CN119216875A - A method and device for preparing composite welding wire containing flux core - Google Patents
A method and device for preparing composite welding wire containing flux core Download PDFInfo
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- CN119216875A CN119216875A CN202411640350.4A CN202411640350A CN119216875A CN 119216875 A CN119216875 A CN 119216875A CN 202411640350 A CN202411640350 A CN 202411640350A CN 119216875 A CN119216875 A CN 119216875A
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- 230000004907 flux Effects 0.000 title claims abstract description 77
- 238000003466 welding Methods 0.000 title claims abstract description 65
- 239000002131 composite material Substances 0.000 title claims abstract description 41
- 238000000034 method Methods 0.000 title claims abstract description 25
- 229910045601 alloy Inorganic materials 0.000 claims abstract description 67
- 239000000956 alloy Substances 0.000 claims abstract description 67
- 239000011162 core material Substances 0.000 claims abstract description 66
- 239000000463 material Substances 0.000 claims abstract description 27
- 238000002360 preparation method Methods 0.000 claims abstract description 19
- 229910007570 Zn-Al Inorganic materials 0.000 claims abstract description 18
- 230000008569 process Effects 0.000 claims abstract description 18
- 229920001169 thermoplastic Polymers 0.000 claims abstract description 14
- 239000004416 thermosoftening plastic Substances 0.000 claims abstract description 14
- 238000010438 heat treatment Methods 0.000 claims abstract description 13
- 239000000843 powder Substances 0.000 claims description 92
- 229910000679 solder Inorganic materials 0.000 claims description 43
- 229910052751 metal Inorganic materials 0.000 claims description 20
- 239000007921 spray Substances 0.000 claims description 17
- 239000002184 metal Substances 0.000 claims description 16
- 238000005507 spraying Methods 0.000 claims description 16
- 238000004519 manufacturing process Methods 0.000 claims description 10
- 238000002156 mixing Methods 0.000 claims description 9
- 238000000137 annealing Methods 0.000 claims description 8
- 239000004033 plastic Substances 0.000 claims description 6
- UYFXWCIZFDKSTJ-UHFFFAOYSA-J aluminum;cesium;tetrafluoride Chemical group [F-].[F-].[F-].[F-].[Al+3].[Cs+] UYFXWCIZFDKSTJ-UHFFFAOYSA-J 0.000 claims description 4
- 238000010104 thermoplastic forming Methods 0.000 claims description 4
- ZLMJMSJWJFRBEC-UHFFFAOYSA-N Potassium Chemical compound [K] ZLMJMSJWJFRBEC-UHFFFAOYSA-N 0.000 claims description 2
- 229910052700 potassium Inorganic materials 0.000 claims description 2
- 239000011591 potassium Substances 0.000 claims description 2
- 238000005476 soldering Methods 0.000 claims description 2
- 238000005219 brazing Methods 0.000 abstract description 24
- 238000011049 filling Methods 0.000 abstract description 24
- 238000012545 processing Methods 0.000 abstract description 10
- 239000000428 dust Substances 0.000 abstract description 5
- 231100000331 toxic Toxicity 0.000 abstract description 5
- 230000002588 toxic effect Effects 0.000 abstract description 5
- 238000009792 diffusion process Methods 0.000 abstract description 3
- 229910052782 aluminium Inorganic materials 0.000 description 25
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 21
- 229910000838 Al alloy Inorganic materials 0.000 description 13
- 239000011701 zinc Substances 0.000 description 10
- 238000005242 forging Methods 0.000 description 9
- 230000000694 effects Effects 0.000 description 8
- 238000001125 extrusion Methods 0.000 description 8
- 239000011159 matrix material Substances 0.000 description 7
- 238000005096 rolling process Methods 0.000 description 6
- 238000003723 Smelting Methods 0.000 description 5
- 238000004626 scanning electron microscopy Methods 0.000 description 5
- AZDRQVAHHNSJOQ-UHFFFAOYSA-N alumane Chemical group [AlH3] AZDRQVAHHNSJOQ-UHFFFAOYSA-N 0.000 description 4
- 238000005266 casting Methods 0.000 description 4
- 230000000052 comparative effect Effects 0.000 description 4
- 238000009749 continuous casting Methods 0.000 description 4
- 238000000921 elemental analysis Methods 0.000 description 4
- 230000006698 induction Effects 0.000 description 4
- 238000011068 loading method Methods 0.000 description 4
- 230000010358 mechanical oscillation Effects 0.000 description 4
- 239000011812 mixed powder Substances 0.000 description 4
- 230000001105 regulatory effect Effects 0.000 description 4
- 241000276425 Xiphophorus maculatus Species 0.000 description 3
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical group [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 3
- 229910052792 caesium Inorganic materials 0.000 description 3
- TVFDJXOCXUVLDH-UHFFFAOYSA-N caesium atom Chemical group [Cs] TVFDJXOCXUVLDH-UHFFFAOYSA-N 0.000 description 3
- 239000002994 raw material Substances 0.000 description 3
- 229910052725 zinc Inorganic materials 0.000 description 3
- 229910009369 Zn Mg Inorganic materials 0.000 description 2
- 229910007573 Zn-Mg Inorganic materials 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 2
- 230000008859 change Effects 0.000 description 2
- 239000003153 chemical reaction reagent Substances 0.000 description 2
- 230000001276 controlling effect Effects 0.000 description 2
- 238000002844 melting Methods 0.000 description 2
- 229910001092 metal group alloy Inorganic materials 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 238000000465 moulding Methods 0.000 description 2
- 230000002787 reinforcement Effects 0.000 description 2
- 229910018134 Al-Mg Inorganic materials 0.000 description 1
- 229910016569 AlF 3 Inorganic materials 0.000 description 1
- 229910018467 Al—Mg Inorganic materials 0.000 description 1
- 229910000611 Zinc aluminium Inorganic materials 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- HXFVOUUOTHJFPX-UHFFFAOYSA-N alumane;zinc Chemical compound [AlH3].[Zn] HXFVOUUOTHJFPX-UHFFFAOYSA-N 0.000 description 1
- 238000012512 characterization method Methods 0.000 description 1
