CN101489709A - 热交换器制造方法 - Google Patents
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- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
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- F28F1/10—Tubular elements and assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with projections, with recesses
- F28F1/12—Tubular elements and assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with projections, with recesses the means being only outside the tubular element
- F28F1/126—Tubular elements and assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with projections, with recesses the means being only outside the tubular element consisting of zig-zag shaped fins
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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Abstract
本发明涉及一种用于制造热交换器的方法,其包含以下步骤:a)对一钢片进行热浸镀精制,以便形成一防蚀层(3),该防蚀层(3)含有锌及介于0.5%与60%之间的铝;b)将该防蚀层(3)从该钢片的一侧移除;c)由此钢片制造一热交换器导管(2),该防蚀层(3)设置在外侧上;d)提供由铝或一铝合金制成的肋片(6);e)提供一助熔剂;f)在所述肋片(6)与该热交换器导管(2)的该外部之间的连接区域中提供一含有铝及硅的焊接材料(8);g)在一硬钎焊过程中将该热交换器导管(2)与所述肋片(6)连接。
Description
技术领域
本发明涉及一种用于制造具有权利要求1的特征的热交换器的方法。
背景技术
许多年来,特别在发电厂技术中,空气冷却式热交换器已被用于水蒸汽的再冷却。这种热交换器涉及以A形方式设置的热交换器束的排列,其中水蒸汽在导管内部冷凝。至环境空气的热传递通过与导管连接的肋片而得以改良。为了确保尽可能数十年的运作寿命,抗腐蚀性对于这种空气冷却式热交换器而言是重要的。由此,曾作出一系列努力来以抗腐蚀方式设计这种热交换器的热交换器导管。由美国专利US-PS5,042,574已知在使用铝硅焊料的情况下在回火炉中将镀铝扁平导管与以波状方式折叠的铝肋片条连接。此类型的连接的缺陷为:焊接仅可通过绕开镀铝扁平导管及/或借助经覆镀的铝肋片而制成。除了由于需准备多种不同材料而导致相对较高的费用以外,其另外所涉及的缺点为:在周边上由至少一个纵向焊缝所封闭的扁平导管在焊接区中可能不被镀铝,因为否则其不可能确保完好的焊接。由钢制成的扁平导管与折叠式铝肋片条的硬钎焊所呈现的问题为:钎焊必须在约600℃的量值级(亦即,接近于铝的软化温度)的相对较高的温度下执行。所需焊料通常由在稍低于铝的软化点时熔融的铝硅共熔混合物构成。助熔剂的选择是困难的,其在焊料熔化之前必须移除连接表面的氧化层,但同样地在接近于软化温度时液化。因此,在焊接期间正确的温度引导通常仅可根据经验来判定。
因为铝与钢的温度膨胀系数不同,所以可能会因为高焊接温度且因为后续冷却至环境温度而产生显著的材料应力,使得相互连接的部分可能变形,在此情况下,如果由于在硬钎焊期间熔化而未完好地施加铝镀层或因为在钢导管与铝镀物之间形成中间铁铝层,则焊接连接甚至可能破裂。
因此,在EP 1 250 208 B1中建议通过使用锌铝合金及通过使用以四氟化钾铝的特殊助熔剂来将焊接温度自迄今的大约600℃降低至介于370℃与470℃之间的温度范围。因为温度较低,材料应力同样地较小。然而,助熔剂的处理由于重金属含量而要求特定保护性措施,以便避免环境污染。
