CN107366793A - 一种组合式局部更换弯头 - Google Patents
一种组合式局部更换弯头 Download PDFInfo
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Abstract
一种组合式局部更换弯头,在弯头部上设有一开口,该开口位于弯头部上对应进料端冲刷的位置,且开口上通过连接体可拆卸设置有密封件,紧贴所述密封件的内表面依次设置有金属基层、金属与陶瓷高温结合层、陶瓷层和陶瓷釉层,且陶瓷釉层的内表面为弧形凹面,并正对进料端的冲击点。本发明通过将弯头易磨损部位设置成一个开口,然后在该开口上设置可更换的密封件,密封件内依次设置金属基层、金属与陶瓷高温结合层、陶瓷层和陶瓷釉层,不仅大幅度增强了该部位的耐磨耐冲刷性能,大幅度提高了弯头的使用寿命,而且该部位一旦出现磨损,可以直接更换该部位即可,不用再更换整个弯头,从而降低了生产成本。
Description
技术领域
本发明属于机械领域中管路连接的弯头,具体的说是一种组合式局部更换弯头。
背景技术
在管路系统中,弯头是改变管路方向的管件,在矿山和化工领域输送料浆、粉料方面具有广泛应用。现有的弯头一般都是金属材质,在输送料浆、粉料时,由于料浆和粉料具有一定的压力,在管道输送过程中会冲击到弯头的特定内壁,从而导致该部分极易磨损,限制弯头使用寿命的主要因素即为此,由于现有的弯头都是一体成型的,一旦局部磨损就会导致整个弯头报废,不仅提高了生产的成本,而且也导致生产弯头的材料的浪费。
发明内容
为解决现有技术中弯头使用寿命短、局部磨损后需要整体更换所导致的成本高的问题,本发明提供了一种组合式局部更换弯头,通过将弯头易磨损点替换为可更换的密封件,并在密封件内依次设置金属基层、金属与陶瓷高温结合层、陶瓷层和陶瓷釉层,不仅大幅度增强了该部位的耐磨耐冲刷性能,大幅度提高了弯头的使用寿命,而且该部位一旦出现磨损,可以直接更换该部位即可,不用再更换整个弯头,从而降低了生产成本。
本发明为解决上述技术问题所采用的技术方案为:一种组合式局部更换弯头,包括弯头部、设置在弯头部两侧的进料端和出料端,所述弯头部上具有一开口,该开口位于弯头部上对应进料端冲刷的位置,且开口上通过连接体可拆卸设置有密封件,紧贴所述密封件的内表面依次设置有金属基层、金属与陶瓷高温结合层、陶瓷层和陶瓷釉层,且陶瓷釉层的内表面为弧形凹面,并正对进料端的冲击点;
所述金属基层为熔点高于1800℃的合金层,所述陶瓷层为表面具有微小孔隙的陶瓷,以使该陶瓷与金属基层在烧结时,金属基层的成分进入到微小孔隙中从而形成金属与陶瓷高温结合层,所述陶瓷釉层为陶瓷层外表面施加的釉料烧结后形成;
所述陶瓷层由主料、制孔剂和填充剂在1500℃条件下烧制而成,按照重量比,所述主料由40-45份煅烧高岭土、10-15份的木节粘土和20-24份的石英砂组成,制孔剂由4-6份细度不超过30微米的碳化硅细粉和2-3份的碱石灰组成,填充剂由3-5份细度不超过45微米的蓝晶石细粉、6-9份细度不超过5微米的活性氧化铝微粉和2-3份的滑石粉组成;
所述陶瓷釉层选用烧结温度不超过1400℃的釉料烧结即可。
所述金属与陶瓷高温结合层为金属基层与陶瓷层和陶瓷釉层在高温下烧结后固化形成的连接层。
