substrate)。所述外层可以包括铝，从而形成铝包覆的颗粒。在一个实施方案中，所述基体可以包括非金属性粉末，比如氧化物和/或氟化物。所述氧化物可以包括氧化锂。所述氟化物可以包括氟化钡和/或氟化钙。在另一个实施方案中，在添加所述外层之前可以将第二层添加到所述基体，例如，所述第二层可以是水分屏障层(moisture barrier layer)。所述水分屏障层的添加可以被用来防止非金属性粉末的过早降解。在一个实施方案中，所述水分屏障层可以包括铁、锰、镍和/或任何其他适合的水分屏障组分。In one embodiment, the flux portion may comprise a material comprising particles, wherein each particle comprises a substrate substantially clad with an outer layer. The outer layer may comprise aluminum, thereby forming aluminum-coated particles. In one embodiment, the matrix may comprise non-metallic powders, such as oxides and/or fluorides. The oxide may include lithium oxide. The fluoride may include barium fluoride and/or calcium fluoride. In another embodiment, a second layer may be added to the substrate prior to adding the outer layer, for example, the second layer may be a moisture barrier layer. The addition of the moisture barrier layer can be used to prevent premature degradation of non-metallic powders. In one embodiment, the moisture barrier layer may include iron, manganese, nickel, and/or any other suitable moisture barrier component.
在一个实施方案中，铝包覆的颗粒可以具有从约50μm至约300μm的范围内的直径。在一个实施方案中，颗粒的基体可以在所述颗粒的重量的从约70％至约95％的范围内。在另一个实施方案中，颗粒的基体可以在所述颗粒的重量的从约80％至约88％的范围内。在一个实施方案中，颗粒的外层可以在所述颗粒的重量的从约5％至约30％的范围内。在另一个实施方案中，颗粒的外层可以在所述颗粒的重量的从约12％至约20％的范围内。在一个实施方案中，颗粒的外层可以具有在从约2μm至约10μm的范围内的厚度。In one embodiment, the aluminum-coated particles may have a diameter ranging from about 50 μm to about 300 μm. In one embodiment, the matrix of the particle may range from about 70% to about 95% by weight of the particle. In another embodiment, the matrix of the particle may range from about 80% to about 88% by weight of the particle. In one embodiment, the outer layer of the particle may range from about 5% to about 30% by weight of the particle. In another embodiment, the outer layer of the particle may range from about 12% to about 20% by weight of the particle. In one embodiment, the outer layer of the particle may have a thickness in the range of from about 2 μm to about 10 μm.
本文中所描述的铝包覆的颗粒可以用各种方式制备。在一个实施方案中，所述铝包覆的颗粒可以通过化学气相沉积被形成。化学气相沉积可以是被用来生产高纯度、高性能的固体材料的化学工艺。在典型的化学气相沉积工艺中，基底被暴露于一种或更多种前驱体，所述前驱体在基底表面上反应和/或分解以产生期望的沉积层，例如铝。在一个实施方案中，铝层可以通过涉及三异丁基铝和/或三乙基铝的反应被沉积在基底上。在另一个实施方案中，铝包覆的颗粒可以通过物理气相沉积被形成。物理气相沉积可以包括通过汽化形式的材料(例如，铝)的某种形式的冷凝将薄膜沉积到各种表面(例如，基底表面)上的任何类型的方法。在一个实施方案中，在物理气相沉积中使用的包覆方法可以涉及物理工艺，比如高温真空蒸发或等离子溅射轰击。The aluminum-coated particles described herein can be prepared in a variety of ways. In one embodiment, the aluminum-coated particles may be formed by chemical vapor deposition. Chemical vapor deposition can be a chemical process used to produce high purity, high performance solid materials. In a typical chemical vapor deposition process, a substrate is exposed to one or more precursors that react and/or decompose on the surface of the substrate to produce a desired deposited layer, such as aluminum. In one embodiment, the aluminum layer may be deposited on the substrate by a reaction involving triisobutylaluminum and/or triethylaluminum. In another embodiment, aluminum-coated particles can be formed by physical vapor deposition. Physical vapor deposition can include any type of method that deposits thin films onto various surfaces (eg, a substrate surface) by some form of condensation of a material in vaporized form (eg, aluminum). In one embodiment, the cladding method used in physical vapor deposition may involve physical processes such as high temperature vacuum evaporation or plasma sputter bombardment.
