Anti-deformation industrial furnace water beam structure of gradient composite material and preparation method

Abstract

The invention discloses an anti-deformation industrial furnace water beam structure made of a gradient composite material and a preparation method. The water beam structure sequentially comprises a high-temperature-resistant gradient layer, a thermal stress buffer layer and a heat conduction base body layer from outside to inside. Wherein the high-temperature-resistant gradient layer is composed of a ceramic and / or metal ceramic material, and the components of the high-temperature-resistant gradient layer are in continuous or stepped transition from the outer surface to the inside in the thickness direction to form a metal material for resisting high-temperature oxidation and hot corrosion; the thermal stress buffer layer is composed of a metal-based composite material, the coefficient of thermal expansion (CTE) of the thermal stress buffer layer is between that of the high-temperature-resistant gradient layer and that of the heat-conducting matrix layer, and the thermal stress buffer layer is used for relieving And the heat-conducting matrix layer is made of a high-heat-conductivity metal material and is used for rapidly conducting out heat. Through collaborative optimization of materials and structures, the problems that a traditional water beam is concentrated in thermal stress and poor in thermal shock resistance are solved, and the water beam is suitable for long-term stable operation of a high-temperature industrial furnace.

Description

Technical Field

[0001] The present invention relates to the technical field of high-temperature components of industrial heating furnaces, and specifically to a deformation-resistant industrial furnace water beam structure based on a gradient composite material, which is suitable for supporting and cooling workpieces in high-temperature furnaces in industries such as steel and metallurgy. Background Art

[0002] Traditional industrial furnace water beams are mostly made of homogeneous heat-resistant steel (such as 310S stainless steel). However, the sharp temperature difference between high temperatures (>1000°C) and cooling water (<100°C) can easily lead to thermal stress concentration, resulting in thermal fatigue cracking and creep deformation. Existing technologies improve high-temperature resistance by spraying ceramic coatings (such as Al2O3) on the surface. However, the large difference in thermal expansion coefficients between the coating and the substrate makes the interface prone to delamination and failure. Therefore, there is an urgent need for a water beam structure that combines high-temperature resistance, thermal shock resistance, and high thermal conductivity. Summary of the Invention

[0003] In response to the above problems, the present invention proposes a gradient composite water beam structure, which realizes the coordinated optimization of thermal-mechanical-heat transfer performance through the gradient design of materials and structures, and significantly improves the deformation resistance and service life of the water beam.

[0004] To achieve the above purpose, the present invention provides a gradient composite material anti-deformation industrial furnace water beam structure, which comprises a high temperature resistant gradient layer, a thermal stress buffer layer and a heat conductive matrix layer from the outside to the inside; wherein,

[0005] High temperature resistant gradient layer: composed of ceramic and / or cermet materials, whose composition transitions to metal material continuously or stepwise from the outer surface to the inner surface along the thickness direction, used to resist high temperature oxidation and thermal corrosion;

[0006] Thermal stress buffer layer: composed of a metal matrix composite material, whose thermal expansion coefficient (CTE) is between that of the high-temperature gradient layer and the heat-conducting matrix layer, and is used to relieve interfacial thermal stress;

[0007] Thermal conductive base layer: Made of high thermal conductivity metal material, used to quickly dissipate heat.

[0008] Furthermore, the ceramic material of the high temperature resistant gradient layer is selected from at least one of ZrO2, Al2O3, and SiC;

[0009] The metal ceramic material is WC-Co or Cr3C2-NiCr.

[0010] Furthermore, the metal matrix composite material of the thermal stress buffer layer is NiCrAlY alloy, Inconel series high temperature alloy or Ti-Al intermetallic compound.

[0011] Furthermore, the metal material of the heat-conducting base layer is copper alloy, 316L stainless steel or aluminum alloy.

[0012] Furthermore, the thickness of the high-temperature resistant gradient layer is 0.5-3 mm, the total thickness of the thermal stress buffer layer is 1-5 mm, and the thickness of the thermal conductive base layer is 5-20 mm; the high-temperature resistant gradient layer and the thermal stress buffer layer are transitioned through a composition gradient, and the thickness of the transition zone accounts for 20%-50% of the high-temperature resistant gradient layer.

[0013] Furthermore, the cross-sectional shape of the cooling water channel is circular, rectangular or irregular, and the top corners are rounded to reduce flow resistance.

[0014] The outer layer of the high-temperature resistant gradient layer is a high-melting-point ceramic (such as ZrO2), which gradually transitions inward to a metal ceramic (such as WC-Co) and a metal (such as NiCrAlY), forming a continuous gradient interface. There is no clear interface material property (such as thermal expansion coefficient, elastic modulus), a continuous composition gradient, and the change in the gradient direction follows a certain functional relationship (such as linear, exponential or polynomial). The outer layer of high-melting-point ceramic (ZrO2) is resistant to high temperatures, and the inner layer of metal (NiCrAlY) provides toughness.