所述连接体为分别设置在弯头部上开口处和设置在密封件的连接法兰盘,密封件与其上的连接法兰盘通过螺栓可拆卸连接,且该连接法兰盘将密封件内的金属基层、金属与陶瓷高温结合层、陶瓷层和陶瓷釉层卡在密封件内表面上,两个连接法兰盘通过螺栓连接,且两者之间设置有密封垫片。
所述陶瓷层、金属基层的烧结方法为:
1)按照所述的比例称取各物料混合,并依次向其中加入与物料总重相等的水、物料总重1-2%的丙酮和物料总重0.8-1%的工业植物油,拌合均匀制成细度为300-400目的泥浆,备用;
2)使用步骤1)制得的泥浆在金属基层的内表面塑型,再将静置晾干后入窑炉进行初次烧结,然后随炉冷却至常温;
所述初次烧结分为低温塑形段、中温烘烤段和氧化烧结段三部分,其中,低温塑形段是指使炉内温度从常温在6h均匀升高到400℃,并保持该温度1-2h,在此过程中,保持炉内氧气含量不高于5%;
所述中温烘烤段是指,使炉内温度从400℃在4h均匀升高到1000℃,在此过程中,保持炉内氧气含量不低于40%;
所述氧化烧结段是指,使炉内温度从1000℃在2h均匀升高到1500℃,并保持该温度2-3h,在此过程中,保持炉内氧气含量不低于40%;
3)选用陶瓷领域中烧结温度不超过1400℃的釉料制成料浆,并对初次烧结后形成的陶瓷层表面施釉并再次烧结,从而在陶瓷层表面形成光滑致密的陶瓷釉层。
本发明中,以烧制陶瓷的常规原料高岭土、木节粘土和石英作为主料,其中混入碳化硅和碱石灰作为制孔剂,既可确保烧成后的陶瓷素坯中含有一些开放型气孔或称开口气孔,而且也不会影响其强度;碳化硅在高温氧化气氛中容易发生氧化反应:SiC+2O2→CO2+SiO2,该反应开始温度较高,1000℃开始明显氧化,颗粒越细,则氧化速度越快,反应产物CO2的逸出容易造成陶瓷坯体表面形成开口气孔,这些气孔在高温下会被软化的金属基层的分子迁移所填充,从而形成金属与陶瓷高温结合层;而反应产物SiO2具有较高活性,与氧化铝反应生成莫来石,从而在陶瓷内形成莫来石增强体;同时,本发明中填充剂在高温下,其中的蓝晶石细粉,既可确保生成较多的莫来石相,保证制品的力学强度,蓝晶石从1100℃左右开始分解、生成莫来石和SiO2,1300℃以后显著分解转化,由于该莫来石化反应伴随有16-18%的体积膨胀,因此还可填充由于碳化硅氧化产生的孔隙,使单个孔隙变小,整体孔隙率降低,并且会改变陶瓷内孔隙的形状和分布,从而使其在与釉料结合烧制时,部分釉料渗入孔隙内填充和堵塞孔隙。
有益效果:本发明与现有技术相比,具备以下优点:
1)本发明通过将弯头易磨损部位设置成一个开口,然后在该开口上设置可更换的密封件,密封件内依次设置金属基层、金属与陶瓷高温结合层、陶瓷层和陶瓷釉层,不仅大幅度增强了该部位的耐磨耐冲刷性能,大幅度提高了弯头的使用寿命,而且该部位一旦出现磨损,可以直接更换该部位即可,不用再更换整个弯头,从而降低了生产成本;
2)本发明的陶瓷层以烧制陶瓷的常规原料高岭土、木节粘土和石英作为主料,其中混入碳化硅和碱石灰作为制孔剂,既可确保烧成后的陶瓷素坯中含有一些开放型气孔或称开口气孔,而且也不会影响其强度,通过加入高温下体积膨胀的蓝晶石粉,使得开放型气孔明显缩小,从而在陶瓷内部和表面形成细小的气孔,从而使其在高温下与金属基层形成金属与陶瓷高温结合层,使两者紧密结合,进一步增强了耐磨性和耐冲刷性;
3)本发明的陶瓷层在使用原料制成泥浆时,除了加入常规的水之外,还加入了丙酮和工业植物油,这两种物质混合在泥浆里,在低温塑形阶段能够缓慢的气化,从而脱离泥浆,并在表面形成微小的气孔,而且也能增强泥料的粘性,防止泥浆表面出现裂纹导致在后续烧制中损坏。
