永久型陰極板導(dǎo)電桿銅—鋼異種金屬連接工藝及性能分析
發(fā)布時(shí)間：2018-08-02 18:08
【摘要】：永久型陰極板銅電解技術(shù)是一種高效綠色的新型銅電解技術(shù)。此種技術(shù)的重要特點(diǎn)是將傳統(tǒng)方法中只能使用一次的電解始極板替換為可以反復(fù)使用的不銹鋼陰極板。由于傳統(tǒng)電解方法需要對(duì)工藝生產(chǎn)中種板加工系統(tǒng)和始極板剝離系統(tǒng)投入大量的人力和物力,而永久型陰極板銅電解技術(shù)則恰好省略了這兩大系統(tǒng),因而其生產(chǎn)成本更低,生產(chǎn)效率更高。永久型陰極板銅電解技術(shù)因其效率高,壽命長(zhǎng),產(chǎn)量高,綠色環(huán)保特別適合優(yōu)質(zhì)電解銅大批量、大規(guī)模的生產(chǎn),所以其成為了目前全球銅電解技術(shù)的主要發(fā)展趨勢(shì),也成為了我國(guó)當(dāng)前被大型銅電解廠(chǎng)和在建銅電解工程所更換和引進(jìn)的主流技術(shù)。陰極板導(dǎo)電桿作為此項(xiàng)新型技術(shù)的關(guān)鍵部件,在我國(guó)目前還沒(méi)有出現(xiàn)完全自主和廣泛使用的結(jié)構(gòu)設(shè)計(jì)和制造工藝,仍需要大量進(jìn)口。因此,實(shí)現(xiàn)陰極板導(dǎo)電桿國(guó)產(chǎn)化的工藝與制造具有重要的工程與經(jīng)濟(jì)意義。由于永久型陰極板導(dǎo)電桿一般采用鋼銅包覆結(jié)構(gòu),焊縫處于結(jié)構(gòu)內(nèi)部,其結(jié)合界面具有不可見(jiàn)性,而且銅和鋼物理性能相差較大,在焊接過(guò)程中容易產(chǎn)生變形、裂紋等焊接缺陷,因此使用傳統(tǒng)的焊接工藝很難適應(yīng)此種特殊結(jié)構(gòu)的連接。高頻感應(yīng)釬焊具有焊接溫度較低,熱源可控性強(qiáng),內(nèi)部焊縫的熱源可達(dá)性好,而且釬料中的合金元素能有效避免焊接缺陷產(chǎn)生等優(yōu)點(diǎn)。所以本文提出了采用高頻感應(yīng)釬焊的方法進(jìn)行永久型陰極板導(dǎo)電桿的模擬釬焊試驗(yàn)。針對(duì)永久型陰極板導(dǎo)電桿的模擬試驗(yàn),首先,本文選用Sn-Cu系二元共晶釬料作為實(shí)驗(yàn)所用釬料,并在焊接前在不銹鋼工件的施焊表面進(jìn)行釬料的預(yù)置涂敷;其次,本課題共設(shè)計(jì)十八組工藝試驗(yàn),主要分為五大部分,其中涉及加熱電流、中停時(shí)間等五個(gè)重要的工藝參數(shù)并在其中涉及兩種工件類(lèi)型;然后,再利用光學(xué)顯微鏡,掃描電子顯微鏡(SEM),能譜儀(EDS),X射線(xiàn)衍射儀(XRD)分析研究了不同工藝參數(shù)下形成釬焊接頭的微觀(guān)組織、物相種類(lèi)及元素分布,同時(shí)采用智能金屬導(dǎo)體電阻率儀、電子萬(wàn)能試驗(yàn)機(jī)和顯微硬度計(jì)對(duì)銅-鋼焊接接頭的導(dǎo)電性能、硬度、強(qiáng)度等各項(xiàng)性能進(jìn)行了檢測(cè),通過(guò)不同試樣各項(xiàng)性能的不同反映出試樣在化學(xué)成分、組織結(jié)構(gòu)上對(duì)接頭性能的影響以及實(shí)驗(yàn)工藝對(duì)接頭性能造成的差異。通過(guò)光學(xué)顯微鏡,掃描電子顯微鏡和能譜儀的分析結(jié)果可得,第一種工件在合理工藝參數(shù)下焊后釬縫無(wú)明顯的焊接缺陷且界面清晰;接頭可明顯分為銅側(cè)反應(yīng)擴(kuò)散層、焊縫中間層和鋼側(cè)反應(yīng)擴(kuò)散層;銅側(cè)反應(yīng)擴(kuò)散層的厚度均大于鋼側(cè)反應(yīng)擴(kuò)散層的厚度;第二種工件為銅鋼包覆模擬工件,此類(lèi)工件焊后釬縫平整無(wú)缺陷;接頭處只含有一個(gè)反應(yīng)擴(kuò)散層,此反應(yīng)擴(kuò)散層與銅側(cè)母材無(wú)明顯界面區(qū)分,與不銹鋼側(cè)母材的界面清晰明顯;焊接時(shí)由于包覆結(jié)構(gòu),工件內(nèi)部熱量集中,預(yù)置錫層完全擴(kuò)散至銅側(cè)母材中。綜合釬焊接頭組織形貌、元素分布、物相組成和試樣導(dǎo)電性能檢測(cè)結(jié)果可得,影響試樣接頭導(dǎo)電性能的原因主要有兩個(gè):第一,加熱電流越大,加熱時(shí)間越長(zhǎng),保溫時(shí)間越長(zhǎng),即工件的焊接熱輸入過(guò)大,試樣的導(dǎo)電性能則會(huì)出現(xiàn)下降趨勢(shì),這主要是由于工件焊接時(shí),長(zhǎng)時(shí)間處于高溫條件下Cu與Sn會(huì)生成Cu3Sn,此銅錫化合物會(huì)對(duì)導(dǎo)電過(guò)程中載流子的定向移動(dòng)速度產(chǎn)生阻礙,導(dǎo)致試樣導(dǎo)電率的下降;第二,接頭缺陷越少,致密性越好,導(dǎo)電性能越好,這主要是由于接頭連續(xù)性不好,接觸表面連接情況不均一影響電流在高低電勢(shì)的流動(dòng)。通過(guò)接頭強(qiáng)度接頭硬度的檢測(cè)結(jié)果可得,第二類(lèi)工件的接頭拉伸強(qiáng)度明顯優(yōu)于第一類(lèi)工件的接頭拉伸強(qiáng)度,第二類(lèi)工件的接頭硬度也高于第一類(lèi)工件的接頭硬度,這說(shuō)明包覆結(jié)構(gòu)會(huì)使焊接時(shí)的熱量在內(nèi)部較集中,導(dǎo)致銅錫鋼進(jìn)行了充分的冶金反應(yīng)并且生成了較多類(lèi)似Cu3Sn的脆硬相。綜合以上試驗(yàn)及檢測(cè)結(jié)果,本文獲得的最佳工藝參數(shù)能夠得到焊縫成形美觀(guān)、連接強(qiáng)度優(yōu)良、導(dǎo)電性能良好的銅-鋼釬焊接頭。
