WO2020253007A1 - 一种废液处理罐及其加工方法 - Google Patents
一种废液处理罐及其加工方法 Download PDFInfo
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- WO2020253007A1 WO2020253007A1 PCT/CN2019/112824 CN2019112824W WO2020253007A1 WO 2020253007 A1 WO2020253007 A1 WO 2020253007A1 CN 2019112824 W CN2019112824 W CN 2019112824W WO 2020253007 A1 WO2020253007 A1 WO 2020253007A1
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- Prior art keywords
- tank body
- tank
- waste liquid
- liquid treatment
- welding
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- 239000002699 waste material Substances 0.000 title claims abstract description 47
- 239000007788 liquid Substances 0.000 title claims abstract description 43
- 238000000034 method Methods 0.000 title claims description 27
- 238000003754 machining Methods 0.000 title abstract 4
- 238000003466 welding Methods 0.000 claims abstract description 73
- 238000003756 stirring Methods 0.000 claims abstract description 48
- 239000000463 material Substances 0.000 claims abstract description 21
- 238000005260 corrosion Methods 0.000 claims abstract description 18
- 230000007797 corrosion Effects 0.000 claims abstract description 16
- 239000007769 metal material Substances 0.000 claims abstract description 7
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 29
- CBENFWSGALASAD-UHFFFAOYSA-N Ozone Chemical compound [O-][O+]=O CBENFWSGALASAD-UHFFFAOYSA-N 0.000 claims description 10
- 238000005516 engineering process Methods 0.000 claims description 9
- 229910001069 Ti alloy Inorganic materials 0.000 claims description 7
- 229910000765 intermetallic Inorganic materials 0.000 claims description 7
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 claims description 6
- 229910045601 alloy Inorganic materials 0.000 claims description 5
- 239000000956 alloy Substances 0.000 claims description 5
- 229910000881 Cu alloy Inorganic materials 0.000 claims description 3
- 229910000861 Mg alloy Inorganic materials 0.000 claims description 3
- 229910052697 platinum Inorganic materials 0.000 claims description 3
- 239000010935 stainless steel Substances 0.000 claims description 3
- 229910001220 stainless steel Inorganic materials 0.000 claims description 3
- 229910000831 Steel Inorganic materials 0.000 claims description 2
- 230000001788 irregular Effects 0.000 claims description 2
- 238000010422 painting Methods 0.000 claims description 2
- 238000005498 polishing Methods 0.000 claims description 2
- 238000007789 sealing Methods 0.000 claims description 2
- 239000010959 steel Substances 0.000 claims description 2
- 230000000694 effects Effects 0.000 claims 1
- 230000002708 enhancing effect Effects 0.000 claims 1
- 238000004519 manufacturing process Methods 0.000 abstract description 8
- 238000012545 processing Methods 0.000 description 24
- 238000002347 injection Methods 0.000 description 13
- 239000007924 injection Substances 0.000 description 13
- 238000003672 processing method Methods 0.000 description 6
- 239000002994 raw material Substances 0.000 description 4
- 239000000243 solution Substances 0.000 description 4
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 3
- 229910052782 aluminium Inorganic materials 0.000 description 3
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 3
- 238000010586 diagram Methods 0.000 description 3
- 239000010936 titanium Substances 0.000 description 3
- 229910052719 titanium Inorganic materials 0.000 description 3
- 239000002351 wastewater Substances 0.000 description 3
- 229910000838 Al alloy Inorganic materials 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 2
- 238000006073 displacement reaction Methods 0.000 description 2
- 238000009434 installation Methods 0.000 description 2
- 239000003973 paint Substances 0.000 description 2
- 230000001681 protective effect Effects 0.000 description 2
- 239000010865 sewage Substances 0.000 description 2
- 229910000975 Carbon steel Inorganic materials 0.000 description 1
- 229910001093 Zr alloy Inorganic materials 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 239000006227 byproduct Substances 0.000 description 1
- 239000010962 carbon steel Substances 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 238000003912 environmental pollution Methods 0.000 description 1
- 238000009776 industrial production Methods 0.000 description 1
- 239000013067 intermediate product Substances 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 231100000614 poison Toxicity 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 238000004080 punching Methods 0.000 description 1
- 238000005096 rolling process Methods 0.000 description 1
- 238000007493 shaping process Methods 0.000 description 1
- 238000010008 shearing Methods 0.000 description 1
- 238000005728 strengthening Methods 0.000 description 1
