Stainless steel flux-cored wire

Abstract

It is an object to provide a stainless steel flux-cored wire in which the amount of hexavalent chromium in fume can be reduced while maintaining the weldability excellent. The stainless steel flux-cored wire contains, as percentage to the total mass of the wire: Cr: 11-30 mass %; metal Si, Si oxide and Si compound: 0.5-4.0 mass % in total in terms of Si [Si]; fluorine compound: 0.01-1.0 mass % in terms of F [F]; TiO.sub.2: 1.5 mass % or above; ZrO.sub.2+Al.sub.2O.sub.3: 3.2 mass % or below; Na compound, K compound and Li compound: 0.50 mass % or below in total of each of an amount in terms of Na [Na], an amount in terms of K [K] and an amount in terms of Li [Li]; and satisfies {([Na]+[K]+[Li])[Cr].sup.2}/([Si]+4.7[F])10, where [Cr] represents Cr content.

Claims

1. A flux-cored wire for arc welding filled up with flux in an outer sheath made of stainless steel containing, as percentage to the total mass of the wire: Cr: 11-30 mass %; metal Si, Si oxide and Si compound: 1.1-4.0 mass % in total in terms of Si [Si]; fluorine compound: 0.01-1.0 mass % in terms of F [F]; TiO.sub.2: 1.5 mass % or above; ZrO.sub.2+Al.sub.2O.sub.3: 3.2 mass % or below; Na compound, K compound and Li compound: 0.50 mass % or below in total of each of an amount in terms of Na [Na], an amount in tell is of K [K] and an amount in terms of Li [Li]; wherein, when [Cr] represents Cr content (mass %),
{([Na]+[K]+[Li])[Cr].sup.2}/([Si]+4.7[F])10 is satisfied.

2. The flux-cored wire for arc welding filled up with flux in an outer sheath made of stainless steel according to claim 1, wherein
{([Na]+[K]+[Li])[Cr].sup.2}/([Si]+4.7[F])9.3 is satisfied.

3. The flux-cored wire for arc welding filled up with flux in an outer sheath made of stainless steel according to claim 1, wherein
{([Na]+[K]+[Li])[Cr].sup.2}/([Si]+4.7[F])9.1 is satisfied.

4. The flux-cored wire for arc welding filled up with flux in an outer sheath made of stainless steel according to claim 1, wherein: Cr: 11-24 mass %.

5. The flux-cored wire for arc welding filled up with flux in an outer sheath made of stainless steel according to claim 1, wherein: Cr: 11-22 mass %.

6. A flux-cored wire for arc welding filled up with flux in an outer sheath made of stainless steel containing, as percentage to the total mass of the wire: Cr: 11-22 mass %; metal Si, Si oxide and Si compound: 0.5-4.0 mass % in total in terms of Si [Si]; fluorine compound: 0.01-1.0 mass % in terms of F [F]; TiO.sub.2: 1.5 mass % or above; ZrO.sub.2Al.sub.2O.sub.3: 3.2 mass % or below; Na compound, K compound and Li compound: 0.50 mass % or below in total of each of an amount in terms of Na [Na], an amount in terms of K [K] and an amount in terms of Li [Li]; wherein, when [Cr] represents Cr content (mass %),
{([Na]+[K]+[Li])[Cr].sup.2}/([Si]+4.7[F])10 is satisfied.

7. The flux-cored wire for arc welding filled up with flux in an outer sheath made of stainless steel according to claim 6, wherein {([Na]+[K]+[Li])[Cr].sup.2}/([Si]+4.7[F])9.3 is satisfied.

8. The flux-cored wire for arc welding filled up with flux in an outer sheath made of stainless steel according to claim 6, wherein
{([Na]+[K]+[Li])[Cr].sup.2}/([Si]+4.7[F])9.1 is satisfied.

9. The flux-cored wire for arc welding filled up with flux in an outer sheath made of stainless steel according to claim 6, wherein: metal Si, Si oxide and Si compound: 1.0-4.0 mass % in total in terms of Si [Si].

