CN107881502B - Production method of wear-resistant elbow for pipeline - Google Patents
Production method of wear-resistant elbow for pipeline Download PDFInfo
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- CN107881502B CN107881502B CN201711236482.0A CN201711236482A CN107881502B CN 107881502 B CN107881502 B CN 107881502B CN 201711236482 A CN201711236482 A CN 201711236482A CN 107881502 B CN107881502 B CN 107881502B
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- wear
- elbow
- resistant
- core
- bent pipe
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C24/00—Coating starting from inorganic powder
- C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
- C23C24/10—Coating starting from inorganic powder by application of heat or pressure and heat with intermediate formation of a liquid phase in the layer
- C23C24/103—Coating with metallic material, i.e. metals or metal alloys, optionally comprising hard particles, e.g. oxides, carbides or nitrides
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- C23C28/02—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material
- C23C28/021—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material including at least one metal alloy layer
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
- C23C4/06—Metallic material
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- 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
- C23C4/129—Flame spraying
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
- F16L43/00—Bends; Siphons
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Materials Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Physics & Mathematics (AREA)
- Plasma & Fusion (AREA)
- General Engineering & Computer Science (AREA)
- Branch Pipes, Bends, And The Like (AREA)
- Bending Of Plates, Rods, And Pipes (AREA)
Abstract
The invention relates to a production method of a wear-resistant elbow for a pipeline, which solves the defects of complex processing technology and higher cost of the existing elbow. The method comprises the steps of spraying a metal layer on the inner wall of a bent pipe in advance, then pouring metal slurry into a gap between a core and the inner wall of the bent pipe, drying the metal slurry, taking out the core, heating the core by using a high-frequency induction coil to enable a slurry layer to be molten and attached to the inner wall of the bent pipe to form a lower half wear-resistant cladding layer, and then replacing the core to form the rest wear-resistant cladding layer. The method has simple process and low cost, is suitable for bent pipes with various sizes and angles, and the manufactured bent pipe has excellent performance and long service life.
Description
Technical Field
The invention relates to the technical field of pipeline conveying, in particular to a production method of a wear-resistant elbow of a pipeline.
Background
In the fields of current industrial production and the like, a large amount of pipeline is used for conveying powder raw materials, waste residues and the like, and during the use process, the pipeline is inevitably worn, so that the shutdown maintenance and the replacement are caused, and huge direct and indirect economic losses are caused. And the pipe bends are the most susceptible to wear in all pipe configurations used. It is particularly important to develop wear resistant pipe elbows and methods of making them.
At present, the wear resistance and the service life of the elbow are improved by adopting methods of adding a ceramic lining or pasting a ceramic sheet in the elbow, but the methods have the defects of complex production process, high production cost, easy peeling, difficult transportation and the like. The wear resistance of the metal pipeline can be improved by casting a wear-resistant metal layer in the metal pipeline through a centrifugal casting method, and the method is a production method of the traditional bimetallic centrifugal casting wear-resistant pipe. The method has certain limitation, the method using centrifugal casting needs to have a symmetrical structure, and obviously the bent pipe cannot meet the requirement. In addition, for the small-diameter pipeline, the bonding strength between the cladding layer and the base metal of the bimetallic pipeline obtained by the centrifugal casting method cannot be ensured. In conclusion, the existing production methods of the wear-resistant elbow have defects, and improvement is urgently needed.
Disclosure of Invention
The invention aims to solve the defects of the existing production process of the wear-resistant elbow for the pipeline and provides a novel production method of the wear-resistant elbow for the pipeline. According to the method, nickel metal powder is uniformly adhered to the inner wall of the pipeline through an adhesive, the nickel metal powder is tightly combined with base metal through heating and melting, the upper part and the lower part are respectively subjected to cladding forming, and finally the wear-resistant bent pipe with good appearance and excellent performance is obtained. In order to achieve the purpose, the technical scheme adopted by the invention is as follows:
a production method of a wear-resistant elbow for a pipeline comprises the following steps: (a) spraying a metal coating after rust removal on the inner wall of the bent pipe; (b) placing the core into the elbow, filling metal slurry into a gap between the core and the inner wall of the elbow, sealing two ends of the elbow and baking at a certain temperature; (c) and after the slurry is dried, taking out the core, placing the bent pipe in a high-frequency induction coil for heating, and melting and attaching the slurry layer to the inner wall of the bent pipe to form a wear-resistant cladding layer.
Further, the inner wall of the elbow is firstly subjected to sand blasting rust removal treatment, and then a flame spraying gun is used for spraying a Ni60 coating with the thickness of 0.08mm to 0.12mm on the inner wall of the elbow.
Further, the metal slurry is a mixture of Ni60 powder dispersed in a rosin alcohol solution, wherein the mass fraction of rosin in the rosin alcohol solution is 5% -10%, and the mass fraction of Ni60 powder in the metal slurry is 90% -93%. The Ni60 powder is selected because the Ni60 powder has good wear-resisting and corrosion-resisting properties and wettability, and three binders, namely polyvinyl alcohol, potash water glass and nitrocellulose, are used in the exploration process, wherein the potash water glass is difficult to remove slag on the surface, the polyvinyl alcohol is easy to oxidize and difficult to form good metallurgical bonding, and the nitrocellulose is not only toxic, but also is easy to form a film on the surface, and the operation time is too short, so that the rosin alcohol solution is finally selected as the binder.
