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WO2023066265A1 - 一种异形包覆型材 - Google Patents

一种异形包覆型材 Download PDF

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Publication number
WO2023066265A1
WO2023066265A1 PCT/CN2022/126020 CN2022126020W WO2023066265A1 WO 2023066265 A1 WO2023066265 A1 WO 2023066265A1 CN 2022126020 W CN2022126020 W CN 2022126020W WO 2023066265 A1 WO2023066265 A1 WO 2023066265A1
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WO
WIPO (PCT)
Prior art keywords
cladding
composite
stainless steel
special
welding
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PCT/CN2022/126020
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English (en)
French (fr)
Inventor
刘嘉勋
刘洪成
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天津市宁河县隆昌异型轧钢厂
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Publication of WO2023066265A1 publication Critical patent/WO2023066265A1/zh

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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16S—CONSTRUCTIONAL ELEMENTS IN GENERAL; STRUCTURES BUILT-UP FROM SUCH ELEMENTS, IN GENERAL
    • F16S3/00—Elongated members, e.g. profiled members; Assemblies thereof; Gratings or grilles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
    • B23K31/02—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to soldering or welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass

Definitions

  • the invention relates to a special-shaped cladding profile, which belongs to the technical field of metal manufacturing.
  • Stainless steel composite materials are usually made of stainless steel as cladding material, plain carbon steel or ordinary low alloy steel as base material, and composite materials are made by metallurgical bonding. This composite material has the advantages of corrosion resistance and rust resistance of stainless steel and high plasticity and low cost of ordinary steel, and has an incomparable price advantage over pure stainless steel of the same specification.
  • Stainless steel clad plates and stainless steel clad pipes are two typical products in stainless steel clad materials. At present, these two products have been widely used in engineering. Due to the incomparable cost-effectiveness of stainless steel composite materials and all stainless steel products, some other types of stainless steel composite materials have also emerged in recent years.
  • Explosive cladding is to place stainless steel plates on carbon steel substrates overlappingly, with a certain distance between the stainless steel plates and carbon steel substrates. Explosives are laid flat on the stainless steel plate, and the energy of explosive explosion causes the stainless steel plate to hit the carbon steel substrate at high speed, generating high temperature and high pressure to realize solid phase welding at the interface of the two materials.
  • Hot-rolled composite is made of carbon steel substrate and stainless steel plate in a physically pure state, rolled under high vacuum conditions. The two metals diffuse during rolling to achieve complete metallurgical bonding.
  • the above-mentioned manufacturing method is only suitable for manufacturing hot-rolled bars or hot-rolled profiles of various shapes, and cannot directly manufacture irregular-shaped composite steel profiles.
  • the primary technical problem to be solved by the present invention is to provide a special-shaped cladding profile.
  • a special-shaped cladding profile comprising:
  • a first composite material including a first core material and a first cladding material, the first cladding material covers the first core material and has different materials;
  • the second composite material includes a second core material and a second cladding material, the second cladding material covers the second core material and is a different material, the second cladding material and the first cladding material
  • the cladding is the same material
  • the second composite material is welded to the first composite material to form a weld seam within the first cladding material and the second cladding material;
  • the depth of the welding seam is smaller than the thickness of the first cladding material or the second cladding material.
  • the welding seam is a material for welding the cladding material.
  • the tensile strength of the deposited metal of the solder of the welding seam is higher than the tensile strength of the deposited metal of the solder required for welding the cladding material.
  • the first composite material constitutes the bottom of the special-shaped cladding profile, and multiple pieces of the second composite material together constitute the main body of the special-shaped cladding profile;
  • the welding seam includes a first welding seam and a second welding seam, the joints of two adjacent second composite materials are welded to form the first welding seam, and the welding depth of the first welding seam is smaller than that of the first welding seam
  • the thickness of the second cladding material; the joint of the first composite material and the second composite material is welded to form the second weld, and the welding depth of the second weld is smaller than that of the first cladding material and the thickness of the second cladding material.
  • the first core material and the first cladding material are integrated by a hot rolling process; the second core material and the second cladding material are integrated by a hot rolling process.
  • the main body includes two wing plates and a web, both of which are the second composite material, the two wing plates are parallel to each other, and the web Both ends of the plate are vertically connected to the midline positions of the two wing plates, so as to be spliced together to form an H-shaped main body.
  • the misalignment dimension between the wing plate and the web plate is not more than 1mm.
  • both the first composite material and the second composite material are stainless steel composite plates.
  • the special-shaped cladding profile provided by the technical solution of the invention solves the technical contradiction of low cost of carbon steel but no antirust and high cost of stainless steel. Therefore, the stainless steel composite profile of the present invention is anti-rust, low in cost, and high in structural strength, which solves the technical problem that the clad profile obtained by the hot rolling process cannot be a special-shaped profile, and is suitable for wide application, especially for outdoor applications.
  • Figure 1A is a schematic structural view of a special-shaped cladding profile provided by an embodiment of the present invention.
