Характеристика сварочных электродов — состав, параметры, виды

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характеристики сварочных электродов

Сварочный электрод представляет собой металлический или неметаллический сердечник, на который нанесено определенное покрытие, придающее ему особые сварные свойства. Такие стержни являются расходными материалами при проведении сварочных работ. Они плавятся, и за счёт этого образуют шов между изделиями или поверхностями. Существуют и неплавящиеся электроды, но о них мы поговорим в другой раз. Сегодня мы будем разбираться в том какие характеристики имеют электроды и каким образом они влияют на их качества и удобство работы.

Какие характеристики имеют электроды?

Параметры, о которых пойдет речь, напрямую влияют на свойства электродов, их назначение и свойства, проявляющиеся при сварке. Благодаря определенному составу или типу расходников, удается создать надежное соединение, которое прослужит в течение долгих лет.

Состав металла

Основным фактором, влияющим на выбор электродов, является материал, с которым вы будете работать. Его состав определяет такие свойства как прочность, вязкость, пластичность и т. д. Они могут меняться в зависимости от типа сплава и стали. Все они оказывают влияние на то, как будет вести себя металл во время сварки и при эксплуатации.

При выборе электродов необходимо, чтобы их состав и покрытие были максимально близки по составу к свариваемому металлу. В этом случае соединение будет надежным и прочным.

Состав покрытия

Среди разных вариаций, выделяется четыре типа покрытий (обмазок) электродов:

  • Основное. Имеет в составе карбонаты магния и кальция.
  • Рутиловое — рутил + кремнезем, карбонат магния и кальция, ферромарганец.
  • Целлюлозное — состоит из органических смол, талька, ферросплавов, целлюлозы.
  • Кислое. Содержит оксиды железа и марганца.

Самыми распространенными считаются электроды с рутиловым и основным покрытием. Они могут использоваться с большей частью материалов, и подходят для разных типов работ. Стержни с такой обмазкой могут применяться как в промышленности, так в домашнем хозяйстве. Ими удобно выполнять мелкие работы или ремонт.

Некоторые модели электродов имеют смешанное покрытие, состоящее из двух типов. Это бывает необходимо, когда для сварки требуются особые свойства.

Покрытие электродов определяет такие качества как:

  • стабильное горение дуги;
  • вязкость металла;
  • отделяемость шлака;
  • равномерное формирование соединения.

Коэффициент наплавки

При просмотре характеристик различных электродов, можно увидеть такой параметр как “коэф. наплавки”. Он отображает количество электродов, потраченных на создание шва. По сути данный параметр отражает эффективность работы конкретных электродов.

Новичку или человеку, не имеющему отношения к сварке, этот параметр не скажет ничего, однако опытные мастера могу по нему определить количество требуемого материала и время, которое нужно затратить на создание соединения. Помимо этого профессионал может также определить положении, в котором сварка будет наиболее эффективной.

Во время сварки не вся масса электрода идет на формирование шва. В процессе некоторая часть электрода расходуется на выгорание, испарение и разбрызгивание. Коэф. наплавки нельзя назвать точным параметром, так как на практике он зависит от других факторов, таких как: используемый ток, покрытие, свариваемый материал и т. д. Несмотря на это коэф. наплавки отражает количество электрода, которое уйдет на образование шва без каких-либо потерь. Общий расход при этом будет больше. И это нужно учитывать при подсчете количества требуемых электродов.

Диаметр

При выборе электродов еще одним важным параметром является их диаметр. Чем с большей заготовкой или конструкций вам предстоит иметь дело, тем больший диаметр электрода вам пригодится. Отдельно нужно учитывать марку стали, ее характеристики, форму кромок и соединение, которое нужно установить.

Увеличение диаметра пропорциональное увеличению толщины материала, объясняется способностью более толстого электрода выдерживать больший ток, генерируя больший нагрев, необходимый для того чтобы расплавить большую толщину металла.

Разные изготовители предусматривают для своих электродов разное сечение. Это позволяет использовать одну модель расходников для разных материалов и работ. При подборе нужно диаметра, следует обращать внимание на такие закономерности:

  • Стержни с сечением 1 мм подходят для сварки сталей толщиной 1,5 мм.
  • 1,6 мм применяются для работы с материалами толщиной от 2 мм.
  • 2 мм используются для 2 мм изделий, с током работы до 70 А.
  • Ø 2,5 мм подходит для деталей толщиной до 3 мм при силе тока до 100А.
  • Наибольшей популярностью пользуются электроды сечением 3 мм. Они могут применяться для сварки сталей толщиной до полсантиметра.
  • Ø 4 мм предназначаются для обычных и профессиональных аппаратов и для работы с конструкциями толщиной до сантиметра.
  • Сечение электродов более 5 мм подходит для работы исключительно со специальным сварочным оборудованием.

