Multi-layer composite wear-resistant boot for protecting magnetic flux leakage detector

Abstract

The utility model discloses a multilayer composite wear-resisting boot for protecting a magnetic flux leakage detector, which comprises a wear-resisting boot shell and a wear-resisting composite ceramic chip, the top of the wear-resisting boot shell is sequentially provided with a first embedding groove and a second embedding groove which are communicated with each other from top to bottom, the first embedding groove is used for embedding the wear-resisting composite ceramic chip, and the second embedding groove is used for embedding the wear-resisting composite ceramic chip. The wear-resistant composite ceramic chip is of a three-layer nested structure and comprises a first structural layer, a second structural layer and a third structural layer, the third structural layer is embedded in the first structural layer, the second structural layer is embedded in the third structural layer, and the first structural layer and the second structural layer are embedded in the third structural layer. The first structural layer is a high-entropy ceramic layer, the second structural layer is a graphene reinforced polymer layer, and the third structural layer is a silicon nitride layer. The utility model has the advantages that the wear resistance, the impact resistance and the magnetic field compatibility are obviously improved, and the magnetic sensor is suitable for a dynamic environment in steel detection.

Description

Technical Field

[0001] This utility model relates to the technical field of non-destructive testing equipment, and in particular to a multi-layer composite wear-resistant boot for protecting magnetic flux leakage detectors. Background Technology

[0002] In the steel manufacturing industry, magnetic flux leakage (MFL) detectors are widely used to detect surface and near-surface defects in steel bars, such as cracks and corrosion. Detectors are typically equipped with wear-resistant boots to protect their sensitive components (such as magnetic field sensors) from friction and impact wear on the steel surface. Existing wear-resistant boots mostly use a single material, such as silicon nitride (Si3N4), which has high hardness and is non-magnetic, meeting basic requirements for wear resistance and magnetic field compatibility. However, silicon nitride is brittle and prone to fracture under high impact or complex surface conditions, leading to a shortened lifespan of the wear-resistant boot. Furthermore, a single material cannot simultaneously meet the comprehensive requirements of wear resistance, flexibility, and magnetic field compatibility. Therefore, a multi-layered composite wear-resistant boot is needed, combining the advantages of multiple materials to improve durability and detection stability. Summary of the Invention

[0003] The purpose of this invention is to address the shortcomings of the existing technology by providing a multi-layer composite wear-resistant boot for protecting magnetic flux leakage detectors. This multi-layer composite wear-resistant boot consists of a wear-resistant boot shell and a wear-resistant composite ceramic sheet. The wear-resistant composite ceramic sheet has a three-layer nested structure, including a first structural layer, a second structural layer, and a third structural layer. The first structural layer is a high-entropy ceramic layer, the second structural layer is a graphene-reinforced polymer layer, and the third structural layer is a silicon nitride layer. By combining the high hardness of the high-entropy ceramic, the flexibility of the graphene-reinforced polymer, and the non-magnetic nature of the silicon nitride, this invention solves the problems of insufficient wear resistance, high brittleness, and limited impact protection capabilities of traditional wear-resistant boots. Simultaneously, it maintains magnetic field compatibility, improving the service life and detection accuracy of the magnetic flux leakage detector.

[0004] The objective of this utility model is achieved through the following technical solution:

[0005] A multilayer composite wear-resistant boot for protecting a magnetic flux leakage detector includes a wear-resistant boot shell and a wear-resistant composite ceramic sheet. The top of the wear-resistant boot shell has a first embedding groove and a second embedding groove connected from top to bottom. The first embedding groove is used to embed the wear-resistant composite ceramic sheet, and the second embedding groove is used to embed the magnetic flux leakage detector. The wear-resistant composite ceramic sheet has a three-layer nested structure, including a first structural layer, a second structural layer, and a third structural layer. The third structural layer is embedded in the first structural layer, and the second structural layer is embedded in the third structural layer. The first structural layer is a high-entropy ceramic layer, the second structural layer is a graphene-reinforced polymer layer, and the third structural layer is a silicon nitride layer.