  • Fig. 1B is a partial sectional view of part B in Fig. 1A;
  • Fig. 2 is a flow chart of manufacturing a special-shaped cladding profile provided by an embodiment of the present invention.
  • one metal material located on the surface layer, cladding material
  • another metal material core material
  • the present invention utilizes coated plates or pipes to obtain special-shaped clad profiles by welding, and ensures that the clad material does not penetrate the outer surface during the welding process, so it can break through process limitations and obtain various special-shaped profiles. It not only takes advantage of the material advantages of clad profiles, but also reduces the processing cost of special-shaped profiles.
  • the following uses carbon steel clad stainless steel I-shaped profiles as an example for illustration.
  • Figure 1A is a special-shaped cladding profile provided by an embodiment of the present invention, which includes: a first composite material 1 and a second composite material 2, wherein the first composite material 1 constitutes the bottom plate of the special-shaped cladding profile , multiple pieces of the second composite material 2 jointly constitute the main part constituting the special-shaped cladding profile.
  • Both the first composite material 1 and the second composite material 2 use various carbon steels as core materials to reduce the proportion of stainless steel cladding materials and effectively reduce the overall cost of the product. Using various grades of stainless steel and two-way stainless steel as cladding materials is very convenient. Good anti-corrosion effect.
  • the present invention is not limited to the composite plate of carbon steel and stainless steel, as long as the base plate and the main body are both composite profiles, and the composite profile phase has the same cladding material, which is located on the outer surface of the entire composite profile , suitable for welding processing.
  • the invention is not limited to composite sheets, but may also be in other shapes, such as composite pipes (cladding covering the entire tubular core). Just to make the description clearer and easier to understand, the following only introduces the situation of composite panels.
  • the composite billet is formed by heating the cladding material and pressing it with the core material, and finally, the composite billet is heated to a certain temperature and then rolled to form the stainless steel clad plate. Based on the special shape of this product, it is impossible to prefabricate the carbon steel core material and then roll the stainless steel cladding material. Therefore, the present invention divides the stainless steel composite profile into several components and adopts a special The welding method welds each component into shape.
  • the first composite material 1 includes a first core material 101 and a first cladding material 102
  • the second composite material 2 includes a second core material 103 and a second cladding material 104
  • both the first core material 101 and the second core material 103 are made of metallic carbon steel
  • the first cladding material 102 and the second cladding material 104 are both made of stainless steel pipes.
  • the joints of multiple second composite materials 2 are welded to each other to form a first weld 3
  • the joints of the first composite material 1 and the second composite material 2 are welded to each other to form Second weld 4.
  • stainless steel materials have good corrosion resistance and are not easy to rust, but the cost is high; metal carbon steel materials are easy to oxidize and rust, but the cost is low.
  • the outer side of the material is provided with a cladding material that is not easy to rust. At the same time, during welding, the weld seam does not penetrate the cladding material, so that the core material does not come into contact with oxygen, thereby saving energy on the premise of ensuring corrosion resistance. Production cost of stainless steel composite profiles.
  • the bottom plate is the first composite material 1.
  • the first composite material 1 is a stainless steel composite plate.
  • the bottom plate 1 is in the shape of a rectangle.
  • the hole 11 is preferably a bolt hole, and the bolt hole 11 is used for installing a bolt connector 12 so as to be able to connect with other components.
  • the number and positions of the connecting holes 11 can be selected according to needs.
  • the main body includes a plurality of second composite materials 2.
  • the second composite material 2 is a stainless steel composite plate.
  • the dimensions and specifications of the multiple second stainless steel composite plates can be the same or different.
  • the multiple second stainless steel composite plates The plates are spliced together into a set shape, and then the joints of any two adjacent second stainless steel clad plates are fixed by set flux welding to form the first weld 3, so that multiple second stainless steel clad plates are welded into a Sets the body of the shape.
  • multiple second stainless steel composite plates include two wing plates 21 and a web 22, the two wing plates 21 are rectangular and parallel to each other, the web 22 is rectangular and the web 22 The two ends of each are vertically connected to the midline positions of the two wing plates 21, and the staggered size of the wing plate 21 and the web 22 is not more than 1mm, so as to be jointly spliced into an H-shaped main body.
  • the stainless steel composite member also needs to ensure the corrosion resistance of the cladding material in contact with the corrosive medium.
  • the misalignment of the cladding surface should not exceed 1mm, especially when the stainless composite steel plates of different thicknesses are aligned.
  • part of the stainless steel may be melted in the weld at the root of the base layer, which will increase the alloy elements of the weld metal at the root of the base layer, making the weld hard and brittle, and at the same time reduce the thickness of the butt joint at the wrong side.
  • the thickness of the stainless steel will reduce the service life, affect the quality of the weld on the surface of the cladding material, and make it difficult to ensure the corrosion resistance of the welded structure.
  • the H-shaped main body is a new profile, which not only has all the properties of H-shaped steel, but also has very good anti-corrosion properties on the surface, effectively solving the anti-corrosion problem in harsh corrosive environments.
