CN115449792A - Metal fiber felt-based self-fluxing alloy and aluminized composite protective layer for heating surface of pipe for boiler - Google Patents
Metal fiber felt-based self-fluxing alloy and aluminized composite protective layer for heating surface of pipe for boiler Download PDFInfo
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- CN115449792A CN115449792A CN202211039835.9A CN202211039835A CN115449792A CN 115449792 A CN115449792 A CN 115449792A CN 202211039835 A CN202211039835 A CN 202211039835A CN 115449792 A CN115449792 A CN 115449792A
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Images
Classifications
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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
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/06—Ferrous alloys, e.g. steel alloys containing aluminium
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
- C22C38/34—Ferrous alloys, e.g. steel alloys containing chromium with more than 1.5% by weight of silicon
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
- C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
- C22C38/54—Ferrous alloys, e.g. steel alloys containing chromium with nickel with boron
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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
- C23C24/02—Coating starting from inorganic powder by application of pressure only
- C23C24/04—Impact or kinetic deposition of particles
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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
- 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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- 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
- C23C4/131—Wire arc spraying
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23M—CASINGS, LININGS, WALLS OR DOORS SPECIALLY ADAPTED FOR COMBUSTION CHAMBERS, e.g. FIREBRIDGES; DEVICES FOR DEFLECTING AIR, FLAMES OR COMBUSTION PRODUCTS IN COMBUSTION CHAMBERS; SAFETY ARRANGEMENTS SPECIALLY ADAPTED FOR COMBUSTION APPARATUS; DETAILS OF COMBUSTION CHAMBERS, NOT OTHERWISE PROVIDED FOR
- F23M5/00—Casings; Linings; Walls
- F23M5/08—Cooling thereof; Tube walls
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E20/00—Combustion technologies with mitigation potential
- Y02E20/12—Heat utilisation in combustion or incineration of waste
Abstract
The invention relates to a metal fiber felt-based self-fluxing alloy and aluminized composite protective layer for a heating surface of a pipe for a boiler, which comprises a metal fiber felt-based self-fluxing alloy composite layer and a metal fiber felt-based aluminized composite layer. The protective layer has high strength, strong toughness and high temperature resistance, and can effectively prevent the heated surface from being corroded by high temperature to be thinned and even to explode, thereby further prolonging the service life. The invention also relates to a preparation method of the protective layer, which adopts a metal fiber felt aluminizing and induction cladding composite technology, has simple operation, low cost and high production efficiency, and is expected to develop into a novel long-acting protection technology suitable for the high-temperature corrosion of the heating surface of the waste boiler.
Description
Technical Field
The invention belongs to the technical field of protection of a heat distribution pipeline, and relates to a metal fiber felt-based self-fluxing alloy and aluminized composite protective layer for a heating surface of a pipe for a boiler and a preparation method thereof.
Background
With the accelerated implementation of the national strategy for developing new energy, the domestic waste incineration power generation industry develops rapidly in recent years. However, for a long time, the bottleneck problem restricting the technical development of the waste incineration power generation is that the high-temperature corrosion of four pipes (a water-cooled wall, a superheater, a reheater and an economizer) of a boiler is serious. Particularly, under the great background that the development of high-parameter boilers is well-established in recent years, the improvement of main parameters of the boilers causes more serious high-temperature corrosion, the heating surface of a pipeline is quickly thinned, so that the phenomenon of pipe explosion is frequent, the non-regular production halt of an enterprise is caused, great potential safety hazards are brought, and the economic burden of the enterprise is increased.
At present, the four-tube heating surface high-temperature corrosion protection of the waste incineration boiler in China generally adopts a method, about 60 percent of surfacing welding and about 25 percent of induction fusion welding, and the rest is about 15 percent of thermal spraying, high-temperature ceramic coating and the like, namely the surfacing welding and the induction fusion welding are taken as main techniques and basically occupy the domination position of the market. Although the overall application effect of the two technologies is better, in recent years, problems begin to be exposed, such as that the surfacing welding gradually exposes short plates with low production efficiency, high cost and the like, and the high-temperature service life is influenced by a higher dilution rate; the induction welding also has the problems of how to further improve the service life under high-parameter conditions, long-term stability of the coating and the like due to the thin (< 0.5 mm) coating existing in the technology. Therefore, the development of a new protection technology with excellent protection performance, long service life and competitive production efficiency and preparation cost becomes an urgent task for scientific and technical personnel in the high-temperature anticorrosion field in China.
Disclosure of Invention
Aiming at the problems of surfacing and induction fusion welding in the prior art, the invention provides a metal fiber felt-based self-fluxing alloy and aluminized composite protective layer for the heating surface of a pipe for a boiler, which has high strength, strong toughness and high temperature resistance, and can effectively prevent the heating surface from being corroded and thinned at high temperature and even bursting, thereby further prolonging the service life.
The invention also provides a preparation method of the metal fiber felt-based self-fluxing alloy and aluminized composite protective layer for the heating surface of the boiler tube, the method adopts a metal fiber felt aluminizing and induction cladding composite technology, the operation is simple, and the novel long-acting protective technology suitable for high-temperature corrosion of the heating surface of the garbage boiler is expected to be developed.
To this end, the invention provides in a first aspect a composite protective layer of metal fiber felt-based self-fluxing alloy and aluminizing for the heating surface of a pipe for a boiler, comprising a metal fiber felt-based self-fluxing alloy composite layer and a metal fiber felt-based aluminizing composite layer.
Preferably, the metal fiber felt is a high-density iron-chromium-aluminum fiber felt with the porosity of less than 30%.
In some embodiments of the invention, in the metal fiber felt-based iron-based self-fluxing alloy composite layer, the thickness of the iron-based self-fluxing alloy layer is 2mm ± 0.02mm.
In further embodiments of the invention, the metal fiber mat has a thickness of 0.3-5mm ± 0.02mm, preferably 2-3mm ± 0.02mm.
In still other embodiments of the present invention, the thickness of the aluminized composite layer is 0.3-0.5mm ± 0.05mm.
In the invention, the thickness of the metal fiber felt-based self-fluxing alloy and aluminized composite protective layer is more than or equal to 3mm.