Description

BRIEF DESCRIPTION OF THE DRAWING

(1) FIG. 1 is a graph showing the relation between {([Na]+[K]+[Li])[Cr].sup.2}/([Si]+4.7[F]) and the amount of hexavalent chromium in fume.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

(2) Below, the present invention will be described in detail. The flux-cored wire has spread to wide fields because it has excellent weldability and high performance. Particularly in the welding material for stainless steel, the use ratio of the flux-cored wire is high. However, in the fume generated in welding using a conventional flux-cored wire for welding stainless steel, Cr is contained by 10 mass % or above, and a part of the Cr is present in the form of hexavalent chromium.

(3) With respect to hexavalent chromium in working environment, its harmful effect to the human body has been questioned, and there has been a strong movement to strengthen the restriction of hexavalent chromium in working environment. For example, the Occupational Safety & Health Administration (OSHA), United States Department of Labor made the permissible exposure limit (PEL) of hexavalent chromium stricter in 2006 from 50 g/m.sup.3 to 5 g/m.sup.3, or 1/20 of the conventional value. Therefore, although it has been required to reduce hexavalent chromium in welding fume, the weldability is poor according to prior arts, and no technology has been established for practical use.

(4) According to the present invention, a stainless steel flux-cored wire has been developed which reduced hexavalent chromium in fume while maintaining excellent weldability.

(5) Next, the reason for adding an element and the reason for limiting the composition of the flux-cored wire in the present invention will be described.

(6) [Cr: 11-30 Mass %]

(7) When Cr content which is an indispensable element for stainless steel is below 11 mass %, a passive film is not formed and the corrosion resistance required for the weld metal as a welding wire for welding stainless steel is not exerted. Also, when the Cr amount exceeds 30 mass %, the Cr content in fume becomes extremely high, thereby the content of hexavalent chromium increases, and hexavalent chromium is not reduced sufficiently. Accordingly, Cr content is to be 11-30 mass %.

(8) [Si: 0.5-4.0 Mass %]

(9) In order to reduce elution of hexavalent chromium from fume, amorphization of fume is effective. Also, addition of Si is effective for amorphization of fume. Therefore, in order to reduce elution of hexavalent chromium, Si is added in the form of metal Si, Si oxide and/or Si compound. When the amount of these metal Si, Si oxide and Si compound is 0.5 mass % or above in total of respective amounts in terms of Si, the effect of amorphization can be secured. However, when the total of the amounts in terms of Si exceeds 4.0 mass %, the removability of slag deteriorates. Therefore, the amount to be added of these metal Si, Si oxide and Si compound is to be 0.5-4.0 mass % in total of respective amounts in terms of Si, preferably 1.0-4.0 mass %. As additive raw materials of Si, the metal Si included in the outer sheath, the metal Si, silica sand, feldspar, potassium fluoride and the like in the added raw material of the flux can be cited. All these raw materials are effective in increasing SiO.sub.2 in fume, and the effect of reducing hexavalent chromium can be secured in any of these adding raw materials.

(10) [Na Compound, K Compound and Li Compound: 0.50 Mass % or Below in Total of Each of an Amount in Terms of Na, an Amount in Terms of K and an Amount in Terms of Li]

(11) Alkaline metals including Na, K and Li react with Cr in fume and form a hexavalent chromium compound soluble in water such as sodium chromate for example. Therefore, by increasing the alkaline metals in fume, the hexavalent chromium content in fume increases. Accordingly, the amount of the Na compound, K compound and Li compound is to be 0.50 mass % or below in total of each of an amount in terms of Na, an amount in terms of K and an amount in terms of Li. More preferable range of the amount of the Na compound, K compound and Li compound is 0.30 mass % or below in total of the amounts in terms of respective elements. Also, as the sources of Na, K and Li, oxides, fluorides and the like thereof can be cited.