  • the wing plate 21 and the web plate 22 of the H-shaped main body are formed by hot-rolling the stainless steel cladding material on the surface and the carbon steel or low-alloy structural steel at the core. That is, the core material is carbon steel or low-alloy structural steel, the cladding material is stainless steel, and the two are hot rolled into one.
  • cladding material Various grades of stainless steel and duplex stainless steel can be used for the cladding material; ordinary carbon structural steel and low alloy structural steel (such as: Q235, Q275, Q355, etc.) can be used as the core material.
  • ordinary carbon structural steel and low alloy structural steel such as: Q235, Q275, Q355, etc.
  • the weldability of dissimilar materials mainly depends on the metallurgical compatibility, physical properties, surface state, etc. of the two materials. The greater the difference in these properties between two or more materials to be welded, the poorer the weldability.
  • the weldability of dissimilar materials is also related to the welding process, including factors such as the size of the welded joint, the form of the groove, the orientation of the weld, the parameters of the welding process, and the operating level of the welding process.
  • the carbon content of carbon steel is higher than that of stainless steel, so it is easy to cause intergranular corrosion when welding stainless steel with carbon steel electrodes.
  • stainless steel electrodes low-carbon or even ultra-low carbon stainless steel electrodes should be selected; for carbon steel welding, carbon steel electrodes should be selected.
  • stainless steel electrodes are not used to weld carbon steel, because long-term contact between stainless steel and carbon steel will produce a "carburization reaction", which will affect the characteristics of stainless steel.
  • the grade of the welding wire is selected to be a stainless steel welding wire of one grade higher than that of the cladding material (stainless steel as the cladding material 102 ). That is, the tensile strength of the deposited metal of the solder of the weld seam is higher than the tensile strength of the deposited metal of the solder required for welding the cladding material stainless steel.
  • the weld seam is formed by a stainless steel wire welding process, but two stainless steel clad plates whose core material is carbon steel are welded into one. Also, as mentioned above, the welding does not penetrate through the stainless steel as the cladding material (shown by h1 and h2 in FIG. 1B ), so the "carburization reaction" does not occur.
  • the specifications of the H-shaped main body are: 1. Parts specifications within the YB3001-2005 standard; 2. Parts specifications within the GB/T11263-2005 standard. Part performance meets or exceeds the above two standards.
  • the length, size and tolerance of the product can be equal to the standard requirements, part technical requirements, and quality requirements meet or exceed the above two standards.
  • the H-shaped main body has the following advantages:
  • the model of the internal core material can be adjusted (for example: adjusting the internal core material from Q235 to Q275 or Q355), so as to effectively solve the strength of all stainless steel low problem
  • the position where the wing plate 21 and the web plate 22 are in contact can be welded and fixed by using a set flux.
  • the H-shaped main body in the above embodiment is only one embodiment, and in other embodiments, the shape of the main body can be adaptively changed as required.
  • the H-shaped main body After the H-shaped main body is welded, place the H-shaped main body on the base plate 1 so that the two wing plates 21 and one web 22 are in contact with the surface of the base plate 1. At this time, the set flux can be used to Weld and fix the positions where the two wing plates 21 and one web 22 are in contact with the bottom plate 1. At this time, the H-shaped main body and the bottom plate 1 are relatively fixed to form the stainless steel composite profile.
  • the set flux is A132 or A137.
  • the welding depth of the first welding seam 3 is not greater than the cladding material thickness of the second composite material 2
  • the welding depth of the second welding seam 4 is not greater than the first welding depth. Thickness of cladding material of composite material 1 and second composite material 2.
  • first welding seam 3 and the second welding seam 4 are formed in the cladding material of the stainless steel clad plate in this application, carburization should be avoided for welding the cladding material, because the carburization of the weld seam will greatly reduce the Corrosion resistance of rust composite steel components, so the welding of the cladding material and the cladding material should choose the electrode corresponding to the material of the cladding material, such as A132 or A137.
  • the depth of the welds of the first weld 3 and the second weld 4 is less than the thickness of the cladding material, so welding to the core base material should be avoided to prevent damage to the core base material.
  • the welding depth (weld depth) of the first welding seam 3 and the second welding seam 4 it is necessary to determine the welding depth (weld depth) of the first welding seam 3 and the second welding seam 4 according to the cladding material thickness of the first stainless steel clad plate and the cladding material thickness of the second stainless steel clad plate.
  • the cladding material will wrap the base layer, if the stainless steel composite plate is placed on a horizontal plane, from the perspective of the longitudinal section, the stainless steel clad plate will include the top cladding material, the middle base layer and the bottom cladding.
  • the material has a three-layer structure, and the thickness of the cladding material in this embodiment refers to the thickness of the top cladding material or the thickness of the bottom cladding material.
  • the stainless steel composite profile also includes a plurality of reinforcing ribs 5, the reinforcing ribs 5 are the third stainless steel composite plate, and the adjacent two sides of the third stainless steel composite plate are respectively welded and fixed to the wing plate 21 and the bottom plate 1, so as to A third weld 6 is formed.
