Method for surfacing with use of lying electrode

FIELD: processes for surfacing with use of lying electrode, possibly restoration of worn surfaces of parts in different industry branches.

SUBSTANCE: method for surfacing bead of rollers of road building machines comprises steps of arranging roller in such a way that its axis is vertical; dividing surfaced zone of bead by technological sectors; forming electrodes of n mutually joined rods bent along arcs of sectors and arranging them on surfaced area of respective sector with gap; supplying flux and additive powder material to surfaced zone; connecting electrode and part with power source for exciting electric arc and performing surfacing; placing electrodes on sectors of bead simultaneously along the whole circle; electrically connecting front end of one electrode with bead; at surfacing narrow beads, forming electrodes of n mutually joined rods arranged one over another.

EFFECT: enlarged manufacturing possibilities of method for surfacing parts with annular worn surface, lowered cost, enhanced efficiency of process.

3 cl, 5 dwg, 1 ex

 

The invention relates to welding, in particular to the surfacing of a recumbent electrode, and can be used for surfacing of worn surfaces.

A device for welding of worn parts in U.S. Pat. RU # 2209130, publ. 27.07.2003, this device lie electrode formed of “n” are connected in parallel rods hardfacing wire, and its consumable part is obtained in the form of a plate of given width, and the gap between the electrode and fused surface exhibit attached to the electrode rods with split rings from a material with low resistance.

This device is of limited use, since it is only intended for welding of straight portions and are not designed for the welding of parts with curved worn surface type “flange”.

The closest analogue is the way of surfacing recumbent electrode, which consists in the arrangement of electrode gap on the clean surface, applying to the clean surface flux and flux-cored filler material, the connection electrode and the workpiece to a power source for the excitation of the electric arc, and performing deposition (see U.S. Pat RU # 2133177, 1998).

However, this method of ethnological and is intended only for welding of straight portions of the worn surface place intimi electrodes, but not for reconstruction of surfaces with complex curvilinear profile of the worn surface. Changing the shape of the electrode plates is difficult and associated with high costs. The method has low productivity and limited application.

The proposed method solves the problem of improving the processability, as well as opportunities surfacing recumbent electrodes worn on the surface of the curved shape, including circular surface type “flange”, while simplifying deposition process, increasing productivity and reducing costs.

For solving the tasks in the proposed method of welding a recumbent electrode, which consists in the arrangement of electrode gap on the clean surface, applying to the clean surface flux and flux-cored filler material, the connection electrode and the workpiece to a power source for the excitation of the electric arc and performing welding, according to the invention for welding flange rollers construction and road machines rink set with vertical axis facing surface of the flange is divided into the technology sector, and the electrodes are formed of n interconnected rods, which are curved in the form of arcs of sectors, have PA surfaced surface of the corresponding sector.

To the ome, in the proposed method according to the invention, the electrodes can be placed on sectors of the flanges simultaneously over the entire circumference, and the beginning of one of the electrodes can be closed with the flange.

In addition, in the proposed method according to the invention for welding a narrow flanges of electrodes placed on sectors with vertical bars one on top of another.

The technical result of the proposed method consists in the possibility of recovery curved worn surfaces of any shape, including circular surfaces of the flanges of rollers construction and road machines, while simplifying technology, cost reduction and productivity improvement.

Figure 1 shows the location of the rink during welding of the flanges lying electrode.

Figure 2 shows the location of the electrode of the curved rods, mounted in the electrode holder, on the sector of the flange during welding.

Figure 3 shows an example of fusing with the location of electrodes, each of which is supplied with electrode holder, simultaneously over the entire circumference of the flanges.

Figure 4 shows an example of welding and positioning of the electrode of the bars on the worn surface of the flange.

Figure 5 shows an example of a deposition on a narrow flange.

Curved recumbent electrodes 1 are designed for surfacing pas worn surface is the efficiency of the flange 2 of the cylindrical rollers 3 road-building machines.

For welding the flange 2 is divided into sector 4 (see figure 2, 3).

Recumbent electrode 1 formed from “n” rods 5, bent in the shape of an arc corresponding to sector 4. When forming the electrode rods are fastened to each other mainly by electric welding.

