Gas shielded solid wires and abroad Overview of
Gas protection welding method of its unique advantages in the manufacturing sector in industrialized countries is widely used. Development so far, the U.S. gas shielded solid wires for about 31% of its total welding consumables, Japan 41%, 53% in Western Europe. The development of gas protection welding and metal structure manufacturing inseparable. Currently, the United States, Japan, Europe and other developed countries and regions, the proportion of welded structural components increasing consumption of welding gas arc welding of metal materials about all of the weight of the total weight of the welding material 50% to 75%. Gas shielded arc welding technology, greatly improved the structure of industry, metal manufacturing technology.
Our solid wires for gas protection research and development started in 50's, but always remain at the research stage. Over the past 10 years, gas shielded solid wires for the development of rapid, in China's Protection of solid wires for gas production more than 150 enterprises, from Germany, Sweden, Canada, Japan, and Taiwan import 50 sets of various production equipment, equipment made or developed by more than 100 articles, capacity of annual output of 20 million tons. Welding production volume in 2002 was about 1.5 million tons. Solid wire output of about 250,000 tons, approximately 17% of the total welding materials, but the comparison with foreign countries, there is a great gap.
1 gas shielded solid wires for applications of
1.1 Protection of solid wires for gas development
Gas shielded solid wire welding of metal structures associated with the development of growth, in China's "Plan" and the "Plan" period, the national key projects to meet the technology and equipment manufacturing requirements of large machinery, the introduction of foreign advanced technology and equipment for welding, large-scale technical transformation of key mechanical enterprises, large metal structure manufacturing enterprise in China, with the United States, Germany, Japan and other countries, multinationals in manufacturing large metal structure, with quantity of foreign gas welding equipment, welding and other equipment, and to carry out welding training. We are using the foreign gas welding mature technologies and production processes,
Formed a large metal structure, welding gas production industry, fundamentally changed the structure of the industry's manufacturing technology of metal level, promote the protection of our gas welding technology. Since the early 90s the past 10 years to 1992, the 1st "National CO2 exchange will promote the use of welding technology" as an opportunity, gas metal arc welding technology in the industry, dissemination and application of structural booming gas development and application of welding technology increased capacity, application of work from large machinery enterprises to promote the small and medium enterprises, and large machinery enterprises in gas welding applications co-product from the production, promotion to the production of common products
, Gas welding equipment and welding consumables, accessories basically domestic supply, a group of welding equipment, welding materials, protection of gas and accessories manufacturers to seize the market opportunity to grow quickly, and gradually formed a gas welding industry.
1.2 Protection of solid wires for gas applications
With the technological transformation of China's large enterprise welding, gas shielded solid wires in the manufacture of metal structures are widely used, such as Taiyuan Heavy Machinery (Group) Company, 1st Heavy Machinery Co., Ltd., Dalian Heavy Industry Group Co., Ltd., CITIC West Yang Mine Machinery Factory, Beijing Coal Machinery Factory and other enterprises, gas welding to complete the welding of metal structures in the total weight of 50 ~ 80% of enterprises in the large metal structure, play an irreplaceable role.
Gas welding is mainly used for manufacturing large-scale bridge and gantry crane ,4-23m3 mechanical excavator ,1-6m3 excavator, such as large-scale gasifier and coke handling equipment and large gear, hoist, pile reclaimer, bar-forging equipment, oxygen bottles press, satellite launchers and other large equipment. Gas shielded arc welding technology in recent years, the application of small and medium enterprises have come a long way.
The early 80s to late 80s, my target was Q235, 16Mn and other major structural steel production 490MPa grade CO2 gas shielded solid wires, has achieved some self-sufficiency, but most rely mainly on gas-shielded welding wire from the United States, Japan, Germany and other countries imports, to protect our country bare wire CO2 gas has formed a certain scale of production, yield and quality has greatly improved, for Q235, Q345 and Q390 steel structure of the CO2 gas shielded welding solid wires, metal structure manufactured to meet requirements, using the most solid wires mainly ER49-1 and ER50-6 are two kinds of specifications mainly ¦Õ1.2mm, ¦Õ1.
