A wear-resistant precast slab and wear-resistant sheet

Abstract

This invention provides a wear-resistant precast slab and a wear-resistant sheet. The wear-resistant precast slab includes a wear-resistant body and a cast body. The wear-resistant bodies are distributed in a predetermined layout. The cast body includes a base layer disposed on the lower surface of multiple wear-resistant bodies and a filling portion filling the gaps between the multiple wear-resistant bodies. The cast body covers the lower surface and sides of the multiple wear-resistant bodies, forming a semi-enclosed structure, which increases the stability of the composite of the wear-resistant body and the cast body and reduces the probability of the wear-resistant bodies falling off under operating conditions. Simultaneously, the cast body serves to support and protect the wear-resistant bodies, and also acts as a connecting or mounting component for the wear-resistant sheet. The wear-resistant bodies, as the main wear-resistant material, are arranged in both the surface and deep layers of the wear-resistant sheet, ensuring consistent wear resistance and hardness between the surface and deep layers, maintaining high wear resistance and hardness, extending the replacement cycle of the wear-resistant sheet, and reducing production costs. The wear-resistant sheet is formed by assembling multiple wear-resistant precast slabs.

Description

Technical Field

[0001] This invention relates to the field of wear-resistant plate technology, specifically to a wear-resistant precast plate and a wear-resistant plate comprising the wear-resistant precast plate. Background Technology

[0002] Wear-resistant steel plates are special steel plate products designed for use under conditions of large-area wear. They are widely used in industries such as metallurgy, coal, cement, power, glass, mining, building materials, and brick and tile manufacturing. Commonly used wear-resistant steel plates typically use ordinary low-carbon steel or low-alloy steel with good toughness and plasticity as the base material. A certain thickness of alloy wear-resistant layer with high hardness and excellent wear resistance is then laminated onto the surface through a welding method. The alloy wear-resistant layer generally accounts for 1 / 3 to 1 / 2 of the total thickness. During operation, the low-carbon steel plate acts as the base material, providing comprehensive properties such as strength, toughness, and plasticity against external forces, while the alloy wear-resistant layer provides the wear resistance required for the specified working conditions. Additionally, cast wear-resistant steel plates are also available.

[0003] However, the wear-resistant plate formed by combining low-carbon steel plate and alloy wear-resistant layer is only a single-sided composite layered structure. Under actual operating conditions, its stability is insufficient, leading to partial detachment of the welded alloy wear-resistant layer, affecting the service life of the wear-resistant plate. Furthermore, the production cost of welding is relatively high. As for cast wear-resistant plates, their hardness and wear resistance are generally increased through quenching. However, the quenching effect often gradually decreases with increasing thickness; that is, the hardness and wear resistance of the deeper layers of the wear-resistant plate are lower than that of the surface layer. This means that once the surface layer of the cast wear-resistant plate is worn, the hardness and wear resistance of its deeper structure decrease significantly. Summary of the Invention

[0004] The purpose of this invention is to solve the problems mentioned in the background art and to provide a composite wear-resistant plate in which a metal casting material is partially covered with a wear-resistant material.

[0005] The present invention adopts the following technical solution: a wear-resistant precast plate, comprising a wear-resistant body and a casting body, wherein a plurality of the wear-resistant bodies are distributed in a predetermined layout, the casting body comprises a base layer and a filling part, the base layer is disposed on the lower surface of the plurality of wear-resistant bodies, and the filling part fills the gap between the plurality of wear-resistant bodies.

[0006] Furthermore, the predetermined layout distribution includes at least one of an array distribution, a discrete distribution, or a random distribution.

[0007] Furthermore, the wear-resistant material is granular or blocky.

[0008] Furthermore, the wear-resistant body has a polyhedral structure, and at least one surface of the polyhedral structure is a plane or an arc surface; the wear-resistant prefabricated plate is a flat plate or a curved plate.

[0009] Furthermore, the wear-resistant body includes a non-metallic wear-resistant body and a coating layer covering the surface of the non-metallic wear-resistant body, wherein the coating layer includes at least a cemented carbide coating layer.

[0010] Furthermore, the non-metallic wear-resistant body is composed of one or a mixture of several of the following monomers: silicon carbide, boron carbide, chromium carbide, molybdenum carbide, aluminum oxide, silicon nitride, titanium carbide, zirconium oxide, or tungsten carbide.

[0011] Furthermore, at least one surface of the wear-resistant body is provided with a mating groove, and the casting body has a corresponding protrusion at the corresponding position, the protrusion of the casting body filling the corresponding mating groove.

[0012] Furthermore, the lower surface of the wear-resistant body is provided with the mating groove, the depth or width of the mating groove near the edge of the wear-resistant body is less than the depth or width away from the edge of the wear-resistant body, or the width of the mating groove near the lower surface of the wear-resistant body is less than the width away from the lower surface of the wear-resistant body.