Each electrode 1 is placed on the sector with a gap 6 relative to the clean surface of the flange 1. A gap of 6 exhibit attached to the electrode with split rings 7 of the inorganic material with a low resistance.

Before applying the electrodes are secured in elds of application 8.

The method is implemented as follows.

Before applying rink 3 set with vertical axis (see figure 1).

Clean the surface of the flange 2, which has a ring surface, conventionally divided into the technology sector 4. The number of technological sectors 4 sets out the calculation of the optimal length of the electrode in order to be able to bend the electrode in the form of arcs and the corresponding sector.

The surfacing of worn surfaces of the flanges 2 rollers 3 road-building machines perform recumbent electrodes 1. The electrodes are formed from “n” rods 5, bent in the form of arcs of sectors 4 and bonded together primarily by welding, improves the quality and increases the ease of welding.

When overlaying the recumbent electrode of prod is in, which is fixed to the electrode holder 8 can be installed on one of the technological sectors 4 of the flange 2 with a gap 6 is relatively clean surface. The gap put split rings 7 of the inorganic material with a low resistance. Before welding the electrode is filled with welding flux. Then, its surface is cleaned of flux and fill required for surfacing the amount of powder filler material (MRP). When connected to a power source (not shown) between the electrode and torch the surface of the arc excites and is surfacing. Next on the same technology consistently perform welding on other sectors of the flanges restoring the flange completely.

The method involves the surfacing at the same time the entire annular surface of the flange. For this purpose, the electrodes 1 of the curved rods 5 have in each of the technology sectors 4 simultaneously over the entire circumference of the flanges 2. On the fill electrodes of the welding flux. Then the surface is cleaned of flux and electrodes fill the estimated amount of the powder filler material (MRP)required for deposition of a layer of metal.

When overlaying each of the electrodes is connected to a power source, and the arc is excited by a single electrode, the beginning of which is crowned with the flange. When s is the country of current from the power source first melting of the electrode, closed with the flange, and the next arc goes to the beginning of the electrode of the next sector and is the melting of the electrode and so consistently is melting all of the electrodes to the full restoration of rings worn surface of the flanges. This allows you to simplify the way to increase productivity and reduce costs.

When overlaying the narrow ribs (see figure 5) the electrodes can be placed on sectors with vertical bars on one another, which allows to increase the height of the hardfacing layer and to prevent runoff of metal flange.

Example.

Held welding flange track roller caterpillar tractor T-35-01

The average thickness of flange wear was 6 mm, and the width of the flanges ≈26 mm

When restoring flange rink was installed with vertical axis. At the rink around flange fixed special fluconazolee device.

Before applying a facing surface of the flange is conventionally divided into three sectors, the average length of which is equal to ~300 mm, the number of sectors (sector length) is dictated by the technological conditions for the selection of the length of the electrode and the possibilities of their bend in the shape of an arc sector. This choice is optimal, because it is established in this case, to prevent overheating when the selected current density.

The welding was performed elek is childbirth which are formed from 4 bent rods welding wire grade SV-VA diameter D=4 mm

The electrodes were placed on the sectors along the entire circumference, and the shanks of each electrode is attached to an angle of 30° to the plane recorded in each respective electrode holder. The electrodes on the flange disposed with a gap relative to the clean surface, equal to 3 mm, which exhibited attached to the electrodes with split rings, made of paper twine diameter D=3 mm

The welding was performed under a layer of flux an-348A. On the electrodes as an additional filler material filled in the required amount of the mixture of iron powder PIV with high-alloyed powder. The beginning of one of the electrodes closed with the flange. When connected to a power source is consistent with the melting of all of the electrodes from the first to the last and full recovery ring worn surface of the flanges. Current welding 450-500 And voltage - 32-34 Century

The tests showed that the flange has a layer of surfacing across the worn surface, equal to 5-6 mm, and the service life of the flanges after welding corresponds to the lifetime of the new flange.

Technical and economic effect of the proposed method consists of expanding opportunities surfacing and restoration of details with the ring and the wear surface type “flange roller” while simplifying the way the improving technology, reducing costs, and improving its performance.

