WO2013004018A1 - 混凝土输送管道及其制造方法 - Google Patents
混凝土输送管道及其制造方法 Download PDFInfo
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- WO2013004018A1 WO2013004018A1 PCT/CN2011/076951 CN2011076951W WO2013004018A1 WO 2013004018 A1 WO2013004018 A1 WO 2013004018A1 CN 2011076951 W CN2011076951 W CN 2011076951W WO 2013004018 A1 WO2013004018 A1 WO 2013004018A1
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- concrete conveying
- inner layer
- conveying pipe
- manufacturing
- concrete
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D13/00—Centrifugal casting; Casting by using centrifugal force
- B22D13/02—Centrifugal casting; Casting by using centrifugal force of elongated solid or hollow bodies, e.g. pipes, in moulds rotating around their longitudinal axis
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
- F16L57/00—Protection of pipes or objects of similar shape against external or internal damage or wear
- F16L57/06—Protection of pipes or objects of similar shape against external or internal damage or wear against wear
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
- F16L58/00—Protection of pipes or pipe fittings against corrosion or incrustation
- F16L58/02—Protection of pipes or pipe fittings against corrosion or incrustation by means of internal or external coatings
- F16L58/04—Coatings characterised by the materials used
- F16L58/08—Coatings characterised by the materials used by metal
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
- F16L9/00—Rigid pipes
- F16L9/14—Compound tubes, i.e. made of materials not wholly covered by any one of the preceding groups
- F16L9/153—Compound tubes, i.e. made of materials not wholly covered by any one of the preceding groups comprising only layers of metal and concrete with or without reinforcement
Definitions
- Concrete conveying pipes include various pipes such as concrete conveying pipes and concrete conveying rainbows.
- the working environment of the concrete conveying pipeline is extremely bad.
- the cylinder wall is subjected to the continuous cyclic pressure of 10-12MPa, and it must withstand the friction of the piston and concrete slurry, and also bear the acid-base corrosion of the concrete slurry. . Therefore, the production requirements of concrete conveying rainbow are very high.
- the concrete conveying cylinder is produced by first machining the inner surface to the required precision, and then using the method of plating hard chrome to meet the requirements of use.
- the concrete conveying rainbow is a very wearable wearing part in the pumping mechanism, a small area damage caused by the hard chrome-plated concrete conveying rainbow will cause the entire plating hard chrome layer to peel off from the conveying cylinder wall successively, thereby causing Concrete delivery cylinders are scrapped, and the recycling of scrapped concrete delivery cylinders is inconvenient and can result in huge waste.
- nickel plating on the inner surface of the conveying cylinder can reduce the production cost, it still has pollution to the environment, and is not substantially different from the hard chrome plating process, and is easily limited by the production capacity and the production efficiency. low.
- this method can improve the hardness of the inner surface of the concrete conveying cylinder and achieve the wear resistance requirement, As the carbon content increases, the anti-corrosion function of the inner wall will decrease.
- the 38CrMoAl alloy steel is nitrided to manufacture the transfer cylinder.
- An object of the present invention is to provide a concrete conveying pipe which is excellent in strength and wear resistance of a pipe and which does not cause environmental pollution in a production process, and a manufacturing method thereof.
- a concrete conveying pipe comprising an outer layer as a substrate and an inner layer formed on an inner surface of the outer layer, the inner layer being a casting layer formed by casting a wear resistant anticorrosive material.
- the concrete conveying pipe is a concrete conveying cylinder.
- the wear resistant anticorrosive material is wear resistant cast iron or wear resistant cast steel.
- the material of the inner layer is Ni-Hard 4, Crl 5 or Cr 20 .
- the mass percentage of each component of the inner layer material is: C is 2.2%-3.3%, Cr is 11%-30%, Si is 0.5%-1.2%, Mn is 0.5%-1.7%, and Mo is 0.6%. -2.8%, Cu is 0.3% - 0.8%.
- the wear-resistant anticorrosive material is shaft steel or stainless steel.
- the inner layer has a thickness of 0.5 mm to 4 mm. Further, the inner layer has a thickness of 0.5 mm to 2 mm.
