Method of making a wear tube and wear tube

Abstract

The application discloses a preparation method of a wear-resistant pipe and the wear-resistant pipe, and the preparation method comprises the following steps: S1, providing a base layer pipe; S2, welding or spraying a high-hardness wear-resistant material on the outer wall of the base layer pipe to form a wear-resistant layer; and S3, welding or spraying a metal material on the side of the wear-resistant layer, which is away from the base layer pipe, to form a support layer. By sequentially forming the wear-resistant layer and the support layer on the outer wall of the base layer pipe, the welding equipment or the spraying equipment is located outside the base layer pipe to perform construction, so that the preparation method is not affected by the pipe diameter of the base layer pipe, and the welding or spraying operation can be performed on the base layer pipe of any type. When the wear-resistant layer or the support layer welded or sprayed has a quality defect, the defect position can be directly repaired, so that the welding or spraying quality of the wear-resistant layer and the support layer is ensured, and then the machining quality of the whole wear-resistant pipe is ensured.

Description

Technical Field

[0001] This invention relates to the field of composite pipe manufacturing technology, and in particular to a method for preparing a wear-resistant pipe and a wear-resistant pipe made by the method. Background Technology

[0002] Wear-resistant pipes are composite metal pipes with high wear resistance, commonly used as dry sludge spray nozzles in waste incinerators. During the operation of a waste incinerator, dry sludge needs to be continuously transported into the furnace through dry sludge spray nozzles for extended periods at high flow rates. Therefore, the dry sludge causes wear to the inner wall of the nozzles during transport. Since high-hardness wear-resistant pipe materials cannot be manufactured through casting, existing wear-resistant pipes consist of a standard carbon steel pipe with a layer of high-hardness wear-resistant material welded to its inner wall to form a wear-resistant layer. This wear-resistant layer inside the carbon steel pipe absorbs the scouring effect from the dry sludge, thereby reducing the overall wear of the wear-resistant pipe and extending its service life. Existing wear-resistant pipes have the following shortcomings: 1) When the diameter of the wear-resistant pipe is small, such as pipes with a diameter of less than φ42, the welding equipment used for welding the wear-resistant layer cannot be inserted into the carbon steel pipe to perform the welding operation; 2) When the wear-resistant layer is welded inside the carbon steel pipe, if defects occur during the welding process, the defects cannot be repaired, which affects the overall performance of the wear-resistant pipe. Summary of the Invention

[0003] One objective of this invention is to provide a method for preparing wear-resistant pipes, which can process a wide range of pipe diameters and produce wear-resistant pipes with good overall processing quality.

[0004] Another objective of this invention is to provide a wear-resistant tube that is easy to manufacture and has excellent performance.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] A method for preparing a wear-resistant tube is provided, comprising the following steps:

[0007] Step S1: Provide the base pipe;

[0008] Step S2: Weld or spray a high-hardness wear-resistant material onto the outer wall of the base tube to form a wear-resistant layer;

[0009] Step S3: Weld or spray metal material onto the side of the wear-resistant layer away from the base tube to form a support layer.

[0010] Furthermore, in step S1, the outer wall of the base tube is polished.

[0011] Furthermore, in step S2, before welding or spraying the wear-resistant layer, the base tube is preheated at a temperature of 200℃-400℃.

[0012] Furthermore, a spraying device is provided, through which the wear-resistant layer is sprayed onto the base pipe;

[0013] Provide a welding equipment for welding the support layer onto the wear-resistant layer.

[0014] Furthermore, along the length of the base tube, the spraying equipment continuously applies the high-hardness wear-resistant material in a spiral pattern to the base tube from one end to the other; and / or,

[0015] Along the length of the base tube, the welding equipment continuously welds the metal material onto the wear-resistant layer in a spiral pattern from one end of the base tube to the other.

[0016] Furthermore, the wear-resistant layer is formed by multiple layers of welding or spraying, achieving the designed thickness, with each layer of welding or spraying having a thickness of 0.8-1.2 mm; and / or,

[0017] The support layer is formed by multiple layers of welding or spraying, and the support layer reaches the designed thickness, with each layer of welding or spraying having a thickness of 0.8-1.2 mm.

