CN113618034B - 一种输送管的制备方法及输送管 - Google Patents
一种输送管的制备方法及输送管 Download PDFInfo
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Abstract
本发明公开了一种输送管的制备方法及输送管,该方法包括如下步骤:在离心铸造机管端处均布固定4‑8片预制的陶瓷骨架;熔炼金属液并将熔炼好的金属液倒入离心铸造机浇注成型壁厚为2‑3mm的管坯;其中,金属液各元素含量质量百分比为:碳2.2%~3.2%,硅0.8%~1.5%,锰0.5%~0.8%,铬10%~15%,钒0.5%~2.0%,磷+硫≤0.1%,余量为铁及其他元素;将制备好的管坯放入热处理炉,缓慢升温至920~980℃,保温3~6h后取出,将取出的管坯冷却后再次放入热处理炉缓慢升温至250~350℃,保温3~6h后获成品输送管。本申请提高输送管整体耐磨性能,同时增强铸管断裂抵抗性。
Description
技术领域
本发明涉及输送管技术领域,具体涉及一种输送管的制备方法及输送管。
背景技术
输送管是混凝土泵送过程中必不可少的零部件。泵送过程中,输送缸将混凝土通过输送管泵送到几十米高的作业区,混凝土中的石料在高压作业环境下对输送管管壁冲刷磨损,在管连接处由于混凝土物料的运动方向发生改变,伴随着剧烈的冲击,加剧对管端处的磨损。这就要求输送管具有轻量化、高耐磨和抗冲击等性能特点。
目前,输送管分为单层管和双层管两种结构形式。单层管输送管大多采用45Mn2作为原材料,经高频淬火处理,硬化输送管内壁以增强其耐磨性能。双层管输送管大多采用高铬钢管作为内管,内管厚度在2~3mm,经整体淬火工艺,管壁完全淬透,保证钢管整体具有较高的硬度,外管采用低合金结构钢,增强输送管整体强韧性。目前单层管和双层管的制备具有以下缺点:
(1)淬火工艺差:由于输送管管壁较薄,淬火工艺难度大,钢管原料淬透性差等原因,导致输送管存在径向硬度分布不均匀、淬硬层深度差异明显等问题,导致输送管在受到物料冲刷及冲击的过程中,导致管壁磨损不均,存在薄弱点,最终导致爆管的风险。(2)薄弱点明显:输送管输送物料过程中,管与管之间呈M型分布,物料中的石子硬物对管端处的冲击磨损较为严重,而输送管的制备过程中,缺少对管端处的制备工艺加强。随着物料对薄弱点的冲蚀,输送管在高压作业环境下,薄弱点开裂,导致其失效,需要整体更换输送管。(3)成本:双层输送管内管采用高铬钢管,制备工艺复杂,制造难度大,成本高。
发明内容
本发明的目的在于提供一种输送管的制备方法及输送管,以解决现有技术中输送管耐磨性能和抗冲击能力差的问题。
为达到上述目的,本发明是采用下述技术方案实现的:
一种输送管的制备方法,包括如下步骤:
在离心铸造机管端处均布固定4-8片预制的陶瓷骨架;
熔炼金属液并将熔炼好的金属液倒入离心铸造机浇注成型壁厚为2-3mm的管坯;其中,金属液各元素含量质量百分比为:碳2.2%~3.2%,硅0.8%~1.5%,锰0.5%~0.8%,铬10%~15%,钒0.5%~2.0%,磷+硫≤0.1%,余量为铁及其他元素;
将制备好的管坯放入热处理炉,缓慢升温至920~980℃,保温3~6h后取出,将取出的管坯冷却后再次放入热处理炉缓慢升温至250~350℃,保温3~6h后获成品输送管。
