CN106382456B - 一种大容积9100qp钢轻型气瓶及制作工艺 - Google Patents

一种大容积9100qp钢轻型气瓶及制作工艺 Download PDF

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CN106382456B
CN106382456B CN201610777087.2A CN201610777087A CN106382456B CN 106382456 B CN106382456 B CN 106382456B CN 201610777087 A CN201610777087 A CN 201610777087A CN 106382456 B CN106382456 B CN 106382456B
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CN106382456A (zh
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任方杰
邓春锋
武春学
张永峰
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CSSC Shuangrui Luoyang Special Equipment Co Ltd
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Abstract

本发明涉及一种大容积9100QP钢轻型气瓶及制作工艺，该气瓶包括两端开口的瓶体、有孔端塞、无孔端塞、外表面重防腐漆层及内表面耐蚀性复合涂层；瓶体的一端通过内螺纹与有孔端塞旋紧固定，有孔端塞通过螺纹与外部管路连接；瓶体的另一端通过内螺纹与无孔端塞旋紧固定；瓶体的内表面和外表面分别设有内表面耐蚀性复合涂层和外表面重防腐漆层；通过所述内表面耐蚀性复合涂层进行性能测试，膜层与基体的结合强度在50MPa以上，结合强度高；采用所述气瓶外表面重防腐漆层，根据实验室试验结果和实际使用结果，证明在气瓶全生命周期内防腐层可以满足防腐要求。