- 238000013329 compounding Methods 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 239000003814 drug Substances 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 230000003287 optical effect Effects 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 239000002893 slag Substances 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- 238000009210 therapy by ultrasound Methods 0.000 description 1
- 238000002604 ultrasonography Methods 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
- B23K35/40—Making wire or rods for soldering or welding
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Metal Extraction Processes (AREA)
Abstract
The invention discloses a preparation method and a device of a composite welding wire containing a flux core, which relate to the technical field of brazing, in particular to a preparation method of a composite welding wire containing a flux core, comprising the steps of preparing a superplastic welded pipe by adopting Zn-Al superplastic alloy; heating the superplastic welded pipe to superplastic deformation temperature, ultrasonically vibrating the superplastic welded pipe, performing thermoplastic drawing on the superplastic welded pipe, and continuously pouring the flux-cored material into the inner cavity of the superplastic welded pipe to obtain the composite welding wire containing the flux core. According to the invention, the superplastic alloy is used as the welding pipe sheath material for temperature control drawing, and has ultrahigh extensibility, so that the welding pipe sheath has excellent processing and forming properties, and the drawing times required by flux-cored wire forming can be effectively reduced. Meanwhile, the filling core materials are synchronously filled in the thermoplastic drawing process, so that the toxic dust overflow and diffusion are reduced, the process is simple, and the automatic and efficient filling can be adopted.
Description
Technical Field
The invention relates to the technical field of brazing, in particular to a preparation method and a device of a composite welding wire containing a flux core.
Background
The welding wire is a key material in the welding process and mainly comprises a solid welding wire and a flux-cored wire, wherein the flux-cored wire is internally filled with specific welding flux, and a tubular-like structure is formed. The flux contains various alloy elements and auxiliary materials, and can improve metallurgical performance and mechanical performance in the welding process.
According to the difference of aluminum content, the melting point of the Zn-Al solder alloy is in the range of 382-500 ℃, and the plastic strength and wettability of the solder are also changed due to the change of the aluminum content, so that the preparation of the Zn-Al solder with the aluminum content flexibly adjusted in the solder formula has good application prospect. In the traditional flux-cored electrode preparation method, firstly, the share of Zn and Al is calculated and prepared during smelting of solder metal powder, a longer tiny welded pipe is formed in a continuous casting and extrusion mode, a brazing flux is added into an elongated welded pipe in a manual powder filling mode, and flux-cored wires with different specifications are manufactured through multiple reducing drawing and forming. However, in the process of powder production, toxic dust is easy to overflow and diffuse, which is not beneficial to the safety of workers and the environmental protection, and the drawing molding times are more, the drawing die expenditure is high, the working procedure is complex, and the time consumption is long.
In the preparation method of the composite solder flux-cored aluminum welding wire disclosed in patent CN103612026A, a composite aluminum alloy is rolled into a composite alloy strip through a rolling mill, the composite alloy strip is thinned to 0.3-0.6 mm, the strip width is 9-12 mm, the composite alloy strip is rolled into a U shape, after a flux core is added into a U-shaped groove of the composite alloy strip, the composite alloy strip is rolled into an O shape, the diameter is reduced to 2.4-3.0 mm, the diameter is continuously reduced, the composite solder flux-cored aluminum welding wire with the diameter of 1.0-3.0 mm is prepared, and the traditional alloy outer skin is replaced by an outer skin in the form of the composite strip, so that the processing performance of the composite solder flux-cored aluminum welding wire is improved. However, the flux-cored wire can meet the specification of a specific flux-cored wire only by reducing the diameter for many times in the manufacturing process of the flux-cored wire, the production efficiency is low, and toxic dust is easy to overflow and diffuse due to the fact that a medicine core is added into a U-shaped groove, so that the production environment is bad.
Disclosure of Invention
The invention aims to overcome the defects and shortcomings of the prior art, and provides a preparation method of a composite welding wire containing a flux core, which can reduce the drawing forming times, realize the efficient filling of brazing flux powder and improve the welding performance of the welding wire.
Another object of the invention is to provide a composite welding wire preparation device containing the flux core.
The above object of the present invention is achieved by the following technical scheme:
the invention provides a preparation method of a composite welding wire containing a flux core, which comprises the following steps:
S1, preparing a superplastic welded pipe by adopting a Zn-Al superplastic alloy;
s2, mixing solder metal powder and soldering flux to prepare a flux-cored material;
and S3, heating the superplastic welded pipe to a superplastic deformation temperature, ultrasonically vibrating the superplastic welded pipe, performing thermoplastic drawing on the superplastic welded pipe, and continuously pouring the flux-cored material into the inner cavity of the superplastic welded pipe in the drawing process to obtain the composite welding wire containing the flux core.
