CN104384749B - 一种等离子喷焊用防腐蚀镍基合金粉末 - Google Patents
一种等离子喷焊用防腐蚀镍基合金粉末 Download PDFInfo
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Abstract
本发明涉及一种等离子喷焊用防腐蚀镍基合金粉末，其重量配比为Cr：20～25％、Mo：10～18％、Cu：≤3％、Fe：≤4％、Nb：≤4％、Al：≤1％、Si：≤3％、C：≤0.01％、O：≤0.1％、Ni为余量，上述合金粉末粒度为40～500目。本发明的镍基合金粉末的优点在于，既适用于还原性的腐蚀性介质又适用于氧化性的腐蚀性介质，具有出色的防腐蚀通用性，可应用于燃烧含高硫、高氯、高碱煤质的烟气腐蚀防护。在对锅炉等设备进行等离子喷焊时，喷焊层厚度可控，因而可控制增加锅炉设备的重量；喷焊层的硬度小于原基体材料硬度，不影响设备的加工制作；该粉末喷焊在锅炉受热面上时，其喷焊层的线性膨胀系数与原基体材料接近，不影响受热面的热胀冷缩，不会增加受热面设备的内应力。
Description
[技术领域]
本发明涉及喷焊用合金粉末，具体涉及一种等离子喷焊用防腐蚀镍基合金粉末。
[背景技术]
电厂锅炉省煤器、水冷壁、过热器、再热器等受热面因烟气侧存在高温烟气腐蚀而导致爆管是引起停炉事故的主要原因之一，特别是燃烧高硫、高氯、高碱燃料时，烟气会强烈加剧对受热面的腐蚀，从而大大缩减锅炉的使用寿命。比如我国西部的新疆地区，蕴藏大量廉价的硫、碱、氯含量高的煤种，燃烧这种煤时由于其产生的烟气的强腐蚀性，常规锅炉设备的使用寿命仅几个月，不具备实际工业意义，必须掺入一定比例的优质煤种才能使用，但燃料成本大大增加。如何解决燃烧高硫、高氯、高碱煤种的腐蚀锅炉设备问题，成为当前各相关行业非常关注的问题。
防止烟气腐蚀，其中一种方法就是采用等离子喷焊工艺，将镍基合金粉末喷焊在被腐蚀的金属表面，以达到保护设备的效果。但针对高硫、高氯、高碱煤种燃烧产生的强腐蚀烟气，现有的镍基合金粉末综合防腐效果均不理想。
[发明内容]
本发明的目的在于解决现有的防腐镍基合金粉末喷焊层在面对锅炉中的强腐蚀烟气时，防腐效果不好的技术问题。
为了实现上述目的，发明了一种等离子喷焊用防腐蚀镍基合金粉末，其重量配比为Cr：20～25％、Mo：10～18％、Cu：≤3％、Fe：≤4％、Nb：≤4％、Al：≤1％、Si：≤3％、C：≤0.01％、O：≤0.1％、Ni为余量。
所述合金粉末利用合金成分Ni、Cr、Mo、Cu等的相互作用和分别在氧化性介质和还原性介质中的抗腐蚀作用，按以上配比配制，形成一种综合防腐效果达到最佳的通用性防腐合金。该镍基合金在80％氧化性浓硫酸和30％还原性盐酸中的腐蚀速率是不锈钢材料SS304的几十分之一甚至几百分之一；相比具有较好耐蚀性的镍基合金Inconel 625材料也只有其腐蚀速率的几分之一；在20％的NaOH溶液中则没有明显的腐蚀特征。良好的综合耐腐蚀效果适应于成分及特性非常复杂的高硫、高碱、高氯燃煤烟气，从而大大提高燃用该煤种锅炉的使用寿命。
添加的其它一些成分，可改善材料的防腐性能及有利于合金粉末的加工生产。
进一步的，该镍基合金粉末由金属通过用真空感应炉或手工电弧炉或自耗真空电弧炉或非电弧炉熔炼，熔炼时用氩气或氮气保护，再通过水雾化或气雾化法制得。制得的合金粉末球化情况和流动性良好，适用于等离子喷焊操作。
适用于喷焊操作的合金粉末粒度为40～500目。
在对锅炉等设备进行等离子喷焊时，采用本发明镍基合金粉末形成的喷焊层的厚度可以简单的控制在需要的范围。
该合金粉末喷焊层的硬度小于原基体材料硬度，不影响设备的加工制作(如弯制、切割等)。
该粉末喷焊在锅炉受热面上时，其喷焊层的线性膨胀系数与原基体材料接近，不影响受热面的热胀冷缩，不会增加受热面设备的内应力。
[具体实施方式]
结合实施例对于本发明做进一步的说明，实施例仅用于解释本发明而不用于限定其保护范围。在不脱离本发明设计精神的前提下，本领域任何人员对本发明的技术方案的各种改变和改进，均应落入本发明权利要求书确定的保护范围内。
实施例一
本发明提供一种用于火电厂锅炉膜式水冷壁烟气腐蚀的防腐材料。
步骤1合金熔炼
以质量百分比计，所述镍基合金粉末化学成分选定为：Cr:22％、Mo：13％、Cu：1.6％、Si：2.0％、Fe：3％、Nb：3％、Al：≤1％、C：≤0.01％、O：≤0.1％、Ni为余量。用真空感应炉或手工电弧炉进行或自耗真空电弧炉或非电弧炉熔炼。熔炼时用氩气或氮气保护。
步骤2制粉
用水雾化或气雾化法将熔融状态合金雾化。雾化时调节雾化水或雾化气的流量和压力，以控制粉末的粒度和均匀性；
步骤3粉末粒度筛选
从制成的粉末中筛选出粒度范围在40～500目的粉末，用于水冷壁喷焊；
步骤4喷焊
用等离子喷焊工艺将筛选出来的粉末喷焊在单根水冷壁管或水冷壁片上。喷焊层厚度按要求控制。
