CN104526167B - Hydrogenation reactor cylinder electric smelting manufacturing process - Google Patents

Hydrogenation reactor cylinder electric smelting manufacturing process Download PDF

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Publication number
CN104526167B
CN104526167B CN201410617459.6A CN201410617459A CN104526167B CN 104526167 B CN104526167 B CN 104526167B CN 201410617459 A CN201410617459 A CN 201410617459A CN 104526167 B CN104526167 B CN 104526167B
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electric smelting
heat
hydrogenation reactor
base material
raw material
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CN104526167A (en
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不公告发明人
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South Zeng Cai Science and Technology Ltd.
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South Zeng Cai Science And Technology Ltd
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K28/00Welding or cutting not covered by any of the preceding groups, e.g. electrolytic welding
    • B23K28/02Combined welding or cutting procedures or apparatus

Abstract

Present invention is primarily targeted at, it is provided that a kind of efficiently, low cost, there is the hydrogenation reactor cylinder manufacturing process of excellent mechanical performances.The method is, electric smelting head and base material are connected to two poles, during shaping, raw metal silk material delivers to substrate surface via conveying mechanism and electric smelting head, under the accumulation of graininess auxiliary material is protected, electric arc is produced between raw material thread material and base material, melt portions heap applies auxiliary material and forms melted slag bath, electric current flows through raw material thread material and melted auxiliary material slag bath forms resistance heat and electroslag heat, at arc heat, resistance heat, raw material thread material is made to melt under electroslag three kinds of hot composite high-energy Sources of heat, molten bath, local is formed at substrate surface, continue transferring raw material silk material and auxiliary material, hierarchy slicing data according to formed parts, adopt the electric smelting head relative movement with base material of computerizeing control, realize molten bath quickly cooling Layer by layer solidification accumulation on base material, final shaping hydrogenation reactor cylinder.

Description

Hydrogenation reactor cylinder electric smelting manufacturing process
Technical field
The present invention relates to a kind of hydrogenation reactor cylinder electric smelting manufacturing process.
Background technology
Hydrogenation reactor is the nucleus equipment of various hydrogenation process or hydrogenation plant.Its work condition environment is harsh, technical difficulty is big, manufacturing technology requires height, involves great expense, especially because of the particularity of hydrogenation plant operating condition, reactor corrodes in high temperature hydrogen, hydrogen embrittlement, the temper brittleness damage of chrome-molybdenum steel, Polythionic acid stress corrosion crack, under the influence of the hydrogen of austenitic stainless steel overlay cladding causes the multiple damage factors such as stripping, it is easy to damage occurs so that scrapping.For preventing these destructive damages from occurring, not only there is correct design, select to material and relevant correct manufacturing process also relation is very big.Reactor be designed and manufactured as merit, be one of the important symbol embodying a national general technical merit in the sense.
Hydrogenation reactor material obtains the positive research and development of countries in the world, by the 21/4Cr1Mo steel grade begun most, has developed 21/4Cr1MoV, 3Cr1MoV series, and supporting with the addition of the alloying elements such as Cb, Ti, B, Ca, defines multiple material under series.Simultaneously, along with being gradually increased of container dimensional requires more and more higher with security performance, prepared by hydrogenation reactor material, the most gradually being changed into thicker equipment and materials forging is formed by roll of steel plate weldering. forging stock is through upset, pulling, upset, the forging process of punching, the segregation in centre can be washed out and be mingled with, the mechanical property making shell ring material is improved, thus improving the resistant to hydrogen lesion capability of reactor. material passes through forging, and be aided with subsequent heat treatment process stabilizing tissue and improve performance, therefore the roll of steel plate that compares is welded, endoplasm characteristic (the pure property of forging moulding material, compactness, homogenieity) good;Weld seam is few, does not particularly have longitudinal seam, improves the reliability of the resistance to circumferential stress of reactor;Manufacture assembling easily to ensure simultaneously.
Although the method is widely used in the industrial production, but due to complex process, chemistry with mechanical property control difficulty big, also result in quality stability poor, heat treatment phase uneven microstructure, the shortcomings such as percent defective is high, and forging structure stock utilization is low, when wall thickness is relatively thin, its manufacturing expense is of a relatively high.And estimate in terms of result from final crystal grain, general also only about 4-6 level, additionally, hydrogenation reactor is limited to segmentation material forging the mode of welding composition that the restriction of ingot smelting and FMT is used, also because the continuous trend of mechanical fiber has seriously been isolated in the increase of weld seam, the mechanical property of strong influence material and the security of tankage. and the most easily cause manufacturing schedule to delay, add cost.