  • the reinforcing rib 5 is in the shape of a right triangle, one right-angled side of the reinforcing rib 5 is welded and fixed to the wing plate 21, and the other right-angled side of the reinforcing rib is welded and fixed to the bottom plate 1, wherein the reinforcing rib 5
  • the number of ribs can be determined according to needs, which can be four, eight or more. Meanwhile, the position of the reinforcing rib 5 can also be determined according to needs. It is easy to understand that, in other embodiments, the reinforcing rib 5 may also be a stainless steel composite plate of other shapes.
  • the cladding material can be 36Ti and various other grades
  • the stainless steel core material is low-alloy structural steel such as Q295 or Q355
  • the section of the stainless steel composite profile can be 0.5-1mm thick.
  • the anti-corrosion inside the hole of the stainless steel composite profile can be inserted with a 1.5-2mm stainless steel sleeve, and the two sides are sealed and welded with self-fusion welding or stainless steel welding wire.
  • the upper part 121 of the bolt connection 12 is made of duplex stainless steel, which guarantees its tensile strength and anti-corrosion performance. And because of its short length and less steel consumption, it has three advantages of ensuring performance, saving precious metals and solving anti-corrosion problems.
  • the lower part 123 of the bolted connector 12 is threaded through the intermediate connecting part 122, wherein the upper part 121, the intermediate connecting part 122 and the lower part 123 all have high-strength connecting threads, thus, through the threaded connection, the bolted connector 12
  • the lower part 123 is mechanically connected to the upper part 121 . Because the length of the lower part 123 is longer, it can be better buried in the ground, so that duplex stainless steel materials can be reasonably saved to save costs.
  • the intermediate connecting portion 122 is a stainless steel nut whose force strength has reached that of a carbon steel nut of the same level, and the stainless steel nut is in the form of double nuts.
  • using the stainless steel composite profile can effectively solve the anti-corrosion problem, and at the same time, it can save about 8% of precious high-end stainless steel metal materials, effectively reducing production costs.
  • a method for manufacturing a special-shaped cladding profile provided by an embodiment of the present invention specifically includes the following steps:
  • a rectangular first stainless steel composite plate of appropriate thickness is selected as the bottom plate 1, and then connecting holes 11 are respectively opened at the four corners of the rectangular bottom plate 1, and the size of the connecting holes depends on the size of the connecting piece.
  • two second stainless steel composite plates with the same size are selected as the wing plate 21, and another second stainless steel composite plate corresponding to the size of the wing plate 21 is selected as the web 22, wherein the length of the web 22 is the same as that of the wing plate 22.
  • the plates 21 are of equal length.
  • the two wing plates 21 are placed in parallel in advance, and then the web 22 is inserted between the two wing plates 21, so that the two ends of the web 22 are vertically connected to the midline positions of the two wing plates 21 respectively, thereby Spliced together to form an H-shaped main body.
  • A132 or A137 is used to weld and fix the joint where the two wing plates 21 are in contact with the web 22 , so as to form the first weld 3 .
  • the H-shaped main body is placed on the first stainless steel composite plate 1 so that the two wing plates 21 and one web 22 are in contact with the first stainless steel composite plate 1 .
  • A132 or A137 is used to weld and fix two wing plates 21 and one web 22 at the positions where they are in contact with the first stainless steel composite plate 1, thereby forming Second weld 4.
  • the third stainless steel composite plate in the shape of a right triangle is selected as the reinforcing rib 5, and one right-angled side of the reinforcing rib 5 is welded and fixed to the wing plate 21, and at the same time, the other right-angled side of the reinforcing rib 5 is welded and fixed to the bottom plate 1,
  • the third welding seam 6 is formed at the position where the two right-angle sides of the reinforcing rib 5 contact the wing plate 21 and the bottom plate 1 .

