CN117265455B - Thermal spraying process for wear-resistant valve plate with flow guiding device - Google Patents
Thermal spraying process for wear-resistant valve plate with flow guiding device Download PDFInfo
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- CN117265455B CN117265455B CN202311557861.5A CN202311557861A CN117265455B CN 117265455 B CN117265455 B CN 117265455B CN 202311557861 A CN202311557861 A CN 202311557861A CN 117265455 B CN117265455 B CN 117265455B
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- thermal spraying
- flow guiding
- guiding device
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- 238000007751 thermal spraying Methods 0.000 title claims abstract description 129
- 238000000034 method Methods 0.000 title claims abstract description 45
- 230000008569 process Effects 0.000 title claims abstract description 37
- 238000005507 spraying Methods 0.000 claims abstract description 63
- 238000007789 sealing Methods 0.000 claims abstract description 47
- 238000003754 machining Methods 0.000 claims abstract description 14
- 238000000576 coating method Methods 0.000 claims abstract description 13
- 239000011248 coating agent Substances 0.000 claims abstract description 12
- 238000004519 manufacturing process Methods 0.000 claims abstract description 3
- 238000004321 preservation Methods 0.000 claims description 25
- 239000000843 powder Substances 0.000 claims description 24
- 238000005520 cutting process Methods 0.000 claims description 13
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 12
- 239000007921 spray Substances 0.000 claims description 10
- 229920000742 Cotton Polymers 0.000 claims description 7
- 238000005488 sandblasting Methods 0.000 claims description 7
- 238000007599 discharging Methods 0.000 claims description 6
- 238000010438 heat treatment Methods 0.000 claims description 6
- 229910052759 nickel Inorganic materials 0.000 claims description 6
- 238000009413 insulation Methods 0.000 claims description 4
- 238000001816 cooling Methods 0.000 claims description 3
- 229910052593 corundum Inorganic materials 0.000 claims description 3
- 239000010431 corundum Substances 0.000 claims description 3
- 239000011229 interlayer Substances 0.000 claims description 3
- 238000002844 melting Methods 0.000 claims description 3
- 230000008018 melting Effects 0.000 claims description 3
- 238000007788 roughening Methods 0.000 claims description 3
- 238000000746 purification Methods 0.000 claims description 2
- 238000010583 slow cooling Methods 0.000 claims 1
- 230000007547 defect Effects 0.000 abstract description 8
- 239000012535 impurity Substances 0.000 description 10
- 239000002245 particle Substances 0.000 description 8
- 238000010008 shearing Methods 0.000 description 7
- 239000010410 layer Substances 0.000 description 5
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- 230000002035 prolonged effect Effects 0.000 description 5
- 229910052751 metal Inorganic materials 0.000 description 4
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- 229910000851 Alloy steel Inorganic materials 0.000 description 2
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- 229910045601 alloy Inorganic materials 0.000 description 2
- 239000000956 alloy Substances 0.000 description 2
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- 239000010962 carbon steel Substances 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- 229910001080 W alloy Inorganic materials 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
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- 238000005242 forging Methods 0.000 description 1
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- 229910052739 hydrogen Inorganic materials 0.000 description 1
- 239000001257 hydrogen Substances 0.000 description 1
- 230000003993 interaction Effects 0.000 description 1
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 description 1
- 239000002932 luster Substances 0.000 description 1
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Classifications
-
- 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
-
- 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
- C23C4/02—Pretreatment of the material to be coated, e.g. for coating on selected surface areas
-
- 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
- C23C4/18—After-treatment
Abstract
The invention discloses a thermal spraying process of a wear-resistant valve plate with a flow guiding device, and belongs to the technical field of valve plate surface spraying treatment. The method comprises the steps of rough machining a valve plate thermal spraying blank with a flow guiding device; manufacturing a thermal spraying tool, wherein the thermal spraying tool comprises a fixed platform, a V-shaped block, a side fixed block, an inclined fixed block and a top fixed block which are arranged in the fixed platform; fixing the valve plate with the flow guiding device on a thermal spraying tool; and (3) performing integral thermal spraying on two sealing surfaces of the thermal spraying blank of the valve plate with the flow guiding device. According to the thermal spraying process provided by the invention, after the thermal spraying blank of the valve plate with the flow guiding device is assembled and fixed through the thermal spraying tool, the deformation amount generated in the whole thermal spraying process of the two sealing surfaces of the valve plate with the flow guiding device can be effectively reduced, and the defects that the wear-resistant valve plate with the flow guiding device cannot be seriously deformed after being integrally sprayed, and the ultra-thick wear-resistant coating cannot be cracked and the like can be overcome.