6mm two kinds of carbon steel welding wire production in the domestic situation of supply exceeding demand, solid wires for gas shielded arc welding quality is also very different. At present, the domestic production of a certain size, quality manufacturers have relatively stable Kam Tai Metal Industrial Co., Ltd., Atlantic Wire Co., Ltd., Yichang Monkey Wire Co., Ltd., Lion Welding Materials Co., Ltd., Changzhou Hua Tong Wire Co., Ltd., Ezhou Namtha Special Welding Materials Co., Ltd., Harbin Welding Will
Limited. 600MPa class high strength steel, stainless steel, aluminum and aluminum alloy solid wire of a few relatively stable quality manufacturers (such as the Golden Lion Welding Company, South Tower of special welding materials, etc.). Above 700MPa grade high strength steel wire, heat-resistant steel wire manufacturers less (such as Will welding, etc.), for 800MPa grade high strength steel, high alloy steel, high toughness steel and other special steel solid wires are still mainly rely on imports.
In China, "June 5" and "Plan" period, our company has with the United States, Germany, Japan and other countries to produce for the national key project to provide a number of heavy machinery and equipment. Cooperation in order to better meet the quality requirements of products, in the early 80s successfully introduced CO2 gas shielded welding method, which Panasonic S series gas-welding equipment for nearly 100 units of Miller CY-650 welder 12 units. In recent years, technological transformation, respectively, KR ¢ò 500 to buy Panasonic Welding of Tangshan 50, Europe to the Greek CPX-500 welding machine 35 sets. Currently, CO2 gas shielded arc welding process for Product accounted for more than 80%
Become the main means of welding, all kinds of wire in the dosage of 200 to 300 tons of varieties of various solid wires at home and abroad, specifications for the ¦Õ1.2mm, ¦Õ1.4mm, ¦Õ1.5mm. CO2 gas shielding gas mainly. Using a small amount of argon mixed gas-rich. Most of the wire for the 500 ~ 800MPa strength of structural steel with a wire, as well as stainless steel, heat-resistant steel, wear resistant surfacing, non-ferrous metal wire. Before the main wire from Japan, Germany, the Netherlands and other countries import. In recent years, with the development of China's CO2 welding wire, in addition to co-products, have all realized the localization of welding material, effectively reducing manufacturing costs.
2 promote the use of the problems encountered
2.1 Wire species
2.1.1 Carbon steel wire single species
CO2 carbon steel welding wire in China only ER49-1 and ER50-6 two varieties of a single CO2 gas shielded welding, there are flying more convex bead shape shortcoming, we have to bear the fatigue load weld metal structure or the appearance of co-product of high quality requirements of welding, the most used argon-rich mixed gas. Generally only use ER50-6CO2 wire, while the United States and Japan YGW15 ER70S-2 welding wire, in addition to sulfur, low silicon content, but also added zirconium, titanium and lead deoxidizer, welding on the surface of stainless steel, impurity less sensitive, so the rich mixed gas arc welding, argon use ER70S-2 and YGW15 wire appropriate.
2.1.2 High-strength steel, manufacturers of heat-resistant steel wire less
In recent years, as companies adjust product structure, welding of metal materials ranging from common Q235, Q345 to the high-strength steels (such as Wel-ten80C), high toughness steel, heat-resistant steel (such as 21CrMo10) and other areas, and China is class wire manufacturers rarely, are often long lead times, high prices, can not meet production requirements. Some special steel wire still rely on imports. In actual production, steel welding for the above, only imports of wire or change the use of welding processes.
2.2 The wire structure is irrational
Mn low carbon steel wire element of foreign content limit is equivalent to ER49-1 wire, wire drawing, welding and mechanical properties are better than ER49-1 wire. Due to the impact of raw materials and traditional concepts, the current number of users still ER49-1 wire-based, the wire is the imitation of the former Soviet Union products, chemical composition unreasonable, Mn element content higher, not only in the welding of low carbon steel wire waste Roberts also will bring difficulties to increase the annealing process, based on years of testing and practice, ER50S-6 Welding wire feed stable, little spatter, weld shape is beautiful, wire deposited metal strength and ER49-1 equivalent
Its plasticity, toughness than ER49-1 wire. Therefore, in the welding of low carbon steel should be preferred ER50S-6 welding wire, CO2 welding wire structure of our country more reasonable.
2.3 CO2 welding wire welding process performance
Wire through the last few years on research and application at home and abroad, we are the mechanical properties of domestic wire, is less than similar foreign wire bad, but can basically meet the requirements, and wire the process performance problems are more prominent, to a certain extent, restricted the CO2 welding wire development. Currently domestic wire in stiffness, wire stability, spatter, weld shape, fitness and foreign wire and so there is a certain gap between the development of production can not meet the requirements of welding.