在焊剂部分20中铝包覆的颗粒的存在可以提供在图1中图示说明的焊接焊条10中使用的铝的减少。在比如焊接的应用中，铝包覆的颗粒可以充当除氮剂和除氧剂，以从焊接熔池消除氮和氧。例如，铝包覆的颗粒可以将更多氧和的氮从焊接熔池去除，获得具有提高的物理性质的更纯净的焊缝金属。经由铝包覆的颗粒使铝在焊剂部分中被传递可以提供铝在焊条的芯中的更均匀的分布，并且可以提供更大的表面积，使得铝更具有化学反应性。因此，在一个实施方案中，至少一些通常存在于焊条的焊剂部分的铝被替换为铝包覆的颗粒。在一个实施方案中，焊剂部分包括直至约5％至约30％重量的铝包覆颗粒。在又另一个实施方案中，焊剂部分包括约12％至约20％重量的铝包覆的颗粒。当然，在焊条的焊剂部分中存在的铝包覆的颗粒的总的百分比可以依据焊条类型、期望的性能以及构造。The presence of aluminum-coated particles in the flux portion 20 may provide a reduction in the aluminum used in the welding electrode 10 illustrated in FIG. 1 . In applications such as welding, aluminum-coated particles can act as nitrogen and oxygen scavengers to eliminate nitrogen and oxygen from the weld puddle. For example, aluminum coated particles can remove more oxygen and nitrogen from the weld puddle, resulting in a purer weld metal with improved physical properties. Having the aluminum delivered in the flux portion via the aluminum coated particles can provide a more even distribution of the aluminum in the core of the electrode and can provide a larger surface area making the aluminum more chemically reactive. Thus, in one embodiment, at least some of the aluminum normally present in the flux portion of the electrode is replaced with aluminum coated particles. In one embodiment, the flux portion includes up to about 5% to about 30% by weight aluminum coated particles. In yet another embodiment, the flux portion includes from about 12% to about 20% by weight aluminum-coated particles. Of course, the overall percentage of aluminum-coated particles present in the flux portion of the electrode may depend on the electrode type, desired properties, and configuration.
在一个实施方案中，在整个焊条中铝包覆的颗粒可以完全替换铝。因此，如果常规的焊条包括焊剂部分的重量的约10％的铝，那么焊条的一个实施方案可以包括焊剂部分的重量的约10％的铝包覆的颗粒，而不添加铝。当然，本领域普通技术人员将理解，由于各种制造技术，依据制造工艺和使用的材料，痕量的铝可能存在于焊条中。因此，有意添加的铝的量可以被替换为铝包覆的颗粒。In one embodiment, the aluminum coated particles can completely replace the aluminum throughout the electrode. Thus, if a conventional electrode includes about 10% aluminum by weight of the flux portion, one embodiment of the electrode may include about 10% aluminum-coated particles by weight of the flux portion without added aluminum. Of course, those of ordinary skill in the art will appreciate that traces of aluminum may be present in the electrode due to various manufacturing techniques, depending on the manufacturing process and materials used. Thus, the amount of intentionally added aluminum can be replaced by aluminum coated particles.
如在表1中示出的实施例中说明的，随着在焊剂部分中来自铝包覆的颗粒的铝的分数增加，在焊接过程期间存在的氮和氧的量减少。As illustrated in the examples shown in Table 1, as the fraction of aluminum from aluminum-coated particles in the flux portion increases, the amount of nitrogen and oxygen present during the soldering process decreases.