实施例二
本发明提供一种用于火电厂锅炉过热器烟气腐蚀的防腐材料。
步骤1合金熔炼
以质量百分比计，所述镍基合金粉末化学成分选定为：Cr:22％、Mo：13％、Cu：1.6％、Si：2.0％、Fe：3％、Nb：3％、Al：≤1％、C：≤0.01％、O：≤0.1％、Ni为余量。用真空感应炉或手工电弧炉进行或自耗真空电弧炉或非电弧炉熔炼。熔炼时用氩气或氮气保护。
步骤2制粉
用水雾化或气雾化法将熔融状态合金雾化。雾化时调节雾化水或雾化气的流量和压力，以控制粉末的粒度和均匀性；
步骤3粉末粒度筛选
从制成的粉末中筛选出粒度范围在40～500目的粉末，用于锅炉过热器喷焊；
步骤4喷焊
用等离子喷焊工艺将筛选出来的粉末喷焊在单根过热器管或过热器管屏上。喷焊层厚度按要求控制。
实施例三
本发明提供一种用于火电厂锅炉四管附件(防磨件、阻流件、支吊件等)烟气腐蚀的防腐材料。
步骤1合金熔炼
以质量百分比计，所述镍基合金粉末化学成分选定为：Cr:22％、Mo：13％、Cu：1.6％、Si：2.0％、Fe：3％、Nb：3％、Al：≤1％、C：≤0.01％、O：≤0.1％、Ni为余量。用真空感应炉或手工电弧炉进行或自耗真空电弧炉或非电弧炉熔炼。熔炼时用氩气或氮气保护。
步骤2制粉
用水雾化或气雾化法将熔融状态合金雾化。雾化时调节雾化水或雾化气的流量和压力，以控制粉末的粒度和均匀性；
步骤3粉末粒度筛选
从制成的粉末中筛选出粒度范围在40～500目的粉末，用于锅炉附件喷焊；
步骤4喷焊
用等离子喷焊工艺将筛选出来的粉末喷焊在需要防护的附件上。喷焊层厚度按要求控制。
本发明涉及的合金粉末不仅适用于燃煤锅炉设备，同样适用于垃圾锅炉等其它燃料锅炉和其它石油、化工设备的腐蚀防护。
本发明涉及的合金粉末材料不仅适用于燃煤烟气的防腐，同样适用于其它腐蚀介质的防护。
本发明涉及的合金粉末不仅可用于等离子喷焊工艺，同样可用于热喷涂、重熔等腐蚀防护工艺。
Claims (1)
1.一种等离子喷焊用防腐蚀镍基合金粉末，其特征在于合金粉末重量配比为Cr：22～25％、Mo：10～18％、Cu：1.6％、Fe：≤4％、Nb：3～4％、Al：1％、Si：＜3％、C：＜0.01％、O：0.1％、Ni为余量；
该镍基合金粉末由金属通过用真空感应炉或手工电弧炉或自耗真空电弧炉熔炼，熔炼时用氩气或氮气保护，再通过水雾化或气雾化法制得；其应用粒度为40～500目。
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| CN107312997B (zh) * | 2017-06-23 | 2019-08-20 | 安徽绿环泵业有限公司 | 一种化工泵过流部件喷焊方法 |
| CN107322180A (zh) * | 2017-07-12 | 2017-11-07 | 江苏新航合金科技有限公司 | 一种生物质锅炉防腐堆焊用镍基丝材及其制备方法 |
| CN109317864A (zh) * | 2018-12-06 | 2019-02-12 | 衢州学院 | 一种镍基粉末钎焊材料的制备方法及其应用工艺 |
| CN112048642A (zh) * | 2020-08-25 | 2020-12-08 | 上海繁威能源工程有限公司 | 一种抗高温氯腐蚀的耐蚀合金材料及应用方法 |
| CN115821115B (zh) * | 2022-11-18 | 2024-01-09 | 江阴市诚信合金材料有限公司 | 一种高稳定性镍铬电阻合金丝及其生产工艺 |
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| US5935350A (en) * | 1997-01-29 | 1999-08-10 | Deloro Stellite Company, Inc | Hardfacing method and nickel based hardfacing alloy |
| CN1331634C (zh) * | 2004-12-22 | 2007-08-15 | 攀钢集团攀枝花钢铁研究院 | 一种镍基喷熔合金粉及其制备方法 |
| CN101591482B (zh) * | 2008-11-28 | 2011-03-16 | 中国电力科学研究院 | 一种耐磨耐蚀纳米结构Ni基涂层及制备方法 |
| CN102828138A (zh) * | 2012-09-14 | 2012-12-19 | 兰州理工合金粉末有限责任公司 | 用于等离子堆焊的镍铬钼钨合金粉末 |
| CN102851544B (zh) * | 2012-10-09 | 2015-04-01 | 天津市铸金表面工程材料科技开发有限公司 | 耐蚀镍基合金堆焊粉末 |
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