Description
Technical Field
The invention relates to a thermal spraying process of a wear-resistant valve plate with a flow guiding device, and belongs to the technical field of valve plate surface spraying.
Background
The flat gate valve is a sliding valve with a parallel valve plate as a closing member, has the advantages of small flow resistance, short structural length, good sealing performance, small operation torque and the like, and is widely applied to the fields of petrochemical industry, coal chemical industry, silicon chemical industry, metallurgy, electric power, hydrogen energy, water industry and the like.
The flat gate valve can be divided into a flat gate valve with a flow guiding device and a flat gate valve without a flow guiding device according to a valve plate structure. The plate gate valve with the flow guiding device is the largest difference from the plate gate valve without the flow guiding device that the flow guiding hole with the same diameter as the flow channel is processed on the valve plate, when the flow guiding hole of the valve plate is aligned with the flow channel, the whole channel of the valve is smooth and straight, the flow resistance is extremely small, and the medium can pass through without obstruction. The flat gate valve with the flow guiding device is in a fully opened or fully closed state, and the valve plate with the flow guiding device is always in close contact with the sealing surface of the valve seat, so that the sealing surface of the valve seat is effectively protected and cannot be directly washed by a medium, and the service life of the valve is prolonged.
The flat gate valve may be classified into a soft seal flat gate valve and a metal seal flat gate valve according to a seal form. The soft material (such as polytetrafluoroethylene) and the valve plate arranged on the surface of the valve seat of the soft sealing flat gate valve form a sealing pair, and the valve plate and the valve seat sealing surface of the metal sealing flat gate valve form the sealing pair after hardening treatment. At present, the method of hardening the valve plate and the valve seat sealing surface of the metal sealing flat gate valve into build-up welding or spraying hard alloy is only suitable for the conventional working condition.
As petrochemical plants move to higher parameters, more and more demanding conditions are presented. If the medium is high-temperature heavy oil, the medium contains water vapor and catalyst powder, the gas-liquid-solid three-phase flow can reach 54m/s, the high requirement is put forward on the integral wear resistance of the valve, the hardness is more than or equal to 60HRC, and the thickness of the processed coating is more than or equal to 3mm. Conventional metal seal flat gate valves with flow guiding devices cannot meet the use requirements, have a short service life, usually about 3 months, and have the following main problems:
1) The valve plate with the flow guiding device is subjected to non-integral hardening treatment, and only the sealing surface around the outer ring of the flow guiding hole is subjected to hardening treatment, namely, the small ring molded surface contacted with the sealing surface of the valve seat ring is easily damaged under the erosion of high-speed gas-liquid-solid three-phase flow medium, so that the flow guiding device with the flow guiding device cannot be in close contact with the sealing surface of the valve seat or the valve plate breaks down.
2) When the sealing surface with the flow guiding device and the valve seat adopts a build-up welding method, the hardness after processing is generally not more than 48HRC, and the hardness can not meet the working condition requirement. When the method of spraying hard alloy is adopted, although the hardness can meet the requirement that the working condition requirement is more than or equal to 60HRC, the thickness of the coating after processing is generally below 1.2mm, and the working condition requirement cannot be met.
3) The orifice of the valve plate with the flow guiding device and the valve seat is not hardened, and the acute angle shearing function of the orifice can not be utilized to cut off strip-shaped or block-shaped impurities, large particles and the like in the opening and closing process of the valve plate with the flow guiding device. Strip-shaped or block-shaped impurities and large particles are easily accumulated on the sealing surface of the valve plate and the valve seat with the flow guiding device, so that the service life of the valve is greatly shortened.
In the existing spraying technology, the problems are as follows:
1) If the two planes of the valve plate with the flow guiding device and the valve seat are in contact with each other, the valve plate with the flow guiding device is subjected to integral spraying treatment, and serious deformation can occur due to high temperature in the spraying process, so that the valve plate with the flow guiding device cannot be processed to the size required by the drawing.
2) Ultra-thick wear-resistant coatings are very prone to defects such as cracks.
Disclosure of Invention
The invention aims to provide a thermal spraying process for a wear-resistant valve plate with a flow guiding device, which can prevent the wear-resistant valve plate with the flow guiding device from serious deformation after being integrally sprayed, prevent the ultra-thick wear-resistant coating from generating defects such as cracks and the like, and ensure that the orifice of the valve plate with the flow guiding device and a valve seat has an acute angle shearing function.