表1Table 1
因此，在焊条的焊剂部分中使用具有铝包覆的颗粒的材料可以提供在焊接焊条中存在的铝的量的减少，而不降低焊接焊条的保护性能，并且在所得到的焊缝中没有任何不利的冶金效应。事实上，相比于常规的焊条，使用根据本文中讨论的各种实施方案的焊条可以获得提高的冶金性质，因为留在焊缝中的铝的总量被减少。Thus, the use of a material having aluminum-coated particles in the flux portion of the electrode can provide a reduction in the amount of aluminum present in the welding electrode without reducing the protective properties of the welding electrode and without any Unfavorable metallurgical effects. In fact, improved metallurgical properties may be obtained using electrodes according to various embodiments discussed herein as compared to conventional electrodes because the total amount of aluminum left in the weld is reduced.
除了铝包覆的颗粒，在一个实施方案中，其他化合物，比如铝金属粉末和/或铝合金粉末(例如，55％Al，45％Mg)也可以被包括在焊剂部分中。在一个实施方案中，在焊剂部分中来自铝包覆的颗粒的铝的量在焊剂部分中的全部铝的重量的从约10％至约100％的范围内。在另一个实施方案中，在焊剂部分中来自铝包覆的颗粒的铝的量在焊剂部分中的全部铝的重量的从约19％至约81％的范围内。In addition to aluminum coated particles, in one embodiment, other compounds such as aluminum metal powder and/or aluminum alloy powder (eg, 55% Al, 45% Mg) may also be included in the flux portion. In one embodiment, the amount of aluminum from the aluminum-coated particles in the flux portion ranges from about 10% to about 100% by weight of the total aluminum in the flux portion. In another embodiment, the amount of aluminum from the aluminum-coated particles in the flux portion ranges from about 19% to about 81% by weight of the total aluminum in the flux portion.
注意的是，取决于铝包覆的颗粒的反应性，在焊条中使用的铝包覆的颗粒的百分比可能需要被调节以获得期望的性能。因此，将理解的是，在形成特定的焊条的过程中，本领域技术人员可以决定所采用的铝包覆的颗粒的合适的量，铝包覆的颗粒是否与铝组合，或者单独使用。同样地，所使用的铝包覆的颗粒的总量可以依据焊条的期望的性能，所述性能针对其提供所需的除氧和除氮以及产生具有符合期望的冶金性质(比如韧性)的焊缝的能力。Note that depending on the reactivity of the aluminum coated particles, the percentage of aluminum coated particles used in the electrode may need to be adjusted to obtain the desired performance. Thus, it will be appreciated that one skilled in the art can determine the appropriate amount of aluminum-coated particles to employ, whether aluminum-coated particles are used in combination with aluminum, or alone, in forming a particular electrode. Likewise, the total amount of aluminum-coated particles used may depend on the desired properties of the electrode for it to provide the required oxygen and nitrogen scavenging as well as produce a weld with desirable metallurgical properties, such as toughness. ability to sew.
铝包覆的颗粒一般地可以是无定形的，因此从制造角度来说在形成焊接焊条的焊剂部分的材料中布置铝包覆的颗粒是方便的。在混合过程期间铝包覆的颗粒可以被添加到焊接焊条的焊剂部分，以形成要被添加到焊条的焊剂部分。随后在制造过程期间焊剂部分被添加以形成最终的焊接焊条。如本文中讨论的，焊剂部分可以基本上被金属性电极部分围绕，并且充当焊条的芯。将理解的是，金属性电极部分可以由在任何可应用的焊接应用中使用的任何适合的一种或多种金属化合物和/或合金形成。此外，焊条可以被制造以用于许多焊接应用，并且，同样地，本领域技术人员将理解，焊条的物理尺寸(例如，焊条的直径)以及作为焊条的一部分的焊剂部分的整合与已知的焊接焊条类似。The aluminum-coated particles may generally be amorphous and it is therefore convenient from a manufacturing standpoint to arrange the aluminum-coated particles in the material forming the flux portion of the welding electrode. Aluminum coated particles may be added to the flux portion of the welding electrode during the mixing process to form the flux portion to be added to the electrode. The flux portion is then added during the manufacturing process to form the final welding electrode. As discussed herein, the flux portion may be substantially surrounded by the metallic electrode portion and serve as the core of the electrode. It will be appreciated that the metallic electrode portion may be formed from any suitable metal compound(s) and/or alloy(s) used in any applicable welding application. In addition, electrodes can be manufactured for many welding applications, and, as such, those skilled in the art will appreciate that the physical dimensions of the electrodes (e.g., the diameter of the electrode) and the integration of the flux portion as part of the electrodes are consistent with known Welding electrodes are similar.
