An integrally cast high abrasion resistance hardfacing plate
Patent Information
- Application Number
- CN202522114557.4
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-09-30
- Publication Date
- 2026-09-08
- Estimated Expiration
- 2035-09-30
AI Technical Summary
[0002]在工业生产中，如矿山、水泥等行业的物料输送设备常需使用堆焊板来应对高磨损工况，传统的堆焊板多为平板结构，直线型结构无法适配曲面设备的安装需求，单一硬度材料结合强度不足，难以平衡抗冲击与耐磨性能，均质结构导致应力分布不均易开裂，导致使用寿命短，且因缺乏有效的加强结构设计，在复杂应力作用下易变形损坏，另外因防滑性能不佳，存在安全隐患，现有技术多采用折弯成型工艺制造曲面防护件，但存在接缝处强度衰减、分层剥离风险高等缺陷，特别是在回转窑、球磨机等旋转设备中，物料离心力产生的环形磨损轨迹要求防护部件具有周向均布的强化区域，这些问题严重影响了设备的运行效率和维护成本，鉴于此，我们提出一种整体铸造高耐磨堆焊板
本申请技术方案中提供的一个或多个技术方案，至少具有如下技术效果或优点：该堆焊板通过弧形整体结构和多层复合设计，显著提升了产品的耐磨性能与承载能力，离心铸造工艺确保了材料的致密性和均匀性，蜂窝形加强筋组增强了结构刚性，当物料冲击发生时，蜂窝状加强筋将集中载荷分解为多向分力，防止变形，通过过渡层的塑性变形吸收能量，加固层的高弹性模量阻止变形过量，最终由表面耐磨块承担剩余摩擦功，菱形耐磨块的合理布局及角度设置优化了摩擦分布，延长了使用寿命，基板、过渡层、加固层与耐磨层的递进式架构实现了性能梯度提升，而防滑条和防滑纹路则进一步提高了安装安全性与稳定性，整体设计兼顾了高强度、高耐磨与易维护的特点，有效降低了设备的停机检修频率，节约了生产成本。
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Abstract
Description
Technical Field
[0001] This application relates to the field of weld overlay plate technology, and more specifically, to an integrally cast high wear-resistant weld overlay plate. Background Technology
[0002] In industrial production, such as mining and cement industries, material conveying equipment often requires the use of weld overlay plates to cope with high-wear conditions. Traditional weld overlay plates are mostly flat structures, and straight structures cannot adapt to the installation requirements of curved equipment. The single hardness of the material is insufficient in terms of bonding strength, making it difficult to balance impact resistance and wear resistance. The homogeneous structure leads to uneven stress distribution, which easily causes cracking and results in a short service life. Furthermore, due to the lack of effective reinforcement structural design, they are prone to deformation and damage under complex stress. In addition, poor anti-slip performance poses safety hazards. Existing technologies mostly use bending forming processes to manufacture curved protective parts, but there are defects such as strength at the joints and high risk of delamination. Especially in rotating equipment such as rotary kilns and ball mills, the annular wear trajectory generated by the centrifugal force of the material requires the protective parts to have a circumferentially distributed reinforced area. These problems seriously affect the operating efficiency and maintenance costs of the equipment. In view of this, we propose an integrally cast high wear-resistant weld overlay plate. Utility Model Content
[0003] 1. Technical problems to be solved The purpose of this application is to provide an integrally cast high wear-resistant weld overlay plate, which solves the technical problems in the background art mentioned above. It achieves a significant improvement in the wear resistance and load-bearing capacity of the product through an arc-shaped integral structure and multi-layer composite design. The centrifugal casting process ensures the density and uniformity of the material, the honeycomb reinforcing ribs enhance the structural rigidity and prevent deformation, the reasonable layout and angle setting of the rhomboid wear-resistant blocks optimize the friction distribution and extend the service life, the progressive architecture of the base plate, transition layer, reinforcing layer and wear-resistant layer realizes the performance gradient improvement, and the anti-slip strips and anti-slip textures further improve the installation safety and stability. The overall design takes into account the characteristics of high strength, high wear resistance and easy maintenance, effectively reducing the frequency of equipment downtime maintenance and saving production costs.