Therefore, how can develop required fine grain, all organize, and the good material of comprehensive mechanical property and integral forming method are the difficult point that need to capture of hydrogenation reactor new material research and development and important development direction.
Summary of the invention
In view of this, present invention is primarily targeted at, it is provided that a kind of efficiently, low cost, there is the hydrogenation reactor cylinder manufacturing process of excellent mechanical performances.
For reaching above-mentioned purpose, the hydrogenation reactor cylinder manufacturing process of the present invention is the high energy thermal source using arc heat, resistance heat, electroslag heat to be composited, and the raw metal silk material of fusing conveying continuously, on base material, Layer by layer solidification stack shaping manufactures hardware;
Electric smelting head and base material are connected to two poles, during shaping, raw metal silk material delivers to substrate surface via conveying mechanism and electric smelting head, under the accumulation of graininess auxiliary material is protected, electric arc is produced between raw material thread material and base material, melt portions heap applies auxiliary material and forms melted slag bath, electric current flows through raw material thread material and melted auxiliary material slag bath forms resistance heat and electroslag heat, at arc heat, resistance heat, raw material thread material is made to melt under electroslag three kinds of hot composite high-energy Sources of heat, molten bath, local is formed at substrate surface, continue transferring raw material silk material and auxiliary material, hierarchy slicing data according to formed parts, adopt the electric smelting head relative movement with base material of computerizeing control, realize molten bath quickly cooling Layer by layer solidification accumulation on base material, final shaping hydrogenation reactor cylinder.
In the present invention, hydrogenation reactor monolithic molding cylinder, a diameter of 2-7m, length 2-18m.
In the present invention, shaping raw materials used silk material is the low-alloy steel material of special preparation, raw material thread material diameter 2-8mm, C content 0.08-0.12%, workpiece C content 0.04-0.08% after shaping, workpiece grain size 7-9 level for hydrogenation reactor component.
In the present invention, control base material or deposit preheating is 120~450 DEG C with interlayer temperature, electric smelting head is 300~800mm/min with the relative moving speed of base material, realize the rapid solidification in molten bath, thus obtain crystal grain fine and closely woven, without gross segregation, the material of even tissue, improve the mechanical properties such as the plasticity of Forming Workpiece, toughness and high-temerature creep greatly.
In the present invention, during successively shaping, raw material thread is in formation molten bath, lower metal surface, and after molten drop enters molten bath with shape of plasma jet, solidification makes double layer of metal form one, it is achieved layering shapes, overall fusion, it is ensured that shape the overall performance of barrel components.
In the present invention, single electric smelting head is 20~50Kg/h to raw material thread material melting efficiency, additionally realizes Quick-forming for raising deposition efficiency, and the quantity of electric smelting head can be adjusted to 1~100 on demand, when many electric smelting head is arranged, adjacent electric smelting head spacing is 50~500mm.
In the present invention, base material can be 309 stainless steel materials or carbon steel or alloy steel material, when for 309 stainless steel material, workpiece can be synthesized as dissimilar material joining, for base material can be removed when carbon steel or alloy steel material in follow-up machining, substrate sizes, shape are mated with hydrogenation reactor cylinder inboard wall size shape, and thickness is not less than 5mm.
The present invention has broken away from the constraint of frock, mould and the specific purpose tool of complexity;Shaping is near net-shaped blank, only need to finish on a small quantity after production, is greatly simplified manufacturing procedure, shortens production life cycle;Workpiece formed thereby has mechanics and a chemical property of the conventional forging process that matches in excellence or beauty, and intensity, toughness, the performance such as anti-corrosion are the most prominent;It is simultaneously achieved the monolithic molding of hydrogenation reactor cylinder, breaches the limitation of conventional forging process technology, substantially increase efficiency, provide cost savings.
Accompanying drawing explanation
Figure 1A is the principle schematic for the electric smelting method in detailed description of the invention is described;
Figure 1B is the partial enlarged drawing in Figure 1A near position shown in A;
Fig. 2 is the hydrogenation reactor cylinder manufacturing process schematic diagram for illustrating in embodiment.
Detailed description of the invention
With reference to the accompanying drawings the detailed description of the invention of the present invention is illustrated.Figure 1A is the principle schematic for the electric smelting method in detailed description of the invention is described;Figure 1B is the partial enlarged drawing in Figure 1A near position shown in A.Owing to being schematic diagram, thus, in figure, parts are schematic, and its true form is not limited by the illustration with size relationship etc..
