High-wear-resistance, corrosion-resistance and rotation-resistance steel wire rope and preparation method thereof

Abstract

The steel wire rope comprises an independent steel wire rope core, an inner-layer rope strand and an outer-layer rope strand from inside to outside, and the twisting directions of the inner-layer rope strand and the outer-layer rope strand are opposite to achieve rotation resistance. The outer-layer rope strand adopts a surface contact structure formed by a round core wire and a Z-shaped special-shaped steel wire, and a composite coating which takes nickel-phosphorus alloy as a matrix and is provided with tungsten carbide particles in a dispersed manner is arranged on the surface of the steel wire of the outer-layer rope strand. And meanwhile, the rope core and the inner-layer stranded steel wires adopt zinc-aluminum-magnesium alloy coatings. The preparation method comprises the key steps of steel wire coating treatment, stranding, reverse rope combining, pre-tensioning, pressurizing and lubricating and the like. By combining the unique structure, material and process, the problems of insufficient wear resistance and corrosion resistance and unstable structure in the prior art are comprehensively solved, the service life of the steel wire rope is remarkably prolonged, the safety performance of the steel wire rope is remarkably improved, and the steel wire rope is particularly suitable for severe working conditions such as heavy hoisting and ocean engineering.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of steel wire rope, in particular to a high wear-resistant corrosion-resistant anti-rotation steel wire rope and a preparation method thereof. BACKGROUND

[0002] Steel wire rope is widely used in key fields such as cranes, elevators, mine hoists, ship navigation and large bridges. Its performance is directly related to the safe operation and service life of the equipment. The steel wire rope of the prior art, especially the multi-layer strand anti-rotation steel wire rope, usually faces the following technical problems: 1. Insufficient wear resistance: under the working conditions of high-speed operation or frequent friction with pulleys and drums, the outer layer of steel wire is severely worn, resulting in a decrease in the diameter of the steel wire rope, a decrease in strength, and a shortening of the service life.

[0003] 2. Poor corrosion resistance: in harsh environments such as humidity, acid and alkali, or marine climate, the steel wire is prone to electrochemical corrosion, which not only reduces the effective cross-sectional area of the steel wire, but also causes stress corrosion cracking, causing safety hazards.

[0004] 3. Balance between structural stability and anti-rotation performance: in order to obtain anti-rotation performance, a multi-layer strand structure is usually used, but the stress distribution between the strands is uneven, and structural deformation and internal wire breakage are prone to occur under load, and the residual torsional stress is large, affecting the use precision and safety.

[0005] 4. Poor lubrication retention: traditional lubricating grease or lubricating oil is prone to loss or deterioration under high temperature and high pressure, and cannot provide continuous and effective lubrication and corrosion protection for the internal steel wire.

[0006] Therefore, there is an urgent need in the art for a new steel wire rope structure and manufacturing method that can simultaneously achieve excellent wear resistance, corrosion resistance, anti-rotation performance and long service life. SUMMARY

[0007] The purpose of the present application is to overcome the shortcomings of the prior art and provide a high-performance steel wire rope with reasonable structure design, excellent wear resistance and corrosion resistance, good anti-rotation performance and long service life, and a preparation method thereof.

[0008] To achieve the above-mentioned purpose, the technical solution adopted by the present application is: a high wear-resistant corrosion-resistant anti-rotation steel wire rope, the innovation point of which is that it comprises, from the inside to the outside: an independent steel wire rope core; one or more inner layer strands twisted around the independent steel wire rope core, the twist direction of the inner layer strands being the first direction; one or more outer layer strands twisted around the inner layer strands, the twist direction of the outer layer strands being opposite to the first direction; The outer layer strand is composed of a plurality of round-section core wires and profile-section steel wires filling and covering the core wires to form a surface contact structure; and the surface of the steel wires of the outer layer strand is provided with a tungsten carbide ceramic particle composite plating layer.

[0009] Further, the tungsten carbide ceramic particle composite plating layer takes nickel-phosphorus alloy as a matrix, wherein 25%-40% of tungsten carbide particles in volume percentage are dispersedly distributed.

[0010] Further, the average particle size of the tungsten carbide particles is 0.5-2 μm.

[0011] Further, the surface of the steel wires of the independent steel wire rope core and the inner layer strand is provided with a zinc-aluminum-magnesium alloy plating layer.

[0012] Further, the profile-section steel wire is a Z-shaped or T-shaped steel wire.

[0013] Further, the lay direction of the inner layer strand is right lay, and the lay direction of the outer layer strand is left lay.

