CN107723611A - 一种阀门用耐腐蚀法兰的加工工艺 - Google Patents
一种阀门用耐腐蚀法兰的加工工艺 Download PDFInfo
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Abstract
本发明涉及一种阀门用耐腐蚀法兰的加工工艺,属于阀门设备技术领域。该加工工艺包括㈠熔炼原料;㈡壳模制备;㈢壳模焙烧;㈣浇注;㈤浇注成型后,待铸件冷却到室温,进行破碎模壳脱模,之后切除铸件的保温冒口,得到铸件;㈥对铸件进行打磨和抛光,打磨和抛光后将铸件置于工业洗涤剂中,利用超声波发生装置清洗;㈦将超声波清洗后的铸件用水进行冲洗;㈧采用热风机对铸件进行烘干;㈨在铸件表面电镀锌镍合金镀层;㈩在纯铝镀层通过雾化喷涂的方法涂覆耐火涂层。采用本发明的成分质量百分比铸造的阀门用耐腐蚀法兰具有耐腐蚀、耐高温、强度高和使用寿命长的优点。
Description
技术领域
本发明涉及一种阀门用耐腐蚀法兰的加工工艺,属于管道连接技术领域。
背景技术
法兰又叫法兰盘或突缘,使管子与管子相互连接的零件,连接于管端。法兰上有孔眼,可穿螺栓,通常是指在一个类似盘状的金属体的周边开上几个固定用的孔用于连接其它的东西。现有的法兰连接就是把两个管道、管件或器材,先各自固定在一个法兰盘上,两个法兰盘之间,加上法兰垫,用螺栓紧固在一起,完成连接。法兰连接是管道施工的重要连接方式,法兰连接使用方便,能够承受较大的压力,在工业管道中,法兰连接的使用十分广泛。
阀门是流体输送系统中的控制部件,具有截止、调节、导流、防止逆流、稳压、分流或溢流泄压等功能;在阀门中法兰的应用比较普遍,通常用于连接阀门的进口和出口,目前的阀门用法兰不具有耐火性能,结构简单,使用寿命短。
发明内容
本发明要解决的技术问题是,针对现有技术不足,提出一种阀门用耐腐蚀法兰的加工工艺。
本发明为解决上述技术问题提出的技术方案是:一种阀门用耐腐蚀法兰的加工工艺,包括以下步骤:
㈠熔炼原料:
a、配料:所述阀门用耐腐蚀法兰中各成分的质量百分比为:C:0.01-0.05%,Al: 0.51-0.67%,Zn: 0.76-0.98%, Mn:0.62-0.74%, Cr:0.02-0.04%,Ni:0.16-0.18%,Cu:0.17-0.25%,Mo:0.01-0.02%,Ce:0.05-0.07%,Eu:0.02-0.03%,Lu:0.32-0.46%,Ag:0.06-0.07%,Ga:0.05-0.08%,Sn:0.35-0.43%,Zr:0.04-0.06%,Re:0.02-0.05%,氧化镁:0.05-0.07%,余量为Fe;
b、按预定的法兰中各成分的质量百分比将原料加入熔炉内,将熔炉内的温度提高到1250摄氏度至1300摄氏度,原料被熔炼形成合金溶液;
㈡壳模制备,具体步骤如下:
A、蜡模制备:制作与铸造件的造型一致并包含有保温冒口的蜡模,并对蜡模进行修整;
B、在蜡模上制作壳模;
C、脱蜡:采用蒸汽脱蜡,蒸汽的压力为0.5MPa, 时间为15~25分钟,制得壳模;
㈢壳模焙烧
采用分段升温焙烧方式对壳模进行焙烧,在焙烧中:首先在200摄氏度以前升温速度控制在100摄氏度/小时,其次,在200摄氏度保温30分钟,然后,全速升温到1200摄氏度,且保持1200摄氏度50分钟,最后出炉冷却;