[0015] To achieve the above object, the preparation method of the above industrial furnace water beam structure of the present invention comprises the following steps:

[0016] The heat-conducting base layer is formed by powder metallurgy or casting process;

[0017] Depositing a thermal stress buffer layer on the thermally conductive substrate layer by additive manufacturing technology (3D printing) or plasma spraying process;

[0018] Depositing a high-temperature resistant gradient layer on the thermal stress buffer layer by additive manufacturing technology (3D printing) or plasma spraying process;

[0019] The metallurgical bonding between the layers is achieved by hot isostatic pressing (HIP) or diffusion welding.

[0020] Furthermore, the method also includes the step of machining cooling water channels inside the base layer.

[0021] The present invention has the following advantages:

[0022] 1) Gradient layer design: High-temperature resistant gradient layer: The outer layer is a high-melting-point ceramic (such as ZrO2), which gradually transitions inward to a metal ceramic (such as WC-Co) and a metal (such as NiCrAlY), forming a continuous gradient interface. There is no clear interface material properties (such as thermal expansion coefficient, elastic modulus), a continuous composition gradient, and the change in the gradient direction follows a certain functional relationship (such as linear, exponential, or polynomial). The outer layer of high-melting-point ceramic (ZrO2) is resistant to high temperatures, and the inner layer of metal (NiCrAlY) provides toughness. Thermal stress buffer layer: A metal-based composite material with a gradient CTE (thermal expansion coefficient) (such as Inconel 625 and Ti alloy composite) is used to gradually change the thermal expansion coefficient from the outer layer to the inner layer, smoothly transferring thermal stress and reducing interlayer stress. Thermal stress is gradually released in the gradient direction and is not concentrated at a single interface. Thermal conductive matrix layer: The inner layer is a high-thermal conductivity copper alloy, which dissipates heat quickly to prevent heat accumulation inside.

[0023] 2.Structural optimization:

[0024] The high-temperature gradient layer features a microporous structure (pore size 50-200μm) to relieve local thermal stress. This gradient material design reduces peak thermal stress and increases the number of thermal shock cycles, extending overall lifespan and significantly reducing maintenance costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 It is a schematic cross-sectional view of the water beam structure of the present invention. DETAILED DESCRIPTION

[0026] The embodiments of the present invention are described in detail below with reference to the accompanying drawings.

[0027] In the description of the present invention, it should be understood that the terms "center", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc., indicating the orientation or position relationship, are based on the orientation or position relationship shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present invention.

[0028] The terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the quantity of the technical features being referred to. Thus, a feature specified as "first" or "second" may explicitly or implicitly include one or more of such features. In the description of the present invention, unless otherwise specified, "plurality" means two or more.

[0029] In the description of the present invention, it should be noted that, unless otherwise expressly specified or limited, the terms "mounted," "connected," and "connected" should be understood broadly. For example, they may refer to fixed connections, detachable connections, or integral connections; they may refer to direct connections, indirect connections through an intermediary, or internal communication between two components. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on the specific circumstances.

[0030] like Figure 1 As shown, the anti-deformation industrial furnace water beam structure of the gradient composite material of the present invention includes, from the outside to the inside, a high-temperature resistant gradient layer, a thermal stress buffer layer and a heat-conducting base layer.

[0031] Among them, the high-temperature resistant gradient layer is composed of ceramic or cermet materials, and its composition transitions continuously or stepwise from the outer surface to the inner surface to metal materials along the thickness direction, which is used to resist high-temperature oxidation and thermal corrosion; the thermal stress buffer layer is composed of a metal-based composite material, and its thermal expansion coefficient (CTE) is between that of the high-temperature resistant gradient layer and the thermal conductive base layer, which is used to relieve interfacial thermal stress; the thermal conductive base layer is composed of a high-thermal conductivity metal material, using a modified 310S heat-resistant steel (with 1.2% Nb + 0.3% Y added to improve high-temperature creep resistance), and is equipped with a cooling water channel inside to quickly remove heat.

[0032] The ceramic material of the high-temperature resistant gradient layer is selected from at least one of ZrO2, Al2O3, and SiC, and the metal ceramic material is WC-Co or Cr3C2-NiCr; the metal-based composite material of the thermal stress buffer layer is NiCrAlY alloy, Inconel series high-temperature alloy or Ti-Al intermetallic compound; the metal material of the thermal conductive base layer is copper alloy, 316L stainless steel or aluminum alloy.

[0033] The thickness of the high-temperature resistant gradient layer is 0.5-3mm, the total thickness of the thermal stress buffer layer is 1-5mm, and the thickness of the heat-conductive base layer is 5-20mm; the high-temperature resistant gradient layer and the thermal stress buffer layer are transitioned through a composition gradient, and the thickness of the transition zone accounts for 20%-50% of the high-temperature resistant gradient layer. The total wall thickness of the water beam complies with the latest national standards.

[0034] The cross-sectional shape of the cooling water channel is circular, rectangular or irregular, and the top corners are rounded to reduce flow resistance.

