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Welding Wire
Nov 13, 2017

Welding Wire is used as a filler metal or both as a conductive wire solder material. In gas welding and gas shielded tungsten arc welding, the wire is used as a filler metal; in submerged arc welding, electroslag welding and other gas-metal arc welding, the wire is both a filler metal.

At the same time the wire is also a conductive electrode. The surface of the wire is not coated with anti-oxidant flux.

Classification

Rolling class

Most of the wire belongs to this category, including carbon steel wire, low alloy steel wire, alloy steel wire, stainless steel wire and non-ferrous metal wire.

Common wire:

SKD11> 0.5 ~ 3.2mm HRC 56 ~ 58 welding cold work steel, metal stamping die, die cutting, cutting tools, molds, workpiece hard surface production of high hardness, wear resistance and high toughness of argon welding rod, Warming warm, or easy to produce cracking phenomenon.

63 degree blade edge welding wire> 0.5 ~ 3.2mm HRC 63 ~ 55, mainly used in welding broach die, hot work with high hardness die, hot forging die, hot die, screw die, wear hard surface, high speed steel , Knife-edge repair.

SKD61> 0.5 ~ 3.2mm HRC 40 ~ 43 welding zinc, aluminum die-casting mold, with good heat resistance and crack resistance, hot air die, aluminum hot forging die, aluminum copper die-casting mold, with good heat resistance Grind, crack resistance. Hot mold usually hot tortoise shell crack-shaped, mostly caused by thermal stress, but also due to surface oxidation or die-casting of raw materials caused by corrosion, heat treatment adjusted to the appropriate hardness to improve their life, the hardness is too low or too high are not Be applicable.

70N> 0.1 ~ 4.0mm Wire characteristics and uses: high hardness steel joints, zinc aluminum die casting cracking, welding reconstruction, pig iron / cast iron welding. Can be directly surfacing all kinds of cast iron / pig iron materials, but also can be used as a welding mold cracking, the use of cast iron welding, try to lower the current arc welding with short distance, the steel part of the preheating, after welding Heated and slowly cooled.

60E> 0.5 ~ 4.0mm Features and Uses: Special welding high tensile steel joints, hard surface production of the base, crack welding. High-strength welding wire, high nickel-chromium alloy composition, professional anti-cracking bottom welding, filling with the end, strong pull, and repair steel cracking phenomenon after welding. Tensile strength: 760 N / mm2 Tensile elongation: 26%

8407-H13> 0.5 ~ 3.2mm HRC 43 ~ 46 Zinc, aluminum, tin and other non-ferrous alloys and copper alloy die-casting mold can be used as hot forging or stamping die. With high toughness, abrasion resistance and good thermal corrosion resistance, high temperature softening, high temperature fatigue resistance, welding heat can be made for the punch, reamer, rolling knife, grooving knives, scissors, etc. do heat treatment When the need to prevent decarburization, hot tool steel welding hardness is too high prone to rupture.

- Explosion-proof base welding wire> 0.5 ~ 2.4mm HB ~ 300 high hardness steel bonding, hard surface production of the base, crack welding. High-strength welding wire, high nickel-chromium alloy composition, for anti-cracking bottom welding, filling primer, strong pull, and can repair the welding of steel rebuilding.

718> 0.5 ~ 3.2mm HRC 28 ~ 30 large appliances, toys, telecommunications, electronics, sports equipment and other plastic products die steel. Plastic injection mold, heat-resistant mold, corrosion-resistant mold, machinability, erosion good, excellent surface gloss after grinding, long service life. Preheat temperature of 250 ~ 300 after the hot temperature of 400 ~ 500 , for multi-layer welding repair, the use of back-welding method, less prone to poor fusion and other defects.

738> 0.5 ~ 3.2mm HRC 32 ~ 35 Semitransparent and need to have the surface gloss of the plastic mold steel products, large molds, complex shapes and high precision plastic mold steel. Plastic injection mold, heat-resistant mold, corrosion-resistant mold, etching good, with excellent processing performance, easy cutting and polishing, and electrical erosion, toughness and wear resistance. Preheat temperature of 250 ~ 300 after the hot temperature of 400 ~ 500 , for multi-layer welding, the use of back-welding method, less prone to poor fusion and other defects.

P20Ni> 0.5 ~ 3.2mm HRC 30 ~ 34 plastic injection mold, heat-resistant mold (copper mold). It is designed to be alloyed with low sensitivity to welding cracking and contains about 1% nickel, suitable for PA, POM, PS, PE, PP, ABS plastic with good polishing, no porosity and cracks after welding, good after grinding Finish, degassing by vacuum, forging, pre-hardened to HRC 33 degrees, uniform distribution of section hardness, mold life of 300,000 or more. Preheat temperature of 250 ~ 300 after the hot temperature of 400 ~ 500 , for multi-layer welding repair, the use of back-welding method, less prone to poor fusion and other defects.