2.4 The tensile strength of wire, from Alice
2.4.1 The tensile strength of wire
Generally measured by the tensile strength of wire hardness of wire, wire on the push wire feeder, the wire is a measure of the hardness of the important indicators of their technological properties. Wire hardness and chemical composition of the drawing process. Currently the wire manufacturers and users generally only concerned physical and chemical performance wire, tensile strength index ignored by experiment and practice, we consider a number of domestic wire hardware better, therefore, our company provides carbon steel wire standard ¦Õ1.2mm The tensile strength of wire 1000 ~ 1200MPa, basically to ensure the stability of wire (such as Kam Tai, Monkey King, the Atlantic Ocean, China through companies such as wire).
2.4.2 Wire from Alice
Alice from the right wire in the wire has a certain influence, Alice from the large, wire and wire management friction, increasing the wire resistance, with the production of straightening the wire, welding wire used in China are foreign (¦Õ1.2 ) Alice from generally less than 5mm, Japan KC-50 Wire Alice from zero: the domestic wire of Alice from less than 5mm of the few manufacturers that should arouse enough attention. According to the above, the provisions of our standard wire should be less than 10mm from the following Alice.
The quality of copper wire 2.5
At present the use of chemical plating copper wire and plating two methods. Plating, low cost, small porosity, coating adhesion strength is low, electroplating high cost of porosity, coatings and high binding strength. Japanese wire commonly used electroplating, electroless plating in Western Europe, China Zeyi plating, but a few manufacturers using electroplating.
2.5.1 uniform copper coating, poor adhesion, easy out copper scrap
Observed under the optical microscope, Japan KC-50 wire, found more uniform coating, no copper accumulation phenomenon, the smaller the pinhole, dense coating. The relatively poor domestic wire, welding wire through the wheel out of copper wire scrap, severe large shed, plug wire tube, the workers often had to guide wire tube with compressed air blowing to remove copper scrap.
2.5.2 Copper Plating rust, saving time is short
Corrosion is mainly domestic wire and copper coating substrate interface rust. Some just sent to the factory wire, surface rust discovered, and some storage for some time and found corrosion, can save almost half of small wire, while Japan, Germany Wire can be stored more than 3 years, the quality can be seen to be further Guochan wire Dutong increase.
Quality copper wire has restricted the development of China's gas shielded welding wire and application. Therefore, it is necessary to develop reasonable technical specifications; second is to strengthen the pre-plated, rust to enhance fat capacity; Third, to resolve copper agents, lubricants, plating, wire drawing die quality. If foreign lubricants easy to clean, rust and welding spatter, drawing mode for the rotary, so avoid the pull wire surface marks, reducing the wire's ellipticity.
2.6 vigorously developed non-copper wire
Non-copper wire is the application of nanotechnology and modern intermetallic compound gel coating technology, the new surface layer of wire processing, compared with traditional copper wire, has a stable arc, less spatter, forming beautiful, strong rust prevention , smoke toxicity and pollution, and low cost. Currently 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 application of non-copper wire, to achieve a certain effect, but the wire quality is not stable, mainly for the conductive properties are poor,
Wire is not stable, tip wear and serious in the future should be continually research, development, control of non-copper wire manufacturing technology, improve product quality to meet the actual requirements of production.
2.7 Wire Packing
Foreign wire to plastic packaging, and placed in moisture-proof silicone agent class, attractive and durable packaging, usually a ton of wires installed a wooden box for easy storage, handling, requisitioned. Domestic wire due to packaging, common in moisture absorption, scattered disk, wire tray, box destruction, the number of such phenomena are not allowed (Kam Tai of the Atlantic, the Monkey King and other welding wire packaging company is better). Therefore, the welding wire package can not be ignored.
2.8 Wire technical standards
Wire system standard revision of solid wires for gas to protect the further application, and my wire standard, most of the existing relevant standards and the U.S. equivalent, due to financial and other reasons, long period of modifications, some standards continue to lag behind standards in foreign countries can not meet the production requirements of the development, in the actual production, we can according to foreign standards relevant to carry out wire of the selection, testing and product inspection. Therefore hope that the step up to international standards of our wire standard revision.