[0018] Furthermore, in step S3, the outer surface of the support layer is polished.

[0019] Furthermore, the thickness of the support layer is greater than or equal to the wall thickness of the base tube.

[0020] Furthermore, the high-hardness wear-resistant material includes iron-based materials, nickel-based materials, cobalt-based materials, or carbide hard phase materials.

[0021] A wear-resistant tube is also provided, which is made by the above-described method for preparing a wear-resistant tube.

[0022] The beneficial effects of this invention are as follows: By sequentially forming a wear-resistant layer and a support layer on the outer wall of the base pipe, the welding or spraying equipment is located outside the base pipe during welding or spraying, making the preparation method unaffected by the diameter of the base pipe and allowing welding and spraying operations to be performed on base pipes of any type. When quality defects occur in the welded or sprayed wear-resistant layer or support layer, the defective location can be directly repaired to ensure the welding and spraying quality of the wear-resistant layer and support layer, thereby ensuring the overall processing quality of the wear-resistant pipe. Attached Figure Description

[0023] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments.

[0024] Figure 1 This is a cross-sectional view of the wear-resistant tube according to an embodiment of the present invention.

[0025] Figure 2 This is a schematic diagram of the spraying equipment for applying a wear-resistant layer according to an embodiment of the present invention.

[0026] Figure 3 This is a schematic diagram of the welding support layer of the welding equipment according to an embodiment of the present invention.

[0027] In the picture:

[0028] 1. Base pipe; 2. Wear-resistant layer; 3. Support layer; 4. Spraying equipment; 41. Spraying gun head; 5. Welding equipment; 51. Welding gun head. Detailed Implementation

[0029] To make the technical problems solved by the present invention, the technical solutions adopted, and the technical effects achieved clearer, the technical solutions of the embodiments of the present invention will be further described in detail below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0030] like Figures 1 to 3 As shown, this invention provides a method for preparing a wear-resistant tube (hereinafter referred to as the preparation method), used to prepare a wear-resistant tube. The preparation method includes the following steps:

[0031] Step S1: Provide a base pipe 1. The base pipe 1 is made of carbon steel, alloy steel, etc., such as GB5310-20G, GB5310-15CrMo, GB5310-07Cr19Ni10. Polish the outer wall of the base pipe 1 to remove rust, scale, and other impurities. Polishing methods include: manual grinding, mechanical grinding with a grinding wheel, abrasive belt, or wire wheel, shot blasting, and sandblasting. After polishing, the base pipe 1 will have a metallic luster, and the surface will be free of rust and scale residue.

[0032] Step S2: Weld or spray a high-hardness wear-resistant material onto the outer wall of the base tube 1 to form a wear-resistant layer 2. The high-hardness wear-resistant material includes iron-based materials (e.g., JG-8), nickel-based materials (e.g., Ni60A), cobalt-based materials (e.g., Co01), or carbide hard phase materials (e.g., NiCr-Cr3C2, WC), etc.

[0033] Specifically, a spraying device 4 and a welding device 5 are provided. The spraying device 4 is used to apply a high-hardness wear-resistant material to the outer wall of the base tube 1 by spraying. The welding device 5 is used to apply the high-hardness wear-resistant material to the outer wall of the base tube 1 by welding. Both the welding and spraying processes are existing technologies. Welding is a special application of welding, which uses welding to change the thickness and surface texture of a metal material. In this embodiment, a high-hardness wear-resistant material can be applied to the outer wall of the base tube 1 by welding to form a wear-resistant layer 2 covering the outside of the base tube 1. The spraying process involves heating powder or wire-shaped material to a molten or melted state using a heat source, then atomizing it with a high-pressure, high-speed airflow and spraying it onto the surface of the part to form a coating layer. In this embodiment, a high-hardness wear-resistant material can be applied to the outer wall of the base tube 1 by spraying to form a wear-resistant layer 2 covering the outside of the base tube 1.