According to the preparation method of the composite welding wire containing the flux core, the superplastic alloy is used as the welding pipe sheath material for temperature control drawing, and has the ultrahigh extensibility, so that the welding pipe sheath has excellent processing and forming properties, and the drawing in a larger diameter-changing range can be realized, and the drawing times required by the forming of the flux-cored wire can be effectively reduced. Meanwhile, the filling core materials are synchronously filled in the thermoplastic drawing process, so that the toxic dust overflow and diffusion are reduced, the process is simple, and the automatic and efficient filling can be adopted. Furthermore, on the basis of adopting a specific superplastic alloy as a welding pipe sheath material, the invention ensures that the welding wire is melted to form the required solder component during welding by regulating and controlling the solder metal powder component in the flux-cored material, thereby realizing the effect of flexibly regulating the aluminum content in the solder.
When the deformation amount in the drawing engineering is large, the friction force and the resistance between the die and the workpiece are increased, the deformation is difficult, the roughness of the inner surface of the formed tube cavity is too large, the problem of powder clamping in a local area is easy to cause when brazing flux is directly filled, and the welding strength and the effect are affected.
Among them, the superplastic alloy of the present invention refers to those metallic materials having superplasticity, which refers to a phenomenon in which the elongation exceeds 100%.
The superplastic alloy can realize that the diameter change amplitude of drawing is not less than 22mm, for example, a pipe with the outer diameter phi 30mm can be subjected to variable-diameter drawing into a pipe with the outer diameter phi 8 mm.
In some of these embodiments, in step S1, the Zn-Al superplastic alloy is ZnAl5 and/or ZnAl22. The elongation of the ZnAl5 or ZnAl22 superplastic alloy reaches more than 2500% at 200-300 ℃, and the drawing forming performance is excellent.
In some embodiments, in the step S1, the Zn-Al superplastic alloy is subjected to plastic deformation at 250-300 ℃, the plastic deformation is more than or equal to 80%, and annealing is performed for 1.5-3 hours at 290-310 ℃ to obtain the superplastic welded pipe. Preferably, the plastic deformation is 80-120%.
In some embodiments, in step S2, the solder metal powder is at least one of Zn powder, al powder, zn-based intermediate alloy powder, or Al-based intermediate alloy powder. Preferably, the content of Al and Zn in the solder metal powder is not less than 85wt%, more preferably, not less than 90wt%.
Preferably, the Zn-based master alloy or Al-based master alloy includes, but is not limited to, a Zn-Al master alloy, a Zn-Mg master alloy or an Al-Mg master alloy.
Alternatively, the Zn-Al master alloy includes, but is not limited to, znAl2, znAl10, znAl15, znAl20, znAl30, znAl50.
Optionally, the Zn-Mg master alloy comprises ZnMg2.
Optionally, the al—mg master alloy comprises AlMg2.
In some of these embodiments, in step S2, the flux is selected from aluminum-based fluxes including, but not limited to, cesium fluoroaluminate flux (CsF-AlF 3 -KF) and/or potassium fluoroaluminate flux.
In some of these embodiments, in step S2, the mass ratio of Zn-Al superplastic alloy to solder metal powder is (1.5-22): 1.
In some of these embodiments, in step S2, the ratio of the total mass of the Zn-Al superplastic alloy and the solder metal powder to the mass of the flux is (8-9): 1-2, preferably (8.5-8.8): 1.2-1.5.
In some embodiments, in step S3, the thermoplastic drawing is performed on the superplastic welded pipe, and the flux core material is continuously poured into the inner cavity of the superplastic welded pipe, which specifically includes thermoplastic forming the superplastic welded pipe in a die with gradually smaller axial outer diameter, forming a drawing part with smaller outer diameter on one side of the superplastic welded pipe, drawing the drawing part of the superplastic welded pipe in a direction away from the die, and simultaneously pouring the flux core material into the inner cavity of the superplastic welded pipe, wherein in the drawing process, the pouring terminal of the flux core material moves synchronously along with the drawing part in the drawing direction.
Alternatively, the drawing speed is 20-30mm/min.
In some embodiments, in step S3, the superplastic deformation temperature is 250 to 300 ℃.
In some embodiments, in step S3, the frequency of the ultrasound is 16-22 khz, and the power is 300-800 w.
A composite welding wire preparation device containing a flux core comprises a drawing die module, an ultrasonic module, a temperature control module and a powder spraying traction module;
The drawing die module is used for thermoplastic forming of the superplastic welded pipe, so that the outer diameter of the superplastic welded pipe is reduced to a preset value;
the ultrasonic module is connected with the drawing die module and is used for ultrasonic vibration of the superplastic welded pipe;
The temperature control module is arranged at the front end of the drawing die module and is used for heating the superplastic welded pipe to a preset temperature so as to enable the superplastic welded pipe to have superplastic deformation;
The powder spraying traction module is arranged at the rear end of the drawing die module and comprises a clamp for a welded pipe capable of horizontally moving and a flux core material spray head, and is used for thermoplastic drawing of the superplastic welded pipe, and simultaneously, flux core materials are poured into the inner cavity of the superplastic welded pipe.
The device for preparing the composite welding wire containing the flux core is used for preparing composite welding flux, high-melting-point metal or reinforcement is automatically filled in a hollow welding flux pipe in a powder form, and then the metal-based composite welding flux wire is obtained through multiple reducing treatment. The traditional method is to mix high-melting point metal elements or reinforcements during casting to prepare cast ingots, and the components of the metal skin are changed, so that the plasticity and strength of the cast ingots are also changed, the rheological behavior of the metal is changed during deformation processing, the problems of stretch-breaking, cracking, unstable compounding and the like are easy to occur, the conventional forming processing technology needs to be improved, such as extrusion temperature, extrusion speed, extrusion force and the like, the experimental research cost is high, and the flexible adjustment of the aluminum content in the solder formula is difficult to realize.