[0004] 2. Technical Solution This application provides an integrally cast high wear-resistant weld overlay plate, comprising: a weld overlay plate body, the weld overlay plate body having an overall arc-shaped structure, formed by centrifugal casting, and having multiple perforations cast along the circumference; the weld overlay plate body having a base plate, a transition layer, a reinforcing layer and a wear-resistant layer arranged sequentially from the outside to the inside; a honeycomb-shaped reinforcing rib group arranged between the base plate and the transition layer; and multiple rhomboid wear-resistant blocks fixed along the inner wall of the wear-resistant layer.
[0005] By adopting the above technical solution, the body of the weld overlay plate conforms to the curved surface of the equipment through an arc design, reducing stress concentration. Centrifugal casting makes the material distribution more uniform and dense, improving the overall strength. Multiple perforations are set for fixing bolt structural components, facilitating installation and positioning. The body of the weld overlay plate is arranged from the outside to the inside as a base plate, a transition layer, a reinforcing layer, and a wear-resistant layer, forming a gradient performance protection system. The base plate serves as the basic load-bearing layer, the transition layer achieves a smooth material transition to reduce the risk of interface cracking, the reinforcing layer enhances impact resistance, and the wear-resistant layer directly contacts the material to provide high-hardness protection. In addition, a honeycomb-shaped reinforcing rib group is set between the base plate and the transition layer, which greatly improves the bending and torsional stiffness and optimizes mechanical properties. Multiple rhomboid wear-resistant blocks are fixed along the inner circumference of the wear-resistant layer. The contact area is optimized through geometric shape, reducing local pressure and extending service life.
[0006] Optionally, the substrate is uniformly fixed with multiple anti-slip strips along its outer circumference and is uniformly arranged along the arc surface of the substrate.
[0007] By adopting the above technical solution, the anti-slip strip adopts a raised design to increase the friction with the mounting surface and prevent loosening and displacement caused by vibration. It is especially suitable for equipment fixing under high-frequency vibration conditions.
[0008] Optionally, the substrate is made of QB carbon steel, the transition layer is made of high manganese steel, the reinforcing layer is made of chromium-molybdenum alloy, and the wear-resistant layer is made of tungsten carbide particle-reinforced coating. The weld overlay plate body forms a performance-progressive architecture through the substrate, transition layer, reinforcing layer and wear-resistant layer.
[0009] By adopting the above technical solution, the substrate is made of QB carbon steel, which has good plasticity and weldability and is easy to process and shape. The transition layer is made of high manganese steel, which absorbs impact energy by utilizing work hardening characteristics. The reinforcement layer is made of chromium-molybdenum alloy, which has both high temperature strength and corrosion resistance. The wear-resistant layer is made of tungsten carbide particle-reinforced coating, which significantly improves surface hardness through hard phase particle dispersion reinforcement. The resulting performance-progressive architecture allows each layer to complement each other's advantages, achieving a progressive protection upgrade from the substrate to the surface.
[0010] Optionally, the honeycomb reinforcing rib assembly includes multiple hexagonal frames arranged in an array along the arc surface of the transition layer and multiple arc-shaped ribs. The arc-shaped ribs are respectively connected in series to fix the multiple hexagonal frames. The honeycomb reinforcing rib assembly is made of ductile iron.
[0011] By adopting the above technical solution, the honeycomb reinforcing rib group is composed of multiple hexagonal frames and multiple arc-shaped ribs, which can imitate the high-efficiency load-bearing characteristics of natural honeycomb, maximize the structural stiffness while reducing weight. In addition, the honeycomb reinforcing rib group is made of ductile iron, which has high elastic modulus and toughness, and can effectively absorb dynamic loads and suppress crack propagation.
[0012] Optionally, the transition layer and the arc surface adjacent to the substrate are provided with hexagonal grooves and arc-shaped strip grooves that match the honeycomb reinforcing ribs, and the transition layer is fixed with hexagonal protrusions in the hexagonal grooves.