[Abstract]:The permanent cathode plate copper electrolysis technology is a new type of high efficiency and green copper electrolysis technology. The important feature of this technology is to replace the electrolytic initial plate which can only be used once in the traditional method as the stainless steel cathode plate which can be used repeatedly. Because the traditional electrolysis method needs the processing system of the seed plate and the peeling system of the beginning plate in the process production. The permanent cathode plate copper electrolysis technology has omitted the two systems, thus the production cost is lower and the production efficiency is higher. The permanent cathode plate copper electrolysis technology has high efficiency, long life, high output, green environmental protection especially suitable for large quantity of electrolytic copper, so it is produced in large scale. As the main development trend of the current global copper electrolysis technology, it has also become the mainstream technology for the replacement and introduction of the large copper electrolysis plant and the copper electrolysis project in China. As the key component of this new technology, the cathode plate conductance pole has not yet appeared in our country, which is fully Autonomous and widely used. Therefore, it is still necessary to import a lot of materials. Therefore, it is of great engineering and economic significance to realize the process and manufacture of the homemade of the cathodic plate conductance rod. As the permanent cathode plate guide rod is usually covered with steel and copper cladding structure, the weld is inside the structure, its bonding interface is invisible, and the physical properties of copper and steel are quite different, and welding in welding. It is easy to produce welding defects such as deformation and crack in the process, so it is difficult to adapt to the connection of this special structure with the traditional welding process. High frequency induction brazing has the advantages of low welding temperature, strong controllability of heat source, good heat source of the internal weld, and the alloy elements in the solder can effectively avoid welding defects. In this paper, the simulation brazing test of permanent cathodic plate conductance rod is carried out by high frequency induction brazing. For the simulation test of permanent cathode plate conductance rod, first of all, the Sn-Cu two element eutectic solder is used as the filler of the experiment, and the preset coating on the welding surface of the stainless steel workpiece is applied before the welding. Secondly, we have designed eighteen groups of process tests, which are divided into five parts, including five important process parameters, such as heating current and mid stop time, and involving two kinds of workpiece types. Then, the different processes are analyzed by optical microscopy, scanning electron microscope (SEM), EDS, and X ray diffractometer (XRD). The microstructure, phase type and element distribution of the brazed joint are formed under the parameters, and the electrical properties, hardness and strength of the copper steel welded joint are detected by the intelligent metal conductor resistivity instrument, the electronic universal testing machine and the microhardness tester, and the sample in chemistry is reflected by