㈣浇注
将步骤㈠得到的合金溶液向壳模内进行浇注,浇注时,浇注温度为1300~1350摄氏度,在五分钟内浇注完毕;
㈤浇注成型后,待铸件冷却到室温,进行破碎模壳脱模,之后切除铸件的保温冒口,得到铸件;
㈥对铸件进行打磨和抛光,打磨和抛光后将铸件置于工业洗涤剂中,利用超声波发生装置对所述工业洗涤剂施加超声波,超声波的频率和声强分别是8KHZ~16MHZ和9~11W/cm2,清洗15分钟;
其中:所述工业洗涤剂由以下各组分的原料组成:磷酸三钠13-16份,单硬脂酸甘油脂15-18份,硬脂酰二乙醇胺5-6份,无味松节油13-14份,乙醇7-11份,三乙醇胺15-17份,对羟基苯甲酸3-5份,氯化钠3-6份,水41-45份;
㈦将超声波清洗后的铸件用水进行冲洗;
㈧采用热风机对铸件进行烘干;
㈨在铸件表面电镀锌镍合金镀层,镀层厚度为50±10μm;
㈩在纯铝镀层通过雾化喷涂的方法涂覆耐火涂层, 涂层喷涂厚度0.5-1.2mm,固化5-9小时后进行第二次喷涂,涂层喷涂厚度1.5-2.5mm,固化12-16 小时,制得阀门用耐腐蚀法兰;
所述耐火涂层其原料组成按重量份包括:氧化铝:14~16份;氧化锌: 5~8份;偶联剂:5~9份;炭黑:11~13份;陶土:17~19份;硅藻土:6~8份;所述偶联剂为乙烯基摩尔分数为0.11~0.12%的甲基乙烯基有机聚硅氧烷。
上述技术方案的改进是:所述阀门用耐腐蚀法兰中各成分的质量百分比为:C:0.01%,Al: 0.51%,Zn: 0.76%, Mn:0.62%, Cr:0.02%,Ni:0.16%,Cu:0.17%,Mo:0.01%,Ce:0.05%,Eu:0.02%,Lu:0.32%,Ag:0.06%,Ga:0.05%,Sn:0.35%,Zr:0.04%,Re:0.02%,氧化镁:0.05%,余量为Fe。
上述技术方案的改进是:所述阀门用耐腐蚀法兰中各成分的质量百分比为:C:0.05%,Al:0.67%,Zn: 0.98%, Mn:0.74%, Cr:0.04%,Ni:0.18%,Cu:0.25%,Mo:0.02%,Ce:0.07%,Eu:0.03%,Lu:0.46%,Ag:0.07%,Ga:0.08%,Sn:0.43%,Zr:0.06%,Re:0.05%,氧化镁:0.07%,余量为Fe。
上述技术方案的改进是:步骤㈥中所述工业洗涤剂由以下各组分的原料组成:磷酸三钠13份,单硬脂酸甘油脂18份,硬脂酰二乙醇胺5份,无味松节油14份,乙醇7份,三乙醇胺15份,对羟基苯甲酸3份,氯化钠3份,水45份。
上述技术方案的改进是:步骤㈩中所述耐火涂层其原料组成按重量份包括:氧化铝:16份;氧化锌:8份;偶联剂:9份;炭黑:13份;陶土:17份;硅藻土:6份;所述偶联剂为乙烯基摩尔分数为0.11~0.12%的甲基乙烯基有机聚硅氧烷。
本发明采用上述技术方案的有益效果是:(1)采用本发明的成分质量百分比铸造的阀门用耐腐蚀法兰具有耐腐蚀、耐高温、强度高和使用寿命长的优点;(2)由于原料含有Zn、Ni,加强了法兰的耐腐蚀性能,原料中还添加了稀土元素,进一步提高了法兰的力学性能和耐腐蚀性能(3)对铸件进行打磨和抛光,使得制得的铸件更加精细;(4)打磨和抛光后通过超声波对铸件进行清洗,更加高效,清洗更加彻底;(5)在超声波清洗中采用了工业洗涤剂,有效的去除了难以清理的油污等杂质,保证了清洗的质量;(6)发明在法兰的表面通过雾化喷涂的方法涂覆耐火涂层,在锌镍合金镀层外又有了一层耐火涂层,使得法兰不仅具有耐腐蚀性能,还具有了耐火性能,大大延长了使用寿命,保证了工作的稳定。