[0013] By adopting the above technical solution, hexagonal grooves and arc-shaped grooves matching the honeycomb reinforcing ribs are set on both the transition layer and the substrate. The fitting design ensures that the reinforcing ribs and the main structure are closely matched and avoids relative sliding. At the same time, mechanical interlocking improves the connection reliability and enhances the shear resistance of the overall structure.
[0014] Optionally, the inner wall of the wear-resistant layer is evenly distributed with ten rhomboid wear-resistant blocks along the circumference. The long diagonal of each rhomboid wear-resistant block forms an angle of ° with the radial direction. The rhomboid wear-resistant block is arranged in an arc shape, and the inner arc surface is provided with anti-slip texture.
[0015] By adopting the above technical solution, the diamond-shaped wear-resistant block is designed with a 90° angle between its long diagonal and radial direction, which enables the diamond-shaped wear-resistant block to generate a self-locking effect when under load, reducing the tendency of displacement. In addition, the arc shape fits the curvature radius of the equipment, ensuring the fit. The anti-slip texture further increases the friction between the block and the material, preventing abnormal wear caused by slippage.
[0016] 3. Beneficial effects One or more technical solutions provided in this application have at least the following technical effects or advantages: The weld overlay plate significantly improves the wear resistance and load-bearing capacity of the product through its arc-shaped overall structure and multi-layer composite design. The centrifugal casting process ensures the density and uniformity of the material. The honeycomb reinforcing ribs enhance the structural rigidity. When material impact occurs, the honeycomb reinforcing ribs decompose the concentrated load into multi-directional components to prevent deformation. Energy is absorbed through the plastic deformation of the transition layer, and the high elastic modulus of the reinforcement layer prevents excessive deformation. Finally, the remaining friction work is borne by the surface wear-resistant blocks. The reasonable layout and angle setting of the rhomboid wear-resistant blocks optimize the friction distribution and extend the service life. The progressive architecture of the substrate, transition layer, reinforcement layer and wear-resistant layer realizes the performance gradient improvement, while the anti-slip strips and anti-slip textures further improve the installation safety and stability. The overall design takes into account the characteristics of high strength, high wear resistance and easy maintenance, effectively reducing the frequency of equipment downtime maintenance and saving production costs. Attached Figure Description
[0017] Figure 1 This is a schematic diagram of the overall structure of a monolithically cast high wear-resistant weld overlay plate disclosed in a preferred embodiment of this application; Figure 2 This is a schematic diagram of the overall exploded structure of a monolithically cast high wear-resistant weld overlay plate disclosed in a preferred embodiment of this application; Figure 3 This application discloses a preferred embodiment of a monolithically cast high wear-resistant weld overlay plate. Figure 2Enlarged structural diagram at point A in the middle; Figure 4 This application discloses a preferred embodiment of a monolithically cast high wear-resistant weld overlay plate. Figure 2 Enlarged structural diagram at point B; The following are the labels in the diagram: 1. Substrate; 11. Anti-slip strip; 2. Transition layer; 21. Hexagonal groove; 22. Arc-shaped groove; 23. Hexagonal protrusion; 3. Reinforcing layer; 4. Wear-resistant layer; 41. Rhomboid wear-resistant block; 42. Anti-slip texture; 5. Perforation; 6. Honeycomb reinforcing rib group; 61. Hexagonal frame; 62. Arc-shaped rib. Detailed Implementation
[0018] The present application will be further described in detail below with reference to the accompanying drawings. Reference Figures 1 to 4 This application provides an integrally cast high wear-resistant weld overlay plate, comprising: a weld overlay plate body, the weld overlay plate body having an overall arc-shaped structure, formed by centrifugal casting, and having multiple perforations 5 cast along the circumference; the weld overlay plate body having, from the outside to the inside, a base plate 1, a transition layer 2, a reinforcing layer 3, and a wear-resistant layer 4 sequentially arranged; a honeycomb-shaped reinforcing rib group 6 is arranged between the base plate 1 and the transition layer 2; and multiple rhomboid wear-resistant blocks 41 are fixed along the inner circumference of the wear-resistant layer 4. The weld overlay plate body, through its arc-shaped design, conforms to the curved surface of the equipment, reducing stress concentration; centrifugal casting makes the material distribution more uniform and dense, improving overall strength; and multiple perforations 5 are provided for bolting. The components are fixed for easy installation and positioning. The weld overlay plate body is provided with a base plate 1, a transition layer 2, a reinforcing layer 3 and a wear-resistant layer 4 from the outside to the inside, forming a gradient performance protection system. The base plate 1 serves as the basic load-bearing layer, the transition layer 2 achieves a smooth material transition to reduce the risk of interface cracking, the reinforcing layer 3 enhances the impact resistance, and the wear-resistant layer 4 directly contacts the material to provide high hardness protection. In addition, a honeycomb-shaped reinforcing rib group 6 is provided between the base plate 1 and the transition layer 2, which greatly improves the bending and torsional stiffness and optimizes the mechanical properties. Multiple rhomboid wear-resistant blocks 41 are fixed along the inner circumference of the wear-resistant layer 4. The contact area is optimized by geometric shape, reducing local pressure and extending service life.
