CABLE-TYPE WELDING WIRE

Abstract

A cable-type welding wire provided in the present application, includes a central welding wire and n peripheral welding wires arranged so as to be spirally wound on the central welding wire, with each of the peripheral welding wires having a diameter of d.sub.peripheral, and adjacent peripheral welding wires being arranged to be tangential to each other, wherein, the peripheral welding wires have a lay length of T, which satisfies the equation of T=m×(d.sub.peripheral+d.sub.central)/2, where m is a multiple of the lay length, d.sub.peripheral is a diameter of the peripheral welding wire, d.sub.central is a diameter of the central welding wire, and 3.2≤m<20. This application can obtain a smaller penetration depth when the welding parameters remain constant due to a small multiple of the lay length of the cable-type welding wire, and can further reduce welding arcing current.

Claims

1. A cable welding wire, comprising a central welding wire and n peripheral welding wires spirally winding around the central welding wire, with each of the peripheral welding wires having a diameter of d.sub.peripheral, and adjacent peripheral welding wires being arranged to be tangential to each other, wherein, the peripheral welding wire has a lay length T, which satisfies the equation of T=m×(d.sub.peripheral+d.sub.central)/2, where m is a multiple of the lay length, d.sub.peripheral is a diameter of the peripheral welding wire, d.sub.central is a diameter of the central welding wire, and 3.2≤m<20.

2. The cable welding wire of claim 1, wherein, an included angle between a rotation direction of the peripheral welding wire and a direction perpendicular to a length of the central welding wire or between a normal plane of the peripheral welding wire and a plane where the central welding wire is located is a helix angle α, which satisfies the equation of α=arctan(m/2π).

3. The cable welding wire of claim 1, wherein, an included angle between a rotation direction of the peripheral welding wire and a direction perpendicular to a length of the central welding wire or between a normal plane of the peripheral welding wire and a plane where the central welding wire is located is a helix angle α, which satisfies the equation of α=−9E-08 m.sup.6+2E-05 m.sup.5−0.0011 m.sup.4+0.0405 m.sup.3−0.8968 m.sup.2+11.971 m−3.3502.

4. The cable welding wire of claim 2, wherein, 26.99°≤α<72.56°.

5. The cable welding wire of claim 4, wherein, when a thickness of a surfacing layer is required to be less than 3 mm, m≤9, α≤55.08°; when the thickness of a surfacing layer is required to be 3 mm to 6 mm, m≤14, α≤65.83°; and when the thickness of a surfacing layer is required to be more than 6 mm, m<20, α<72.56°.

6. The cable welding wire of claim 5, wherein, 0.5 mm≤d.sub.peripheral≤2 mm.

7. The cable welding wire of claim 1, comprising at least 3 peripheral welding wires.

8. The cable welding wire of claim 1, wherein, the peripheral welding wire is a solid welding wire and/or a seamless flux-cored welding wire and/or a seamed flux-cored welding wire.

9. The cable welding wire of claim 8, wherein, the central welding wire is a solid welding wire or a flux-cored welding wire or a cable welding wire.

10. The cable welding wire of claim 3, wherein, 26.99°≤α<72.56°.

11. The cable welding wire of claim 2, comprising at least 3 peripheral welding wires.

12. The cable welding wire of claim 3, comprising at least 3 peripheral welding wires.

13. The cable welding wire of claim 2, wherein, the peripheral welding wire is a solid welding wire and/or a seamless flux-cored welding wire and/or a seamed flux-cored welding wire.

14. The cable welding wire of claim 3, wherein, the peripheral welding wire is a solid welding wire and/or a seamless flux-cored welding wire and/or a seamed flux-cored welding wire.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] In order to make a clearer description of technical solutions in specific implementations of the present application or prior art, drawings involved in description for the specific implementations or the prior art will be briefly introduced, and apparently, the drawings described below illustrate some implementations of the present application, for one with ordinary skill in the art, other drawings can also be obtained in accordance with these drawings without delivering creative efforts.

[0018] FIG. 1 is a schematic structural view of the cross-section of the peripheral welding wires having a central line with a helix angle α of 72.56°, when a minimum multiple of the lay length m of an equal-diameter 1+6 cable-type welding wire is equal to 20.