[0013] Furthermore, the structure of the connecting groove includes at least one of a T-shaped groove, a dovetail groove, or a trapezoidal groove.

[0014] Furthermore, at least one end of the groove extends out of the side of the wear-resistant body.

[0015] Furthermore, the wear-resistant body and the cast body are made of different materials, the wear resistance of the wear-resistant body is higher than that of the cast body, and the melting point of the wear-resistant body is higher than that of the cast body; the cast body in the wear-resistant precast plate is formed by casting together with multiple wear-resistant bodies.

[0016] Furthermore, the casting is made of at least one of cast iron material, alloy material, wear-resistant and heat-resistant material, wear-resistant and corrosion-resistant material, or wear-resistant, heat-resistant and corrosion-resistant material.

[0017] Furthermore, the filling part and the base layer are made of different materials, and the material used in the filling part has at least one of the properties of wear resistance, heat resistance or corrosion resistance that is higher than that of the material used in the base layer.

[0018] Furthermore, a wear-resistant plate includes two sets of wear-resistant precast plates, the two sets of wear-resistant precast plates being arranged back to back of each other, and their base layers being welded together.

[0019] Furthermore, a wear-resistant plate includes at least two wear-resistant precast plates and a second casting body. The wear-resistant precast plates are arranged in an array. The second casting body includes a second base layer and a second filling part. The second base layer is disposed on the lower surface of the wear-resistant precast plate, and the second filling part is disposed in the gap between multiple wear-resistant precast plates. The second base layer and the second filling part are formed by casting.

[0020] The wear-resistant precast plate of this invention has the following beneficial effects: the cast body covers the lower surface and sides of multiple wear-resistant bodies, forming a semi-enclosed structure, which increases the stability of the composite of wear-resistant bodies and the cast body, reduces the probability of wear-resistant bodies falling off under operating conditions, extends the service life of the wear-resistant plate, and the casting production method has relatively low production costs. Meanwhile, the cast body serves to support and protect the wear-resistant bodies, and also acts as a connecting or mounting component for the wear-resistant plate. The wear-resistant bodies, as the main wear-resistant material, are arranged in both the surface and deep layers of the wear-resistant plate, ensuring consistent wear resistance and hardness between the surface and deep layers, maintaining high wear resistance and hardness, extending the replacement cycle of the wear-resistant plate, and reducing production costs. Attached Figure Description

[0021] Appendix Figure 1 This is a schematic diagram of the structure of a planar wear-resistant precast slab in this invention;

[0022] Appendix Figure 2 This is an appendix to the present invention. Figure 1 A schematic diagram of the cross-sectional structure of a local area of ​​the mid-plane wear-resistant precast slab;

[0023] Appendix Figure 3 This is a schematic diagram of the structure of a curved wear-resistant precast slab in this invention;

[0024] Appendix Figure 4 This is a schematic diagram showing the structure and location of the first type of connecting groove 11 in this invention;

[0025] Appendix Figure 5 This is a schematic diagram showing the structure and location of the second type of connecting groove 11 in this invention;

[0026] Appendix Figure 6 This is a schematic diagram of the structure and location of the third type of connecting groove 11 in this invention;

[0027] Appendix Figure 7 This is a schematic cross-sectional view of a casting mold according to the present invention;

[0028] Appendix Figure 8 This is a schematic diagram of the structure of a wear-resistant plate in this invention;

[0029] Appendix Figure 9 This is a schematic diagram of another wear-resistant plate material in this invention;

[0030] Appendix Figure 10 This is a real photo of a planar wear-resistant precast slab formed by casting multiple wear-resistant bodies 1 and casting bodies 2.

[0031] The reference numerals in the attached drawings are explained as follows: wear-resistant body 1, bonding groove 11, casting body 2, base layer 21, filling part 22, moving mold 3, mold cavity 31, pouring channel 32, fixed mold 4. Detailed Implementation

[0032] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort. The invention will be further described below in conjunction with the drawings:

[0033] Example 1

[0034] Refer to the instruction manual appendix Figure 1-3 In this embodiment, the wear-resistant precast plate includes multiple wear-resistant bodies 1 and casting bodies 2.

[0035] The wear-resistant body 1 is granular or blocky and has a polyhedral structure, wherein the polyhedral structure includes an upper surface, a lower surface and one or more side surfaces. The upper surface, lower surface and side surfaces are planar or curved surfaces. For example, the wear-resistant body 1 is a columnar structure, and the attached figure in the specification shows a quadrangular prism structure.