具体实施方式
实施例一
本实施例的阀门用耐腐蚀法兰的加工工艺包括以下步骤:
㈠熔炼原料:
a、配料:所述阀门用耐腐蚀法兰中各成分的质量百分比为:C:0.01%,Al: 0.51%,Zn:0.76%, Mn:0.62%, Cr:0.02%,Ni:0.16%,Cu:0.17%,Mo:0.01%,Ce:0.05%,Eu:0.02%,Lu:0.32%,Ag:0.06%,Ga:0.05%,Sn:0.35%,Zr:0.04%,Re:0.02%,氧化镁:0.05%,余量为Fe;
b、按预定的法兰中各成分的质量百分比将原料加入熔炉内,将熔炉内的温度提高到1250摄氏度至1300摄氏度,原料被熔炼形成合金溶液;
㈡壳模制备,具体步骤如下:
A、蜡模制备:制作与铸造件的造型一致并包含有保温冒口的蜡模,并对蜡模进行修整;
B、在蜡模上制作壳模;
C、脱蜡:采用蒸汽脱蜡,蒸汽的压力为0.5MPa, 时间为15~25分钟,制得壳模;
㈢壳模焙烧
采用分段升温焙烧方式对壳模进行焙烧,在焙烧中:首先在200摄氏度以前升温速度控制在100摄氏度/小时,其次,在200摄氏度保温30分钟,然后,全速升温到1200摄氏度,且保持1200摄氏度50分钟,最后出炉冷却;
㈣浇注
将步骤㈠得到的合金溶液向壳模内进行浇注,浇注时,浇注温度为1300~1350摄氏度,在五分钟内浇注完毕;
㈤浇注成型后,待铸件冷却到室温,进行破碎模壳脱模,之后切除铸件的保温冒口,得到铸件;
㈥对铸件进行打磨和抛光,打磨和抛光后将铸件置于工业洗涤剂中,利用超声波发生装置对所述工业洗涤剂施加超声波,超声波的频率和声强分别是8KHZ~16MHZ和9~11W/cm2,清洗15分钟;
其中:所述工业洗涤剂由以下各组分的原料组成:磷酸三钠13份,单硬脂酸甘油脂18份,硬脂酰二乙醇胺5份,无味松节油14份,乙醇7份,三乙醇胺15份,对羟基苯甲酸3份,氯化钠3份,水45份;
㈦将超声波清洗后的铸件用水进行冲洗;
㈧采用热风机对铸件进行烘干;
㈨在铸件表面电镀锌镍合金镀层,镀层厚度为50±10μm;
㈩在纯铝镀层通过雾化喷涂的方法涂覆耐火涂层, 涂层喷涂厚度0.5-1.2mm,固化5-9小时后进行第二次喷涂,涂层喷涂厚度1.5-2.5mm,固化12-16 小时,制得阀门用耐腐蚀法兰;
所述耐火涂层其原料组成按重量份包括:氧化铝:16份;氧化锌:8份;偶联剂:9份;炭黑:13份;陶土:17份;硅藻土:6份;所述偶联剂为乙烯基摩尔分数为0.11~0.12%的甲基乙烯基有机聚硅氧烷。
实施例二
本实施例的阀门用耐腐蚀法兰的加工工艺,包括以下步骤:
㈠熔炼原料:
a、配料:所述阀门用耐腐蚀法兰中各成分的质量百分比为:C:0.05%,Al:0.67%,Zn:0.98%, Mn:0.74%, Cr:0.04%,Ni:0.18%,Cu:0.25%,Mo:0.02%,Ce:0.07%,Eu:0.03%,Lu:0.46%,Ag:0.07%,Ga:0.08%,Sn:0.43%,Zr:0.06%,Re:0.05%,氧化镁:0.07%,余量为Fe;