1. Method of surfacing a recumbent electrode, which consists in the arrangement of electrode gap on the clean surface, applying to a clean surface flux and flux-cored filler material, the connection electrode and the workpiece to a power source for the excitation of the electric arc and performing welding, characterized in that the welding flange rollers construction and road machines rink set with vertical axis and facing surface of the flange is divided into the technology sector, and the electrodes are formed from n interconnected rods, bent in the form of arcs of sectors, and have surfaced on the surface of the corresponding sector.

2. The method according to claim 1, characterized in that the electrodes are placed on the sectors of the flanges simultaneously over the entire circumference, and the beginning of one of the electrodes close to the flange.

3. The method according to claim 1 or 2, characterized in that the surfacing of the narrow flanges of the electrodes is formed of n interconnected rods, which have on one another.



 

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FIELD: processes for surfacing with use of lying electrode, possibly restoration of worn surfaces of parts in different industry branches.

SUBSTANCE: method for surfacing bead of rollers of road building machines comprises steps of arranging roller in such a way that its axis is vertical; dividing surfaced zone of bead by technological sectors; forming electrodes of n mutually joined rods bent along arcs of sectors and arranging them on surfaced area of respective sector with gap; supplying flux and additive powder material to surfaced zone; connecting electrode and part with power source for exciting electric arc and performing surfacing; placing electrodes on sectors of bead simultaneously along the whole circle; electrically connecting front end of one electrode with bead; at surfacing narrow beads, forming electrodes of n mutually joined rods arranged one over another.

EFFECT: enlarged manufacturing possibilities of method for surfacing parts with annular worn surface, lowered cost, enhanced efficiency of process.

3 cl, 5 dwg, 1 ex

FIELD: processes for surfacing by means of lying electrode, possibly manufacture of crowns of teeth of digging machines working in condition of intensified wear.

SUBSTANCE: method comprises steps of placing electrodes with gap on part to be surfaced; using flux and additive powder material; exciting electric arc between electrode and surfaced surface; performing multi-layer surfacing alternatively on upper and lower sides of crown; using steel substrate whose width is equal to distance between lateral faces of crown and whose length is equal approximately to difference of length values of new and worn crowns along axis of lateral side; arranging steel substrate in direction of plane crossing axes of lateral faces of crown and welding it to crown along contour of wear; fixing crown with welded substrate in such a way that at first its upper side is arranged horizontally, then its lower side is arranged horizontally; placing electrodes across lengthwise axis of crown at first on substrate and then on surfaced zones until their complete restoration.

EFFECT: enhanced quality of restored surface, lowered cost and simplified technique of process.

3 cl, 5 dwg, 1 ex

FIELD: restoration of cast iron rolling rolls with journals damaged at operation.

SUBSTANCE: method comprises steps of mechanically removing damaged layer and performing electric arc surfacing of rotated roll in place of damaged layer removal while feeding steel austenite wire electrode with diameter 3 - 5 mm to welding zone. Surfacing is realized at density of electric current 30 - 40 A/sq. mm and at electrode feeding speed 80 - 110 m/h. After surfacing journal is subjected to spontaneous cooling.

EFFECT: possibility for completely restoring geometry size of operational properties of damaged roll at keeping the same values of its hardness and strength.

1 tbl, 1 ex

FIELD: machine engineering, namely apparatuses for surfacing at restoring defective or damaged parts.

SUBSTANCE: surfacing machine tool includes column with yoke, cross piece, carriage, face chuck, table with adjustable inclination angle, surfacing head having mechanism for reciprocation motion in horizontal plane, mechanism for vertically moving surfacing head, mechanism for rotating in horizontal plane surfacing head with mouthpiece. On surfacing head there are mounted: reel with surfacing wire, mechanism for feeding wire to surfacing zone through mouthpiece and mechanism for reciprocation motion of surfacing head in horizontal plane. Machine tool is provided with matching device having actuating organ and providing kinematic connection between mechanism for rotating surfacing head and mechanism for vertical motion of surfacing head. Handle and flywheel kinematically joined with toothed rack of cross piece are secured to carriage. Matching device is in the form of worm reduction gear of rotation mechanism that is kinematically joined through first cone reduction gear with face chuck and through set of gear wheels - with connection coupling. The last through spring of actuating organ in the form of electromagnet and through second and third cone reduction gears is joined with lead nut of vertical motion mechanism.

EFFECT: enhanced operating efficiency, enlarged functional possibilities of machine tool.