- 239000003440 toxic substance Substances 0.000 description 1
- 230000037303 wrinkles Effects 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
- B23K20/122—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding
-
- C—CHEMISTRY; METALLURGY
- C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F1/00—Treatment of water, waste water, or sewage
-
- C—CHEMISTRY; METALLURGY
- C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F1/00—Treatment of water, waste water, or sewage
- C02F1/001—Processes for the treatment of water whereby the filtration technique is of importance
-
- C—CHEMISTRY; METALLURGY
- C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F1/00—Treatment of water, waste water, or sewage
- C02F1/30—Treatment of water, waste water, or sewage by irradiation
- C02F1/32—Treatment of water, waste water, or sewage by irradiation with ultraviolet light
Definitions
- the invention belongs to the field of waste liquid treatment, in particular to a waste liquid treatment tank with high-strength corrosion resistance, in particular to a waste liquid treatment tank that uses friction stir welding technology for tank body shaping.
- the waste liquid produced in the industrial production process contains a large number of raw materials, intermediate products and by-products produced in the production. It has a wide variety, complex composition, and a variety of toxic substances. Environmental pollution is very dangerous to human health and difficult to handle.
- the commonly used waste liquid treatment tanks mostly use titanium alloy as the raw material of the entire tank body, resulting in high manufacturing costs, difficult processing, and low yield.
- a sewage environmental protection pretreatment tank (patent application number: 201711360315.7) invented a convenient mobile waste liquid pretreatment tank , which reduces the processing cost of the tank and the large amount of engineering.
- the invention patent "Tank Processing Method” reduces the amount of overlap before welding, thereby reducing the welding thickness and avoiding welding seams.
- the wrinkle defect caused by the shrinking neck improves the processing yield of the tank body, but the processing is complicated and the degree of automation is not high.
- the invention patent "Processing and Preparation of Tank Body and Its Processing Method” (Patent Application Number: 201910081756.6) realizes automation by installing a welding robot arm at one end of the cylinder section opening. The operation improves the production efficiency of the tank, but the installation and control of the manipulator is more complicated, which increases the difficulty of production.
- the purpose of the present invention is to solve the problems of high manufacturing cost, difficult processing, and low yield of existing waste liquid tanks, and to design a method of using friction stir welding technology to combine two different materials to produce waste with high strength and good corrosion resistance. Liquid treatment tank.
- a waste liquid treatment tank which comprises an inner tank body and an outer tank body.
- the inner tank body is made of corrosion-resistant metal materials
- the outer tank body is made of ordinary metal materials, and is characterized by the inner layer
- the tank body and the outer tank body are integrated by friction stir welding.
- the waste liquid treatment tank of the present invention is manufactured by the following method:
- friction stir welding technology is used to weld the inner and outer layers of the tank together to ensure the connection between the inner and outer tanks and improve the strength of the tank.
- the accessories include an ultraviolet lamp, an ozone generator, a filter plate, a water inlet pipe, a water outlet pipe, and a control valve installed inside and outside the water inlet and outlet pipes.
- the shape of the inner and outer layer tanks is ellipse, circle, square, triangle or irregular shape.
- the inner tank body is corrosion-resistant stainless steel, titanium alloy or platinum
- the outer tank body is steel, alloy, copper alloy or magnesium alloy with high strength and low cost.
- the method of friction stir welding of the inner and outer tanks is as follows: sleeve the inner tank into the outer tank, and fix the inner and outer tanks radially and axially, so that the inner and outer tanks are only in the circumferential direction. Exercise, use friction stir welding to weld the tank body to connect the inner and outer tank bodies to increase the strength of the tank body.
- the shaft shoulder diameter of the stirring head used in the friction stir welding is in the range of 1-100mm, and the needle length is in the range of 1-50mm.
