The application of hardfacing is one of the ways to restore the functional properties of worn elements. The possibility of using filler materials rich in chrome allows for better wear resistance than base materials used so far. The paper presents the results of research on the use of 3 different grades of covered electrodes for the regeneration of worn track staves. The content of the carbon in the covered electrodes was from 0,5% to 7% and the chromium from 5% to 33%. The microscopic and hardness tests revealed large differences in the structure and properties of the welds. The differences in the hardness of the welds between the materials used were up to 150 HV units. The difference in wear resistance, in the ASTM G65 test, between the best and worst materials was almost 12 times big.
This research is focused on the analysis of heat-affected sub-zones in 2 mm thick steel S960MC samples, with the aim of observing and evaluating the mechanical properties after exposure to temperatures corresponding to individual heat-affected sub-zones. Test samples were prepared using a Gleeble 3500 thermo-mechanical simulator. The samples were heated in the range from 550°C to 1350°C and were subsequently quickly cooled. The specimens, together with the base material, were then subjected to tensile testing, impact testing, and micro-hardness measurements in the sample cross-section, as well as evaluation of their microstructure. Fracture surfaces are investigated in samples after impact testing. The heat-affected sub-zones studied indicate high sensitivity to the thermal input of welding. There is a significant decrease in tensile strength and yield strength at temperatures around 550°C.
Materials based on cast irons are often used for protection against wear. One of the methods of creating protective surface with cast iron structures is hardfacing. The application of hardfacing with self shielded flux cored wire with high carbon content is one of the economical ways often used to protect machinery parts exposed to both abrasion and erosion. The wear resistance of hardfacings depends on their chemical composition, structure obtained after hardfacing, parameters of depositing process andspecific conditions of wear. As the base material in the investigation the steel grade S235JR was used. The wear behavior mechanism of hardfacings made with one type of self shielded flux cored wire and different process parameters were evaluated in thispaper. Structures obtained in deposition process were different in hardness, amount of carbides and resistance to wear with two investigated impingement angles. The erosion tests showed that impingement angle 30° gives lower erosion rate than angle 60°.
The main goal of the article is to identify artificially created defects like lack of fusion and incomplete penetration in buttweld joint using non-destructive volumetric methods. These defects are the most serious defects in welds of steel constructionsfrom the safety point of view. For identification, an ultrasonic phased array technique and a conventional X-ray using digital imaging were used. The theoretical part of the article describes the current state of the given issue and provides basic theoretical knowledge about ultrasonic and X-ray welding tests. In the experimental part, the procedure and results of testing butt weld joint are described by both non-destructive methods. The butt weld joint was made from steel S420MC. Each indication obtained by the ultrasonic and x-ray technique is supplemented by the macrostructure of the weld taken from the indication position. The results of the experimental work mentioned in the article point to the possibility and reliability of the identification of melting defects by selected nondestructive methods in terms of their character and orientation.
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W pracy przedstawiono przykładowe wyniki badań kwalifikowania technologii spawania produkcyjnego odlewu staliwnego żaroodpornego w gatunku GX40NiCrNb35-45 przy użyciu materiału dodatkowego w gatunku WZ 35 45 Zr wg PN-EN ISO 14343. Badanie kwalifikowania technologii spawania wykonano zgodnie z PN-EN ISO 11970. Złącze próbne wykonano metodą 141 i następnie przeprowadzono badania nieniszczące oraz niszczące określające własności mechaniczne złącza. Wykonane badania pozwoliły spełnić wymagania zawarte w PN-EN ISO 11970 i były podstawą do wystawienia protokołu kwalifikowania technologii spawania.
EN
The paper presents the results of qualification of production welding procedures for heat-resistant cast steel in grade GX40NiCrNb35-45 with used filler material in grade WZ 35 45 Zr (PN-EN ISO 14343). Qualification of welding technology was made in accordance to PN-EN ISO 11970. Test welded joint was made using 141 method and non-destructive and destructive testing were performed in order to determine the mechanical properties of the welded joint. Completed tests met the requirements of PN-EN ISO 11970 and were the basis of the welding procedure qualification record.
In this work, a model of phase transformations during multipass weld surfaced steel casts is presented. In the temperature field calculation algorithm, the influence of the heat of overlaying beads and a self-cooling of previously overlayed beads have been taken into account. The fusion area, full and part transformation zones, by solidus, A1 and A3 and A A1 temperatures has been determined, respectively. The temperatures of the beginning and the end of the phase changes during cooling were determined on the basis of the time-temperature-transformation welding diagram. In the phase change kinetic description, the JMAK law and KM formula were used. Theoretical considerations are illustrated by example of volume share calculations of particular structural components during the weld surfaced 230-450 W steel cast. The results of computation in the graphical forms are presented: welding thermal cycle diagrams and structural share change histories at selected points, as well as temperature and the phase share distributions in cross section.
