Stainless Steel Clad Plate Shape and Bonding Control
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Solution Overview
Problem
Existing stainless steel clad plates suffer from issues of poor shape and poor interface bonding, which are not effectively addressed by existing manufacturing processes.
Innovation Solution
A method of manufacturing stainless steel clad plates involves stacking slabs in a specific order of a composite slab, which are not effectively addressed by existing manufacturing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If explosive welding is used to manufacture stainless steel clad plate, then the composite bonding is achieved, but the shape quality and interface bonding quality deteriorate
Solution Approach 1:
The patent replaces the explosive welding method with a conventional rolling process. Instead of using explosion forces to bond the stainless steel cladding layer to the carbon steel base layer, the invention uses mechanical rolling pressure and controlled temperature conditions to achieve metallurgical bonding. This substitution eliminates the harmful effects of explosive welding (poor shape quality, vibration, noise, smoke and dust pollution) while maintaining effective interface bonding, with bonding strength meeting or exceeding requirements of ≥300 MPa.
Solution Approach 2:
The patent implements precise control of temperature and pressure parameters during the rolling process to achieve excellent interface bonding and shape quality. The heating temperature is controlled at 1150-1220°C with holding time of 30-50 minutes, followed by controlled rolling with specific reduction rates (40-60% total reduction). These parameter optimizations enable the conventional rolling process to produce clad plates with bonding strength ≥300 MPa and shape deviation ≤3 mm/m, resolving the contradiction between bonding quality and shape quality.
2Shape
If conventional rolling process is used, then the shape quality improves, but the interface bonding quality may deteriorate without proper process control
Solution Approach 1:
The patent applies preliminary surface treatment to the cladding layers before rolling to ensure optimal bonding conditions. The surfaces are ground and polished to remove oxide scales and achieve a smooth, clean surface with specific roughness parameters (Ra ≤ 0.8 μm). This preliminary preparation ensures that when the rolling process is applied, maximum bonding strength is achieved while maintaining excellent shape quality, preventing the common problem of poor interface bonding in conventional rolling.
Solution Approach 2:
The patent introduces a separating agent (oil-based or water-based) applied to the cladding layer surfaces before stacking. This intermediary substance prevents premature bonding during stacking while allowing controlled metallurgical bonding during the heating and rolling process. The separating agent ensures uniform bonding across the interface and prevents defects, enabling the conventional rolling process to achieve bonding strength ≥300 MPa with excellent shape control (deviation ≤3 mm/m).
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method of manufacturing stainless steel plates involves stacking slabs in a specific order of a composite slab, which are not effectively addressed by existing manufacturing processes.
Implementation Method 1
performing three times of vacuuming and two times of vacuum breaking on the composite slab through the seamless steel tube, finally making the vacuum degree ≤10-2Pa
Implementation Method 2
heating the composite slab, uniform heating temperature is 1150~1220°C, total heating time is ≥1.2min/mm×t
Implementation Method 3
performing cooling after rolling: the unified clad plate enters ultra-rapid cooling system for intermittent cooling
Data Source
Figure 1a~1b
Figure 1c
Figure 1d(A)~1d(B)
AI summary
The present application discloses a stainless steel clad plate with excellent shape and a preparation method thereof. The method comprises three overall steps: composite slab preparation, composite slab rolling, and clad plate separation and straightening. In the composite slab preparation step, three times of vacuuming and two times of vacuum breaking are performed on a composite slab through a seamless steel tube, so that a vacuum degree is finally achieved to be ≤10-2 Pa. In the composite slab rolling step, an intermittent cooling, a straightening, and a stacked cooling between two steel plates at a temperature of Tf-150°C~Tf+150°C are performed. In the clad plate separation and straightening step, a leveling is performed on a leveling machine, when performing a transverse leveling, controlling a leveling force of the leveling machine to be F1=ν×a×b×ct×σt/(d×(ν-ct/a)); when performing a longitudinal leveling, controlling a leveling force of the leveling machine to be F2= a×b×cl×σl/(d+cl). The clad plate has an excellent shape and an excellent interface bonding quality, a flatness deviation is ≤3mm/m, a clad interface bonding rate is 100%, a shear strength is ≥300MPa, and a yield rate and a production efficiency are high.