High Compaction Density Alumina Ceramic Sheet Wear-Resistant Tube Elbow

Technical performance index of toughened high-alumina ceramic-lined composite pipe fittings
 

Ceramic SMD Wear-resistant pipe parameters

Brief Introduction of Toughened High Alumina Ceramic Lined Composite Pipe
The outer wall of the composite pipe adopts Q235 steel pipe as the basic material. According to the drawings, the processes of blanking, cutting, welding, and rust removal are carried out, and the outer wall pipe of the composite pipe is processed. Wear-resistant pipe fittings are lined with ceramic sheets (rings). Its production process is carried out under strict quality control and supervision. The production of lined ceramics is mainly through powder preparation, pressing of ceramic sheets (rings), sintering and other processes to form lined ceramic sheets (rings). On the premise that the outer wall steel pipe and the inner lining ceramic are qualified, the lining ceramic is pasted to the inner wall of the steel pipe with imported adhesive, and then the anti-corrosion treatment is carried out to make the wear-resistant composite pipe. The products are strictly inspected, and the qualified composite pipes can be packaged and shipped out.

Production process of alumina ceramic composite pipe fittings
Blanking and grouping: CNC intersecting wire cutting machine ensures the blanking accuracy, and the process control implements the "Blanking and Grouping Process Regulations".
Welding: Comply with the welding procedure specification required by the American ASME standard, and implement the project procedure specification WPS, welding procedure qualification record PQR, and welder skill appraisal WPQR. Non-destructive inspection is carried out for each pipe fitting, and PT (color inspection), MT (magnetic particle inspection), UT (ultrasonic inspection), RT (radio inspection) are supported.
Sandblasting and rust removal: All pipe fittings are subjected to steel shot white sandblasting and rust removal, and the grade conforms to GB8923-88 and reaches the Sa2.5 standard. Process control implements "Rust Removal Process Regulations".
Porcelain: Thanks to the advantages of self-made ceramic tiles, we can achieve effective control of product quality, and provide ceramic tiles with the most suitable size according to product specifications. The process control of the porcelain sticking process shall implement the "Porcelain Sticking Process Regulations".
Painting and anti-corrosion: After strict rust removal, the pipe fittings are transferred to the painting process after being pasted with porcelain. The process control implements the "Painting Process Regulations".
4.26 The combined elbow should be delivered as a whole; the connecting part of the two elbows in the combined elbow should also be covered with ceramics, which is required to be consistent with the elbow.
Alumina lined ceramic
Alumina ceramic is a ceramic material with more than 95% AL2O3 as the main raw material and corundum (α-AL2O3) as the main crystal phase. It has high mechanical strength, high hardness, high high temperature insulation resistance, chemical resistance and thermal conductivity. Good and other excellent comprehensive technical performance, high density, low wear, impact resistance product performance characteristics, smooth surface and convenient construction, mainly used in coal, coal preparation, steel, mining, thermal power plants and other industries equipment wear-resistant lining, especially suitable for In the coal preparation plant, the heavy medium coal conveying pipeline, the conveying channel of the mine and the wharf, the discharge port of the spiral pipeline of the blanking chute and the dust equipment are more worn.
     Alumina lined ceramic Wear-resistant pipe parts are widely used in developed countries in Europe and America. After the imported coal preparation technology entered my country in the 1980s, it has gradually occupied a dominant position in my country in recent years, and is currently the product with the longest wear-resistant life.

