The 19th Beijing Essen Welding & Cutting Fair
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Application cases and solutions for welding materials for pressure vessel manufacturing
Main products and common welding consumables
Our company is a pressure vessel manufacturing and design unit, which covers energy, chemical, petrochemical, coal chemical, fine chemical, fertilizer, paper, clean energy and offshore engineering, such as various towers, heat exchangers, and reactions. And converters, etc.
Commonly used welding consumables include carbon steel, chrome molybdenum steel, low temperature steel (2.5Ni, 3.5Ni), low alloy high strength steel, stainless steel (including dual phase and urea grade) and nickel base alloy, among which carbon steel, chromium Molybdenum steel, low temperature steel (2.5Ni, 3.5Ni) and low alloy high strength steel are mainly composed of welding rod and submerged arc welding wire, stainless steel (including dual phase and urea grade), nickel base alloy, etc., mainly composed of welding rod and welding strip.
In recent years, with the improvement of equipment capacity and technological level, the degree of welding automation has also increased accordingly. The proportion of welding rods has been gradually reduced, the proportion of welding wire and welding belts has been gradually increased, and the production efficiency and welding quality have also increased accordingly.
Welding material application case and solution
In actual production, the recommended welding consumables according to the relevant standards may not meet the additional indicators required, such as the performance index of some steel after normalizing + tempering, and some welding methods are used for the first time, after the welding test is available. For production in our factory, the examples are listed below for reference.
Case 1: Selection of welding consumables for Q345R steel welded joints after normalizing + tempering
The mechanical tensile properties of Q345R steel in GB713-2008 and National Standard No. 1 are: plate thickness >60~100mm, Rm≥490MPa; plate thickness>100~150mm, Rm≥480MPa. The following test is carried out by using different welding consumables. As shown in Table 1, the test results of test Nos. 5-11, 9-83, and 121087 can satisfy the lower limit of the corresponding thickness. That is, when the welding rod is improved by two grades, the welding flux is specially customized, and the normal temperature tensile value after the evaluation reaches or exceeds the standard lower limit of the parent metal.
Case 2: Selection and application of electrode surfacing welding consumables
First, reduce the thickness of surfacing and save costs (the surface is not processed after surfacing).
The 8 sets of equipment manufactured by our company for a project require the whole surfacing to be welded with a 5mm thick stainless steel layer. The thickness of the submerged arc welding is about 8mm. The cost of welding consumables is about 1.6 million yuan, and the thickness of each welding material is reduced by 1mm. The cost savings of 200,000 yuan, the benefits are very impressive, so the target is reduced by at least 2mm. The welding test was carried out for the first time, and the results are shown in Table 2. The welding test was carried out for the second time, and the results are shown in Table 3.
It can be seen from Table 3 that by increasing the CrNi content of the base layer and changing the electroslag flux, the overlay welding of 5.5 mm thickness not only ensures the test results are acceptable, but also meets the requirement of a minimum thickness of 5 mm.
The submerged arc electrode surfacing dilution rate is 18%~25%, and the electroslag zone electrode surfacing dilution rate is 7%~10%. The most important thing for corrosion resistant surfacing is to reduce the dilution rate, and the electroslag surfacing can just guarantee at this point. Only from the perspective of welding consumables, at least 400,000 yuan can be saved.
Second, replace the nickel-based flux to ensure the appearance and quality of the appearance (the surface after surfacing is processed). The ammonia synthesis tower casing (multi-layer high pressure) manufactured by our company for a project has a bottom forging material of 12Cr2Mo1IV. It is required to weld a certain type of material according to requirements. The effect of welding with flux and submerged arc flux is shown in Fig. 1. It shows that for the first build-up welding, the fusion is very poor. After adjusting several welding parameters, the forming is not good, even according to the laboratory parameters given by the welding material factory is not good. The final reason for the analysis may be the problem of flux. The technical content of the flux is very high. After negotiation, the flux for electroslag is urgently purchased from Jingqun consumables. The surface of the surfacing is very well formed. Figure 2 shows the formation after surface penetration testing. effect.
Expectations and suggestions for the future development and development of welding consumables
As far as non-standard pressure vessel manufacturers are concerned, some special welding materials in China are still quite different from those in Europe, the United States and Japan, such as nickel-based, dual-phase steel, urea-grade stainless steel, 12Cr2Mo1 CrMo steel and other special purposes. For steel grades, the test samples provided by some domestic welding consumables manufacturers do not meet the technical additional requirements, and the weldability is not as good as the imported materials. However, the biggest problem with imported welding consumables is that the procurement cycle is too long and the procurement cost is too high, which seriously affects the manufacturing cycle of the product and increases the manufacturing cost. Therefore, we are very much looking forward to the rise of domestic welding consumables and the introduction of products that can compete with imports. It is also known that some welding consumables do not produce steel wire and steel strips themselves. Therefore, it is also expected that the country can vigorously support a part of the welding consumables to develop steel wire and steel strips themselves or jointly (seamlessly connect) to make better matching welding consumables. .
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