CN104141837B - 高Al水泥-ZnAl合金球墨铸铁给排水管的生产方法 - Google Patents
高Al水泥-ZnAl合金球墨铸铁给排水管的生产方法 Download PDFInfo
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- 229910001141 Ductile iron Inorganic materials 0.000 title claims abstract description 44
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- 239000000956 alloy Substances 0.000 title claims abstract description 33
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 12
- 239000004568 cement Substances 0.000 claims abstract description 27
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims abstract description 17
- 239000011248 coating agent Substances 0.000 claims abstract description 14
- 238000000576 coating method Methods 0.000 claims abstract description 14
- 229910052742 iron Inorganic materials 0.000 claims abstract description 12
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims abstract description 9
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 7
- 238000009750 centrifugal casting Methods 0.000 claims abstract description 6
- 238000005507 spraying Methods 0.000 claims abstract description 6
- 239000004744 fabric Substances 0.000 claims description 9
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- 239000004570 mortar (masonry) Substances 0.000 claims description 3
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- 229910052725 zinc Inorganic materials 0.000 abstract description 4
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- 230000035939 shock Effects 0.000 abstract description 2
- 238000006056 electrooxidation reaction Methods 0.000 abstract 2
- 239000010410 layer Substances 0.000 description 12
- 229910000521 B alloy Inorganic materials 0.000 description 2
- 239000011398 Portland cement Substances 0.000 description 2
- 239000011083 cement mortar Substances 0.000 description 2
- 230000007797 corrosion Effects 0.000 description 2
- 238000005260 corrosion Methods 0.000 description 2
- 230000018044 dehydration Effects 0.000 description 2
- 238000006297 dehydration reaction Methods 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 239000011241 protective layer Substances 0.000 description 2
- 208000037656 Respiratory Sounds Diseases 0.000 description 1
- 238000000137 annealing Methods 0.000 description 1
- 238000005266 casting Methods 0.000 description 1
- 239000008187 granular material Substances 0.000 description 1