The second aspect of the invention provides a method for preparing a metal fiber felt-based self-fluxing alloy and aluminized composite protective layer for a heating surface of a pipe for a boiler, which comprises the following steps:
step A, carrying out sand blasting coarsening and decontamination treatment on the heating surface of the water-cooled wall tube bank and the two surfaces of the metal fiber felt respectively and independently to obtain a clean water-cooled wall tube bank with a roughened heating surface and a clean metal fiber felt with a roughened two surfaces;
step B, cold spraying or brushing an iron-based self-fluxing alloy coating on the heating surface of the clean water-cooled wall tube bank with the roughened heating surface to obtain the water-cooled wall tube bank with the iron-based self-fluxing alloy coating on the heating surface;
c, paving a metal fiber felt on a heating surface of the water-cooled wall tube bank with the iron-based self-fluxing alloy coating on the heating surface, and pressing the metal fiber felt tightly to the heating surface of the tube bank through the iron-based self-fluxing alloy coating to obtain the water-cooled wall tube bank with the iron-based self-fluxing alloy coating and the metal fiber felt adhered to the heating surface;
d, starting a transmission chain and a high-frequency induction coil for conveying the water-cooled wall tube bank, enabling the water-cooled wall tube bank with the iron-based self-fluxing alloy coating and the metal fiber felt adhered to the heating surface to be automatically fed, heating the water-cooled wall tube bank with the iron-based self-fluxing alloy coating and the metal fiber felt adhered to the heating surface through the fixed induction coil, controlling the automatic feeding speed to completely dry the adhesive, but not melting the coating, and obtaining the water-cooled wall tube bank with the iron-based self-fluxing alloy coating-the metal fiber felt bottom layer on the heating surface;
e, moving the water-cooled wall tube bank with the heating surface provided with the iron-based self-fluxing alloy coating-metal fiber felt bottom coating in a reverse direction, controlling the automatic feeding speed, and finishing the induction cladding of the iron-based self-fluxing alloy coating on the heating surface of the tube bank, so that the iron-chromium-aluminum fiber felt and the heating surface of the tube bank which are respectively positioned on the two sides of the iron-based self-fluxing alloy coating are fixedly connected by virtue of the melting-recrystallization process of the iron-based self-fluxing alloy coating, and the cold-wall tube bank with the heating surface provided with the metal fiber felt-iron-based self-fluxing alloy composite cladding coating is obtained;
and F, when the cold wall tube bank with the metal fiber felt-based self-melting alloy composite cladding coating on the clad heating surface just comes out of the induction coil and the surface of the tube bank is still in a red hot state, spraying an aluminum alloy coating on the surface of the cladding coating by using electric arc or flame, and under the dual high-temperature action of the residual temperature of induction cladding and thermal spraying, enabling the aluminum alloy coating to penetrate into pores on the surface of the metal fiber felt to seal the surface of the metal fiber felt so as to obtain the metal fiber felt-based self-melting alloy and aluminized composite protective layer on the heating surface of the water wall tube bank.
According to the method, in step F, when the cold-wall tube bank with the metal fiber felt-based-iron-based self-melting alloy composite cladding coating on the heating surface after cladding comes out of the induction coil for 300-500mm, an aluminum alloy coating is sprayed on the surface of the cladding coating by electric arc or flame in a red hot state at 650-800 ℃.
In some embodiments of the invention, the metal fiber mat comprises 1Cr13Al4, 1Cr21Al4, 0Cr21Al6, 0Cr23Al5, 0Cr25Al5, 0Cr21Al6Nb, 0Cr27Al7Mo2.
Preferably, the iron-based self-fluxing alloy material consists of iron-based self-fluxing alloy and a binder, wherein the iron-based self-fluxing alloy material consists of the following components in percentage by weight:
in some embodiments of the invention, in step D, the speed of the auto feed is 10-30mm/s.
In other embodiments of the present invention, in step E, the speed of the auto feed is 0.5-1.5mm/s.
According to some embodiments of the invention, step G is further included after step F, and the quality of the metal fiber felt-based self-fluxing alloy and aluminized composite protective layer used for the heating surface of the tube for the boiler is detected.
In a third aspect of the present invention, there is provided a pipe for a boiler having a heating surface provided with a composite protective layer of a metal fiber felt-based self-fluxing alloy and aluminizing for a heating surface of a pipe for a boiler as set forth in the first aspect of the present invention or a composite protective layer of a metal fiber felt-based self-fluxing alloy and aluminizing for a heating surface of a pipe for a boiler as prepared by the method of the second aspect of the present invention.
The metal fiber felt-based self-fluxing alloy and aluminized composite protective layer for the heating surface of the pipe for the boiler, provided by the invention, has the advantages of high strength, strong toughness and high temperature resistance, and can effectively prevent the heating surface from being corroded and thinned at high temperature and even being exploded, so that the service life is further prolonged. Compared with the induction fusion welding thickness of about 0.5mm and the surfacing layer of 2.5mm, the total thickness of the protective layer reaches more than 3mm, so the protective life is longer; in terms of cost, the cost of the coating is reduced by more than 60% compared with that of surfacing and is reduced by more than 20% compared with that of an induction fusion welding coating.
The preparation method of the protective layer provided by the invention adopts a metal fiber felt aluminizing and induction cladding composite technology, and has the advantages of simple operation and low cost; compared with the surfacing welding, the surfacing welding has the advantages that the heat input quantity on the surface of the tube bank is larger, so that the problem of dilution rate and the problem of thermal deformation control of the tube bank exist, the two problems do not exist, the production efficiency is higher, and the novel long-acting protection technology suitable for high-temperature corrosion of the heating surface of the waste boiler is expected to be developed.
Drawings
The invention will be explained below with reference to the drawings.
FIG. 1 is a schematic view of the induction cladding and aluminum spraying process of the water wall tube bank.
The reference numerals of fig. 1 have the following meanings; 13 fins; 21 coating the curved surface of the pipe; 22 tube root and fin coating; 50 spraying aluminum (the aluminum spraying operation is performed in the place); 60 a coil support; 70 a drive chain roller; 80 high frequency induction remelting coil (rectangular copper tube).