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Przedstawiono wyniki badań złączy spawanych ze staliwa GX8CrNi12-1. Jest to staliwo o mikromikrostrukturze martenzytycznej do stosowania w temperaturze pokojowej i podwyższonej na urządzenia ciśnieniowe. Złącza były wykonane w pozycji naściennej (PC) oraz w pozycji pionowej z dołu do góry (PF). Zastosowanie takich pozycji jest podyktowane warunkami przemysłowymi i koniecznością spawania odlewów staliwnych w wymienionych pozycjach. Spawanie w ww. pozycjach daje w pełni pewność, że próbki zostały pobrane z miejsc o najmniejszej i największej ilości wprowadzonego energii liniowej łuku. W artykule opisano proces spawania ręcznego elektrodą otuloną (111) i obróbkę cieplną po spawaniu. Złącza próbne poddano badaniom niszczącym: badanie na rozciąganie poprzeczne, udarności, twardości, makroskopowe i mikroskopowe. W otrzymanych wynikach badań zauważalne są różnice we właściwościach złączy wykonywanych w różnych pozycjach, co związane jest z ilością ciepła wprowadzonego do złącza podczas procesu spawania.
EN
The article presents test results concerning welded joints made of cast steel GX8CrNil2-l. The above-named cast steel has a martensitic microstructure and can be used in pressure equipment operated at ambient and high temperature. The test joints were made in the horizontal position and in the vertical up position. The foregoing was dictated by the fact that the above-named positions arę used in industrial conditions, e.g. when welding steel castings. The welding process performed in the above-named positions ensured that specimens were sampled from areas exposed to the lowest and highest are linear energy. The article describes the process of manual metal arc welding (111) and the post-weld heat treatment. The test joints were subjected to destructive tests including transverse tensile tests, impact strength tests, hardness measurements as well as macro and microscopic tests. The test results revealed differences in properties of joints made in different positions, resulting from various heat inputs to joints during welding.
Use of welding technology for the repair of steel castings is particularly common in two areas. These include weld surfacing of protrusions that remained incomplete after casting, or filling the surface defects (cavities). These defects are more common for steel casting than for graphite cast iron, due to the lower fluidity of steel. This article describes a suitable technological process of repairing the defects on the casting using the welding technology. A specimen produced for this purpose was prepared by carving a groove into a cast steel plate 20 GL, which was then filled with a weld metal using MAG (135) technology. The following evaluation of the basic characteristics of the repaired site point to the suitability of the selected technological parameters of the repair procedure. Metallographic evaluation was carried out, further evaluation of mechanical properties by tensile test, bend test and Vickers hardness test. The proposed methodology for the evaluation repair of foundry defects in steel castings also meets the requirements for the approval of welding procedures in accordance with the relevant valid legislation.
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W pracy przedstawiono wyniki badań wpływu charakterystyki łuku spawalniczego na właściwości napoin wykonanych drutem rdzeniowym samoosłonowym. Proces napawania prowadzony był z użyciem łuku zwarciowego, mieszanego oraz łuku impulsowego. Otrzymane napoiny charakteryzowały się dużymi różnicami w uzyskanej twardości rzędu nawet 200HV10. Charakterystyka łuku wpłynęła również na stopień wymieszania napoiny z materiałem podłoża oraz samą strukturę napoiny. Najkorzystniejsze właściwości napoiny zanotowano dla łuku impulsowego.
EN
The paper presents results of research on cladding made with different characteristics of welding arc and their effect on the properties of the hardfacing made with self shield cored wire. Hardfacing was done with short circuit characteristic, mixed and with pulse current. The obtained deposits were varied in hardness values up to 200HV10. It was observed that characteristic of welding arc has large influence on the dilution rate and the structures of the deposits. The best properties of the deposits were noted to the pulsed arc current.