- 238000003475 lamination Methods 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 238000009428 plumbing Methods 0.000 description 1
- 230000000284 resting effect Effects 0.000 description 1
- 238000003756 stirring Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
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- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
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- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
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Abstract
本发明涉及球墨铸铁给排水管的生产方法,具体是一种高Al水泥-ZnAl合金球墨铸铁给排水管的生产方法。该生产方法的工序包括:离心铸造球墨铸铁管,球墨铸铁管外表面喷涂ZnAl合金涂层,球墨铸铁管内表面涂覆高铝水泥内衬层。本发明的优点是:高铝水泥内衬层耐磨性好,抗冲击能力强,不容易脱落,能提高内衬的使用寿命;而ZnAl合金外涂层,由于ZnAl合金活跃性比Zn的活跃性强,Al、Zn和Fe发生电化学腐蚀,是Al和Zn发生电化学腐蚀,不会影响到Fe,ZnAl合金形成的氧化层更加稳定,附着在离心球墨铸铁管表面能够更好的起到防腐效果,使球墨铸铁管具有更好的抗腐蚀、和衰老能力。
Description
技术领域
本发明涉及球墨铸铁给排水管的生产方法,具体是一种高Al水泥-ZnAl合金球墨铸铁给排水管的生产方法。
背景技术
目前,给排水管多采用球墨铸铁管。传统的给排水球墨铸铁管内壁一般涂覆普通硅酸盐水泥保护层。硅酸盐水泥保护层易产生气泡、裂纹,与球墨铸铁管的结合面不紧密,耐腐耐磨抗冲击能力较弱。而球墨铸铁管外表面则喷涂金属Zn,其作用是金属Zn比铁容易氧化,在地下或空气中首先被氧化,形成氧化层从而保护其内部离心球墨铸铁管受到氧化,起到防腐效果。
发明内容
本发明旨在解决现有球墨铸铁给排水管存在的上述问题,而提供一种防腐性更高,内壁更光滑,寿命更长,结构更加稳定,具有更广的适用范围的高Al水泥-ZnAl合金球墨铸铁给排水管的生产方法。
本发明解决所述问题采用的技术方案是:
一种高Al水泥-ZnAl合金球墨铸铁给排水管的生产方法,包括:离心铸造球墨铸铁管,球墨铸铁管外表面喷涂金属涂层,球墨铸铁管内表面涂覆水泥内衬层;
球墨铸铁管外表面喷涂金属涂层的步骤是:
(1)喷涂前预处理,球墨铸铁管喷涂金属涂层前,外表面要经过打磨处理,去除一切附着物;
(2)喷涂ZnAl合金涂层,打磨处理后的球墨铸铁管在热管状态下喷涂ZnAl合金,管子温度控制在40℃-50℃,ZnAl合金涂层厚度按ZnAl合金涂层重量的平均值不小于300g/m2控制;
(3)ZnAl合金密度为6.5g/cm3
球墨铸铁管内表面涂覆水泥内衬层的步骤是:
(1)制备水泥砂浆,水泥为高铝水泥,按重量百分比计,高铝水泥的化学组成中:SiO23-9%,Al2O335-45%,Fe2O310-17%,CaO36-40%;灰砂比:1:1.0-2.5;砂浆稠度:95-125mm;
(2)布料,布料量以水泥内衬层在干燥状态下的干料重量为依据,在干燥状态下的干料密度ρ为2200kg/m3;干料重计算公式:M=π*DE*σ*ρ*L,其中:M:干料重量;DE:插口外径;σ:水泥内衬厚度;ρ:高Al水泥混合料密度;L:管子有效长度;
(3)养生,自然养生2小时以上,再进行蒸汽养生,蒸汽养生时,养生窑通蒸汽后,通过调整蒸汽量,温度控制在30~60℃之间,相对湿度保持在80%以上;蒸汽阀门关闭时蒸汽压力≥0.1MPa,养生时间≥8小时;
(4)内衬内磨,内磨后的水泥内衬层达到表面光滑、无波纹和台阶,露出砂粒。
采用上述技术方案的本发明,与现有技术相比,其优点是:
高铝水泥内衬层耐磨性好,抗冲击能力强,不容易脱落,能提高内衬的使用寿命;而ZnAl合金外涂层,由于ZnAl合金活跃性比Zn的活跃性强,Al、Zn和Fe发生电子腐蚀是Al和Zn发生电子腐蚀,不会影响到Fe,ZnAl合金形成的氧化层更加稳定,附着在离心球墨铸铁管表面能够更好的起到防腐效果,使球墨铸铁管具有更好的抗腐蚀、和衰老能力。
作为优选,本发明更进一步的技术方案是:
所述离心铸造的球墨铸铁管的化学成分按重量百分比计是:C:3.4-3.6%,Si:2.4-2.6%,Mn:0.08-0.15%,S:0.005-0.015%,P:小于0.05%,Ti:小于0.04%,Cr:小于0.05%。
具体实施方式
以下通过实施例详述本发明,目前仅在于更好的理解本发明内容。
本实施例给出的是生产DN900高Al水泥-ZnAl合金球墨铸铁给排水管的生产方法,其步骤如下:
(1)按离心铸造球墨铸铁管常规工艺铸造DN900球墨铸铁管,DN900球墨铸铁管的化学成分按重量百分比计是:C:3.5%,Si:2.5%,Mn:0.12%,S:0.011%,P:0.03%,Ti:0.02%,Cr:0.03%。