Detailed Description
In order that the invention may be readily understood, a more particular description thereof will be rendered by reference to the appended drawings. However, before the invention is described in detail, it is to be understood that this invention is not limited to particular embodiments described. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting.
Unless otherwise defined, all terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although any methods and materials similar or equivalent to those described herein can also be used in the practice or testing of the present invention, the preferred methods and materials are now described.
The terms "about," "substantially," and "essentially," when used in conjunction with a range of elements, concentrations, temperatures, or other physical or chemical properties or characteristics, cover variations that may exist in the upper and/or lower limits of the range of properties or characteristics, including variations that may result, for example, from rounding, measurement methods, or other statistical variations. As used herein, numerical values associated with amounts, weights, and the like, are defined as "about" as all numerical values for each particular value plus or minus 1%. For example, the term "about 10%" should be understood to mean "9% to 11%".
Term of
The term "waterwall" as used herein is also referred to as a "waterwall" or "waterwall tube". The steel pipes are usually vertically laid on the inner wall surface of the boiler wall, and are mainly used for absorbing heat emitted by flame and high-temperature flue gas in the boiler.
The term "four boiler tubes" and "boiler tubes" used in the present invention may be used interchangeably, and include water walls, superheaters, reheaters, and economizers.
II, embodiment
Aiming at the problems of surfacing and induction fusion welding technologies, the invention adopts a metal fiber felt aluminizing and induction fusion welding composite technology to develop a novel long-acting protection technology suitable for high-temperature corrosion of a heating surface of a waste boiler.
The invention abandons the idea that the traditional protective layer directly prepares a coating on the surface of the pipeline, and adopts the technical path that the prefabricated metal fiber felt is used as the protective layer, then is connected with the pipeline, and finally blocks the pores. The preparation of the protective layer is not influenced by the structural shape of the pipeline and the environmental conditions, the process design can be more flexible, and the production efficiency can be improved and the cost can be reduced. In fact, similar methods have been used, such as mounting ceramic patches on the heated surfaces of waterwalls. Although the method has a certain protection effect, the method is not applied in large batch since the following main reasons: due to the inherently brittle nature of ceramic materials, once individual patches crack or strip corrosive gases into the pipeline surface, rapid failure of the overall protective layer can result; the ceramic material has low thermal conductivity, prevents effective conduction of heat energy, reduces energy conversion efficiency, and prevents heat transfer to cause the temperature of gas in the furnace to rise, thereby aggravating the hot corrosion of other components on a gas passage; the ceramic patch joint is not tightly sealed and becomes an inlet of corrosive gas.
Therefore, in the first aspect of the present invention, a metal fiber felt-based self-fluxing alloy and aluminizing composite protective layer for a heating surface of a boiler pipe is formed by using a metal fiber felt newly developed in more than 20 years as a main body of the protective layer, and the composite protective layer comprises a metal fiber felt-based self-fluxing alloy composite layer and a metal fiber felt-based aluminizing composite layer.
In the invention, the metal fiber felt is a high-density iron-chromium-aluminum fiber felt, and the porosity of the metal fiber felt is less than 30%.
In some embodiments of the invention, in the metal fiber felt-based-iron-based self-fluxing alloy composite layer, the thickness of the iron-based self-fluxing alloy layer is 2mm ± 0.02mm; the thickness of the metal fiber felt is 0.3-5mm +/-0.02 mm, preferably 2-3mm +/-0.02 mm; the thickness of the aluminized composite layer is 0.3-0.5mm +/-0.05 mm; the thickness of the metal fiber felt-based self-fluxing alloy and aluminized composite protective layer is more than or equal to 3mm.
It will be appreciated by those skilled in the art that in practice, the metal fiber felt-based self-fluxing alloy and aluminized composite protective layer for a heating surface of a boiler tube provided by the present invention will naturally form a very thin layer of Al on the outer surface of the metal fiber felt-based aluminized composite layer 2 O 3 The ceramic film has the thickness of less than or equal to 0.01mm and has certain reinforcing effect on the metal fiber felt-based self-fluxing alloy and aluminized composite protective layer.
The invention relates to a preparation method of a metal fiber felt-based self-fluxing alloy and aluminized composite protective layer for a heating surface of a pipe for a boiler, which comprises the following steps:
step A, pretreatment: respectively and independently carrying out sand blasting coarsening and cleaning treatment on the heating surface of the water-cooled wall tube bank and the two surfaces of the metal fiber felt to obtain a clean water-cooled wall tube bank with a coarsened heating surface and a clean metal fiber felt with a coarsened two surfaces;
b, manufacturing an iron-based self-fluxing alloy coating: cold spraying or brushing an iron-based self-fluxing alloy coating on the heating surface of the clean water-cooled wall tube bank with the roughened heating surface to obtain the water-cooled wall tube bank with the iron-based self-fluxing alloy coating on the heating surface;
step C, pressing and adhering: paving a metal fiber felt on a heating surface of a water-cooled wall tube bank with an iron-based self-fluxing alloy coating on the heating surface, and pressing the metal fiber felt tightly with the heating surface of the tube bank through the iron-based self-fluxing alloy coating to obtain the water-cooled wall tube bank with the iron-based self-fluxing alloy coating and the metal fiber felt adhered on the heating surface;
step D, drying the binder: starting a transmission chain and a high-frequency induction coil for conveying the water-cooled wall tube bank, enabling the water-cooled wall tube bank with the iron-based self-fluxing alloy coating and the metal fiber felt adhered on the heating surface to automatically feed, heating the water-cooled wall tube with the iron-based self-fluxing alloy coating and the metal fiber felt adhered on the heating surface through the fixed induction coil, and controlling the automatic feeding speed to be 10-30mm/s, so that the heating speed is controlled, the adhesive is completely dried, the coating is not melted, and the water-cooled wall tube bank with the iron-based self-fluxing alloy coating-metal fiber felt bottom layer on the heating surface is obtained;
step E, cladding: the method comprises the following steps of moving a water-cooled wall tube bank with an iron-based self-fluxing alloy coating-metal fiber felt bottom coating on a heating surface in a reverse direction, controlling the automatic feeding speed to be 0.5-1.5mm/s, and finishing induction cladding of the iron-based self-fluxing alloy coating on the heating surface of the tube bank, so that an iron-chromium-aluminum fiber felt and the heating surface of the tube bank which are respectively positioned on two sides of the iron-based self-fluxing alloy coating are fixedly connected by means of the melting-recrystallization process of the iron-based self-fluxing alloy coating, and obtaining a cold-wall tube bank with a metal fiber felt-iron-based self-fluxing alloy composite cladding coating on the heating surface;
step F, aluminum spraying: when the cold wall tube bank with the metal fiber felt-based self-fluxing alloy composite cladding coating on the heating surface after cladding just comes out of the induction coil and the surface of the tube bank is still in a red hot state, the aluminum alloy coating is sprayed on the surface of the cladding coating by electric arc or flame, under the dual high-temperature action of the residual temperature of the induction cladding and the thermal spraying, the aluminum alloy coating penetrates into pores on the surface of the metal fiber felt, the hole sealing is carried out on the surface of the metal fiber felt, and therefore the metal fiber felt-based self-fluxing alloy and aluminized composite protective layer is obtained on the heating surface of the water wall tube bank.