- the pressure of the stirring head is 0-5mm; the shape of the stirring head is round table, tapered thread, Terraces and triangles.
- the speed range of the stirring head is 10-5000 rpm, and the welding speed is 1-1000 mm/min.
- the position of the stir needle during the friction stir welding process should be within ⁇ 1mm at the junction of the outer tank body and the inner tank body to ensure that an intermetallic compound that enhances the joint performance is formed in the joint, and the resulting intermetallic compound is enhanced The role of joint performance.
- the path of the friction stir welding is circular welding in the circumferential direction, linear welding in the axial direction, and thread-like welding path; when the path is axial, it can be welded along the axial "s" type, or it can be welded along the axial direction in one direction. .
- the waste liquid treatment tank provided by the present invention includes a sub-tank body, an end cover, a water injection pipe, a water outlet pipe, a filter screen, an ultraviolet lamp and an ozone generator.
- the tank is divided into inner and outer layers.
- the inner layer uses materials with good corrosion resistance to prevent corrosion by waste liquid.
- the outer layer uses materials with light weight, low processing cost and high strength as the outer wall, reducing processing costs and strengthening the tank body Strength of.
- the end cap is also divided into two layers, the inner end cap layer uses a material with good corrosion resistance to prevent corrosion by waste liquid, and the outer layer uses a light-weight, inexpensive and strong material as the outer wall to enhance strength.
- the water injection pipe is located at the upper end cover of the tank body, and the water outlet pipe is located at the lower end cover of the tank body, both of which are processed by materials with good corrosion resistance.
- the filter plate is located in the upper part of the tank and is made of corrosion-resistant materials to filter the waste residue in the waste water and provide convenience for the next step of processing the waste liquid.
- the ultraviolet lamp and the ozone generator are installed in the lower part of the tank body, and a protective cover is installed on the outside of the ultraviolet lamp and the ozone generator.
- a cylinder with the same diameter as the inner tank is used to fix the radial movement of the tank, and fix the axial movement of the tank at both ends, so that the tank only moves in the circumferential direction, and the stirring head moves along at a certain speed.
- Axial movement completes the welding of the entire tank.
- the position of the stirring needle during welding should be within ⁇ 1mm at the junction of the outer tank body and the inner tank body to ensure the formation of intermetallic compounds that enhance the performance of the joint.
- the tank body of the present invention is divided into inner and outer layers, which reduces the processing cost of the tank body and the processing difficulty of the tank body; the waste liquid is injected through the water injection port, flows through the filter plate, and the waste residue in the waste liquid is filtered before flowing into the tank body
- the lower part is processed by ultraviolet rays and ozone.
- the processing method uses friction stir welding technology to weld the inner and outer layers of the tank, which reduces the difficulty of processing, enhances the strength of the tank, and improves the processing quality and yield of the tank.
- the entire processing process can realize fully automated processing, which improves The processing efficiency of the tank.
- FIG. 1 The overall diagram of the waste liquid tank of the embodiment of the present invention.
- Figure 2 is a cross-sectional view of a waste liquid tank in an embodiment of the present invention.
- FIG. 1 Schematic diagram of aluminum/titanium friction stir welding.
- Fig. 4 is a schematic flowchart of a tank processing method provided by an embodiment of the present invention.
- the tank waste liquid treatment tank includes a sub-tank body 3, an end cover 4, a water injection pipe 2, a water outlet pipe 5, a filter screen 9, an ultraviolet lamp 7 and an ozone generator 12.
- the tank body is divided into two layers, the inner tank body 8 is made of titanium alloy with strong corrosion resistance, the thickness is 5mm, the diameter is 4000mm, and the depth is 6000mm; the quality of the outer tank body 6 Lightweight and high-strength aluminum alloy is used as the material, with a thickness of 10mm, a diameter of 4010mm, and a depth of 6010mm.
- the end caps are also divided into inner end caps 10 and outer end caps 11.
- the inner end caps 10 are made of titanium alloy with strong corrosion resistance as raw materials, with a diameter of 4010mm and a thickness of 5mm.