- a method of manufacturing a concrete conveying pipe comprising providing an outer layer as a base of a concrete conveying pipe; manufacturing an inner layer: pouring a molten wear-resistant anticorrosive material onto an inner surface of the outer layer Forming a casting layer as an inner layer; annealing: annealing the inner layer material.
- the manufacturing method is used to manufacture a concrete delivery cylinder.
- the material of the outer layer is made of low carbon steel or medium carbon steel; in the step of manufacturing the inner layer, the molten inner layer material is uniformly poured into the interlayer space formed between the mold and the outer layer by centrifugal casting.
- the pouring temperature is 1380 ° C - 1450 ° C and the speed is 850 r / min - 1000 r / min.
- the inner wall of the inner layer is further subjected to laser quenching treatment.
- the quenching temperature of the laser surface quenching treatment is 920 ° C - 1080 ° C, and the quenching and hardening depth is 0.3 mm - 2 mm.
- the hardening depth of the laser quenching is gradually deepened from the inside of the cylinder to the outside of the cylinder in the axial direction of the mixed soil conveying pipe.
- the method of manufacturing the concrete delivery cylinder further includes performing an induction hardening treatment on the inner layer.
- the outer layer is formed by casting by centrifugal casting.
- the inner layer is made of a wear-resistant material which can be heat-treated and hardened, and the outer layer can be made of a common carbon steel material, thereby improving the overall strength of the pipe body and Wear resistance, on the other hand, reduces the cost of concrete piping.
- the inner layer material is evenly poured onto the outer layer to form an inner layer, so that the inner layer material and the outer layer material of the concrete conveying pipe are completely combined to form a pipe body of the composite concrete conveying pipe, and the combination between the two materials It is dense and does not cause environmental pollution.
- Fig. 1 is a schematic view showing the structure of a concrete conveying rainbow according to the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
- a concrete conveying pipe according to the present invention is exemplified by a concrete conveying rainbow, which comprises an outer layer 30 as a rainbow body and an inner layer 20 formed on an inner surface of the outer layer 30.
- the inner layer 20 is wear-resistant.
- the casting layer formed by casting the anticorrosive material.
- the inner layer 20 of the concrete conveying rainbow is made of a wear-resistant material which can be heat-treated and hardened.
- the conditions to be satisfied are wear-resisting, anti-corrosion and heat-hardening, and the hardness after treatment can reach 60HRC or more, and the heat treatment deformation is small.
- Wear-resistant materials such as Ni-Hard4, Crl 5, Cr20, etc. can be used as the wear-resistant material. This is because the wear-resistant cast iron can be heat-treated and has a high hardness, which can be used for corrosion protection and wear resistance.
- the inner layer material may also be selected from wear-resistant cast steel, bearing steel and stainless steel, which are wear-resistant, corrosion-resistant and heat-hardenable, or heat-treated stainless steel.
- the thickness of the inner layer material is 0.5mm-4.0mmm, and the selection of the specific value is determined according to the specific type and type of the concrete conveying cylinder.
- the thickness of the inner layer material conveying the rainbow is 0.5-2 mm.
- the concrete transfer cylinders are exemplified in the following embodiments.
- the outer layer 30 is used as a rainbow body, and the material thereof can be selected from ordinary low carbon steel or medium carbon steel, such as 20 steel, 45 steel, etc., and the thickness thereof is determined by the design thickness of the concrete conveying rainbow and the thickness of the inner layer 20.
- the material of the inner layer is Ni-Hard 4, Crl 5 or Cr 20 .
- the mass percentage of each component of the inner layer material is, for example, C: 2.2% to 3.3%, Cr of 11% to 30%, Si of 0.5% to 1.2%, Mn of 0.5% to 1.7%, and Mo of 0.6% to 2.8. %, Cu is from 0.3% to 0.8%.
- the inner layer 20 of the concrete conveying cylinder is made of wear-resistant material
- the outer layer 30 is made of ordinary carbon steel material, which improves the strength and wear resistance of the whole cylinder on the one hand, and reduces the concrete conveying rainbow on the other hand. the cost of.
- the inner layer material is evenly poured onto the outer layer by centrifugal casting to form the inner layer 20, so that the inner layer material and the outer layer material of the concrete conveying cylinder are completely combined to form a composite concrete conveying cylinder block, two kinds
- the bond between the materials is dense and integral, without affecting the overall mechanical properties of the concrete delivery cylinder.