According to the method, in the step F, when the cold wall tube bank with the metal fiber felt-based-iron-based self-melting alloy composite cladding coating on the heating surface after cladding comes out of the induction coil for 300-500mm, an aluminum alloy coating is sprayed on the surface of the cladding coating by electric arc or flame under the red hot state of 650-800 ℃.
According to some embodiments of the present invention, step G is further included after step F, and the quality of the metal fiber felt-based self-fluxing alloy and aluminized composite protective layer used for the heating surface of the boiler tube is tested.
The method can also be understood as a method for preparing a boiler tube with a metal fiber felt-based self-fluxing alloy and an aluminized composite protective layer on a heating surface, which comprises the following steps:
(1) Pretreatment: respectively and independently carrying out sand blasting coarsening and cleaning treatment on the heating surface of the water-cooled wall tube bank and the two surfaces of the metal fiber felt to obtain a clean water-cooled wall tube bank with a coarsened heating surface and a clean metal fiber felt with a coarsened two surfaces;
(2) Preparing an iron-based self-fluxing alloy coating: cold spraying or brushing an iron-based self-fluxing alloy coating on the heating surface of the clean water-cooled wall tube bank with the roughened heating surface to obtain the water-cooled wall tube bank with the iron-based self-fluxing alloy coating on the heating surface;
(3) And (3) compression adhesion: paving a metal fiber felt on a heating surface of a water-cooled wall tube bank with an iron-based self-fluxing alloy coating on the heating surface, and pressing the metal fiber felt tightly with the heating surface of the tube bank through the iron-based self-fluxing alloy coating to obtain the water-cooled wall tube bank with the iron-based self-fluxing alloy coating and the metal fiber felt adhered on the heating surface;
(4) Drying the binder: and starting a transmission chain and a high-frequency induction coil for conveying the water-cooled wall tube bank, enabling the water-cooled wall tube bank with the iron-based self-fluxing alloy coating and the metal fiber felt adhered on the heating surface to automatically feed, heating the water-cooled wall tube with the iron-based self-fluxing alloy coating and the metal fiber felt adhered on the heating surface through the fixed induction coil, and controlling the automatic feeding speed to be 10-30mm/s, so that the heating speed is controlled, the adhesive is completely dried, the coating is not melted, and the water-cooled wall tube bank with the iron-based self-fluxing alloy coating-metal fiber felt bottom layer on the heating surface is obtained.
(5) Cladding: the method comprises the following steps of moving a water-cooled wall tube bank with an iron-based self-fluxing alloy coating-metal fiber felt bottom coating on a heating surface in a reverse direction, controlling the automatic feeding speed to be 0.5-1.5mm/s, and finishing induction cladding of the iron-based self-fluxing alloy coating on the heating surface of the tube bank, so that an iron-chromium-aluminum fiber felt and the heating surface of the tube bank which are respectively positioned on two sides of the iron-based self-fluxing alloy coating are fixedly connected by means of the melting-recrystallization process of the iron-based self-fluxing alloy coating, and obtaining a cold-wall tube bank with a metal fiber felt-iron-based self-fluxing alloy composite cladding coating on the heating surface;
(6) Aluminum spraying: when the cold wall tube bank with the metal fiber felt-based self-melting alloy composite cladding coating on the heating surface after cladding just comes out of the induction coil and the surface of the tube bank is still in a red hot state, the aluminum alloy coating is sprayed on the surface of the cladding coating by electric arc or flame, under the dual high-temperature action of the residual temperature of the induction cladding and the thermal spraying, the aluminum alloy coating penetrates into pores on the surface of the metal fiber felt to seal the holes on the surface of the metal fiber felt, and the boiler tube with the metal fiber felt-based self-melting alloy and aluminized composite protective layer on the heating surface is provided.
According to the method, in the step (6), when the cold wall tube bank with the metal fiber felt-based-iron-based self-melting alloy composite cladding coating on the heating surface after cladding comes out of the induction coil for 300-500mm, an aluminum alloy coating is sprayed on the surface of the cladding coating by electric arc or flame under the red hot state of 650-800 ℃ on the surface of the tube bank.
According to some embodiments of the invention, the method further comprises a step (7) of detecting the quality of the metal fiber felt-based self-fluxing alloy and aluminized composite protective layer used for the heating surface of the pipe for the boiler after the step (6).
In some embodiments of the present invention, in step C or step (3), the fiber mat and the heated surface of the tube bank are tightly attached to each other through the iron-based self-fluxing alloy adhesive layer by repeatedly tapping with a wood hammer, a rubber hammer or a copper hammer, so as to achieve the purpose of making the composite coating tightly attached to the water-cooled wall.