1. Unique attachment technology
Our company has developed and developed "three insurances": the advanced technology of British Morocco Hi-Tech has been introduced, and the arched principle design is used to customize various radian buckle-groove self-locking arc ceramics according to the size of various pipe diameters. sheet to ensure that there is no gap between the ceramic and the tube wall. It completely solved the problem of ceramic falling off and filled the domestic blank. Currently applying for the National Spark Program project. The ceramic piece forms a 360-degree mechanical self-supporting structure (it will not fall off without glue). The ceramic piece is close to the inner wall of the steel pipe. The flakes will not fall off. The gap between the ceramic piece and the inner wall of the steel pipe is filled with special adhesive glue that is wear-resistant and heat-resistant, which plays a double protection. Make sure that the ceramic piece does not fall off permanently.
2. High-precision tile cutting
The maximum angle of the elbow is designed to be no more than 15 degrees. The parameters such as the width, corner taper and angle of the ceramic block are designed by CAD, and the ceramic block is accurately cut by the diamond cutting blade. The gap between the tiles in the direction of material flow is less than 0.5mm. The gap between the tiles in the vertical direction of the material flow shall not be greater than 1mm, and the level difference between adjacent tiles shall not exceed 1mm.
3. Can withstand harsh working conditions
The alumina ceramics produced by our company are made of high-purity, ultra-fine, single and narrow particle size, high-quality alumina powder treated by spray drying and granulation as raw materials, scientific formula component design and optimized sintering process. The green body only needs to be sintered at a temperature of 1520°C to make the material fully dense, and the lower sintering temperature ensures that the material has a fine-grained structure and solves the problem of deformation.
4. Service life: 5 years for straight pipe packages and 3 years for curved pipe packages under normal conditions.
The alumina ceramic material is selected with high hardness and good wear resistance. The large thickness ceramic block is used as the lining, and the thickness of the lining ceramic layer has two specifications of 4-25mm, which is much larger than the thickness of 3mm and 5mm of the ceramic layer of the general small ceramic sheet and the centrifugal composite casting pipe, so the service life is very long. Under normal working conditions, the service life of the lining with a thickness of 15mm can reach more than 15 to 20 years, and the service life of the lining with a thickness of 25mm can reach more than 30 years.
5. Easy to install
The outer steel shell (material: Q235, thickness of 6-12mm) is lined with a ceramic layer, and the elbow structure is a shrimp joint. The port connection form can adopt various forms according to different design requirements. The elbow has the advantages of light weight, small volume and on-site construction. Good solderability and other advantages
6. High hardness
The HRC of alumina ceramics is greater than or equal to 85, and its hardness is second only to diamond, far exceeding the hardness of wear-resistant steel and stainless steel.
7. Wear resistance
Alumina ceramics use a unique formula of alumina added with a variety of wear-resistant materials, dry pressing, high density, high toughness, high wear resistance and other characteristics. Tested by the Shanghai Institute of Silicate, Chinese Academy of Sciences, the wear resistance of the wear-resistant ceramics produced by our company is 266 times that of manganese steel and 171.5 times that of high-chromium cast iron.
8. Corrosion resistance and high temperature resistance
Alumina ceramics are inorganic oxides with extremely high molecular structure stability, no electrochemical corrosion, and are resistant to corrosion by various acids, alkalis, salt solutions and organic substances. Ceramic temperature resistance up to 1000 ºC.
9. Good self-lubrication, not easy to scale
Alumina ceramics have good self-lubrication and non-adhesion, the roughness is only 1/6 of that of steel pipes, and the flow resistance is small. Its inner diameter design can be reduced by about 15% compared with steel pipes.
10. Impact resistance
The wear-resistant ceramics produced by our company introduce Cr2O3 and TiO2, which are very similar to the lattice of alumina, and add imported ZnO whiskers to form a solid solution with alumina during the sintering process, which can refine the crystal. Due to the high price of this raw material, other domestic manufacturers have not adopted this formula. Our company's wear-resistant ceramic fracture toughness KIC≥4.8Mpa/m2
11. Bonding firmly
In the bonding of ceramic lining plate and steel plate, we use imported special adhesive. The product has the characteristics of strong adhesion, good heat resistance, acid and alkali resistance, corrosion resistance and aging resistance. As a special adhesive for ceramic linings of our company, it has been used by hundreds of customers in the past ten years, and the reliability is very good. So far, there is no case of product falling off. The maximum temperature resistance of special glue is 1000 ºC.
12.light weight, easy to connect
Its density is 3.62g/cm3, which is only one third of that of steel, which reduces the self-weight of the pipeline. There are many ways to connect: flanges, looper flanges, quick connectors, welding.

Shanxi Huazhan Wear-resistant Material Technology Co., Ltd. is located in Gudan Industrial Park, Taiyuan City, Shanxi Province. Covering an area of 25,000 square meters, there are more than 30 engineers and technicians. In the past 20 years, we have been committed to the customization, production and service of wear-resistant and heat-resistant steel products, specializing in providing solutions for wear-resistant and heat-resistant products in power, metallurgy, mining, steel mills, petrochemical, new energy and other industries. A major breakthrough has been made in core technologies such as Wen: the introduction of advanced production technology, a monthly production of 300 tons of wear-resistant pipes, and advanced testing equipment. Our products involve more than 110 varieties in 12 categories and are currently the largest manufacturer of wear-resistant pipe fittings in China.
The company has an independent R&D and design team, 70% of the front-line employees have 10 years of casting experience, the products have passed the Is09001 quality system certification, and have a number of invention patents. The company has always pursued the "quality first, reputation first" business policy, strict quality management, and formed a strict quality restraint mechanism and a reliable quality assurance operation system. Because of reliable product quality, honest business philosophy, and scientific and technological effects, it has won the trust of users, and the scale of the enterprise is developing rapidly. project.