进一步地,所述熔炼金属液步骤中选用碳铬铁FeCr65C1.0作为铬添加剂,选用钒铁作为钒添加剂。
进一步地,所述金属液熔炼温度为1500~1600℃,浇注温度1450~1550℃。
进一步地,所述熔炼金属液是在中频感应熔炼炉内进行的。
进一步地,所述管坯的冷却形式为:采用喷淋头在管坯内旋转喷淋冷却管坯。
进一步地,所述陶瓷骨架包括安装支腿。
进一步地,所述陶瓷骨架的制备方法如下:
将氧化镍、氧化铝、铝和粒度为150目~400目氧化锆按一定比例混合搅拌,并滴入聚乙烯醇溶液,静置陈腐10~20h后,放入100~200℃烘箱内烘干;
将烘干后的料坯放入研磨机并加入粒度为100目~200目的氧化钇研磨5~10h,充分混匀后放入磨具压制成型;
将成型的料坯放入烧结炉,经1500~1600℃烧结10~20h后,制成陶瓷骨架。
进一步地,所述聚乙烯醇溶液的浓度为3%。
进一步地,所述磨具压制成型的坯料厚度为1~2mm。
本发明还公开了一种根据上述任一项所述制备方法制备得到的输送管。
根据上述技术方案,本发明的实施例至少具有以下效果:
1、本申请的制备方法通过金属液中各元素含量质量百分比的限定,能够制造出以高铬铸铁为基体的输送管,提高输送管整体耐磨性能,且金属液中限定了钒元素和铬元素的质量百分比,钒元素能在铸铁中能细化晶粒组织,含钒碳化物VC有较高的硬度,保证输送管耐磨性能,同时VC能增强铸管断裂抵抗性;
2、本申请在管端处分布氧化锆为主陶瓷骨架,陶瓷骨架能很好的抵抗混凝土输送变向时对管端的冲击和磨损;
3、本申请采用整体热处理工艺,将含钒高铬合金铸管进行硬化处理,同时加强合金铸管与陶瓷骨架的结合,减少输送管内应力,提高整体强韧性;
4、采用本发明制备方法制备的输送管,铸管内壁洛氏硬度不低于55HRC,冲击功不低于7.5J,耐磨性能提升60%以上;
5、本申请将陶瓷骨架嵌入输送管两端,采用预埋形式与铸管在高温下熔合一体,结合力强,具有高耐磨和高强韧性,减少高速物料对管端处的冲击磨损,减轻整根管更换带来的经济损失。
附图说明
图1为本发明陶瓷骨架的示意图;
图2为本发明陶瓷骨架的布置示意图;
图3为本发明具有陶瓷骨架的输送管的立体图。
具体实施方式
为使本发明实现的技术手段、创作特征、达成目的与功效易于明白了解,下面结合具体实施方式,进一步阐述本发明。
在本申请中,VC---VanadiumCarbide碳化钒。
一种输送管的制备方法,包括如下步骤:在离心铸造机管端处均布固定4-8片预制的陶瓷骨架;熔炼金属液并将熔炼好的金属液倒入离心铸造机浇注成型壁厚为2-3mm的管坯;其中,金属液各元素含量质量百分比为:碳2.2%~3.2%,硅0.8%~1.5%,锰0.5%~0.8%,铬10%~15%,钒0.5%~2.0%,磷+硫≤0.1%,余量为铁及其他元素;将制备好的管坯放入热处理炉,缓慢升温至920~980℃,保温3~6h后取出,将取出的管坯冷却后再次放入热处理炉缓慢升温至250~350℃,保温3~6h后获成品输送管。
本申请的制备方法通过金属液中各元素含量质量百分比的限定,能够制造出以高铬铸铁为基体的输送管,提高输送管整体耐磨性能,且金属液中限定了钒元素和铬元素的质量百分比,钒元素能在铸铁中能细化晶粒组织,含钒碳化物VC有较高的硬度,保证输送管耐磨性能,同时VC能增强铸管断裂抵抗性。
