Processing technology of high-temperature-resistant hubbed flat welding flange

Abstract

The invention relates to the technical field of flange machining, and discloses a high-temperature-resistant hubbed flat welding flange machining technology which comprises the following steps that a high-performance high-temperature-resistant alloy material is selected; a multidirectional forging process is adopted; preliminarily forming the forged flange by using a laser cutting technology; the neck and the sealing face of the flange are finely machined through the electrolytic polishing technology; performing composite heat treatment; a method of combining ultrasonic flaw detection and magnetic powder flaw detection is adopted; preparing a nano ceramic coating on the surface of the flange; and a laser shock peening process is introduced. The processing technology of the high-temperature-resistant hubbed flat welding flange has remarkable advantages. By means of a series of advanced technologies and technological means, various performance indexes of the flange are improved, the flange can stably and reliably work in severe environments such as extreme high temperature, and the quality and safety of products are guaranteed.

Description

Technical Field

[0001] The present invention relates to the technical field of flange processing, and particularly to a processing technology for high-temperature resistant necked - on flat - welding flanges. Background Art

[0002] In modern industry, especially in equipment operating under harsh environments such as high temperature and high pressure, high - temperature resistant necked - on flat - welding flanges are key connecting components. However, traditional flange processing technologies often have some limitations.

[0003] In terms of material treatment, ordinary purification means are difficult to effectively remove tiny impurities and defects, affecting the purity and performance of materials. Forging processes may have problems such as uneven organizational structure and poor mechanical properties, and lack intelligent control. In surface treatment, traditional methods may not achieve ideal surface quality and sealing performance. The effect of heat treatment processes may not be ideal enough to fully optimize the properties of materials. Nondestructive testing technologies may not be accurate enough, resulting in some potential defects not being detected in a timely manner.

[0004] At the same time, traditional coating technologies may be insufficient in terms of properties such as high - temperature resistance, corrosion resistance, and wear resistance, and cannot meet the increasingly demanding usage requirements. Moreover, the fatigue life and stress corrosion resistance of flanges also need to be further improved. These problems have restricted the application of traditional high - temperature resistant necked - on flat - welding flanges in a wider range of fields and harsher environments, and cannot well meet the needs of the rapid development of modern industry for high - performance connecting components.

[0005] Therefore, to solve these problems in the prior art, there is an urgent need to develop an innovative processing technology for high - temperature resistant necked - on flat - welding flanges with better comprehensive performance to meet the continuous development needs of modern industry. The present invention emerges under such a background, aiming to overcome the deficiencies of the prior art and provide a more advanced and reliable processing technology to achieve the manufacture of high - performance high - temperature resistant necked - on flat - welding flanges. Summary of the Invention

[0006] (1) Technical Problems to be Solved

[0007] Aiming at the deficiencies of the prior art, the present invention provides a processing technology for high - temperature resistant necked - on flat - welding flanges to solve the above problems.

[0008] (2) Technical Solutions

[0009] To achieve the above - mentioned purpose, the present invention provides the following technical solutions: A processing technology for high - temperature resistant necked - on flat - welding flanges includes the following steps:

[0010] Select high-performance high-temperature resistant alloy materials, such as nickel-based alloys, and conduct ultrasonic purification treatment on them. The ultrasonic frequency is set at 25 MHz, and the treatment time is 40 minutes to remove impurities and micro-defects with a diameter of not less than 0.1 micron on the surface and inside of the materials;

[0011] Adopt the multi-directional forging process, combined with an intelligent temperature control system, and apply pressure in three directions. The pressure magnitudes are 120 MPa, 100 MPa, and 80 MPa respectively, to make the organizational structure of the material more uniform and dense; at the same time, add 0.8% of rare earth element cerium by total mass to the material to further improve the high-temperature resistance and oxidation resistance of the material; during the forging process, adjust the forging pressure and direction in real time according to the deformation of the material, and feedback data through pressure sensors and displacement sensors to achieve intelligent forging; precisely control the forging temperature between 1150 °C and 1250 °C to avoid performance degradation caused by overheating or overcooling of the material;