- the abrasive material is melted and poured by means of centrifugal casting, which does not cause environmental pollution, and the process is relatively simple, and the pouring cost is not high.
- the invention also provides a method for manufacturing concrete conveying rainbow, comprising providing an outer layer as a cylinder base body of a concrete conveying cylinder; manufacturing an inner layer: pouring a molten wear-resistant anticorrosive material onto an inner surface of the outer layer to form a pouring The layer acts as an inner layer; annealing: annealing the inner layer material.
- the inner layer material is made of a wear-resistant material which can be heat-hardened
- the outer layer material is made of low carbon steel or medium carbon steel.
- the molten inner layer material is uniformly poured into the interlayer space formed between the standard mold and the outer layer by centrifugal casting, and the pouring temperature is 1380 ° C - 1450 ° C, and the rotation speed is 850. r/min- 1000 r/min.
- the production process of the concrete composite concrete conveying cylinder is:
- the inner layer anti-corrosion and wear-resistant material should meet the requirements of wear-resisting, anti-corrosion and heat-hardening. The hardness after treatment can reach above 60HRC, and the heat treatment deformation is small; specifically, the inner layer
- the material may be made of wear-resistant cast iron, such as Ni-Hard4, Crl 5, Cr20, etc., the inner layer material thickness is 0.5mm-4.0mm; the outer layer material is low carbon steel or medium carbon steel, such as 20 steel, 45 steel, The thickness is determined by the thickness of the concrete conveyance rainbow design and the thickness of the cast inner layer material;
- the step of welding the flange may be placed before the centrifugal casting, that is, the flanges 10 and 40 at both ends are welded to the outer layer, and the inner layer is formed on the inner wall of the outer layer by centrifugal casting.
- the method of manufacturing the concrete conveying rainbow further comprises laser quenching the inner wall of the inner layer after the annealing step. ⁇ Laser hardening machine is used for laser surface quenching of anti-corrosion and wear-resistant materials on the inner wall of concrete conveying cylinder. The laser quenching temperature is 920 °C -1080 °C, and the quenching depth is 0.3mm-2mm. After quenching, air cooling, quenching hardness requirement is 60 ⁇ 65HRC.
- the laser quenching depth is gradually deepened from the cylinder to the outer cylinder. This is because the wear failure of the concrete conveying cylinder is much more serious in the Hongkou than in the rainbow.
- the quenching depth of the outer cylinder is about twice the depth of the starting point in the cylinder.
- mesh quenching may be used in the intermediate portion of the concrete conveying rainbow.
- the concrete delivery cylinder is honed and polished to achieve the final required design accuracy. Compared with the existing production process of concrete conveying cylinders, the combination of the laser surface hardening process and the new materials has significant advantages.
- the manufacturing process further comprises the steps of: first forming the outer layer by centrifugal casting in the step of providing the outer layer, and then manufacturing the inner layer by centrifugal casting. And after the centrifugal casting outer layer is cooled for a certain time, the inner layer is centrifugally poured and mixed!
- the cooling time of the 3 ⁇ 4 earth transport rainbow is generally 15 seconds - 35 seconds.
- the two-liquid centrifugal casting process is used to make the composite concrete conveying rainbow, that is, the outer steel is poured first, and the inner layer anti-corrosion and wear-resistant material is poured after stopping for a certain time.
- the composite concrete conveyed by this method is more densely bonded between the two materials, but the casting cost is increased because the process is more complicated than casting only the inner layer material.
- a method of manufacturing a concrete delivery cylinder further includes performing an induction hardening treatment on the inner layer.
- the quenching process of high-frequency quenching can be used to harden the inner layer material, and the same quenching effect can be obtained, and the quenching speed can be improved.
- the structure and manufacturing method of the above concrete conveying rainbow can be equally adapted to various concrete conveying pipes, including concrete conveying pipes, the difference being that: the inner layer thickness of the concrete conveying pipe is generally larger than the concrete conveying.
- the thickness of the inner cylinder of the concrete conveying pipe is generally 2mm-4mm. This is because the greater the inner layer thickness, the better the wear resistance of the concrete conveying pipe, and the concrete conveying cylinder needs to cooperate with the piston, and the wear is certain. After the amount, it can't fit well with the piston.