(12) [Fluorine Compound: 0.01-1.0 Mass % in Terms of F]

(13) As a result of intensive experiments and studies, the present inventors found out that addition of a fluorine compound was effective in reducing hexavalent chromium in fume. In fume, fluorine reacts with alkaline metals, and forms alkaline metal fluoride. Therefore, by adding fluorine, an effect of suppressing the alkaline metals from reacting with chromium and forming a hexavalent chromium compound is secured. Unless the content of the fluorine compound in terms of F is 0.01 mass % or above, the effect of reducing hexavalent chromium cannot be secured, the pit resistance deteriorates, and the weldability deteriorates. On the other hand, when the fluorine compound is added exceeding 1.0 mass %, the weldability deteriorates. Therefore, the fluorine compound is to be 0.01-1.0 mass % in terms of F, and more preferably 0.01-0.80 mass %.

(14) [{([Na]+[K]+[Li])[Cr].sup.2}/([Si]+4.7[F])10]

(15) When [Cr] represents Cr content, [Si] represents an amount in terms of Si, [F] represents an amount in terms of F, [Na] represents an amount in terms of Na, [K] represents an amount in terms of K, and [Li] represents an amount in terms of Li, a parameter expressed by {([Na]+[K]+[Li])[Cr].sup.2}/([Si]+4.7[F]) is to be 10 or below. As a result of intensive experiments and studies, the present inventors found out that there was a strong correlation between the parameter and the hexavalent chromium amount in fume. Also, by making the parameter 10 or below, hexavalent chromium in fume can be greatly reduced in both cases that the shield gas is 100% CO.sub.2 and a gas mixture (80% Ar-20% CO.sub.2).

(16) In the parameter, the elements appearing in the dominator are factors contributing more to reducing hexavalent chromium in fume when they are bigger, and the elements appearing in the numerator are factors contributing more to reducing hexavalent chromium in fume when they are smaller. The parameter is an indicator obtained by experimentally studying the balance of the two factors.

(17) [TiO.sub.2: 1.5 Mass % or above, ZrO.sub.2+Al.sub.2O.sub.3: 3.2 Mass % or below]

(18) When the amount to be added of alkaline metals is restricted as described above in order to suppress generation of hexavalent chromium, deterioration of the arc stability becomes a problem. TiO.sub.2 has an effect of stabilizing an arc in addition to an effect of improving slag covering, and is effective in improving the arc stability when the alkaline metals are reduced. In order to secure these effects sufficiently, TiO.sub.2 should be added by 1.5 mass % or above, preferably 2.0 mass % or above. Also, TiO.sub.2 is to be 8.0 mass % or below. ZrO.sub.2 and Al.sub.2O.sub.3 are preferable raw materials added as slag forming agents. For the purpose, it is preferable to add ZrO.sub.2 and Al.sub.2O.sub.3 by 0.1 mass % or above in total. However, when ZrO.sub.2 and Al.sub.2O.sub.3 are added too much, the slag removability is deteriorated, and therefore the amount to be added is to be 3.2 mass % or below in total, preferably 2.7 mass % or below. As the sources for TiO.sub.2, rutile, ilminite, titanium oxide, potassium titanate and the like can be cited, and these raw materials are added solely or combining two kinds or more. As the sources for ZrO.sub.2, zirconium sand, zirconium oxide and the like can be cited.

(19) [Other Compositions]

(20) As the other compositions, Ni, Mo, Mn and Fe are contained by 50-80 mass % in total. Not only that Ni, Mo, Mn and Fe are included in the outer sheath, they are added to the flux as metal powder. As the other oxides, Al.sub.2O.sub.3 and MgO can be cited.

EXAMPLES

(21) Next, with respect to examples in relation with the present invention, their effects will be described in comparison with comparative examples that deviate from the scope of the present invention. Table 1 and Table 2 below illustrate the composition of the flux-cored wires of the examples and the comparative examples.