The technical problems to be solved by the invention are realized by adopting the following technical scheme:
a thermal spraying process of a wear-resistant valve plate with a flow guiding device comprises the following process steps:
step 1: rough machining a valve plate thermal spraying blank with a flow guiding device;
firstly, roughly machining a bottom arc surface and a plane, two side surfaces, an inclined plane, a top plane and an upper plane of the thermal spraying blank of the valve plate with the flow guiding device;
after the rough machining of the upper plane and the lower plane is finished, respectively machining diversion Kong Mangkong with the depth of 5mm at the diversion hole positions of the upper plane and the lower plane of the valve plate with the diversion device;
step 2: manufacturing a thermal spraying tool;
the thermal spraying tool comprises a fixed platform, a V-shaped block, a side fixed block, an inclined fixed block and a top fixed block which are arranged in the fixed platform;
the two V-shaped surfaces of the V-shaped block are contacted with the arc surface at the bottom of the thermal spraying blank of the valve plate with the flow guiding device;
the heights of the side fixing blocks, the inclined fixing blocks and the top fixing blocks are 20-30 mm thinner than the thickness of the thermal spraying blank with the flow guiding device valve plate, and the thickness is not less than 30mm;
the side fixing blocks are welded with two side surfaces of the thermal spraying blank with the valve plate with the flow guiding device;
the inclined fixing block is welded with two inclined planes of the thermal spraying blank with the valve plate of the flow guiding device;
the top fixing block is welded with the top plane of the thermal spraying blank of the valve plate with the flow guiding device;
the height of all welded seams is 5-10 mm lower than the upper and lower planes of the valve plate thermal spraying blank with the flow guiding device;
step 3: fixing the valve plate with the flow guiding device on a thermal spraying tool;
the thermal spraying tool further comprises a plurality of groups of locking bolts and locking nuts;
the hot spraying blank with the flow guiding device valve plate is welded with the side fixing blocks, the inclined fixing blocks and the top fixing blocks and then placed in a groove of the fixing platform, the side surfaces of the two sides, the inclined surface and the top plane are locked and fixed through the locking bolts and the locking nuts, and the arc surface of the bottom is locked and fixed through the V-shaped blocks, the locking bolts and the locking nuts;
step 4: the whole thermal spraying of two sealing surfaces of the thermal spraying blank of the valve plate with the flow guiding device comprises the following substeps:
(1) Spraying surface purification treatment is carried out on the two sealing surfaces;
(2) Carrying out spraying surface roughening treatment on the two sealing surfaces;
(3) Placing the valve plate thermal spraying blank with the flow guiding device and the thermal spraying tool into a heat treatment furnace for preheating, wherein the preheating temperature is 540+/-10 ℃;
(4) Discharging, and spraying base powder on the spraying surface of the blank of the valve plate with the flow guiding device;
(5) Starting a heat preservation device, and setting the temperature to 650+/-10 ℃;
(6) Discharging the thermal spraying blank with the valve plate of the flow guiding device and the thermal spraying tool and placing the thermal spraying blank and the thermal spraying tool on the heat preservation device;
(7) Powder spraying is carried out by adopting a spray gun, the spray gun is 150-200 mm away from the surface of a workpiece during spraying, a one-step spraying and melting mode is adopted, remelting is carried out immediately after powder spraying, and the remelting temperature is 1000-1050 ℃; covering the remelted area by adopting a heat preservation assembly to preserve heat;
(8) Cooling the spray coating.
In step 4 (2), when the two sealing surfaces of the thermal spraying blank with the flow guiding device are roughened, 36# or 46# white corundum is adopted for sand blasting, and the sand blasting pressure is 0.5-0.7 MPa.
As a preferred example, in step 4 (3), when the thermal spraying blank of the valve plate with the flow guiding device and the thermal spraying tool are preheated, the surface of the blank of the valve plate with the flow guiding device is preheated to be blue, and the thermal spraying blank is kept for at least 3 hours.
In step 4 (4), when the base powder is sprayed on the spraying surface of the valve plate blank with the flow guiding device, the base powder adopts nickel-based self-fluxing powder Ni65, the spraying thickness is 0.2-0.3 mm, and then the base powder is fed into the furnace again for heat preservation for 4 hours.
As a preferred example, in the step 4 (7), the powder is nickel-based self-fluxing powder Ni65, the spraying thickness is 4-5 mm, the interlayer temperature is controlled at 450+/-20 ℃, and the spraying width of each spraying path is 8-12 mm.
As a preferred example, in step 4 (7), the heat-insulating member is made of heat-insulating cotton.
In step 4 (7), when the flow guiding hole is sprayed and remelted, the joint of the plane of the sealing surface and the blind hole is subjected to edge wrapping treatment, and a ring profile of at least 5mm is sprayed along the direction from the center of the blind hole to the inner diameter.
In step 4 (8), as a preferred example, when the sprayed coating is cooled, the thermal spraying blank of the valve plate with the flow guiding device after thermal spraying is slowly cooled in a heat preservation cotton heat preservation mode, or the thermal spraying blank of the valve plate with the flow guiding device is put into a heat treatment furnace for stress relief treatment and then is air cooled.