b、按预定的法兰中各成分的质量百分比将原料加入熔炉内,将熔炉内的温度提高到1250摄氏度至1300摄氏度,原料被熔炼形成合金溶液;
㈡壳模制备,具体步骤如下:
A、蜡模制备:制作与铸造件的造型一致并包含有保温冒口的蜡模,并对蜡模进行修整;
B、在蜡模上制作壳模;
C、脱蜡:采用蒸汽脱蜡,蒸汽的压力为0.5MPa, 时间为15~25分钟,制得壳模;
㈢壳模焙烧
采用分段升温焙烧方式对壳模进行焙烧,在焙烧中:首先在200摄氏度以前升温速度控制在100摄氏度/小时,其次,在200摄氏度保温30分钟,然后,全速升温到1200摄氏度,且保持1200摄氏度50分钟,最后出炉冷却;
㈣浇注
将步骤㈠得到的合金溶液向壳模内进行浇注,浇注时,浇注温度为1300~1350摄氏度,在五分钟内浇注完毕;
㈤浇注成型后,待铸件冷却到室温,进行破碎模壳脱模,之后切除铸件的保温冒口,得到铸件;
㈥对铸件进行打磨和抛光,打磨和抛光后将铸件置于工业洗涤剂中,利用超声波发生装置对所述工业洗涤剂施加超声波,超声波的频率和声强分别是8KHZ~16MHZ和9~11W/cm2,清洗15分钟;
其中:所述工业洗涤剂由以下各组分的原料组成:磷酸三钠13份,单硬脂酸甘油脂18份,硬脂酰二乙醇胺5份,无味松节油14份,乙醇7份,三乙醇胺15份,对羟基苯甲酸3份,氯化钠3份,水45份;
㈦将超声波清洗后的铸件用水进行冲洗;
㈧采用热风机对铸件进行烘干;
㈨在铸件表面电镀锌镍合金镀层,镀层厚度为50±10μm;
㈩在纯铝镀层通过雾化喷涂的方法涂覆耐火涂层, 涂层喷涂厚度0.5-1.2mm,固化5-9小时后进行第二次喷涂,涂层喷涂厚度1.5-2.5mm,固化12-16 小时,制得阀门用耐腐蚀法兰;
所述耐火涂层其原料组成按重量份包括:氧化铝:16份;氧化锌:8份;偶联剂:9份;炭黑:13份;陶土:17份;硅藻土:6份;所述偶联剂为乙烯基摩尔分数为0.11~0.12%的甲基乙烯基有机聚硅氧烷。
本发明不局限于上述实施例。凡采用等同替换形成的技术方案,均落在本发明要求的保护范围。
Claims (5)
1.一种阀门用耐腐蚀法兰的加工工艺,其特征在于:包括以下步骤:
㈠熔炼原料:
a、配料:所述阀门用耐腐蚀法兰中各成分的质量百分比为:C:0.01-0.05%,Al: 0.51-0.67%,Zn: 0.76-0.98%, Mn:0.62-0.74%, Cr:0.02-0.04%,Ni:0.16-0.18%,Cu:0.17-0.25%,Mo:0.01-0.02%,Ce:0.05-0.07%,Eu:0.02-0.03%,Lu:0.32-0.46%,Ag:0.06-0.07%,Ga:0.05-0.08%,Sn:0.35-0.43%,Zr:0.04-0.06%,Re:0.02-0.05%,氧化镁:0.05-0.07%,余量为Fe;
b、按预定的法兰中各成分的质量百分比将原料加入熔炉内,将熔炉内的温度提高到1250摄氏度至1300摄氏度,原料被熔炼形成合金溶液;
㈡壳模制备,具体步骤如下:
A、蜡模制备:制作与铸造件的造型一致并包含有保温冒口的蜡模,并对蜡模进行修整;
B、在蜡模上制作壳模;
C、脱蜡:采用蒸汽脱蜡,蒸汽的压力为0.5MPa, 时间为15~25分钟,制得壳模;
㈢壳模焙烧