- the outer end caps 11 uses aluminum alloy plates with light weight and high specific strength, with a diameter of 4030mm and a thickness of 10mm.
- the water injection pipe 2 and the water outlet pipe 5 are located on both ends of the cover, the water injection pipe 2 is located on the upper end cover 1, the water outlet pipe 5 is on the lower end cover 4, and the nozzle diameter is 60mm; and a control valve is installed on the water pipe to control the water flow in and out.
- the filter screen 9 is made of titanium alloy as a raw material, the mesh shape is circular, and the diameter is 1 mm, and is installed in the middle and upper part of the tank body to filter waste residues in wastewater.
- the ultraviolet lamp 7 and the ozone generator 12 are installed in the middle and lower part of the tank, and a protective cover is installed to prevent the waste water from destroying them.
- FIG. 4 is a schematic flowchart of a tank processing method according to an embodiment of the present invention.
- the specific operation process includes:
- S01 uses a shearing machine to cut the blanks of the two materials into square materials with a size of 12560mm in length, 6000mm in width, 12591.4mm in length and 6010mm in width.
- S02 uses a rolling machine to roll square materials into circular welding parts; in this process, the roundness of the circular welding parts needs to be controlled to facilitate subsequent installation.
- S03 welds the inner drum-shaped welded parts into a tank body; fixes the two ends of the welded parts to prevent axial movement of the drum-shaped welded parts during the welding process, and uses a barrel-shaped object of the same diameter to fix the diameter of the welded parts Movement in the direction and circumferential direction; after the completion of the fixation, use the friction stir welding technology to join the joints, after the completion of the welding, the flashes generated around the welding joints are treated and coated with anti-corrosion paint.
- S05 Prepare end caps; according to the inner end cap diameter of 4010mm, thickness of 5mm, outer end cap diameter of 4030mm, thickness of 10mm, the dimensions are stamped by a punching machine, and water injection holes and water outlet holes are processed at both ends of the cap .
- S09 connects the upper end cover and the tank body; first weld the inner end cover and the tank body, and fix the other end of the inner tank body that needs to be welded to prevent axial displacement of the tank body.
- the other end is butted with the end cover, and the same
- the diameter of the arc-shaped object fixes the radial movement of the welding piece.
- the stirring head only rotates, and the tank body and the end cover move in the circumferential direction simultaneously to complete the welding on one side, and the outer end cover on the same side is used The welding is completed in the same welding method. After the welding is completed, the welding seam is treated with flash removal;
- the inner and outer tanks are welded by friction stir welding technology, that is, aluminum/titanium dissimilar alloy friction stir welding lap.
- the welding schematic diagram is shown in FIG. 3.
- the shaft shoulder diameter of the stirring head is 20mm
- the needle length is 10mm
- the pressure of the stirring head is 0.1mm during the welding process to ensure that the bottom of the stirring needle touches the titanium alloy plate.
- Friction stir welding of dissimilar alloys is easy to form intermetallic compounds in the joints.
- the speed of the friction stir welding of aluminum/titanium dissimilar alloys is 1000rpm and the welding speed is 100mm/min, intermetallic compounds that are beneficial to the mechanical properties of the joint can be formed in the joint. Improve the mechanical properties of the tank.
- the outer tank can also be made of carbon steel, magnesium alloy, copper alloy and other metal materials with good strength and easy to friction stir processing.
- the inner tank can also be made of corrosion-resistant materials such as stainless steel, platinum, zirconium alloy, etc. Layer tank materials can be combined in any combination.
- the processing method of the new tank body is made by friction stir welding of two layers of different materials, which reduces the processing cost, reduces the processing difficulty, can realize automatic processing, and improves the production efficiency.