其他实施方案在此关于图2被详细描述。图2图示说明焊接丝焊条100的截面。如在图2中图示说明的，焊接丝焊条100描绘丝焊条的实施方案，其中芯材料部分200可以基本上被包含在金属套部分300之内，并且芯材料200被包含在焊接丝焊条100的芯之内。金属套300的组成包括，但不限于，钢、镍、铝以及焊接丝制造领域的技术人员已知的其他金属和合金。在图2中表示的配置中，在焊接操作期间芯材料部分200被采用来提供反应性的芯颗粒或金属合金化化合物，以便将所述金属合金化化合物传递到焊缝金属中。在一个实施方案中，芯材料在焊接丝焊条的重量的从约5％至约50％的范围内。在另一个实施方案中，芯材料在焊接丝焊条的重量的从约10％至约30％的范围内。Other embodiments are described in detail herein with respect to FIG. 2 . FIG. 2 illustrates a cross section of welding wire electrode 100 . As illustrated in FIG. 2 , welding wire electrode 100 depicts an embodiment of a wire electrode in which core material portion 200 may be substantially contained within ferrule portion 300 and core material 200 is contained within welding wire electrode 100 within the core. The composition of the ferrule 300 includes, but is not limited to, steel, nickel, aluminum, and other metals and alloys known to those skilled in the art of welding wire fabrication. In the configuration shown in FIG. 2, the core material portion 200 is employed to provide reactive core particles or metal alloying compounds during the welding operation for delivery of the metal alloying compounds into the weld metal. In one embodiment, the core material ranges from about 5% to about 50% by weight of the welding wire electrode. In another embodiment, the core material ranges from about 10% to about 30% by weight of the welding wire electrode.
焊接丝焊条被用在许多不同类型的焊接操作中，但是主要适用于热丝焊接工艺。一种这样的热丝工艺是热丝GTAW，其是气体钨极弧焊或者钨极惰性气体工艺的进一步发展。所述GTAW工艺最初使用电弧来熔化基础材料并且使用氩气来保护焊接熔池。随着热丝GTAW的发展，其中在GTA焊接工艺中填充金属以丝的形式被添加到焊缝。对于常规的GTAW，填充丝以冷态(即，环境温度)被引导到焊接熔池的前边缘中。需要来自电弧的能量熔化所述丝，降低了工艺的效率。在热丝焊接中，填充丝被电阻加热直至接近熔化温度，并且在钨极后面被添加到焊接熔池。这防止所述丝冷却焊接熔池并且允许填充金属在钨极后面横过焊接熔池流出，典型地获得平滑且均匀的焊道。由于焊接电弧几乎全部的能量可被利用于熔透(penetration)或产生焊接熔池和熔合，两倍至三倍的更快的行进速度可以被实现。Welding wire electrodes are used in many different types of welding operations, but are primarily suited for the hot wire welding process. One such hot wire process is hot wire GTAW, which is a further development of the gas tungsten arc welding or tungsten inert gas process. The GTAW process initially uses an electric arc to melt the base material and argon to shield the weld puddle. With the development of hot wire GTAW, in which filler metal is added to the weld in the form of wire in the GTA welding process. With conventional GTAW, the filler wire is guided into the leading edge of the weld puddle in a cold state (ie, ambient temperature). Energy from the arc is required to melt the filament, reducing the efficiency of the process. In hot wire welding, a filler wire is resistively heated to near melting temperature and added to the weld puddle behind the tungsten electrode. This prevents the wire from cooling the weld puddle and allows the filler metal to flow behind the tungsten across the weld puddle, typically resulting in a smooth and uniform weld bead. Since almost all of the energy of the welding arc can be utilized for penetration or creation of the weld pool and fusion, two to three times faster travel speeds can be achieved.