- the cooling time after centrifugally pouring the outer layer in the two-liquid centrifugal casting method is generally 20 seconds. 40 seconds. From the above description, it can be seen that the above-described embodiments of the present invention achieve the following technical effects: According to the concrete conveying pipe and the manufacturing method thereof of the present invention, the overall strength and wear resistance of the pipe are excellent, and the material cost is not high. . For the purpose of centrifugal casting, the bond between the inner layer material and the outer layer material is densely formed to form a whole without affecting the overall mechanical properties of the concrete conveying pipe.
- the centrifugally casted method is used to melt and pour the wear-resistant material without environmental pollution, and the process is relatively simple, and the pouring cost is not high.
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- General Engineering & Computer Science (AREA)
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Abstract
一种混凝土输送管道及其制造方法。该混凝土输送缸，包括作为缸体基体的外层（30）和形成在外层（30）内表面上的内层（20），内层（20）为由耐磨防腐材料浇注形成的浇注层。该混凝土输送管道的制造方法，包括提供外层（30），作为混凝土输送缸的缸体基体；制造内层（20）：将熔化的耐磨防腐材料浇注到外层（30）的内表面上，形成浇注层作为内层；退火：对内层（20）材料进行退火处理。在该混凝土输送管道中，内层材料和外层材料之间的结合致密形成一个整体，管道体整体的强度和耐磨性很好，并且材料成本不高。
Description
混凝土输送管 其制造方法
技术领域 本发明涉及建筑工程机械领域， 更具体地， 涉及一种混凝土输送管道及其 制造方法。 背景技术 混凝土输送管道包括混凝土输送管、 混凝土输送虹等多种管路。 混凝土输 送管道的工作环境极其恶劣， 以混疑土输送缸为例， 其缸壁要 受 10-12MPa 的连续循环压力冲击， 要承受活塞、 混凝土浆的摩擦， 还要承受混凝土浆的酸 碱腐蚀。 因此， 混凝土输送虹的生产要求非常之高。 目前混凝土输送缸的生产方式为先将内表面机械加工至所要求的精度， 再 釆用电镀硬铬的方式来满足使用要求。 不过， 由于混凝土输送虹是泵送机构里 面一个极易磨损的易损件， 镀硬铬的混凝土输送虹一旦局部出现小面积损坏会 导致整个电镀硬铬层陆续从输送缸壁上剥落， 从而造成混凝土输送缸报废， 而 且报废的混凝土输送缸回收利用不方便， 会造成巨大浪费。 另外， 电镀硬铬工 艺对环境污染严重， 受环保部门严密监管， 产能收到严重制约， 而且电镀工艺 本身生产效率氐下， 电镀过程中对工人的健康产生严重影响。 由于环保和加工 成本的因素的影响， 电镀工艺成本占整个混凝土输送缸成本的一半以上， 而且 产能已经严重受限， 不能够满足生产需要， 急需需求新型替代工艺来生产混凝 土输送紅。 