(22) TABLE-US-00001 TABLE 1 Chemical composition of wire (mass %) Shield gas Si Na K Li Na + K + Li F Example 1 100%CO.sub.2 1.9 0.03 0.02 0.00 0.05 0.02 2 80%Ar20%CO.sub.2 3.8 0.03 0.02 0.00 0.05 0.02 3 100%CO.sub.2 0.6 0.02 0.05 0.00 0.07 0.45 4 100%CO.sub.2 3.9 0.45 0.02 0.00 0.47 0.92 5 100%CO.sub.2 3.8 0.02 0.46 0.00 0.48 0.97 6 100%CO.sub.2 3.8 0.02 0.02 0.44 0.48 0.95 7 100%CO.sub.2 2.3 0.08 0.02 0.00 0.10 0.90 8 80%Ar20%CO.sub.2 2.4 0.02 0.00 0.01 0.03 0.02 9 100%CO.sub.2 3.3 0.02 0.05 0.00 0.07 0.95 10 100%CO.sub.2 1.9 0.03 0.02 0.00 0.05 0.02 Compar- 1 100%CO.sub.2 0.4 0.10 0.02 0.00 0.12 0.48 ative 2 100%CO.sub.2 4.1 0.05 0.07 0.04 0.16 0.84 example 3 80%Ar20%CO.sub.2 2.0 0.52 0.00 0.00 0.52 0.90 4 100%CO.sub.2 1.9 0.00 0.56 0.00 0.56 0.25 5 100%CO.sub.2 3.7 0.00 0.00 0.53 0.53 0.10 6 100%CO.sub.2 3.0 0.32 0.17 0.07 0.56 0.50 7 80%Ar20%CO.sub.2 2.2 0.04 0.02 0.02 0.08 0.00 8 100%CO.sub.2 2.8 0.11 0.05 0.00 0.16 1.05 9 80%Ar20%CO.sub.2 1.8 0.25 0.19 0 0.44 0.6 10 100%CO.sub.2 1.8 0.02 0 0.03 0.05 0.4 11 100%CO.sub.2 1.5 0.02 0 0.03 0.05 0.4 12 100%CO.sub.2 1.9 0.03 0.02 0.00 0.05 0.02 13 100%CO.sub.2 1.5 0.15 0.10 0.00 0.25 0.04 14 100%CO.sub.2 1.8 0.16 0.10 0.00 0.26 0.06 15 100%CO.sub.2 1.5 0.15 0.10 0.00 0.25 0.04 16 100%CO.sub.2 1.5 0.15 0.10 0.00 0.25 0.04 17 100%CO.sub.2 1.5 0.08 0.06 0.00 0.14 0.04 18 100%CO.sub.2 1.2 0.08 0.10 0.01 0.19 0.08 19 100%CO.sub.2 1.4 0.20 0.14 0.00 0.34 0.08 20 100%CO.sub.2 1.3 0.13 0.01 0.11 0.25 0.05 21 100%CO.sub.2 1.7 0.10 0.10 0.00 0.20 0.09 22 100%CO.sub.2 1.1 0.11 0.29 0.00 0.40 0.18 23 100%CO.sub.2 1.1 0.10 0.27 0.00 0.37 0.18