In some embodiments, the drawing die block comprises an outer die and a die core, wherein the inner diameter of the outer die is changed from large to small along the axial direction and is used for being connected with the outer wall of the superplastic welded pipe, and the die core is used for being connected with the inner wall of the superplastic welded pipe.
In some embodiments, the ultrasonic module comprises an ultrasonic generator and a frequency modulator, a transducer, a horn and a working head connected in sequence. When the deformation of the superplastic welded pipe workpiece is large, the friction force and resistance between the die and the workpiece are increased, so that the deformation is difficult, the roughness of the inner surface of the pipe cavity is overlarge, and after the ultrasonic treatment is adopted, the outer surface of the die core and the inner wall of the pipe cavity of the welding flux are separated and touched in a pulse mode, so that the outer wall of the die core and the inner wall of the welding flux are scraped at high frequency, and the surface quality of the inner wall of the pipe cavity is improved.
Compared with the prior art, the invention has the beneficial effects that:
The invention provides a preparation method of a composite welding wire containing a flux core, which takes a superplastic alloy as a welding pipe sheath material for temperature control drawing, wherein the superplastic alloy has ultrahigh extensibility, so that the welding pipe sheath has excellent processing and forming properties, and the drawing times required by the molding of the flux core welding wire can be effectively reduced. Meanwhile, the filling core materials are synchronously filled in the thermoplastic drawing process, so that the toxic dust overflow and diffusion are reduced, the process is simple, and the automatic and efficient filling can be adopted.
Furthermore, on the basis of adopting a specific superplastic alloy as a welding pipe sheath material, the invention ensures that the welding wire is melted to form the required solder component during welding by regulating and controlling the solder metal powder component in the flux-cored material, thereby realizing the effect of flexibly regulating the aluminum content in the solder.
Drawings
FIG. 1 is a schematic drawing showing the process flow of forming a superplastic welded pipe according to example 1 of the present invention.
FIG. 2 is a schematic drawing showing the process flow of forming a superplastic welded pipe according to example 2 of the present invention.
FIG. 3 is a schematic drawing showing the process flow of forming a superplastic welded pipe according to example 3 of the present invention.
Fig. 4 is a SEM and elemental analysis chart of a welding interface of the flux-cored wire of example 1 of the present invention to an aluminum sheet (brazing temperature 450 ℃). The lower half of fig. 4 is an aluminum alloy and the upper half is a solder.
Fig. 5 is a SEM and elemental analysis chart of the weld interface of the flux-cored wire of example 2 of the present invention with an aluminum sheet (brazing temperature 450 ℃). The lower half of fig. 5 is an aluminum alloy and the upper half is a solder.
Fig. 6 is a SEM and elemental analysis chart of the weld interface of the flux-cored wire of example 3 of the present invention with an aluminum sheet (brazing temperature 450 ℃). The lower half of fig. 6 is an aluminum alloy and the upper half is a solder.
Fig. 7 is a SEM and elemental analysis chart of the weld interface of the flux-cored wire of example 4 of the present invention to an aluminum sheet braze (braze temperature 490 ℃). The lower half of fig. 7 is an aluminum alloy and the upper half is a solder.
Fig. 8 is a graph showing the morphology of the welding interface of the flux-cored wire of comparative example 1 of the present invention with an aluminum sheet being brazed (brazing temperature 450 ℃). The lower half of fig. 8 is an aluminum alloy and the upper half is a solder.
Wherein, 1, alloy smelting furnace, 2, crystallizer, 3, supporting wheel, 4, roller, 401, first extrusion die, 402, second extrusion die, 403, first roller, 404, second roller, 5, blank, 51, O-shaped pipe, 6, forging press, 7, forging press, 8, pipe blank, 81, superplastic pipe, 82, solder pipe, 91, ultrasonic wave generating and frequency modulating device, 92, ultrasonic transducer, 93, amplitude transformer, 94, working fixing head, 10, electromagnetic heater, 11, ejector rod, 12, mold core, 13, drawing external die, 14, flux core powder, 15, clamp, 16, air compressor, 17, high pressure nozzle, 18, powder pump.
Detailed Description
The invention will be further described with reference to the following specific embodiments, but the examples are not intended to limit the invention in any way. Raw materials reagents used in the examples of the present invention are conventionally purchased raw materials reagents unless otherwise specified.
The following examples and comparative examples were prepared from the following raw materials:
AlMg2 alloy powder, beijing optical collector winning science and technology Co.
ZnMg2 alloy powder, hebei beyond metal alloy materials Co.
ZnAl20 Hebei beyond the metal alloy materials Co.
Cesium fluoroaluminate flux, wuhan biosciences limited.
Example 1
The flux-cored electrode of the ZnAl8-0.03Mg alloy comprises 8 weight percent of Al, 0.03 weight percent of Mg and the balance of Zn.
ZnAl8 is one of common high-strength zinc-aluminum alloys, and trace Mg element can improve the wettability of the solder, and the Zn-Al hypereutectic alloy is used when the mass percentage of Al is 8%.