[0034] Specifically, before welding or spraying the wear-resistant layer 2, the base tube 1 is preheated at a temperature of 200℃-400℃. Preheating the base tube 1 improves the bonding performance between the wear-resistant layer 2 and the base tube 1, preventing cracking defects. In practical applications, the preheating temperature of the base tube 1 can be rationally selected based on the material properties of the high-hardness wear-resistant material. Preheating methods include flame heating or electromagnetic induction heating. The temperature of the base tube 1 should be monitored during preheating, welding, and spraying to ensure it remains within the set value and prevent overheating or insufficient preheating.

[0035] Step S3: Metal material is welded or sprayed onto the side of the wear-resistant layer 2 facing away from the base tube 1 to form the support layer 3. The metal material includes carbon steel (e.g., ER70S-6), alloy steel (e.g., ER80S-B2), and stainless steel (e.g., ER308, ER2594, ER316). The support layer 3 ensures the overall strength and rigidity of the wear-resistant tube and guarantees its normal use as a dry sludge spray pipe in the waste incinerator. Of course, if the material of the support layer 3 requires preheating during the spraying or welding process, the base tube 1 and wear-resistant layer 2 can be preheated before spraying or welding the support layer 3. After forming the support layer 3, its outer surface is polished to make the entire outer surface of the wear-resistant tube smooth for installation and use in the waste incinerator.

[0036] It is understood that the wear-resistant pipe manufactured by this method includes a base tube 1, a wear-resistant layer 2, and a support layer 3. The base tube 1 is located on the inner side of the wear-resistant pipe, the support layer 3 is located on the outer side of the wear-resistant pipe, and the wear-resistant layer 2 is located between the base tube 1 and the support layer 3. (Refer to...) Figure 1As shown, during the transport of the medium (dry sludge) within the wear-resistant pipe, the medium first erodes the inner base pipe 1. Since the base pipe 1 is made of ordinary carbon steel, its wear resistance is relatively weak. Over time, the base pipe 1 gradually thins and eventually disappears under the erosion of the medium. When the base pipe 1 is damaged or completely disappears, the medium erodes the wear-resistant layer 2 located in the middle layer of the wear-resistant pipe. Because the wear-resistant layer 2 is made of high-hardness wear-resistant material, it has strong wear resistance, extending the service life of the entire wear-resistant pipe. Simultaneously, by sequentially forming the wear-resistant layer 2 and the support layer 3 on the outer wall of the base pipe 1, during welding or spraying, the welding equipment 5 or the spraying equipment 4 is located outside the base pipe 1 for construction. This makes the preparation method unaffected by the pipe diameter of the base pipe 1, allowing welding and spraying operations to be performed on base pipes of any type. When quality defects occur in the wear-resistant layer 2 or support layer 3 that has been welded or sprayed, the defective location can be repaired directly to ensure the quality of the weld and spraying of the wear-resistant layer 2 and support layer 3, thereby ensuring the processing quality of the entire wear-resistant pipe.

[0037] Optionally, a wear-resistant layer 2 is formed by spraying a coating onto the base pipe 1 using a spraying device 4, and a support layer 3 is formed by welding a welding device 5 onto the wear-resistant layer 2. Spraying the coating onto the base pipe 1 first prevents surface melting due to high temperatures, reducing damage to the structure of the base pipe 1. Then, welding the support layer 2 improves the formation efficiency of the support layer 3, achieving both the goal of ensuring the processing quality of the wear-resistant pipe and improving processing efficiency.