the different properties of different samples. The influence of the composition and structure on the joint properties and the difference between the experimental process and the joint performance. Through the optical microscope, the scanning electron microscope and the analytical results of the energy spectrometer, the first workpiece has no obvious welding defects and the interface is clear under the reasonable process parameters, and the joint can be clearly divided into the copper side reaction expansion. The thickness of the reaction diffusion layer on the copper side is larger than the thickness of the reaction diffusion layer on the steel side, the thickness of the reaction diffusion layer on the copper side is greater than the thickness of the reaction diffusion layer on the steel side. The second workpiece is coated with copper and steel, and the joint is smooth and smooth after welding. The joint is only containing a reaction diffusion layer, and the reaction diffusion layer has no obvious interface distinction with the copper side material. The interface of the stainless steel side is clear and obvious; the coating structure and the internal heat of the workpiece are concentrated in the welding. The prepositioned tin layer diffuses completely to the copper side material. The microstructure of the joint, the distribution of elements, the composition of the phase and the test result of the conductivity of the sample can be obtained. There are two main reasons that affect the conductivity of the joint. The longer the heating time is, the longer the heating time is, the longer the heat preservation time is, that is, the heat input of the workpiece is too large and the conductivity of the sample will decline. This is mainly because the Cu and Sn will generate Cu3Sn for a long time under high temperature, and the copper tin compound will produce resistance to the directional moving speed of the carrier in the conduction process. Second, the less defects of the joint, the less the defects, the better the compactness and the better the electrical conductivity, which is mainly due to the poor continuity of the joint and the inhomogeneous contact of the contact surface on the flow of the high and low potential. The tensile strength of the joint strength of the second kinds of workpiece is clear by the result of the hardness of joint strength joint. The tensile strength of the joint of the first kind is superior to that of the first kind, and the joint hardness of the second kind of workpiece is also higher than the hardness of the first kind of workpiece. This indicates that the coating structure will make the heat of the welding more concentrated inside, leading to the full metallurgical reaction of the copper tin steel and the formation of more like Cu3Sn like brittle hard phases. The results show that the copper-steel brazed joint with beautiful weld shape, excellent bonding strength and good conductivity can be obtained by the optimum process parameters obtained in this paper.