[0012] Use laser cutting technology to conduct preliminary shaping on the forged flange. The laser power is 600 W, and the cutting speed is 25 mm / s to improve the processing accuracy and efficiency;

[0013] Use electrolytic polishing technology to conduct fine processing on the neck and sealing surface of the flange. The polishing current density is 12 A / dm 2 , and the polishing time is 25 minutes; adopt a special electrolyte formula, including 35% phosphoric acid, 55% sulfuric acid, and 10% additives, to improve the polishing effect and surface quality, make the surface roughness reach below Ra0.15, and enhance the sealing performance;

[0014] Conduct composite heat treatment. First, conduct high-temperature solution treatment, hold at 1200 °C for 2.5 hours, then conduct rapid cooling, and the cooling rate is 60 °C / s. Then conduct low-temperature aging treatment, hold at 650 °C for 4.5 hours; the parameters such as temperature, time, and cooling rate during the composite heat treatment process are precisely optimized according to the characteristics of the material and the usage requirements of the flange, and precise control is achieved through the temperature control system and cooling device; improve the strength and toughness of the flange and enhance its high-temperature resistance;

[0015] Adopt a method combining ultrasonic flaw detection and magnetic particle flaw detection to conduct comprehensive detection on the heat-treated flange. The probe frequency of ultrasonic flaw detection is 12 MHz, and the magnetic field strength of magnetic particle flaw detection is 2500 Gauss to ensure no internal defects and surface cracks;

[0016] Prepare a nano-ceramic coating on the flange surface. This coating is deposited by plasma spraying technology. The power of plasma spraying is 35 kW, the powder feeding rate is 35 g / min, and the coating thickness is 120 microns. The main components of the coating are alumina and titanium oxide, and 4% of the total mass of carbon nanotubes is added. The diameter of the carbon nanotubes is 8 to 40 nanometers. It has excellent high-temperature resistance, corrosion resistance and wear resistance, and significantly improves the service life of the flange.

[0017] Introduce the laser shock peening process to form a residual compressive stress layer with a certain depth on the flange surface, and further improve the fatigue life and stress corrosion resistance of the flange. The parameters of laser shock peening are: laser energy is 8 J, pulse width is 10 ns, spot diameter is 3 mm, and the coverage rate is 80%.

[0018] As a preferred technical solution of the present invention, 0.5% of the total mass of rare earth element yttrium is added to the high-performance high-temperature alloy material to further improve the high-temperature resistance and oxidation resistance of the material.

[0019] As a preferred technical solution of the present invention, in the multi-directional forging process, the forging pressure and direction are adjusted in real time according to the deformation of the material, and data is fed back through pressure sensors and displacement sensors to achieve intelligent forging.

[0020] As a preferred technical solution of the present invention, in the electrolytic polishing technology, a special electrolyte formula is adopted, which contains 30% phosphoric acid, 50% sulfuric acid and 20% additives, to improve the polishing effect and surface quality.

[0021] As a preferred technical solution of the present invention, parameters such as temperature, time and cooling rate in the composite heat treatment process are precisely optimized according to the characteristics of the material and the usage requirements of the flange, and precise control is achieved through a temperature control system and a cooling device.

[0022] As a preferred technical solution of the present invention, carbon nanotubes are added to the nano-ceramic coating to enhance the toughness and bonding force of the coating. The diameter of the carbon nanotubes is 10 to 50 nanometers.