[0038] Specifically, refer to Figure 2 As shown, Figure 2 The arrows in the diagram indicate the direction of movement of the base tube 1. The specific processing method for the wear-resistant layer 2 is as follows: The spraying equipment 4 includes a spray gun head 41 for outputting high-hardness wear-resistant material and a drive assembly for mounting and driving the base tube 1. The base tube 1 is mounted on the drive assembly, which drives the base tube 1 to rotate around its own axis and move relative to the spray gun head 41 along the length of the base tube 1. The spray gun head 41 is located on one side of the base tube 1. The high-hardness wear-resistant material, atomized by high-temperature and high-pressure airflow, is sprayed from the spray gun head 41 and deposited onto the outer wall of the base tube 1. Along the length of the base tube 1, the high-hardness wear-resistant material is continuously deposited on the base tube 1 in a spiral pattern from one end to the other to form the wear-resistant layer 2. It can be understood that, due to the continuous spraying of the high-hardness wear-resistant material from the spray gun head 41, the trajectory of the adhesion points of the high-hardness wear-resistant material on the base tube 1 is spiral-shaped under the rotation and movement of the base tube 1. This method ensures that the base tube 1 is heated evenly in the circumferential direction, thereby preventing the base tube 1 from bending and deforming due to uneven heating during spraying.

[0039] Specifically, refer to Figure 3 As shown, Figure 3The arrows in the diagram indicate the direction of movement of the base tube 1. The specific processing method for the support layer 3 is as follows: The welding equipment 5 includes a welding torch 51 for outputting metal material and a drive assembly for mounting and driving the movement of the base tube 1 (whose outer wall is covered with a wear-resistant layer 2). The base tube 1 is mounted on the drive assembly, which drives the base tube 1 to rotate around its own axis and move relative to the welding torch 51 along the length of the base tube 1. The welding torch 51 is located on one side of the base tube 1. Metal material is output from the welding torch 51 in the form of welding wire or welding strip and deposited onto the outer wall of the wear-resistant layer 2. Along the length of the base tube 1, the metal material is continuously deposited into the wear-resistant layer 2 in a spiral pattern from one end of the base tube 1 to the other to form the support layer 3. It can be understood that, due to the continuous output of metal material from the welding torch 51, the trajectory of the metal material's attachment point on the wear-resistant layer 2 is spiral-shaped under the rotation and movement of the base tube 1. This method ensures that the base tube 1 and the wear-resistant layer 2 are heated evenly in the circumferential direction, thereby preventing the base tube 1 from bending and deforming due to uneven heating during welding.

[0040] Optionally, the wear-resistant layer 2 and the support layer 3 can be welded or sprayed in multiple layers. In this embodiment, the thickness of each layer or spray is 0.8-1.2 mm. In practical applications, the actual number of welded or sprayed layers of the wear-resistant layer 2 and the support layer 3 is selected according to the design thickness of the wear-resistant layer 2 and the support layer 3. For example, when the design thickness of the wear-resistant layer 2 is 2 mm, it can be formed by welding or spraying two layers, with each layer having a thickness of 1 mm.

[0041] Optionally, the thickness of the support layer 3 is greater than or equal to the wall thickness of the base pipe 1. It is understood that the support layer 3 essentially serves to replace the base pipe 1 in the waste incinerator. Over time, the base pipe 1 may become damaged or even disappear due to erosion by the medium. Therefore, the support layer 3 provides support for the entire wear-resistant pipe. The thickness of the support layer 3 is not less than that of the base pipe 1, so that the support layer 3 has structural strength comparable to that of the base pipe 1 for installation and use.

[0042] Specifically, the thickness of the wear-resistant layer 2 can be determined by comprehensively considering the wear-resistant characteristics of the high-hardness wear-resistant material and the designed service life of the wear-resistant tube. The purpose is to allow the wear-resistant layer 2 to withstand the scouring effect of the medium inside the wear-resistant tube, thereby ensuring the overall performance of the wear-resistant tube 2 in the waste incinerator.

[0043] Optionally, after welding or spraying the wear-resistant layer 2, the wear-resistant layer 2 is inspected and any defects in it are repaired. Similarly, after welding or spraying the support layer 3, the support layer 3 is inspected and any defects in it are repaired.

[0044] The beneficial effects of this embodiment are as follows: By sequentially forming a wear-resistant layer 2 and a support layer 3 on the outer wall of the base pipe 1, and during welding or spraying, the welding equipment 5 or the spraying equipment 4 is located outside the base pipe 1 for construction, making the preparation method unaffected by the pipe diameter of the base pipe 1, and allowing welding and spraying operations to be performed on base pipes of any type. When quality defects occur in the welded or sprayed wear-resistant layer 2 or support layer 3, the defective location can be directly repaired to ensure the welding and spraying quality of the wear-resistant layer 2 and support layer 3, thereby ensuring the overall processing quality of the wear-resistant pipe.