In the invention, the metal fiber felt is prepared by weaving metal fibers with micron-sized diameters into sheets with certain thickness (0.3 mm-5 mm), and is prepared by non-woven laying, overlapping and high-temperature sintering. The commercially available metal fiber felts are various, and the research of the inventor finds that the metal fiber felts really suitable for the garbage boiler can only be iron chromium aluminum fiber felts and stainless steel fiber felts, wherein the iron chromium aluminum fiber felts have relatively more advantages. Table 1 shows the overall properties of the iron chromium aluminum fiber mats. As can be seen from Table 1, the main mechanical performance index of the Fe-Cr-Al fiber is superior to that of the coating made of the same material.
TABLE 1 iron chromium aluminum fiber Properties
As can be seen from table 1, the metal fiber mat has the following characteristics:
(1) High strength and toughness
Due to the drawing action among the fibers, the strength of the felt is much higher than that of a coating made of the same material and with the same thickness, and meanwhile, the strength is high, so that the fatigue strength is high, fatigue cracks are not easy to generate, and the felt is not easy to expand even if micro cracks exist; and the strength is high and abrasion resistance is enough to resist the thinning caused by erosion and abrasion of fly ash particles in high-temperature flue gas.
(2) High temperature resistance
The service temperature of the stainless steel fiber is less than 600 ℃, the iron-chromium-aluminum is less than 1000 ℃, the stainless steel fiber can resist high-temperature oxidation and severe chloride corrosion which is painful in a garbage furnace, the high-temperature corrosion resistance is better than that of a coating made of the same material and thickness, and the stainless steel fiber is a very ideal high-temperature corrosion protection material.
(3) The metal fiber felt has good heat conductivity, does not influence the heat exchange performance of a boiler system, and has a thermal expansion coefficient very close to that of the pipeline metal, so that the felt is not easy to fall off as long as the felt is fixed with the pipe wall.
(4) The metal fiber felt has a foldable flexible structure, is very suitable for being attached to the special-shaped surfaces of water-cooled walls or various pipelines, and the thickness can be selected optionally according to the requirement.
(5) Low cost
For example, the currently marketed iron-chromium-aluminum fiber felt with the thickness of 2-3mm is less than 2200 yuan per meter 2 The stainless steel fiber felt is less than 3500 yuan/m 2 Even if other surface treatments are added, the total price is not more than 5500 yuan/m at the highest 2 Not only than build-up welding>13000 yuan/m 2 ) Much lower than induction welding: (>8000 yuan/m 2 ) It is also very low.
However, the reason why the metal fiber felt cannot be directly applied to the high-temperature corrosion protection of the heating surface of the boiler is that the short plate is also very prominent, and two problems exist:
(1) Because the metal fiber is lapped and weaved with each other during the weaving process, a large amount of pores are bound to exist, and the metal fiber felt has the characteristic of high porosity (30-80%). In industry, a fiber felt labyrinth-like microporous pore passage is often used for a precision filter material. The size of the pores is generally related to the thickness of the fibers, with finer fibers having smaller pores. The diameter (0.05-0.3 mm) and distribution of pores among fibers have the characteristic of being very uniform, which also provides a good foundation for experimental research of the hole sealing technology. Therefore, how to reduce the ultra-high porosity to below 3-5% is the problem to be solved first.
(2) How to ensure that the metal fiber felt is tightly combined with the outer wall of the pipeline and does not fall off under the long-term service condition.
Aiming at the two problems, the preparation of the metal fiber felt protective layer on the surface of the water wall is taken as an example, and the corresponding strategy is as follows:
(1) First, a high density iron chromium aluminum fiber felt (porosity < 30%) was selected as the protective layer body. Secondly, a layer of iron-based self-melting alloy mixed with the adhesive (the thickness is about 2 mm) is sprayed or brushed on the heating surface of the water-cooled wall tube bank in a cold mode, the fiber felt is laid on the surface of the tube bank, and the fiber felt and the heating surface of the tube bank are tightly attached through the iron-based self-melting alloy adhesive layer through rolling of a self-made automatic feeding profiling roller press.
(2) And (3) automatically feeding the water-cooled wall tube bank, and finishing iron-based self-fluxing alloy coating cladding on the heating surface of the tube bank through a fixed induction coil. By means of the melting-recrystallization process of coating remelting, after natural cooling, the iron-chromium-aluminum fiber felt and the heating surface of the tube bank are fixedly connected.
(3) By means of high temperature of induction cladding waste heat, aluminum alloy (aluminum is more than 85 percent, and the balance is chromium, nickel, silicon and the like) is sprayed on the surface of the metal fiber felt, and the thickness of the coating is about 0.3-0.5mm, so that the aims of sealing the pores on the upper surface of the fiber felt and penetrating into the pores of the fiber felt as far as possible by means of high-permeability aluminum alloy are fulfilled.
The invention has the advantages that:
(1) The invention aims at innovating a novel long-acting high-temperature corrosion protection technology with comprehensive performance and service life not lower than that of surfacing and induction fusion welding and cost lower than that of surfacing and induction fusion welding. The metal fiber felt related to the main body of the invention is a novel material developed at home and abroad after 2000 years, and is mainly applied to filters in coal, petroleum and chemical industries. Through retrieval, no report that the method is used for surface corrosion protection of boiler pipelines is found at home and abroad, so the method belongs to the integrated innovation of transplantation technology.
(2) The invention abandons the idea that the traditional protective layer directly prepares a coating on the surface of the pipeline, and adopts the prefabricated metal fiber felt as the protective layer, and the technical path is firstly connected with the pipeline and finally blocks the pores on the surface of the metal fiber felt. The advantage of this is that the preparation process of prefabricated protective layer is not restricted by pipeline structure shape and environmental condition, only considers the connection with the bank of tubes, and simple process.
(3) The invention uses the iron-based self-melting alloy as the intermediate carrier for connecting the iron-chromium-aluminum fiber felt and the tube row, mainly considers that the iron-based self-melting alloy is similar to the main material elements of the iron-chromium-aluminum fiber felt and the matrix of the tube row of the water wall, the interface bonding is better than that of the nickel-based self-melting alloy, and the cost of the iron-based self-melting alloy is much lower, wherein the metal fiber felt comprises 1Cr13Al4, 1Cr21Al4, 0Cr21Al6, 0Cr23Al5, 0Cr25Al5, 0Cr21Al6Nb and 0Cr27Al7Mo2. Table 2 shows the chemical composition and the main properties of the iron-based self-fluxing alloy, and it can be seen that the coating properties such as melting point, hardness, thermal expansion coefficient, etc. are more advantageous than those of the nickel-based self-fluxing alloy.