NAK80> 0.5 ~ 3.2mm HRC 38 ~ 42 plastic injection mold, mirror steel. High hardness, good mirror effect, good discharge processability, excellent welding performance, after grinding, smooth as a mirror, the world's most advanced, the best plastic mold steel, adding easy to cut elements, cutting easy, with high strength and toughness and resistance No deformation characteristics of the mill, suitable for a variety of transparent plastic mold steel products. Preheat temperature 300 ~ 400 after the hot temperature of 450 ~ 550 , for multi-layer welding, the use of back-welding method, less prone to poor fusion and other defects.

S136> 0.5 ~ 1.6mm HB ~ 400 plastic injection mold, corrosion resistance, good permeability. High purity, high specularity, good polishing, excellent anti-rust and anti-acid ability, less heat treatment deformation, suitable for PVC, PP, EP, PC, PMMA plastic, corrosion-resistant and easy to process modules and fixtures, Precision molds, such as rubber molds, camera parts, lenses, cases and more.

Ace Steel> 0.5 ~ 2.4mm HB200 iron mold, shoe mold, soft steel welding, easy engraving erosion, S45C, S55C steel and other repair. Fine texture, soft, easy to process, there will be no pores, preheat temperature 200 ~ 250 after the heat temperature 350 ~ 450 .

BeCu (Beryllium copper)> 0.5 ~ 2.4mm HB300 high thermal conductivity copper alloy mold material, the main element is beryllium, which is suitable for plastic injection molding mold inserts, core, die punch, hot runner cooling system, thermal conductivity Mouth, blow mold the overall cavity, wear plates and so on. Tungsten copper materials are used in resistance welding, EDM, electronic packaging and precision machinery and equipment.

CU (Argon Welding)> 0.5 ~ 2.4mm HB200 This welding branch has a wide range of applications. It can be used to weld and repair electrolytic pieces, copper alloys, steel, bronze, pig iron and general copper parts. Good mechanical properties, can be used for welding copper alloy repair, can also be used for welding steel and pig iron, iron bonding.

Oil and steel wire> 0.5 ~ 3.2mm HRC 52 ~ 57 Blanking die, gauge, drawing die, punching punch, can be widely used in metal cold stamping, embossed jewelry, etc., special tool steel, wear- .

Cr steel wire> 0.5 ~ 3.2mm HRC 55 ~ 57 blanking die, cold forming die, cold die, punch, high hardness, high toughness, good line cutting. Warming up before warming up warm, welding after make hot action.

MA-1G> 1.6 ~ 2.4mm, super-mirror wire, mainly used in military products or demanding products. Hardness HRC 48 ~ 50 martensitic aging steel, aluminum die-casting mold, low pressure casting mold, forging mold, blanking die, plastic mold surfacing. Special hardened high toughness alloy, ideal for aluminum gravity die-casting mold, gate, extend the service life of 2 to 3 times, can produce very precise mold, super mirror (gate welding, the use of thermal fatigue cracking is not easy).

High-speed steel wire (SKH9)> 1.2 ~ 1.6mm HRC 61 ~ 63 high-speed steel, durability of 1.5 to 3 times the ordinary high-speed steel for the manufacture and processing of high temperature alloys, stainless steel, titanium, high strength steel and other difficult materials Tool, welding and broaching knife, hot work hard tool, mold, hot forging die, hot die, screw die, wear hard surface, high speed steel, punching, cutting tools, electronic components, thread rolling die, dental board , Drill Wheel, Rolling Word Mold, Compressor Blade and all kinds of mold machinery parts and so on .... After the European industrial standards of strict quality control, high carbon content, excellent composition of the internal composition of the material evenly, hardness and stability, and wear resistance, toughness, high temperature and so on .... Characteristics are generally better than the same level of material.

Nitride parts welding wire> 0.8 ~ 2.4mm HB ~ 300 for nitrided molds, parts surface repair.

Folding casting category

Some alloys, such as cobalt-chromium-tungsten alloys, can not be forged, rolled and drawn, but are made by casting. It is mainly used for manual surfacing on the workpiece surface to meet the special performance requirements such as oxidation resistance, wear resistance and corrosion resistance under high temperature. Continuous casting and liquid extrusion can be made up to several meters of cobalt chrome tungsten wire for automatic wire filling gas tungsten arc welding to improve the welding efficiency and quality surfacing, but also improve working conditions. Cast iron welding sometimes also used cast wire.