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Life Sciences & Earth Sciences (AREA)
- Hydrology & Water Resources (AREA)
- Environmental & Geological Engineering (AREA)
- Water Supply & Treatment (AREA)
- Organic Chemistry (AREA)
- Mechanical Engineering (AREA)
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Abstract
一种废液处理罐，其包括内层罐体（8）和外层罐体（6），内层罐体（8）由耐腐蚀金属材料制备而成，外层罐体（6）由普通金属材料制备，所述的内层罐体（8）和外层罐体（6）通过搅拌摩擦焊接成一个整体。该废液处理罐采用两层不同材料搅拌摩擦焊接而成，不仅减少了加工成本，降低了加工难度，能实现自动化加工，提高了生产效率。
Description
本发明属于废液处理领域，尤其是一种具有高强耐腐蚀性能的废液处理罐，具体地说是一种利用搅拌摩擦焊技术进行罐体成型的废液处理罐。
在工业生产过程中产生的废液，含有大量的生产中产生的原料、中间产物和副产品，种类繁多，成分复杂，多种有毒物质，污染环境对人类健康有很大危险，处理难度大。现今常用的废液处理罐较多使用钛合金作为整个罐体的原材料，致使制造成本高，加工困难，成品率低。
为了解决现有的污水处理系统移动不便和对废液一次性处理的问题，发明专利“一种污水环保预处理罐”(专利申请号：201711360315.7)发明了一种方便移动的废液预处理罐，降低了罐体的加工成本和工程量的大等问题。
为了提高罐体加工的成品率和罐体的加工质量，发明专利“罐体加工方法”(专利申请号：201110175089.1)通过减小焊接前的搭接量，进而减少焊接厚度，避免由于焊接接缝造成的缩颈部的皱褶缺陷，提高罐体的加工成品率，但是加工复杂，自动化程度不高。
为解决罐体加工自动化程度低，生产效率低下等问题，发明专利“罐体的加工制备及其加工方法”(专利申请号：201910081756.6)通过在筒节的一端开口处安装焊接机械臂，实现自动化作业，提高了罐体的生产效率，但机械手安装和控制较为复杂，增加了生产的难度。
发明内容
本发明的目的是针对现有的废液罐制造成本高，加工困难，成品率低的问题，设计一种利用搅拌摩擦焊接技术将二种不同材料进行结合加工出强度高、耐腐蚀好的废液处理罐。
本发明的技术方案是：
一种废液处理罐，它包括内层罐体和外层罐体，内层罐体由耐腐蚀金属材料制备而成，外层罐体由普通金属材料制备，其特征是所述的内层罐体和外层罐体通过搅拌摩擦焊接成一个整体。
本发明的废液处理罐采用以下方法制造而成：
首先，将内外层罐体材料毛胚剪切成适当尺寸的方料，将方料卷成圆桶形焊接件；
其次，将内外两层圆桶形焊接件分别焊接成内外层罐体，并去除焊缝进行打磨、喷漆处理；
第三，加工与上述罐体相匹配的上下端盖；
第四，安装旋液处理所需的各类附件；
第五，将内侧端盖和内侧罐体连接，实现内侧罐体的密封，将完成密封好的内层罐体套入外层罐体中，再将外端盖和外罐体进行焊接；
最后，采用搅拌摩擦焊接技术将内外层罐体焊接在一起，保证内外罐体相连接，提高罐体强度。
所述的附件包括紫外线灯、臭氧发生器、过滤板、进水口水管、出水孔水管以及安装在进出水管上内外的控制阀。
所述的内外层罐体的形状为椭圆形、圆形、方形、三角形或不规则形状。