Further, the bent pipe filled with the metal slurry is baked for 3-5 hours at 70-90 ℃.
Furthermore, the induction frequency of the elbow pipe heated in the high-frequency induction coil is 200-.
Furthermore, the core has two types, one type is a cylinder, and the other type is composed of a cylinder and a segment of fan ring wrapped on the surface of the cylinder.
Further, the forming process of the wear-resistant cladding layer is divided into two steps, wherein the lower half part of the wear-resistant cladding layer is formed according to the steps (a) - (c), and then the upper half part of the core forming wear-resistant cladding layer is replaced according to the same method. Only the lower half part of the bent pipe can be molded firstly, so that the situation that the upper half part of the metal layer cannot be effectively metallurgically bonded with the substrate pipeline to cause the wear-resistant cladding layer to be molded separately is prevented; meanwhile, the upper half part of the bent pipe is prevented from failing to achieve effective metal combination and even collapse of the metal of the cladding layer and the metal of the substrate pipeline in the heating process.
The invention uses the rosin alcohol mixed solution as the binder, the Ni metal powder is uniformly bonded on the inner wall of the bent pipe, the high-frequency induction coil is used for heating, and the molten base metal and the molten metal powder are tightly combined through wettability in the melting process. Practice shows that the combination of the base metal and the molten metal powder has certain thickness requirement on the wear-resistant cladding layer through the principle, and the thickness of the wear-resistant cladding layer formed by direct one-step melting cannot meet the use requirement, because the upper half part of the bent pipe has local collapse phenomenon after the thickness exceeds a certain thickness, and the wear-resistant performance of the bent pipe is influenced. In order to solve the problem, a method of forming the lower half wear-resistant cladding layer firstly and then forming the upper half wear-resistant cladding layer is adopted, and finally the wear-resistant cladding layer with consistent thickness, attractive appearance and good performance is obtained.
In addition, in the practical process, the wear-resistant cladding layer is easy to crack due to the excessively high heating speed. The analysis suggests that this is caused by the excessive expansion and contraction of the base metal and the cladding metal due to insufficient heat transfer between the metal base material and the wear-resistant cladding metal. Therefore, the inner surface of the bent pipe is coated with the cladding metal layer in advance, so that the wettability and the oxidation resistance of the inner surface of the pipeline are improved, and the cladding metal layer is used as a transition layer to prevent cracking caused by different expansion speeds between the inner coating and the base material in the induction heating process.
Compared with the prior art, the invention has the following beneficial effects: (1) the invention has simple process and low cost, and is suitable for bent pipes with various sizes and angles; (2) the process solves the problems that effective metal combination cannot be achieved between the upper cladding metal and the metal substrate due to insufficient wettability, and even the upper metal is separated and collapsed; (3) the wear resistance of the pipeline processed by the process is improved by 2.5-3.3 times compared with that of a common Q235 bent pipe.
Drawings
FIG. 1 is a schematic cross-sectional view of a bend before machining;
FIG. 2 is a schematic cross-sectional view of the bent pipe after the lower half portion of the wear-resistant cladding layer is formed.
Wherein, 1-bending pipe, 2-core, 3-filling the gap of metal slurry, and 4-wear-resistant cladding layer.
Detailed Description
In order to make those skilled in the art fully understand the technical solutions and advantages of the present invention, the following description is further provided with reference to the specific embodiments and the accompanying drawings.
Example 1
Firstly, carrying out sand blasting and rust removing treatment on the inner wall of a bent pipe to be processed (bent 90 degrees and phi 47mm), and spraying a Ni60 metal coating with the thickness of about 0.1mm on the inner wall of the bent pipe by using a flame spraying gun after rust removing. After the bent pipe is cooled, a core consisting of a cylinder and a fan ring is placed into the bent pipe, and metal slurry is poured into a gap between the core and the inner wall of the bent pipe, wherein the metal slurry comprises the following components: the metal slurry comprises a rosin alcohol solution and Ni60, wherein the mass fraction of rosin in the rosin alcohol solution is 6.7%, and the mass fraction of Ni60 in the metal slurry is 92.3%. And sealing two ends of the bent pipe, baking the bent pipe in an oven at 80 ℃ for 4 hours, and taking out the core after the slurry is dried. And finally, placing the bent pipe in a high-frequency induction coil for heating, wherein the high-frequency induction parameters are as follows: the induction frequency is 220KHz, the current is 1400A, and the heating time is 14 s. And (3) closing the high-frequency inductor after the slurry layer is melted and the mirror reflection occurs, and attaching the metal Ni to the inner wall of the bent pipe to form the lower half part of the wear-resistant cladding layer. This process is illustrated in fig. 1-2.
After the lower half part of the wear-resistant cladding layer is formed, the upper half part of the wear-resistant cladding layer is formed by using another cylindrical core according to the same method, and finally the wear-resistant bent pipe with good appearance and excellent performance is obtained.