Fold medicine core class

Use a thin steel coil into a round or shaped steel tube, filled with a certain composition of the powder, made of drawn sewn cored wire, or filled with powder filled steel tube made of a seamless flux cored wire (see photo). With this welding wire welding deposition efficiency, good adaptability to steel, short trial period, so its use and use of the growing range. This wire is mainly used for carbon dioxide gas shielded welding, submerged arc welding and electroslag welding. Flux cored wire powder ingredients generally similar to the electrode coating. The flux-cored wire, which contains slagging, gas-forming and stable arc components, does not require shielding gas when welding, and is called self-shielded flux cored wire and is suitable for construction of large welded structural projects.

As early as the early 1950s gas protection flux cored wire began to develop the market, but only in 1957 began widespread commercial use. This method can be said to be taken from the submerged arc welding and CO2 welding (refers to the solid) combination of the advantages of flux wrapped in the wire and by the protection of the outer CO2 gas can produce a softer and stable welding arc and low spatter For its characteristics. Only the beginning of the development of large wire diameter wire (2.0-4.0mm), for the major parts of the flat welding and horizontal welding. Until 1972, the development of small diameter wire began to greatly expand the use of flux cored wire.

Self-shielded flux cored wire, which was developed shortly after the gas-guarded flux-cored welding wire was asked, soon became widely accepted by the industry for specific uses.

The biggest difference between the two has been described in the second unit, the unit will do the overall discussion.

Folding introduction

The control of the manufacturing process of the flux cored wire is very strict. Since the molten filler metal comes from the ingredients contained in the steel sheet and the flux, the size and chemical composition of the flux-cored wire must be carefully checked in advance to ensure the quality.

Due to the limited internal space of the welding consumables, the more the size of the flux particles becomes more important, the formation of a bird-like nest between the particles together and the uneven flux compositional elements.

Most of the flux-cored wire by a flat strip of thin metal strip by rolling into a U-shaped section, granular flux filled in the U-shaped metal groove and then by the final seal rolling step, the flux tight roll Pressure in the tube wire

The rolled wire into a tube through a series of pull action to become the last need of wire diameter, the pull action can also be filled flux evenly fixed in the welding wire skin.

It is the key to the quality of the flux cored wire that how to prevent some of the wires from forming hollow without flux due to poor control in the manufacturing / production process. In addition, the surface of the wire should be smooth, smooth and clean, otherwise it will affect the smooth wire feeding and the transmission of welding current. Wire into a roll or into a barrels to avoid wire entanglement or damage to each other, usually rolls into a plastic wrap and placed desiccant to prevent damp materials, the encapsulated material and then into the carton and sent.

When the base metal is thicker, the cross-section is mostly BUTT and the amount of flux is less. Most of the carbon steel and low-alloy steel have such wire cross-sections with a diameter of 2.8 mm or less, such as stainless steel Alloy and wire diameter is larger, the wire larger space for flux and alloying elements cross-sectional shape is multi-spliced or heart-shaped (LAP and HEART SHAPED) joints.

Folding features

As mentioned before, flux cored wires highlight the advantageous properties of many welding methods. For example, the flux fraction plays a role with coated electrodes to improve the chemical composition and mechanical properties of the molten metal. Production efficiency and gas metal arc welding and submerged arc welding characteristics.

Flux cored wire can be used for welding carbon steel, low alloy high tensile steel, high strength quenched and tempered steel, stainless steel and hardfaced wear-resistant steel.

Flux cored wire is a promising new welding materials, domestic varieties and the amount of flux cored wire is increasing. Compared with solid wire flux cored wire has the following advantages and disadvantages.

advantages:

1) The welding of various steel, adaptability Emphasis on flux composition and the proportion of the extremely convenient and easy to provide the required chemical composition of the weld.

2) good process performance, beautiful appearance of the weld joint gas and slag protection, get a good shape. Adding arc stabilizers to stabilize the arc, droplet transfer uniform.

3) Depositing speed, high production efficiency In the same welding current flux cored wire current density, melting speed, the deposition rate of about 85% -90%, the productivity of about 3-5 times higher than the electrode arc welding.

4) The welding current can be used for all-position welding.

shortcomings

1) wire manufacturing process is complicated

2) welding, wire feeding more difficult than the solid wire

3) The appearance of the wire is easy to rust and the powder is easy to absorb moisture. Therefore, the requirements for the preservation of a flux cored wire are more strict

Flux function

As with the coated electrode, the manufacturer of flux cored wire has its own unique formulation for the flux composition. The composition of the flux varies depending on the applicable function of the welding consumables.

