Hard surface surfacing is to surfacing the worn parts by surfacing one or more layers of wear-resistant alloy materials on the surface of the wear parts to effectively improve the wear resistance of the workpiece and prolong its service life. Therefore, the application of hard surface surfacing technology is more and more extensive, and the pre-protection of equipment is getting more and more attention. This paper focuses on the typical application of our company's surfacing products in the power industry, such as coal roller surfacing, fan blades, various liners.
Vertical grinding roller hard surface surfacing
The surface wear-resistant surfacing technology is used for the wear repair of the vertical grinding roller grinding system, which is economical and ensures the high performance of the grinding system, optimizes the grinding process, saves maintenance costs, and the service life ratio of the parts after surface hardening The unhardened parts are increased by 1.5 to 2 times, which greatly reduces the wear rate of the parts.
(1) Surface wear-resistant surfacing Most vertical grinding rolls and grinding discs are made of high-chromium cast iron, which is a highly wear-resistant material and is suitable for surface hardening treatment. After the surface is worn, the self-protected arc welding of HB100 series vertical grinding wire (see Table 1) is adopted. The welding point temperature during the wire surfacing process is relatively low, and the product is not deformed. It can be welded first with HB100 or HB100A. Repair, and finally cover with HB100H welding wire. HB100 series welding wire has the characteristics of excellent welding process performance, beautiful weld bead formation and small welding spatter. No welding or flux protection is required for welding, which simplifies the welding process and saves on welding accessories costs. Fine cracks appear during surfacing, which is the result of stress release. It does not affect the normal use under low-impact mining conditions. The welding wire generally has a welding current of 350~450A and an arc voltage of 35~40V.
Table 1 Welding wire composition and its function
Note: The wire diameter is 2.8/3.2mm.
(2) New products for casting surfacing welding carbon steel casting new products and reserved size for surfacing welding, metal welding after surfacing is good, the strength is also in line with the requirements, the use situation is better than the new product, especially the wear resistance is more excellent. With this solution, the total cost of purchase is only about 50% of the original new casting (high chromium cast iron).
Restoration scheme: In order to make the surfacing metal have better contact with the substrate, HB-YD688(Q)φ1.6mm welding wire can be used to weld the bottom layer of a certain thickness, then HB100 or HB100A for welding, and finally a certain thickness is welded with HB100H welding wire. Cover layer. Related build-up products are shown in the drawings.
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Surfacing products
2. Application of wear-resistant composite board
HB-58 wear-resistant steel plate is mainly used for wind turbine blades, burner pipelines, stacker and reclaimer hoppers, silo liners, coal mill liners, pulverized coal conveying pipes, coal powder distributor partitions, unloading in the power industry. Coal equipment lining, fan coal mill striking lining, feed trough and hopper lining, and broken lining. In addition, it can also be used in the wear-repairing engineering of coal mills, boiler tubes, fan bodies and blades, (powder, coal, ash) pipes and containers, screw feeder blades, wear-resistant linings Repair of layers and valves.
The composition and properties of HB-58 wear-resistant composite board are shown in Table 2.
Table 2 Wear plate related parameters
The performance characteristics of HB-58 wear-resistant composite board are as follows:
(1) High wear resistance The alloy system is universally used for international wear-resistant composite steel plates. It has excellent anti-wear grain wear performance. Metallurgical fusion method is used to achieve metallurgical bonding between wear-resistant layer and substrate. The wear layer thickness is 3.5~12mm, and the wear resistance is much higher than that of heat-treated wear-resistant steel and cast wear-resistant cast iron. The wear resistance is also much higher than that of spray welding or thermal spraying.
(2) Impact resistance Since the substrate of the wear-resistant composite steel plate adopts a low-carbon steel plate with good plasticity, energy can be absorbed in the process of impact, and thus the wear-resistant composite steel plate has strong impact resistance and crack resistance, and can be applied. Under the conditions of strong vibration and impact.
(3) It is easy to process wear-resistant composite steel plate, which can be made into standard size plate. It is light in weight and convenient in processing. Because of the soft substrate, it can be formed into cold-formed inner shape and can be cut by plasma arc, carbon arc and other heat sources. It can be welded and welded to make the field welding work both time-saving and convenient. Therefore, this material is in line with the current international manufacturing industry adopting the welded structure instead of the casting structure and reducing the structural weight.
(4) The high performance price is higher than the cost of using the wear-resistant composite steel plate to manufacture the parts, but the service life of the parts is increased. Considering the maintenance cost, spare parts cost and downtime loss, the performance price ratio is higher than that of ordinary materials. It is 2~3 times higher, and the cost per unit area is only 1/2 of the surfacing of the same component electrode.
3. Conclusion
Our company's surfacing products have been applied in many large and medium-sized enterprises in China, which not only reduces the production cost, but also greatly prolongs the service life of the workpiece and prolongs the equipment maintenance cycle.
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