[0023] Compared with the prior art, the present invention provides a processing technology for high-temperature resistant necked flat welding flanges, which has the following beneficial effects:

[0024] Through ultrasonic purification treatment of high-performance high-temperature resistant alloy materials, impurities and microdefects on the surface and inside of the materials are effectively removed, improving the purity and quality of the materials and laying a good foundation for subsequent processing. The multi-directional forging process combined with an intelligent temperature control system and the addition of rare earth element cerium makes the material structure more uniform and dense, significantly improving the mechanical properties and high-temperature resistance of the material. At the same time, intelligent forging is realized, improving the processing accuracy and efficiency. The laser cutting technology ensures the initial forming accuracy and efficiency of the flange, providing an accurate blank for subsequent processing. The electrolytic polishing technology improves the surface quality of the flange neck and sealing surface, reduces the surface roughness, enhances the sealing performance, and ensures the sealing reliability of the flange during use. The composite heat treatment further optimizes the strength, toughness, and high-temperature resistance of the flange, adapting to various complex working environments. The flaw detection method ensures that the flange has no internal defects and surface cracks, improving the qualified rate and safety of the product. The preparation of the nano-ceramic coating improves the high-temperature resistance, corrosion resistance, and wear resistance of the flange, extending its service life. The laser shock peening process forms a residual compressive stress layer on the surface of the flange, effectively improving the fatigue life and stress corrosion resistance of the flange.

[0025] Generally speaking, the processing technology of the high-temperature resistant slip-on flange of the present invention has significant advantages. Through a series of advanced technologies and process means, not only are various performance indicators of the flange improved, enabling it to work stably and reliably in harsh environments such as extreme high temperatures, but also the quality and safety of the product are guaranteed. At the same time, the process has strong adaptability and operability, and can be flexibly adjusted and optimized according to different requirements and material characteristics, providing strong technical support for the wide application of high-temperature resistant slip-on flanges. This is of great significance for promoting the development of related industries, such as the petrochemical and energy fields, and helps to improve the overall industrial level and ensure the safe operation of key equipment. Brief Description of the Drawings

[0026] Figure 1 It is a schematic structural diagram of the present invention. Detailed Embodiments

[0027] The present invention will be further described in detail below with reference to the drawings and embodiments. Obviously, the described embodiments are only a part of the embodiments of the invention, rather than all of the embodiments. Without conflict, the embodiments in the present application and the features in the embodiments can be combined with each other. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the invention without creative efforts shall fall within the scope of protection of the invention.

[0028] In addition, "a plurality of" means more than two. In addition, the technical solutions between various embodiments can be combined with each other, but it must be based on the ability of those of ordinary skill in the art to implement. When the combination of technical solutions results in contradictions or cannot be implemented, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection required by the invention.

[0029] Please refer to Figure 1 , a processing technology for high-temperature resistant necked slip-on flanges:

[0030] Example 1:

[0031] Select high-performance high-temperature resistant nickel-based alloy materials and perform ultrasonic purification treatment on them. Set the ultrasonic frequency to 25 MHz and the treatment time to 40 minutes to remove impurities and microdefects with a diameter of not less than 0.1 micrometer on the surface and inside of the materials.

[0032] Adopt a multi-directional forging process and combine it with an intelligent temperature control system. Apply pressures of 120 MPa, 100 MPa, and 80 MPa in three directions respectively to make the organizational structure of the materials more uniform and dense. At the same time, add 0.8% of rare earth element cerium by total mass to the materials to improve their high-temperature resistance and oxidation resistance. During the forging process, according to the deformation of the materials, feedback data through pressure sensors and displacement sensors, and adjust the forging pressure and direction in real time to achieve intelligent forging. Precisely control the forging temperature between 1150 °C and 1250 °C.

[0033] Use laser cutting technology to perform preliminary shaping on the forged flanges. The laser power is 600 W and the cutting speed is 25 mm / s to improve the processing accuracy and efficiency.

[0034] Use electrolytic polishing technology to perform fine processing on the neck and sealing surface of the flanges. The polishing current density is 12 A / dm 2 , and the polishing time is 25 minutes. Adopt a special electrolyte formula containing 35% phosphoric acid, 55% sulfuric acid, and 10% additives to improve the polishing effect and surface quality, make the surface roughness reach below Ra0.15, and enhance the sealing performance.