As a preferred example, after the two sealing surfaces of the blank are thermally sprayed integrally, the valve plate with the flow guiding device is cut, wherein the cutting includes linear cutting of a blind hole of a flow guiding hole in the valve plate with the flow guiding device, and linear cutting of a T-shaped groove at the top plane of the valve plate with the flow guiding device.
As a preferable example, the thickness of the spray coating of the whole thermal spraying of the two sealing surfaces of the valve plate with the flow guiding device is 3.2-3.8 mm, and the hardness is 60-65 HRC.
The beneficial effects of the invention are as follows:
(1) According to the thermal spraying process for the wear-resistant valve plate with the flow guiding device, provided by the invention, after the thermal spraying blank of the valve plate with the flow guiding device is assembled and fixed through the thermal spraying tool through the special thermal spraying tool fixture, the deformation amount generated in the whole thermal spraying process of two sealing surfaces of the valve plate with the flow guiding device can be effectively reduced, the wear-resistant valve plate with the flow guiding device can not be seriously deformed after being integrally sprayed, the ultra-thick wear-resistant coating can not have defects such as cracks, and the service life of the valve plate can be prolonged.
(2) After the rough machining of the upper plane and the lower plane of the valve plate thermal spraying blank with the flow guiding device is finished, only a blind hole with the depth of 5mm is machined in the flow guiding hole position, a T-shaped groove is not machined, and the integral strength of the valve plate thermal spraying blank with the flow guiding device is improved.
(3) The heat preservation device can continuously ensure that the spray coating of the valve plate blank with the flow guide device keeps heat continuously in the thermal spraying process, and can avoid the defects of cracks and the like of the ultra-thick wear-resistant coating.
(4) After the diversion hole wire cutting processing, the diversion hole wire cutting processing device and the two sealing surface orifices form a wear-resistant shearing function, strip-shaped or block-shaped impurities, large particles and the like can be cut off, the strip-shaped or block-shaped impurities and the large particles cannot be accumulated on the sealing surfaces of the valve plate and the valve seat with the diversion device, and the service life of the valve is prolonged.
(5) After the integral thermal spraying, processing and high-precision grinding of the two sealing surfaces of the diversion hole valve plate, the thickness of a spraying layer is 3.2-3.8 mm, and the hardness is 60-65 HRC; preferably, the thickness of the spray coating is 3.3-3.5 mm, the hardness is 61-64 HRC, and the wear resistance and the service life of the valve plate are improved.
Drawings
FIG. 1 is a schematic top view of a thermal spray tool according to an embodiment of the present invention;
FIG. 2 is a schematic diagram of a front view structure of a thermal spraying tool according to an embodiment of the present invention;
FIG. 3 is a partial cross-sectional view taken along the direction A-A in FIG. 1;
fig. 4 is a schematic structural view of a valve plate according to an embodiment of the present invention.
In the figure:
1. a fixed platform;
2. a valve plate with a flow guiding device; 21. a deflector aperture; 22. sealing surfaces; 23. a T-shaped groove;
3. a V-shaped block;
4. a locking bolt;
5. a lock nut;
6. a side fixing block;
7. an inclined fixing block;
8. a top fixed block;
9. a heat preservation device;
10. and (5) heat preservation cotton.
Detailed Description
Embodiments of the present invention are described in detail below, examples of which are illustrated in the accompanying drawings, wherein the same or similar reference numerals refer to the same or similar elements or elements having the same or similar functions throughout. The embodiments described below by referring to the drawings are exemplary only for explaining the present invention and are not to be construed as limiting the present invention.
In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise" indicate orientations or positional relationships are based on the orientations or positional relationships shown in the drawings, are merely for convenience in describing the present invention and simplify the description, and do not indicate or imply that the devices or elements referred to must have a specific orientation, be configured and operated in a specific orientation, and therefore should not be construed as limiting the present invention. Furthermore, the terms "first," "second," and the like, are used for descriptive purposes only and are not to be construed as indicating or implying a relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defining "a first" or "a second" may explicitly or implicitly include one or more of the described features. In the description of the present invention, the meaning of "a plurality" is two or more, unless explicitly defined otherwise.
In the description of the present invention, it should be noted that, unless explicitly specified and limited otherwise, the terms "mounted," "connected," and "connected" are to be construed broadly, and may be either fixedly connected, detachably connected, or integrally connected, for example; can be mechanically connected, electrically connected or can be communicated with each other; can be directly connected or indirectly connected through an intermediate medium, and can be communicated with the inside of two elements or the interaction relationship of the two elements. The specific meaning of the above terms in the present invention can be understood by those of ordinary skill in the art according to the specific circumstances.