[0006] The bottom of the first structural layer is provided with a third embedding groove for embedding the third structural layer, and the top of the third structural layer is provided with a fourth embedding groove for embedding the second structural layer. The bottom of the third embedding groove is flush with the top of the third structural layer, and the top of the fourth embedding groove is flush with the top of the second structural layer.

[0007] The thickness of the periphery and the middle of the first structural layer are 1.5 mm and 0.8 mm, respectively. The depth of the third embedding groove is 0.7 mm. The thickness of the periphery and the middle of the third structural layer are 0.7 mm and 0.5 mm, respectively. The depth of the fourth embedding groove is 0.2 mm. The thickness of the second structural layer is 0.2 mm.

[0008] The wear-resistant composite ceramic sheet has alloy blocks on both sides. The alloy blocks and the wear-resistant composite ceramic sheet are embedded together in the first embedding groove. The tops of the alloy blocks and the wear-resistant composite ceramic sheet are flush with the top of the first embedding groove.

[0009] The magnetic flux leakage detector is embedded in the second embedding slot, and the top of the magnetic flux leakage detector is flush with the top of the second embedding slot.

[0010] The upper cross-section of the wear-resistant boot shell is trapezoidal, and the lower cross-section is rectangular.

[0011] Two multi-layer composite wear-resistant boots are provided, and the two multi-layer composite wear-resistant boots are positioned opposite each other on both sides of the steel bar to be tested. The wear-resistant composite ceramic plates of the multi-layer composite wear-resistant boots are in contact with the steel bar to be tested. The multi-layer composite wear-resistant boots rotate around the circumference of the steel bar to be tested under the drive of the rotating device.

[0012] The advantages of this invention are: significantly improved wear resistance, impact resistance and magnetic field compatibility, making it suitable for dynamic environments in steel testing. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the working process of the wear-resistant boot of this utility model;

[0014] Figure 2 This is a top view of the wear-resistant boot of this utility model;

[0015] Figure 3 This is an elevation view of the wear-resistant composite ceramic sheet of this utility model;

[0016] Figure 4 This is a plan view of the wear-resistant composite ceramic sheet of this utility model;

[0017] like Figures 1-4 As shown in the figure, the labels represent:

[0018] 1. Wear-resistant boot shell; 2. Wear-resistant composite ceramic sheet; 21. First structural layer; 22. Second structural layer; 23. Third structural layer; 3. Alloy block; 4. Magnetic flux leakage detector; 5. Steel rod.

[0019] The direction of the steel bar, a. Detailed Implementation

[0020] The features and other related features of this utility model will be further described in detail below with reference to the accompanying drawings and embodiments, so as to facilitate the understanding of those skilled in the art:

[0021] Example: Figures 1-4 As shown, this embodiment relates to a multi-layer composite wear-resistant boot for protecting a magnetic flux leakage detector. It mainly includes a wear-resistant boot shell 1 and a wear-resistant composite ceramic sheet 2. The upper cross-section of the wear-resistant boot shell 1 is trapezoidal, and the lower cross-section is rectangular. From top to bottom, the top of the wear-resistant boot shell 1 has a first embedding groove and a second embedding groove that are connected. The first embedding groove is used to embed the wear-resistant composite ceramic sheet 2, and the second embedding groove is used to embed the magnetic flux leakage detector 4. The magnetic flux leakage detector 4 is embedded in the second embedding groove, and the top of the magnetic flux leakage detector 4 is flush with the top of the second embedding groove. Alloy blocks 3 are provided on both sides of the wear-resistant composite ceramic sheet 2. The alloy blocks 3 and the wear-resistant composite ceramic sheet 2 are embedded together in the first embedding groove, and the tops of the alloy blocks 3 and the wear-resistant composite ceramic sheet 2 are flush with the top of the first embedding groove. In this embodiment, a magnetic flux leakage detector 4 is first installed in the second embedded groove of the wear-resistant boot shell 1, then a wear-resistant composite ceramic sheet 2 is installed in the middle of the first embedded groove of the wear-resistant boot shell 1, and the wear-resistant composite ceramic sheet 2 is fixed on the magnetic flux leakage detector 4 by mechanical clamping or bonding. Finally, alloy blocks 3 are clamped on both sides of the wear-resistant composite ceramic sheet 2.