下面通过具体的实施例对本申请进行说明。
实施例1
步骤(1)耐磨陶瓷制备:选用150份150目粒度的氧化锆粉体、50份200目粒度的氧化镍粉体、200份150目粒度的氧化铝粉体以及20份150目粒度的铝粉。将粉体充分混匀后,逐滴加入35份3%的聚乙烯醇溶液,同时搅拌均匀,静置陈腐20h后,将预混粉体放入100℃烘箱内烘干2h,加入5份100目氧化钇粉体,放入研磨机研磨10h,充分混匀后放入磨具中压制成型,坯料厚度1.8mm。成型坯料经1600℃烧结15h后,制成输送管预埋陶瓷骨架。
步骤(2)陶瓷预埋安装:将步骤(1)制备的陶瓷坯料安装到离心铸造机型腔内,沿管端四周均匀分布安装6片陶瓷骨架。
步骤(3)离心铸造:选用中频熔炼炉熔炼金属液,金属液各元素含量百分比为:碳2.2%,硅0.8%,锰0.8%,铬12%,钒0.5%,磷+硫≤0.1%,余量为铁及其他元素。选用中碳铬铁FeCr65C1.0作为铬添加剂,选用钒铁作为钒添加剂。中频熔炼温度1500℃,于浇注温度1450℃开始离心浇注,输送管内壁2.5mm。
步骤(4)整体热处理:将步骤(3)制备的输送管放入热处理炉,缓慢升温至980℃,保温4h后,出炉管内喷淋冷却。随后将输送管放入热处理炉缓慢升温至300℃,保温3h,炉内冷却至室温后取出。
采用本发明制备的输送管内管,铸管基体平均硬度59HRC,平均冲击吸收功为9.5J,陶瓷骨架平均硬度85HRA,通过湿砂橡胶轮磨损实验,磨损率为0.054%,耐磨性能提升67%。
实施例2
步骤(1)耐磨陶瓷制备:选用250份400目粒度的氧化锆粉体、50份200目粒度的氧化镍粉体、100份200目粒度的氧化铝粉体以及20份200目粒度的铝粉。将粉体充分混匀后,逐滴加入35份3%的聚乙烯醇溶液,同时搅拌均匀,静置陈腐15h后,将预混粉体放入150℃烘箱内烘干2h,加入5份100目氧化钇粉体,放入研磨机研磨10h,充分混匀后放入磨具中压制成型,坯料厚度1.0mm。成型坯料经1500℃烧结15h后,制成输送管预埋陶瓷骨架。
步骤(2)陶瓷预埋安装:将步骤(1)制备的陶瓷坯料安装到离心铸造机型腔内,沿管端四周均匀分布安装4片陶瓷骨架。
步骤(3)离心铸造:选用中频熔炼炉熔炼金属液,金属液各元素含量百分比为:碳2.6%,硅1.5%,锰0.5%,铬10%,钒1.0%,磷+硫≤0.1%,余量为铁及其他元素。选用中碳铬铁FeCr65C1.0作为铬添加剂,选用钒铁作为钒添加剂。中频熔炼温度1600℃,于浇注温度1550℃开始离心浇注,输送管内壁2.0mm。
步骤(4)整体热处理:将步骤(3)制备的输送管放入热处理炉,缓慢升温至960℃,保温4h后,出炉管内喷淋冷却。随后将输送管放入热处理炉缓慢升温至350℃,保温6h,炉内冷却至室温后取出。
采用本发明制备的输送管内管,铸管基体平均硬度57HRC,平均冲击吸收功为10.0J,陶瓷骨架平均硬度82HRA,通过湿砂橡胶轮磨损实验,磨损率为0.060%,耐磨性能提升63%。
实施例3