所述的内层罐体为耐腐蚀的不锈钢、钛合金或铂金，外层罐体为强度高、成本低的钢、合金、铜合金或镁合金
所述的内外层罐体搅拌摩擦焊接的方法是：将内层罐体套入外层罐体 中，对内外层罐体进行径向和轴向进行固定，使内外层罐体只做周向运动，使用搅拌摩擦焊接的方式对罐体进行焊接，将内外两层罐体连接，增加罐体的强度。
所述的搅拌摩擦焊接所用的搅拌头轴肩直径范围为1-100mm，针长范围为1-50mm，焊接过程中搅拌头下压量为0-5mm；搅拌头形状为圆台，锥形螺纹，梯台和三角形。
所述的搅拌摩擦焊接过程中的搅拌头转速范围为10-5000rpm、焊速为1-1000mm/min。
所述的搅拌摩擦焊接过程中搅拌针的位置应在外层罐体与内层罐体交界处±1mm之间，以确保这接头中形成增强接头性能的金属间化合物，生成的金属间化合物具有增强接头性能的作用。
所述的搅拌摩擦焊接的路径为沿周向圆形焊接，沿轴向直线焊接，螺纹状焊接路径；其中路径为轴向时可以沿轴向“s”型焊接，也可以是单方向沿轴向焊接。
本发明提供的废液处理罐包括有分罐体、端盖、注水管、出水管、过滤网、紫外线灯和臭氧发生器。
所述罐体分为内外两层，内层使用耐腐蚀性良好的材料，防止被废液腐蚀，外层使用质量轻、加工成本低且强度大的材料作为外壁，减少加工成本，增强罐体的强度。
所述端盖也分为两层，内层端盖层使用耐腐蚀性良好的材料，防止被废液腐蚀，外层使用质量轻、价格低廉且强度大的材料作为外壁，增强强度。
所述注水管位于罐体上端盖处，出水管位于罐体下端盖处，两者均由耐腐蚀性良好的材料加工而成。
所述过滤板位于罐体中上部分，使用耐腐蚀材料制造，将废水中的废渣过滤，为下一步处理废液提供方便。
所述紫外线灯和臭氧发生器安装在罐体中下部分，紫外线灯臭氧发生器的外部都安装有保护罩。
在焊接过程中用与内层罐体直径相当的圆柱体固定罐体的径向运动，并在两端固定罐体的轴向运动，使罐体只做周向运动，搅拌头以一定速度沿轴向运动，完成整个罐体的焊接。焊接时搅拌针的位置应在外层罐体与内层罐体交界处±1mm之间，以确保这接头中形成增强接头性能的金属间化合物。
进一步的，将另一端未连接的端盖连接，先完成内层端盖的连接，在完成外层端盖的连接。
进一步的，安装注水管和出水管。
本发明的有益效果是：
本发明的罐体分为内外两层，减少了罐体加工成本，降低了罐体的加工难度；通过注水口注入废液，流过过滤板，将废液中的废渣过滤，再流入罐体的下半部分，通过紫外线和臭氧进行在处理。所述加工方法通过对内外两层罐体使用搅拌摩擦焊接技术进行焊接，降低加工难度，增强罐体的强度，提高罐体的加工质量和成品率，整个加工过程可以实现全自动化加工，提高了罐体的加工效率。
图1本发明实施案例的废液罐总体图。
图2本发明实施案例的废液罐剖视图。
图3铝/钛搅拌摩擦焊接示意图。
图4本发明实施例提供的罐体加工方法的流程示意图。
图中：1、上端盖；2、注水管；3、罐体；4、下端盖；5、出水管；6、外层罐体；7、紫外线灯；8、内层罐体；9、过滤网；10、上内层端盖；11、上外层端盖；12、臭氧发生器。
为使本发明实施案例的目的、技术方案和优点更加清楚，下面将结合本发明实施案例和附图，对本发明中的技术方案进行清楚、完整地描述。应理解下述具体实施方式仅用于说明本发明而不用于限制本发明的范围。
具体实施方案1。
如图1所示，所述罐废液处理罐包括有分罐体3、端盖4、注水管2、出水管5、过滤网9、紫外线灯7和臭氧发生器12。
如图2所示，所述罐体分为两层，内层罐体8为耐腐蚀性强的钛合金制造而成，厚度5mm，直径为4000mm，深度为6000mm；外层罐体6使用质量轻、比强度大的铝合金作为材料，厚度为10mm，直径为4010mm，深度为6010mm。