[0022] like Figures 1-4As shown, the wear-resistant composite ceramic sheet 2 has a three-layer nested structure, including a first structural layer 21, a second structural layer 22, and a third structural layer 23. The third structural layer 23 is embedded within the first structural layer 21, and the second structural layer 22 is embedded within the third structural layer 23. The first structural layer 21 is a high-entropy ceramic layer, which is composed of five or more metal cations in equimolar or near-equimolar proportions to form a single solid solution structure. The hardness of the high-entropy ceramic is 20~40 GPa, exhibiting excellent wear resistance. It directly contacts the surface of the steel rod 5 to be tested, protecting the internal structure of the multi-layer composite wear-resistant boot. The second structural layer 22 is a graphene-reinforced polymer layer, which is a mixture of 1%~10wt% graphene and epoxy resin (5wt% graphene-epoxy resin is used in this embodiment). It provides flexibility and can absorb the impact force of the steel rod 5 to be tested, preventing the high-entropy ceramic layer from fracture due to brittleness. The third structural layer 23 is a silicon nitride layer, with a hardness of 1500~2000. HV, completely non-magnetic silicon nitride, is used to protect the magnetic field sensor of the flux leakage detector 4, ensuring uninterrupted magnetic field signal transmission. The bottom of the first structural layer 21 has a third embedding groove for embedding the third structural layer 23, and the top of the third structural layer 23 has a fourth embedding groove for embedding the second structural layer 22. The bottom of the third embedding groove is flush with the top of the third structural layer 23, and the top of the fourth embedding groove is flush with the top of the second structural layer 22. The wear-resistant composite ceramic sheet 2 has a thickness of 1.5 mm. The thicknesses of the periphery and center of the first structural layer 21 are 1.5 mm and 0.8 mm, respectively. The depth of the third embedding groove is 0.7 mm. The thicknesses of the periphery and center of the third structural layer 23 are 0.7 mm and 0.5 mm, respectively. The depth of the fourth embedding groove is 0.2 mm, and the thickness of the second structural layer 22 is 0.2 mm.

[0023] like Figure 1 As shown, two multi-layer composite wear-resistant boots are provided, positioned opposite each other on both sides of the steel rod 5 to be tested. The steel rod 5 to be tested moves horizontally along its axial direction (see...). Figure 1 (a) The wear-resistant composite ceramic sheet 1 of the multi-layer composite wear-resistant boot contacts the steel bar 5 to be tested. The multi-layer composite wear-resistant boot rotates around the circumference of the steel bar 5 to be tested under the drive of the rotating device. The magnetic flux leakage detector 4 inside the multi-layer composite wear-resistant boot performs defect detection on the steel bar 5 to be tested.

[0024] In addition, the wear-resistant composite ceramic sheet 2 also has the following manufacturing method:

[0025] Preparation of the third structural layer 23:

[0026] Silicon nitride powder was sintered into a third structural layer 23 using either SPS (spark plasma sintering) or HP (hot pressing) processes at a temperature of 1700–1800°C, a pressure of 30 MPa, and a holding time of 10 minutes. Subsequently, the surface of the third structural layer 23 was roughened to enhance its adhesion to the second structural layer 22.

[0027] Preparation and filling of the second structural layer 22:

[0028] To prepare the graphene-reinforced polymer, 1% to 10 wt% (5 wt% in this example) of graphene powder was mixed with epoxy resin and dispersed uniformly by ultrasonication. The mixture was then coated or injection molded onto the third structural layer 23 to form the second structural layer 22. The mixture was cured at 80°C for 24 hours to ensure stable bonding of the graphene-reinforced polymer.

[0029] Preparation and coating of the first structural layer 21:

[0030] High-entropy ceramic powder is sintered into a first structural layer 21 with a thickness of 0.8 mm using either the SPS or HP process. The sintering temperature is 1500~1600°C, and the pressure is 40 MPa. Subsequently, a high-temperature resistant adhesive (such as Loctite EA 9497 epoxy resin) is used to bond the first structural layer 21 to the third structural layer 23, and the bonding is carried out at a temperature below 200°C (60°C in this embodiment) for 12 hours to ensure a tight bond between the three nested layers.