在一个实施方案中，焊接丝焊条被使用在热丝工艺中，所述热丝工艺包括，但不限于，热丝激光混合工艺、热丝的前后排列工艺、热丝钨极惰性气体工艺以及热丝电子束工艺。In one embodiment, the welding wire electrode is used in a hot wire process including, but not limited to, a hot wire laser hybrid process, a hot wire tandem process, a hot wire tungsten inert gas process, and a hot wire process. Wire Electron Beam Process.
热丝焊接工艺提供将金属合金化化合物的颗粒直接传递到焊接熔池中而无需使它们在电弧中反应的益处，由此在焊接操作期间保护合金化化合物免受在电弧中遇到的氧化。在热丝焊接过程期间为了达到将金属合金化化合物传递到焊接熔池中，至少一层金属性包覆物被沉积到金属合金化化合物的每个颗粒的外表面上。The hot wire welding process offers the benefit of delivering particles of metal alloying compounds directly into the weld pool without reacting them in the arc, thereby protecting the alloying compounds from oxidation encountered in the arc during the welding operation. To achieve delivery of the metal alloying compound into the weld pool during the hot wire welding process, at least one layer of metallic coating is deposited on the outer surface of each particle of the metal alloying compound.
在一个实施方案中，提供用于与热丝焊接工艺一起使用的焊接丝焊条。所述焊接丝焊条包括金属套，所述金属套包括芯，以及被包含在所述金属套的所述芯之内的芯材料，其中所述芯材料包括至少一种金属合金化化合物的颗粒，其中所述颗粒中的每个具有外表面，其中至少一层金属性包覆物通过气相沉积工艺被沉积到每个颗粒的所述外表面上，以形成金属性包覆的颗粒，并且其中所述金属性包覆的颗粒中的每个被沉积到焊接熔池中，所述焊接熔池在热丝焊接过程期间被形成。In one embodiment, a welding wire electrode for use with a hot wire welding process is provided. The welding wire electrode comprises a metal sheath comprising a core, and a core material contained within said core of said metal sheath, wherein said core material comprises particles of at least one metal alloying compound, wherein each of the particles has an outer surface, wherein at least one layer of metallic coating is deposited on the outer surface of each particle by a vapor deposition process to form metallically coated particles, and wherein the Each of the metallically coated particles is deposited into a weld puddle that is formed during the hot wire welding process.
在一个实施方案中，金属合金化化合物包括金属碳化物、金属硼化物、金属硫化物、金属氮化物、金属氧化物、石墨、金刚石颗粒以及其混合物。代表性的金属碳化物包括碳化钛、碳化锆、碳化铪、碳化钒、碳化铌、碳化钽、碳化铬、碳化钼以及碳化钨。代表性的金属硼化物包括硼化镍、硼化钴、硼化钛、硼化铼、硼化锆以及硼化铪。代表性的金属硫化物包括硫化钨和硫化钼。代表性的金属氮化物包括氮化钛、氮化硼、氮化铬、氮化锆、氮化钒、氮化铌、氮化钽、氮化钨以及氮化铪。In one embodiment, metal alloying compounds include metal carbides, metal borides, metal sulfides, metal nitrides, metal oxides, graphite, diamond particles, and mixtures thereof. Representative metal carbides include titanium carbide, zirconium carbide, hafnium carbide, vanadium carbide, niobium carbide, tantalum carbide, chromium carbide, molybdenum carbide, and tungsten carbide. Representative metal borides include nickel boride, cobalt boride, titanium boride, rhenium boride, zirconium boride, and hafnium boride. Representative metal sulfides include tungsten sulfide and molybdenum sulfide. Representative metal nitrides include titanium nitride, boron nitride, chromium nitride, zirconium nitride, vanadium nitride, niobium nitride, tantalum nitride, tungsten nitride, and hafnium nitride.
被沉积到金属合金化化合物的每个颗粒的外表面上的金属性包覆物包括这样的金属，所述金属包括镍、钴、铬、铁、铝、镁、钛、锆、锰和硅。The metallic coating deposited on the outer surface of each particle of the metal alloying compound includes metals including nickel, cobalt, chromium, iron, aluminum, magnesium, titanium, zirconium, manganese, and silicon.