[0036] Multiple wear-resistant bodies 1 are arranged in an array, discretely, or randomly, with gaps between adjacent wear-resistant bodies 1. The casting body 2 includes a filling part 22 located within the gaps between the multiple wear-resistant bodies 1 and a base layer 21 located on the lower surface of the multiple wear-resistant bodies 1, thereby forming a semi-enclosed structure in which the casting body 2 covers the lower surface and sides of the multiple wear-resistant bodies 1. The filling part 22 and the base layer 21 are formed by casting metal material, so that the multiple wear-resistant bodies 1 and the casting body 2 are combined to form a plate. The base layer 21 serves as a connecting layer or mounting layer for the wear-resistant precast plate. The upper surface of the wear-resistant bodies 1 and the wear-resistant precast plate is the wear-resistant working surface, which is the contact surface that bears the direct wear of materials.

[0037] In this embodiment, the wear-resistant precast slab is a flat plate structure or a curved plate structure, as shown in the appendix of the instruction manual. Figure 1 When the wear-resistant precast slab is a flat plate structure, multiple wear-resistant bodies 1 are distributed in a planar array, and the upper surface of each wear-resistant body 1 is flat. (Refer to the attached instruction manual.) Figure 3 When the wear-resistant precast slab is a curved panel structure, multiple wear-resistant bodies 1 are distributed in an array along the curved surface, and the upper surface of the wear-resistant body 1 is a curved surface.

[0038] In the wear-resistant precast slab, the function of the cast body 2 is to support and protect the wear-resistant body 1, with the wear-resistant body 1 bearing the main wear-resistant function. The wear-resistant body 1 and the cast body 2 are made of different materials. The wear resistance of the wear-resistant body 1 is higher than that of the cast body 2, and the melting point of the wear-resistant body 1 is higher than that of the cast body 2, ensuring that the wear-resistant body 1 will not melt locally or entirely during the casting process of the cast body 2.

[0039] The casting 2 is made of cast iron or alloy materials, specifically cast iron, alloy cast iron, ductile iron, or alloys. The wear-resistant body 1 includes a non-metallic wear-resistant body and a hard alloy coating layer covering the surface of the non-metallic wear-resistant body. The hard alloy coating layer not only prevents the reaction between the non-metallic wear-resistant body and the steel, but also solves the problem of the difficulty in achieving a stable composite between the non-metallic wear-resistant body and the steel.

[0040] Specifically, the non-metallic wear-resistant body is composed of one or a mixture of several of the following monomers: silicon carbide, boron carbide, chromium carbide, molybdenum carbide, alumina, silicon nitride, titanium carbide, zirconium oxide, or tungsten carbide, with silicon carbide being the preferred choice. Silicon carbide has a hardness second only to diamond and possesses strong wear resistance, with a service life 5-20 times that of cast iron. Furthermore, it has a lower cost per unit volume, making it a cost-effective wear-resistant material.

[0041] The cemented carbide coating is a cemented carbide powder slurry. The preparation method of the cemented carbide powder slurry and its coating on the surface of the non-metallic wear-resistant body is as follows:

[0042] ① Preparation of cemented carbide powder slurry

[0043] A certain proportion of cemented carbide powder, solvent, organic functional monomer, initiator, dispersant and thickener are added into a ball mill and ball-milled for a certain time to obtain cemented carbide powder slurry.

[0044] The cemented carbide powder comprises a hard phase powder and a binder phase powder. The hard phase powder includes, but is not limited to, one or more of the following: WC powder, TiC powder, titanium carbonitride (Ti(C,N)) powder, NbC powder, or TaC powder. The binder phase powder includes, but is not limited to, one or more of the following: Co powder, Ni powder, FeCo powder, or FeNi alloy powder. The cemented carbide powder accounts for 40% to 99% of the total weight of the slurry; the weight ratio of the hard phase powder to the binder phase powder is 1:10 to 100:0.1, preferably 1:10 to 10:1. Preferably, the combined mass of the hard phase powder and the binder phase powder accounts for 40% to 70% of the total mass of the cemented carbide powder slurry.

[0045] The solvent is alcohol, acetone, toluene, or a mixture thereof.

[0046] The organic functional monomers include, but are not limited to, one or more of the following: 1,6-hexanediol diacrylate, pentaerythritol hexaacrylate, hydroxyethyl acrylate, trimethylolpropane triacrylate, pentaerythritol triacrylate, pentaerythritol tetraacrylate, and acrylic acid. The organic functional monomers mentioned in this invention refer to organic compounds capable of forming polymers with an initiator under thermal or photoinitiation conditions.

[0047] The initiator is either a thermal initiator or a photoinitiator. The thermal initiator is one or more of the following, but not limited to: benzoic acid peroxide, azobisisobutyronitrile, sodium azobiscyanopentate, sodium azo(2-(2-imidazoline)propane)hydrochloride, and azo(2-amidinylpropane)hydrochloride. The photoinitiator is one or more of the following, but not limited to: 1-hydroxycyclohexylphenyl ketone, trimethylbenzoyl-diphenylphosphine oxide, and phenylbis(2,4,6-trimethylbenzoyl)phosphine oxide. The amount of initiator added is 0.01% to 10% of the weight of the organic monomer. The initiator is added last, 0.01 h to 1 h before discharge.