发明内容
由此出发,本发明的目的在于提供一种用于制造热交换器的方法,其中将铝或铝合金制成的肋片固定于由钢片制成的热交换器导管上,所述热交换器导管具有外侧的能够焊接的防蚀层,其中可省去使用含重金属的助熔剂,但仍能同时确保在防蚀层与钢导管之间不形成不合人意的铁铝中间金属连接或所述连接的中间相,以便即使在更高的焊接温度下仍能确保肋片与热交换器导管之间的牢固连接。
通过具有权利要求1及4的特征的方法来实现此目的。
本发明构思的有利的其他扩展结构是从属权利要求的主题。
在根据本发明的方法中规定:通过热浸镀精制用于制造热交换器导管的钢片。热浸镀精制方法导致在所精制的产品上沉积防蚀层,以便保护基板以免受腐蚀侵蚀。
通常,在熔融液体的金属浴槽中发生实际热浸镀精制之前,清洁、在连续炉中再结晶或加热在热浸镀精制中所采用的扁平制品,且将其冷却至金属熔体的温度。当穿过浴槽时,基板的两侧被涂覆有防蚀层。
然而,仅在热交换器导管的外部上需要腐蚀保护。虽然已知将包括具有封闭导管端的肋片的整个热交换器导管浸渍于金属熔体中,以便为整个热交换器导管连同肋片设置防蚀层。然而,由于肋片的表面大于热交换器导管的表面,故需要很大量的金属熔体,这增加了顾及用于发电厂中水蒸气的冷凝的热交换器的尺寸的成本。热交换器导管的长度通常介于6与12米之间,此外,其需要相应大的热浸镀装置。此外,由于在后续热浸镀中的高温在构件中会产生应力,从而导致其变形。
相反地,根据本发明的方法,在热浸镀方法中预先施加防蚀层且将其从钢片的一侧特别是以机械方式移除。以此方式去除防蚀层的一侧随后形成由此钢片制成的热交换器导管的内侧。因此,防蚀层仅存在于热交换器导管的外部上。用于在外侧涂覆热交换器导管的制造方法本身考虑以下事实,即:必须设有用于移除防蚀层的机械的装置,结果是成本低廉并且因此相当地经济。
根据本发明的方法尤其适于用于在发电厂中冷凝水蒸汽的热交换器的制造,因为用于给水的水化学性方面通常要求在与蒸汽接触的各表面上不能有非铁金属,诸如铝或铜。此外,在冷凝过程中形成磁铁层,其保护热交换器导管以在内部上免受腐蚀,故在内部不需要额外的腐蚀保护。
本发明的重要优点在于:在外侧将采用防蚀层,其至少含有锌及介于0.5%与60%之间、优选为4%与55%之间的铝。锌的存在防止或减少形不合人意的金属间的铁铝中间层或铁铝连接的中间相,其在后续的硬钎焊期间可能会导致以往铝化的钢导管的脱落。由于不再需要以与迄今相同的方式来考虑不合人意的金属间的铁铝中间层,故制造方法同样明显地简化,因为关于用于制造硬钎焊连接的温度及时间段的参数范围可选择为大于以往的与镀铝钢导管相关的硬钎焊连接的参数范围。
另外的优点为:可免除含铯助熔剂。实际上,可与含有铝及硅的焊接材料一起使用基于四氟化钾铝的助熔剂。
在根据本发明的方法的第一变型中设定:至少在局部区域中,肋片上镀覆有焊接材料。尤其在是波状肋片条的构件的肋片上,肋片的两侧进行焊接剂镀覆,以便将这种肋片条在其面对热交换器导管的表面的一侧上分别上述肋片连接。与肋片的焊接在此在波状肋片条的弧形的区域中进行。经镀覆的焊接材料在焊接过程中熔融且流入待连接的组件之间的相应的焊接间隙中。
另一替代实施方式规定:肋片是未镀覆的,亦即,不设有焊接剂层,焊接材料单独地引入至肋片与热交换器导管之间的焊接间隙中。此方法所提供的优点为:对于肋片,可使用更有利的原始材料。即使将焊接材料单独地引入至焊接间隙中,可靠的焊接仍是可能的。
在该方法的第三变型中可考虑的是,省略肋片的焊接材料及焊料涂层的供应,然而,在此情况下,防蚀层由含有锌及介于0.5%与60%之间的铝以及硅的合金形成,且在此情况下,焊接材料由防蚀层本身形成。在此方法中,钢片也未镀覆有铝层,但被设有以热浸镀方法施加的防蚀层,其同时构成焊接材料。当然,有可能的是,亦在此变型中,将焊接材料单独地添加至连接区。不言而喻,也不排除对肋片进行焊料涂覆。最后,可组合所有三个变型方案,其中在热交换器导管上的防蚀层同时形成用于焊接过程所需的焊接材料的变型方案是对于方法技术及经济原因的最有吸引力的解决方案。
与采用哪一个变型方案无关,如果通过由含有55%的铝、43.4%的锌及1.6%的硅的浴槽的热浸镀精制来制造防蚀层,则认为该变型方案是有利的。在根据本发明的方法中,认为防蚀层中60%的铝的上限为合适的。但原则上,也可以考虑的是在此方法中使用具有显著较低的铝含量的防蚀层。特别是铝含量可低于50%。在另一实施方式中,可通过由包含5%的铝、硅及微量稀土的锌浴槽的热浸镀精制来制造防蚀层。
