Piercing-rolling plug arc-spraying film durability
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Solution Overview
Problem
Conventional piercing-rolling plugs with arc-sprayed films face durability issues when piercing long billets or high-temperature strength billets, leading to reduced production efficiency and plug lifespan.
Innovation Solution
A method using a system with multiple arc-spraying booths to divide the plug's surface into sections, allowing each booth to form the film separately, with spray guns operating within a controlled intersection angle of 35 to 90 degrees to enhance film adhesiveness and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single arc-spraying booth is used to form the film on the plug surface, then the equipment complexity is reduced, but the film formation time increases and production efficiency decreases
Solution Approach 1:
The plug surface is divided into multiple sections along the axial direction, with each section sprayed by a separate arc-spraying booth. This segmentation allows parallel processing of different surface regions, reducing total film formation time while maintaining equipment manageability through modular booth design.
2Productivity
If the spray gun operates at a small intersection angle, then the film formation speed increases, but the film adhesiveness to the plug surface deteriorates
Solution Approach 1:
The intersection angle between the spray stream and plug surface is optimized to a specific range (35-90 degrees) to achieve the best balance between film formation speed and adhesiveness. This parameter optimization ensures that the molten material adheres properly to the shotblasted surface while maintaining efficient spray deposition.
3Reliability
If arc-spraying is performed in a vacuum environment, then the film purity and quality improve, but the equipment complexity and cost increase
Solution Approach 1:
Arc-spraying is performed in an air environment rather than vacuum, simplifying equipment requirements. The shotblasting process creates a rough surface that enhances mechanical interlocking of the sprayed film, providing adequate adhesiveness without requiring vacuum conditions. This approach maintains film quality while significantly reducing equipment complexity.
4Manufacturing precision
If the plug is rotated at high speed during arc-spraying, then the film uniformity improves, but the centrifugal force reduces material deposition efficiency
Solution Approach 1:
The plug rotation speed is dynamically adjusted to an optimal range that balances film uniformity and deposition efficiency. The rotation provides sufficient centrifugal force to distribute material evenly across the surface while maintaining enough deposition rate to ensure efficient film formation. This dynamic optimization resolves the trade-off between uniformity and productivity.
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
This approach maintains high production efficiency and significantly extends the durability life of the piercing-rolling plug, even with long or high-temperature billets, by ensuring strong adhesiveness and uniform film formation across the plug surface.
Implementation Method 1
an arc-spraying device for performing arc-spraying of iron wires on a shotblasted surface of a base metal of the plug
Implementation Method 2
melting the iron wires by an arc, and spraying molten material thereof onto the surface of the base metal of the plug
Data Source
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AI summary
Provided is an equipment system for producing a piercing-rolling plug to be used for producing a seamless steel tube/pipe, which includes a shotblasting device for applying shotblasting on a surface of the plug, and an arc-spraying device for performing arc-spraying of iron wires on a surface of a base metal of the plug to which the shotblasting is applied, so as to form a film containing oxide and Fe thereon. The arc-spraying device includes plural spraying booths each of which separately forms part of the film in turn in each of sections into which the surface of the base metal of the plug is divided along an axial direction of the plug. The production efficiency of the plug can therefore be maintained at a high level, and steady enhancement of the durability life of the plug can be realized during the piercing-rolling.