Зная все эти параметры, можно легко подобрать расходники для предстоящих работ. Конечно, это средние значения. Если вам требуется более точная информация, ее можно найти на упаковках с электродами. Изготовители подробно указывают характеристики и возможное применение своих изделий.

Температура прокалки

Прокаливание электродов нужно чтобы уменьшить количество содержащейся в них влаги. Без такой процедуры получить качественное соединение не удастся. С ее помощью происходит уплотнение соединения, которое напрямую влияет на работу и процесс сварки.

Есть некоторые модели, которые могут обойтись без предварительной прокалки, но их немного.

Главный, и самый эффективный способ прокалки электродов — это использование специальной печи для прокалки. С ее помощью вы сможете равномерно прогреть стержни и привести их в рабочее состояние.

Печь представляет собой металлический короб с лотками, куда помещаются электроды. Вы выставляете нужную температуру и время, и закрываете его. Изнутри стенки печи отделываются теплоизоляционным материалом, который сохраняет тепло и позволяет ему равномерно распределиться по всей площади.

Помимо использования печи, существуют и народные методы прокалки электродов. Сразу нужно отметить, что их можно использовать только для мелких, домашних работ, и только в том случае, когда вам не нужно высокое качество сварки. Добиться постоянной температуры в течение определенного времени дома непросто. Самый очевидный и наиболее подходящий вариант — использовать для этого духовку. Прокаливать электроды на газу или открытом огне не стоит, поскольку процедура будет неэффективной. Одни части стержня будут охлаждаться быстрее других. Из-за разницы температур может пострадать покрытие.

Требования по времени и температуре прокалки отличаются для разных моделей и марок электродов. Точные параметры подготовки нужно смотреть на упаковках с электродами.

Масса наплавленного металла

Этот параметр используется для расчета расхода электродов на образование одного метра шва. Он вычисляется по простой формуле: N=G*K, где

  • N — расход материала на 1 м шва;
  • G — масса наплавленного металла в метровом шве;
  • K — коэф. перехода от массы к расходу.

Временное сопротивление

Этот параметр относится к характеристикам готового шва. Его также иногда называют “пределом прочности”. Он отображает стойкость полученного соединения к деформации и разрушению. Этому параметру дают и другое определение — способность выдерживать давление определенного уровня.

Различные материалы имеют разные показатели прочности, которые прописываются в ГОСТе. На практике они могут несколько отличаться. Однако не учитывать теоретические характеристики нельзя. Именно по ним можно подобрать электроды для будущих работ.

Разные электроды могут работать с разными сталями и сплавами, обладающими разной прочностью.

Ударная вязкость

Еще один механический параметр, важный для готового соединения. Он показывает сопротивляемость металла к внешним нагрузкам. По сути этот параметр отражает стойкость полученного шва. Его обязательно нужно учитывать при выборе электродов.

Относительное удлинение

Этот параметр показывает степень пластичности шва, проявляющуюся при статических нагрузках. Это свойство очень важно для сталей, изготовленных по стандартам Э42, 46, 50.

Материал стержня электрода

В качестве основы электрода обычно используется сварочная проволока, сделанная из определенного материала, на которую наносится определенное покрытие. Обмазка защищает сварочную ванну от попадания в нее лишних примесей и кислорода, способных навредить соединению. При сварке стержень плавится и заполняет собой сварочную ванну, образуя шов. Существует 3 основных вида проволок:

  • Углеродистые — содержат до 0,12% углерода. Применяются для сварки низко — и среднеуглеродистых сталей.
  • Легированные — изготавливаются из легированной стали и используются для работы с конструкциями и деталями, выполненными из материалов с низким уровнем легирования. Также могут применяться с жаропрочными сталями.
  • Высоколегированные — применяются для сварки хромистых и хромоникелевых сталей. Могут использоваться с нержавейкой.

Химический состав сварочной проволоки должен быть похож на состав материала, с которым вы собрались работать. В этом случае соединение получится качественным и надежным.

Заключение

Все параметры и характеристики электродов, по которым мы прошлись, оказывают влияние на эффективность сварки и ее качество. Электроды необходимо подбирать таким образом, чтобы они наилучшим образом соответствовали свариваемому материалу. При сварке важен не только итоговый результат, но также возможность работать комфортно и быстро.

В идеале нужно подбирать те электроды, которые лучше всего отвечают вашим требованиям. Но на практике часто приходится делать выбор в пользу более дешевых аналогов, которые иногда могут показывать себя значительно хуже.

 

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