• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    The invention provides a flux filling method, in a continuous manufacturing process of a flux-cored wire, when the flux is continuously filled into a cavity in the forming process, a belt charger feeds the flux, a flux layer in a flux supplying cylinder can not freely fall down, and is continuously accumulated on the surface of the belt charger, and flows off, at the same time, the accumulated flux layer is cut from a gap between the lower end of the supplying cylinder and the surface of the belt charger and is conveyed, and the conveyed flux layer flows off in a layer-shaped way from the terminal of the belt charger to the predetermined guide plate, the flux can not freely fall down, and slides down in the layer-shaped way on the guide plate to be continuously supplied relative to the upward opening part of a strip steel in the moving forming process. In this way, the flux can be continuously and uniformly filled into the cavity of the strip steel.
    公开号:NL2004289A
    申请号:NL2004289
    申请日:2010-02-23
    公开日:2010-08-30
    发明作者:Shinichi Nishimoto
    申请人:Kobe Seiko Sho Kobe Steel Kk；
    IPC主号:
    专利说明:

    FLUX FILLING METHOD
    BACKGROUND OF THE INVENTION
    1. Field of the Invention
    The present invention relates to a method for continuously filling a space in a running band steel material (hereinafter also referred to as hoop, steel band, or steel hoop) with flux during the process for manufacturing a flux-cored welding wire.
    2. Description of the Related Art
    There is a general method for manufacturing a flux-cored wire with a small diameter of 0.8 to 1.6 mm in which the following steps are continuously performed in the recited order on the same line: uncoiling a coiled hoop (band steel) and forming it into a U-shaped band steel (tube); filling the running U-shaped hoop with flux during the forming; and further drawing the tubularly formed wire filled with flux and winding it into a coiled product flux-cored wire.
    A conventional general method for filling the running U-shaped hoop (casing tube) with flux during the forming is as shown in FIG. 5.
    In FIG. 5, flux 106 is continuously fed by a belt feeder 10 to the upwardly open portion 114 of the running U-shaped hoop 100a from a position over the hoop 100a and from a direction perpendicular to the running direction of the hoop 100a. The belt feeder 10 rotates with its terminal end at the position over the U-shaped hoop 100a. Upstream of and over the belt feeder 10, a hopper (not shown) for feeding flux is installed. From the hopper, flux 1 flows down toward the surface of a belt 11 that is the surface of the running belt feeder 10.
    A flux layer 106a deposited on the belt 11 and transported toward the hoop 100a falls freely from the terminal end 11a of the belt feeder (the terminal end of the belt 11) toward the upwardly open portion 114 of the running hoop. Then, like the hoop 100a shown in C of FIG. 4B, the space in the hoop (band steel) is continuously filled with a predetermined amount of flux 106.
    At this time, flux must be put in uniformly in the longitudinal direction of the hoop 100a. For this purpose, improved flux feeders, methods for controlling the feeding of flux, and the like have been proposed. These are disclosed, for example, in Japanese Unexamined Patent Application Publication Nos. 3-52797 and 60-145299.
    Japanese Unexamined Patent Application Publication No. 3-52797 discloses a belt-type flux feeder characterized in that the diameter of the roller on the side where flux falls is 6 mm or less, the overall thickness of the belt is 1 mm or less, and the belt is made of or coated with polytetrafluoroethylene.
    Japanese Unexamined Patent Application Publication No. 60-145299 discloses a method including: obtaining the mass and running velocity at a band steel mass measurement point set upstream of the position where flux is put in; and controlling the response time between the start of band steel mass measurement and the transmission of a command to regulate the putting in of flux, on the basis of the time required to regulate the amount of flux put in and the time the band steel takes to move from the measurement point to the point where flux is put in. The method further includes inputting a powder coefficient determined by the flux property into a flux feeding device and thereby regulating the amount to be fed.
    However, even if these conventional flux feeder and method for controlling the feeding of flux are used, it is difficult to uniform the flux filling rate in the longitudinal direction of a flux-cored wire in the above-described continuous manufacturing process of a flux-cored wire with a small diameter. In the above-described continuous manufacturing process of a flux-cored wire with a small diameter, the step of filling with flux is not a separate and independent step but is performed during the above-described series of manufacturing steps. In addition, the velocity of the hoop running through the series of manufacturing steps is relatively high in consideration of the production efficiency; the hoop to be filled with flux is relatively small in diameter as described above; and the upwardly open portion 114 of the hoop is also small in width.
    Under such conditions, it is very difficult, as described above, to continuously fill a running steel hoop uniformly in the longitudinal direction by the above-described method. Therefore, as schematically shown in FIG.