A preparation method of a composite welding wire containing a flux core is shown in fig. 1, and comprises the following steps:
(1) Preparing a ZnAl5 superplastic alloy pipe, namely mixing materials according to the mass ratio (Al 5%) of various metal elements in the alloy ZnAl5, putting the materials into a smelting furnace 1, heating the materials to 720 ℃ to a molten state, preserving the heat for 25 minutes, pouring the materials into a crystallizer 2 and a die after deslagging, adopting a continuous casting and rolling mode, preparing a platy blank 5 with the thickness of 15mm at the rolling speed of 25mm/min, and cutting the blank 5 into round plates. The continuous casting and rolling mode specifically comprises that after the crystallizer 2 discharges, materials are supported and conveyed through the supporting wheels 3, and rolled and deformed under the action of the two rollers 4, so that a platy blank 5 with the thickness of 15mm is obtained.
The blank 5 of the round plate is subjected to 250 ℃ hot forging, the hot forging is die forging, the forging speed is 10mm/min, the outer diameter of a forging head 6 is phi 20mm, the diameter of a female die of a forging die 7 is phi 30mm, a cylinder with a cover at one end and the outer diameter of phi 30mm and the inner diameter of phi 20mm can be obtained through die forging, the covers at the head and the bottom of the cylinder are removed, and the cylinder is divided into a tube blank 8 with the length of 150mm and the mass of about 400 g.
And (3) annealing the tube blank 8, wherein the annealing process is to heat 300 ℃ and keep the temperature for 2 hours, and then cool along with the furnace.
(2) The flux core powder 14 is prepared by thoroughly mixing the intermediate alloy powder and the flux and then loading the mixed powder into a powder pump container in a powder spraying traction module.
Wherein the intermediate alloy powder is composed of 100.09 g of ZnAl and 6.09 g of AlMg, and the brazing flux is 80 g of cesium fluoroaluminate brazing flux.
(3) Drawing and powder filling, namely carrying out thermoplastic drawing powder filling processing on the tube blank 8, wherein the used equipment is drawing-powder filling equipment.
The drawing-powder filling device comprises a drawing die module, an ultrasonic module, a temperature control module and a powder spraying traction module.
The drawing die module comprises a drawing outer die 13 and a die core 12, wherein the aperture of the drawing outer die 13 is phi 8.01mm, the outer diameter of the die core 12 is phi 6.00mm, the tube blank 8 is heated to form a superplastic tube 81, and after passing through the drawing outer die 13 and the die core 12, a solder tube 82 is finally formed, the outer diameter of the solder tube 82 is phi 8mm, and the inner diameter of the solder tube 82 is phi 6.00mm.
The ultrasonic module comprises an ultrasonic generating and frequency modulating device 91, an ultrasonic transducer 92, an amplitude transformer 93 and a working fixing head 94 which are connected in sequence. The ultrasonic working head is driven by an ultrasonic generating and frequency modulation device 91, and can convert electric energy into mechanical energy through an ultrasonic transducer 92, the amplitude is changed through an amplitude transformer 93, and the mechanical oscillation effect is transmitted to a working fixed head 94, the working fixed head 94 is connected with a mold core 12 through a push rod 11, the ultrasonic frequency of the working fixed head is 20kHz, and the power is 500W.
The temperature adjusting module is an electromagnetic heater 10 and is arranged at the front end of the drawing die, the temperature adjusting device is an induction heating system, and the temperature is controlled at 250 ℃ so that the superplastic pipe 81 keeps superplastic.
The powder spraying traction module comprises a clamp 15 and a flux core material pouring structure, wherein the clamp 15 is used for clamping a welded pipe and applying traction force, and drawing and forming are carried out at a speed of 25 mm/min. The clamp 15 is connected with a high-pressure spray head 17B at the tail part of the traction piece, the flux-cored powder 14 prepared in the step (2) is sprayed into a welded pipe at a high speed by the high-pressure spray head 17, and the high-pressure spray head 17 is respectively connected with an air compressor 16 and a powder pump 18;
the clamp 15 and the high-pressure nozzle 17B are pulled and moved to the right along the drawing direction together with the tail of the welded pipe, and when the welded pipe is drawn to be long, the flux-cored powder 14is continuously sprayed into the pipe cavity until the pipe cavity is filled, so that the flux-cored wire with the outer diameter of 8mm and the inner diameter of 6mm is formed.
Example 2
The ZnAl10 alloy flux-cored electrode comprises, by weight, 10% of Al and the balance of Zn. The mass percentage of Al is 10 percent, namely Zn-Al hypereutectic alloy.
A preparation method of a composite welding wire containing a flux core is shown in fig. 2, and comprises the following steps:
(1) Preparing a ZnAl5 superplastic alloy pipe, namely mixing materials according to the mass ratio (Al 5%) of various metal elements in the alloy ZnAl5, placing the materials in a smelting furnace 1, heating the materials to 720 ℃ to a molten state, preserving heat for 25 minutes, pouring the materials into a crystallizer 2 and a first extrusion die 401 after slagging off, extruding the materials to form cylindrical bars with the diameter of phi 100mm, extruding the cylindrical bars by a second extrusion die 402 when the bars are cooled to 300 ℃, extruding castings into a through pipe with the outer diameter of phi 30mm and the inner diameter of phi 20mm, and dividing the through pipe into pipe blanks 8 with the length of 150mm, wherein the weight of each pipe blank 8 is 400.35g.
And (3) annealing the tube blank 8, wherein the annealing process is to heat 300 ℃ for 2 hours, and then cool along with the furnace to obtain the superplastic tube blank.