现有技术中， 也试图进行技术改进来解决这些问题。 例如， 釆用输送虹内 部镀镍的方式， 然而， 输送缸内表面镀镍虽然可以减少生产成本， 但是对环境 仍然存在污染， 与镀硬铬工艺没有本质的区别， 容易受产能限制而且生产效率 低。 再如， 有釆用输送缸内表面渗碳加热处理的方式来强化混凝土输送缸内表 面硬度， 不过， 这种方式虽然可以提高混凝土输送缸内表面的硬度， 达到耐磨 性要求，但是随着含碳量的增加， 内壁的防腐功能将下降。还有釆用 38CrMoAl 合金钢经过氮化处理的方式制造输送缸， 不过这种方式虽然可以达到输送虹所 需的硬度、 耐磨性， 但是其防腐蚀能力不够， 而且氮化处理的时间长， 会产生 一定的有害气体， 污染环境。
发明内容 本发明目的在于提供一种管道的强度和耐磨性好且生产过程中不会产生 环境污染的混凝土输送管道及其制造方法。 根据本发明的一个方面， 提供了一种混凝土输送管道， 包括作为基体的外 层和形成在外层内表面上的内层， 内层为由耐磨防腐材料浇注形成的浇注层。 进一步地， 混凝土输送管道为混凝土输送缸。 进一步地， 耐磨防腐材料为耐磨铸铁或为耐磨铸钢。 进一步地， 内层的材料为 Ni-Hard4、 Crl5或 Cr20。 进一步地， 内层材料的各成分的质量百分比为： C 为 2.2%-3.3% , Cr 为 11%-30% , Si 为 0.5%- 1.2% , Mn 为 0.5%-1.7% , Mo 为 0.6%-2.8% , Cu 为 0.3%-0.8%。 进一步地， 耐磨防腐材料为轴 钢或为不锈钢。 进一步地， 内层的厚度为 0.5mm-4mm。 进一步地， 内层的厚度为 0.5mm-2mm。 根据本发明的另一个方面， 提供了一种混凝土输送管道的制造方法， 包括 提供外层， 作为混凝土输送管道的基体； 制造内层： 将熔化的耐磨防腐材料浇 注到外层的内表面上， 形成浇注层作为内层； 退火： 对内层材料进行退火处理。 进一步地， 制造方法用于制造混凝土输送缸。 进一步地， 外层的材料釆用低碳钢或中碳钢； 在制造内层的步骤中， 通过 离心浇注的方式将熔化后的内层材料均匀浇注到模具与外层之间形成的夹层 空间中， 浇注温度为 1380°C -1450°C , 转速为 850 r/min- 1000 r/min。 进一步地， 在退火步骤之后， 还包括对内层的内壁进行激光淬火处理。 进一步地， 激光表面淬火处理的淬火温度为 920°C -1080°C , 淬火淬透深度 为 0.3mm-2mm„
进一步地， 激光淬火的淬透深度沿混疑土输送管道的轴向方向从缸内向缸 外逐步加深。 进一步地， 混凝土输送缸的制造方法还包括对内层进行高频淬火处理。 进一步地， 在提供外层的步骤中， 是通过离心浇注的方式浇注形成外层。 根据本发明的混凝土输送管道及其制造方法， 内层釆用可进行热处理硬化 的耐磨材料制成， 外层可釆用普通的碳钢材料制成， 一方面提高了管道体整体 的强度和耐磨性， 另一方面降低了混凝土输送管道的成本。 另外， 将内层材料 均匀浇注到外层上形成内层， 因此该混凝土输送管道内层材料和外层材料完整 的结合在一起形成复合型混凝土输送管道的管体， 两种材料之间的结合致密， 且不会产生环境污染。 附图说明 构成本申请的一部分的附图用来提供对本发明的进一步理解， 本发明的示 意性实施例及其说明用于解释本发明， 并不构成对本发明的不当限定。 在附图 中： 图 1是根据本发明的混凝土输送虹的结构示意图。 具体实施方式 下面将参考附图并结合实施例来详细说明本发明。 如图 1所示， 根据本发明的混凝土输送管道， 以混凝土输送虹为例， 包括 作为虹体基体的外层 30和形成在外层 30内表面上的内层 20 , 内层 20为由耐 磨防腐材料浇注形成的浇注层。 混凝土输送虹的内层 20 釆用可进行热处理硬 化的耐磨材料制成， 其要满足的条件为耐磨、 防腐并可以进行热处理硬化， 并 且处理后的硬度能够达到 60HRC 以上， 热处理变形较小。 耐磨材料可选用耐 磨铸铁， 如 Ni-Hard4, Crl 5 , Cr20等等。 这是因为耐磨铸铁可以进行热处理强 化， 且硬度较高， 可以防腐， 也耐磨。 另夕卜， 内层材料也可以选用耐磨铸钢、 轴承钢和不锈钢等具有耐磨、 防腐且可以进行热处理硬化的材料， 或者选用可 热处理的不锈钢等材料。 内层材料厚度为 0.5mm-4.0mmm, 具体数值的选用根 据混凝土输送缸的具体型号和类型等确定。 优选地， 输送虹的内层材料的厚度 为 0.5-2mm„