[0048] The dispersant is one or more of ZN-1344, SP-710, and SP-6000, but is not limited to these. The amount of dispersant added is 0.01% to 10% of the weight of the cemented carbide powder.

[0049] The thickener is one or more of carboxymethyl cellulose (CMC), polyvinyl alcohol (PVA), polyvinyl butyral (PVB), and polyacrylamide (PAM), but is not limited to these. The amount of thickener added is 0.01% to 20% of the solvent weight.

[0050] The ball mill may be a drum ball mill or a planetary ball mill, but is not limited to these. The grinding balls are cemented carbide balls. The ball-to-material ratio is 1:10 to 10:1. The ball milling time is 0.1 h to 50 h.

[0051] The cemented carbide layer is WC-Co, WC-Ni, TiC-Fe, or Ti(C,N)-Ni, but is not limited to these. The thickness of the cemented carbide layer is 0.01 mm to 100 mm.

[0052] ② Preparation of cemented carbide wear-resistant body 1

[0053] The process includes: coating the surface of the wear-resistant body 1 with cemented carbide powder using dip-coating or spraying methods; then placing the wear-resistant body 1 into a sintering furnace and performing metal degreasing and sintering through thermal or photo-initiation to obtain the wear-resistant body 1 coated with a cemented carbide layer: wear-resistant body 1@cemented carbide. This step can be completed in the following manner:

[0054] Method 1

[0055] (1) Immersion method

[0056] (1.1) Thermal initiation method: If the initiator added in step S1 is a thermal initiator, the wear-resistant body 1 is immersed in the cemented carbide powder slurry prepared in step 1 for 0.1 min to 60 min, then removed and placed in an oven at 50 to 100°C for baking for 0.01 h to 12 h. The organic matter in the slurry undergoes a polymerization reaction under the action of the initiator, coating the wear-resistant body 1. The coating thickness is controlled within the range of 0.01 mm to 100 mm. If the coating thickness does not meet the standard, the immersion process is repeated or the following spraying method is performed.

[0057] (1.2) Photoinitiation method: If the initiator added in step S1 is a photoinitiator, the wear-resistant body 1 is immersed in the cemented carbide powder slurry prepared in step 1 for 0.1 min to 60 min, then removed and placed in an ultraviolet oven for irradiation for 0.01 h to 12 h. The organic matter in the slurry undergoes a polymerization reaction under the action of the initiator, coating the wear-resistant body 1. The coating thickness is controlled within the range of 0.01 mm to 100 mm. If the coating thickness does not meet the standard, the immersion process is repeated or the following spraying method is performed.

[0058] Preferably, the cemented carbide powder slurry is subjected to vacuum degassing treatment before impregnation.

[0059] Preferably, the dip-coating method is suitable for wear-resistant bodies 1 with smaller dimensions, such as granular or spherical materials.

[0060] Method 2

[0061] (2) Spraying method

[0062] (2.1) If the initiator added in step S1 is a thermal initiator, the hard alloy slurry is uniformly sprayed onto the surface of the wear-resistant body 1 using a spray bottle, and then placed in an oven at a temperature of 50-100°C for baking for 0.01-12 hours. The organic matter in the slurry reacts and coats the wear-resistant body 1. The coating thickness is controlled within the range of 0.01-100 mm. If the coating thickness does not meet the standard, the dipping process is repeated or the spraying method described below is performed.

[0063] (2.2) If the initiator added in step S1 is a photoinitiator, the hard alloy slurry is uniformly sprayed onto the surface of the wear-resistant body 1 using a spray bottle, and then placed in an ultraviolet oven for irradiation for 0.01h to 12h. The organic matter in the slurry reacts and coats the wear-resistant body 1. The coating thickness is controlled within the range of 0.01mm to 100mm. If the coating thickness does not meet the standard, the dipping process is repeated or the spraying method described below is performed.

[0064] Preferably, the hard alloy slurry is subjected to vacuum degassing treatment before spraying.

[0065] Preferably, the spraying method is suitable for larger wear-resistant bodies 1, such as columnar structures, conical structures, slatted structures, and sheet-like structures.

[0066] When wear-resistant precast plates are used directly as wear-resistant plates, such as as liners in ball mills, the base layer 21 can be fixed to the target area of ​​the inner wall of the ball mill cylinder by welding, riveting, or connecting with nuts and bolts. Simultaneously, the upper surface of the wear-resistant body 1 contacts the material to be ground inside the cylinder. Non-metallic wear-resistant bodies can significantly increase the wear resistance of the wear-resistant precast plates, improve grinding efficiency, reduce energy consumption, and extend the replacement cycle.

[0067] The wear-resistant precast plate in this patent can be manufactured by distributing multiple wear-resistant bodies 1 in an array within a casting mold and by casting liquid metal material.