(23) TABLE-US-00002 TABLE 2 (Na + K + ZrO.sub.2 + Li) Cr.sup.2/ Cr TiO.sub.2 Al.sub.2O.sub.3 (Si + 4.7 F) Ni Mo Example 1 19 5.5 0.2 9.1 9.2 0.0 2 19 2.0 0.2 4.6 9.1 0.0 3 19 6.4 1.2 9.3 9.2 0.0 4 12 2.5 1.4 8.2 0.0 0.0 5 12 1.7 1.3 8.3 0.0 0.0 6 12 2.1 1.2 8.4 0.0 0.0 7 24 3.3 0.4 8.8 8.5 3.1 8 22 1.6 0.1 5.8 12 0.0 9 27 3.2 0.2 6.6 9 0.0 10 18 2.1 3.4 8.1 12 2.1 Compar- 1 19 7.2 2.1 16.3 9 0.0 ative 2 22 1.8 0.8 9.6 12 0.0 example 3 24 4.4 2.0 48.1 8 3.0 4 19 0.3 1.4 65.7 11 2.3 5 22 4.3 2.2 61.5 12 2.2 6 24 2.1 0.5 60.3 19 0.0 7 19 1.5 3.3 13.1 9 0.0 8 19 2.2 0.9 7.5 9 0.0 9 22 3.5 3.6 46.1 9 0.0 10 22 1.9 3.3 6.6 11 0.0 11 22 1.4 3.0 7.7 9 0.0 12 23 2.6 0.9 13.3 12 0.0 13 19 1.2 2.4 53.5 9 0.0 14 18 1.4 2.3 40.5 9 0.0 15 19 1.2 2.4 53.5 12 0.0 16 24 1.1 2.3 85.3 12 2.2 17 19 1.3 2.6 29.9 9 0.0 18 19 3.3 1.7 43.5 10 0.0 19 19 4.2 1.8 69.1 9 0.0 20 19 3.4 2.1 58.8 9 0.0 21 20 5.1 1.2 37.7 9 0.0 22 19 6.6 1.7 74.2 9 0.0 23 22 6.5 1.8 92.0 12 0.0

(24) Welding was performed using these welding wires, and fume was taken. The fume was taken by a method of performing welding for five minutes continuously in accordance with JIS Z 3930:2001 (Determination of emission rate of particulate fume in arc welding) and taking the fume generated during the welding by a filter. The welding condition was 200 A of the welding current and 30 V of the arc voltage. Also, from the welding fume taken, hexavalent chromium included therein was analyzed. The analytical method for hexavalent chromium in fume was in accordance with ISO 16740:2005. The analytical results of the hexavalent chromium and the weldability in welding are shown in Table 3 below.

(25) (Method for Evaluating Weldability)

(26) Using stainless steel of 304 type as a base metal, bead-on-plate welding was performed in the form of flat horizontal fillet welding. The welding condition was welding current: 190-210 A, arc voltage: 28-31 V in all cases.

(27) (Criteria for Evaluating Weldability)

(28) With respect to the arc stability, the stability of transfer of the molten droplet and the generated amount of the spatter were organoleptically evaluated. One that greatly generated coarse droplets transfer and the spatter was evaluated to be unstable in an arc. With respect to the slag removability, one in which the slag was naturally removed after welding without seizure of slag was determined to be excellent.

(29) TABLE-US-00003 TABLE 3 Hexavalent chromium Fume generated Evaluation of weldability in fume (ppm) amount (mg/min) Arc stability Slag removability Others Example 1 300 393 Good Good 2 120 221 Good Good 3 310 381 Good Good 4 400 458 Good Good 5 350 442 Good Good 6 190 472 Good Good 7 470 427 Good Good 8 170 192 Good Good 9 210 430 Good Good 10 200 402 Good Good Compar- 1 730 419 Good Good ative 2 430 439 Good Poor example 3 1200 285 Good Good 4 1500 427 Good Good 5 2100 432 Good Good 6 1400 441 Good Good 7 620 387 Good Good Pit generated 8 300 521 Unstable arc Good 9 1500 245 Good Good 10 320 399 Good Poor 11 380 404 Unstable arc Poor 12 900 417 Good Good 13 1000 442 Good Poor 14 1000 457 Good Poor 15 800 488 Good Poor 16 2000 469 Good Poor 17 780 436 Good Poor 18 1000 472 Good Good 19 1800 489 Good Good 20 1000 495 Good Good 21 1000 487 Good Good 22 1500 475 Good Good 23 3000 492 Good Good