为了描述方便， 以下实施例中均以混凝土输送缸为例。 外层 30作为虹体基体，其材料可选用普通的低碳钢或者中碳钢，如 20钢， 45钢等， 其厚度由混凝土输送虹的设计厚度与内层 20的厚度共同决定。 内层 的材料为 Ni-Hard4、 Crl5或 Cr20。 内层材料的各成分的质量百分比例如为： C 为 2.2%-3.3%, Cr为 11%-30% , Si为 0.5%-1.2%, Mn为 0.5%- 1.7% , Mo为 0.6%-2.8%, Cu为 0.3%-0.8%。 混凝土输送缸的内层 20釆用耐磨材料制成， 外层 30釆用普通的碳钢材料 制成， 一方面提高了缸体整体的强度和耐磨性， 另一方面降低了混凝土输送虹 的成本。另外，通过离心浇注的方式将内层材料均匀浇注到外层上形成内层 20 , 因此该混凝土输送缸内层材料和外层材料完整的结合在一起形成复合型混凝 土输送缸缸体， 两种材料之间的结合致密形成一个整体， 不会影响混凝土输送 缸的整体的机械性能。 另外， 釆用离心浇注的方式将耐磨材料熔化后浇注， 不 会产生环境污染， 且工艺较为简单， 浇注成本不高。 本发明还提供了一种混凝土输送虹的制造方法， 包括提供外层， 作为混凝 土输送缸的缸体基体； 制造内层： 将熔化的耐磨防腐材料浇注到外层的内表面 上， 形成浇注层作为内层； 退火： 对内层材料进行退火处理。 选取混凝土输送缸的材料时， 其内层材料釆用可进行热处理硬化的耐磨材 料， 其外层材料釆用低碳钢或中碳钢。 在制造内层的步骤中， 通过离心浇注的 方式将熔化后的内层材料均匀浇注到标准模具与外层之间形成的夹层空间中， 浇注温度为 1380°C -1450°C , 转速为 850 r/min- 1000 r/min。 具体的复合型混凝土输送缸的生产工艺过程为：
1、 选取复合混凝土输送缸的材料： 内层防腐耐磨材料要满足的条件为耐 磨、 防腐并可以进行热处理硬化， 处理后的硬度能够达到 60HRC 以上， 热处 理变形较小； 具体地， 内层材料可选用耐磨铸铁， 如 Ni-Hard4 , Crl 5 , Cr20 等等， 内层材料厚度为 0.5mm-4.0mm; 外层材料为低碳钢或者中碳钢， 如 20 钢， 45钢，其厚度由混凝土输送虹设计厚度与浇注的内层材料的厚度共同决定；
2、 下料清洗， 通过选择的内层的厚度计算确定混凝土输送虹内层材料的 重量， 清洗外层材料制作的钢管， 以防止浇注过程中出现夹渣等缺陷；
3、 使用离心浇注机在内层材料的熔化液体状态将内层的防腐耐磨材料均 匀的浇注到标准模具与用外层材料制成的钢管形成的夹层中， 浇注温度 1380 °C -1450°C , 转速为 850 r/min-1000 r/min, 内层材料冷却后与外层复合在一起， 形成复合混凝土输送缸缸体； 浇注过程中不允许出现任何针孔、 夹渣、 疏松、 冷隔、 偏析与裂紋；
4、 用焊接方法分别将同两端法兰 10和 40连接到步骤 3制作的复合混凝 土输送紅紅体上， 形成混凝土输送紅；
5、 对内层材料进行退火处理， 以改善加工性， 提高淬硬性。
6、 对复合混凝土输送紅进行机械加工， 除内壁预留 0.01mm-0.05mm的余 量外， 其他加工部位完全达到设计要求。 用这种方法制造的混凝土输送虹， 缸体整体的强度和耐磨性很好， 并且材 料成本不高。 用于釆用了离心浇注的方式， 内层材料和外层材料之间的结合致 密形成一个整体， 不会影响混凝土输送缸的整体的机械性能。 另外， 釆用离心 浇注的方式将耐磨材料熔化后浇注， 不会产生环境污染， 且工艺较为简单， 浇 注成本不高。 上述的工艺步骤中， 焊接法兰的步骤可以放置于离心浇注之前， 即先将两 端法兰 10和 40焊接在外层上， 再将内层通过离心浇注形成于外层内壁上。 另外， 混凝土输送虹的制造方法还包括在退火步骤后对内层的内壁进行激 光淬火处理。 釆用激光淬火机床对混凝土输送缸内壁的防腐耐磨材料进行激光表面淬 火处理， 激光淬火温度为 920°C -1080°C , 淬火淬透深度为 0.3mm-2mm。 淬火 后， 空冷， 淬火硬度要求为 60〜65HRC。 以混凝土输送缸的轴向的中心为衡量 起点， 激光淬火深度从缸内往缸外口逐步加深。 这是由于混凝土输送缸的磨损 失效现象在虹口比虹内严重很多， 缸外口的淬火深度约为缸内衡量起点深度的 2倍。 为了提高生产效率和节约成本， 可在所述混凝土输送虹中间部位釆用网 状淬火。 在激光淬火后， 对混凝土输送缸进行珩磨、 抛光处理， 使之达到最终要求 的设计精度。