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Abstract

一种异形包覆型材，包括：底板和主体部，底板为第一复合材（1），主体部包括至少一块第二复合材（2），第二复合材（2）焊接于第一复合材（1）上，形成第二焊缝（4），第一复合材（1）和第二复合材（2）均包括芯材（101、103）和包覆材（102、104），包覆材（102、104）为不锈钢材料制成并且包覆芯材（101、103），芯材（101、103）为与包覆材（102、104）不同的材料，第二焊缝（4）的深度小于包覆材（102、104）的厚度；该异形包覆型材结构强度高，成本低，能够防锈，适于室外应用。

Description

一种异形包覆型材 技术领域
本发明涉及一种异形包覆型材，属于金属制造技术领域。
背景技术
不锈钢复合材通常是以不锈钢做包覆材，以普碳钢或普通低合金钢做基材，通过冶金结合的方式制成复合材料。这种复合材料兼具不锈钢耐蚀防锈和普通钢高塑性低成本的优点，具有同规格纯不锈钢无法比拟的价格优势，因此，越来越受到人们的高度重视。不锈钢复合板与不锈钢复合管是不锈钢复合材中的两个典型的产品，目前，这两种产品已经在工程上得到广泛应用。由于不锈钢复合材具有普通钢材和全不锈钢钢材无法比拟的性价比，近年来，一些其它类型的不锈钢复合材也应运而生。
工业化生产不锈钢复合板主要有两种方法：爆炸复合和热轧复合。爆炸复合是将不锈钢板重叠置于碳钢基板上，不锈钢板和碳钢基板之间用垫子间隔出一定的距离。不锈钢板上面平铺炸药，炸药爆炸的能量，使不锈钢板高速撞击碳钢基板，产生高温高压使两种材料的界面实现固相焊接。热轧复合是以碳钢基板和不锈钢板处于物理纯净状态，在高度真空条件下进行轧制而成。在轧制过程中两种金属扩散实现完全的冶金结合。
目前，在本申请人的专利号为CN201910485098.7的中国发明专利中，公开了一种热轧复合钢的制造方法及热轧复合钢，该制造方法通过对包覆管材和芯材的尺寸进行设计，使包覆管材的内径小于芯材的外径，然后将包覆管材加热后与芯材组合，实现了包覆管材和芯材的压合，操作方便，并且通过使包覆管材与芯材在复合钢坯加热后轧制的过程中始终紧密结合，避免了在包覆管材和芯材的界面产生裂缝，从而可以得到合格的热轧复合钢。
然而上述制造方法仅适于制造各种形状的热轧棒材或热轧型材，无法直接制造出不规则形状的复合钢型材。
发明内容
本发明所要解决的首要技术问题在于提供一种异形包覆型材。
为实现上述技术目的，本发明采用以下技术方案：
一种异形包覆型材，包括：
第一复合材，包括第一芯材和第一包覆材，所述第一包覆材覆盖所述第一芯材，并且具有不同材料；
第二复合材，包括第二芯材和第二包覆材，所述第二包覆材覆盖所述第二芯材，并且是不同材料，所述第二包覆材与所述第一包覆材是相同材料；
所述第二复合材焊接于所述第一复合材上，形成位于所述第一包覆材和所述第二包覆材内的焊缝；
所述焊缝的深度小于所述第一包覆材或所述第二包覆材的厚度。
其中较优地，所述焊缝为焊接所述包覆材的材料。
其中较优地，所述焊缝的焊料的熔敷金属抗拉强度，高于焊接所述包覆材所需焊料的熔敷金属抗拉强度。
其中较优地，所述第一复合材构成所述异形包覆型材的底部，多块所述第二复合材共同构成所述异形包覆型材的主体部；
所述焊缝包括第一焊缝和第二焊缝，相邻两个所述第二复合材的拼接处焊接形成所述第一焊缝，所述第一焊缝的焊接深度小于所述第二包覆材的厚度；所述第一复合材与所述第二复合材的拼接处焊接形成所述第二焊缝，所述第二焊缝的焊接深度同时小于所述第一包覆材和所述第二包覆材的厚度。
其中较优地，所述第一芯材与所述第一包覆材通过热轧工艺形成一体；所述第二芯材与所述第二包覆材通过热轧工艺形成一体。
其中较优地，所述主体部包括两块翼板和一块腹板，所述两块翼板和一块腹板均为所述第二复合材，所述两块翼板相互平行，所述腹板的两端分别垂直连接于所述两块翼板的中线位置，以共同拼接成H型主体部。
其中较优地，所述翼板与所述腹板的错边尺寸不超过1mm。
其中较优地，所述第一复合材和所述第二复合材均为不锈钢复合板材。
本发明具有以下技术效果：
本发明技术方案提供的异形包覆型材解决了碳钢成本低却不防锈；不锈钢成本又太高的技术矛盾。因此，本发明的不锈钢复合型材既防锈，成本也低，而且结构强度高，解决了热轧工艺得到的包覆型材不能为异形型材的技术难题，适于广泛应用，尤其适于室外应用。
附图说明
图1A为本发明实施例提供的一种异形包覆型材的结构示意图；
图1B为图1A中B部分的局部剖面图；
图2为本发明实施例提供的一种异形包覆型材的制造流程图。
具体实施方式
下面结合附图和具体实施例对本发明的技术内容进行详细具体的说明。