附图说明
图1为本发明的整体结构示意图;
图2为本发明密封件的结构示意图;
附图标记:1、密封件,101、金属基层,102、金属与陶瓷高温结合层,103、陶瓷层,104、陶瓷釉层,2、弯头部,3、进料端,4、出料端,5、连接体。
具体实施方式
下面结合具体实施例对本发明做进一步的阐述,以下各实施例中所用的原料均为本领域常规的原料或者是从市面上能够购买得到。
如图所示,一种组合式局部更换弯头,包括弯头部2、设置在弯头部2两侧的进料端3和出料端4,所述弯头部2上具有一开口,该开口位于弯头部2上对应进料端3冲刷的位置,且开口上通过连接体5可拆卸设置有密封件1,紧贴所述密封件1的内表面依次设置有金属基层101、金属与陶瓷高温结合层102、陶瓷层103和陶瓷釉层104,且陶瓷釉层104的内表面为弧形凹面,并正对进料端3的冲击点。
以上为本发明的基本实施方式,可在以上基础上做进一步的改进、优化和限定:
如,所述金属与陶瓷高温结合层102为金属基层101与陶瓷层103和陶瓷釉层104在高温下烧结后固化形成的连接层;
又如,所述连接体5为分别设置在弯头部2上开口处和设置在密封件1的连接法兰盘,密封件1与其上的连接法兰盘通过螺栓可拆卸连接,且该连接法兰盘将密封件1内的金属基层101、金属与陶瓷高温结合层102、陶瓷层103和陶瓷釉层104卡在密封件1内表面上,两个连接法兰盘通过螺栓连接,且两者之间设置有密封垫片;
再如,所述金属基层101为熔点高于1800℃的合金层,所述陶瓷层103为表面具有微小孔隙的陶瓷,以使该陶瓷与金属基层101在烧结时,金属基层101的成分进入到微小孔隙中从而形成金属与陶瓷高温结合层102,所述陶瓷釉层104为陶瓷层103外表面施加的釉料烧结后形成;
本发明中,陶瓷层103的组分和烧制方法可以使以下三种方式:
方案一
所述陶瓷层103由主料、制孔剂和填充剂在1500℃条件下烧制而成,按照重量比,所述主料由40份煅烧高岭土、10份的木节粘土和20份的石英砂组成,制孔剂由4份细度不超过30微米的碳化硅细粉和2份的碱石灰组成,填充剂由3份细度不超过45微米的蓝晶石细粉、6份细度不超过5微米的活性氧化铝微粉和2份的滑石粉组成;
所述陶瓷釉层104选用烧结温度不超过1400℃的釉料烧结即可,其目的是堵塞陶瓷层103表面的微小气孔,减小弯头内流体的冲击阻力;
所述陶瓷层103、金属基层101的烧结方法为:
1)按照所述的比例称取各物料混合,并依次向其中加入与物料总重相等的水、物料总重1%的丙酮和物料总重0.8%的工业植物油,拌合均匀制成细度为300目的泥浆,备用;
2)使用步骤1)制得的泥浆在金属基层101的内表面塑型,再将静置晾干后入窑炉进行初次烧结,然后随炉冷却至常温;
所述初次烧结分为低温塑形段、中温烘烤段和氧化烧结段三部分,其中,低温塑形段是指使炉内温度从常温在6h均匀升高到400℃,并保持该温度1h,在此过程中,保持炉内氧气含量不高于5%;
所述中温烘烤段是指,使炉内温度从400℃在4h均匀升高到1000℃,在此过程中,保持炉内氧气含量不低于40%;
所述氧化烧结段是指,使炉内温度从1000℃在2h均匀升高到1500℃,并保持该温度2h,在此过程中,保持炉内氧气含量不低于40%;