[0014] A method for manufacturing a high-wear-resistance corrosion-resistance rotation-resistance steel wire rope, which has the following steps: a) preparing the steel wires of the independent steel wire rope core, the inner layer strand and the outer layer strand; b) performing chemical plating treatment on the steel wires for the outer layer strand to form the tungsten carbide ceramic particle composite plating layer on the surface thereof; c) twisting the treated steel wires into strands respectively; d) twisting the inner layer strand and the outer layer strand in opposite lay directions around the periphery of the independent steel wire rope core in sequence to form a steel wire rope; e) performing pre-tensioning treatment on the steel wire rope obtained in step d); f) performing pressurized lubrication treatment on the pre-tensioned steel wire rope.

[0015] Further, the chemical plating treatment in step b) is performed in a plating solution containing nickel salt, reducing agent and tungsten carbide particles, the reaction temperature is 85-95 ℃, and the reaction time is 1-3 hours.

[0016] Further, the pre-tensioning treatment in step e) applies a tension of 40%-60% of the minimum breaking tension of the steel wire rope, and the holding time is not less than 10 minutes.

[0017] The present application has the following advantages: Excellent wear resistance: the outer layer strand adopts the surface contact structure of Z-shaped profile-section steel wires and round steel wires, which increases the contact area and reduces the fretting wear. More importantly, the Ni-P-WC composite plating layer on the surface of the outer layer steel wires provides extremely high hardness and wear resistance, and the wear resistance is much higher than that of the traditional galvanized layer.

[0018] Excellent corrosion resistance: the zinc-aluminum-magnesium alloy coating on the core and inner layer strands has a "self-repairing" function that protects the cut and scratches by forming insoluble corrosion products, with a corrosion resistance life 3-5 times that of ordinary zinc plating. The Ni-P matrix of the outer layer strands also has excellent corrosion resistance.

[0019] Excellent resistance to rotation and structural stability: the structure of "independent metal core + inner layer strands (Z twist) + outer layer strands (S twist)" balances the moment of force through the opposite twist directions of the inner and outer layer strands, effectively resisting rotation under load. Pre-tensioning further eliminates the residual stress from twisting, making the structure more stable.

[0020] Long-term internal lubrication and corrosion protection: the pressurized immersion lubrication process ensures that the lubricating grease reaches the innermost part of the wire rope, combined with the coating on the surface of each steel wire, forming a "coating corrosion protection + grease corrosion protection and lubrication" double protection system, greatly extending the overall life of the wire rope.

[0021] High strength and toughness: by optimizing the carbon content of each layer of steel wire and using pre-tensioning process, the wire rope maintains high strength while also having good toughness and fatigue resistance. BRIEF DESCRIPTION OF DRAWINGS

[0022] Figure 1 The structure of the present application is shown in the figure.

[0023] Explanation of reference signs: 1 - independent steel wire core; 2 - inner layer strand; 3 - outer layer strand; 31 - round section core wire; 32 - Z-shaped profiled steel wire; 4 - Ni-P-WC composite coating. DETAILED DESCRIPTION

[0024] The present application will be further described below with reference to the accompanying drawings.

[0025] In order to make the purpose, technical solutions and advantages of the present application clearer and more apparent, the present application will be further described in detail below with reference to the accompanying drawings and specific embodiments. It should be understood that the specific embodiments described herein are only used to explain the present application and do not limit the present application. EMBODIMENT

[0026] A high wear-resistant, corrosion-resistant and anti-rotation steel wire rope with a diameter of 28 mm is prepared.

[0027] Structure: Independent steel wire core 1: 1x7 structure, steel wire diameter 1.8 mm, material 82B high carbon steel, hot-dip plated Zn-5%Al-0.1%Mg alloy, coating weight 200g / m².

[0028] The inner layer has 2:9 strands, each strand has a 1×19 structure, the wire diameter is 1.2mm, the material is 77A high carbon steel, hot-dip galvanized with Zn-5%Al-0.1%Mg alloy, the coating weight is 150g / m², and the twist direction is right twist (Z).

[0029] The outer layer consists of 3 to 16 strands, with each strand containing 6 round core wires (31) and 10 Z-shaped steel wires (32). The steel wires are made of 82B high-carbon steel. The surface is coated with a Ni-P-WC composite layer (4) with a thickness of approximately 25 μm, containing tungsten carbide particles with an average diameter of 1 μm and a volume percentage of approximately 35%. The twist direction is left-handed (S).

[0030] Preparation method: 1. Prepare steel wires of various specifications according to conventional drawing processes.

[0031] 2. The core and inner strands of the rope are hot-dip galvanized with aluminum-magnesium alloy.

[0032] 3. Chemical plating of the outer strands of steel wire: The main components of the plating solution are nickel sulfate 25g / L, sodium hypophosphite 30g / L, complexing agents (sodium citrate, lactic acid), stabilizers, and uniformly suspended tungsten carbide particles (40g / L). The pH is controlled at 4.8, the temperature at 90℃, and the time at 2 hours.

[0033] 4. Twist the core, inner strands and outer strands separately on the twisting machine.

