Welding application problems encountered
Carbon steel wire, a single species

China CO2 carbon steel wire only ER49-1 and ER50-6 two varieties, a single CO2 gas welding, there is more than splash, raised bead molding and other shortcomings, we bear the fatigue loads weld metal structure or appearance of the cooperation of high quality welding products, most use of argon-rich gas mixture. Generally only use ER50-6CO2 wire, while the United States and Japan YGW15 ER70S-2 wire, with the exception of sulfur, silicon content is low, but also added zirconium, titanium and lead deoxidizer, welding on the surface of stainless steel, impurities less sensitive, so in argon-rich gas mixture used welding wire ER70S-2 and YGW15 more appropriate.

2 high-strength steel, heat-resistant steel Welding Wires Manufacturer less

In recent years, with the adjustment of product structure, welding metal materials ranging from common Q235, Q345 to high-strength steel (such as the Wel-ten80C), high toughness steel, heat-resistant steel (such as 21CrMo10) and other areas, but China which rare class wire manufacturers, are often long lead times, high prices, can not meet production requirements. Some special steel wire is still dependent on imports. In actual production, steel welding for more, only to change the selection of imported wire or welding processes.

2.1 wire structure is irrational

Foreign elements in low-carbon steel wire Mn wire limit is equivalent to ER49-1, wire drawing, welding and mechanical properties are better than ER49-1 wire. Due to the impact of raw materials and traditional values, the current number of users is still mainly ER49-1 wire, the wire is the imitation of the former Soviet Union, chemical composition unreasonable, Mn element content higher, not only in the low-carbon steel welding wire waste, And Roberts will bring difficulties to increase the annealing process, based on years of testing and practice, ER50S-6 welding wire stable, spatter, weld appearance, strength of deposited metal wire and ER49-1 equivalent, but its plasticity, toughness than ER49-1 wire. Therefore, the welding mild steel, should be preferred ER50S-6 welding wire, CO2 welding wire to make our structure more reasonable.

3 CO2 welding wire welding performance

Through these years of research and application of welding wire at home and abroad, we are the mechanical properties of wire made despite poor than similar foreign wire, but can basically meet the requirements, and welding process performance problems are more prominent, to a certain extent, restricted the CO2 Gas Shielded Welding Wire development. Present in the stiffness of domestic wire, wire stability, spatter, weld, and other aspects of the applicability of a certain gap between foreign wire, welding production can not meet the requirements of the development.

4 wire tensile strength, from Alice

4.1 The tensile strength of wire

Usually by wire to measure the tensile strength of wire hardness, type of push wire feeder wire, the wire is a measure of the hardness of the important process performance indicators. Wire hardness and chemical composition, the drawing process. At present, the welding wire manufacturers and users generally only paid attention to wire the physical and chemical properties, ignoring the tensile strength indicators, through testing and practice, we believe that hard-wire some of the more well-made, therefore, our standard φ1.2mm carbon steel wire wire tensile strength of 1000 ~ 1200MPa, the basic guarantee of the stability of the wire (such as Kam Tai, Monkey King, Atlantic, China through companies such as wire).

Alice from the wire of 4.2

Alice from the wire to the wire has a certain influence, Alice from the large, wire tube with guide wire friction, increasing wire resistance, with the production of straightening the wire, our use of foreign wire (φ1.2 ) Alice from generally less than 5mm, Japan KC-50 wire from the zero of Alice: Alice from the wire and made much smaller than 5mm, which should attract enough attention of manufacturers. Based on the above, our company standard wire should be less than 10mm from the following Alice.

The quality of copper wire 5

Copper wire currently used plating and electroplating of two ways. Plating, low cost, small porosity, coating with low intensity, high cost of plating, porosity, coating with high strength. Plated wire commonly used in Japan, Western Europe, the use of electroless plating, chemical plating our places, but a few manufacturers to adopt plating.