所述端盖也分为内层端盖10和外层端盖11，内层端盖10以耐腐蚀性强的钛合金为原材料加工而成，直径为4010mm，厚度为5mm，外层端盖11则使用质量轻、比强度大的铝合金板材，直径为4030mm，厚度为10mm。
所述注水管2和出水管5位于两端盖上，注水管2位于上端盖1，出水管5在下端盖上4，管口直径60mm；并在水管上安装有控制阀，控制水流进出。
所述过滤网9使用钛合金为原材料制成，网孔形状为圆形，直径为1mm，安装于罐体的中上部用于过滤废水中的废渣。
所述紫外线灯7和臭氧发生器12安装于罐体的中下部，且安装有保护罩，以免废水将其破坏。
工作原理：关闭出水管5阀门，打开注水口2阀门，废液从注水口2流入废液处理罐中，经过过滤网9将废液中的废渣过滤，打开紫外线灯7和臭氧发生器12对废液进行处理，当废液罐中的废液接近过滤网9时关闭注水管2阀门，对废液处理一段时间后打开出水管5阀门，将废液排出，完成一次废液的处理。
具体实施方案2
请参阅图4，图4为本发明实施例提供的罐体加工方法的流程示意图；
本发明提供的废液处理罐加工方法，具体操作流程包括：
S01利用剪板机将两种材料的毛胚分别剪切成尺寸为长12560mm、宽为6000mm和长12591.4mm、宽6010mm内外罐体的方料。
S02利用卷圆机将方料卷成圆形焊接件；在此过程中需要控制圆形焊接件的圆度，以便于后面的安装。
S03将内层圆桶形焊接件焊接成罐体；对焊接件两端进行固定，防止在焊接过程中圆桶形焊接件发生轴向运动，使用相同直径的圆桶状物体固定焊接件的径向和周向运动；完成固定后，使用搅拌摩擦焊接技术对接缝进行对接，焊接完成后对焊缝周边产生的飞边进行处理，并涂上防腐蚀漆。
S04将外层圆桶形焊接件焊接成罐体；对焊接件两端进行固定，防止在焊接过程中焊接件发生轴向运动，使用相同直径的圆桶状物体固定焊接件的径向和周向运动；完成固定后，使用搅拌摩擦焊接技术对接缝进行对接，焊接完成后对焊缝周边产生的飞边进行处理，并涂上防腐蚀油漆。
S05制备端盖；按照内层端盖直径为4010mm，厚度为5mm，外层端盖直径为4030mm，厚度为10mm的尺寸利用冲压机冲压完成，并在两端盖处加工出注水孔和出水孔。
S06将上端盖和罐体连接；先对内层端盖和罐体进行焊接，将内层罐体需要焊接的另一端固定，防止罐体发生轴向位移，另一端与端盖对接，并用相同直径的圆桶状物体固定焊接件的径向运动，在搅拌摩擦焊接过程中搅拌头只做旋转，罐体和端盖同步进行周向运动，完成一侧的焊接，同一侧的外端盖使用同样的焊接方式完成焊接，焊接完成后对焊缝进行去飞边处理；
S07将已焊接完的内层罐体套入外层罐体中，使用同样的方法对外层罐体和端盖进行焊接，并对焊缝进行去飞边处理；
S08对内外罐体进行焊接；将已焊接完一侧端盖的内层罐体套入外层罐体中，对罐体进行径向和轴向进行固定，使罐体只做周向运动，在罐体离端盖50mm处使用搅拌摩擦焊接的方式对罐体进行焊接，将内外两层罐体连接，增加罐体的强度。焊接路径为螺纹状路径，从一侧向另一侧焊接，其中螺纹的导程为20mm。
S09将上端盖和罐体连接；先对内层端盖和罐体进行焊接，将内层罐体需要焊接的另一端固定，防止罐体发生轴向位移，另一端与端盖对接，并用相同直径的圆弧状物体固定焊接件的径向运动，在搅拌摩擦焊接过程中搅拌头只做旋转，罐体和端盖同步进行周向运动，完成一侧的焊接，同一侧的外端盖使用同样的焊接方式完成焊接，焊接完成后对焊缝进行去飞边处理；
S09固定、安装注水、出水管和控制阀。