3)选用陶瓷领域中烧结温度不超过1400℃的釉料制成料浆,并对初次烧结后形成的陶瓷层103表面施釉并再次烧结,从而在陶瓷层103表面形成光滑致密的陶瓷釉层104。
方案二
所述陶瓷层103由主料、制孔剂和填充剂在1500℃条件下烧制而成,按照重量比,所述主料由45份煅烧高岭土、15份的木节粘土和24份的石英砂组成,制孔剂由6份细度不超过30微米的碳化硅细粉和3份的碱石灰组成,填充剂由5份细度不超过45微米的蓝晶石细粉、9份细度不超过5微米的活性氧化铝微粉和3份的滑石粉组成;
所述陶瓷釉层104选用烧结温度不超过1400℃的釉料烧结即可,其目的是堵塞陶瓷层103表面的微小气孔,减小弯头内流体的冲击阻力;
所述陶瓷层103、金属基层101的烧结方法为:
1)按照所述的比例称取各物料混合,并依次向其中加入与物料总重相等的水、物料总重2%的丙酮和物料总重1%的工业植物油,拌合均匀制成细度为400目的泥浆,备用;
2)使用步骤1)制得的泥浆在金属基层101的内表面塑型,再将静置晾干后入窑炉进行初次烧结,然后随炉冷却至常温;
所述初次烧结分为低温塑形段、中温烘烤段和氧化烧结段三部分,其中,低温塑形段是指使炉内温度从常温在6h均匀升高到400℃,并保持该温度2h,在此过程中,保持炉内氧气含量不高于5%;
所述中温烘烤段是指,使炉内温度从400℃在4h均匀升高到1000℃,在此过程中,保持炉内氧气含量不低于40%;
所述氧化烧结段是指,使炉内温度从1000℃在2h均匀升高到1500℃,并保持该温度3h,在此过程中,保持炉内氧气含量不低于40%;
3)选用陶瓷领域中烧结温度不超过1400℃的釉料制成料浆,并对初次烧结后形成的陶瓷层103表面施釉并再次烧结,从而在陶瓷层103表面形成光滑致密的陶瓷釉层104。
方案三
所述陶瓷层103由主料、制孔剂和填充剂在1500℃条件下烧制而成,按照重量比,所述主料由42.5份煅烧高岭土、12.5份的木节粘土和22份的石英砂组成,制孔剂由5份细度不超过30微米的碳化硅细粉和2.5份的碱石灰组成,填充剂由4份细度不超过45微米的蓝晶石细粉、7.5份细度不超过5微米的活性氧化铝微粉和2.5份的滑石粉组成;
所述陶瓷釉层104选用烧结温度不超过1400℃的釉料烧结即可,其目的是堵塞陶瓷层103表面的微小气孔,减小弯头内流体的冲击阻力;
所述陶瓷层103、金属基层101的烧结方法为:
1)按照所述的比例称取各物料混合,并依次向其中加入与物料总重相等的水、物料总重1.5%的丙酮和物料总重0.9%的工业植物油,拌合均匀制成细度为350目的泥浆,备用;
2)使用步骤1)制得的泥浆在金属基层101的内表面塑型,再将静置晾干后入窑炉进行初次烧结,然后随炉冷却至常温;
所述初次烧结分为低温塑形段、中温烘烤段和氧化烧结段三部分,其中,低温塑形段是指使炉内温度从常温在6h均匀升高到400℃,并保持该温度1.5h,在此过程中,保持炉内氧气含量不高于5%;
所述中温烘烤段是指,使炉内温度从400℃在4h均匀升高到1000℃,在此过程中,保持炉内氧气含量不低于40%;
所述氧化烧结段是指,使炉内温度从1000℃在2h均匀升高到1500℃,并保持该温度2.5h,在此过程中,保持炉内氧气含量不低于40%;
3)选用陶瓷领域中烧结温度不超过1400℃的釉料制成料浆,并对初次烧结后形成的陶瓷层103表面施釉并再次烧结,从而在陶瓷层103表面形成光滑致密的陶瓷釉层104。