TABLE 2 chemical composition and key properties of iron-based self-fluxing alloys
(4) By looking up related documents, the metal fiber felt used as a high-temperature flue gas filter of a coal-fired boiler is found to be very easy to block pores by coal tar in the using process, so that the filtration is ineffective and difficult to remove, and the problem becomes a great problem which troubles the industry all the time. It is inspired that the aluminum alloy coating is selected for hole sealing. The alumetizing of the metal surface is a common method for improving the corrosion resistance of metal materials in industry, and the corrosion resistance mechanism is that a steel matrix is protected due to the protection effect of a sacrificial anode formed by the negative potential of aluminum and steel. Belongs to a main method with obvious anti-corrosion effect and lower cost, and the aluminum coating is applied to the high-temperature service environment of the boiler waste incineration and is very easy to react quickly to generate compact Al 2 O 3 And (5) oxidizing the film. Although the film thickness is only in the order of microns, ceramic films have an effect of "one to ten" compared to metal coatings for high temperature corrosion protection. And the ceramic film is very thin, so that the heat conduction is not influenced.
In order to achieve the ideal effect of aluminizing and hole sealing, the invention adopts a method of spraying an aluminum alloy coating with the thickness of about 0.3mm on the surface of a cladding layer by electric arc or flame when the water-cooled wall tube bank just comes out of an induction coil after cladding and the surface of the tube bank is still in a red hot state, namely under the double high-temperature action of induction cladding residual temperature and thermal spraying, the liquid aluminum alloy coating is easier to permeate into pores on the surface of a metal fiber felt, thereby achieving the effect of hole sealing. Therefore, although the metal fiber felt has high porosity, after double-sided plugging, the corrosion gas can not enter the surface of the substrate through the pores to corrode the pipeline.
(5) Compared with the induction fusion welding thickness of about 0.5mm and the surfacing layer of 2.5mm, the total thickness of the protective layer reaches more than 3mm, so the protective life is longer; in terms of cost, the cost of the coating is reduced by more than 60% compared with that of surfacing and is reduced by more than 20% compared with that of an induction fusion welding coating; compared with the surfacing welding, the surfacing welding has the advantages that the heat input quantity on the surface of the tube bank is larger, so that the problem of dilution rate and the problem of thermal deformation control of the tube bank exist, and the two problems do not exist in the invention; the production efficiency must be much higher than that of the build-up welding.
In a third aspect of the present invention, there is provided a pipe for a boiler having a heating surface provided with a composite protective layer of a metal fiber felt-based self-fluxing alloy and aluminizing for a heating surface of a pipe for a boiler as set forth in the first aspect of the present invention or a composite protective layer of a metal fiber felt-based self-fluxing alloy and aluminizing for a heating surface of a pipe for a boiler as prepared by the method of the second aspect of the present invention.
III, detection method
The porosity of the metal fiber felt-based self-fluxing alloy and aluminized composite protective layer according to the invention is monitored in accordance with GB/T l7721-1999 (Metal covering porosity test).
The measuring method of the corrosion resistance of the boiler pipe or the protective layer comprises laboratory measurement and field measurement. Wherein, the laboratory measurement is to introduce corrosive gas (such as one or more of chlorine, sulfur and alkali metal) which is configured according to proportion into a tubular furnace, put a test piece into the furnace for an acceleration test, and measure by adopting a metal corrosion test method-a gravimetric method, namely, the change of weight of the metal test piece before and after corrosion (a weight loss method) is utilized to represent the corrosion speed; the field measurement is performed by directly placing a test piece in the boiler, for example, by a hanging method or by welding the test piece to the boiler, and detecting the corrosion reduction of the test piece.
IV, examples
The present invention will be described in detail below with reference to the accompanying drawings and specific examples. The experimental methods described below are, unless otherwise specified, conventional laboratory methods. The experimental materials described below, unless otherwise specified, are commercially available.
Example 1:
(1) And respectively carrying out sand blasting coarsening and cleaning treatment on the heating surface of the water-cooled wall tube bank and the two surfaces of the metal fiber felt by an automatic sand blasting machine to obtain a clean water-cooled wall tube bank with a coarsened heating surface and a clean metal fiber felt with a coarsened two surfaces.
(2) And (3) carrying out cold spraying/brushing on the iron-based self-fluxing alloy coating with the thickness of about 2mm +/-0.02 mm on the heating surface of the water-cooled wall tube bank (the components are shown in a table 2), thus obtaining the water-cooled wall tube bank with the iron-based self-fluxing alloy coating on the heating surface.
(3) An iron-chromium-aluminum fiber felt (1 Cr13Al4, the porosity is less than 30%) with the thickness of about 2mm +/-0.02 mm is laid on the surface of a water-cooled wall tube bank, and the fiber felt is tightly attached to the heating surface of the tube bank through an iron-based self-melting alloy coating by manually tapping repeatedly with a wood hammer or a rubber hammer or a copper hammer, so that the water-cooled wall tube bank with the iron-based self-melting alloy coating and the metal fiber felt adhered to the heating surface is obtained.
(4) Rapid heating and drying process: and starting a transmission chain and a high-frequency induction coil for conveying the water-cooled wall tube bank, enabling the tube bank to be rapidly and automatically fed, rapidly heating by the fixed induction coil, controlling the heating speed to completely dry the adhesive, and obtaining the water-cooled wall tube bank with the heated surface provided with the iron-based self-fluxing alloy coating-the bottom layer of the metal fiber felt.
(5) Low-speed cladding stroke: and (4) moving the water-cooled wall tube bank reversely, and controlling the automatic feeding speed according to the speed required by induction cladding to complete the induction cladding of the iron-based self-fluxing alloy coating on the heating surface of the tube bank. Therefore, by means of the melting-recrystallization process of coating remelting, the iron-chromium-aluminum fiber felts on the two surfaces of the coating are fixedly connected with the heating surface of the tube bank, and the cold wall tube bank with the heating surface provided with the metal fiber felt-iron-based self-melting alloy composite cladding coating is obtained, and the structure is shown in figure 1.