与现有的混凝土输送缸的生产工艺相比， 激光表面淬火工艺与新材料相结 合的工艺方法具有显著的优势。 单就激光淬火硬化混凝土输送缸内壁来比较， 如表 1所示， 可以发现激光淬火工艺与电镀硬铬工艺相比有无可比拟的优势。 表 1： 激光表面淬火工艺与现有工艺对比数据
由上可知， 釆用激光淬火生产混凝土输送虹， 不但可以保证设计要求， 降 氐生产成本， 无环境污染， 而且可重复利用减少浪费， 产生明显的经济效益。 根据本发明的一个实施例， 制造过程还包括在提供外层的步骤中， 先通过 离心浇注的方式先形成外层， 再通过离心浇注的方式制造内层。 且在离心浇注 外层冷却一定时间后再离心浇注内层， 混！ ¾土输送虹的冷却时间一般为 15 秒 -35秒。 釆用双液离心浇注工艺制作复合混凝土输送虹， 即先浇注外层钢材， 停顿 若干时间后浇注内层防腐耐磨材料。 这种方法浇注制作的复合混凝土输送虹两 种材料间的结合更加致密， 但是由于工艺比仅浇注内层材料复杂， 因此浇注成 本增加。 根据本发明的另一个实施例， 混凝土输送缸的制造方法还包括对内层进行 高频淬火处理。 除了釆用激光淬火的方式之外， 还可釆用高频淬火这种淬火工艺来硬化处 理内层材料， 能够得到同样的淬火效果， 而且能够提高淬火速度。 上述混凝土输送虹的结构和制造方法可同样适应于多种混凝土输送管道， 包括混凝土输送管， 其不同在于： 混凝土输送管的内层厚度一般大于混凝土输
送缸的厚度， 混凝土输送管的内层厚度一般为 2mm-4mm, 这是由于内层厚度 越大， 混凝土输送管的耐磨性越好， 而混凝土输送缸由于需与活塞配合， 其磨 损一定量后就不能艮好地和活塞配合了， 内层厚度过大也无法继续使用； 对于 混凝土输送管而言， 釆用双液离心浇注方法中离心浇注外层后的冷却时间一般 为 20秒 -40秒。 从以上的描述中， 可以看出， 本发明上述的实施例实现了如下技术效果： 根据本发明的混凝土输送管道及其制造方法， 管道整体的强度和耐磨性很 好， 并且材料成本不高。 用于釆用了离心浇注的方式， 内层材料和外层材料之 间的结合致密形成一个整体， 不会影响混凝土输送管道的整体的机械性能。 另 夕卜， 釆用离心浇注的方式将耐磨材料熔化后浇注， 不会产生环境污染， 且工艺 较为简单， 浇注成本不高。 以上所述仅为本发明的优选实施例而已， 并不用于限制本发明， 对于本领 i或的技术人员来说， 本发明可以有各种更改和变化。 凡在本发明的 ^"神和原则 之内， 所作的任何修改、 等同替换、 改进等， 均应包含在本发明的保护范围之 内。
Claims
权 利 要 求 书
1. 一种混凝土输送管道， 包括： 作为基体的外层 （30 ) 和形成在所述外层
( 30 ) 内表面上的内层（20 ), 其特征在于， 所述内层（20 )为由耐磨防 腐材料浇注形成的浇注层。
2. 居权利要求 1所述的混凝土输送管道， 其特征在于， 所述混凝土输送 管道为混凝土输送缸。
2. 根据权利要求 2所述的混凝土输送管道， 其特征在于， 所述耐磨防腐材 料为耐磨铸铁或为耐磨铸钢。
3. 根据权利要求 2所述的混凝土输送管道， 其特征在于， 所述内层的材料 为 Ni-Hard4、 Crl5或 Cr20。
4. 根据权利要求 3所述的混凝土输送管道， 其特征在于， 所述内层材料的 各成分的质量百分比为：
C为 2.2%-3.3%, Cr为 l l%-30% , Si为 0.5%- 1.2%, Mn为 0.5%- 1.7%, Mo为 0.6%-2.8%, Cu为 0.3%-0.8%。
5. 根据权利要求 2所述的混凝土输送管道， 其特征在于， 所述耐磨防腐材 料为轴^钢或为不锈钢。
6. 根据权利要求 2所述的混凝土输送管道， 其特征在于， 所述内层 （20 ) 的厚度为 0.5mm-4mm。
7. 根据权利要求 6所述的混凝土输送管道， 其特征在于， 所述内层的厚度 为 0.5mm-2mm„
8. 一种混凝土输送管道的制造方法， 其特征在于， 包括：
提供外层， 作为所述混凝土输送管道的基体；
制造内层： 将熔化的耐磨防腐材料浇注到所述外层的内表面上， 形 成浇注层作为内层；
退火： 对内层材料进行退火处理。