通常，将一种金属材料(位于表层，包覆材)利用诸如热轧、模压成型等工艺包覆在另一种金属材料(芯材)上，得到的包覆型材，由于工艺限制，只能是板材、管材等不能为异型型材(例如，轮廓线为不规则形状)。本发明利用包覆型板材或管材等，通过焊接得到异形的包覆型材，并且在焊接过程中保证不穿透外表面的包覆材，所以能够得突破工艺限制，得到多种异形型材。既利用了包覆型材的材料优势，又降低了异形型材的加工成本。以下用碳钢包覆不锈钢的工字型材为例进行说明。
请参照图1A所示，为本发明实施例提供的一种异形包覆型材，其包括：第一复合材1和第二复合材2，其中，第一复合材1构成异形包覆型材的底板，多块第二复合材2共同构成构成异形包覆型材的主体部。第一复合材1和第二复合材2均选用各种碳钢作为芯材，降低不锈钢包覆材的占比，有效降低产品整体成本，用各种牌号不锈钢及双向不锈钢做包覆材，很好的起到防腐效果。在此需要说明，本发明并不受限于碳钢和不锈钢的复合板材，只要是底板和主体部均为复合型材，并且该复合型材相有相同的包覆材，位于整个复合型材的外表面，适于焊接加工。本发明并不受限于复合板材，也可以是其他形状，例如复合管材(包覆材覆盖整个管状的芯材)。只是为了描述更清楚，方便理解，以下只介绍复合板材的情况。
通过将包覆材加热后与芯材进行压合，从而形成复合坯，最后，将 复合坯加热到一定温度后进行轧制即可形成该不锈钢复合板材。基于本产品的特殊形状导致无法采用碳钢芯材进行预制后再进行不锈钢包覆材轧制，所以将本发明将不锈钢复合型材拆分成若干个组件进行不锈钢包覆材轧制后采取特殊的焊接的方法将各个组件焊接成型。
参照图1B所示，在本实施例中，第一复合材1包括第一芯材101和第一包覆材102，第二复合材2包括第二芯材103和第二包覆材104。本实施例中，第一芯材101和第二芯材103均由金属碳钢制成，第一包覆材102和第二包覆材104均由不锈钢管材制成。同时，参照图1所示，具体焊接时，多块第二复合材2的拼接处相互焊接，形成第一焊缝3，第一复合材1与第二复合材2的拼接处相互焊接，形成第二焊缝4。
需要理解的是，不锈钢材料的耐腐性较好不易生锈，但成本较高；金属碳钢材料易氧化生锈，但成本较低，在本实施例中，通过在便宜且易锈的芯材的外侧设置不易生锈的包覆材的结构形式，同时，在焊接时，使得焊缝不焊穿包覆材，使得芯材不接触氧气，进而在保证耐腐蚀性的前提下，能够节约不锈钢复合型材的生产成本。
在本实施例中，具体的，底板为第一复合材1，本实施例中，该第一复合材1为不锈钢复合板材，该底板1呈矩形形状，在底板1的四角分开开设四个连接孔11，优选为螺栓孔，该螺栓孔11用于安装螺栓连接件12，从而能够与其他部件进行连接。在其他实施例中，可根据需要选择连接孔11的数量和位置。
主体部包括多块第二复合材2，本实施例中，第二复合材2为不锈钢复合板材，多块第二不锈钢复合板材的尺寸和规格可相同也可不同，该多块第二不锈钢复合板材相互拼接成设定形状，然后将任意两个相邻的第二不锈钢复合板材的拼接处通过设定焊剂焊接固定，以形成第一焊缝3，从而将多块第二不锈钢复合板材焊接成设定形状的主体部。具体的，在本实施例中，多块第二不锈钢复合板材包括两块翼板21和一块腹板22，两块翼板21呈矩形形状并相互平行，腹板22呈矩形形状且腹板22的两端分别垂直连接于两块翼板21的中线位置，且翼板21与腹板22的错边尺寸不超过1mm，以共同拼接成H型主体部。考虑到不锈钢复合构件除了要满足构件的力学性能外,还需要保证与腐蚀介质相接触的包覆材的耐腐蚀性能，因此，在组对焊件时，要求以包覆材为基准对齐，包覆材面 错边不要超过1mm，尤其是不等厚度不锈复合钢板组对时更应注意这一点。如果包覆材之间错边过大，基层根部焊缝有可能熔化部分不锈钢，使基层根部的焊缝金属合金元素增加，导致焊缝变得硬而脆，同时减薄了错边对接处的不锈钢厚度，会降低使用寿命，影响包覆材表面的焊缝质量，难以保证焊接结构的耐腐蚀性能。
在上述实施例中，H型主体部是一种新的型材，不仅具备H型钢所具有的全部性能，而且具备表面非常好的防腐性能，有效地解决了恶劣的腐蚀环境下的防腐问题。本实施例中，H型主体部的翼板21与腹板22采用热轧的方式将表面的不锈钢包覆材与芯部的碳钢或低合金结构钢压合而成。即，芯材为碳钢或低合金结构钢，包覆材为不锈钢，两者热轧成一体。
包覆材可选用各种牌号的不锈钢及双相不锈钢；芯材可选用普通碳素结构钢及低合金结构钢(例如：Q235、Q275、Q355等)。