The paper presents the capabilities of welding techniques to creating properties of wear resistant high chromium cast iron alloy. The use of the right kind of welding sequence allows you to change the structure and properties of the obtained welds. Tests were conducted for one type of additive material in the form of self shielded core wire. In order to determine the effect of the type of welding sequence on the properties of welds performed welding using string bead and weave bead. The resulting weld was tested on hardness and research structure in an optical microscope. In the following studies have been made erosive tests wear of made hardfacing. String beads gave structure rich in carbides and harder about 270 HV of the weld with weave bead. Also, wear resistance was nearly twice as better for welds made with string beads. In the experiment a decisive role in the resistance to wear plays a high hardness of the deposit and the presence of carbides in its structure. Changes in the basic parameters of the deposition process allows for the formation of structure and properties of hardfacing welds in a wide range.
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W pracy przedstawiono zagadnienie wpływu zmian nastaw prądu napawania z użyciem drutu rdzeniowego z wypełnieniem metalicznym i odpowiadające temu zmiany uzyskiwanych przekrojów napoin. Wykorzystywane do tego celu próby i określone równania pozwalają zdaniem autorów z dużą dokładnością określić ilość wykonywanych ściegów dla zadanych przekrojów napoin i spoin. W pracy zebrano wyniki badań nad wielkościami geometrycznymi złącza wykonanego przy określonych nastawach prądu. Do prób automatycznego napawania wykorzystano materiał dodatkowy T 46 3 MM 2 H5 o średnicy 1,2mm. Wykonane napoiny zostały przygotowane do badań metalograficznych makroskopowych i analizowane pod kątem uzyskanej geometrii ściegu oraz uzyskanej masy ściegu.
EN
The paper presents the problem of determining changes in the settings of the welding current and corresponding to the changes in cross-section welds obtained when using metal cored wire. Used for this purpose tests and determined equations, according to the authors, allows to determine the number of joints performed for specified sections of welding beads. Tests were carried out with automatic feed welding torch, using the additive material T 46 3 MM 2 H5 with diameter of 1.2 mm. The paper presents results of research on weight of bead and geometric quantities joint made by certain weldign current settings. The resulting welds have been tested and analyzed metallographic macroscopic for checking geometry and weight of bead.
W pracy dokonano oceny zmiany mikrostruktury i właściwości mechanicznych w niejednorodnym złączu spawanym ze stali X20Cr- MoV11-1 i X10CrMoVNb9-1. Przedstawiono wyniki badań przeprowadzonych na doczołowym złączu spawanym rur ϕ38,0 mm × 7,1 mm, które wykonano metodą TIG z zastosowaniem podgrzewania wstępnego (200oC). Zakres przeprowadzonych badań obejmował: badania wizualne, badania makro- i mikroskopowe, pomiary twardości i badania właściwości mechanicznych złącza spawanego. Wykazano, że otrzymanie jednocześnie wymaganych właściwości plastycznych i twardości jest możliwe po zastosowaniu wyżarzania w temperaturze 770°C/1h. Przedstawiono wybrane wyniki badań stali X20CrMoV11-1 w stanie wyjściowym oraz po długotrwałej eksploatacji w warunkach pełzania.
EN
In the paper the microstructure and mechanical properties changes in heterogeneous welded joint made of X20CrMoV11-1 and X10CrMo- VNb9-1 steels have been discussed. The results of investigations carried out on butt welded joint of pipe ϕ38.0 mm × 7.1 mm have been presented. The study was performed on preheated (200oC) welded joint made with TIG welding method. The scope of the research work included visual observations, macro and microscopic examinations, measurements of hardness and the study of mechanical properties of welded joint. It has been proved that the required plasticity properties and hardness is possible to obtain by applying annealing at a temperature of 770°C/1 hour. Selected test results are presented for X20CrMoV11-1 steel in initial state and after long-term service under creep conditions.
The welding technologies are widely used for design of protection layer against wear and corrosion. Hardfacing, which is destined for obtaining coatings with high hardness, takes special place in these technologies. One of the most effective way of hardfacing is using self shielded flux cored arc welding (FCAW-S). Chemical composition obtained in flux cored wire is much more rich in comparison to this obtained in solid wire. The filling in flux cored wires can be enriched for example with the mixture of hard particles or phases with specified ratio, which is not possible for solid wires. This is the reason why flux cored wires give various possibilities of application of this kind of filler material for improving surface in mining industry, processing of minerals, energetic etc. In the present paper the high chromium and niobium flux cored wire was used for hardfacing process with similar heat input. The work presents studies of microstructures of obtained coatings and hardness and geometric properties of them. The structural studies were made with using optical microscopy and X- ray diffraction that allowed for identification of carbides and other phases obtained in the structures of deposited materials. Investigated samples exhibit differences in coating structures made with the same heat input 4,08 kJ/mm. There are differences in size, shape and distribution of primary and eutectic carbides in structure. These differences cause significant changes in hardness of investigated coatings.