In the present invention, unless expressly stated or limited otherwise, a first feature "above" or "below" a second feature may include both the first and second features being in direct contact, as well as the first and second features not being in direct contact but being in contact with each other through additional features therebetween. Moreover, a first feature being "above," "over" and "on" a second feature includes the first feature being directly above and obliquely above the second feature, or simply indicating that the first feature is higher in level than the second feature. The first feature being "under", "below" and "beneath" the second feature includes the first feature being directly under and obliquely below the second feature, or simply means that the first feature is less level than the second feature.
The following disclosure provides many different embodiments, or examples, for implementing different features of the invention. In order to simplify the present disclosure, components and arrangements of specific examples are described below. They are, of course, merely examples and are not intended to limit the invention. Furthermore, the present invention may repeat reference numerals and/or letters in the various examples, which are for the purpose of brevity and clarity, and which do not themselves indicate the relationship between the various embodiments and/or arrangements discussed. In addition, the present invention provides examples of various specific processes and materials, but one of ordinary skill in the art will recognize the application of other processes and/or the use of other materials.
The embodiment provides a thermal spraying process of a wear-resistant valve plate with a flow guiding device, which comprises the following steps:
first, a blank for thermal spraying of the valve plate 2 with the deflector is rough-machined, and as shown in fig. 4, the blank for thermal spraying is preferably formed by forging, preferably an alloy steel or a carbon steel material. Firstly, rough machining is carried out on an arc surface and a plane, two side surfaces, an inclined surface, a top plane and an upper plane and a lower plane at the bottom of a thermal spraying blank of the valve plate 2 with the flow guiding device. After the rough machining of the upper plane and the lower plane is finished, blind holes with the depth of 5mm are respectively machined at the positions of the guide holes 21 of the upper plane and the lower plane, T-shaped grooves 23 are not machined, the overall strength of the thermal spraying blank of the valve plate 2 with the guide device is improved, the deformation quantity generated in the overall thermal spraying process of the two sealing surfaces 22 of the valve plate 2 with the guide device can be effectively reduced, and the subsequent machining to the size required by a drawing is ensured.
Secondly, a thermal spraying tool is manufactured, and as shown in fig. 1-3, the thermal spraying tool comprises a fixed platform 1, a V-shaped block 3, a locking bolt 4, a locking nut 5, a side fixing block 6, an inclined fixing block 7 and a top fixing block 8. Wherein:
the two V-shaped surfaces of the V-shaped block 3 are contacted with the arc surface at the bottom of the thermal spraying blank of the valve plate 2 with the flow guiding device;
the heights of the side fixing blocks 6, the inclined fixing blocks 7 and the top fixing blocks 8 are 20-30 mm thinner than the thickness of the thermal spraying blank of the valve plate 2 with the flow guiding device, the thickness is not less than 30mm, and the length is determined according to the thermal spraying blank of the valve plate 2 with the flow guiding device with different specifications; the side fixing blocks 6 are welded with two side surfaces of the thermal spraying blank of the valve plate 2 with the flow guiding device, the inclined fixing blocks 7 are welded with two inclined surfaces of the thermal spraying blank of the valve plate 2 with the flow guiding device, and the top fixing blocks 8 are welded with the top plane of the thermal spraying blank of the valve plate 2 with the flow guiding device; after welding, the heights of all welding seams are required to be ensured to be 5-10 mm lower than the upper plane and the lower plane of the thermal spraying blank of the valve plate 2 with the flow guiding device.
The thermal spraying blank with the flow guiding device valve plate 2 is welded with the side fixing block 6, the inclined fixing block 7 and the top fixing block 8 and then placed in the groove of the fixing platform 1, the two side faces, the inclined plane and the top plane are locked and fixed through the locking bolt 4 and the locking nut 5, and the arc surface at the bottom is locked and fixed through the V-shaped block 3, the locking bolt 4 and the locking nut 5. After the thermal spraying blank with the flow guiding device valve plate 2 is assembled and fixed through the thermal spraying tool, the deformation generated in the whole thermal spraying process of the two sealing surfaces 22 of the flow guiding device valve plate 2 can be effectively reduced, and the subsequent processing to the size required by the drawing is ensured.
Then, the two sealing surfaces 22 of the valve plate 2 with the flow guiding device are integrally thermally sprayed, and the steps comprise:
1) In the embodiment, rust, oxide skin, impurities, dirt and the like on the sprayed surface are removed by adopting a shot blasting method, and grease is removed by adopting an ultrasonic cleaning method, so that the sprayed surface achieves the cleanliness required by thermal spraying.