[0019] FIG. 2 is a structural diagram illustrating the front view with a value of the helix angle α for the peripheral welding wire having a central line with a helix angle α of 72.56°, when a minimum multiple of the lay length m of an equal-diameter 1+6 cable-type welding wire is equal to 20.

[0020] FIG. 3 is a schematic structural view of the cross-section of the peripheral welding wires having a central line with a helix angle α of 55.08°, when a multiple of the lay length m of an equal-diameter 1+5 cable-type welding wire is equal to 9.

[0021] FIG. 4 is a structural diagram illustrating the front view with a value of the helix angle α for the peripheral welding wire having a central line with a helix angle α of 55.08°, when a multiple of the lay length m of an equal-diameter 1+5 cable-type welding wire is equal to 9.

[0022] FIG. 5 is a schematic structural view of the cross-section of the peripheral welding wires having a central line with a helix angle α of 38.51°, when a multiple of the lay length m of an equal-diameter 1+4 cable-type welding wire is equal to 5.

[0023] FIG. 6 is a structural diagram illustrating the front view with a value of the helix angle α for the peripheral welding wire having a central line with a helix angle α of 38.51°, when a multiple of the lay length m of an equal-diameter 1+4 cable-type welding wire is equal to 5.

[0024] FIG. 7 is a schematic structural view of the cross-section of the peripheral welding wires having a central line with a helix angle α of 49.41°, when a 1+7 cable-type welding wire has d.sub.peripheral=1 mm, d.sub.central=2 mm, n=7, and a multiple of the lay length m 7.33.

[0025] FIG. 8 is a schematic structural view of the cross-section of the peripheral welding wires having a central line with a helix angle α of 49.41°, when a 1+7 cable-type welding wire has d.sub.peripheral=1 mm, d.sub.central=2 mm, n=7, and a multiple of the lay length m 7.33.

[0026] FIG. 9 is a schematic structural view of the cross-section of the peripheral welding wires having a central line with a helix angle α of 55.08°, when a (1+6)+10 cable-type welding wire has d.sub.peripheral=1 mm, d.sub.central=3 mm (1+6 cable-type welding wire), n=10, and a multiple of the lay length m 9.

[0027] FIG. 10 is a schematic structural view of the cross-section of the peripheral welding wires having a central line with a helix angle α of 55.08°, when a (1+6)+10 cable-type welding wire has d.sub.peripheral=1 mm, d.sub.central=3 mm (1+6 cable-type welding wire), n=10, and a multiple of the lay length m 9.

[0028] FIG. 11 is a schematic structural view of the cross-section of the peripheral welding wires having a central line with a helix angle α of 26.99°, when a 1+3 cable-type welding wire has d.sub.peripheral=0.8 mm, d.sub.central=0.8 mm, n=3, and a multiple of the lay length m 3.2.

[0029] FIG. 12 is a schematic structural view of the cross-section of the peripheral welding wires having a central line with a helix angle α of 26.99°, when a 1+3 cable-type welding wire has d.sub.peripheral=0.8 mm, d.sub.central=0.8 mm, n=3, and a multiple of the lay length m 3.2.

DETAILED DESCRIPTION

[0030] Technical solutions of the present application will be described clearly and completely as follows in conjunction with the drawings, apparently, the described embodiments are just part rather than all embodiments of the present application. Based on the embodiments in the present application, all other embodiments obtained by one with ordinary skill in the art without delivering creative efforts shall fall into the protection scope of the present application.

[0031] In the description of the present application, it should be noted that, orientation or position relationships indicated by terms such as “centre”, “upper”, “lower”, “left”, “right”, “vertical”, “horizontal”, “inner”, “outer”, etc. are orientation or position relationships indicated on the basis of the accompanying drawings, are only intended to facilitate description or simplified description of the present application, rather than indicating or implying that the involved apparatus or element shall have specific orientations, or be configured and operated specifically, and therefore shall not be construed as limit on the present application. In addition, terms such as “first”, “second”, “third”, which are merely intended to deliver description, can not be construed as indicating or implying relative importance.