Claims (4)
1.一种组合式局部更换弯头,包括弯头部(2)、设置在弯头部(2)两侧的进料端(3)和出料端(4),其特征在于:所述弯头部(2)上具有一开口,该开口位于弯头部(2)上对应进料端(3)冲刷的位置,且开口上通过连接体(5)可拆卸设置有密封件(1),紧贴所述密封件(1)的内表面依次设置有金属基层(101)、金属与陶瓷高温结合层(102)、陶瓷层(103)和陶瓷釉层(104),且陶瓷釉层(104)的内表面为弧形凹面,并正对进料端(3)的冲击点;
所述金属基层(101)为熔点高于1800℃的合金层,所述陶瓷层(103)为表面具有微小孔隙的陶瓷,以使该陶瓷与金属基层(101)在烧结时,金属基层(101)的成分进入到微小孔隙中从而形成金属与陶瓷高温结合层(102),所述陶瓷釉层(104)为陶瓷层(103)外表面施加的釉料烧结后形成;
所述陶瓷层(103)由主料、制孔剂和填充剂在1500℃条件下烧制而成,按照重量比,所述主料由40-45份煅烧高岭土、10-15份的木节粘土和20-24份的石英砂组成,制孔剂由4-6份细度不超过30微米的碳化硅细粉和2-3份的碱石灰组成,填充剂由3-5份细度不超过45微米的蓝晶石细粉、6-9份细度不超过5微米的活性氧化铝微粉和2-3份的滑石粉组成;
所述陶瓷釉层(104)选用烧结温度不超过1400℃的釉料烧结即可。
2.根据权利要求1所述的一种组合式局部更换弯头,其特征在于:所述金属与陶瓷高温结合层(102)为金属基层(101)与陶瓷层(103)和陶瓷釉层(104)在高温下烧结后固化形成的连接层。
3.根据权利要求1所述的一种组合式局部更换弯头,其特征在于:所述连接体(5)为分别设置在弯头部(2)上开口处和设置在密封件(1)的连接法兰盘,密封件(1)与其上的连接法兰盘通过螺栓可拆卸连接,且该连接法兰盘将密封件(1)内的金属基层(101)、金属与陶瓷高温结合层(102)、陶瓷层(103)和陶瓷釉层(104)卡在密封件(1)内表面上,两个连接法兰盘通过螺栓连接,且两者之间设置有密封垫片。
4.根据权利要求1所述的一种组合式局部更换弯头,其特征在于:所述陶瓷层(103)、金属基层(101)的烧结方法为:
1)按照权利要求1所述的比例称取各物料混合,并依次向其中加入与物料总重相等的水、物料总重1-2%的丙酮和物料总重0.8-1%的工业植物油,拌合均匀制成细度为300-400目的泥浆,备用;
2)使用步骤1)制得的泥浆在金属基层(101)的内表面塑型,再将静置晾干后入窑炉进行初次烧结,然后随炉冷却至常温;
所述初次烧结分为低温塑形段、中温烘烤段和氧化烧结段三部分,其中,低温塑形段是指使炉内温度从常温在6h均匀升高到400℃,并保持该温度1-2h,在此过程中,保持炉内氧气含量不高于5%;
所述中温烘烤段是指,使炉内温度从400℃在4h均匀升高到1000℃,在此过程中,保持炉内氧气含量不低于40%;
所述氧化烧结段是指,使炉内温度从1000℃在2h均匀升高到1500℃,并保持该温度2-3h,在此过程中,保持炉内氧气含量不低于40%;
3)选用陶瓷领域中烧结温度不超过1400℃的釉料制成料浆,并对初次烧结后形成的陶瓷层(103)表面施釉并再次烧结,从而在陶瓷层(103)表面形成光滑致密的陶瓷釉层(104)。
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