2) And (3) coarsening the sprayed surface, wherein the coarsening is to enable the purified sprayed surface to form a uniform uneven rough surface, so that the bonding strength of the sprayed surface and the sprayed layer is improved. Because the thickness of the processed coating is more than or equal to 3mm, 36# or 46# white corundum is adopted for sand blasting treatment in the embodiment, and the sand blasting pressure is 0.5-0.7 MPa. After sand blasting, the sprayed surface has no oxide and other attachments, and the sprayed surface is exposed out of metallic luster. After the blasting is completed, dust and sand on the sprayed surface are blown off with clean, dry compressed air.
3) The thermal spraying blank with the flow guiding device valve plate 2 and the thermal spraying tool are placed into a heat treatment furnace for preheating. Preheating until the spraying surface of the blank of the valve plate 2 with the flow guiding device blus, keeping the temperature at 540+/-10 ℃ and preserving the temperature for 3 hours.
4) And discharging, namely spraying base powder on the spraying surface of the blank with the valve plate 2 of the flow guiding device, wherein the powder is nickel-based self-fluxing powder Ni65, the spraying thickness is 0.2-0.3 mm, and then feeding the blank into the furnace again for heat preservation for 4 hours.
5) And starting the heat preservation device 9, wherein the heat preservation device 9 adopts tungsten alloy or other high-temperature resistant resistance wires to heat, and the set temperature is 650+/-10 ℃.
6) And discharging the thermal spraying blank and the thermal spraying tooling of the valve plate 2 with the flow guiding device and placing the thermal spraying blank and the thermal spraying tooling on the heat preservation device 9. The heat preservation device 9 can continuously ensure that the spray coating of the blank with the valve plate 2 of the flow guiding device keeps heat continuously in the thermal spraying process, and can avoid the defects of cracks and the like of the ultra-thick wear-resistant coating.
7) The spray gun neutral flame is adopted to spray powder, the spray gun is 150-200 mm away from the surface of the workpiece during spraying, the one-step spraying and melting mode is adopted, the powder is nickel-based self-fluxing powder Ni65, the spraying thickness is 4-5 mm, the interlayer temperature is controlled at 450+/-20 ℃, the spraying width of each spray gun is 8-12 mm, the spray gun is remelted immediately after spraying, and the remelting temperature is 1000-1050 ℃. And when mirror reflection appears on the surface of the spray coating in the remelting process, the spray coating is molten, and the remelting gun is immediately moved to an adjacent area at a constant speed for remelting. The remelted area is covered with insulation cotton 10 for insulation. And when the position of the deflector hole 21 is sprayed and remelted, the joint of the plane and the blind hole is subjected to edge wrapping treatment, and the inner diameter of the blind hole is at least sprayed with a 5mm ring molded surface along the center.
8) The spray coating is cooled, and as a priority, the alloy steel is slowly cooled in a heat preservation mode by adopting a heat preservation component, and preferably, the heat preservation component adopts heat preservation cotton 10, and the carbon steel enters a heat treatment furnace for stress relief treatment and then is air cooled.
Finally, the two sealing surfaces 22 of the valve plate 2 with the flow guiding device are processed and ground with high precision after the whole thermal spraying is finished. Also includes a wire cutting process of the deflector hole 21 and the T-shaped groove 23. After wire cutting processing of the diversion holes 21, the diversion holes and the two orifices of the sealing surfaces 22 form a wear-resistant shearing function, strip-shaped or block-shaped impurities, large particles and the like can be cut off, and the strip-shaped or block-shaped impurities and the large particles cannot be accumulated on the sealing surfaces of the valve plate and the valve seat with the diversion device, so that the service life of the valve is greatly prolonged.
After the integral thermal spraying, processing and high-precision grinding of the two sealing surfaces 22 of the valve plate 2 with the flow guiding device, the thickness of a spraying layer is 3.2-3.8 mm, the hardness is 60-65 HRC, and the thickness of the spraying layer is 3.3-3.5 mm and the hardness is 61-64 HRC as a priority.
According to the thermal spraying process for the wear-resistant valve plate with the flow guiding device, provided by the invention, after the thermal spraying blank of the valve plate with the flow guiding device is assembled and fixed through the thermal spraying tool by the special thermal spraying tool fixture, the deformation amount generated in the whole thermal spraying process of two sealing surfaces of the valve plate with the flow guiding device can be effectively reduced, and the defects that the wear-resistant valve plate with the flow guiding device cannot be seriously deformed and the ultra-thick wear-resistant coating cannot be cracked after being sprayed wholly can be overcome.
After the rough machining of the upper plane and the lower plane of the valve plate thermal spraying blank with the flow guiding device is finished, only a blind hole with the depth of 5mm is machined in the flow guiding hole position, a T-shaped groove is not machined, and the integral strength of the valve plate thermal spraying blank with the flow guiding device is improved.