[0032] In the description of the present application, it should be noted that, unless specified and defined otherwise, the terms of “installation”, “interconnection” and “connection” shall be understood in a broad sense, for example, a fixed connection, a removable connection, an integral connection, a mechanical connection, an electrical connection, a direct connection, an indirect connection via intermediate medium, or further, internal communication between two elements, a wireless connection, or a wired connection. Case-by-case interpretation can be made to the above terms in the present application by one with ordinary skill in the art.

[0033] Moreover, technical features involved in different implementations described in the present application below may be combined with each other as long as no conflicts occur therebetween.

[0034] Through a large number of tests, it is found in the present application that when the parameters such as welding current are constant, the smaller the lay length multiple m of the peripheral welding wire, the smaller the helix angle α; and when other parameters remain unchanged, the smaller the welding penetration depth, the lower the dilution rate. In addition, when the lay length multiple m is small, if 6 peripheral welding wires with an equal diameter and 1 central welding wire are used, it is difficult to produce extrusion plastic deformation between the welding wires with relatively high hardness during a twisting process, which is adverse to cable formation. In this case, a cable can be formed by twisting 5 peripheral welding wires and 1 central welding wire or 4 peripheral welding wires and 1 central welding wire, or by reducing the diameter of the peripheral welding wires, thereby ensuring a smaller helix angle α, making the fusion width of surfacing welds larger and the penetration depth smaller, and because the total number of welding wire is reduced, arcing current of the welding wires is smaller, which makes it easier to further reduce the penetration depth. Therefore, it is urgent and of great importance to further reduce the helix angle α while ensuring a compact structure and stable welding wire feed, so as to reduce the welding penetration depth to guarantee quality in the design of a thin surfacing layer, enabling efficient consumable electrode gas protection surfacing and the application of submerged arc surfacing. Based on this, after a lot of theoretical and experimental research, the present application provides a cable-type welding wire, comprising a central welding wire and n peripheral welding wires arranged, so as to be spirally wound on the central welding wire, with each of the peripheral welding wires having a diameter of d.sub.peripheral, and adjacent peripheral welding wires being arranged to be tangential to each other, wherein, the peripheral welding wires have a lay length of T, which satisfies the equation of T=m×(d.sub.peripheral+d.sub.central)/2, where m is a multiple of the lay length, d.sub.peripheral is a diameter of the peripheral welding wire, d.sub.central is a diameter of the central welding wire, and 3.2≤m<20.

[0035] The cable-type welding wire has a small multiple of the lay length, and can obtain a smaller penetration depth when the welding parameters remain constant and further reduce the welding arcing current, which in turn boosts a reduction in the welding penetration depth, making a significant contribution to control the dilution rate of the surfacing layer. With a smaller penetration depth and a lower dilution rate during welding, the cable-type welding wire can be used in the field of surfacing requiring shallower penetration, a lower dilution rate and a thinner surfacing layer.

[0036] In a preferred implementation, an included angle between a rotation direction of the peripheral welding wire and a direction perpendicular to a length of the central welding wire or between a normal plane of the peripheral welding wire and a plane where the central welding wire is located is a helix angle α, which satisfies the equation of α=arctan(m/2π) or α=−9E-08 m.sup.6+2E-05 m.sup.5−0.0011 m.sup.4+0.0405 m.sup.3−0.8968 m.sup.2+11.971 m−3.3502.

[0037] The above implementation is obtained by the following calculation method: For the central line of each peripheral welding wire of the cable-type welding wire, it is essentially a cylindrical spiral line spirally wound around the central line of the central welding wire, the helix angle is constant and the calculation formula thereof is α=arctan(H/πD), where H is a helical pitch, D is the diameter of the cylindrical spiral line, in this implementation, the peripheral welding wire has a lay length of T, which satisfies the equation of T=m×(d+d)/2 and equivalent to the helical pitch, and D=d.sub.peripheral+d.sub.central, hence α=arctan(m/2π), and α=−9E-08 m.sup.6+2E-05 m.sup.5−0.0011 m.sup.4+0.0405 m.sup.3−0.8968 m.sup.2+11.971 m−3.3502 is a polynomial function relationship of the above formula. In a preferred implementation, 26.99°≤α<72.56°, in the case that other conditions remain unchanged, the smaller the helix angle α of the peripheral welding wire, the smaller the penetration depth, and the larger the fusion width, making it easier to increase the welding speed, that is, to further reduce the welding penetration depth, and it is particularly suitable for surfacing methods with strict requirements on the dilution rate of a base material by corrosion and wear.