当焊接铝时,所使用的助熔剂也具有决定性的意义。为了焊接的目的,必须通过移除始终存在的氧化层来将结合区域的表面清洁至金属光洁状态,且其必须在焊接期间通过使用助熔剂来保护以免受形成新的氧化物。事实证明:由氟化钾铝(KAlF4)组成的助熔剂已证明为尤其有效的。特别是要在受控气氛(CAB)中,特别是在氮气氛中执行该方法。
因为在根据本发明的方法中要以机械方式移除防蚀层中的一个,可能有利的是以不同的厚度将防蚀层施加至钢片上,且将防蚀层中的较薄的防护层移除。以此方式,减少了比钢更为贵重的涂层材料的损耗以及减少用于移除防蚀层的耗费。
移除防蚀层时优选以机械方式、特别是通过切削加工的方法来执行。这可通过旋转的毛刷来完成,因为毛刷的几何形状同时允许对表面的精加工。原则上,热浸镀方法中所施加的防蚀层具有较小厚度,使得旋转的毛刷工具优选适于以经济的方式来特定地移除这种较小厚度。当然,对于较大的层厚度,亦有可能在毛刷处理之前连接刨削或刮削工具,以便执行腹板材料的粗加工。试验表明:优选装备有金刚石的毛刷头部会引起有利的处理结果。这种毛刷头部可以这样地构造,使得它拥有较长使用寿命且同时具有高的移除效率。
不言而喻,本发明的范围内不排除在通过旋转毛刷的机械移除之后为其他精加工步骤,如果这是必要的话。可想到的是,表面紧接在毛刷处理之后经受研磨处理,其中,即使没有通过研磨头的极精细的加工,也有可能单独通过毛刷处理来实现具有240至1000微米的粒度大小的表面。
附图说明
在下文通过附图中所示出的实施例而更详细地阐述本发明。
图1为穿过包含周边肋片的传热器的导管的壁的纵向截面;
图2为图1的根据另一实施例的视图;及
图3为图1的在第三实施例中的视图。
具体实施方式
在图1至图3中,用1来表示用于未详细示出的热交换器的由碳钢组成的热交换器导管2的壁,该热交换器为用于蒸汽涡轮机的空气冷却式冷凝设备的形式。热交换器导管2可以具有介于6与12米之间的长度。根据图1的实施例,热交换器导管2设有含有锌(Zn)及铝(Al)的防蚀层3。防蚀层3通过热浸镀方法被施加至壁1的外表面4。
图1进一步示出:波状的肋片条5固定于热交换器导管2的所示出的壁1上。肋片条5由多个彼此平行地定向的肋片2构成,它们通过弧形的部段7一体地相互连接。肋片条5由铝制成。其在两侧上通过在焊接过程期间熔融的含有铝及硅的焊接材料8镀覆。焊接材料8含有介于7.5%与12%之间的硅。在受控的炉气氛中,将KAlF4(钾铝四氟化物)作为助熔剂供给焊接过程。在焊接期间,焊接材料8置换()助熔剂(未详细图示),且造成防蚀层3与肋片条5的弧形的部段7之间的连接。在焊接过程中,在相互待连接的构件的边界面中的极窄区内的原子之间发生扩散交换。由于防蚀层3优选含有55%的铝、43.4%的锌及1.6%的硅,锌的存在引起由钢制成的热交换器导管2与防蚀层3之间的牢固的结合,然而,至少没有显著地形成会导致影响的强度的铁铝中间层。
图2的实施例与图1的实施例的不同之处在于:焊接材料8未被镀覆在肋片6上,但被单独地引入至焊接间隙中,且当然在使用钾铝氟化物的助熔剂的情况下被引入至焊接间隙中。
在第三实施例中,如图3中所示,省去了以经覆镀的肋片的形式的焊接添加剂,如图1中所示的。同样地也未添加单独的焊接材料,如图2所示的。而是,防蚀层3由55%的铝、43.4%的锌及1.6%的硅所组成的合金制成,其通过热浸镀精制而被施加至热交换器导管2上且在焊接过程期间在使用KAlF4作为助熔剂来进行熔融,使得防蚀层3在肋片6和热交换器导管2之间直接接触。通过防蚀层3中的锌及铝含量允许在由铝制成的肋片6与由钢材料制成的热交换器导管2之间建立结合。
附图标记列表
1 壁
2 热交换器导管
3 防蚀层
4 1的表面
5 肋片条
6 肋片
7 9的弧形的部段
8 焊接材料
Claims (9)
1.一种用于制造一热交换器的方法,其包含以下步骤:
a)对一钢片进行热浸镀精制,以便形成防蚀层(3),该防蚀层(3)含有锌和介于0.5%与60%之间的铝;
b)从该钢片的一侧将防蚀层(3)移除;
c)由该钢片制造一热交换器导管(2),其中该防蚀层(3)设置在外侧上;
d)提供由铝或一铝合金制成的肋片(6);
e)提供一助熔剂;
f)在所述肋片(6)与该热交换器导管(2)的外侧之间的连接区域中提供一含有铝及硅的焊接材料(8);
g)在一硬钎焊过程中将该热交换器导管(2)与所述肋片(6)连接。