[0035] Perform composite heat treatment. First, perform high-temperature solution treatment, hold at 1200 °C for 2.5 hours, then perform rapid cooling with a cooling speed of 60 °C / s, and then perform low-temperature aging treatment, hold at 650 °C for 4.5 hours. The parameters such as temperature, time, and cooling speed during the composite heat treatment process are precisely optimized according to the characteristics of the materials and the usage requirements of the flanges, and precise control is achieved through a temperature control system and a cooling device to improve the strength and toughness of the flanges and enhance their high-temperature resistance.

[0036] Adopt a method combining ultrasonic flaw detection and magnetic particle flaw detection to comprehensively detect the heat-treated flange. The probe frequency of ultrasonic flaw detection is 12 MHz, and the magnetic field strength of magnetic particle flaw detection is 2500 Gauss to ensure no internal defects and surface cracks.

[0037] Prepare a nano-ceramic coating on the flange surface. This coating is deposited by plasma spraying technology. The power of plasma spraying is 35 kW, the powder feeding rate is 35 g / min, and the coating thickness is 120 microns. The main components of the coating are alumina and titanium oxide, and 4% by total mass of carbon nanotubes with a diameter ranging from 8 nm to 40 nm are added. This coating has excellent high-temperature resistance, corrosion resistance, and wear resistance, which can significantly improve the service life of the flange.

[0038] Introduce the laser shock peening process to form a residual compressive stress layer with a certain depth on the flange surface, further improving the fatigue life and stress corrosion resistance of the flange. The parameters of laser shock peening are: laser energy is 8 J, pulse width is 10 ns, spot diameter is 3 mm, and the coverage rate is 80%.

[0039] Example 2:

[0040] The material selection and ultrasonic purification treatment are the same as in Example 1.

[0041] In the multi-directional forging process, the applied pressures are 110 MPa, 90 MPa, and 70 MPa respectively, and 0.8% by total mass of rare earth element cerium is added to the material. The intelligent control and temperature control during the forging process are the same as in Example 1.

[0042] The parameters of laser cutting remain unchanged.

[0043] In the electrolytic polishing technology, the polishing current density is 10 A / dm 2 , and the polishing time is 20 minutes. The electrolyte formula is 30% phosphoric acid, 50% sulfuric acid, and 20% additive.

[0044] The process of composite heat treatment is the same as in Example 1. The high-temperature solution treatment temperature is 1180 °C, the holding time is 2 hours, the cooling rate is 50 °C / s, and the low-temperature aging treatment temperature is 600 °C, the holding time is 4 hours.

[0045] The method and parameters of flaw detection are the same as in Example 1.

[0046] In the preparation of the nano-ceramic coating, the power of plasma spraying is 30 kW, the powder feeding rate is 30 g / min, and the coating thickness is 100 microns. 3% by total mass of carbon nanotubes with a diameter ranging from 10 nm to 40 nm are added to the coating composition.

[0047] The parameters of the laser shock peening process are as follows: the laser energy is 6 J, the pulse width is 8 ns, the spot diameter is 2 mm, and the coverage rate is 70%.

[0048] Example 3:

[0049] The material selection and ultrasonic purification treatment are the same as those in Example 1.

[0050] In the multi-directional forging process, the applied pressures are 130 MPa, 110 MPa, and 90 MPa respectively, and 0.8% of rare earth element cerium by total mass is added to the material. The intelligent control and temperature control during the forging process are the same as those in Example 1.

[0051] The parameters of the laser cutting remain unchanged.

[0052] In the electrolytic polishing technology, the polishing current density is 15 A / dm 2 , and the polishing time is 30 minutes. The electrolyte formula is 40% phosphoric acid, 60% sulfuric acid, and 10% additive.

[0053] The process flow of the composite heat treatment is the same as that in Example 1. The high-temperature solution treatment temperature is 1220 °C, the holding time is 3 hours, the cooling rate is 70 °C / s, the low-temperature aging treatment temperature is 700 °C, and the holding time is 5 hours.

[0054] The method and parameters of flaw detection are the same as those in Example 1.