[0038] Experimental research shows that when the thickness of a surfacing layer is required to be more than 6 mm, m<20, α<72.56°, by controlling a smaller welding current and a higher welding speed, the penetration depth during the surfacing welding of the cable-type welding wire consumable electrode can be controlled to be 3 mm or even lower; when the thickness of a surfacing layer is required to be within 3 mm to 6 mm, m≤14, α≤65.83°, by controlling a smaller welding current and a higher welding speed, the penetration depth during the surfacing welding of the cable-type welding wire consumable electrode can be controlled to be 2 mm or even lower; when the thickness of a surfacing layer is required to be below 3 mm, m≤9, α≤55.08°, by controlling a smaller welding current and a higher welding speed, the penetration depth during the surfacing welding of the cable-type welding wire consumable electrode can be controlled to be 1 mm or even lower. Hence the present application lays down an important theoretical and experimental research foundation for the application of ordinary metal inert gas welding and submerged-arc welding in the field of surfacing welding. Metal inert gas welding and submerged-arc welding surfacing of the cable-type welding wire can significantly reduce welding production costs and improve economic benefits. Agitation in a molten pool of the cable-type welding wire can accelerate the discharge of gases and slag inclusions, which plays an important role in ensuring the quality of surfacing metal.

[0039] In a preferred implementation, 0.5 mm≤d.sub.peripheral≤2 mm. The cable-type welding wire comprises at least 3 peripheral welding wires. The peripheral welding wire is a solid welding wire and/or a seamless flux-cored welding wire and/or a seamed flux-cored welding wire. The central welding wire is a solid welding wire or a flux-cored welding wire or a cable-type welding wire.

[0040] After testing and research, it is found that in working conditions, such as a corrosion environment containing H2S and those requiring an effective thickness of the surfacing layer less than 3 mm, a cable-type welding wire with α≤50° shall be adopted as underlay surfacing, a cable-type welding wire with α≤65° shall be adopted as the filling layer, and a cable-type welding wire with α≤75° shall be adopted as the surface layer. For flux-cored welding wire with a helix angle α≤60°, due to the difficulty in production and processing in case of a flux-cored peripheral welding wire, the peripheral welding wire should be a solid thin welding wire, and a flux-cored welding wire structure, i.e., the central welding wire, is used as a base transition layer, the filling layer and above use a full flux-cored cable-type welding wire with α≥60°.

Embodiment 1

[0041] The structure of the cable-type welding wire for surfacing provided by this embodiment is 1+6, as shown in FIG. 1 and FIG. 2, that is, the number of the peripheral welding wires is 6, the number of the central welding wires is 1, and each welding wire has a diameter of 1.33 mm and is a solid welding wire, the lay length multiple m is 18, the helix angle α is 70.76°.

Embodiment 2

[0042] The structure of the cable-type welding wire for surfacing provided by this embodiment is 1+5, as shown in FIG. 3 and FIG. 4, that is, the number of the peripheral welding wires is 5, the number of the central welding wires is 1, and each welding wire has a diameter of 1.0 mm and is a solid welding wire, the lay length multiple m is 9, the helix angle α is 55.08°.

Embodiment 3

[0043] The structure of the cable-type welding wire for surfacing provided by this embodiment is 1+4, as shown in FIG. 5 and FIG. 6, that is, the number of the peripheral welding wires is 4, the number of the central welding wires is 1, and each welding wire has a diameter of 2 mm and is a solid welding wire, the lay length multiple m is 5, the helix angle α is 38.51°.

Embodiment 4

[0044] The structure of the cable-type welding wire for surfacing provided by this embodiment is 1+7, as shown in FIG. 7 and FIG. 8, that is, the number of the peripheral welding wires is 7, the number of the central welding wires is 1, and each welding wire has a diameter of 0.5 mm and is a solid welding wire, the lay length multiple m is 7.33, the helix angle α is 49.41°.