(30) When the amount of hexavalent chromium in fume was 500 ppm or below, it was determined that there was an effect of reducing the amount of hexavalent chromium in fume. Further, the generated amount of the fume was also measured. As a result of it, in all of the examples 1 to 10 of the present invention, the amount of hexavalent chromium is 500 ppm or below, and it is known that the amount of hexavalent chromium can be reduced. On the other hand, in the cases of the comparative examples, the amount of hexavalent chromium exceeded 500 ppm with the exception of the comparative examples 2, 8, 10 and 11. Also, in the comparative examples 2, 8, 10 and 11, the weldability was as poor as not reaching a practical level. In the comparative example 1, because Si was less, the value of the parameter did not satisfy the required range, and the amount of hexavalent chromium in fume became high. In the comparative example 2, because Si was too high, although the amount of hexavalent chromium became low, the slag removability deteriorated to a large extent. In the comparative examples 3 to 6, because the added amount of the alkaline metals was too much, the value of the parameter did not satisfy the required range, and the amount of hexavalent chromium became high. In the comparative example 7, because F was too low, the pit resistance deteriorated. In the comparative example 8, because F was too high, the amount of the spatter increased and the weldability deteriorated. In the comparative example 9, although the range of respective compositions was satisfied, the parameter did not satisfy the required range, and therefore the amount of hexavalent chromium became high. In the comparative example 10, because the added amount of ZrO.sub.2 was too much, the slag removability deteriorated. In the comparative example 11, because the added amount of TiO.sub.2 was less, the slag removability and the arc stability deteriorated. In the comparative examples 12 to 23, because the parameter could not satisfy the required range, the amount of hexavalent chromium exceeded 500 ppm in all cases. Also, in all cases of the comparative examples 13 to 17, because the added amount of TiO.sub.2 was 1.5 mass % or below, the slag removability deteriorated.

(31) Next, the value of the parameter was changed. The result of the study on the influence of the parameter will be described below. Table 4 below shows the composition of the welding wire used. Also, the relation between the value of the parameter {([Na]+[K]+[Li])[Cr].sup.2}/([Si]+4.7[F]) and the amount of hexavalent chromium in fume is shown in Table 5 below and FIG. 1.

(32) TABLE-US-00004 TABLE 4 Si Na K Li Na + K + Li F Cr Example 11 1.9 0.03 0.02 0.00 0.04 0.02 19.1 12 1.9 0.03 0.02 0.00 0.04 0.02 18.8 Compar- 24 1.9 0.03 0.02 0.00 0.04 0.02 22.5 ative 25 1.5 0.15 0.10 0.00 0.25 0.04 18.9 example 26 1.8 0.16 0.10 0.00 0.26 0.06 18.1 27 1.5 0.15 0.10 0.00 0.25 0.04 19.4 28 1.5 0.15 0.10 0.00 0.25 0.04 23.7 29 1.5 0.08 0.06 0.00 0.14 0.04 18.8 30 1.2 0.08 0.10 0.01 0.19 0.08 19.2 31 1.4 0.20 0.14 0.00 0.34 0.08 19.3 32 1.3 0.13 0.01 0.11 0.25 0.05 19.0 33 1.7 0.10 0.10 0.00 0.20 0.09 20.2

(33) TABLE-US-00005 TABLE 5 (Na + K + Li) Cr.sup.2/ Hexavalent chromium (Si + 4.7 F) in fume (ppm) Example 11 8.1 300 12 7.7 200 Comparative 24 11.2 900 example 25 52.0 1000 26 41.6 1000 27 54.8 800 28 81.8 2000 29 29.8 780 30 42.3 1000 31 70.9 1800 32 59.3 1000 33 38.1 1000

(34) As shown in FIG. 1, when the relation between the parameter and hexavalent chromium satisfies the condition of
{([Na]+[K]+[Li])[Cr].sup.2}/([Si]+4.7[F])10,
the amount of hexavalent chromium in fume becomes 500 ppm or below.

(35) Accordingly, it is known that, according to the present invention, welding of stainless steel becomes possible in which the amount of hexavalent chromium in fume is low and the weldability is excellent.