The surfacing technologies are used for constitution of protection layer against wear and is destined for obtaining coating with high hardness. Among many weldings methods currently used to obtain the hard surface layer one of the most effective way of hardfacing is using flux cored arc welding. This additional material gives more possibilities to make expected hard surface layer. Chemical composition, property and economic factors obtained in flux cored wire are much richer in comparison to these obtained with other additional materials. This is the reason why flux cored wires give possibilities of application this kind of material for improving surface in different sectors of industry. In the present paper the imperfection in the layers was used for hardfacing process in different situations to show the possible application in the surface layer. The work presents studies of imperfection of the welds, contains the picture of microstructures, macrostructures and shows the results of checking by visual and penetrant testing methods.
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W artykule przedstawiono podstawowe zagadnienia związane ze spawalnością i spawaniem staliwa G17CrMo5-5 przeznaczonego do pracy w podwyższonej temperaturze. Staliwo to może być wykorzystane do wykonania komory zaworowej turbiny parowej. W pracy opisano sposoby przygotowania materiału do spawania oraz proces spawania metodami TIG/MMA i obróbkę cieplną po spawaniu. Próby spawania przeprowadzono w pozycjach PH i PC. Próbne złącza poddano badaniom niszczącym w zakresie: badanie pracy łamania, badanie rozkładu twardości oraz wykonano badania makroskopowe. W otrzymanych wynikach badań zauważalne są różnice w właściwościach złączy wykonywanych w różnych pozycjach co związane jest z ilością ciepła wprowadzonego do złącza podczas procesu spawania.
EN
The article presents basic issues related to weldability and welding of cast steel G17CrMo5-5 designed for use at elevated temperatures. This cast steel can be used to perform the valve chamber of the steam turbine. This paper describes how to prepare material for welding and TIG welding process / MMA and post-weld heat treatment. Welding tests carried out in positions PH and PC. The trial joints were tested destructive in terms of: breaking work testing, hardness distribution testing and macroscopic tests were performed. There are noticeable differences in the obtained tests results in the properties of joints made at different positions which is related to the amount of heat introduced into the connector during the welding process.
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W pracy przedstawiono wybrane aspekty technologii wykonywania powierzchni grzewczych tj. wężownic przegrzewaczy pary z wykorzystaniem kompleksowego stanowiska do spawania metodą zmechanizowaną TIG. Próby spawania wykonano na rurach ze stali VM12-SHC o średnicy 44,5mm i grubości ścianki 7,1 mm. Przedstawiono wyniki badań niszczących oraz nieniszczących oraz wskazano na problemy jakie można spotkać w czasie spawania tego typu stali. Przeprowadzone próby spawania złącza doczołowego dowiodły, iż spawanie orbitalne metodą TIG jest procesem bardzo skutecznym pod względem powtarzalności oraz jakości wykonanych połączeń spawanych. Odpowiednio przygotowane oprogramowanie procesu spawania, czy też bieżąca kontrola stanu technicznego urządzenia, powodują iż wskaźnik wadliwość wykonywanych złącz wynosi poniżej 1%. Z tego względu metoda spawania orbitalnego TIG jest rekomendowana w przypadku, gdy spawane są elementy w gatunkach o utrudnionej spawalności tj. VM12-SHC.
EN
The paper presents selected aspects of technology performance of the heating surfaces, ie. steam superheater coils using a comprehensive outcome for mechanized TIG welding. Welding was carried out on steel pipes VM12-SHC having a diameter of 44,5 mm and a wall thickness 7,1 mm. The results of destructive and non-destructive tests were presented and the problems that can be encounter during this type of welding steel were pointed out. The butt joint welding tests that were made have proved that orbital TIG welding is a process very effective in terms of reproducibility and the quality of the welded joints. Properly prepared welding process software or the current control of the technical condition of the appliance, cause that the impairment indicator of the performed connectors is less than 1%. Therefore, the orbital TIG welding method is recommended when the elements are welded in the species hindered weldability, ie. VM12-SHC.
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W pracy przedstawiono wyniki badań nad napoinami wykonanymi prądem pulsującym. Głównym celem pracy było określenie wielkości geometrycznych wykonanych napoin przy założonych wartościach napawania impulsowego. Podczas prób napawania zmieniano częstotliwość impulsu, napięcie impulsu, czas impulsu i długość wolnego wylotu drutu. Parametry procesu były tak dobierane by uzyskać jak najwyższe i najszersze napoiny przy zachowaniu dużej stabilności procesu napawania. Jednym z głównych kryteriów określających przydatności napoiny do użycia jest stopień wymieszania materiału napoiny z materiałem podłoża. We wszystkich badanych napoinach procentowy udział metalu podłoża w napoinie wahał się między 20% a 30%. Uzyskanie niższych wartości wymieszania prowadziło w tym przypadku do zmniejszenia stabilności procesu napawania i wpływało negatywnie na jakość otrzymywanych napoin.