采用分段升温焙烧方式对壳模进行焙烧,在焙烧中:首先在200摄氏度以前升温速度控制在100摄氏度/小时,其次,在200摄氏度保温30分钟,然后,全速升温到1200摄氏度,且保持1200摄氏度50分钟,最后出炉冷却;
㈣浇注
将步骤㈠得到的合金溶液向壳模内进行浇注,浇注时,浇注温度为1300~1350摄氏度,在五分钟内浇注完毕;
㈤浇注成型后,待铸件冷却到室温,进行破碎模壳脱模,之后切除铸件的保温冒口,得到铸件;
㈥对铸件进行打磨和抛光,打磨和抛光后将铸件置于工业洗涤剂中,利用超声波发生装置对所述工业洗涤剂施加超声波,超声波的频率和声强分别是8KHZ~16MHZ和9~11W/cm2,清洗15分钟;
其中:所述工业洗涤剂由以下各组分的原料组成:磷酸三钠13-16份,单硬脂酸甘油脂15-18份,硬脂酰二乙醇胺5-6份,无味松节油13-14份,乙醇7-11份,三乙醇胺15-17份,对羟基苯甲酸3-5份,氯化钠3-6份,水41-45份;
㈦将超声波清洗后的铸件用水进行冲洗;
㈧采用热风机对铸件进行烘干;
㈨在铸件表面电镀锌镍合金镀层,镀层厚度为50±10μm;
㈩在纯铝镀层通过雾化喷涂的方法涂覆耐火涂层, 涂层喷涂厚度0.5-1.2mm,固化5-9小时后进行第二次喷涂,涂层喷涂厚度1.5-2.5mm,固化12-16 小时,制得阀门用耐腐蚀法兰;
所述耐火涂层其原料组成按重量份包括:氧化铝:14~16份;氧化锌: 5~8份;偶联剂:5~9份;炭黑:11~13份;陶土:17~19份;硅藻土:6~8份;所述偶联剂为乙烯基摩尔分数为0.11~0.12%的甲基乙烯基有机聚硅氧烷。
2.根据权利要求1所述的阀门用耐腐蚀法兰的加工工艺,其特征在于:所述阀门用耐腐蚀法兰中各成分的质量百分比为:C:0.01%,Al: 0.51%,Zn: 0.76%, Mn:0.62%, Cr:0.02%,Ni:0.16%,Cu:0.17%,Mo:0.01%,Ce:0.05%,Eu:0.02%,Lu:0.32%,Ag:0.06%,Ga:0.05%,Sn:0.35%,Zr:0.04%,Re:0.02%,氧化镁:0.05%,余量为Fe。
3.根据权利要求1所述的阀门用耐腐蚀法兰的加工工艺,其特征在于:所述阀门用耐腐蚀法兰中各成分的质量百分比为:C:0.05%,Al:0.67%,Zn: 0.98%, Mn:0.74%, Cr:0.04%,Ni:0.18%,Cu:0.25%,Mo:0.02%,Ce:0.07%,Eu:0.03%,Lu:0.46%,Ag:0.07%,Ga:0.08%,Sn:0.43%,Zr:0.06%,Re:0.05%,氧化镁:0.07%,余量为Fe。
4.根据权利要求1所述的阀门用耐腐蚀法兰的加工工艺,其特征在于:步骤㈥中所述工业洗涤剂由以下各组分的原料组成:磷酸三钠13份,单硬脂酸甘油脂18份,硬脂酰二乙醇胺5份,无味松节油14份,乙醇7份,三乙醇胺15份,对羟基苯甲酸3份,氯化钠3份,水45份。
5.根据权利要求1所述的阀门用耐腐蚀法兰的加工工艺,其特征在于:步骤㈩中所述耐火涂层其原料组成按重量份包括:氧化铝:16份;氧化锌:8份;偶联剂:9份;炭黑:13份;陶土:17份;硅藻土:6份;所述偶联剂为乙烯基摩尔分数为0.11~0.12%的甲基乙烯基有机聚硅氧烷。
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