    6, the hoop 100a tends to be filled with flux ununiformly in the longitudinal direction shown by the horizontal arrow in the figure. As a result, the flux filling rate (% by weight of flux to the total wire weight per unit length, also called flux rate) in the longitudinal direction of a completed flux-cored wire 110 tends to be ununiform.
    If the ununiformity is extreme, the flux-cored wire 110 has parts where there is no flux or the flux filling rate is less than the standard value. This tendency or probability increases with increase in the running speed of the hoop through the series of manufacturing steps, and with decrease in the diameter of the hoop to be filled with flux.
    FIG. 7 is a sectional view (longitudinal sectional view) schematically showing a flux-cored wire obtained by drawing the hoop 100a of FIG. 6. FIG. 7 shows that when the flux filling rate of a flux-cored wire 110 in the longitudinal direction shown by the horizontal arrow in the figure is ununiform, the thickness of the hoop serving as a casing and the diameter of the flux-cored wire 110 are also ununiform. This is because the wire (hoop) filled with flux is drawn with the wire external diameter limited and therefore the hoop tends to bulge inward. If the amount of flux is small, the amount of flux that prevents bulging is small, and therefore the thickness of the hoop serving as a casing increases. If the amount of flux is large, the flux prevents the hoop serving as a casing from thickening, and therefore the thickness of the hoop serving as a casing decreases.
    Such abnormal or unsteady parts, that is, parts where the amount of flux is too small or zero, or parts where the diameter of the flux-cored wire is ununiform significantly affect the shape accuracy or welding quality. Therefore, also in the actual manufacturing process of a flux-cored wire, such abnormal or unsteady parts must be detected and eliminated. For this purpose, for example, Japanese Examined Patent Application Publication No. 4-15904 and Japanese Patent No. 3553761 propose a flux filling rate measuring device that continuously detects such abnormal or unsteady parts using an electromagnetic induction phenomenon while running a flux-cored wire in an in-line manner in the manufacturing line of a flux-cored wire.
    Therefore, in the above-described continuous manufacturing process of a flux-cored wire with a small diameter, it is particularly important to provide a flux filling method capable of uniforming the flux filling rate in the longitudinal direction of a flux-cored wire even if the running velocity of the hoop is relatively high in consideration of the production efficiency, and the hoop (wire) to be filled with flux has a relatively small diameter.
    SUMMARY OF THE INVENTION
    The present invention is made in consideration of the above-described circumstances, and an object of the present invention is to provide a flux filling method for manufacturing a flux-cored welding wire, capable of filling a space in a hoop with flux continuously and uniformly even if the running velocity of the hoop is high, and the hoop has a small diameter.
    An aspect of the present invention is a method used in a manufacturing process of a flux-cored welding wire. The process includes the steps of forming a hoop into a tubular shape, filling the hoop that is running with flux during the forming, and further drawing the tubularly-formed wire filled with flux. The method is for filling a space in the hoop with the flux and includes the following requirements (a) to (g): (a) the flux is continuously fed to an upwardly open portion of the hoop that is formed in a U-shape in cross section and running, from a position over the hoop and from a direction perpendicular to the running direction of the hoop; (b) the flux is fed by a belt feeder that rotates with its terminal end at the position over the hoop; (c) a hopper for feeding the flux is installed upstream of and over the belt feeder, and the flux is caused to continuously flow down toward the surface of the belt feeder through a feed pipe installed under the hopper; (d) the lower end of the feed pipe is installed close to the surface of the belt feeder so that the flux layer in the feed pipe can flow down while being continuously deposited on the surface of the belt feeder, without falling freely, and so that the deposited flux layer can be fed from the clearance between the lower end of the feed pipe and the surface of the belt feeder and transported toward the hoop; (e) the amount of flux flowing down through the feed pipe and the transport velocity of the belt feeder are regulated so that the clearance between the lower end of the feed pipe and the surface of the belt feeder is equal to the thickness of the flux layer deposited on the surface of the belt feeder and transported toward the hoop and so that the width of the flux layer being transported is substantially the same as the internal diameter of the feed pipe; (f) a guide plate for the flux is installed toward the upwardly open portion of the running hoop so as to block the route of the flux flowing down from the terminal end of the belt feeder, under the terminal end of the belt feeder; and (g) the flux transported on the belt feeder is caused to flow down laminarly from the terminal end of the belt feeder toward the guide plate so that after flowing down laminarly, the flux slides down on the guide plate without falling freely and is continuously fed to the upwardly open portion of the running hoop, and the space in the hoop is continuously filled with a predetermined amount of the flux.