This manufacturing process be raw material thread material 1 is melted and successively (state time shown in Fig. 1 for being accumulated to n-th layer) be deposited on the material 2 of basis, thus ultimately form required hardware.
Being embodied as operation is:
A. the surface of the base material 2 being positioned on workbench 21 delivered to by raw material thread material 1 by wire feeder 5, and it covers the graininess auxiliary material carried by powder feeding mechanism 4.
B. power supply 12 is started, supply voltage makes to form electric arc 9 between raw material thread material 1 and base material 2 and produces arc heat, arc heat makes partial supplementary material 3 melt, form auxiliary material slag bath 8, electric current flows through raw material thread material 1 via electric smelting 6 and forms resistance heat, and forms electroslag heat by melted slag bath 8, and three kinds of thermals source are composited high energy thermal source, melt raw material silk material, in formation molten bath, base material 2 surface 11.
C. electric smelting 6 and the relative movement of base material 2 and the temperature of base material 2 are controlled, it is achieved molten bath 11 and base material heat exchange solidification deposition.
D. wire feeder 5 continues transferring raw material silk material 1 and auxiliary material 3 with powder feeding mechanism 4, and when auxiliary material 3 covers molten bath 11 and base material 2, raw material thread material 1 is successively deposited on base material 2, final Forming Workpiece.
Wherein, the relative movement mode of device (computer) (numerical simulation, Mathematical Modeling) hierarchy slicing Data Control electric smelting 6 according to Forming Workpiece and base material 2 is controlled.
In the present invention illustrates, electric smelting tip electrode just connects, and workpiece connects to bear only makees signal effect, it is also possible to electric smelting head connects negative, and workpiece just connects, or takes AC power.
In the present invention, in order to ensure to form good high energy thermal source, especially for producing sufficient electroslag heat, can suitably regulate the parameter such as relative moving speed of the composition of auxiliary material, the diameter of raw material thread material, electric current, base material and raw material thread material.
In the present invention, the form of raw material thread 1 can be pole shape, banding, real core or medicine core;The diameter of raw material thread 1 can be dimensioned so as to 2~8mm according to Forming Workpiece;Different according to silk material 1 diameter, the length (energized length) stretching out electric smelting head is 20mm~150mm.
In the present invention, auxiliary material 3 cladding thickness is 15mm~120mm, uses the effect of auxiliary material 3 to include: to cover electric arc 9, prevent electric arc from splashing;Cover molten bath 11, completely cut off air, make molten pool metal from the infringement of oxygen, nitrogen, hydrogen etc. in air;Molten pool metal is formed insulation;Go the removal of impurity during metallurgical reaction, mix alloy;The slag bath 8 (skull 7) formed mechanically protects deposition metal 10 well shaping etc..
The composition of auxiliary material 3 comprises oxide or oxide and halide, owing to auxiliary material 3 participates in melt tank reaction, adjust workpiece (hardware, product) composition, thus according to the composition of hardware to be formed and efficiency requirements, alloy powder and/or elemental metals powder can be added in auxiliary material, reduce production cost.
It addition, in C operation, can incidentally reclaim remaining auxiliary material and remove slag bath 8 and solidify and the operation of skull 7 that formed.During removal, machine can be started at relative movement rear 400mm~500mm of raw material thread 1 and remove or artificial removal's operation.
Using the electric smelting manufacturing process of present embodiment, raw material thread utilization rate is close to 100%;Compare existing process technology (forge, casting etc.), manufacturing process's few (need not the heat treatment of complexity), the cycle is short, and efficiency is high, the machine-finish allowance of hardware is the least, decreases the finishing time simultaneously and has saved substantial amounts of material.
[embodiment]
This example describes and melts manufacturing process making hydrogenation reactor cylinder process by Horizontal electric, cylinder material is 21/4Cr1Mo, reference and ASME standard SA387F22, after the making of traditional handicraft cylinder, inwall needs 309 stainless steel layers of built-up welding thickness about 7mm, and the equipment used includes:
(1) revolving support platform;
(2) electric smelting power supply;
(3) electric smelting head;
(4) automatic wire feeding device;
(5) auxiliary material automatic transport and auxiliary material automatic recycling device;
(6) heater;
(7) cooling device;
(8) base material;
(9) device is controlled.