[0019] Reference Figure 1 and Figure 2 Multiple anti-slip strips 11 are evenly fixed along the outer circumference of the substrate 1 and are evenly arranged along the arc surface of the substrate 1. The anti-slip strips 11 adopt a raised design to increase the friction with the mounting surface and prevent loosening and displacement caused by vibration. They are especially suitable for fixing equipment under high-frequency vibration conditions.
[0020] Reference Figure 1 and Figure 2The substrate 1 is made of Q235B carbon steel, the transition layer 2 is made of high manganese steel, the reinforcing layer 3 is made of chromium-molybdenum alloy, and the wear-resistant layer 4 is made of tungsten carbide particle-reinforced coating. The weld overlay plate body forms a progressive performance architecture through the substrate 1, transition layer 2, reinforcing layer 3, and wear-resistant layer 4. The substrate 1, made of Q235B carbon steel, has good plasticity and weldability, making it easy to process and shape. The transition layer 2, made of high manganese steel, absorbs impact energy by utilizing its work hardening properties. The reinforcing layer 3, made of chromium-molybdenum alloy, combines high-temperature strength and corrosion resistance. The wear-resistant layer 4, made of tungsten carbide particle-reinforced coating, significantly improves surface hardness through hard phase particle dispersion reinforcement. The resulting progressive performance architecture allows each layer to complement each other's advantages, achieving a gradual upgrade in protection from the substrate to the surface.
[0021] Reference Figure 2 and Figure 3 The honeycomb-shaped reinforcing rib group 6 includes multiple hexagonal frames 61 and multiple arc-shaped ribs 62 arranged in an array along the arc surface of the transition layer 2. The arc-shaped ribs 62 are connected in series to the multiple hexagonal frames 61. The honeycomb-shaped reinforcing rib group 6 is made of ductile iron. The honeycomb-shaped reinforcing rib group 6 is composed of multiple hexagonal frames 61 and multiple arc-shaped ribs 62 to form a topological structure that can imitate the high-efficiency load-bearing characteristics of natural honeycomb. It maximizes the structural stiffness while being lightweight. Moreover, the honeycomb-shaped reinforcing rib group 6 is made of ductile iron, which has a high elastic modulus and toughness and can effectively absorb dynamic loads and suppress crack propagation.
[0022] Reference Figure 2 and Figure 4 The transition layer 2 and the substrate 1 are provided with hexagonal grooves 21 and arc-shaped grooves 22 that match the honeycomb reinforcing rib group 6 on their adjacent arc surfaces. The transition layer 2 is fixed with hexagonal protrusions 23 in the hexagonal grooves 21. The interlocking design ensures that the reinforcing ribs and the main structure are closely matched by the hexagonal grooves 21 and arc-shaped grooves 22 that match the honeycomb reinforcing rib group 6 on both the transition layer 2 and the substrate 1, avoiding relative sliding. At the same time, the mechanical interlocking improves the connection reliability and enhances the shear resistance of the overall structure.