    It is preferable that the flux filling method be applied to a flux-cored welding wire with a small diameter of 1.6 mm or less .
    The present invention makes it possible to uniform the flux filling rate in the longitudinal direction of a flux-cored wire by combining the above-described requirements, especially the above-described characteristic requirements (d) to (g), even if the running velocity of a hoop is relatively high, and the hoop (wire) to be filled with flux has a relatively small diameter.
    Therefore, the present invention makes it possible to continuously manufacture a flux-cored wire at a relatively high running velocity while uniforming the flux filling rate of a flux-cored wire with a small diameter, and is effective in both the quality improvement and quality assurance of a flux-cored welding wire, and the improvement of yield and production efficiency.
    BRIEF DESCRIPTION OF THE DRAWINGS
    FIG. 1 is a perspective view showing an embodiment of the flux filling method of the present invention; FIG. 2 is a side view of FIG. 1; FIG. 3 is a partial side view showing another embodiment of the flux filling method of the present invention; FIG. 4A is an explanatory diagram showing a continuous manufacturing process of a seamed flux-cored welding wire, and FIG. 4B is an explanatory diagram showing the cross sectional shape of a hoop in each forming step of FIG. 4A; FIG. 5 is a side view showing an embodiment of a conventional flux filling method; FIG. 6 is a sectional view showing the status of flux filling in the longitudinal direction of a hoop by a conventional flux filling method; and FIG. 7 is a sectional view showing the status of flux filling in the longitudinal direction of a welding wire by a conventional flux filling method.
    DESCRIPTION OF THE PREFERRED EMBODIMENTS
    The embodiments of the flux filling method of the present invention will now be described with reference to FIGS. 1 to 3. FIG. 1 is a perspective view showing an embodiment of the flux filling method in the process for manufacturing a flux-cored wire of FIG. 4A to be described below. FIG. 2 is a side view of FIG. 1. FIG. 3 is a partial side view showing another embodiment of the flux filling method.
    (Preconditions)
    The present invention is based on the premise that, in the continuous manufacturing process of a flux-cored welding wire, the running hoop is filled with flux while being formed. The details of the continuous manufacturing process of a flux-cored welding wire are to be described below. So, the above-described requirements (a) to (c), which are premises of the flux filling method of the present invention, will be first described in order.
    Requirements (a) to (c):
    In FIGS. 1 and 2, reference numeral 100a denotes a half-formed hoop that runs in the direction of arrow in FIG.
    1 (left to right in the figure) and that is formed into a U shape in cross section. Reference numeral 10 denotes a belt feeder, the terminal end of which is located over the hoop 100a. A small-diameter roll 12 at the terminal end and a large-diameter roll 13 at the starting end on the right side of the figure rotate a belt 11 toward the hoop 100a. The belt feeder 10 continuously feeds flux 3, 4, and 5 to an upwardly open portion 114 of the hoop 100a from a position over the hoop 100a and from a direction perpendicular to the running direction of the hoop 100a.
    Upstream of and over the belt feeder 10, a flux feed hopper 17 is installed. The flux feed hopper 17 constantly stores an adequate amount of flux for the continuous manufacturing process of a flux-cored wire. Through a feed pipe 16 installed under the hopper 17, flux 1 is caused to flow down continuously toward the surface of the belt feeder 10 (belt 11).
    It is preferable that, to reduce moisture in the flux 6 (105) fed to the hoop 100a, flux be dried in an off-line process (preliminary batch processing), or flux before feeding (filling) be heated and dried, for example, in the flux feed hopper 17. If the hydrogen content of a welding wire is high, a large quantity of porosities due to hydrogen is generated in the welded site, resulting in welding defects. Therefore, for the flux-cored welding wire, which is excellent in welding bead shape and welding efficiency compared to the solid wire, the low hydrogen content characteristic is an important quality characteristic. In this regard, it is preferable to previously control the moisture content in the flux within the range of 500 ppm or less.
    (Characteristic Requirements)
    Transportation of flux to hoop:
    As described above, when flux 1 is caused to flow down continuously toward the surface of the belt feeder 10 (belt 11), as in the requirement (d), and particularly as shown in FIG. 2, the lower end of the feed pipe 16 is installed close to the surface of the belt feeder 10. Due to this, the flux layer 1 in the feed pipe 16 does not fall freely but flows down while being continuously deposited (fed) as a flux layer 2 on the surface of the belt feeder 10 (belt 11). In addition, the deposited flux layer 2 is fed from the clearance Cl between the lower end of the feed pipe and the surface of the belt feeder and transported toward the hoop 100a as a flux layer 3 having a uniform thickness t and density.
