Combustion Chamber Wear Layer Bonding
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Solution Overview
Problem
Lining elements for combustion chambers face challenges such as limited size due to material constraints, uneven heating leading to cracks, and inadequate heat transfer, resulting in reduced service life and increased manufacturing costs.
Innovation Solution
A method involving a flat wear layer materially connected to the carrier element over a significant surface area, using techniques like explosive or roll cladding, to ensure optimal heat transfer and durability, allowing for larger, cost-effective lining elements with improved wear resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If cast materials are used for lining elements, then resistance to abrasive and corrosive stress is improved, but component size is limited due to risk of cracking from uneven heating
Solution Approach 1:
The invention uses a composite structure consisting of a support element made of metal or metal alloy and a wear layer made of cast material. The support element provides structural integrity and thermal management capabilities, while the wear layer provides resistance to abrasive and corrosive stress. This composite approach allows the lining element to be larger than what could be made from cast material alone, as the support element can be designed with internal cooling channels to prevent thermal stress cracking.
Solution Approach 2:
The wear layer is applied only to the front side or specific wear-prone areas of the support element, rather than the entire component. This localized application provides protective properties where needed while maintaining the structural benefits of the support element material in other areas, enabling larger component sizes with controlled thermal stress distribution.
2Device complexity
If larger lining elements are manufactured, then the number of connection points for fluid lines is reduced, but cast materials crack due to uneven heating
Solution Approach 1:
The support element is designed as a composite structure with integrated cooling channels that allow cooling liquid to flow through the component. This internal cooling system enables larger lining elements to be manufactured without increasing the number of external connection points, as the cooling fluid distributes thermal stress uniformly throughout the structure, preventing cracking from uneven heating.
3Object-affected harmful factors
If deposition welding is used to apply wear layer, then wear resistance is improved, but flatness is poor requiring post-processing
Solution Approach 1:
The invention separates the wear layer application process from the structural support function. Instead of building up the wear layer through deposition welding which creates uneven surfaces, the wear layer is applied as a pre-formed layer with controlled flatness onto the support element. This extraction of the wear layer formation process allows for better surface quality without requiring extensive post-processing.
4Duration of action of stationary object
If thicker wear layers are applied by deposition welding, then service life is extended, but heat transfer between wear layer and support element is inadequate
Solution Approach 1:
The support element is designed with internal cooling channels that allow cooling liquid to flow through the structure. This enables effective heat transfer from the wear layer to the cooling fluid, even when the wear layer is relatively thick. The cooling channels are positioned to maximize heat extraction from the support element, maintaining thermal efficiency while allowing the wear layer sufficient thickness to extend service life.
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 extends the service life of lining elements by ensuring even heat distribution and mechanical durability, reducing manufacturing costs and the risk of leaks, while allowing for tailored wear layers adapted to specific combustion chamber stresses.
Implementation Method 1
using techniques like explosive or roll cladding
Implementation Method 2
using techniques like explosive or roll cladding
Implementation Method 3
it ensures particularly good heat transfer between the wear layer and the support element
Data Source
Figure 1~2
Figure 3
AI summary
In a process for manufacturing a lining element (1), in particular a sliding grate element for a combustion chamber of a combustion plant, a support element (3) made of a metal or a metal alloy is provided with a wear layer (2) at least on one surface. The wear layer (2) is present as a planar element, wherein the wear layer (2) is bonded to the surface of the support element (3) in a metallurgical manner.