2 cl, 4 dwg, 1 tbl

FIELD: machine part restoration, namely restoration methods suitable for using in aircraft engines, machine engineering and other branches of technology for restoring rubbing surfaces of cylindrical parts.

SUBSTANCE: method comprises steps of mounting on surface of part prepared for restoration before surfacing, blank of additive material in the form of band; using band with thickness 0.1 - 5.0 mm and mounting it at gap no more than 0.2 mm; performing multi-layer surfacing of additive material in vacuum by means of scanning electron beam; mechanically working part after surfacing each layer of additive material.

EFFECT: simplified process of surfacing material, elimination of residual stresses and deformations in article.

11 cl, 2 dwg, 1 tbl

FIELD: processes for restoring steam turbine blades with damaged edges.

SUBSTANCE: method comprises steps of removing worn portion and then surfacing in impulse mode metal whose ductility exceeds that of blade material; welding on protection cover strip by two seams while forming one seam on base material of blade and forming other seam on surfaced metal. Surfaced metal has high cracking resistance; its melting temperature is less than that of base material of blade. Heat treatment with use of heat insulation jacket is performed after surfacing and welding on of protection cover strips.

EFFECT: lowered non-uniformity of structure-phase composition of material of restored blade, reduced tension residual stresses, enhanced resistance of blade against cracking, corrosion and erosion.

4 cl, 1 dwg, 1 tbl

FIELD: power production machine engineering, possibly manufacture of such parts whose surface layer operate in condition of erosion-corrosion actions, high mechanical loads, influence of cryogenic temperatures, for example in power production or chemical-production plants.

SUBSTANCE: method comprises steps of placing copper plate on substrate and melting it by means of electric-arc welding with use of non-consumable electrode; before placing plates, applying flux layers onto mutually joined surfaces; insulating ( for preventing contact with arc plasma) end edges of copper plate and portions of substrate near edges of plate along the whole perimeter; realizing surfacing at melting temperature of copper plate that causes no fusion of base metal of substrate.

EFFECT: enhanced quality of surfacing.

6 cl, 3 dwg, 1 ex

FIELD: restoration of worn surfaces, namely semichambers of rubber mixers.

SUBSTANCE: method comprises steps of placing on restored part metallic cover plate compensating wear; fusing cover plate along its whole thickness by annular or lengthwise seams at predetermined pitch with use of plasma arc and additional arc. The last burns between melt metal and alloy powder wire that is fed behind plasma arc. Spacing between said arcs is selected in range consisting of (0.4 - 0.6) of length of melt metal bath.

EFFECT: possibility for providing seam root minimally alloyed with powder wire components at keeping wear resistance of remaining metal of seam.

2 dwg

FIELD: restoring or strengthening worn parts by electric arc surfacing, manufacture of new parts operating in condition of variable dynamic loads combined with high wear and corrosion.

SUBSTANCE: method comprises steps of forming at least partial coating at least of one layer on part by electric arc surfacing with use of consumable electrode; forming said layer of alternating preliminarily set at least in one direction zones of metals with different linear expansion factors. At least one zone of said layer includes metal whose linear expansion factor is less than that of main metal of part. Such layer is formed by filling preliminarily formed grooves with metal or by applying beads.

EFFECT: enhanced operational properties of parts due to creation of in part designed favorable fields of residual stresses.

10 cl, 17 dwg, 7 ex

FIELD: welding, namely apparatuses for surfacing inner cylindrical surfaces, possibly electric-arc corrosion protection flux surfacing.

SUBSTANCE: apparatus for belt type surfacing of cylindrical surfaces of small-diameter openings is in the form of surfacing attachment and it includes guiding duct for passing welding material. At outlet of said duct there is electric current supply mouthpiece with pressing device. Guiding duct is rectangular one, it has shaped working surface. Contact surface of belt and pressing device is arranged over level of contact surface of belt and current-supply mouthpiece without their direct contact. Width of working surface of electric current supply mouthpiece and pressing device is less than that of fed belt. Pressing device is in the form of pressing roller or pressing plate whose working surface is rounded.

EFFECT: enhanced efficiency of surfacing, enlarged manufacturing possibilities of surfacing head, improved stability of belt feed, enhanced quality of surfaced coating due to optimization of constructional members of attachment.

3 cl, 3 dwg

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