(6) When the tube bank just comes out of the induction coil after cladding, and the surface of the tube bank is still in a red hot state, spraying an aluminum alloy coating with the thickness of about 0.3mm +/-0.05 mm on the surface of the cladding layer by electric arc or flame. In the spray zone, i.e. within 500mm of the tube bank coming out of the induction coil, the temperature drop is about 800-650 ℃. Under the dual high-temperature action of the induction cladding residual temperature and the thermal spraying, the aluminum alloy coating can more easily penetrate into the pores on the surface of the metal fiber felt, so that the hole sealing effect is achieved.
(7) And (3) quality control: detecting the quality of the surface coating of the tube bank, repairing local defects, obtaining a metal fiber felt-based self-fluxing alloy and aluminized composite protective layer on the heating surface of the water wall tube bank, and measuring the thickness of the protective layer to be more than 3mm.
The corrosion resistance of the coating is measured by a laboratory, corrosive gases (chlorine, sulfur, alkali metal chloride and other gases) which are prepared in proportion are introduced into a tubular furnace, a test piece is put into the furnace for an accelerated corrosion test, and then the change of weight loss before and after the corrosion of the metal test piece is measured, and the result shows that the corrosion amount is very small.
The actual consumption rate in production is directly used for detecting the corrosion resistance of the 20G water-cooled wall tube bank with the novel fiber reinforced composite coating in the embodiment, and compared with the corrosion resistance of the 20G water-cooled wall tube bank with the original coating, the result shows that the corrosion reduction amount of the 20G water-cooled wall tube bank test piece with the novel fiber reinforced composite coating in the embodiment is less than 0.1 mu m/h, which indicates that the 20G water-cooled wall tube bank with the novel fiber reinforced composite coating in the embodiment has good corrosion resistance, the service life of the 20G water-cooled wall tube bank can reach 10 years, the service life of the 20G water-cooled wall tube bank without the coating is prolonged by more than 8 years, and the service life of the 20G water-cooled wall tube bank with the original coating (common arc spraying anticorrosive coating) is prolonged by at least 5 years.
Example 2:
example 2 a composite protective layer of a metal fiber felt-based self-fluxing alloy and aluminized aluminum was obtained on the heated surface of the waterwall tube bank using the same procedure and procedure as in example 1, except that the thickness of the iron-chromium-aluminum fiber felt used was about 2.5mm ± 0.02mm, the thickness of the aluminum alloy coating was about 0.04mm ± 0.05mm, and the thickness of the protective layer prepared was above 3mm.
The corrosion resistance of the coating is measured by adopting a laboratory, corrosive gases (such as chlorine, sulfur, alkali metal chloride and the like) which are prepared in proportion are introduced into a tube furnace, a test piece is put into the tube furnace for an accelerated corrosion test, then the change of the weight loss of the metal test piece before and after corrosion is measured, and the result shows that the corrosion amount is very small.
The actual consumption rate in production is directly used for detecting the corrosion resistance of the 20G water-cooled wall tube bank with the novel fiber reinforced composite coating in the embodiment, and compared with the corrosion resistance of the 20G water-cooled wall tube bank with the original coating, the results show that the corrosion reduction amount of the 20G water-cooled wall tube bank test piece with the novel fiber reinforced composite coating in the embodiment is less than 0.1 mu m/h, which indicates that the 20G water-cooled wall tube bank with the novel fiber reinforced composite coating in the embodiment has good corrosion resistance, the service life of the 20G water-cooled wall tube bank with the novel fiber reinforced composite coating can reach 10 years, the service life of the 20G water-cooled wall tube bank without the coating is prolonged by more than 8 years, and the service life of the 20G water-cooled wall tube bank with the original coating (common arc spraying anticorrosive coating) is prolonged by at least 5 years.
Example 3:
example 3a composite protective layer of a metal fiber felt-based self-fluxing alloy and aluminized aluminum was obtained on the heated surface of the waterwall tube bank using the same procedure and procedure as in example 1, except that the thickness of the iron-chromium-aluminum fiber felt used was about 3mm + -0.02 mm, the thickness of the aluminum alloy coating was about 0.05mm + -0.05 mm, and the thickness of the protective layer prepared was above 3mm.
The corrosion resistance of the coating is measured by a laboratory, corrosive gases (chlorine, sulfur, alkali metal chloride and other gases) which are prepared in proportion are introduced into a tubular furnace, a test piece is put into the furnace for an accelerated corrosion test, and then the change of weight loss before and after the corrosion of the metal test piece is measured, and the result shows that the corrosion amount is very small.
The actual consumption rate in production is directly used for detecting the corrosion resistance of the 20G water-cooled wall tube bank with the novel fiber reinforced composite coating in the embodiment, and compared with the corrosion resistance of the 20G water-cooled wall tube bank with the original coating, the results show that the corrosion reduction amount of the 20G water-cooled wall tube bank test piece with the novel fiber reinforced composite coating in the embodiment is less than 0.1 mu m/h, which indicates that the 20G water-cooled wall tube bank with the novel fiber reinforced composite coating in the embodiment has good corrosion resistance, the service life of the 20G water-cooled wall tube bank with the novel fiber reinforced composite coating can reach 10 years, the service life of the 20G water-cooled wall tube bank without the coating is prolonged by more than 8 years, and the service life of the 20G water-cooled wall tube bank with the original coating (common arc spraying anticorrosive coating) is prolonged by at least 5 years.
The results of the tests carried out by adopting iron-chromium-aluminum fiber felts of other brands show that the corrosion amount of the coating is very small, the service life of the coating can reach 10 years, the service life is prolonged by more than 8 years compared with the service life of a 20G water-cooled wall tube bank without the coating, and the service life is prolonged by at least 5 years compared with the service life of a 20G water-cooled wall tube bank with the original coating (common arc spraying anticorrosive coating).