2.9 Production of macro control wire
Gas shielded welding wire is a technology-intensive products, to ensure that wire from wire hose normally sent, wire quality play a key role. A few years ago, the domestic metal products industry, wire rope factory, town and township enterprises believe that CO2 welding process is simple, the market demand for large, blind, on the production line, welding wire production plant grown to more than 150, according to statistics, there are only 16 Jiangsu Province, 13 Hebei Province, and Shanxi Province's energy and heavy chemical industry base that, although construction of a wire factory, the product has not. Wire factory due to unreasonable fluctuations in quality, production often not timely delivery and return the issue. For the above,
My company has developed TZL911-2000 "used gas shielded arc welding of carbon steel wire," standards and to take a sub-supplier qualification assessment methods to ensure the welding quality and production cycle.
2.10 Protection of Gas
A few years ago, there is not welding shielding gas, plant, are all by-products in the form of collection (if any lime kiln, ethanol plant, chemical industry, etc.), the high content of gas impurities, mainly water and sulfide, so that not welding gas purity standards. At present, a professional manufacturer of gas only two joint ventures that Praxair and BOC gas company can provide a variety of CO2 and argon-rich gas welding and high purity gases, to meet the product requirements, but there is not timely delivery, affecting the production cycle, high gas prices, increased production costs and other issues.
3 gas to protect the development trend of bare wire
With the development of national economy, China's consumption of welding materials will continue to grow, experts predict that by 2010, the total amount of welding material in China will reach 200 million tons, gas shielded cored wire about 20 ~ 25%, about 40 ~ 500 thousand tons. In order to expedite the development of solid wires for gas shielded our industry, to better meet the needs of welding production, made the following recommendations:
1) ER49-1 welding wire production in China has been unable to meet the development requirements for the welding material technology development and international integration, to be phased out ER49-1 wire. When welding mild steel, should be preferred ZR50-6 wire, steel wire structure so that our CO2 more reasonable.
2) to develop gas-shielded welding wire should be varieties, such as argon-rich mixed gas of carbon steel wire, 700MPa, 800MPa high strength wire, high-alloy steels, heat-resistant steel and high toughness steel wire, so as to meet the development requirements of welding production.
3) to strengthen environmental protection of non-copper wire manufacturing technology to provide users with high-quality non-copper wire, to promote CO2 GMAW process faster development, gradually replacing the traditional copper wire to the development of China's "energy-saving and environmental protection "welding.
4) to further strengthen the protection of solid wires for gas manufacturing technology research, to fully grasp the technical characteristics of imported equipment, and constantly improve the variety and quality of raw materials, formulate a reasonable wire drawing, copper, layer winding, packaging and other production processes of order, solve the wire volume the quality of stability, to shorten the protection of our solid wire and gas raw materials and Foreign Countries.
5) China's accession to the WTO, the domestic market by the world famous welding consumables impact of large enterprises. Domestic consumables business associations and industry should be coordinated and unified leadership under the guidance of break areas, industrial monopoly situation fortress, take the strong cooperation or technology funds complement each other's path, to avoid duplication of investment in low level and vicious competition, and take Group development path, as soon as possible to establish a few reasonable layout and complete variety, quality and cheap base for welding materials (such as Kam Tai Metal Industrial Co., Ltd., Praxair Gases Co), welding materials to ensure our industry as a whole to enter the international market.
6) Currently, the United States, Japan and European standards are gradually to international standards (ISO) approach, it should put some manpower and material resources we have stepped up international standards for gas shielded solid wires for our standard revision and the promotion of gas shielded solid wires development and improvement of product quality, as soon as possible into line with the international development of welding materials.
7) Strengthen communication and collaboration, improve the overall level of domestic CO2 welding wire. Domestic wire manufacturers, should continue to strengthen exchanges and cooperation with each other, especially to strengthen the scientific research units, welding wire plant and the use of collaboration between units, give full play to the advantages of various countries, so that the quality of our CO2 welding wire, constantly improving varieties.
4 Conclusion
Gas shielded solid wire is a high-tech welding materials, its emergence and development of welding production to meet the high quality, high efficiency, automation, low-cost, environmentally friendly direction of the trend. China's only large-scale manufacturing of metal structures to promote efficient MIG welding, metal structure to meet the domestic needs of enterprise survival and development. Throughout the bare wire to protect domestic gas development, China and the industrial developed countries, there is still a gap, which requires welding industry colleagues to work together quickly to develop and produce high-quality wire products,
To better adapt to the continuous development of welding production.

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