    In other words, the flux layer 2 deposited on the surface of the belt feeder 10 (belt 11) is moved toward the hoop 100a, divided by the lower end of the feed pipe 16, fed while coming into contact with this, and made into a flux layer 3 having a uniform thickness t and density. If the thickness t and density of the flux layer 3 being transported are not uniform, the amount of flux fed to the running hoop 100a is not constant. For this reason, the flux filling rate in the longitudinal direction of a flux- cored welding wire with a small diameter of 1.6 mm or less cannot be uniformed.
    Clearance Cl between feed pipe and belt feeder:
    The clearance (distance) Cl between the lower end of the feed pipe 16 and the surface of the belt feeder 10 (belt 11) situated close to each other is important for uniforming the thickness t and density of the flux layer 3 being transported. Cl is such a distance that the flux layer 1 in the feed pipe 16 can flow down while being continuously deposited on the surface of the belt feeder 10 (belt 11) without falling freely. If the clearance Cl is too large, the flux layer 1 in the feed pipe 16 falls freely, and the thickness t and density of the deposited flux layer 2 and the flux layer 3 being transported on the belt feeder 10 (belt 11) toward the hoop 100a cannot be uniformed. If the clearance Cl is too small, the flux layer 1 in the feed pipe 16 and the deposited flux layer 2 can clog the feed pipe 16.
    Cl is determined by various conditions on the flux feed side depending on the diameter of the hoop 100a, the running velocity of the hoop 100a (the velocity of the continuous manufacturing line of a flux-cored welding wire), the conditions affecting the uniformity in the flux filling rate in the longitudinal direction of the flux-cored wire. That is to say, Cl is determined, for example, by the running velocity v of the belt feeder 10 (belt 11), the amount of flux (weight of flux) determined by the height hi to the top surface of the flux in the feed pipe 16 and the internal diameter D1 of the feed pipe 16, and the thickness t of the flux layer 3 being transported (determined by the contact between the deposited flux layer 2 and the lower end of the feed pipe 16). These conditions vary greatly depending on the specification and conditions of the continuous manufacturing process of a flux-cored wire. However, since Cl is equal to the thickness t of the flux layer to be described below, Cl is selected from numerical values within a range of 10 mm or less, like the thickness t of the flux layer .
    Flux height hi:
    As described above, the flux height hi in the feed pipe 16 (that is to say, the height from the belt 11 to the top surface of flux) also affects the thickness t and density of the flux layer 3 being transported. For this reason, it is preferable that the flux height hi be within a certain range. To control the flux height hi, it is preferable that the feed pipe 16 be made of transparent plastic so that the flow and height of the flux in the feed pipe 16 can be seen from outside. This makes it possible to monitor and regulate the height hi of the flux in the feed pipe 16 from outside using a sensor such as an optical sensor or visually and to thereby precisely control the amount of flux (weight of flux) to be filled.
    Thickness t of flux layer 3:
    As described above, by bringing the lower end of the feed pipe 16 and the surface of the belt feeder 10 (belt 11) close to each other, the deposited and moving flux layer 2 is fed while coming into contact with the lower end of the feed pipe 16, and is transported as a flux layer 3 with a thickness t toward the hoop 100a. That is to say, the lower end of the feed pipe 16 serves as a dam that holds back surplus flux in the upper part of the flux layer 3 and supplies the flux to places where the thickness is insufficient, and uniforms the thickness t and density. Therefore, the clearance (distance) Cl is equal to the thickness t of the flux layer 3 being transported to the hoop 100a. In addition, it is ensured that the width D2 (shown in FIG. 1) of the flux layer 3 being transported is substantially the same as the internal diameter D1 of the supply tube.
    Of course, in addition, it is necessary to regulate the amount of flux 1 (amount of flux to be filled, weight of flux) flowing down through the feed pipe 16, which is determined by the flux height hi and internal diameter D1 of the feed pipe 16, and the transport velocity v of the belt feeder 10.
    However, in the continuous manufacturing process of a flux-cored wire with a small diameter of 1.6 mm or less, the amount of flux fed to the running hoop 100a is not very-large and is limited. In this regard, the thickness t of the flux layer deposited on the surface of the belt feeder 10 (belt 11) and transported toward the hoop 100a need not exceed 10 mm. Therefore, the thickness t of the flux layer and the clearance (distance) Cl are selected from numerical values within a range of 10 mm or less.
    Feeding of flux to hoop:
    As described above, the flux layer 3 transported by the belt feeder 10 is continuously fed from the terminal end 11a of the belt feeder 10 to the upwardly open portion 114 of the hoop 100a running under the terminal end 11a of the belt feeder 10 and from a direction perpendicular to the running direction of the hoop 100a (shown by arrow in FIG. 1).