[0034] 5. On the rope-making machine, the inner strand (Z-twist) and the outer strand (S-twist) are twisted onto the outside of the rope core in sequence, and the twist ratio is set to 8.

[0035] 6. After the rope is assembled, apply a tension of 450kN (approximately 50% of its MBL) to the wire rope on the tensioning device for 15 minutes.

[0036] 7. Finally, the wire rope is lubricated by passing it through a pressure impregnation tank (pressure 0.8MPa) filled with VG460 polyurea-based high-temperature grease.

[0037] Comparative Example The commercially available 35W×7 anti-rotation steel wire rope of the same specification, ordinary galvanized, and line contact structure is selected.

[0038] Performance testing The steel wire rope prepared in Example 1 of this invention was compared with the comparative example steel wire rope in terms of performance according to standards such as GB / T 20118 and GB / T 24191. The results are as follows: Test items Example 1 of the present application Comparative example (35W x 7) Minimum breaking load (MBL) 900 kN 880 kN Rotating rate (at 10% MBL) 0.8 ° / m 1.5 ° / m Abrasion test (mass loss after reciprocating friction 10Λ5 times) 15 mg 65 mg Salt spray test (3000 hours) No red rust on surface, plating layer intact Large area of red rust appeared on surface Fatigue test (under 30% MBL load) > 5 million times ~ 0.3 million times Test results show that the wire rope of this invention is significantly superior to traditional products in terms of breaking strength, anti-rotation, wear resistance, corrosion resistance and fatigue life.

[0039] The above merely explains the technical solutions of the present application but not limit the present application. Other modifications or equivalent replacements of the technical solutions of the present application made by those skilled in the art should be covered in the scope of claims of the present application as long as they do not depart from the spirit and scope of the technical solutions of the present application.

Claims

1. A high wear-resistant, corrosion-resistant, and anti-rotation steel wire rope, characterized in that, From the inside out, it includes: A single wire rope core (1); One or more inner strands (2) are twisted around the independent steel wire rope core (1), and the twist direction of the inner strands (2) is the first direction; An outer layer of rope (3) is twisted around the inner layer of rope (2) in one or more layers, and the twist direction of the outer layer of rope (3) is opposite to the first direction; The outer strand (3) is composed of multiple circular cross-section core wires (31) and irregular cross-section steel wires (32) that fill and cover the core wires (31) to form a surface contact structure; and the surface of the steel wires of the outer strand (3) is provided with a tungsten carbide ceramic particle composite coating (4).

2. The high wear-resistant, corrosion-resistant, and anti-rotation steel wire rope according to claim 1, characterized in that: The tungsten carbide ceramic particle composite coating (4) uses a nickel-phosphorus alloy as a matrix, wherein tungsten carbide particles with a volume percentage of 25%-40% are dispersed.

3. The high wear-resistant, corrosion-resistant, and anti-rotation steel wire rope according to claim 2, characterized in that: The average particle size of the tungsten carbide particles is 0.5-2 μm.

4. The high wear-resistant, corrosion-resistant, and anti-rotation steel wire rope according to claim 1, characterized in that: The surfaces of the independent wire rope core (1) and the inner strands (2) are coated with a zinc-aluminum-magnesium alloy.

5. The high wear-resistant, corrosion-resistant, and anti-rotation steel wire rope according to claim 1, characterized in that: The irregular cross-section steel wire (32) is a Z-shaped or T-shaped steel wire.

6. The high wear-resistant, corrosion-resistant, and anti-rotation steel wire rope according to claim 1, characterized in that: The inner strand (2) is twisted to the right, and the outer strand (3) is twisted to the left.

7. A method for preparing a high wear-resistant, corrosion-resistant, and anti-rotation steel wire rope as described in any one of claims 1-6, characterized in that, Includes the following steps: a) The steel wires used to prepare the independent steel wire rope core (1), inner strands (2) and outer strands (3); b) Chemical plating is performed on the steel wire used for the outer strand (3) to form the tungsten carbide ceramic particle composite coating (4) on its surface. c) Twist the treated steel wires into strands; d) The inner strand (2) and outer strand (3) are twisted in opposite directions around the independent wire rope core (1) to form a wire rope; e) Pre-tension the wire rope obtained in step d); f) Apply pressure lubrication to the pre-tensioned wire rope.

8. The high wear-resistant, corrosion-resistant, and anti-rotation steel wire rope according to claim 1, characterized in that: The electroless plating process in step b) is carried out in a plating solution containing nickel salt, reducing agent and tungsten carbide particles, at a reaction temperature of 85-95℃ and a reaction time of 1-3 hours.

9. The high wear-resistant, corrosion-resistant, and anti-rotation steel wire rope according to claim 1, characterized in that: The tension applied during the pre-tensioning process in step e) is 40%-60% of the minimum breaking strength of the wire rope, and the holding time is not less than 10 minutes.

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