[0068] Specifically, taking the manufacture of wear-resistant precast slabs with flat panel structures as an example:

[0069] Refer to the instruction manual appendix Figure 7 The casting mold includes a moving mold 3 and a fixed mold 4, with the moving mold 3 on top and the fixed mold 4 on the bottom. At least one flat mold cavity 31 is provided on the lower surface of the moving mold 3 and at least one flat mold cavity 31 is provided on the upper surface of the fixed mold 4. The moving mold 3 and the fixed mold 4 are engaged with each other, and the flat mold cavity 31 on the moving mold 3 and the fixed mold 4 form a closed mold cavity. A pouring channel 32 is provided on the moving mold 3, and one end of the pouring channel 32 is connected to the closed mold cavity.

[0070] Multiple wear-resistant bodies 1 are arranged in an array within the flat cavity 31 of the fixed mold 4. The moving mold 3 and the fixed mold 4 are then fastened together. Cast iron material, alloy material, wear-resistant and heat-resistant material, wear-resistant and corrosion-resistant material, or wear-resistant, heat-resistant and corrosion-resistant material are poured into the flat cavity 31 through the pouring channel 32 of the mold to fill the gaps between the multiple wear-resistant bodies 1 and to cover the lower surface of the multiple wear-resistant bodies 1, forming a casting 2. After cooling, the casting is removed from the mold to obtain a wear-resistant precast plate composed of the casting 2 and multiple wear-resistant bodies 1.

[0071] Example 2

[0072] This embodiment provides a wear-resistant precast slab with enhanced wear resistance for the filling portion 22.

[0073] Although the wear-resistant precast plate of the present invention uses wear-resistant body 1 as the main wear-resistant material, since the filling part 22 is located in the gap between multiple wear-resistant bodies 1, the filling part 22 will also have a certain contact with the material to be ground under actual use conditions, and needs to withstand the wear of the material.

[0074] Therefore, in order to improve the wear resistance of the filler 22 and reduce production costs, in this embodiment, the filler 22 and the base layer 21 are cast from different materials. The material used for the filler 22 has higher wear resistance than the material used for the base layer 21, and the two are fused together, increasing the stability of the composite of the filler 22 and the base layer 21. For example, the filler 22 is cast from high manganese steel, hard alloy, or other materials, while the base layer 21 is cast from molten iron such as cast iron, alloy cast iron, or ductile iron. Furthermore, a step-by-step casting method is used, first casting the filler 22 and then casting the base layer 21.

[0075] The following is a feasible step-by-step casting method: A casting mold is prepared, comprising a first upper mold, a second upper mold, and a lower mold. The planes where the first and second upper molds interlock are the parting surfaces. A first upper mold cavity is provided on the parting surface of the first upper mold, a second upper mold cavity is provided on the parting surface of the second upper mold, and a lower mold cavity is provided on the parting surface of the lower mold. The first and lower mold cavities match each other to form a first closed mold cavity with uniform thickness, and the second and lower mold cavities match each other to form a second closed mold cavity with uniform thickness. The thickness of the first closed mold cavity is the same as the thickness of the wear-resistant body 1, and the thickness of the second closed mold cavity is greater than that of the first closed mold cavity. A casting channel is opened on the first and second upper molds, and its bottom end is connected to the closed mold cavity.

[0076] Multiple wear-resistant bodies 1 are arranged in an array on the bottom surface of the lower mold cavity. The first upper mold and the lower mold are fastened together. The first filling material is poured into the gap between the multiple wear-resistant bodies 1 through the casting channel. During the casting process, a vibrator is used to vibrate the lower mold to allow the molten first filling material to flow fully, so as to fill the gap between the multiple wear-resistant bodies 1 and reduce the contact between molten iron and gas and impurities. The first filling material forms the filling part after solidification.

[0077] Separate the first upper mold and the lower mold, and fasten the second upper mold onto the lower mold. Cast the second filling material into the second closed mold cavity through the casting channel. During the casting process, use a vibrator to vibrate the lower mold to allow the molten second filling material to flow fully, so as to fill the area on the top surface of multiple wear-resistant bodies 1 in the second closed mold cavity (i.e., the area where the second closed mold cavity is thicker than the first closed mold cavity). This also reduces the contact between molten iron and gas and impurities. After the second filling material solidifies, it forms a base layer that is composite with the filling part.

[0078] Example 3

[0079] This embodiment provides a wear-resistant precast slab for special working conditions.

[0080] For special working conditions, such as wear-resistant and heat-resistant conditions, wear-resistant and corrosion-resistant conditions, the gaps between multiple wear-resistant bodies 1 and the filling parts 22 filling the gaps can become weak areas of the wear-resistant precast slab. When subjected to high temperature or corrosion, these weak areas are easily damaged, which leads to changes in the material properties of the filling parts 22, a decrease in wear resistance, oxidation and thermal decomposition, etc., causing the performance and function of the wear-resistant precast slab to gradually decrease or be completely lost, resulting in its inability to continue to work effectively and affecting its service life.