[0045] like Figure 1 As shown, a wear-resistant pipe is also provided, manufactured by the above-described preparation method. The wear-resistant pipe includes a base pipe 1, a wear-resistant layer 2, and a support layer 3. The base pipe 1 is a carbon steel pipe, and the wear-resistant layer 2 is disposed on the outer wall of the base pipe 1, covering the entire outer wall of the base pipe 1. The support layer 3 is disposed on the side of the wear-resistant layer 2 facing away from the base pipe 1, and also covers the entire outer wall of the wear-resistant layer 2. Because the wear-resistant layer 2 and the support layer 3 are sequentially disposed on the outside of the base pipe 1, allowing for welding or spraying operations to be performed from the outside of the base pipe 1 to form the wear-resistant layer 2 and the support layer 3, the welding equipment 5 or the spraying equipment 4 is avoided from extending into the base pipe 1 for operation. Compared to the prior art method of forming the wear-resistant layer 2 on the inner wall of the base pipe 1, this wear-resistant pipe is easier to manufacture. Meanwhile, a wear-resistant layer 2 is formed on the outside of the base pipe 1, which facilitates the inspection and repair of the processing quality of the wear-resistant layer 2, so as to ensure the processing quality of the wear-resistant layer 2, ensure the overall wear resistance of the wear-resistant pipe during operation, and thus improve the performance of the entire wear-resistant pipe in the waste incinerator.

[0046] The above description is only a preferred embodiment of the present invention. For those skilled in the art, there will be changes in the specific implementation and application scope based on the ideas of the present invention. The content of this specification should not be construed as a limitation of the present invention.

Claims

1. A method for preparing a wear-resistant tube, characterized in that, Includes the following steps: Step S1: Provide the base pipe; Step S2: Weld or spray a high-hardness wear-resistant material onto the outer wall of the base tube to form a wear-resistant layer; Step S3: Weld or spray metal material onto the outer wall of the wear-resistant layer to form a new support layer; Provide a spraying device for spraying the wear-resistant layer onto the base pipe using the spraying device; Provide a welding equipment for welding the support layer onto the wear-resistant layer using the welding equipment; The thickness of the support layer is greater than or equal to the wall thickness of the base tube; The support layer can essentially replace the base tube in the waste incinerator.

2. The method for preparing the wear-resistant tube according to claim 1, characterized in that, In step S1, the outer wall of the base tube is polished.

3. The method for preparing the wear-resistant tube according to claim 1, characterized in that, In step S2, before welding or spraying the wear-resistant layer, the base tube is preheated at a temperature of 200℃-400℃.

4. The method for preparing the wear-resistant tube according to claim 1, characterized in that, Along the length of the base tube, the spraying equipment continuously applies the high-hardness, wear-resistant material in a spiral motion from one end to the other onto the base tube; and / or, Along the length of the base tube, the welding equipment continuously welds the metal material onto the wear-resistant layer in a spiral pattern from one end of the base tube to the other.

5. The method for preparing the wear-resistant tube according to claim 1, characterized in that, The wear-resistant layer is formed by multiple layers of welding or spraying, achieving the designed thickness, with each layer of welding or spraying having a thickness of 0.8-1.2 mm; and / or, The support layer is formed by multiple layers of welding or spraying, and the support layer reaches the designed thickness, with each layer of welding or spraying having a thickness of 0.8-1.2 mm.

6. The method for preparing the wear-resistant tube according to claim 1, characterized in that, In step S3, the outer surface of the support layer is polished.

7. The method for preparing the wear-resistant tube according to any one of claims 1 to 6, characterized in that, The high-hardness wear-resistant material includes iron-based materials, nickel-based materials, cobalt-based materials, or carbide hard phase materials.

8. A wear-resistant pipe, characterized in that, It is made by the method of preparing the wear-resistant tube according to any one of claims 1 to 7.

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