Description

一种大容积9100QP钢轻型气瓶及制作工艺
技术领域
本发明涉及压力容器领域，具体的说是一种适用于海洋腐蚀等特殊环境的一种大容积9100QP钢轻型气瓶及制作工艺。
背景技术
目前，市场上用于盛装高压气体设备主要为气瓶。气瓶在工业、民用和国防等领域广泛使用。在一些特殊使用环境下（如海洋腐蚀环境等），用户对气瓶的容重比（容积和重量的比值）和气瓶耐腐蚀性能提出了更高的要求。现有的气瓶工作压力一般在30MPa以下，且没有成熟的气瓶表面防腐技术，存在着工作压力和容重比小，易发生腐蚀失效等缺点。
发明内容
本发明的目的在于提供一种大容积9100QP钢轻型气瓶及制作工艺，工作压力≤60MPa，适合于海洋腐蚀等特殊环境下使用，结合先进的制造和内表面新型复合涂层技术，解决原有气瓶工作压力和容重比小、易发生腐蚀失效的问题。
为解决上述技术问题，本发明采用的技术方案为：
一种大容积9100QP钢轻型气瓶，该气瓶包括两端开口的瓶体、有孔端塞、无孔端塞、外表面重防腐漆层及内表面耐蚀性复合涂层；瓶体的一端通过内螺纹与有孔端塞旋紧固定，有孔端塞通过螺纹与外部管路连接；瓶体的另一端通过内螺纹与无孔端塞旋紧固定；瓶体的内表面和外表面分别设有内表面耐蚀性复合涂层和外表面重防腐漆层；
所述瓶体由9100QP钢制成，9100QP钢的化学成分如下：C-0.3～0.45%，Si-0.15～0.40%，Mn-0.30～0.5%，P+S-≤0.035%，Cr-1.0～1.5%，Mo-≤0.50%，Ni-2.75～3.5%，Cu-≤0.3%；
所述外表面重防腐漆层采用725-H44-61G型底漆和725-H42-30环氧面漆制成，725-H44-61G型底漆的化学成分按照质量百分比计如下：改性环氧树脂 25-35%，防锈颜填料 20-30%，着色颜料 10-15%，高效偶联助剂 5-7%，高效润湿分散剂 1-3%，非浮型铝粉浆3-6%，固化促进剂 1-3%，环氧固化剂 10-20%，溶剂 15-25%；725-H42-30环氧面漆的化学成分按照质量百分比计如下：环氧树脂 20-30%，防锈颜填料 13-25%，着色颜料 12-20%，高效消泡助剂 2-5%，高效润湿分散剂 2-5%，流变助剂 3-6%，环氧固化剂 15-25%，溶剂 15-25%。
所述瓶体与无孔端塞和有孔端塞之间分别通过紫铜垫片密封。
一种如上所述的大容积9100QP钢轻型气瓶的制作工艺，包括以下步骤：
步骤一：将9100QP大口径无缝钢管热旋压成瓶体；并进行调质热处理，使瓶体力学性能满足Rp0.2≥980MPa，Rm≥1130MPa，Z≥45%，A≥12%，-20℃Akv≥70J，-50℃Akv≥65J；
步骤二：在瓶体表面喷涂外表面重防腐漆层，首先喷涂2～3道725-H44-61G底漆，干膜厚度不小于320μm；再喷涂1～2道725-H42-30环氧面漆，干膜厚度不小于100μm；
步骤三：在瓶体内表面喷涂内表面耐蚀性复合涂层，依次进行前处理、镀膜及后处理。
本发明的有益效果：
本发明提供的一种大容积9100QP钢轻型气瓶，采用所述9100QP无缝钢管制造的气瓶热处理后具有良好的强度和冲击韧性，Rp0.2≥980MPa，Rm≥1130MPa，Z≥45%，A≥12%，-20℃Akv≥70J，-50℃Akv≥65J，气瓶综合力学性能优良，完全满足设计技术要求；通过所述内表面耐蚀性复合涂层进行性能测试，膜层与基体的结合强度在50MPa以上，结合强度高；中性盐雾试验膜层抗腐蚀能力达到240h以上，耐蚀性良好；通过疲劳性能测试（循环4000次以上），表面膜层可以满足气瓶充放压缩空气过程中对膜层伸缩的要求；采用所述气瓶外表面重防腐漆层，根据实验室试验结果和实际使用结果，证明在气瓶全生命周期内防腐层可以满足防腐要求。
附图说明
图1 本发明结构示意图；
附图标记：1、无孔端塞，2、紫铜垫圈，3、瓶体，4、外表面重防腐漆层，5、内表面耐蚀性复合涂层，6、有孔端塞。
具体实施方式
下面结合具体实施方式对本发明做进一步的阐述。
如图所示：一种大容积9100QP钢轻型气瓶，该气瓶包括两端开口的瓶体3、有孔端塞6、无孔端塞1、外表面重防腐漆层4及内表面耐蚀性复合涂层5；瓶体3的一端通过内螺纹与有孔端塞6旋紧固定，有孔端塞6通过螺纹与外部管路连接；瓶体3的另一端通过内螺纹与无孔端塞1旋紧固定；瓶体3的内表面和外表面分别设有内表面耐蚀性复合涂层5和外表面重防腐漆层4；所述瓶体3与无孔端塞1和有孔端塞6之间分别通过紫铜垫片2密封。
所述瓶体3由9100QP钢制成，9100QP钢的化学成分如下：C-0.3～0.45%，Si-0.15～0.40%，Mn-0.30～0.5%，P+S-≤0.035%，Cr-1.0～1.5%，Mo-≤0.50%，Ni-2.75～3.5%，Cu-≤0.3%；所述9100QP钢采用电弧炉加炉外精炼，并经电渣重熔、周期性连轧等技术制成9100QP大口径无缝钢管；
所述外表面重防腐漆层4采用725-H44-61G型底漆和725-H42-30环氧面漆制成，725-H44-61G型底漆的化学成分按照质量百分比计如下：改性环氧树脂 25-35%，防锈颜填料 20-30%，着色颜料 10-15%，高效偶联助剂 5-7%，高效润湿分散剂 1-3%，非浮型铝粉浆3-6%，固化促进剂 1-3%，环氧固化剂 10-20%，溶剂 15-25%；725-H42-30环氧面漆的化学成分按照质量百分比计如下：环氧树脂 20-30%，防锈颜填料 13-25%，着色颜料 12-20%，高效消泡助剂 2-5%，高效润湿分散剂 2-5%，流变助剂 3-6%，环氧固化剂 15-25%，溶剂 15-25%。
一种如上所述的大容积9100QP钢轻型气瓶的制作工艺，包括以下步骤：
步骤一：将9100QP大口径无缝钢管热旋压成瓶体；并进行调质热处理，使瓶体力学性能满足Rp0.2≥980MPa，Rm≥1130MPa，Z≥45%，A≥12%，-20℃Akv≥70J，-50℃Akv≥65J，满足设计要求；
步骤二：在瓶体表面喷涂外表面重防腐漆层，首先喷涂2～3道725-H44-61G底漆，干膜厚度不小于320μm；再喷涂1～2道725-H42-30环氧面漆，干膜厚度不小于100μm；
步骤三：在瓶体内表面喷涂内表面耐蚀性复合涂层，依次进行前处理、镀膜及后处理。
所述外表面重防腐漆层4，采用2～3道725-H44-61G底漆，干膜厚度不小于320μm，采用1～2道725-H42-30环氧面漆，干膜厚度不小于100μm，实际使用结果证明在气瓶全生命周期内防腐层可以满足防腐要求。
所述内表面新型耐蚀性复合涂层5，工艺流程为：前处理清理、镀膜、后处理封闭。性能测试表明：膜层与基体的结合强度在50MPa以上，结合强度高；中性盐雾试验膜层抗腐蚀能力达到240h以上，耐蚀性良好；通过疲劳性能测试循环4000次以上，表面膜层可以满足气瓶充放压缩空气过程中对膜层伸缩的要求。
本发明所述气瓶工作压力≤60MPa，采用进口三轴数控旋压机将9100QP大口径无缝钢管热旋压而成，适用于海洋腐蚀等特殊环境。