众所周知，异种材料的焊接性主要取决于两种材料的治金相容性，物理性能、表面状态等，两种成以上被焊材料的这些性能差异越大，焊接性就越差。除此之外，异种材料的焊接性还与焊接工艺有关，包括焊接接头的尺寸、坡口形式、施焊方位、焊接工艺参数以及焊接过程的操作水平等因素。碳钢的含碳量高于不锈钢，用碳钢焊条焊接不锈钢容易造成晶间腐蚀。所以不锈钢的焊接，应该选择低碳甚至超低碳的不锈钢焊条；碳钢的焊接应该选择碳钢焊条。通常，不用不锈钢焊条来焊接碳钢，因为不锈钢和碳钢长期接触，会产生“渗碳反应”，对不锈钢的特质会产生影响。
本实施例中，焊丝的牌号选择为比包覆材(作为包覆材102的不锈钢)高一个级别的不锈钢焊丝。即，焊缝的焊料的熔敷金属抗拉强度，高于焊接包覆材不锈钢所需焊料的熔敷金属抗拉强度。
这样，焊缝是用不锈钢焊丝焊接工艺形成的，但却将两块芯材为碳钢的不锈钢复合板材焊接为一体。并且，如前述，焊接没有焊穿作为包覆材的不锈钢(图1B中h1和h2所示)，所以不会发生“渗碳反应”。
本实施例中，H型主体部的规格为：一、YB3001～2005标准内的零件规格；二、GB/T11263～2005标准内的零件规格。零件性能满足或优于上述两标准产品的长度、尺寸及公差都可等同于标准要求、零件技术要 求、质量要求满足或优于上述的两个标准。
本实施例中，H型主体部具有下列优点：
一、防腐性能上，远高于目前表面镀锌、镀铬及耐候钢等防腐效果；
二、力学性能上，通过内部芯材结合外部不锈钢包覆材的结构形式，可通过调节内部芯材的型号(例如：将内部芯材从Q235调到Q275或Q355)，从而有效解决全不锈钢强度低的问题；
三、解决了热轧工艺得到的包覆型材，只能是板材、管材等不能为异型型材的技术难题。
当H型主体部拼接完成后，利用设定焊剂将翼板21与腹板22相接触的位置焊接固定即可。能够理解的是，上述实施例中主体部为H型主体部仅为其中一种实施方式，在其他实施例中，主体部的形状可根据需要进行适应性改变。
当H型主体部焊接完成后，将该H型主体部放置于底板1上，使得两块翼板21和一块腹板22均与底板1的表面相接触，此时，可利用该设定焊剂对两块翼板21和一块腹板22与底板1相接触的位置处进行焊接固定，此时，H型主体部与底板1相对固定，共同形成该不锈钢复合型材。
在一实施例中，该设定焊剂为A132或A137，同时，第一焊缝3的焊接深度不大于第二复合材2的包覆材厚度，第二焊缝4的焊接深度不大于第一复合材1和第二复合材2的包覆材厚度。具体的，由于本申请中第一焊缝3和第二焊缝4形成在不锈钢复合板材的包覆材内，对于包覆材的焊接要避免增碳，因为焊缝的增碳会大大降低不锈复合钢构件的耐腐蚀性能，所以包覆材与包覆材的焊接应该选择与包覆材材质相应的焊条，如A132或A137等。同时，在焊接过程中，第一焊缝3和第二焊缝4的焊缝深度均小于包覆材的厚度，应避免焊接到芯部基材上，以防止对芯部基材造成损伤，因此，需要根据第一不锈钢复合板材的包覆材厚度和第二不锈钢复合板材的包覆材厚度确定第一焊缝3和第二焊缝4的焊接深度(焊缝深度)。需要理解的是，由于包覆材会将基层包裹在内，因此，如果将不锈钢复合板材放置在水平面上，从纵截面上来看，不锈钢复合板材共包括顶部包覆材、中间基层和底部包覆材共三层结构，本实施例中的包覆材厚度指的是顶部包覆材的厚度或底部包覆材的厚 度。
在一实施例中，该不锈钢复合型材还包括多个加强筋5，加强筋5为第三不锈钢复合板材，第三不锈钢复合板材的相邻两侧分别与翼板21和底板1焊接固定，以形成第三焊缝6。具体的，在该实施例中，加强筋5呈直角三角形形状，加强筋5的一条直角边与翼板21焊接固定，加强筋的另一条直角边与底板1焊接固定，其中，该加强筋5的数量可根据需要而定，可以是四个、八个或更多，同时，加强筋5的位置也可以根据需要而定。容易理解的是，在其他实施例中，该加强筋5也可以是其他形状的不锈钢复合板材。
综上所述，在本发明实施例中，包覆材可选用36Ti及各种其他牌号，不锈钢芯材为Q295或Q355等其他牌号的低合金结构钢，不锈钢复合型材的断面可用0.5-1mm厚不锈钢封焊，或选用焊丝封焊。不锈钢复合型材的孔内侧防腐可用1.5-2mm的不锈钢套镶入，两面用自熔焊或不锈钢焊丝封焊好。
螺栓连接件12的上部121由双相不锈钢制成，保证其抗拉强度和防腐性能。又因其长度较短，钢材消耗少，所以具有保证性能、节约贵金属以及解决防腐问题的三大优点。
螺栓连接件12的下部123通过中间连接部122进行螺纹连接，其中，上部121、中间连接部122和下部123均具有高强的连接螺纹，由此，通过螺纹连接的方式，使得螺栓连接件12的下部123与上部121通过机械的方式进行连接。因下部123的长度较长，能够更好地埋入地面，从而能够合理地节约双相不锈钢材料，以节约成本。其中，中间连接部122为不锈钢螺母，其受力强度达到了同级别的碳钢螺母，且该不锈钢螺母为双螺母形式。