所述的内外罐体使用搅拌摩擦焊接技术焊接即为铝/钛异种合金搅拌摩擦焊搭接，其焊接示意图如图3所示。搅拌头轴肩直径为20mm，针长为10mm，焊接过程中搅拌头下压量为0.1mm，保证搅拌针底部触碰到钛合金板材。异种合金搅拌摩擦焊接在接头中易形成金属间化合物，铝/钛异种合金搅拌摩擦焊接搅拌头转速为1000rpm、焊速为100mm/min时可以在接头中形成有益于接头力学性能的金属间化合物，提高罐体的力学性能。
具体实施时，外层罐体还可采用碳钢、镁合金、铜合金等强度好且易于搅拌摩擦加工的金属材料，内层罐体还可采用不锈钢、铂金、锆合金等耐腐蚀材料，内外层罐体材料可进行任意组合。
与现在技术相比，新型罐体的加工方法采用两层不同材料搅拌摩擦焊接而成，减少了加工成本，降低了加工难度，能实现自动化加工，提高了生产效率。
本发明方案所公开的技术手段不仅限于上述技术手段所公开的技术手段，还包括由以上技术特征任意组合所组成的技术方案。
以上述依据本发明的理想实施例为启示，通过上述的说明内容，相关工作人员完全可以在不偏离本项发明技术思想的范围内，进行多样的变更以及修改。本项发明的技术性范围并不局限于说明书上的内容，必须要根据权利要求范围来确定其技术性范围。
本发明未涉及部分与现有技术相同或可采用现有技术加以实现。
Claims (10)
- 一种废液处理罐，它包括内层罐体和外层罐体，内层罐体由耐腐蚀金属材料制备而成，外层罐体由普通金属材料制备，其特征是所述的内层罐体和外层罐体通过搅拌摩擦焊接成一个整体。
- 根据权利要求1所述的废液处理罐，其特征是它采用以下方法制造而成：首先，将内外层罐体材料毛胚剪切成适当尺寸的方料，将方料卷成圆桶形焊接件；其次，将内外两层圆桶形焊接件分别焊接成内外层罐体，并去除焊缝进行打磨、喷漆处理；第三，加工与上述罐体相匹配的上下端盖；第四，安装旋液处理所需的各类附件；第五，将内侧端盖和内侧罐体连接，实现内侧罐体的密封，将完成密封好的内层罐体套入外层罐体中，再将外端盖和外罐体进行焊接；最后，采用搅拌摩擦焊技术接将内外层罐体焊接在一起，保证内外罐体相连接，提高罐体强度。
- 根据权利要求2所述的废液处理罐，其特征是所述的附件包括紫外线灯、臭氧发生器、过滤板、进水口水管、出水孔水管以及安装在进出水管上内外的控制阀。
- 根据权利要求1或2所述的废液处理罐，其特征是所述的内外层罐体的形状为椭圆形、圆形、方形、三角形或不规则形状。
- 根据权利要求1或2所述的废液处理罐，其特征是所述的内层罐体为 耐腐蚀的不锈钢、钛合金或铂金，外层罐体为强度高、成本低的钢、合金、铜合金或镁合金
- 根据权利要求1或2所述的废液处理罐，其特征是所述的内外层罐体搅拌摩擦焊接的方法是：将内层罐体套入外层罐体中，对内外层罐体进行径向和轴向进行固定，使内外层罐体只做周向运动，使用搅拌摩擦焊接的方式对罐体进行焊接，将内外两层罐体连接，增加罐体的强度。
- 根据权利要求1或2所述的废液处理罐，其特征是所述的搅拌摩擦焊接所用的搅拌头轴肩直径范围为1-100mm，针长范围为1-50mm，焊接过程中搅拌头下压量为0-5mm；搅拌头形状为圆台，锥形螺纹，梯台和三角形。
- 根据权利要求1或2所述的废液处理罐，其特征是所述的搅拌摩擦焊接过程中的搅拌头转速范围为10-5000rpm、焊速为1-1000mm/min。
- 根据权利要求1或2所述的废液处理罐，其特征是所述的搅拌摩擦焊接过程中搅拌针的位置应在外层罐体与内层罐体交界处±1mm之间，以确保这接头中形成增强接头性能的金属间化合物，生成的金属间化合物具有增强接头性能的作用。
- 根据权利要求1或2所述的废液处理罐，其特征是所述的搅拌摩擦焊接的路径为沿周向圆形焊接，沿轴向直线焊接，螺纹状焊接路径；其中路径为轴向时能够沿轴向“s”型焊接，也能够是单方向沿轴向焊接。
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