    In this case, as in the requirement (f), a guide plate 14 for flux is installed. The guide plate 14 is installed, as shown in FIGS. 1 and 2, toward the upwardly open portion 114 of the running hoop 100a so as to block the flowing-down route of the flux 4 flowing down from the terminal end 11a of the belt feeder under the terminal end 11a of the belt feeder. Reference numeral 15 in FIG. 2 denotes a shielding plate for preventing flux from spattering, the shielding plate 15 being installed across the hoop 100a from the guide plate 14.
    Toward the guide plate 14, as in the requirement (g), the transported flux layer 3 is caused to flow down from the terminal end 11a of the belt feeder, laminarly like the flux layer 4. To cause flux to flow down laminarly toward the guide plate 14, the distance dl and height h2 from the terminal end 11a of the belt feeder to the surface of the guide plate 14 with which the flux layer 4 collides, the angle Θ of the surface of the guide plate 14 with which the flux layer 4 collides, and the running velocity v of the belt feeder 10 (belt 11) (the transport velocity of the flux layer 3) are balanced with each other.
    The term "laminarly" means that there is an appropriate distance between fine particles of flux and the flowability of flux is favorable. That is to say, the term "laminarly" means that flux flows, flows down, or slides down smoothly without being partly interrupted or deflected, and the flow is uniform in thickness and density in the width direction and flow direction.
    Running velocity v of belt feeder 10 (transport velocity of flux layer 3):
    As described above, the running velocity v of the belt feeder 10 affects the uniformity in thickness t and density of the flux layer 3 being transported. Depending on the running velocity v of the belt feeder 10, the flux may not be able to flow down toward the collision surface of the guide plate 14 laminarly like the flux layer 4, and the flux after collision may not be able to slide down on the guide plate 14 laminarly like the flux layer 5 without falling freely.
    If the running velocity v is too high, the thickness t and density of the flux layer 3 being transported on the belt feeder 10 cannot be uniformed in spite of the clearance Cl between the lower end of the feed pipe 16 and the surface of the belt feeder 10 arranged close to each other. In addition, the increased velocity at which flux collides with the guide plate 14 makes it difficult for the flux layer 4 colliding with the guide plate 14 to flow down laminarly, and for the flux layer 5 after collision to slide down laminarly.
    If the running velocity v is too low, the flux layer 1 in the feed pipe 16 and the deposited flux layer 2 tend to clog the feed pipe 16. In addition, the flowability of the transported flux layer 3 at the terminal end 11a of the belt feeder is deteriorated, and a fall (free fall) not in a uniform layer but in clumps due to cracks or aggregation tends to occur. Therefore, in the continuous manufacturing process of a flux-cored wire with a small diameter of 1.6 mm or less, the running velocity v capable of stably feeding flux is selected from numerical values within a range of 0.5 to 10 m/min according to the numerical value within a range of 10 mm or less of the thickness t of the flux layer or the clearance (distance) Cl.
    Laminarly sliding down of flux layer 5 on guide plate 14:
    The flux laminarly flowing down onto the collision surface of the guide plate 14 is caused to slide down on the guide plate 14 laminarly like the flux layer 5, without spattering from the collision surface and falling freely, so as to be continuously fed to the upwardly open portion 114 of the running hoop 100a. For this purpose, as described above, the distance dl and height h2 from the terminal end 11a of the belt feeder to the surface of the guide plate 14 with which the flux layer 4 collides, the angle Θ of the surface of the guide plate 14 with which the flux layer 4 collides, and the running velocity v of the belt feeder 10 (belt 11) (the transport velocity of the flux layer 3) are balanced with each other.
    The balance therebetween also affects the contact length between the guide plate 14 and the flux layer 4. To cause flux to slide down on the guide plate 14 laminarly like the flux layer 5, this contact length is preferably relatively long. In the continuous manufacturing process of a flux-cored welding wire with a small diameter of 1.6 mm or less, the contact length between the guide plate 14 and the flux layer 4 is preferably 5 mm or more.
    In this regard, the angle Θ of the surface of the guide plate 14 with which the flux layer 4 collides is important for regulating the contact length of the flux layer 4 on the collision surface of the guide plate 14. The angle Θ of the collision surface is preferably selected from a range of 40 to 90 degrees so that the contact length between the guide plate 14 and the flux layer 4 is 5 mm or more. The angle Θ of the surface of the guide plate 14 with which the flux layer 4 collides may be the same on the upper and lower sides of the guide plate 14 as shown by Θ1 in FIG. 2. Alternatively, as partially shown in FIG. 3, the upper side of the guide plate 14 may be angled by Θ2, and the lower side of the guide plate 14 may be substantially vertical or may be angled by an angle larger than Θ2.