It should be noted that the above-mentioned embodiments are only preferred embodiments of the present invention, and are used for explaining the present invention, and do not constitute any limitation to the present invention. The present invention has been described with reference to exemplary embodiments, but the words which have been used herein are words of description and illustration, rather than words of limitation. The invention can be modified, as prescribed, within the scope of the claims and without departing from the scope and spirit of the invention. Although the invention has been described herein with reference to particular means, materials and embodiments, the invention is not intended to be limited to the particulars disclosed herein, but rather extends to all other methods and applications having the same functionality.
Claims (10)
1. A composite protecting layer of metal fibre felt-base self-smelting alloy and aluminized aluminium for the heating surface of boiler tube is composed of a composite layer of metal fibre felt-base self-smelting alloy and a composite layer of metal fibre felt-base aluminized aluminium.
2. The metal fiber felt-based self-fluxing alloy and aluminizing composite protective layer of claim 1, wherein the metal fiber felt is a high-density iron-chromium-aluminum fiber felt having a porosity of < 30%.
3. The metal fiber felt-based self-fluxing alloy and aluminizing composite protective layer according to claim 1 or 2, wherein in the metal fiber felt-based self-fluxing alloy composite layer, the thickness of the iron-based self-fluxing alloy layer is 2mm ± 0.02mm, the thickness of the metal fiber felt is 0.3-5mm ± 0.02mm, preferably 2-3mm ± 0.02mm, the thickness of the aluminizing composite layer is 0.3-0.5mm ± 0.05mm, and the thickness of the metal fiber felt-based self-fluxing alloy and aluminizing composite protective layer is greater than or equal to 3mm.
4. A method for preparing a composite protective coating of a metal fiber felt-based self-fluxing alloy and aluminized aluminum for a heated surface of a tube for a boiler according to any one of claims 1 to 3, comprising:
step A, carrying out sand blasting coarsening and decontamination treatment on the heating surface of the water-cooled wall tube bank and the two surfaces of the metal fiber felt respectively and independently to obtain a clean water-cooled wall tube bank with a roughened heating surface and a clean metal fiber felt with a roughened two surfaces;
step B, carrying out cold spraying or brushing on the heating surface of the clean water-cooled wall tube bank with the roughened heating surface to obtain a water-cooled wall tube bank with the heating surface provided with the iron-based self-fluxing alloy coating;
c, paving the metal fiber felt on a heating surface of the water-cooled wall tube bank with the iron-based self-fluxing alloy coating on the heating surface, and pressing the metal fiber felt tightly with the heating surface of the tube bank through the iron-based self-fluxing alloy coating to obtain the water-cooled wall tube bank with the iron-based self-fluxing alloy coating and the metal fiber felt adhered on the heating surface;
d, starting a transmission chain and a high-frequency induction coil for conveying the water-cooled wall tube bank, enabling the water-cooled wall tube bank with the iron-based self-fluxing alloy coating and the metal fiber felt adhered to the heating surface to be automatically fed, heating the water-cooled wall tube bank with the iron-based self-fluxing alloy coating and the metal fiber felt adhered to the heating surface through the fixed induction coil, controlling the automatic feeding speed to completely dry the adhesive, but not melting the coating, and obtaining the water-cooled wall tube bank with the iron-based self-fluxing alloy coating-the metal fiber felt bottom layer on the heating surface;
e, moving the water-cooled wall tube bank with the heating surface provided with the iron-based self-fluxing alloy coating-metal fiber felt bottom coating in a reverse direction, controlling the automatic feeding speed, and finishing the induction cladding of the iron-based self-fluxing alloy coating on the heating surface of the tube bank, so that the iron-chromium-aluminum fiber felt and the heating surface of the tube bank which are respectively positioned on the two sides of the iron-based self-fluxing alloy coating are fixedly connected by virtue of the melting-recrystallization process of the iron-based self-fluxing alloy coating, and the cold-wall tube bank with the heating surface provided with the metal fiber felt-iron-based self-fluxing alloy composite cladding coating is obtained;
and F, when the cold wall tube bundle with the clad heating surface provided with the metal fiber felt base-iron base self-melting alloy composite cladding coating just comes out of the induction coil and the surface of the tube bundle is still in a red hot state, spraying an aluminum alloy coating on the surface of the cladding coating by using electric arc or flame, and under the dual high-temperature action of the residual temperature of induction cladding and thermal spraying, enabling the aluminum alloy coating to penetrate into pores on the surface of the metal fiber felt to seal the hole on the surface of the metal fiber felt, thereby obtaining the metal fiber felt base self-melting alloy and aluminized composite protective layer on the heating surface of the water wall tube bundle.
5. The preparation method of claim 4, wherein in step F, when the cold wall tube bank with the metal fiber felt-based-iron-based self-fluxing alloy composite cladding coating on the heating surface after cladding comes out of the induction coil by 300-500mm, the aluminum alloy coating is sprayed on the surface of the cladding coating by electric arc or flame in a red hot state at 650-800 ℃.
6. The method of claim 4, wherein the metal fiber mat comprises 1Cr13Al4, 1Cr21Al4, 0Cr21Al6, 0Cr23Al5, 0Cr25Al5, 0Cr21Al6Nb, 0Cr27Al7Mo2.
7. The preparation method according to claim 4, wherein the iron-based self-fluxing alloy material consists of an iron-based self-fluxing alloy and a binder, wherein the composition of the iron-based self-fluxing alloy material is as follows:
8. the manufacturing method according to claim 4, wherein in the step D, the speed of the auto-feed is 10-30mm/s; and/or, in step E, the speed of automatic feeding is 0.5-1.5mm/s.
9. The preparation method according to any one of claims 3 to 8, wherein step G is further included after step F, and the quality of the metal fiber felt-based self-fluxing alloy and aluminized composite protective layer used for the heating surface of the tube for the boiler is detected.
10. A pipe for a boiler, having a heating surface with a composite protective layer of metal fiber felt-based self-fluxing alloy and aluminized coating for a heating surface of a pipe for a boiler as set forth in any one of claims 1 to 3 or prepared by the method as set forth in any one of claims 4 to 9.
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