[0081] The precast slab of this embodiment can solve the above problems. The precast slab for special working conditions in this embodiment includes:

[0082] The casting material for casting body 2 is selected from wear-resistant and heat-resistant materials, wear-resistant and corrosion-resistant materials, or wear-resistant, heat-resistant and corrosion-resistant materials according to the actual working conditions.

[0083] For example, when the wear-resistant precast plate is used in the aluminum molten material conveying scenario in a smelter, the wear-resistant precast plate will be subjected to the wear, high temperature and corrosion of the aluminum molten material. The casting body 2 is cast from wear-resistant, heat-resistant and corrosion-resistant materials. In one implementation, the casting body 2 is made of stainless steel.

[0084] In another implementation, to reduce production costs while ensuring the filler 22 possesses wear-resistant, heat-resistant, or corrosion-resistant properties, the filler 22 and the base layer 21 of the casting 2 are cast from different materials. Specifically, the material used for the filler 22 has higher wear-resistant, heat-resistant, wear-resistant, corrosion-resistant, or wear-resistant, heat-resistant, and corrosion-resistant properties than the material used for the base layer 21, and the two are fused together to increase the stability of the composite of the filler 22 and the base layer 21. Depending on the actual working conditions, the filler 22 is cast from wear-resistant and heat-resistant materials, wear-resistant and corrosion-resistant materials, or wear-resistant, heat-resistant, and corrosion-resistant materials, while the base layer 21 is cast from molten iron such as cast iron, alloy cast iron, or ductile iron. Furthermore, a step-casting method is adopted, first casting the filler 22 and then casting the base layer 21, as described in Example 2.

[0085] For example, when wear-resistant precast plates are used in the aluminum molten material conveying scenario in a smelter, the wear-resistant precast plates will be subjected to wear, high temperature and corrosion from the aluminum molten material. Therefore, the filling part 22 needs to be cast from wear-resistant, heat-resistant and corrosion-resistant materials. In one implementation, the filling part 22 is made of stainless steel.

[0086] The difference between the two implementation methods is that if the entire casting 2 is cast using the same type of wear-resistant and heat-resistant material, wear-resistant and corrosion-resistant material, or wear-resistant, heat-resistant and corrosion-resistant material, the overall cost will be higher than if the filling part 22 and the base layer 21 are made of different materials. At the same time, the material of the base layer 21 does not come into contact with the material, so the filling part 22 is not required to have such high wear resistance, heat resistance and corrosion resistance, which will result in material waste and increase production costs.

[0087] Example 4

[0088] Since multiple wear-resistant materials 1 and castings 2 are composited into a flat plate by casting, the stability between wear-resistant materials 1 and castings 2 is mainly determined by the composite interface between the two. The composite interface is formed by liquid phase solidification, solid phase plastic deformation to generate a new surface, and close contact between composite components. Among these factors, the chemical composition of the metal material, smelting and casting processes, and temperature control will affect the stability between wear-resistant materials 1 and castings 2.

[0089] Therefore, in order to improve the stability between the wear-resistant body 1 and the casting body 2, the wear-resistant body 1 is heated as a whole (e.g., by induction heating) before casting the multiple wear-resistant bodies 1 distributed in an array. This allows the wear-resistant body 1 and the casting body 2 to be cast in a high-temperature environment, so that a metallurgical bond is formed between the composite interface of the wear-resistant body 1 and the casting body 2, thereby increasing the stability of the composite between the wear-resistant body 1 and the casting body 2.

[0090] In this embodiment, a wear-resistant precast plate is also provided to improve the connection stability between the wear-resistant body 1 and the casting body 2 through a physical connection structure.

[0091] A bonding groove 11 is provided on the lower surface and / or side of the wear-resistant body 1. During casting, the casting body 2 fills the corresponding bonding groove 11, so that a physical connection structure is formed between the composite interface of the wear-resistant body 1 and the casting body 2, thereby increasing the stability of the composite between the wear-resistant body 1 and the casting body 2.

[0092] In this embodiment, the wear-resistant body 1 has a quadrangular prism structure, and a mating groove 11 is provided on the lower surface or side surface of the wear-resistant body 1, which will be described in detail below:

[0093] See attached document Figure 4 The figure shows a wear-resistant body 1 with a connecting groove 11, wherein the connecting groove 11 is a dovetail groove, which is located at the corner of the lower surface of the quadrangular prism structure and is parallel to the lower surface. The narrow end of the dovetail groove extends out of the side of the wear-resistant body 1, and the wide end of the dovetail groove extends horizontally inward to the inside of the wear-resistant body 1.