(2) The flux core powder 14 is prepared by thoroughly mixing the intermediate alloy powder and the flux and then loading the mixed powder into a powder pump container in a powder spraying traction module.
Wherein the intermediate alloy powder is ZnAl20 200.175 g, and the brazing flux is cesium fluoaluminate brazing flux 105 g.
(3) Drawing and powder filling, namely carrying out thermoplastic drawing powder filling processing on the tube blank 8, wherein the used equipment is drawing-powder filling equipment.
The drawing-powder filling device comprises a drawing die module, an ultrasonic module, a temperature control module and a powder spraying traction module.
The drawing die module comprises a drawing outer die 13 and a die core 12, wherein the aperture of the drawing outer die 13 is phi 8.01mm, the outer diameter of the die core 12 is phi 6.00mm, the tube blank 8 is heated to form a superplastic tube 81, and after passing through the drawing outer die 13 and the die core 12, a solder tube 82 is finally formed, the outer diameter of the solder tube 82 is phi 8mm, and the inner diameter of the solder tube 82 is phi 6.00mm.
The ultrasonic module comprises an ultrasonic generating and frequency modulating device 91, an ultrasonic transducer 92, an amplitude transformer 93 and a working fixing head 94 which are connected in sequence. The ultrasonic working head is driven by an ultrasonic generating and frequency modulation device 91, and can convert electric energy into mechanical energy through an ultrasonic transducer 92, the amplitude is changed through an amplitude transformer 93, and the mechanical oscillation effect is transmitted to a working fixed head 94, the working fixed head 94 is connected with a mold core 12 through a push rod 11, the ultrasonic frequency of the working fixed head is 18kHz, and the power is 400W.
The temperature adjusting module is an electromagnetic heater 10 and is arranged at the front end of the drawing die, the temperature adjusting device is an induction heating system, and the temperature is controlled at 280 ℃ so that the superplastic pipe 81 keeps superplastic.
The powder spraying traction module comprises a clamp 15 and a flux core material pouring structure, wherein the clamp 15 is used for clamping a welded pipe and applying traction force, and drawing and forming are carried out at a speed of 25 mm/min. The clamp 15 is connected with a high-pressure spray head 17 at the tail part of the traction piece, the flux-cored powder 14 prepared in the step (2) is sprayed into a welded pipe at a high speed by the high-pressure spray head 17, and the high-pressure spray head 17 is respectively connected with an air compressor 16 and a powder pump 18;
The clamp 15 and the high-pressure spray head 17 are pulled along with the tail part of the welded pipe along the drawing direction and move to the right, and when the welded pipe is drawn to be longer, the flux-cored powder 14 is continuously sprayed into the pipe cavity until the pipe cavity is full, so that the flux-cored wire with the outer diameter of 8mm and the inner diameter of 6mm is formed.
Example 3
The ZnAl15 alloy flux-cored electrode comprises, by weight, 15% of Al and the balance of Zn. The mass percentage of Al is 15 percent, namely Zn-Al hypereutectic alloy.
A preparation method of a composite welding wire containing a flux core is shown in fig. 3, and comprises the following steps:
(1) Preparing a ZnAl22 superplastic alloy pipe, namely mixing materials according to the mass ratio (Al 22%) of various metal elements in the alloy ZnAl22, placing the materials in a smelting furnace 1, heating to 720 ℃ to a molten state, preserving heat for 25 minutes, pouring the materials into a crystallizer 2 and a die after slag skimming, adopting a continuous casting and continuous rolling mode to roll and deform two sections of a first roller 403 and a second roller 404 when a casting is cooled to 280 ℃, and manufacturing the casting into a platy blank 5 with the thickness of 2mm at the rolling speed of 25 mm/min. The blank 5 was rolled into an O-shaped tube 51 having an outer diameter of phi 8mm and an inner diameter of phi 6.00mm, and a tube blank 8 having a length of 150mm and a weight of 353.25g was cut.
And (3) annealing the tube blank 8, wherein the annealing process is to heat 300 ℃ for 2 hours, and then cool the tube blank along with a furnace to obtain the superplastic tube blank.
(2) The flux core powder 14 is prepared by thoroughly mixing the intermediate alloy powder and the flux and then loading the mixed powder into a powder pump container in a powder spraying traction module.
Wherein the intermediate alloy powder is 164.85 g of Zn powder, and the brazing flux is 80 g of cesium fluoaluminate brazing flux.
(3) Drawing and powder filling, namely carrying out thermoplastic drawing powder filling processing on the tube blank 8, wherein the used equipment is drawing-powder filling equipment.
The drawing-powder filling device comprises a drawing die module, an ultrasonic module, a temperature control module and a powder spraying traction module.
The drawing die module comprises a drawing outer die 13 and a die core 12, wherein the aperture of the drawing outer die 13 is phi 5.01mm, the outer diameter of the die core 12 is phi 4.00mm, the tube blank 8 is heated to form a superplastic tube 81, and after passing through the drawing outer die 13 and the die core 12, a solder tube 82 is finally formed, the outer diameter of the solder tube 82 is phi 5mm, and the inner diameter of the solder tube 82 is phi 4.00mm.
The ultrasonic module comprises an ultrasonic generating and frequency modulating device 91, an ultrasonic transducer 92, an amplitude transformer 93 and a working fixing head 94 which are connected in sequence. The ultrasonic working head is driven by an ultrasonic generating and frequency modulation device 91, and can convert electric energy into mechanical energy through an ultrasonic transducer 92, the amplitude is changed through an amplitude transformer 93, and the mechanical oscillation effect is transmitted to a working fixed head 94, the working fixed head 94 is connected with a mold core 12 through a push rod 11, the ultrasonic frequency of the working fixed head is 20kHz, and the power is 800W.