本文中所描述的金属性包覆的颗粒可以用各种方式制备。在一个实施方案中，金属性包覆的颗粒通过化学气相沉积形成。化学气相沉积可以是被用来生产高纯度、高性能的固体材料的化学工艺。在典型的化学气相沉积工艺中，基底被暴露于一种或更多种前驱体，所述前驱体在基底表面上反应和/或分解以产生期望的沉积层。在另一个实施方案中，金属性包覆的颗粒可以通过物理气相沉积被形成。物理气相沉积可以包括通过汽化形式的材料(例如，镍)的某种形式的冷凝将薄膜沉积到各种表面(例如，基底表面)上的任何类型的方法。在一个实施方案中，在物理气相沉积中使用的包覆方法可以涉及物理工艺，比如高温真空蒸发或等离子溅射轰击。The metallically coated particles described herein can be prepared in a variety of ways. In one embodiment, the metallically coated particles are formed by chemical vapor deposition. Chemical vapor deposition can be a chemical process used to produce high purity, high performance solid materials. In a typical chemical vapor deposition process, a substrate is exposed to one or more precursors that react and/or decompose on the surface of the substrate to produce the desired deposited layer. In another embodiment, metallically coated particles can be formed by physical vapor deposition. Physical vapor deposition can include any type of method that deposits thin films onto various surfaces (eg, a substrate surface) by some form of condensation of a material in vaporized form (eg, nickel). In one embodiment, the cladding method used in physical vapor deposition may involve physical processes such as high temperature vacuum evaporation or plasma sputter bombardment.
在一个实施方案中，第一金属性包覆物的第一层被沉积到每个颗粒的外表面上，并且第二金属性包覆物的第二层被沉积到所述第一金属性包覆物的所述第一层上，其中所述第一金属性包覆物和所述第二金属性包覆物包括相同的金属。在该实施方案中，第一金属性包覆物的第一层，比如镍，被沉积到每个颗粒的外表面上，并且随后镍金属性包覆物的第二层被沉积到所述颗粒的所述第一镍金属性包覆物上。In one embodiment, a first layer of a first metallic coating is deposited onto the outer surface of each particle and a second layer of a second metallic coating is deposited onto said first metallic coating. on said first layer of a cladding, wherein said first metallic cladding and said second metallic cladding comprise the same metal. In this embodiment, a first layer of a first metallic coating, such as nickel, is deposited onto the outer surface of each particle, and subsequently a second layer of nickel metallic coating is deposited onto the particles on the first nickel metallic coating.
在另一个实施方案中，第一金属性包覆物的第一层被沉积到每个颗粒的外表面上，并且第二金属性包覆物的第二层被沉积到所述第一金属性包覆物的所述第一层上，其中所述第一金属性包覆物和所述第二金属性包覆物包括不同的金属。在该实施方案中，第一金属性包覆物的第一层，比如钴，被沉积到每个颗粒的外表面上，并且随后镍金属性包覆物的第二层被沉积到所述颗粒的所述第一钴金属性包覆物上。In another embodiment, a first layer of a first metallic coating is deposited onto the outer surface of each particle, and a second layer of a second metallic coating is deposited onto the first metallic coating. on said first layer of cladding, wherein said first metallic cladding and said second metallic cladding comprise different metals. In this embodiment, a first layer of a first metallic coating, such as cobalt, is deposited onto the outer surface of each particle, and subsequently a second layer of a nickel metallic coating is deposited onto the particles on the first cobalt metallic coating.