2.如权利要求1的方法,其特征在于:至少在局部区域中用该焊接材料(8)镀覆所述肋片(6)。
3.如权利要求1的方法,其特征在于:在将焊接材料(8)引入到所述肋片(6)与该热交换器导管(2)之间的焊接间隙的情况下,将未镀覆的肋片(6)与该热交换器导管(2)焊接。
4.一种用于制造一热交换器的方法,其包括以下步骤:
a)对一钢片进行热浸镀精制,以便形成一防蚀层(3),其中该防蚀层(3)含有锌、介于0.5%与60%之间的铝以及硅;
b)从该钢片的一侧将防蚀层(3)移除;
c)由此钢片制造一热交换器导管(2),该防蚀层(3)设置在外侧上;
d)提供由铝或一铝合金制成的肋片(6);
e)提供一助熔剂;
f)在所述肋片与形式为防蚀层(3)的热交换器导管的外侧之间的连接区域中提供一含有铝及锌的焊接材料;
g)在一硬钎焊过程中将该热交换器导管(2)与所述肋片(6)连接。
5.如权利要求1至4中任一项的方法,其特征在于:该防蚀层(3)通过由一含有55%的铝、43.4%的锌及1.6%的硅的浴槽的热浸镀精制而制成。
6.如权利要求1的方法,其特征在于:该防蚀层(3)通过由一含有5%的铝、硅及微量稀土的锌浴槽的热浸镀精制而制成。
7.如权利要求1至6中任一项的方法,其特征在于:该助熔剂为一种四氟化钾铝化合物。
8.如权利要求1至7中任一项的方法,其特征在于:将所述防蚀层(3)以不同的厚度施加至该钢片上,其中将所述防蚀层中的较薄的防蚀层移除。
9.如权利要求1至7中任一项的方法,其特征在于:该防蚀层(3)的移除以机械的方式进行。
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CN107107226A (zh) * | 2014-10-29 | 2017-08-29 | 法孚低温设备公司 | 耐腐蚀热交换器基体和制造该基体的方法 |
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CN102782438A (zh) * | 2010-02-26 | 2012-11-14 | Nbbk股份有限公司 | 制造板式热交换器的方法 |
CN102350623A (zh) * | 2011-08-31 | 2012-02-15 | 金龙精密铜管集团股份有限公司 | 一种铝合金热交换器的制造方法 |
CN107107226A (zh) * | 2014-10-29 | 2017-08-29 | 法孚低温设备公司 | 耐腐蚀热交换器基体和制造该基体的方法 |
CN107107226B (zh) * | 2014-10-29 | 2020-08-14 | 法孚低温设备公司 | 耐腐蚀热交换器基体和制造该基体的方法 |
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EP2081722A1 (de) | 2009-07-29 |
EP2081722B1 (de) | 2011-01-26 |
AU2007308537A1 (en) | 2008-05-02 |
KR20090032084A (ko) | 2009-03-31 |
US20090307907A1 (en) | 2009-12-17 |
WO2008049383A1 (de) | 2008-05-02 |
ATE496719T1 (de) | 2011-02-15 |
AP2009004751A0 (en) | 2009-02-28 |
KR101044142B1 (ko) | 2011-06-24 |
TW200821073A (en) | 2008-05-16 |
DE102006050681B3 (de) | 2007-12-27 |
ES2360374T3 (es) | 2011-06-03 |
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EP2081722B8 (de) | 2011-03-02 |
AR063360A1 (es) | 2009-01-21 |
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CA2657473A1 (en) | 2008-05-02 |
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