[0094] See attached document Figure 5The figure shows a wear-resistant body 1 with a connecting groove 11, wherein the connecting groove 11 is a strip groove parallel to the lower surface of the quadrangular prism structure, the two ends of the strip groove extend out of the side surface of the quadrangular prism structure, the cross section of the strip groove is T-shaped, and the width of the strip groove on the side closer to the lower surface of the wear-resistant body 1 is smaller than the width on the side farther away from the lower surface of the wear-resistant body 1.

[0095] See attached document Figure 6 The figure shows a wear-resistant body 1 with a connecting groove 11, wherein the connecting groove 11 is a strip groove parallel to the side of the quadrangular prism structure. The two ends of the strip groove extend from the upper and lower surfaces of the quadrangular prism structure, respectively. The cross-section of the strip groove is T-shaped, and the width of the strip groove on the side closer to the side of the wear-resistant body 1 is smaller than the width on the side farther away from the side of the wear-resistant body 1.

[0096] It should be noted that the above only lists some of the shapes of the mating groove 11, and the shapes of the mating groove 11 include, but are not limited to, the above-mentioned types.

[0097] During casting, the casting body 2 fills the gaps between the wear-resistant bodies 1 and forms a covering base layer 21 on the lower surface of the wear-resistant body 1, while also filling the corresponding bonding groove 11, so that an interlocking connection structure is formed between the composite interface of the wear-resistant body 1 and the casting body 2, which increases the stability of the composite between the wear-resistant body 1 and the casting body 2.

[0098] Example 5

[0099] Examples 1-4 propose a wear-resistant precast slab, whose wear-resistant working surface is the side corresponding to the upper surface of the wear-resistant body 1. The wear-resistant precast slab is only suitable for single-sided (wear-resistant working surface) wear resistance scenarios.

[0100] In this embodiment, based on the wear-resistant prefabricated plate in Examples 1-4, a wear-resistant plate with double-sided wear resistance is provided.

[0101] Specifically, refer to the instruction manual appendix. Figure 8 The wear-resistant plate includes two sets of wear-resistant prefabricated plates of the same specifications. The two sets of wear-resistant prefabricated plates are set back to back. The base layers 21 of the two are welded together to form a wear-resistant plate with wear-resistant working surfaces on both sides. The total thickness of the wear-resistant plate can be controlled by controlling the thickness of a single set of wear-resistant prefabricated plates to meet the requirements of specific application scenarios.

[0102] Example 6

[0103] Examples 1-4 present a wear-resistant precast slab that can be used as a wear-resistant precast base slab for mass production. This example presents a method for assembling wear-resistant precast base slabs to form a wear-resistant sheet of the target size.

[0104] Refer to the instruction manual appendix Figure 9A wear-resistant plate comprising multiple wear-resistant precast plates and a second casting.

[0105] Multiple wear-resistant precast slabs are arranged in an array, with gaps between adjacent slabs. The second casting includes a second filling portion within the gaps between the slabs and a second base layer on the lower surface of the slabs, forming a semi-enclosed structure where the second casting covers the lower surface and sides of the slabs. The second filling portion and the second base layer are formed by casting metal, allowing the multiple wear-resistant precast slabs and the second casting to be composited into a slab through casting. The second base layer serves as a connecting or mounting layer for the wear-resistant precast slabs. The upper surface of the wear-resistant precast slab is the wear-resistant working surface, which is the contact surface that directly withstands material wear.

[0106] In this embodiment, the wear-resistant plate can be assembled from planar, plate-shaped prefabricated wear-resistant plates to form a planar wear-resistant plate of the target size. Specifically, multiple prefabricated wear-resistant plates are distributed in an array along the plane. For example, if the prefabricated wear-resistant plate is 100*100mm in size, but the application scenario requires a 200*200mm wear-resistant plate, four prefabricated wear-resistant plates can be arranged in a matrix and assembled into a 200*200mm wear-resistant plate through casting using a second casting body.

[0107] In this embodiment, the wear-resistant plate can also be assembled into a curved wear-resistant prefabricated plate of the target size. Specifically, multiple wear-resistant prefabricated plates are distributed in an array along the curved surface. For example, if the wear-resistant prefabricated plate is a quarter-circular arc-shaped wear-resistant plate, and the application scenario requires a circular tubular wear-resistant plate, four arc-shaped wear-resistant plates can be arranged circumferentially to form a circular tube, and then assembled into a circular tubular wear-resistant pipe by casting through a second casting body.

[0108] The second casting body uses a material that is the same as or compatible with the casting body 2, the second base layer uses a material that is the same as or compatible with the base layer 21, and the second filling part uses a material that is the same as or compatible with the filling part 22.

[0109] To improve the stability between the wear-resistant body 1 and the casting body 2, a second bonding groove is provided on the lower surface and / or side surface of the wear-resistant precast plate. During casting, the second casting body fills the corresponding second bonding groove, so that an interlocking physical connection structure is formed between the composite interface of the wear-resistant precast plate and the second casting body, thereby increasing the stability of the composite between the wear-resistant precast plate and the second casting body.