步骤(1)耐磨陶瓷制备:选用150份200目粒度的氧化锆粉体、50份200目粒度的氧化镍粉体、200份150目粒度的氧化铝粉体以及20份150目粒度的铝粉。将粉体充分混匀后,逐滴加入35份3%的聚乙烯醇溶液,同时搅拌均匀,静置陈腐20h后,将预混粉体放入200℃烘箱内烘干2h,加入5份200目氧化钇粉体,放入研磨机研磨10h,充分混匀后放入磨具中压制成型,坯料厚度2.0mm。成型坯料经1600℃烧结20h后,制成输送管预埋陶瓷骨架。
步骤(2)陶瓷预埋安装:将步骤(1)制备的陶瓷坯料安装到离心铸造机型腔内,沿管端四周均匀分布安装8片陶瓷骨架。
步骤(3)离心铸造:选用中频熔炼炉熔炼金属液,金属液各元素含量百分比为:碳3.2%,硅1.5%,锰0.8%,铬15%,钒2.0%,磷+硫≤0.1%,余量为铁及其他元素。选用中碳铬铁FeCr65C1.0作为铬添加剂,选用钒铁作为钒添加剂。中频熔炼温度1550℃,于浇注温度1480℃开始离心浇注,输送管内壁3.0mm。
步骤(4)整体热处理:将步骤(3)制备的输送管放入热处理炉,缓慢升温至920℃,保温6h后,出炉管内喷淋冷却。随后将输送管放入热处理炉缓慢升温至250℃,保温5h,炉内冷却至室温后取出。
采用本发明制备的输送管内管,铸管基体平均硬度62HRC,平均冲击吸收功为7.5J,陶瓷骨架平均硬度87HRA,通过湿砂橡胶轮磨损实验,磨损率为0.037%,耐磨性能提升77%。
上述三个实施例中,制备的陶瓷骨架22如图1和图2所示,其包括整体的骨架结构12和位于骨架结构上的安装支腿11,此种设计便于将陶瓷骨架嵌入铸管,高温铸造环境下与铸管熔合,结合力强不易脱落。图2为陶瓷骨架22在管端21处的布置示意图。
在另外一些实施例中,陶瓷骨架的形状还可以为其它形式。可根据工况要求设计陶瓷骨架分部,其他结构形式的骨架预埋同样可以达到增强管端耐磨性和韧性的要求。
实施例4
步骤(1)耐磨陶瓷制备:选用150份400目粒度的氧化锆粉体、50份150目粒度的氧化镍粉体、200份400目粒度的氧化铝粉体以及20份150目粒度的铝粉。将粉体充分混匀后,逐滴加入35份3%的聚乙烯醇溶液,同时搅拌均匀,静置陈腐20h后,将预混粉体放入200℃烘箱内烘干2h,加入5份200目氧化钇粉体,放入研磨机研磨5h,充分混匀后放入磨具中压制成型,坯料厚度2.0mm。成型坯料经1600℃烧结10h后,制成输送管预埋陶瓷骨架。
步骤(2)陶瓷预埋安装:将步骤(1)制备的陶瓷坯料安装到离心铸造机型腔内,沿管端四周均匀分布安装6片陶瓷骨架。
步骤(3)离心铸造:选用中频熔炼炉熔炼金属液,金属液各元素含量百分比为:碳3.2%,硅0.8%,锰0.6%,铬15%,钒1.5%,磷+硫≤0.1%,余量为铁及其他元素。选用中碳铬铁FeCr65C1.0作为铬添加剂,选用钒铁作为钒添加剂。中频熔炼温度1550℃,于浇注温度1500℃开始离心浇注,输送管内壁3.0mm。
步骤(4)整体热处理:将步骤(3)制备的输送管放入热处理炉,缓慢升温至980℃,保温3h后,出炉管内喷淋冷却。随后将输送管放入热处理炉缓慢升温至350℃,保温6h,炉内冷却至室温后取出。
采用本发明制备的输送管内管,铸管基体平均硬度61HRC,平均冲击吸收功为7.5J,陶瓷骨架平均硬度88HRA,通过湿砂橡胶轮磨损实验,磨损率为0.041%,耐磨性能提升74%。
实施例5
该实施例提供了一种输送管,该输送管为上述四个实施例中任意一个实施例制造而成的输送管,如图3所示。