The heat preservation device can continuously ensure that the spray coating of the valve plate blank with the flow guide device keeps heat continuously in the thermal spraying process, and can avoid the defects of cracks and the like of the ultra-thick wear-resistant coating.
After the diversion hole wire cutting processing, the diversion hole wire cutting processing device and the two sealing surface orifices form a wear-resistant shearing function, strip-shaped or block-shaped impurities, large particles and the like can be cut off, the strip-shaped or block-shaped impurities and the large particles cannot be accumulated on the sealing surfaces of the valve plate and the valve seat with the diversion device, and the service life of the valve is prolonged. The abrasion-resistant shearing function is embodied in the opening and closing process of the valve, and the two ends of the orifice of the diversion hole 21 are provided with spraying hardening treatment with the depth of 5mm, so that impurities can be sheared between the orifice of the diversion hole 21 and the valve seat due to the upward and downward movement of the valve plate in the opening and closing process of the valve plate; the orifice is hardened, so that the wear-resistant shearing function is realized.
After the integral thermal spraying, processing and high-precision grinding of the two sealing surfaces of the diversion hole valve plate, the thickness of a spraying layer is 3.2-3.8 mm, and the hardness is 60-65 HRC; preferably, the thickness of the spray coating is 3.3-3.5 mm, the hardness is 61-64 HRC, and compared with the surfacing or spraying process of the valve plate in the prior art, the thermal spraying process provided by the invention can improve the wear resistance and the service life of the valve plate.
In the description of the present specification, reference to the terms "certain embodiments," "one embodiment," "some embodiments," "an exemplary embodiment," "an example," "a particular example," or "some examples" means that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the present invention. In this specification, schematic representations of the above terms do not necessarily refer to the same embodiments or examples. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.
Furthermore, the terms "first," "second," and the like, are used for descriptive purposes only and are not to be construed as indicating or implying a relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defining "a first" or "a second" may explicitly or implicitly include at least one such feature. In the description of the present invention, the meaning of "plurality" means at least two, for example, two, three, unless specifically defined otherwise.
Although embodiments of the present invention have been shown and described above, it will be understood that the above embodiments are illustrative and not to be construed as limiting the invention, and that variations, modifications, alternatives and variations may be made to the above embodiments by those skilled in the art within the scope of the invention, which is defined by the claims and their equivalents.
Claims (10)
1. The thermal spraying process of the wear-resistant valve plate with the flow guiding device is characterized by comprising the following process steps of:
step 1: rough machining a valve plate thermal spraying blank with a flow guiding device;
firstly, roughly machining a bottom arc surface and a plane, two side surfaces, an inclined plane, a top plane and an upper plane of the thermal spraying blank of the valve plate with the flow guiding device;
after the rough machining of the upper plane and the lower plane is finished, respectively machining diversion Kong Mangkong with the depth of 5mm at the diversion hole positions of the upper plane and the lower plane of the valve plate with the diversion device;
step 2: manufacturing a thermal spraying tool;
the thermal spraying tool comprises a fixed platform, a V-shaped block, a side fixed block, an inclined fixed block and a top fixed block which are arranged in the fixed platform;
the two V-shaped surfaces of the V-shaped block are contacted with the arc surface at the bottom of the thermal spraying blank of the valve plate with the flow guiding device;
the heights of the side fixing blocks, the inclined fixing blocks and the top fixing blocks are 20-30 mm thinner than the thickness of the thermal spraying blank with the flow guiding device valve plate, and the thickness is not less than 30mm;
the side fixing blocks are welded with two side surfaces of the thermal spraying blank with the valve plate with the flow guiding device;
the inclined fixing block is welded with two inclined planes of the thermal spraying blank with the valve plate of the flow guiding device;
the top fixing block is welded with the top plane of the thermal spraying blank of the valve plate with the flow guiding device;
the height of all welded seams is 5-10 mm lower than the upper and lower planes of the valve plate thermal spraying blank with the flow guiding device;
step 3: fixing the valve plate with the flow guiding device on a thermal spraying tool;
the thermal spraying tool further comprises a plurality of groups of locking bolts and locking nuts;
the hot spraying blank with the flow guiding device valve plate is welded with the side fixing blocks, the inclined fixing blocks and the top fixing blocks and then placed in a groove of the fixing platform, the side surfaces of the two sides, the inclined surface and the top plane are locked and fixed through the locking bolts and the locking nuts, and the arc surface of the bottom is locked and fixed through the V-shaped blocks, the locking bolts and the locking nuts;
step 4: the whole thermal spraying of two sealing surfaces of the thermal spraying blank of the valve plate with the flow guiding device comprises the following substeps:
(1) Spraying surface purification treatment is carried out on the two sealing surfaces;
(2) Carrying out spraying surface roughening treatment on the two sealing surfaces;
(3) Placing the valve plate thermal spraying blank with the flow guiding device and the thermal spraying tool into a heat treatment furnace for preheating, wherein the preheating temperature is 540+/-10 ℃;
(4) Discharging, and spraying base powder on the spraying surface of the blank of the valve plate with the flow guiding device;
(5) Starting a heat preservation device, and setting the temperature to 650+/-10 ℃;
(6) Discharging the thermal spraying blank with the valve plate of the flow guiding device and the thermal spraying tool and placing the thermal spraying blank and the thermal spraying tool on the heat preservation device;
(7) Powder spraying is carried out by adopting a spray gun, the spray gun is 150-200 mm away from the surface of a workpiece during spraying, a one-step spraying and melting mode is adopted, remelting is carried out immediately after powder spraying, and the remelting temperature is 1000-1050 ℃; covering the remelted area by adopting a heat preservation assembly to preserve heat;
(8) Cooling the spray coating.