Claims (2)

1.一种大容积9100QP钢轻型气瓶，其特征在于：该气瓶包括两端开口的瓶体（3）、有孔端塞（6）、无孔端塞（1）、外表面重防腐漆层（4）及内表面耐蚀性复合涂层（5）；瓶体（3）的一端通过内螺纹与有孔端塞（6）旋紧固定，有孔端塞（6）通过螺纹与外部管路连接；瓶体（3）的另一端通过内螺纹与无孔端塞（1）旋紧固定；瓶体（3）的内表面和外表面分别设有内表面耐蚀性复合涂层（5）和外表面重防腐漆层（4）；
所述瓶体（3）由9100QP钢制成，9100QP钢的化学成分如下：C-0.3%～0.45%，Si-0.15%～0.40%，Mn-0.30%～0.5%，P+S-≤0.035%，Cr-1.0%～1.5%，Mo-≤0.50%，Ni-2.75%～3.5%，Cu-≤0.3%；
所述外表面重防腐漆层（4）采用725-H44-61G型底漆和725-H42-30环氧面漆制成，725-H44-61G型底漆的化学成分按照质量百分比计如下：改性环氧树脂 25%-35%，防锈颜填料20%-30%，着色颜料 10%-15%，高效偶联助剂 5%-7%，高效润湿分散剂 1%-3%，非浮型铝粉浆3%-6%，固化促进剂 1%-3%，环氧固化剂 10%-20%，溶剂 15%-25%；725-H42-30环氧面漆的化学成分按照质量百分比计如下：环氧树脂 20%-30%，防锈颜填料 13%-25%，着色颜料 12%-20%，高效消泡助剂 2%-5%，高效润湿分散剂 2%-5%，流变助剂 3%-6%，环氧固化剂 15%-25%，溶剂 15%-25%。
2.如权利要求1所述的大容积9100QP钢轻型气瓶，其特征在于：所述瓶体（3）与无孔端塞（1）和有孔端塞（6）之间分别通过紫铜垫片（2）密封。
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