The basic functions of the flux composition are as follows:

oxygen scavenger and nitrogen removal agent

Since nitrogen and oxygen can cause stomatal or embrittlement of the weld metal, oxygen and oxygen in the flux must be added, such as manganese and silicon. As for the self-shielded flux cored wire, the flux should be additionally added with AL as a nitrogen removal agent. The purpose of adding the oxygen scavenger and the nitrogen scavenger above is to purify the molten metal.

slag forming agent

Calcium, potassium, sodium or silicon are welding slag forming agent, added in the flux can effectively protect the pool from the air pollution, welding slag can make the weld with a better appearance and rapid cooling can support full posture welding The pool. Welding slag coverage can also ease the molten metal cooling rate, this feature is particularly important for low-alloy steel welding.

arc stabilizer

Sodium and potassium keep the arc soft and smooth and reduce spatter.

alloy elements

The addition of alloying elements such as molybdenum, chromium, carbon, manganese, nickel and vanadium can improve (improve) the strength, ductility, hardness and toughness of the molten metal.

gas forming agent

Fluorite, limestone, etc. need to be added in the self-shielded flux cored wire to produce protective gas combustion.

2 types of welding slag

The composition of the flux determines the weldability of the welding consumables and the mechanical properties of the molten metal. If the flux composition is mainly acidic, it will generate acidic welding slag after welding. The same basic (limestone) flux will produce alkaline welding Slag. Acid system of welding consumables is very good, the arc smooth and stable welding process, the shape of a similar jet arc, spatter less, widely welcomed by welding personnel, mechanical melting of the molten metal but up to the AWS standard requirements.

Flux for the alkaline welding consumables can make the filler metal get very good ductility and toughness, but the operation is far worse than the acid system. Most of the droplet transition to the main ball transition, splash more.

The development of flux systems for low-alloy consumables combines the excellent mechanical properties of acid-based work and alkaline systems.

Sparks

Welding discharge welding machine for cold welding wire used in surfacing or welding conditions at room temperature, welding one second after the characteristics of the wire temperature does not exceed 40 degrees Celsius, continuous welding not exceeding 80 degrees Celsius. Mainly used for some heat-resistant parts repair, welding repair, the temperature is generally controlled at 40 degrees Celsius, the wall thickness of 0.4-0.5 mm, the highest not higher than one hundred degrees Celsius.

Welding wire welding heat affected zone is very small, will not produce internal stress. Very suitable for casting defects, parts surface strain, wear, mold defects repair. Why the wire temperature is so low, because the wire melting is micro-melting state, in contact with the workpiece, the external force will soon form a small part of the short circuit to move the workpiece up, due to less melting, the workpiece is much larger. The temperature dissipated quickly. Wire temperature does not continue to rise throughout its redness, anti-red super capacity. Compared with ordinary wire, if the duration is too long, there will be a serious red wire, solder black phenomenon. Even if the welding, welding repair, prone to oxidation, dregs, welding is not high, etc., and affect its follow-up processing. 

CO2 welding

Carbon dioxide gas shielded arc welding (referred to as CO2 welding) shielding gas is carbon dioxide (CO2 + O2 sometimes mixed gas). Due to the special thermal physical properties of CO2 gas, it is not possible for molten metal to form a balanced axial free transition when using a conventional welding power source, which usually requires short circuits and necking of the droplet. Therefore, with MIG welding Compared to the free transition, splash more. However, if the use of high-quality welding machine, the appropriate choice of parameters, you can get a very stable welding process, so that splash to a minimum extent. Due to the low cost of the shielding gas used, good weld formation with short-circuit transitions, coupled with the use of deoxidizer-containing welding wire, results in a high-quality welded joint without internal defects. Therefore, this welding method has now become one of the most important welding methods of ferrous metals. CO2 vertical welding double-sided forming

model

Commonly used wire type:

Common gas shielded flux cored welding wire: LQ122, LQ172, LQ212, LQ337, LQ423, LQ439, LQ451, LQ537, LQ582, LQ585, LQ605, LQ621, LQ666, LQ707, etc. (typically 1.2mm-1.6mm in diameter)

Common self-shielded flux cored wire are: LZ409, LZ410, LZ411, LZ414N, LZ430, LZ570, LZ590, LZ601, LZ603, LZ606, LZ632, LZ641, LZ642, LZ643, LZ650, etc. (general diameter: 1.6mm-3.2mm)

Common submerged arc welding flux cored wire are: LM001, LM414, LM414N, LM430, LM462, LM491, LM504, LM509, LM535, LM551, LM552 and so on (general diameter: 2.4mm-4.0mm)

First, the common general wire

1, DY-YJ502 (Q) titanium slag system of flux cored wire. Process, excellent mechanical properties, can be all-position welding, especially the excellent low temperature toughness, in order to achieve classification societies 3 y certification. Widely used in shipbuilding, steel structure, bridges and so on.