5.1 non-uniform copper layer, combined with weak, easily out of copper scrap

Metallographic microscope in Japan KC-50 wire, found more uniform coating, no copper accumulation phenomenon, the pinhole was smaller, dense coating. The relatively poor domestic wire, welding wire through the wire wheel off copper scrap, severe loss of large, wire tube blockage, workers often had the guide wire tube with compressed air to remove copper scrap.

5.2 copper layer rust easily, saving time is short

Domestic wire corrosion is mainly matrix interface with the copper layer rust. Some just sent to the factory wire, found rust on the surface, kept for some time and found some rust, can save almost half of the wire is small, and Japan, Germany wire can be stored more than three years, showing the quality of domestic copper wire to be further to improve.

Quality copper wire has been restricting the development of China's gas-shielded welding wire and application. Therefore, it is necessary to develop a reasonable process specifications; second is to strengthen the pre-plating process to improve the ability of rust to fat; third is to solve the copper agents, lubricants, brightener, the quality of drawing dies. Easy to clean, such as foreign lubricants, rust, welding spatter, drawing mode for the rotary, pull the surface to avoid wire marks, reducing the wire of the ellipse.

Copper wire is the application of non-nano-technology and modern colloidal intermetallic compound coating technology, a new type of wire surface layer treatment, compared with the traditional copper wire, with a stable arc, low spatter, forming beautiful, rust-proof ability , smoke toxicity and pollution, and low cost. In Japan, the United States and other industrialized countries have been rapidly replacing copper wire of the situation, China Kam Tai, three British, the Monkey King and other companies have developed the production of such wire. In 2003 the company began to promote the use of non-copper wire, to achieve a certain effect, but the welding quality is not very stable, mainly for the poor conductivity, wire less stable, conductive mouth, badly worn, etc., in the future need to continue research and development , to master the non-copper wire manufacturing technology, improve product quality to meet the actual production requirements.

7 Packaging Wire

Foreign wire is plastic packaging, and placed in moisture-proof silicone agent class, attractive and durable packaging, wire a general one ton wooden crates, easy storage, handling, requisitioned. Domestic wire for packaging, often occurs to absorb moisture, scattered disk, wire tray, box damaged and are not allowed and so on (Kam Tai, the Atlantic, the Monkey King and other welding wire packaged good companies). Therefore, the welding wire packaging can not be ignored.

8 wire technology standards

And revision of the standard wire for gas shielded solid wires is essential to further promote the use of, our wire standard, most current standards with the United States for the equivalent, due to financial and other reasons, the standard revision cycle length, part of the standard still lags behind in foreign standards, the development of production can not meet the requirements in the actual production, we can only refer to relevant foreign standards, wire selection, testing and product acceptance. Therefore, we hope to step up international standards of our wire standard revision.

9 production of macro-control wire

Gas-shielded welding wire is technology-intensive products, to ensure that welding wire feed hose from the normal send, wire quality play a key role. A few years ago, the domestic metal products industry, wire rope plant, township and village enterprises believe that CO2 welding process is simple, the market demand, the blind on the production line, welding wire plant development to more than 150, according to statistics, there are only 16 in Jiangsu Province, 13 Hebei Province, Shanxi Province, such as energy and heavy chemical industry base, though built with a wire factory, and have not the product. As the quality of welding wire plant and irrational volatility, production often not timely delivery and return issues. For the above, our company developed a TZL911-2000 "commonly used in gas shielded arc welding of carbon steel wire" standard, and take a sub-supplier qualification assessment methods to ensure welding quality and production cycle.

10 protective gas

A few years ago, still no welding with shielding gas, plant, were collected in the form of by-products (if any lime pit, ethanol plant, chemical industry, etc.), so the higher the gas impurities, mainly water and sulfide, the reach the welding gas purity standards. At present, only two manufacturers of professional gas joint venture, Praxair and BOC gases that companies can offer a variety of CO2 and argon-rich gas welding, and high purity gas, to meet the product requirements, but still there is no timely delivery, affecting the production cycle, high gas prices, increased production costs and other issues.