And carrying out sand blasting abrasion test by utilizing the modified sand blasting machine. Under the conditions of 25g/min of sand blowing amount, 0.4mpa of air pressure and 200 meshes of sand blowing granularity, the wear resistance of the cladding metal layer is measured to be 2.5-3.3 times of that of the common Q235 steel pipe.
Tests have shown that the above process can be applied to bends of various sizes by varying the size and curvature of the core to match different bends. The process solves the problems that effective metal combination cannot be achieved between the upper cladding metal and the metal substrate due to insufficient wettability, and even the upper metal is separated and collapsed.
Claims (3)
1. The production method of the wear-resistant elbow for the pipeline is characterized by comprising the following steps of:
(a) carrying out sand blasting and rust removing treatment on the inner wall of the elbow, and then spraying a Ni60 coating with the thickness of 0.08-0.12 mm on the inner wall of the elbow by using a flame spraying gun;
(b) placing the core into the elbow, filling metal slurry into the gap between the core and the inner wall of the elbow, sealing the two ends of the elbow, and baking at 70-90 deg.C for 3-5 h;
(c) taking out the core after the slurry is dried, placing the bent pipe in a high-frequency induction coil for heating, and melting and attaching the slurry layer to the inner wall of the bent pipe to form a wear-resistant cladding layer;
the forming process of the wear-resistant cladding layer is divided into two steps, wherein the lower half part of the wear-resistant cladding layer is formed according to the steps (a) - (c), and then the upper half part of the core forming wear-resistant cladding layer is replaced according to the same method; the metal slurry is a mixture obtained by dispersing Ni60 powder in a rosin alcohol solution, wherein the mass fraction of rosin in the rosin alcohol solution is 5-10%, and the mass fraction of Ni60 powder in the metal slurry is 90-93%.
2. The method for producing the wear-resistant elbow for the pipeline as claimed in claim 1, wherein the method comprises the following steps: the induction frequency of the bent pipe heated in the high-frequency induction coil is 200-2500KHz, the current is 1300-1500A, and the time is 10-16 s.
3. The method for producing the wear-resistant elbow for the pipeline as claimed in claim 1, wherein the method comprises the following steps: the core has two types, one type is a cylinder, and the other type is composed of a cylinder and a segment of fan ring wrapped on the surface of the cylinder.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201711236482.0A CN107881502B (en) | 2017-11-30 | 2017-11-30 | Production method of wear-resistant elbow for pipeline |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201711236482.0A CN107881502B (en) | 2017-11-30 | 2017-11-30 | Production method of wear-resistant elbow for pipeline |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN107881502A CN107881502A (en) | 2018-04-06 |
| CN107881502B true CN107881502B (en) | 2020-05-05 |
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| Application Number | Title | Priority Date | Filing Date |
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| CN201711236482.0A Expired - Fee Related CN107881502B (en) | 2017-11-30 | 2017-11-30 | Production method of wear-resistant elbow for pipeline |
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Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN1415888A (en) * | 2002-10-04 | 2003-05-07 | 宜兴市宙斯泵业有限公司 | Channel elbow with wearable liner and lining method thereof |
| CN101749506A (en) * | 2008-12-09 | 2010-06-23 | 沈阳铝镁设计研究院 | Wear-resistant elbow |
| CN102732877A (en) * | 2012-06-21 | 2012-10-17 | 西安热工研究院有限公司 | Preparation method of inner-wall wear resistant coating of small-bore pipeline and bend |
| CN206001176U (en) * | 2016-07-20 | 2017-03-08 | 郑州开阳窑具制品有限公司 | Carborundum wear-resistant bend for pipeline |
Family Cites Families (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP3672898B2 (en) * | 2002-08-28 | 2005-07-20 | 神戸樹脂工業株式会社 | Equipment for manufacturing refractory clad pipe joints |
| CN102537536A (en) * | 2012-02-09 | 2012-07-04 | 三一重工股份有限公司 | Composite bending-straight tube, concrete pump truck and manufacture method of composite bending-straight tube |
| CN103008544B (en) * | 2012-12-06 | 2015-02-18 | 华中科技大学 | Bi-metal bent pipe manufacturing process based on evaporative pattern casting and vibration pouring |
-
2017
- 2017-11-30 CN CN201711236482.0A patent/CN107881502B/en not_active Expired - Fee Related
Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN1415888A (en) * | 2002-10-04 | 2003-05-07 | 宜兴市宙斯泵业有限公司 | Channel elbow with wearable liner and lining method thereof |
| CN101749506A (en) * | 2008-12-09 | 2010-06-23 | 沈阳铝镁设计研究院 | Wear-resistant elbow |
| CN102732877A (en) * | 2012-06-21 | 2012-10-17 | 西安热工研究院有限公司 | Preparation method of inner-wall wear resistant coating of small-bore pipeline and bend |
| CN206001176U (en) * | 2016-07-20 | 2017-03-08 | 郑州开阳窑具制品有限公司 | Carborundum wear-resistant bend for pipeline |
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| CN107881502A (en) | 2018-04-06 |
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