The temperature adjusting module is an electromagnetic heater 10 and is arranged at the front end of the drawing die, the temperature adjusting device is an induction heating system, and the temperature is controlled at 280 ℃ so that the superplastic pipe 81 keeps superplastic.
The powder spraying traction module comprises a clamp 15 and a flux core material pouring structure, wherein the clamp 15 is used for clamping a welded pipe and applying traction force, and drawing and forming are carried out at a speed of 25 mm/min. The clamp 15 is connected with the high-pressure spray head 17B at the tail part of the traction piece, the flux-cored powder 14 prepared in the step (2) is sprayed into the welding tube at a high speed by the high-pressure spray head 17, wherein the high-pressure spray head 17 is respectively connected with the air compressor 16 and the powder pump 18, the clamp 15 and the high-pressure spray head 17 are pulled together with the tail part of the welding tube along the drawing direction and move to the right, and when the welding tube is drawn to be longer, the flux-cored powder 14 is continuously sprayed into the tube cavity until the flux-cored wire with the outer diameter of 5mm and the inner diameter of 4mm is formed.
Example 4
The ZnAl22Mg0.1 alloy flux-cored electrode comprises 22 percent of Al, 0.1 percent of Mg0.1 percent of Zn and the balance of Zn by weight percent. The mass percentage of Al is 22 percent, namely Zn-Al hypereutectic alloy.
A preparation method of a composite welding wire containing a flux core is shown in fig. 3, and comprises the following steps:
(1) A ZnAl22 superplastic alloy pipe was produced in the same way as in example 3.
(2) The flux core powder 14 is prepared by thoroughly mixing the intermediate alloy powder and the flux and then loading the mixed powder into a powder pump container in a powder spraying traction module.
Wherein the intermediate alloy powder is 18.83 g of ZnMg2 powder, and the brazing flux is 62 g of cesium fluoaluminate brazing flux.
(3) Drawing and powder filling, namely carrying out thermoplastic drawing powder filling processing on the ZnAl22 superplastic pipe blank, wherein the used equipment is drawing-powder filling equipment.
The drawing-powder filling device comprises a drawing die module, an ultrasonic module, a temperature control module and a powder spraying traction module.
The drawing die module comprises a drawing outer die 13 and a die core 12, wherein the aperture of the drawing outer die 13 is phi 8.01mm, the outer diameter of the die core 12 is phi 6.00mm, the tube blank 8 is heated to form a superplastic tube 81, and after passing through the drawing outer die 13 and the die core 12, a solder tube 82 is finally formed, the outer diameter is phi 8mm, and the inner diameter is phi 6.00mm.
The ultrasonic module comprises an ultrasonic generating and frequency modulating device 91, an ultrasonic transducer 92, an amplitude transformer 93 and a working fixing head 94 which are connected in sequence. The ultrasonic working head is driven by an ultrasonic generating and frequency modulation device 91, and can convert electric energy into mechanical energy through an ultrasonic transducer 92, the amplitude is changed through an amplitude transformer 93, and the mechanical oscillation effect is transmitted to a working fixed head 94, the working fixed head 94 is connected with a mold core 12 through a push rod 11, the ultrasonic frequency of the working fixed head is 18kHz, and the power is 400W.
The temperature adjusting module is an electromagnetic heater 10 and is arranged at the front end of the drawing die, the temperature adjusting device is an induction heating system, and the temperature is controlled at 280 ℃ so that the superplastic pipe 81 keeps superplastic.
The powder spraying traction module comprises a clamp 15 and a flux core material pouring structure, wherein the clamp 15 is used for clamping a welded pipe and applying traction force, and drawing and forming are carried out at a speed of 25 mm/min. The clamp 15 is connected with the high-pressure spray head 17 at the tail part of the traction piece, the flux-cored powder 14 prepared in the step (2) is sprayed into the welding tube at a high speed by the high-pressure spray head 17, wherein the high-pressure spray head 17 is respectively connected with the air compressor 16 and the powder pump 18, the clamp 15, the high-pressure spray head 17 and the tail part of the welding tube are pulled together along the drawing direction and move to the right, and when the welding tube is drawn to be longer, the flux-cored powder 14 is continuously sprayed into the tube cavity until the flux-cored wire with the outer diameter of 8mm and the inner diameter of 6mm is formed.
Comparative example 1
A method for preparing a composite welding wire containing a flux core is different from that of the embodiment 3 in that in the preparation engineering, an ultrasonic module is in a closed state.
Performance testing
1. SEM characterization
The flux-cored wires of examples 1-4 were used to braze between two aluminum sheets at 450-490 ℃ to obtain a weld interface for SEM analysis.
The flux-cored wire of example 1 has a weld interface (brazing temperature 450 ℃ C.) as shown in FIG. 4. It can be seen that there is a continuous metallurgical bond between the aluminum alloy and the braze, and that aluminum atoms diffuse from the matrix to the braze layer and zinc atoms diffuse from the braze to the aluminum matrix when the braze is heated, thus forming a good weld micro-interface.