2. The thermal spraying process of the wear-resistant valve plate with the flow guiding device according to claim 1, wherein in the step 4 (2), when two sealing surfaces of the thermal spraying blank of the valve plate with the flow guiding device are subjected to spraying surface roughening treatment, 36# or 46# white corundum is adopted for sand blasting treatment, and the sand blasting pressure is 0.5-0.7 MPa.
3. The thermal spraying process for the wear-resistant valve plate with the flow guiding device according to claim 1, wherein in the step 4 (3), when the thermal spraying blank of the valve plate with the flow guiding device and the thermal spraying tool are subjected to preheating treatment, the surface of the blank of the valve plate with the flow guiding device is preheated to be blue, and the thermal spraying is kept for at least 3 hours.
4. The thermal spraying process of the wear-resistant valve plate with the flow guiding device according to claim 1, wherein in the step 4 (4), when the base powder is sprayed on the spraying surface of the blank of the valve plate with the flow guiding device, the base powder adopts nickel-based self-fluxing powder Ni65, the spraying thickness is 0.2-0.3 mm, and then the blank is put into a furnace again for heat preservation for 4 hours.
5. The thermal spraying process of the wear-resistant valve plate with the flow guiding device according to claim 1, wherein in the step 4 (7), nickel-based self-fluxing powder Ni65 is adopted as the powder, the spraying thickness is 4-5 mm, the interlayer temperature is controlled at 450+/-20 ℃, and the spraying width of each spraying is 8-12 mm.
6. The thermal spraying process for the wear-resistant valve plate with the flow guiding device according to claim 5, wherein in step 4 (7), the heat preservation component is heat preservation cotton.
7. The thermal spraying process of the wear-resistant valve plate with the flow guiding device according to claim 1, wherein in the step 4 (7), when remelting is sprayed on the flow guiding hole position, the joint of the plane of the sealing surface and the blind hole is subjected to edge covering treatment, and a ring profile of at least 5mm is sprayed along the direction from the center of the blind hole to the inner diameter.
8. The process for thermal spraying of a valve plate with a deflector according to claim 6, wherein in step 4 (8), when the sprayed coating is cooled, the thermal sprayed valve plate with a deflector is subjected to slow cooling by adopting a heat insulation cotton heat insulation mode, or the thermal sprayed valve plate with a deflector is put into a heat treatment furnace for stress relief treatment and then is subjected to air cooling.
9. The thermal spraying process for the wear-resistant valve plate with the diversion device according to claim 1, wherein after the two sealing surfaces of the blank of the thermal spraying of the valve plate with the diversion device are integrally thermally sprayed, cutting the valve plate with the diversion device, wherein the cutting process comprises linear cutting of a diversion hole blind hole on the valve plate with the diversion device, and linear cutting of a T-shaped groove at the top plane of the valve plate with the diversion device.
10. The thermal spraying process of the wear-resistant valve plate with the flow guiding device according to claim 1, wherein the thickness of a spray coating of the whole thermal spraying of two sealing surfaces of the valve plate with the flow guiding device is 3.2-3.8 mm, and the hardness is 60-65 HRC.
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| CN111690923A (en) * | 2020-05-28 | 2020-09-22 | 金湖县赛欧电气有限公司 | Method for supersonic spraying tungsten carbide alloy on sealing surface of valve plate and valve seat |
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| US6017591A (en) * | 1996-11-14 | 2000-01-25 | Ford Global Technologies, Inc. | Method of making adherently sprayed valve seats |
| CN101733569A (en) * | 2009-12-11 | 2010-06-16 | 天津市富赛克阀门有限公司 | Spray welding device of sealing surface of valve plate |
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| CN117265455A (en) | 2023-12-22 |
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