摘要：衬垫焊剂是在基础焊剂的表面上涂上一层树脂膜同时辅以乌洛托品的一种特殊焊剂，它能在焊接时迅速固化得以衬托熔池，使背面形成均一、美观、性能优良的焊缝。FCB法就是在铜板上铺设一层5mm左右厚度的衬垫焊剂，同时铜板下加一个顶升装置，使衬垫焊剂与工件紧密贴合，这种单面焊双面成形的方法节省了普通单面焊时需对钢板进行翻身，碳弧清根等工序。

本文主要通过研究各成分在焊剂中的作用，并针对FCB法的特点设计了一种新型衬垫焊剂，即渣系为MgO-Al2O3-CaF2-TiO2-SiO2-CaO，碱度为2.1的基础焊剂，并对其覆膜，通过研究不同树脂的量对衬垫焊剂的热固化性能的影响，发现在加入7-11%的树脂含量时，固化性能较好，同时也发现了衬垫焊剂的最佳固化温度为450℃左右，最佳固化时间为4min左右。

采用自行设计的简易FCB装置，焊缝表面铺设SJ101，背面放置自行研制的衬垫焊剂，然后对19mm厚的Q235钢板进行焊接，焊接完成后分析背面焊缝的成形性与其脱渣情况，同时对不加以衬垫焊剂的焊缝进行对比，进一步表明衬垫焊剂对背面焊缝成形的重要性。

关键词：FCB法；衬垫焊剂；热固化；背面焊缝

Abstract：Backing Flux is a special flux coated with a layer of resin film on the surface of the base flux, supplemented by urotropine. It can be quickly cured at the time of welding to set up the pool, so that the back surface is uniform, beautiful and excellent Of the weld. FCB method is to lay on the copper plate a layer of thickness of about 5mm backing flux, while the copper plate with a lifting device, so that the backing flux and the workpiece close fit, this single-sided welding double-sided forming method to save the ordinary single Surface welding when the steel plate to be turned over, carbon arc clear root and other processes.

In this paper, a new type of backing flux, MgO-Al2O3-CaF2-TiO2-SiO2-CaO, and basic flux of 2.1, was designed by studying the effect of each component in flux. , And the effect of the amount of different resins on the thermal curing properties of the backing flux was studied. It was found that the curing performance was better when adding 7-11% resin content, and the most Good curing temperature of about 450 ℃, the best curing time of 4min or so.

The self-designed simple FCB device was used to lay the SJ101 on the surface of the weld, and the self-developed backing flux was placed on the back surface. Then, the Q235 steel plate with 19mm thickness was welded. After the welding was completed, the forming performance and the slagging of the back weld were analyzed. The comparison of the welds without the backing flux further indicates the importance of the backing flux for the formation of the back weld.

Keywords：FCB method; Backing flux; Heat curing; Back weld

目录

第一章绪论 1

1.1引言 1

1.2埋弧焊焊剂简介 2

1.2.1焊剂的分类及特点 2

1.2.2我国焊剂的发展现状及趋势 3

1.3衬垫的发展和研究现状 4

1.4国内外FCB法焊接材料研究成果 5

1.5本课题的研究目的及内容 6

1.5.1研究目的 6

1.5.2研究内容 7

第二章衬垫焊剂的配方设计 8

2.1引言 8

2.2基础焊剂的碱度及渣系选择 8

2.2.1碱度范围的确定 8

2.2.2基础焊剂的渣系选择 9

2.3基础焊剂成分的确定 9

2.4基础焊剂的制作 11

2.4.1试验器材 11

2.4.2基础焊剂的原材料 11

2.4.3基础焊剂的手工制作 12

2.4.4焊剂手工制作的注意事项 14

2.5基础焊剂的覆膜 15

2.5.1粘接剂的选择 15

2.5.2覆膜仪器 16

2.5.3覆膜工艺流程 17

2.6衬垫焊剂粒度检验 18

2.7本章小结 19

第三章衬垫焊剂的热固化性能试验 20

3.1引言 20

3.2试验设备 20

3.3固化温度与固化时间对固化率的影响 20