【學(xué)位授予單位】：蘭州理工大學(xué)
【學(xué)位級(jí)別】：碩士
【學(xué)位授予年份】：2017
【分類(lèi)號(hào)】：TG457.1
[Abstract]:The permanent cathode plate copper electrolysis technology is a new type of high efficiency and green copper electrolysis technology. The important feature of this technology is to replace the electrolytic initial plate which can only be used once in the traditional method as the stainless steel cathode plate which can be used repeatedly. Because the traditional electrolysis method needs the processing system of the seed plate and the peeling system of the beginning plate in the process production. The permanent cathode plate copper electrolysis technology has omitted the two systems, thus the production cost is lower and the production efficiency is higher. The permanent cathode plate copper electrolysis technology has high efficiency, long life, high output, green environmental protection especially suitable for large quantity of electrolytic copper, so it is produced in large scale. As the main development trend of the current global copper electrolysis technology, it has also become the mainstream technology for the replacement and introduction of the large copper electrolysis plant and the copper electrolysis project in China. As the key component of this new technology, the cathode plate conductance pole has not yet appeared in our country, which is fully Autonomous and widely used. Therefore, it is still necessary to import a lot of materials. Therefore, it is of great engineering and economic significance to realize the process and manufacture of the homemade of the cathodic plate conductance rod. As the permanent cathode plate guide rod is usually covered with steel and copper cladding structure, the weld is inside the structure, its bonding interface is invisible, and the physical properties of copper and steel are quite different, and welding in welding. It is easy to produce welding defects such as deformation and crack in the process, so it is difficult to adapt to the connection of this special structure with the traditional welding process. High frequency induction brazing has the advantages of low welding temperature, strong controllability of heat source, good heat source of the internal weld, and the alloy elements in the solder can effectively avoid welding defects. In this paper, the simulation brazing test of permanent cathodic plate conductance rod is carried out by high frequency induction brazing. For the simulation test of permanent cathode plate conductance rod, first of all, the Sn-Cu two element eutectic solder is used as the filler of the experiment, and the preset coating on the welding surface of the stainless steel workpiece is applied before the welding. Secondly, we have designed eighteen groups of process tests, which are divided into five parts, including five important process parameters, such as heating current and mid stop time, and involving two kinds of workpiece types. Then, the different processes are analyzed by optical microscopy, scanning electron microscope (SEM), EDS, and X ray diffractometer (XRD). The microstructure, phase type and element distribution of the brazed joint are formed under the parameters, and the electrical properties, hardness and strength of the copper steel welded joint are detected by the intelligent metal conductor resistivity instrument, the electronic universal testing machine and the microhardness tester, and the sample in chemistry is reflected by the different properties of different samples. The influence of the composition and structure on the joint properties and the difference between the experimental process and the joint performance. Through the optical microscope, the scanning electron microscope and the analytical results of the energy spectrometer, the first workpiece has no obvious welding defects and the interface is clear under the reasonable process parameters, and the joint can be clearly divided into the copper side reaction expansion. The thickness of the reaction diffusion layer on the copper side is larger than the thickness of the reaction diffusion layer on the steel side, the thickness of the reaction diffusion layer on the copper side is greater than the thickness of the reaction diffusion layer on the steel side. The second workpiece is coated with copper and steel, and the joint is smooth and smooth after welding. The joint is only containing a reaction diffusion layer, and the reaction diffusion layer has no obvious interface distinction with the copper side material. The interface of the stainless steel side is clear and obvious; the coating structure and the internal heat of the workpiece are concentrated in the welding. The prepositioned tin layer diffuses completely to the copper side material. The microstructure of the joint, the distribution of elements, the composition of the phase and the test result of the conductivity of the sample can be obtained. There are two main reasons that affect the conductivity of the joint. The longer the heating time is, the longer the heating time is, the longer the heat preservation time is, that is, the heat input of the workpiece is too large and the conductivity of the sample will decline. This is mainly because the Cu and Sn will generate Cu3Sn for a long time under high temperature, and the copper tin compound will produce resistance to the directional moving speed of the carrier in the conduction process. Second, the less defects of the joint, the less the defects, the better the compactness and the better the electrical conductivity, which is mainly due to the poor continuity of the joint and the inhomogeneous contact of the contact surface on the flow of the high and low potential. The tensile strength of the joint strength of the second kinds of workpiece is clear by the result of the hardness of joint strength joint. The tensile strength of the joint of the first kind is superior to that of the first kind, and the joint hardness of the second kind of workpiece is also higher than the hardness of the first kind of workpiece. This indicates that the coating structure will make the heat of the welding more concentrated inside, leading to the full metallurgical reaction of the copper tin steel and the formation of more like Cu3Sn like brittle hard phases. The results show that the copper-steel brazed joint with beautiful weld shape, excellent bonding strength and good conductivity can be obtained by the optimum process parameters obtained in this paper.
【學(xué)位授予單位】：蘭州理工大學(xué)
【學(xué)位級(jí)別】：碩士
【學(xué)位授予年份】：2017
【分類(lèi)號(hào)】：TG457.1
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