Графитовые электроды для сварки — характеристика

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графитовые электроды

Все электроды, представленные на рынке можно разделить на две большие группы — плавящиеся и неплавящиеся. Первый вид стержней занимает очень большую долю на рынке и используется практически во всех сферах работ подобного рода. Но кроме них есть и неплавкие электроды, к которым относятся графитовые стержни. Они также очень популярны. По больше части их применяют на больших производствах. В частном хозяйстве они не так востребованы. Главные области, в которых им находят применение — это строительство судов, металлургия, литье стали и пр.

В сталелитейной промышленности графитовые электроды очень часто используются для устранения дефектов и проблемных участков.

Где применяются электроды?

Электроды данного типа производятся из кристаллического углерод-графита. Он обладает серым цветом и металлическим блеском. Он очень легко режется и имеет мягкую структуру. Основное применение графитовых электродов — это резка и сварка цветных металлов. Помимо этого они используются для сварки металлов твердого типа.

Графитовые стержни обладают лучшими сварными качествами, чем угольные.

Температура, при которой углерод начинает плавиться, составляет 3500°С. Во время сварки таких значений достигать не удается, и углерод просто испаряется.

Четких стандартов, по которым изготавливаются электроды такого типа, нет. Они делаются из остатков электродов плавильных печей. При производстве они обрезаются и обтачиваются. Конец графитового электрода затачивается под углом 60°С. Он обладает намного более меньшим сопротивлением, чем уголь, что позволяет проводить работы на гораздо большем токе.

Давайте разберемся в нескольких нюансах применения электродов:

  • Сварка материалов ведется за счёт образования дуги между неплавящимся электродом и материалом. Присадочный материал, как и кромки конструкции или детали, нагреваются до состояния плавления. В этот момент образуется сварочная ванна, которая после затвердевания образует сварочный шов.
  • Для того чтобы вести сварку графитовыми электродами, необходимо использовать постоянный ток прямой полярности. Если использовать обратную полярность, дуга будет нестабильной и начнется сильное науглероживание металла. Такой режим может использоваться только при резке металла.
  • Поскольку графитовые электроды обладают высокой стойкостью к плавлению, они показывают очень маленький расход. При этом во время сварки они почти не растрескиваются. Работы рекомендуется вести на небольшой дуге. В этом случае соединение получится качественным и надежным.

Плюсы и минусы электродов

Электроды такого типа имеют несколько преимуществ, о которых необходимо упомянуть:

  • Они очень просты в производстве, поскольку делаются из остатков производства обычных электродов.
  • Материал из которого они делаются, обладает стойкостью к большой плотности тока.
  • Стержни хорошо проводят ток и обеспечивают эффективную сварку.
  • Графит хорошо выдерживает окислительные среды и легко справляется даже с большими температурами.
  • Стержни могут использоваться с обычным держателем. Для них не требуется специального оборудования.

Среди недостатков расходников такого типа, нужно отметить следующее:

  • Могут использоваться лишь для некоторых типов работ и с ограниченным количеством материалов.
  • Имеют жесткие требования к состоянию наконечников.
  • Во время сварки в наплавленном металле может увеличиваться количество углерода.
  • Графитовые электроды не могут быть тонкими. Минимальный диаметр составляет 6 мм. Это значит, что они могут использоваться не везде.

Какой состав и характеристики имеют электроды?

Графитовые электроды для сварки устроены таким образом. В них имеются две основные части, между которыми установлена изолирующая прокладка. В ее составе имеется окись железа, меди, алюминия. Основные части производятся из кокса. Он представляет собой особый состав прессованного угля. По этой причине во время работы в шве может увеличиваться количество углерода.

В зависимости от модели электродов, они могут иметь разные свойства и могут использоваться для разных типов работ. Основными параметрами графитовых электродов являются:

  • толщина срезаемого металла;
  • размер канавки;
  • диапазон токов.

В качестве примера давайте рассмотрим параметры электродов ЭГП/НР:

  • плотность объема — 1,6 г/куб. см.;
  • примесь золы — 0,2%;
  • сопротивление — 8 мкОм;
  • прочность при изгибе — 11 МПа;
  • упругость — 9 ГПа;

Омедненные графитовые электроды

Среди разновидностей электродов подобного типа, можно найти медно-графитовые стержни. Их основное применение — это сварка медных проводов. Полученное соединение обладает повышенной стойкостью к коррозионным процессам и высоким температурам.

Особенностью сварки медных проводов является выделение большой температуры. Чтобы сохранить изоляцию от разрушения, к скрутке рекомендуется подключать медный радиатор, который будет отводить лишнее тепло. Перед началом сварки, рабочие зоны рекомендуется очистить от лака. После этого нужно сделать плотную скрутку. Концы проводов следует обрезать на одном уровне, чтобы они оказались в зоне сварки. Возле радиатора нужно установить массу. Затем электрод подносится к обрезанным проводам.

При сварке медных проводов, контакт стержня с ними должен быть коротким. Электрод опускается на секунду и тут же отрывается. На месте сварки будет образовываться круглый шар меди.

Процесс сварки медных проводов можно увидеть в этом ролике:

Какую маркировку имеют графитовые электроды?

В отличие от прочих сварочных расходников, графитовые стержни обладают простой и понятной маркировкой. Их название состоит из нескольких букв. Каждая буква обозначает отдельное свойство:

  • П — пропитанный;
  • С — специальный — используются для разных работ;
  • Г — графитированный;
  • Э — электрод.

Графитированные электроды (Г) имеют чистый состав. Они отличаются особой мягкостью, имеют металлический блеск и оставляют черный след на бумаге.

Самые распространенные марки электродов

Чтобы лучше понять какие качества имеют графитовые электроды и для чего они могут использоваться, давайте разберем несколько примеров.

ЭГ

Это стержни, которые делаются из угольного пека и нефтяного кокса. Они могут работать с плотностью тока не больше 25 А/кв. см. Отдельные изготовители делают стержни с ниппелями. Такие электроды используются в электродуговых аппаратах и руднотермических печах. На рынке встречаются модели ЭГ1 и ЭГ2. Они отличаются друг от друга значением сопротивления.

ЭГС

Эти электроды производятся из игольчатого кокса и каменного пека. Их основная область применения — это сталеплавильное производство и рафинировочные устройства.

ЭГП

Данный тип электродов предназначается для резки. Такие стержни изготавливаются из нефтяного кокса и каменноугольного пека, которые дополнительно пропитываются и обрабатываются пеком. Они используются в ферросплавных печах и сталелитейной отрасли.

ЭГСП

В основе таких электродов лежит игольчатый кокс, имеющий особую пропитку из каменноугольного пека. Чаще всего они применяются с электротермическими устройствами и электродуговыми аппаратами. Сопротивление таких электродов может меняться в зависимости от диаметра. На рынке можно найти две модели — ЭГСП 1 и ЭГСП 2.

Заключение

Электроды выполненные из графита имеют узкоспециализированное назначение и используются на производствах с особым оборудованием. На практике, можно встретить лишь небольшое количество подобных электродов, применение которых ограничивается парой-тройкой типов работ. Графитовые электроды особенны своим производством. Они изготавливаются из остатков электродов плавильных печей. Стержни такого рода обладают большим диаметром и хорошей электропроводностью. По этой причине они отлично подходят для работы с конструкциями и их фрагментами, рассчитанными на большую нагрузку разного типа.

 

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