    The above-described requirements for stably feeding flux, including preferable requirements and numerical value ranges, need to be regulated and determined not only theoretically but through trials, in view of the actual flow and deposition of the flux layers 1 and 2, uniformity in thickness t and density of the flux layer 3 being transported, and flowability of the flux layers 4 and 5. In other words, if the requirements are not regulated through trials, a predetermined amount of flux layer 6 (106) cannot be filled into the space in the running hoop 100a continuously and uniformly in the longitudinal direction of the hoop 100a.
    Filling rate of flux 106 into hoop 100a:
    The filling rate (apparent void ratio: ζ) of the flux 6 (106) into the hoop 100a formed in a U-shape is expressed as the following equation:
    where p denotes the bulk density (g/cm3) of the flux, σ denotes the internal space area (cm2) to be filled with flux at a time point E in the forming step, λ denotes the hoop running velocity (cm/min) at the time point E, and κ denotes the amount (g/min) of flux put in from a flux feeder 105.
    The apparent void ratio ζ is preferably selected from the following points of view. If the filling rate of flux is too high and the apparent void ratio ζ is too low, breakage of the wire tends to occur in the subsequent forming step or drawing step. Even if such a wire can be drawn into a flux-cored welding wire at a relatively low drawing velocity, spilling of the flux 106 off from the seam portion 114 tends to occur at the time of wire feeding during welding, which reduces the feedability. If the filling rate of the flux 106 is too low and the apparent void ratio ζ is too high, the flux 106 moves during drawing, so that the flux rate in the longitudinal direction of the wire changes, resulting in a deterioration in welding quality characteristic. Therefore, the apparent void ratio ζ is preferably 5 to 10%. If the apparent void ratio ζ is within this range, the change in flux filling rate in the longitudinal direction of the wire is small, and a flux-cored welding wire of favorable quality characteristics can be manufactured.
    Conventional flux filling method:
    Unlike the flux filling method of the present invention, in the conventional general flux filling method, as shown in FIG. 5, the transported flux layer 106a is caused to fall freely from the terminal end 11a of the belt feeder 10 to the upwardly open portion 114 of the running U-shaped hoop 100a. Therefore, although the prior requirements (a) to (c) of the present invention are satisfied, the characteristic requirements (d) to (g) of the present invention are not satisfied. If all of the characteristic requirements (d) to (g) of the present invention are not satisfied, the flux filling rate in the longitudinal direction of a flux-cored welding wire with a small diameter of 1.6 mm or less cannot be uniformed.
    That is to say, the conventional flux filling method does not satisfy all or some of the requirement (d): continuous deposition on the surface of the belt feeder, flowing down, or feeding of a flux layer, the requirement (e): regulation of the thickness of the flux layer, the requirement (f): guide plate for flux, and the requirement (e): laminarly falling down onto the guide plate and laminarly sliding down on the guide plate of flux.
    Therefore, as shown in FIG. 6, the hoop 100a is inevitably ununiformly filled with flux in the longitudinal direction shown by the horizontal arrow in the figure. In other words, the hoop 100a is ununiformly filled with flux in the longitudinal direction like a discontinuous wave. As a result, as shown in FIG. 7, the flux filling rate in the longitudinal direction of the flux-cored welding wire 110 completed as a product, and the thickness or external diameter of the hoop serving as a casing tend to be ununiform. In addition, the extensibility of the hoop serving as a casing also varies depending on the flux filling rate, and mechanical characteristics, such as the extensibility in the longitudinal direction, of the flux-cored welding wire 110 become ununiform.
    Continuous manufacturing process of flux-cored wire:
    Next, with reference to FIGS. 4A and 4B, a description will be given of the continuous manufacturing process of a flux-cored wire on which the present invention is premised. FIG. 4A is an explanatory diagram (partly plan view) schematically showing a manufacturing process of a flux-cored wire. FIG. 4B is an explanatory diagram showing the cross sectional shape of a hoop in each forming step of FIG.
    4A.
    An uncoiled hoop 100 is, first, cleaned and degreased in advance by a cleaning and degreasing step 102. The hoop 100 after cleaning and degreasing is coated with a trace quantity of non-hydrogen-bearing lubricant or anticorrosive oil only on the surface of the hoop 100 to serve as the wire surface in a lubricant coating step 103a. The hoop 100 coated with lubricant is formed from its flat cross sectional shape shown in A of FIG. 4B into a hoop 100a that is U-shaped in cross section as shown in B of FIG. 4B by a forming roller row (group) 104a.