[0031] Assembly of a three-level nested structure:

[0032] Assemble the three-layer nested structure, ensuring the bottom is aligned, and fix it to the magnetic flux leakage detector 4 by mechanical clamping or adhesive bonding.

[0033] In this embodiment, the wear-resistant composite ceramic sheet 2 is suitable for steel rod testing environments ranging from room temperature to 300°C. Tests show that the wear resistance of the first structural layer 21 (high-entropy ceramic layer) is approximately 30% higher than that of traditional silicon nitride. The impact absorption effect of the second structural layer 22 (graphene-reinforced polymer layer) significantly reduces the risk of breakage of the first structural layer 21, and the third structural layer 23 (silicon nitride layer) ensures accurate transmission of the magnetic field signal. The overall structure is lightweight, durable, and suitable for dynamic testing requirements.

[0034] The beneficial technical effects of this embodiment are: significantly improved wear resistance, impact resistance and magnetic field compatibility, making it suitable for dynamic environments in steel testing.

[0035] Although the above embodiments have described the concept and embodiments of the present invention in detail with reference to the accompanying drawings, those skilled in the art will recognize that various improvements and modifications can still be made to the present invention without departing from the scope of the claims, and therefore will not be elaborated here.

Claims

1. A multi-layer composite wear boot for protecting a magnetic flux leakage probe, characterized by: The wear-resistant boot shell and wear-resistant composite ceramic sheet are provided, the wear-resistant boot shell top is sequentially provided with the first embedding groove and the second embedding groove which are communicated from top to bottom, the first embedding groove is used for embedding the wear-resistant composite ceramic sheet, the second embedding groove is used for embedding the magnetic flux leakage detector, the wear-resistant composite ceramic sheet is a three-layer nested structure, comprising a first structure layer, a second structure layer and a third structure layer, the first structure layer is inlaid with the third structure layer, the third structure layer is inlaid with the second structure layer, the first structure layer is a high-entropy ceramic layer, the second structure layer is a graphene reinforced polymer layer, and the third structure layer is a silicon nitride layer.

2. A multi-layer composite wear boot for protecting a magnetic flux leakage detector as defined in claim 1, wherein: The first structure layer bottom is provided with a third embedding groove for embedding the third structure layer, the third structure layer top is provided with a fourth embedding groove for embedding the second structure layer, the third embedding groove bottom is flush with the third structure layer top, and the fourth embedding groove top is flush with the second structure layer top.

3. A multi-layer composite wear boot for protecting a magnetic flux leakage detector as defined in claim 2, wherein: The first structure layer peripheral and middle thicknesses are 1.5 mm and 0.8 mm respectively, the third embedding groove depth is 0.7 mm, the third structure layer peripheral and middle thicknesses are 0.7 mm and 0.5 mm respectively, the fourth embedding groove depth is 0.2 mm, and the second structure layer thickness is 0.2 mm.

4. A multi-layer composite wear boot for protecting a magnetic flux leakage detector as defined in claim 1, wherein: The wear-resistant composite ceramic sheet two sides are provided with alloy blocks, the alloy blocks and the wear-resistant composite ceramic sheet are embedded in the first embedding groove together, and the alloy blocks and the wear-resistant composite ceramic sheet top are flush with the first embedding groove top.

5. A multi-layer composite wear boot for protecting a magnetic flux leakage detector as defined in claim 1, wherein: The magnetic flux leakage detector is embedded in the second embedding groove, and the magnetic flux leakage detector top is flush with the second embedding groove top.

6. A multi-layer composite wear boot for protecting a magnetic flux leakage detector as defined in claim 1, wherein: The wear-resistant boot shell upper section is trapezoidal, and the lower section is rectangular.

7. A multi-layer composite wear boot for protecting a magnetic flux leakage detector as defined in claim 1, wherein: The multilayer composite wear-resistant boots are provided with two, the two multilayer composite wear-resistant boots are oppositely arranged on the two sides of the steel bar to be detected, the wear-resistant composite ceramic sheets of the multilayer composite wear-resistant boots are in contact with the steel bar to be detected, and the multilayer composite wear-resistant boots rotate around the circumferential direction of the steel bar to be detected under the driving of the rotating device.

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