2, DY-YJ507 (Q) Alkali-based slag cored wire system. Excellent mechanical properties, low diffusion of hydrogen content, with excellent low temperature crack resistance. -40 degrees impact energy can reach more than 80. For machinery manufacturing, utilities, petrochemical equipment.

3, DY-YJ607 (Q) Alkali-based slag cored wire system. Excellent mechanical properties, low diffusion of hydrogen content, suitable for 60 kg high strength and toughness of steel welding.

4, YJ502CrNiCu (Q) titanium all-position welding flux cored wire. For atmospheric corrosion of steel welding. Such as the offshore platform welding.

5, YJ502Ni (Q) titanium all-position welding flux cored wire. Low temperature shock absorption, to meet the temperature of -40 degrees the use of metal structures.

Second, heat-resistant steel series flux cored wire

1, DY-YR302 (Q) titanium slag flux cored wire for 1Cr-0.5Mo and 1.25Cr-0.5Mo heat-resistant steel welding, widely used in the boiler pressure vessel industry.

2, DY-YR312 (Q) for 12CrMoV pearlite heat-resistant steel welding, widely used in boiler pressure vessel industry.

3, DY-YR317 (Q) alkaline slag flux cored wire. Suitable for 12CrMoV pearlite heat-resistant steel welding, with excellent low temperature impact properties.

4, DY-YR402 (Q) for 2.25Cr-1Mo heat-resistant steel welding.

Third, stainless steel gas protection welding medicinal wire

1, DY-YA308 (Q) 18% Cr-8% Ni stainless steel welding.

2, DY-YA308L (Q) ultra-low carbon 18% Cr-8% Ni stainless steel welding.

3, DY-YA309 (Q) dissimilar steel welding or composite steel and surfacing stainless steel transition layer welding.

4, DY-YA316 (Q) 18% Cr-12% Ni stainless steel welding. [1]

Fourth, gas protection flux cored welding wire

1, DY-YD350 (Q) Widely used for surfacing metal wear parts and light soil abrasion parts, HRC35.

2, DY-YD450 (Q) for surfacing resistant to wear-resistant sand and wear-resistant metal parts, HRC45.

3, DY-YD600 (Q) is widely used in parts resistant to abrasion of sand, HRC55-60.

Fifth, submerged arc welding flux cored wire

1, DY-YD14 (M) is mainly used for the repair of carbon steel and low alloy steel parts or as a transition layer of other surfacing materials, HRC26 ± 2.

2, DY-YD224B (M) is mainly used for hot roller and other wear-resistant parts of the welding and repair, HRC59.

3, DY-YD420 (M) 13% martensitic surfacing flux-cored wire with chromium, corrosion-resistant, wear-resistant. For continuous casting roller, steam valve, wedge valve, safety valve and other components of hard surfacing.

4. DY-YD423 (M) is used for hard surfacing of hot rolls and continuous casting rolls at higher temperatures. The surfacing layer has excellent corrosion resistance, wear resistance and thermal shock resistance, HRC45-48.

5, DY-YD430 (M) ferrite flux-cored wire with 17% chromium for hard-facing corrosion-resistant surfacing, with good high temperature corrosion resistance, and stainless steel clad steel welding, HRC23.

6, DY-YD414N (M) nitrogen-containing martensitic flux-cored welding wire to carbon nitrogen to improve its hardness and crack resistance, with good corrosion resistance, wear resistance and thermal shock resistance. Hard surface for continuous casting roller surfacing welding, HRC43.

Store

1, store the wire warehouse should have a dry and ventilated environment, to avoid moisture; refuse to water, acid, alkali and other liquids easy to play

Corrosive substances exist, but should not co-exist with these substances in the same warehouse.

2, the wire should be placed on wooden pallets, can not be placed directly on the floor or close to the wall.

3, access and handling wire careful not to break the packaging, especially the packaging "shrink film."

4, open the wire package should be run out as soon as possible (required within a week), once the wire exposed directly in the air, the anti-rust time will be greatly reduced (especially in humid, corrosive media environment)

5, in accordance with the "first in, first out" principle issued wire, minimize product inventory time.

6, according to the type of wire, size classification storage, to prevent the wrong use.


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