    The hoop 100a formed in a U-shape in cross section is fed with flux 106 from the flux feeder 105 described with reference to FIGS. 1 and 2. Thus, as shown in C of FIG. 4B, the U-shaped space in the hoop 100a is filled with the flux 106 at the given filling rate (void ratio).
    The U-shaped hoop 100a filled with flux 106 is then further formed into a tubular wire 100b shown in D of FIG.
    4B by a forming roller row 104b.
    The formed tubular wire 100b is then coated with the lubricant on the surface of the wire 100b in a lubricant coating step 103b, and is thereafter drawn. As shown in E to F of FIG. 4B, the wire is reduced in diameter from the wire 100c to the wire lOOd by the primary drawing. Further, as shown in F to G of FIG. 4B, the wire is reduced in diameter from the wire lOOd to the wire 100e of the product diameter by the secondary drawing. The secondary drawing step is followed by a means (step) 108 for physically removing the lubricant, and the oil coating means 109 in an in-line manner. A skin pass finishing drawing step by a hole die 501 may be inserted prior to the drawing lubricant coating step. After being coated with oil in the secondary drawing step, the wire is wound by a winder as a product wire 110.
    [Example 1]
    An example of the present invention will be described. Flux-cored welding wires with a product diameter of 1.2 mm were manufactured through the flux-cored welding wire manufacturing process shown in FIG. 4A, using a commercially available hoop made of a mild steel sheet, using a flux that contains Fe-Cr and zircon sand as major ingredients, and using the lubricant that contains molybdenum disulfide as a sulfur extreme pressure agent. The flux-cored welding wires were manufactured from a hoop with a width W of 12 mm, and a thickness t of 0.96 mm, the ratio t/W of the thickness t to the width W being 0.08.
    The U-shaped hoop 100a is filled with flux by the flux feeder shown in FIGS. 1 and 2 (corresponding to 105 in FIG. 4A) under the above-described favorable conditions. That is to say, the lower end of the feed pipe 16 was installed close to the surface of the belt feeder 10 (belt 11) with a clearance Cl of 1 mm therebetween so that the flux layer 1 in the feed pipe 16 can flow down while being continuously deposited on the surface of the belt feeder 10 (belt 11), without falling freely.
    In addition, the deposited flux layer 2 was divided by the lower end of the feed pipe 16, and a flux layer 3 with a uniform thickness t of 1 mm and a uniform density was transported toward the hoop 100a. The flux height hi and internal diameter Dl of the feed pipe 16, the amount of flux 1 flowing down through the feed pipe 16, and the transport velocity v of the belt feeder 10 were also regulated.
    The transported flux layer 3 was continuously fed from the terminal end 11a of the belt feeder 10 to the upwardly open portion 114 of the hoop 100a running thereunder, through the guide plate 14 for flux, in a direction perpendicular to the running direction of the hoop 100a. To cause the transported flux layer 3 to flow down toward the guide plate 14 laminarly like the flux layer 4, the distance dl and height h2 from the terminal end 11a of the belt feeder to the surface of the guide plate 14 with which the flux layer 4 collides, the angle Θ of the surface of the guide plate 14 with which the flux layer 4 collides, and the running velocity v of the belt feeder 10 were balanced with each other. In addition, the distance dl and height h2, the angle Θ of the collision surface, and the running velocity v of the belt feeder 10 were balanced with each other so that the flux laminarly flowing down onto the guide plate 14 can slide down on the guide plate 14 laminarly like the flux layer 5 without falling freely and can be continuously fed to the open portion 114.
    More specifically, according to the predetermined distance dl and height h2, the angle Θ of the collision surface was regulated within a range of 50 to 80 degrees, and the running velocity v was regulated within a range of 5 to 10 m/min so that the contact length between the guide plate 14 and the flux layer 4 is 5 mm or more. These were regulated through trials so that the flux layers 3, 4, and 5 are uniform layers. The filling rate (apparent void ratio: ζ) of flux 6 (106) of the continuously-manufactured flux-cored welding wires was 7%.
    Under the above conditions, flux-cored welding wires with a product diameter of 1.2 mm were continuously manufactured. The resulting wires had no abnormal or unsteady parts, that is, parts where the amount of flux is too small or zero, or parts where the diameter of the flux-cored wire is ununiform. The detection of the abnormal or unsteady parts was performed with respect to the wire lOOd (F of FIG. 4B) after the primary drawing in FIG. 4A, before winding in an in-line manner, while running the flux-cored wire, with a measurement detection device that uses an electromagnetic induction phenomenon and that is disclosed in Japanese Patent No. 3553761.