Embodiment 5

[0045] The structure of the cable-type welding wire for surfacing provided by this embodiment is (1+6)+10, as shown in FIG. 9 and FIG. 10, that is, the number of the peripheral welding wires is 10, the number of the central welding wires is 1, the central welding wire has a diameter of 3 mm, the peripheral welding wire has a diameter of 1 mm, all of the welding wires are solid welding wires, the lay length multiple m of the peripheral welding wire is 9, and the helix angle α is 55.08°.

Embodiment 6

[0046] The structure of the cable-type welding wire for surfacing provided by this embodiment is 1+3, as shown in FIG. 11 and FIG. 12, that is, the number of the peripheral welding wires is 3, the number of the central welding wires is 1, and the peripheral and the central welding wire each have a diameter of 0.8 mm and are solid welding wires, the lay length multiple m of the peripheral welding wire is 3.2, and the helix angle α is 26.99°.

Comparative Example 1

[0047] The welding wire with a structure of a single wire having a diameter of φ4 mm is provided in this comparative example for the conduction of submerged-arc welding.

Comparative Example 2

[0048] The welding wire with a structure of a single wire having a diameter of φ1.2 mm is provided in this comparative example for the conduction of metal inert gas welding.

Comparative Example 3

[0049] The structure of the cable-type welding wire provided by this comparative example is 1+6, as shown in FIG. 1 and FIG. 2, that is, the number of the peripheral welding wires is 6, the number of the central welding wires is 1, and each welding wire has a diameter of 1.33 mm and is a solid welding wire, the lay length multiple m is 20, and the helix angle α is 72.56°, and the corresponding surfacing method is submerged-arc welding.

Comparative Example 4

[0050] The structure of the cable-type welding wire provided by this comparative example is 1+6, as shown in FIG. 1 and FIG. 2, that is, the number of the peripheral welding wires is 6, the number of the central welding wires is 1, and each welding wire has a diameter of 0.8 mm and is a solid welding wire, the lay length multiple m is 20, and the helix angle α is 72.56°, and the corresponding surfacing method is metal inert gas welding.

Comparative Example 5

[0051] The structure of the cable-type welding wire provided by this comparative example is 1+6, as shown in FIG. 1 and FIG. 2, that is, the number of the peripheral welding wires is 6, the number of the central welding wires is 1, and each welding wire has a diameter of 2 mm and is a solid welding wire, the lay length multiple m is 20, and the helix angle α is 72.56°, and the corresponding surfacing method is submerged-arc welding.

[0052] The cable-type welding wires provided by Embodiment 1, 3, 5 and Comparative Examples 1, 3, 5 are subjected to surfacing penetration test, in which Aotai MZE-1000 is selected as the welding machine, using DC reverse connection, Q345E having a thickness of 15.6 mm is used as the base material; and SJ101 is used as the flux. See Table 2 for details of the welding parameters and penetration depth.

TABLE-US-00001 TABLE 1 diameter of diameter of lay length helix peripheral welding central welding lay multiple angle α wire d.sub.peripheral wire d.sub.central length T m 38.51 0.8 0.8 4 5 38.51 2 2 10 5 38.51 1 2 7.5 5 55.08 0.8 0.8 7.2 9 55.08 2 2 18 9 55.08 1 2 13.5 9 67.27 0.8 0.8 12 15 67.27 2 2 30 15 67.27 1 2 22.5 15

[0053] Table 1 shows the correlation between the helix angle α and the lay length multiple m. It can be seen that whether the diameter d of the peripheral welding wire is equal to or different from the diameter d of the central welding wire, the same helix angle α can be obtained, and if the lay length multiple m is changed, then the helix angle α will be changed, that is, the helix angle α for a space curve should be independent of the welding wire diameter, and should only be related to the lay length multiple m of the peripheral welding wire.