EN
The paper presents results of research on cladding made with pulse current. The main objective of this study was to determine geometric size of the welds made with the assumed values of pulse welding. During the experiment surfacing pulse frequency, pulse voltage, pulse duration and length of the stick wire were varied. The process parameters were so diverse to achieve the highest and widest of the deposit while maintaining the high process stability surfacing. One of the main criteria for determining the suitability of the deposit to use is the dilution of the material of the deposit with the parent material. In all examined welds percentage of the base metal in the weld pad fluctuated between 20% and 30%. Obtaining the lower dilution rate led to diminishing the stability of the deposition process and affected adversely the quality of the welds.
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W pracy przedstawiono wyniki badań nad napoinami trudnościeralnymi przeznaczonymi do pracy w warunkach przemysłu cementowego. Głównym celem pracy była próba wykonania pełnego kwalifikowania procesu napawania półautomatycznego zgodnie z wymaganiami PN EN ISO 15614-7 przy wykorzystaniu drutu dającego twardości sięgające do 60 HRC warstwy wierzchniej w jednym przejściu o ściegu szerokim na 10 i 20 mm. Następnie próbki poddano badaniom nieniszczącym to jest badaniom wizualnym i penetracyjnym oraz badaniom niszczącym w postaci badań metalograficznych makroskopowych i mikroskopowych, badaniu twardości. Zastosowanie niniejszej normy nie daje możliwości akceptacji kwalifikowania technologii napawania z wykorzystaniem materiałów dających bardzo twarde warstwy wierzchnie zawierające w swojej strukturze wydzielenia węglikowe.
EN
The paper presents results of research on surface hard wearing designed to work in the cement industry. The main objective of the study was to perform a full qualification semiautomatic welding process in accordance with the requirements of PN EN ISO 15614-7 using a wire giving a hardness of up to 60 HRC surface layer in a single pass with a bead wide for 10 and 20 mm. The samples were then subjected to non-destructive testing is testing and visual and liquid penetrant testing destructive testing in the form of macroscopic and microscopic metallographic, hardness test. Application of this standard does not allow acceptance of qualification of welding technology using materials with a very hard outer layer containing in its structure separating carbide.
The paper discusses the possibility of using pulsed arc hardfacing for depositing high chromium and carbon surfaces. In these studies self-shielded cored wire was used as a material for hardfacing. Pulsed arc is used in welding technologies to better control of transport molten metal in the welding arc and heat input. The correct heat input results in limited dilution surfaces that is very important in wear prevention technologies. The paper presents the results of research on the geometric parameters and hardness of deposited surfaces. The investigation was carried out with various welding parameters that were designed in heat source. The survey was conducted on the specimens that were subjected to metallographic examination hardness test.
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W pracy przedstawiono zagadnienie określania zmian nastaw prądu napawania i odpowiadające temu zmiany uzyskiwanych przekrojów napoin w przypadku użycia drutu litego. Wykorzystywane do tego celu próby pozwalają zdaniem autorów z dużą dokładnością określić liczbę wykonywanych ściegów dla zadanych przekrojów napoin i spoin. W pracy przedstawiono wyniki badań nad wielkościami geometrycznymi złącza wykonanego przy zmieniających się parametrach prądu przy nastawach 150, 200, 250, 300 A. Wykonano próby napawania z automatycznym posuwem palnika, przy wykorzystaniu materiału dodatkowego w postaci drutu litego o średnicy 1,2 mm. Uzyskane napoiny zostały poddane badaniom metalograficznym makroskopowym i przeanalizowane pod kątem uzyskanej geometrii ściegu.
EN
The paper presents the problem of determining changes in the settings of the welding current and corresponding to the change in cross-section welds obtained when using solid wire. Used for this purpose according to the authors attempt to allow has impact on the basic parameters characterizing the welded joint. The paper presents results of research on geometric quantities joint made at changing the parameters set welding current by settings of 150, 200, 250, 300 A. Tests were carried out with automatic feed welding torch, using the additive material with diameter of 1.2 mm. The resulting welds have been tested and analyzed metallographic macroscopic for checking geometry.
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