(2)退火后的DN900球墨铸铁管进行喷涂前预处理,外表面要经过打磨处理,去除一切附着物,如浮灰、油污、沙粒、锈迹。
(3)在加热炉中对DN900球墨铸铁管加热,使其温度达到40℃-50℃;然后吊至喷涂ZnAl合金工位。
(4)调整好DN900球墨铸铁管的旋转速度与喷枪小车的行走速度和送丝电压,然后进行ZnAl合金的喷涂;在喷ZnAl合金丝过程中必须保证ZnAl合金丝完全雾化使其能够均匀稳定的附着在球墨铸铁管的表面。
(4)ZnAl合金层厚度通过调整喷枪小车的行走速度来控制;若ZnAl合金层偏厚,则将小车速度调快,若ZnAl合金层偏薄,则将小车速度调慢;ZnAl合金涂层厚度按ZnAl合金涂层重量的平均值不小于300g/m2控制,通过样快取样进行ZnAl合金涂层厚度的测量。
(5)将喷涂好ZnAl合金涂层的DN900球墨铸铁管退出喷枪小车,检查管壁ZnAl合金附着情况,不能出现漏喷和明显的螺旋纹;待进入水泥内衬层涂覆工序。
(6)制备高铝水泥砂浆,按重量百分比计,高铝水泥的化学组成中:SiO26%,Al2O340%,Fe2O315%,CaO39%;灰砂比:1:2;砂浆稠度:110mm;混料时,先加砂,再加水泥,干混3~5分钟后再加水,充分搅拌,使水泥的小颗粒熟料完全水化;混好的料要及时使用,存放时间超10min后,需开动搅拌机将水泥沙浆进行搅动。
(7)布料,布料量按水泥内衬层在干燥状态下的干料重量计为230kg;布料时不允许有脱料、断料现象,布料小车速度依布料量要求和给料速度来调整。
(8)离心脱水,内衬管的水泥砂浆经脱水后,若衬层质量不合要求,需返回到离心工位进行返工或重新进行布料涂衬。
(9)养生,自然养生2.5小时,之后进行蒸汽养生,蒸汽养生时,养生窑通蒸汽后,调整蒸汽量,使窑内温度控制在45℃左右,相对湿度保持在80%以上;蒸汽阀门关闭时蒸汽压力≥0.1MPa,养生时间8小时。
(10)内衬内磨,内磨后的水泥内衬层达到表面光滑、无波纹和台阶,露出砂粒,即为成品。
Claims (2)
1.一种高Al水泥-ZnAl合金球墨铸铁给排水管的生产方法,包括:离心铸造球墨铸铁管,球墨铸铁管外表面喷涂金属涂层,球墨铸铁管内表面涂覆水泥内衬层;其特征在于:
球墨铸铁管外表面喷涂金属涂层的步骤是:
(1)喷涂前预处理,球墨铸铁管喷涂金属涂层前,外表面要经过打磨处理,去除一切附着物;
(2)喷涂ZnAl合金涂层,打磨处理后的球墨铸铁管在热管状态下喷涂ZnAl合金,管子温度控制在40℃-50℃,ZnAl合金涂层厚度按ZnAl合金涂层重量的平均值不小于300g/m2控制;
球墨铸铁管内表面涂覆水泥内衬层的步骤是:
(1)制备水泥砂浆,水泥为高铝水泥,按重量百分比计,高铝水泥的化学组成中:SiO23-9%,Al2O335-45%,Fe2O310-17%,CaO36-40%;灰砂比:1:1.0-2.5;砂浆稠度:95-125mm;
(2)布料,布料量以水泥内衬层在干燥状态下的干料重量为依据,在干燥状态下的干料密度为2200kg/m3;干料重计算公式:M=π*DE*σ*ρ*L,其中:M:干料重量;DE:插口外径;σ:水泥内衬厚度;ρ:高Al水泥混合料密度;L:管子有效长度;
(3)养生,自然养生2小时以上,再进行蒸汽养生,蒸汽养生时,养生窑通蒸汽后,通过调整蒸汽量,温度控制在30~60℃之间,相对湿度保持在80%以上;蒸汽阀门关闭时蒸汽压力≥0.1MPa,养生时间≥8小时;
(4)内衬内磨,内磨后的水泥内衬层达到表面光滑、无波纹和台阶,露出砂粒。
2.根据权利要求1所述的高Al水泥-ZnAl合金球墨铸铁给排水管的生产方法,其特征在于,所述离心铸造的球墨铸铁管的化学成分按重量百分比计是:C:3.4-3.6%,Si:2.4-2.6%,Mn:0.08-0.15%,S:0.005-0.015%,P:小于0.05%,Ti:小于0.04%,Cr:小于0.05%。
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CN1085196A (zh) * | 1992-09-26 | 1994-04-13 | 中国建筑材料科学研究院水泥科学研究所 | 高铝水泥和白水泥的活化煅烧技术 |
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CN101994874A (zh) * | 2009-08-29 | 2011-03-30 | 韩勇 | 水冷金属型离心球墨铸铁管的生产工艺 |
CN103374692A (zh) * | 2012-04-17 | 2013-10-30 | 新兴铸管股份有限公司 | 一种黑色金属基管道防腐涂层及其喷涂方法 |
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CN1085196A (zh) * | 1992-09-26 | 1994-04-13 | 中国建筑材料科学研究院水泥科学研究所 | 高铝水泥和白水泥的活化煅烧技术 |
CN1800291A (zh) * | 2004-12-30 | 2006-07-12 | 同济大学 | 堵漏防水材料 |
CN101994874A (zh) * | 2009-08-29 | 2011-03-30 | 韩勇 | 水冷金属型离心球墨铸铁管的生产工艺 |
CN103374692A (zh) * | 2012-04-17 | 2013-10-30 | 新兴铸管股份有限公司 | 一种黑色金属基管道防腐涂层及其喷涂方法 |
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