[0055] In the preparation of the nano-ceramic coating, the power of plasma spraying is 40 kW, the powder feeding rate is 40 g / min, and the coating thickness is 150 microns. 5% of carbon nanotubes by total mass are added to the coating composition, and the diameter of the carbon nanotubes is 10 nm to 50 nm.

[0056] The parameters of the laser shock peening process are as follows: the laser energy is 10 J, the pulse width is 12 ns, the spot diameter is 4 mm, and the coverage rate is 90%.

[0057] The above are only the preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

[0058] For those skilled in the art, it is obvious that the present invention is not limited to the details of the above-described exemplary embodiments, and can be implemented in other specific forms without departing from the spirit or basic characteristics of the present invention. Therefore, from any point of view, the embodiments should be regarded as exemplary and non-limiting. The scope of the present invention is defined by the appended claims rather than the above description. Therefore, it is intended to embrace all changes within the meaning and scope of the equivalent elements of the claims in the present invention. Any reference signs in the claims should not be regarded as limiting the claimed rights.

[0059] In addition, it should be understood that although this specification is described according to embodiments, not every embodiment only contains an independent technical solution. This narrative way of the specification is only for clarity. Those skilled in the art should regard the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A processing technology for high-temperature resistant necked-in slip-on flanges Comprising, characterized in that, it comprises the following steps: Select a high-performance high-temperature resistant alloy material, such as nickel-based alloy, and perform ultrasonic purification treatment on it. The ultrasonic frequency is set to 25 MHz, and the treatment time is 40 minutes to remove impurities and micro-defects with a diameter of not less than 0.1 micron on the surface and inside of the material; Adopt a multi-directional forging process, combined with an intelligent temperature control system, apply pressure in three directions, and the pressure magnitudes are 120 MPa, 100 MPa, and 80 MPa respectively, to make the organizational structure of the material more uniform and dense; at the same time, add 0.8% of rare earth element cerium by total mass to the material to further improve the high-temperature resistance and oxidation resistance of the material; during the forging process, adjust the forging pressure and direction in real time according to the deformation of the material, and feedback data through pressure sensors and displacement sensors to achieve intelligent forging; precisely control the forging temperature between 1150 °C and 1250 °C to avoid performance degradation caused by overheating or overcooling of the material; Use laser cutting technology to perform preliminary shaping on the forged flange. The laser power is 600 W, and the cutting speed is 25 mm / s to improve processing accuracy and efficiency; The neck and sealing surface of the flange are finely processed using electrolytic polishing technology, with a polishing current density of 12 A / dm 2 , and the polishing time is 25 minutes; a special electrolyte formula is adopted, which contains 35% phosphoric acid, 55% sulfuric acid and 10% additives, to improve the polishing effect and surface quality, make the surface roughness reach below Ra0.15, and enhance the sealing performance; [[ID= ​ ​ ​ 2. The processing technology of a high-temperature resistant necked-in slip-on flange according to claim 1, characterized in that: ​ 3. A processing technology for high-temperature resistant necked-on slip-on flanges according to claim 1, characterized in that: ​ 4. A processing technology for high-temperature-resistant necked-in slip-on flanges according to claim 1, characterized in that: In the electrolytic polishing technology, a special electrolyte formulation is adopted, which contains 30% phosphoric acid, 50% sulfuric acid and 20% additives, to improve the polishing effect and surface quality.

5. The processing technology of a high-temperature resistant necked-in slip-on flange according to claim 1, characterized in that: In the composite heat treatment process, parameters such as temperature, time and cooling rate are precisely optimized according to the material characteristics and the usage requirements of the flange, and precise control is achieved through a temperature control system and a cooling device.

6. The processing technology of a high-temperature resistant necked-in slip-on flange according to claim 1, characterized in that: Carbon nanotubes are added to the nano-ceramic coating to enhance the toughness and bonding strength of the coating, and the diameter of the carbon nanotubes is 10 nanometers to 50 nanometers.

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