[0023] Reference Figure 2 and Figure 4 The inner wall of the wear-resistant layer 4 has ten rhomboid wear-resistant blocks 41 evenly distributed along the circumference. The long diagonal of each rhomboid wear-resistant block 41 forms a 15° angle with the radial direction. The rhomboid wear-resistant block 41 is set in an arc shape, and the inner arc surface is provided with anti-slip texture 42. Through the design of the long diagonal of the rhomboid wear-resistant block 41 forming a 15° angle with the radial direction, the rhomboid wear-resistant block 41 generates a self-locking effect when under load, reducing the displacement tendency. The arc shape fits the curvature radius of the equipment, ensuring the fit. The anti-slip texture 42 further increases the friction between the material and prevents abnormal wear caused by slippage.
[0024] Working principle: When in use, the body of this weld overlay plate is installed on the wear-prone parts of the material conveying equipment. When the material impacts, the tungsten carbide particle-reinforced coating in the outer wear-resistant layer 4 first bears the frictional loss, and the diamond-shaped wear-resistant blocks 41 on the inner arc surface of the wear-resistant layer 4 disperse the stress at a specific angle. The middle reinforcement layer 3 uses chromium-molybdenum alloy to provide support strength, while the high manganese steel material of the transition layer 2 buffers the impact energy. The base plate 1 on the outside uses Q235B carbon steel to ensure the rigidity of the foundation. A honeycomb-shaped reinforcing rib group 6 is set between the base plate 1 and the transition layer 2, and a mesh support system is formed inside the base plate 1 and the transition layer 2 to effectively transfer the load and suppress deformation. The weld overlay plate body has multiple perforations 5 along the arc surface to facilitate fixed installation. The anti-slip strips 11 and anti-slip textures 42 ensure that the installation is stable and reliable.
Claims
1. A monolithic cast high abrasion resistance hardfacing plate characterized by: It includes: a weld overlay plate body, the weld overlay plate body is an arc-shaped structure, formed by centrifugal casting, and has multiple perforations (5) along the circumference. The weld overlay plate body is provided with a base plate (1), a transition layer (2), a reinforcing layer (3) and a wear-resistant layer (4) from the outside to the inside. A honeycomb-shaped reinforcing rib group (6) is provided between the base plate (1) and the transition layer (2). Multiple rhomboid wear-resistant blocks (41) are fixed along the inner wall of the wear-resistant layer (4).
2. A monoblock cast high abrasion resistance hardfacing plate according to claim 1, characterized in that: The substrate (1) has multiple anti-slip strips (11) uniformly fixed along the outer circumference of the substrate (1) and uniformly arranged along the arc surface of the substrate (1).
3. The monoblock cast high abrasion resistance hardfacing plate according to claim 1, wherein: The substrate (1) is made of Q235B carbon steel, the transition layer (2) is made of high manganese steel, the reinforcing layer (3) is made of chromium-molybdenum alloy, and the wear-resistant layer (4) is made of tungsten carbide particle-reinforced coating. The weld overlay plate body forms a performance-progressive architecture through the substrate (1), transition layer (2), reinforcing layer (3) and wear-resistant layer (4).
4. The monoblock cast high abrasion resistance hardfacing plate of claim 1, wherein: The honeycomb reinforcing rib group (6) includes multiple hexagonal frames (61) arranged in an array along the arc surface of the transition layer (2) and multiple arc-shaped ribs (62). The arc-shaped ribs (62) are connected in series to the multiple hexagonal frames (61). The honeycomb reinforcing rib group (6) is made of ductile iron.
5. The monoblock cast high abrasion resistance hardfacing plate of claim 1, wherein: The transition layer (2) and the arc surface adjacent to the substrate (1) are provided with hexagonal grooves (21) and arc-shaped grooves (22) that match the honeycomb reinforcing rib group (6), and the transition layer (2) is fixed with hexagonal protrusions (23) in the hexagonal groove (21).
6. The monoblock cast high abrasion resistance hardfacing plate of claim 1, wherein: The wear-resistant layer (4) has ten rhomboid wear-resistant blocks (41) evenly distributed along the circumference on the inner wall. The long diagonal of each rhomboid wear-resistant block (41) forms a 15° angle with the radial direction. The rhomboid wear-resistant block (41) is arranged in an arc shape, and the inner arc surface is provided with anti-slip texture (42).