[0035] The preparation method of the industrial furnace water beam structure of the present invention includes the following steps: depositing a high-temperature resistant gradient layer and a thermal stress buffer layer layer by layer through additive manufacturing technology (3D printing) or plasma spraying process; forming a heat-conducting base layer by powder metallurgy or casting process, and processing a cooling water channel inside the base layer; and achieving metallurgical bonding between the layers by hot isostatic pressing (HIP) or diffusion welding.

[0036] Example 1

[0037] 1. Material selection:

[0038] High temperature resistant gradient layer: The outer layer is plasma sprayed ZrO2-8% Y2O3 (thickness 1.5mm), transitioning inward to WC-10Co (thickness 0.8mm);

[0039] Thermal stress buffer layer: laser cladding Inconel 625 / Ti-6Al-4V gradient layer (thickness 2 mm);

[0040] Thermal conductive base layer: cast copper alloy.

[0041] 2. Preparation process:

[0042] The base layer is formed by precision casting; the gradient layer is deposited by a plasma spraying + laser cladding composite process, and finally subjected to hot isostatic pressing (HIP) treatment (temperature 1100°C, pressure 100 MPa).

[0043] The present invention has been described in detail above with reference to the accompanying drawings. However, the present invention is not limited to the above-described embodiments. Various modifications may be made within the scope of knowledge of those skilled in the art without departing from the spirit of the present invention. Many other changes and modifications that do not depart from the spirit and scope of the present invention should be considered within the scope of protection of the present invention.

[0044] In the description of this specification, specific features, structures, materials or characteristics may be combined in an appropriate manner in any one or more embodiments or examples.

[0045] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any modifications or substitutions that can be easily conceived by a person skilled in the art within the technical scope disclosed in the present invention should be included in the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be based on the scope of protection of the claims.

Claims

1. A gradient composite material anti-deformation industrial furnace water beam structure, characterized in that: The water beam structure includes a high temperature resistant gradient layer, a thermal stress buffer layer and a heat conductive base layer from the outside to the inside; wherein, High-temperature resistant gradient layer: composed of ceramic and / or cermet materials, whose composition transitions to metal material continuously or stepwise from the outer surface to the inner surface along the thickness direction, used to resist high-temperature oxidation and thermal corrosion; Thermal stress buffer layer: composed of a metal matrix composite material, whose coefficient of thermal expansion (CTE) is between that of the high-temperature gradient layer and the heat-conducting matrix layer, and is used to relieve interfacial thermal stress; Thermal conductive base layer: Made of high thermal conductivity metal material, used to quickly dissipate heat.

2. The anti-deformation industrial furnace water beam structure made of gradient composite material according to claim 1, characterized in that: The ceramic material of the high temperature resistant gradient layer is selected from at least one of ZrO2, Al2O3, and SiC; The metal ceramic material is WC-Co or Cr3C2-NiCr.

3. The anti-deformation industrial furnace water beam structure made of gradient composite material according to claim 1, characterized in that: The metal matrix composite material of the thermal stress buffer layer is NiCrAlY alloy, Inconel series high temperature alloy or Ti-Al intermetallic compound.

4. The anti-deformation industrial furnace water beam structure made of gradient composite material according to claim 1, characterized in that: The metal material of the heat-conducting base layer is copper alloy, 316L stainless steel or aluminum alloy.

5. The anti-deformation industrial furnace water beam structure made of gradient composite material according to claim 1, characterized in that: The thickness of the high-temperature resistant gradient layer is 0.5-3mm, the total thickness of the thermal stress buffer layer is 1-5mm, and the thickness of the heat-conductive base layer is 5-20mm; the high-temperature resistant gradient layer and the thermal stress buffer layer transition through a composition gradient, and the thickness of the transition zone accounts for 20%-50% of the high-temperature resistant gradient layer.

6. The anti-deformation industrial furnace water beam structure made of gradient composite material according to claim 1, characterized in that: The cross-sectional shape of the cooling water channel is circular, rectangular or irregular, and the top corners are rounded to reduce flow resistance.

7. The anti-deformation industrial furnace water beam structure made of gradient composite material according to claim 1, characterized in that: The outer layer of the high temperature resistant gradient layer is high melting point ceramic, and gradually transitions into metal ceramic and metal towards the inside.

8. A method for preparing an industrial furnace water beam structure according to any one of claims 1 to 4, characterized in that: The following steps are involved: The heat-conducting base layer is formed by powder metallurgy or casting process; Depositing a thermal stress buffer layer on the thermally conductive substrate layer by additive manufacturing technology (3D printing) or plasma spraying process; Depositing a high-temperature resistant gradient layer on the thermal stress buffer layer by additive manufacturing technology (3D printing) or plasma spraying process; The metallurgical bonding between the layers is achieved by hot isostatic pressing (HIP) or diffusion welding.

9. The method for preparing an industrial furnace water beam structure according to claim 8, characterized in that: The method also includes the step of machining cooling water channels inside the base layer.

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