The flux-cored wire of example 2 has a weld interface (brazing temperature 450 ℃ C.) as shown in FIG. 5, and it can be seen that there is a continuous metallurgical bond between the aluminum alloy and the braze, and that a large amount of aluminum is detected on the side of the weld interface near the braze, demonstrating that aluminum atoms diffuse from the matrix to the braze layer during braze heating, resulting in a good weld micro-interface.
The flux-cored wire of example 3 has a weld interface (brazing temperature 450 ℃ C.) as shown in FIG. 6. It can be seen that there is a continuous metallurgical bond between the aluminum alloy and the braze, and that aluminum atoms diffuse from the matrix to the braze layer and zinc atoms diffuse from the braze to the aluminum matrix when the braze is heated, thus forming a good weld micro-interface.
The flux-cored wire of example 4 has a weld interface (brazing temperature 490 ℃ C.) as shown in FIG. 7, and it can be seen that there is a continuous metallurgical bond between the aluminum alloy and the braze, and that aluminum atoms diffuse from the matrix to the braze layer and zinc atoms diffuse from the braze to the aluminum matrix when the braze is heated, thus forming a good weld micro-interface.
The flux-cored wire of comparative example 1 has a welding interface (brazing temperature 450 ℃) as shown in fig. 8, and it can be seen that there is a continuous thick black line between the aluminum alloy and the solder, which is an oxide film on the surface of the aluminum that is not removed, between the aluminum alloy and the solder, because the inner cavity surface of the narrow space is roughened without the application of ultrasonic waves to the mold core, resulting in powder sticking in a local area when the brazing flux is filled, and the oxide film on the surface of the aluminum alloy cannot be effectively removed without the brazing flux during welding, thereby affecting the welding strength and effect.
The above examples of the present invention are merely illustrative of the present invention and are not intended to limit the embodiments of the present invention. Other variations or modifications of the above teachings will be apparent to those of ordinary skill in the art. It is not necessary here nor is it exhaustive of all embodiments. Any modification, equivalent replacement, improvement, etc. which come within the spirit and principles of the invention are desired to be protected by the following claims.
Claims (10)
1. The preparation method of the composite welding wire containing the flux core is characterized by comprising the following steps of:
S1, preparing a superplastic welded pipe by adopting a Zn-Al superplastic alloy;
s2, mixing solder metal powder and soldering flux to prepare a flux-cored material;
And S3, heating the superplastic welded pipe in the step S1 to a superplastic deformation temperature, ultrasonically vibrating the superplastic welded pipe, performing thermoplastic drawing on the superplastic welded pipe, and continuously pouring the flux-cored material in the step S2 into the inner cavity of the superplastic welded pipe in the drawing process to obtain the composite welding wire containing the flux core.
2. The method for preparing the composite welding wire with the flux core according to claim 1, wherein in the step S1, the Zn-Al superplastic alloy is subjected to plastic deformation at 250-300 ℃, the plastic deformation is more than or equal to 80%, and annealing is carried out for 1.5-3 hours at 290-310 ℃ to obtain the superplastic welded pipe.
3. The method of manufacturing a flux-cored composite wire of claim 1 or 2, wherein in step S1, the Zn-Al superplastic alloy is ZnAl5 and/or ZnAl22.
4. The method of manufacturing a flux-cored composite wire of claim 1 wherein in step S2, the solder metal powder is at least one of Zn powder, al powder, zn-based intermediate alloy powder, or Al-based intermediate alloy powder.
5. The method for producing a flux-cored composite wire of claim 1, wherein in step S2, the flux is cesium fluoroaluminate flux and/or potassium fluoroaluminate flux.
6. The method of manufacturing a flux-cored composite welding wire of claim 1, wherein in step S2, the mass ratio of zn—al superplastic alloy to solder metal powder is (1.5-22): 1.
7. The method of producing a flux-cored composite wire of claim 1 wherein in step S2 the ratio of the total mass of Zn-Al superplastic alloy and solder metal powder to the mass of flux is (8-9): (1-2).
8. The method for producing a flux-cored wire of claim 1, wherein in step S3, the flux-cored wire is drawn by thermoplastic drawing the tube while continuously pouring the flux-cored wire into the inner cavity of the tube, and specifically comprises the steps of thermoplastic forming the tube in a die having a gradually smaller outer diameter in an axial direction, forming a drawn portion having a smaller outer diameter on one side of the tube, drawing the drawn portion of the tube in a direction away from the die, and pouring the flux-cored wire into the inner cavity of the tube while synchronously moving a pouring terminal of the flux-cored wire along the drawn portion in a drawing direction during drawing.
9. The method for preparing a flux-cored composite welding wire in accordance with claim 1, wherein in the step S3, the ultrasonic frequency is 16-22 khz and the power is 300-800 w.
10. The device for preparing the composite welding wire containing the flux core is characterized by comprising a drawing die module, an ultrasonic module, a temperature control module and a powder spraying traction module;
The drawing die module is used for thermoplastic forming of the superplastic welded pipe, so that the outer diameter of the superplastic welded pipe is reduced to a preset value;
the ultrasonic module is connected with the drawing die module and is used for ultrasonic vibration of the superplastic welded pipe;
The temperature control module is arranged at the front end of the drawing die module and is used for heating the superplastic welded pipe to a preset temperature so as to enable the superplastic welded pipe to have superplastic deformation;
The powder spraying traction module is arranged at the rear end of the drawing die module and comprises a clamp for a welded pipe capable of horizontally moving and a flux core material spray head, and is used for thermoplastic drawing of the superplastic welded pipe, and simultaneously, flux core materials are poured into the inner cavity of the superplastic welded pipe.
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