TABLE-US-00002 TABLE 2 Voltage Penetration Current I U Rate V Lay length Helix angle depth Welding method A V cm/min multiple m α° mm Comparative submerged arc 500 30 80 / ∞ 3.45 example surfacing of φ4 550 30 80 / ∞ 3.91 1 single wire 600 30 80 / ∞ 5.70 Comparative submerged arc 500 30 80 20 72.56 2.67 example surfacing (1 + 6 550 30 80 20 72.56 3.01 3 type) of φ4 cable 600 30 80 20 72.56 3.50 wires Comparative submerged arc 500 32 80 20 72.56 3.00 example surfacing (1 + 6 700 32 80 20 72.56 3.13 5 type) of φ6 cable 900 32 80 20 72.56 3.50 wires Embodiment submerged arc 500 30 80 18 70.76 1.98 1 surfacing (1 + 6 550 30 80 18 70.76 2.14 type) of φ4 cable 600 30 80 18 70.76 2.25 wires Embodiment submerged arc 400 32 80 5 38.51 0.68 3 surfacing (1 + 4 450 32 80 5 38.51 0.96 type) of φ6 cable 500 32 80 5 38.51 1.12 wires Embodiment submerged arc 500 32 80 9 55.08 0.89 5 surfacing ((1 + 6) 600 32 80 9 55.08 1.23 +10 type) of Φ5 700 32 80 9 55.08 1.48 cable wires

[0054] It can be seen from Table 2 that, compared with a single welding wire, the penetration depth of a cable-type welding wire is smaller under the same conditions of submerged-arc welding, especially the smaller the lay length multiple m of the cable-type welding wire, the smaller the penetration depth. And when the lay length multiple is small, the reduction in the number of peripheral welding wires is conducive to the reduction of the welding current, which is more conducive to the reduction of the surfacing penetration depth in addition with a smaller helix angle α. The designs for the cable-type welding wire used for surfacing provided in embodiment 1, 3 and 5 are only part of the present application. Other designs that are not reflected in the embodiments but are similar to or approximate to the present application are deemed to be within the patent protection scope of the present application.

[0055] The cable-type welding wires provided by embodiments 2, 4, 6 and comparative examples 2, 4 are subjected to surfacing penetration tests, in which Hanshen HC650D is selected as the welding machine, using DC reverse connection, Q345E having a thickness of 15.6 mm is used as the base material; and 82% Ar+18% CO.sub.2 is used as the protective gas. See Table 3 for details of the welding parameters and penetration depth.

TABLE-US-00003 TABLE 3 Lay length Penetration Welding Current I Voltage U Rate V multiple Helix depth method (A) (V) (cm/min) m angle α° (mm) Comparative Φ1.2 single 200 26 40 ∞ 90 3.50 example wire metal 250 26 40 ∞ 90 4.50 2 inert gas 300 30 40 ∞ 90 5.51 welding Comparative Φ2.4 cable 400 30 40 20 72.56 7.11 example wire metal 450 32 40 20 72.56 8.02 4 inert gas 500 34 40 20 72.56 9.50 welding (1 + 6 type) Embodiment Φ3 cable 300 30 40 9 55.08 1.03 2 wire metal 350 32 40 9 55.08 2.28 inert gas 400 34 40 9 55.08 3.87 welding (1 + 5 type) Embodiment Φ3 cable 300 30 40 7.33 49.40 0.82 4 wire metal 350 32 40 7.33 49.40 1.85 inert gas 400 34 40 7.33 49.40 3.83 welding (1 + 7 type) Embodiment Φ2.4 cable 250 30 40 3.2 26.99 0.42 6 wire metal 300 30 40 3.2 26.99 0.53 inert gas 350 32 40 3.2 26.99 0.69 welding (1 + 3 type)

[0056] It can be seen from Table 3 that, compared with a single welding wire, the penetration depth of a cable-type welding wire is smaller under the same conditions of metal inert gas welding, especially the smaller the lay length multiple m of the cable-type welding wire, the smaller the penetration depth. And when the lay length multiple is small, the reduction in the number of peripheral welding wires is conducive to the reduction of the welding current, which is more conducive to the reduction of the surfacing penetration depth in addition with a smaller helix angle α. The designs for the cable-type welding wire used for surfacing provided in embodiment 2, 4 and 6 are only part of the present application. Other designs that are not reflected in the embodiments but are similar to or approximate to the present application are deemed to be within the patent protection scope of the present application.

[0057] Obviously, the above embodiments are merely intended to clearly illustrate rather than limit the numerated implementations. For one with ordinary skill in the art, other different forms of modifications or changes may further be made on the basis of the aforementioned descriptions. It is unnecessary and impossible to exhaust all implementations. And modifications or changes derived herefrom obviously fall into the protection scope of the present application.