. 根据权利要求 8所述的混凝土输送管道的制造方法， 其特征在于： 所述 制造方法用于制造混凝土输送缸。
10. 根据权利要求 9所述的混凝土输送管道的制造方法， 其特征在于：
所述外层的材料釆用 氐碳钢或中碳钢；
在制造内层的步骤中， 通过离心浇注的方式将熔化后的内层材料均 匀浇注到模具与外层之间形成的夹层空间中， 浇注温度为 1380°C-1450 V , 转速为 850 r/min- 1000 r/min。
11. 根据权利要求 9或 10所述的混凝土输送管道的制造方法， 其特征在于， 在所述退火步骤之后， 还包括对所述内层的内壁进行激光淬火处理。
12. 根据权利要求 11所述的混凝土输送管道的制造方法， 其特征在于， 所述 激光表面淬火处理的淬火温度为 920 °C -1080 °C , 淬火淬透深度为 0.3mm-2mm„
13. 根据权利要求 11所述的混凝土输送管道的制造方法， 其特征在于， 所述 激光淬火的淬透深度沿所述混；疑土输送管道的轴向方向从缸内向缸外逐 步加深。
14. 根据权利要求 9或 10所述的混凝土输送缸的制造方法， 其特征在于， 还 包括对所述内层进行高频淬火处理。
15. 根据权利要求 9所述的混凝土输送缸的制造方法， 其特征在于， 在提供 外层的步骤中， 是通过离心浇注的方式浇注形成所述外层。
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| CN106949319A (zh) * | 2017-04-04 | 2017-07-14 | 东莞市昶源涂装配件有限公司 | 一种耐磨防腐蚀的双层塑胶管道及其成型方法 |
| IT201800003964A1 (it) * | 2018-03-26 | 2019-09-26 | Valme S R L Unico Socio | Elemento tubolare per il trasferimento di materiali abrasivi, in particolare calcestruzzo, e procedimento per realizzarlo |
| US11174977B2 (en) | 2018-04-23 | 2021-11-16 | Valme S.R.L.—Unico Socio | Tubular element to transfer abrasive materials, in particular concrete, and method to manufacture it |
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| IT201800003964A1 (it) * | 2018-03-26 | 2019-09-26 | Valme S R L Unico Socio | Elemento tubolare per il trasferimento di materiali abrasivi, in particolare calcestruzzo, e procedimento per realizzarlo |
| EP3546090A1 (en) | 2018-03-26 | 2019-10-02 | Valme S.r.l. - Unico Socio | Method to make a tubular element and tubular element |
| US10987712B2 (en) | 2018-03-26 | 2021-04-27 | Valme S.R.L.—Unico Socio | Tubular element to transfer abrasive materials, in particular concrete, and method to make it |
| US11174977B2 (en) | 2018-04-23 | 2021-11-16 | Valme S.R.L.—Unico Socio | Tubular element to transfer abrasive materials, in particular concrete, and method to manufacture it |
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