[0110] The structure and location of the second connecting groove are the same as or correspond to those of connecting groove 11.

[0111] Obviously, modifications and / or additions can be made to the above-mentioned wear-resistant precast plates and wear-resistant plates, as well as the corresponding methods, without departing from the scope and domain of the present invention.

[0112] It is equally clear that, although the present invention has described the wear-resistant precast slab and wear-resistant sheet in detail, those skilled in the art will certainly be able to obtain many other equivalent forms of wear-resistant precast slabs and wear-resistant sheets and corresponding methods, which have the features described in the claims and are therefore within the scope of protection defined herein.

Claims

1. A wear-resistant precast slab, characterized in that: The device includes a wear-resistant body (1) and a casting body (2). The wear-resistant bodies (1) are distributed in a predetermined layout. The casting body (2) includes a base layer (21) and a filling part (22). The base layer (21) is disposed on the lower surface of the wear-resistant bodies (1), and the filling part (22) fills the gap between the wear-resistant bodies (1).

2. The wear-resistant precast slab according to claim 1, characterized in that: The wear-resistant body (1) has a polyhedral structure, and at least one surface of the polyhedral structure is a plane or an arc surface; the wear-resistant precast plate is a flat plate or a curved plate.

3. The wear-resistant precast slab according to claim 1, characterized in that: The wear-resistant material (1) is granular or blocky.

4. The wear-resistant precast slab according to claim 1, characterized in that: The predetermined layout distribution includes at least one of array distribution, discrete distribution, or random distribution.

5. The wear-resistant precast slab according to claim 1, characterized in that: The wear-resistant body (1) includes a non-metallic wear-resistant body and a coating layer covering the surface of the non-metallic wear-resistant body, wherein the coating layer includes at least a cemented carbide coating layer.

6. The wear-resistant precast slab according to claim 5, characterized in that: The non-metallic wear-resistant body is composed of one or a mixture of several of the following monomers: silicon carbide, boron carbide, chromium carbide, molybdenum carbide, aluminum oxide, silicon nitride, titanium carbide, zirconium oxide, or tungsten carbide.

7. The wear-resistant precast slab according to claim 1, characterized in that: At least one surface of the wear-resistant body (1) is provided with a joint groove (11), and the casting body (2) has a corresponding protrusion at the corresponding position, and the protrusion of the casting body (2) fills the corresponding joint groove (11).

8. The wear-resistant precast slab according to claim 7, characterized in that: The wear-resistant body (1) has a connecting groove (11) on its lower surface. The depth or width of the connecting groove (11) near the edge of the wear-resistant body (1) is less than the depth or width away from the edge of the wear-resistant body (1), or the width of the connecting groove (11) near the lower surface of the wear-resistant body (1) is less than the width away from the lower surface of the wear-resistant body (1).

9. The wear-resistant precast slab according to claim 7, characterized in that: The structure of the connecting groove (11) includes at least one of the following: a T-shaped groove, a dovetail groove, or a trapezoidal groove.

10. The wear-resistant precast slab according to claim 7, characterized in that: At least one end of the joint groove (11) extends out of the side of the wear-resistant body (1).

11. The wear-resistant precast slab according to claim 1, characterized in that: The wear-resistant body (1) and the casting body (2) are made of different materials. The wear resistance of the wear-resistant body (1) is higher than that of the casting body (2), and the melting point of the wear-resistant body (1) is higher than that of the casting body (2). The casting body (2) in the wear-resistant precast plate is formed by casting together with multiple wear-resistant bodies (1).

12. The wear-resistant precast slab according to claim 1, characterized in that: The casting (2) is cast from at least one of cast iron material, alloy material, wear-resistant and heat-resistant material, wear-resistant and corrosion-resistant material or wear-resistant, heat-resistant and corrosion-resistant material.

13. The wear-resistant precast slab according to claim 1, characterized in that: The filling part (22) and the base layer (21) are made of different materials, and the material used in the filling part (22) has at least one of the wear resistance, heat resistance or corrosion resistance that is higher than that of the material used in the base layer (21).

14. A wear-resistant plate, characterized in that: The wear-resistant plate includes two sets of wear-resistant precast plates as described in any one of claims 1-13, the two sets of wear-resistant precast plates are arranged back to back, and their base layers (21) are welded to each other.

15. A wear-resistant plate, characterized in that: The invention comprises at least two wear-resistant precast plates as described in any one of claims 1-13 and a second casting body, wherein the wear-resistant precast plates are arranged in an array, and the second casting body comprises a second base layer (21) and a second filling part (22), wherein the second base layer (21) is disposed on the lower surface of the wear-resistant precast plate, and the second filling part (22) is disposed in the gap between the plurality of wear-resistant precast plates, and the second base layer (21) and the second filling part (22) are formed by casting.

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