在具体施工过程中，利用该不锈钢复合型材能够有效地解决防腐问题，同时，能够节约大约8％的贵重高端不锈钢金属材料，有效地降低生产成本。
参照图2所示，为本发明实施例提供的一种异形包覆型材的制造方法，具体包括以下步骤：
S10、将第一不锈钢复合板材1作为底板，并在底板1上开设连接孔11，用于与其他部件进行连接。
具体的，选取适当厚度的矩形第一不锈钢复合板材作为底板1，然后，在矩形底板1的四角位置分别开设连接孔11，该连接孔的大小根据连接件的大小而定。
S20、将多块第二不锈钢复合板材2相互拼接，以形成设定形状的主体部。
具体的，选取两块尺寸相同的第二不锈钢复合板材作为翼板21，选取另一块与翼板21的尺寸相对应的第二不锈钢复合板材作为腹板22，其中，腹板22的长度与翼板21的长度相等。具体拼接时，预先将两块翼板21平行放置，然后，将腹板22插入两块翼板21之间，使得腹板22的两端分别垂直连接于两块翼板21的中线位置，从而共同拼接成H型主体部。
S30、利用设定焊剂将任意两个相邻的第二不锈钢复合板材的拼接处焊接固定，以形成第一焊缝3。
具体的，当H型主体部拼接完成后，利用A132或A137将两块翼板21与腹板22相接触的拼接处进行焊接固定，从而形成第一焊缝3。
S40、将焊接完成的主体部2放置于第一不锈钢复合板材1上方。
具体的，当主体部2焊接完成后，将该H型主体部放置于第一不锈钢复合板材1上，使得两块翼板21与一块腹板22均与第一不锈钢复合板材1相接触。
S50、利用设定焊剂继续将任一第二不锈钢复合板材与第一不锈钢复合板材的接触位置处焊接固定，以形成第二焊缝4。
具体的，当主体部2放置于第一不锈钢复合板材1上后，利用A132或A137将两块翼板21和一块腹板22与第一不锈钢复合板材1相接触的位置处焊接固定，从而形成第二焊缝4。
S60、将第三不锈钢复合板材作为加强筋5，将加强筋5的相邻两侧分别通过焊剂与主体部1和底板2焊接固定，以形成第三焊缝6。
具体的，选取直角三角形形状的第三不锈钢复合板材作为加强筋5，将加强筋5的一条直角边与翼板21焊接固定，同时，将加强筋5的另一条直角边与底板1焊接固定，其中，加强筋5的两条直角边与翼板21和底板1相接触的位置处形成第三焊缝6。
S70、利用不锈钢钢丝刷对第一焊缝3、第二焊缝4和第三焊缝6进 行清理，以避免有杂质残余在不锈钢复合型材表面。
上面对本发明进行了详细的说明。对本领域的一般技术人员而言，在不背离本发明实质内容的前提下对它所做的任何显而易见的改动，都将构成对本发明专利权的侵犯，将承担相应的法律责任。

Claims (8)

  1. 一种异形包覆型材，其特征在于，包括：
    第一复合材，包括第一芯材和第一包覆材，所述第一包覆材覆盖所述第一芯材，并且具有不同材料；
    第二复合材，包括第二芯材和第二包覆材，所述第二包覆材覆盖所述第二芯材，并且是不同材料，所述第二包覆材与所述第一包覆材是相同材料；
    所述第二复合材焊接于所述第一复合材上，形成位于所述第一包覆材和所述第二包覆材内的焊缝；
    所述焊缝的深度小于所述第一包覆材或所述第二包覆材的厚度。
  2. 如权利要求1所述的异形包覆型材，其特征在于，所述焊缝为焊接所述包覆材的材料。
  3. 如权利要求1所述的异形包覆型材，其特征在于，所述焊缝的焊料的熔敷金属抗拉强度，高于焊接所述包覆材所需焊料的熔敷金属抗拉强度。
  4. 如权利要求1所述的异形包覆型材，其特征在于，所述第一复合材构成所述异形包覆型材的底部，多块所述第二复合材共同构成所述异形包覆型材的主体部；
    所述焊缝包括第一焊缝和第二焊缝，相邻两个所述第二复合材的拼接处焊接形成所述第一焊缝，所述第一焊缝的焊接深度小于所述第二包覆材的厚度；所述第一复合材与所述第二复合材的拼接处焊接形成所述第二焊缝，所述第二焊缝的焊接深度同时小于所述第一包覆材和所述第二包覆材的厚度。
  5. 如权利要求1所述的异形包覆型材，其特征在于，所述第一芯材与所述第一包覆材通过热轧工艺形成一体；所述第二芯材与所述第二包覆材通过热轧工艺形成一体。
  6. 如权利要求4所述的异形包覆型材，其特征在于，所述主体部包括两块翼板和一块腹板，所述两块翼板和一块腹板均为所述第二复合材，所述两块翼板相互平行，所述腹板的两端分别垂直连接于所述两块翼板的中线位置，以共同拼接成H型主体部。
  7. 如权利要求6所述的异形包覆型材，其特征在于，所述翼板与所述腹板的错边尺寸不超过1mm。
  8. 如权利要求1所述的异形包覆型材，其特征在于，所述第一复合材和所述第二复合材均为不锈钢复合板材。
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