如本文中描述的，被沉积到金属合金化化合物的每个颗粒的外表面上的金属性包覆物，在焊接过程期间提供保护，抵抗在电弧中遇到的氧化。由于在焊接过程期间金属合金化化合物被直接传递到焊接熔池，金属性包覆物还提供在被沉积的焊缝金属中金属合金化化合物的回收率的增加。除了保护颗粒抗氧化，金属性包覆物可以减慢或抑制颗粒的熔化，以及因此减慢或抑制可能危害被沉积的材料的性能的有害的氧化物、碳化物或其他化合物的形成。金属性包覆物还可以进一步起作用来在基质(matrix)和颗粒之间(比如在镍基质和氧化物之间)产生更均匀的结构。As described herein, the metallic coating deposited onto the outer surface of each particle of the metal alloying compound provides protection during the welding process against oxidation encountered in the arc. The metallic cladding also provides increased recovery of metal alloying compounds in the deposited weld metal since the metal alloying compounds are delivered directly to the weld pool during the welding process. In addition to protecting the particles against oxidation, the metallic coating can slow or inhibit the melting of the particles and thus the formation of deleterious oxides, carbides or other compounds that may compromise the properties of the deposited material. Metallic coatings can further function to create a more uniform structure between the matrix and the particles, such as between the nickel matrix and the oxide.
本文中所描述的焊接丝焊条，对于堆焊应用是有用的。堆焊是将合金沉积在金属性部件上，以使磨损区域恢复到其原始的尺寸和/或保护新的金属部件以防磨损的专门的焊接工艺。所述工艺提供具有显著的耐磨擦性和耐冲击性的装置，并且其还提供减少用于替换损坏的或磨损的部件的停机时间的益处。The welding wire electrodes described herein are useful for surfacing applications. Overlay welding is a specialized welding process that deposits alloys on metallic parts to restore worn areas to their original dimensions and/or protect new metallic parts from wear. The process provides devices with significant abrasion and impact resistance, and it also offers the benefit of reduced downtime for replacing damaged or worn components.
两种主要的堆焊工艺包括熔覆(overlay)和补焊(build-up)。在熔覆工艺中，焊接的附加的保护层(layers)被添加到金属基底，以便提供增强的耐磨性和耐腐蚀性。补焊工艺是其中焊接的层(layers)被置于金属基底(比如金属部件)上以便使金属部件恢复到其原始的尺寸的工艺。补焊工艺提供优异的抗冲击的保护作用，但是提供低的耐摩擦性。补焊工艺和熔覆工艺的结合可以被用来将较旧的金属部件恢复尺寸，并且随后保护它们以防磨损和腐蚀。The two main overlay processes include overlay and build-up. In the cladding process, welded additional protective layers are added to the metal substrate in order to provide enhanced wear and corrosion resistance. A repair welding process is a process in which welded layers are placed on a metal substrate, such as a metal part, in order to restore the metal part to its original dimensions. The repair welding process provides excellent protection against impact, but provides low abrasion resistance. A combination of repair welding processes and cladding processes can be used to restore older metal components to size and subsequently protect them from wear and corrosion.
在一个实施方案中，提供堆焊金属工件的方法。堆焊方法包括提供金属工件。制备包括多个颗粒的颗粒状金属合金化化合物，其中所述颗粒中的每个具有外表面，并且其中至少一层金属性包覆物被沉积到每个颗粒的所述外表面上，以形成金属性包覆的颗粒。所述方法还包括制备包括金属性包覆的颗粒的芯材料，以及通过将所述芯材料放置到金属套中来形成有芯丝焊条。将所述有芯丝焊条朝工件输送，并且随后采用焊接手段创建焊接熔池并且将所述有芯丝焊条传递到焊接熔池中，其中至少一部分有芯丝焊条被熔化，并且金属性包覆的颗粒被沉积到焊接熔池中。In one embodiment, a method of overlaying a metal workpiece is provided. The welding overlay method involves providing a metal workpiece. preparing a particulate metal alloying compound comprising a plurality of particles, wherein each of the particles has an outer surface, and wherein at least one metallic coating is deposited on the outer surface of each particle to form Metallic coated particles. The method also includes preparing a core material comprising metallically coated particles, and forming a cored wire electrode by placing the core material into a metal sheath. conveying the cored wire electrode towards the workpiece, and subsequently creating a weld puddle using welding means and delivering the cored wire electrode into the weld puddle, wherein at least a portion of the cored wire electrode is melted and metallically clad particles are deposited into the weld pool.