本发明所述一种离心铸造输送管,管端处预埋陶瓷骨架通过高温与铸管结合,骨架形式不仅限于此,可根据工况要求设计陶瓷骨架分部,其他结构形式的骨架预埋同样可以达到增强管端耐磨性和韧性的要求。陶瓷骨架中添加稀土元素能够降低铸造裂纹的风险,不仅限于氧化钇的加入。
上述实施例提供的输送管具有以下优点:
(1)本发明的输送管采用成熟的离心铸造工艺,输送管径向和轴向材质均匀,无气孔、夹杂物少等特点。(2)本发明的输送管直线度高,成型效果好,壁厚均匀。(3)输送管铸管高铬合金保证整体较高耐磨性能,钒元素的加入能够细化晶粒组织,提高铸管强度和韧性。(4)陶瓷骨架嵌入输送管两端,采用预埋形式与铸管在高温下熔合一体,结合力强,具有高耐磨和高强韧性,减少高速物料对管端处的冲击磨损,减轻整根管更换带来的经济损失。
由技术常识可知,本发明可以通过其它的不脱离其精神实质或必要特征的实施方案来实现。因此,上述公开的实施方案,就各方面而言,都只是举例说明,并不是仅有的。所有在本发明范围内或在等同于本发明的范围内的改变均被本发明包含。
Claims (9)
1.一种输送管的制备方法,其特征在于,包括如下步骤:
在离心铸造机管端处均布固定4-8片预制的陶瓷骨架;
熔炼金属液并将熔炼好的金属液倒入离心铸造机浇注成型壁厚为2-3mm的管坯;其中,金属液各元素含量质量百分比为:碳2.2%~3.2%,硅0.8%~1.5%,锰0.5%~0.8%,铬10%~15%,钒0.5%~2.0%,磷+硫≤0.1%,余量为铁及其他元素;
将制备好的管坯放入热处理炉,缓慢升温至920~980℃,保温3~6h后取出,将取出的管坯冷却后再次放入热处理炉缓慢升温至250~350℃,保温3~6h后获成品输送管;
所述陶瓷骨架的制备方法如下:将氧化镍、氧化铝、铝和粒度为150目~400目氧化锆按一定比例混合搅拌,并滴入聚乙烯醇溶液,静置陈腐10~20h后,放入100~200℃烘箱内烘干;将烘干后的料坯放入研磨机并加入粒度为100目~200目的氧化钇研磨5~10h,充分混匀后放入磨具压制成型;将成型的料坯放入烧结炉,经1500~1600℃烧结10~20h后,制成陶瓷骨架。
2.根据权利要求1所述的输送管的制备方法,其特征在于,所述熔炼金属液步骤中选用碳铬铁FeCr65C1.0作为铬添加剂,选用钒铁作为钒添加剂。
3.根据权利要求1所述的输送管的制备方法,其特征在于,所述金属液熔炼温度为1500~1600℃,浇注温度1450~1550℃。
4.根据权利要求1所述的输送管的制备方法,其特征在于,所述熔炼金属液是在中频感应熔炼炉内进行的。
5.根据权利要求1所述的输送管的制备方法,其特征在于,所述管坯的冷却形式为:采用喷淋头在管坯内旋转喷淋冷却管坯。
6.根据权利要求1所述的的输送管的制备方法,其特征在于,所述陶瓷骨架包括安装支腿。
7.根据权利要求1所述的输送管的制备方法,其特征在于,所述聚乙烯醇溶液的浓度为3%。
8.根据权利要求1所述的输送管的制备方法,其特征在于,所述磨具压制成型的坯料厚度为1~2mm。
9.一种根据权利要求1-8任一项所述制备方法制备得到的输送管。
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