    The highest primary drawing velocity at which stable drawing can be performed was 300 m/min, and the highest secondary drawing velocity at which stable drawing can be performed was 1000 m/min. The form accuracy (roundness) of the wound flux-cored welding wires was measured with RONDCOM 30B roundness measuring instrument manufactured by Tokyo Seimitsu Co., Ltd. The variation of the roundness was less than ±5 μπι. This shows that the present invention makes it possible to manufacture a flux-cored welding wire that is uniform in the flux filling rate in the wire longitudinal direction and has high roundness, even if a hoop runs at high velocity and has a small diameter.
    The wire feedability of the flux-cored welding wires was evaluated as being excellent. The wires could be fed uninterruptedly and smoothly. The weldability in the butt welding between mild steel sheets (1 mmt) was also evaluated as being excellent. The arc was consistently stable, there was no welding defect in the welded part, and the toughness of the joint was excellent. When evaluating the wire feedability, a general-purpose wire feeder was used, and the wire feedability to a general-purpose CO2 gas shielded welding machine was evaluated. When evaluating the weldability, CO2 gas shielded welding was performed under the following welding conditions: welding current: 300 A; welding voltage: 32 V; welding speed: 30 cm/mih; and CO2 gas shield gas: 25 L/min. This shows that the present invention makes it possible to increase the drawing velocity and to manufacture flux-cored welding wires with excellent quality characteristics.
    The above results show the significance of the flux filling method in the continuous manufacturing process of a flux-cored welding wire of the present invention that can fill the space in a hoop with flux continuously and uniformly even if the hoop runs at high velocity and has a small diameter.
    The present invention can provide a flux filling method that can fill the space in a hoop with flux continuously and uniformly even if the hoop runs at high velocity and has a small diameter. Therefore, the present invention is suitable to be applied to a continuous manufacturing process of a flux-cored welding wire that is required to have high production efficiency and quality assurance.
    权利要求:
    Claims (2)
    [1]
    A method used in a manufacturing process for a flux-filled welding wire, the process comprising the steps of: forming a steel band into a tubular form, filling the advancing steel band with flux during forming, and further pulling out the tubular flux filled wire, comprising the method of filling a space in the steel strip with flux and comprising the following measures (a) to (g): (a) the flux is continuously supplied to an upwardly open portion of the steel strip which is in section a U-shape is formed and advances, from a position above the steel band and from a direction perpendicular to the direction of travel of the steel band; (b) the flux is supplied by a feed belt that rotates with its terminal end in the position above the steel belt; (c) a funnel for supplying the flux is installed upstream of and above the feed belt, and a continuous downward flow from the flux to the surface of the feed belt is provided by a feed pipe installed under the funnel; (d) the lower end of the feed pipe is installed close to the surface of the feed belt so that the flux layer can flow down into the feed pipe and thereby continuously deposit on the surface of the feed belt without falling free, and such that the deposited flux layer can be supplied from the space between the lower end of the feed pipe and the surface of the feed belt and can be transported in the direction of the steel belt; (e) the amount of flux flowing down through the feed pipe and the transport speed of the feed belt are controlled such that the space between the lower end of the feed pipe and the surface of the feed belt is equal to the thickness of the flux layer that is on the surface of the feed belt. feed belt is deposited and transported in the direction of steel belt and such that the width of the flux layer being transported is substantially the same as the inner diameter of the feed pipe; (f) a flux guide plate is installed below the terminal end of the feed belt, in the direction of the upwardly open portion of the advancing steel band so as to block the route of the flux flowing down from the terminal end of the feed belt; and (g) the flux being transported on the feed belt is caused to flow laminarly from the terminal end of the feed belt toward the guide plate such that, after having flowed down laminarly, the flux on the guide plate toward the bottom slides without falling free and is continuously supplied to the upwardly open portion of the moving steel strip, and the space in the steel strip is continuously filled with a predetermined amount of flux.
    [2]
    The method of filling with flux according to claim 1, wherein the flux-filled welding wire has a small diameter of 1.6 mm or less.
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    同族专利:
    公开号 | 公开日
    JP2010194596A|2010-09-09|
    CN101817131A|2010-09-01|
    KR101159423B1|2012-06-28|
    NL2004289C2|2011-11-01|
    CN101817131B|2016-05-11|
    KR20100097618A|2010-09-03|
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    法律状态:
    优先权:
    申请号 | 申请日 | 专利标题
    JP2009044278|2009-02-26|
    JP2009044278A|JP2010194596A|2009-02-26|2009-02-26|Method of filling flux|
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