所述焊接手段是热丝工艺并且包括热丝激光混合工艺、热丝的前后排列工艺、热丝钨极惰性气体工艺以及热丝电子束工艺。The welding means is a hot wire process and includes a hot wire laser hybrid process, a front and rear arrangement process of hot wires, a hot wire tungsten inert gas process and a hot wire electron beam process.
在金属轴承的生产中，本文中所描述的焊接丝焊条对于提供金属合金化化合物也是有用的，所述金属合金化化合物包括金属硫化物，比如硫化钨和硫化钼。当这些金属硫化物被并入轴承的金属基质时，它们提供增强的润滑性质，这降低在使用期间轴承遇到的摩擦力的量，并且最终降低轴承的磨损率。In the production of metal bearings, the welding wire electrodes described herein are also useful for providing metal alloying compounds including metal sulfides such as tungsten sulfide and molybdenum sulfide. When these metal sulfides are incorporated into the metal matrix of the bearing, they provide enhanced lubricating properties, which reduce the amount of frictional forces encountered by the bearing during use, and ultimately reduce the wear rate of the bearing.
为了说明和描述的目的，实施方案和实施例的上述描述已经被呈现。其不意图是详尽的，或者将本发明限制于所描述的形式。鉴于上面的教导许多改变是可能的。那些改变中的一些已经被讨论，并且其他改变将被本领域技术人员理解。所述实施方案被选择和描述以便最好地说明适合于预期的特定用途的各种实施方案。在此意图的是本发明的范围被所附的权利要求书限定。The foregoing description of the embodiments and examples has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the form described. Many variations are possible in light of the above teachings. Some of those changes have been discussed and others will be understood by those skilled in the art. The embodiments were chosen and described in order to best illustrate the various embodiments as suited to the particular use contemplated. It is intended that the scope of the invention be defined by the appended claims.
参考编号：reference number:
10 焊条10 electrodes
20 焊剂部分20 flux part
30 金属性电极部分30 Metallic electrode part
100 焊条100 electrodes
200 芯材料200 core material
300 金属套300 metal sleeve
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US13/709,684US20130092674A1 (en) | 2009-06-05 | 2012-12-10 | Electrodes incorporating metallic coated particles and methods thereof |
| US13/709,684 | 2012-12-10 | ||
| PCT/IB2013/002720WO2014091290A1 (en) | 2012-12-10 | 2013-12-10 | Electrodes incorporating metallic coated particles and methods of hard surfacing therewith |
| Publication Number | Publication Date |
|---|---|
| CN104812524Atrue CN104812524A (en) | 2015-07-29 |
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN201380061625.2APendingCN104812524A (en) | 2012-12-10 | 2013-12-10 | Electrode incorporating metallically coated particles and method of overlaying welding therewith |
| Country | Link |
|---|---|
| JP (1) | JP3202081U (en) |
| KR (1) | KR20150095814A (en) |
| CN (1) | CN104812524A (en) |
| DE (1) | DE202013012169U1 (en) |
| WO (1) | WO2014091290A1 (en) |
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| CN105499786A (en)* | 2015-12-30 | 2016-04-20 | 北京工业大学 | Method for preparing raw WC (Wolfram Carbide)-containing ceramic reinforced phase wear-resistant hard surface by electroslag surfacing |
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| CN109304561A (en)* | 2018-10-24 | 2019-02-05 | 东莞理工学院 | A cermet type arc spraying flux cored wire |
| CN114589428A (en)* | 2021-12-31 | 2022-06-07 | 西安理工大学 | Ceramic particle reinforced nickel-based flux-cored wire and surface arc cladding method |
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| JP3202081U (en) | 2016-01-21 |
| KR20150095814A (en) | 2015-08-21 |
| DE202013012169U1 (en) | 2015-10-13 |
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| Date | Code | Title | Description |
|---|---|---|---|
| C06 | Publication | ||
| PB01 | Publication | ||
| C10 | Entry into substantive examination | ||
| SE01 | Entry into force of request for substantive examination | ||
| WD01 | Invention patent application deemed withdrawn after publication | ||
| WD01 | Invention patent application deemed withdrawn after publication | Application publication date:20150729 |