Fig. 2 be the electric smelting manufacturing process for representing the present embodiment schematically illustrate figure, figure eliminates the device such as power supply, automatic wire feeding device.Material power parameter is as follows:
1) raw material thread material 101 (C:0.11-0.12%, other element is consistent with SA387F22), diameter 5mm;
2) auxiliary material 301 of special development, composition is 20%CaO+MgO;45%Al2O3+MnO;25%SiO2+TiO;10%CaF2
3) electric smelting head quantity: 39 electric smelting 601, electric smelting power supply is dc source, uses electric smelting 601 to connect power cathode, and base material 201 connects positive source (so connecing, it is possible to be greatly improved working (machining) efficiency);
4) electric smelting technological parameter is: electric smelting electric current 900A, electric smelting voltage 42V, electric smelting 601 and base material 201 relative moving speed 600~700mm/min (molten bath translational speed).
Using hardware electric smelting manufacturing process to make barrel components, implementation step is as follows:
(1) axis horizontal of columnar base material 201 is configured, and be supported on revolving support platform, 39 electric smelting heads are arranged in the top of base material 201 with spacing (CCU determines exact position and the movement) average transverse of about 400mm, and adjust the distance of each electric smelting head and base material 201 surface (outer peripheral face), and choose the starting point of electric smelting;
(2) raw material thread material 101 and auxiliary material are delivered to base material 201 surface, start power supply, import high energy thermal source, melt raw material silk material and auxiliary material, rotate base material 201 simultaneously, start the electric smelting deposition of each electric smelting head ground floor first (each layer is made up of the multiple tracks axially arranged);
(3) after forming a segment distance between electric smelting 601 and electric smelting starting point, start to start auxiliary material retracting device and its unfused auxiliary material is regained, expose skull and removed, in order to lower electric smelting deposition (accumulation) together;Electric smelting deposition metal is cooled down or heats by subsequent start-up cooling device or heater, controls the temperature of its matrix (referring to base material 201 during ground floor, refer to preceding layer deposit when other layer) at 200~300 DEG C;
(4) when base material 201 rotate a circle complete first electric smelting deposition time, under control of the control means, all electric smelting 201 rectilinear movement of simultaneously turning left 3/4 melts width distance, adjust each electric smelting 601 to control to adjust the distance between five electric smelting heads of numbering 18-22 and the surface of base material 201 especially by central authorities simultaneously, to ensure the stability of electric smelting, starting the electric smelting deposition formation of ground floor second afterwards, between ensureing during this to enclose around, overlap joint is good;
(5) after second completes, repeat the shaping that step (4) completes other electric smelting deposition road again, when reaching last one, last one end point of its adjacent electric smelting head and first starting point to overlap well, so that completing the electric smelting deposition of ground floor;
(6) after the electric smelting completing ground floor deposits, one layer of deposit thickness of all electric smelting head automatic liftings (i.e. after layer) height, starting the first electric smelting deposition of the second layer, the end point of ground floor electric smelting head is the starting point of second layer first, successive sedimentation;
(7) after second layer first electric smelting has deposited, all electric smelting heads simultaneously turn right rectilinear movement 3/4 melt track pitch from, the most each electric smelting head adjusts the distance between itself and base material automatically, to ensure the stability of electric smelting, start the electric smelting deposition of second layer second so that it is between circle road, left and right, overlap joint is good;
(8) when completing second layer second electric smelting and having deposited, repeat step (7), then the electric smelting completing other deposits road, when reaching last one, last one end point of its adjacent electric smelting head and first starting point to overlap well, so that completing the electric smelting deposition of the second layer;
(9) repetition step (6) is to step (8), then completes other electric smelting sedimentary, and during this, the moving direction of adjacent electric smelting sedimentary electric smelting head can be contrary, and final continuous electrofusion deposition forms whole barrel components.
After electric smelting shapes, stainless steel substrate 201 becomes a part for hydrogenation reactor cylinder, achieve foreign material to be directly connected to shape, thus change traditional handicraft stainless manufacture of wall built-up welding the most within it 309 after forging hydrogenation reactor cylinder, decrease technique process, improve operating efficiency and quality, it is also possible to ordinary carbon steel is removed in follow-up machining.
According to conventional forging process, hydrogenation reactor cylinder is divided into multistage, each section respectively forging integral assembly welding again form, and the present embodiment is owing to being multiple (34) electric smelting monolithic molding arranged side by side, greatly improves forming efficiency;Naturally also can adjust electric smelting head quantity and arrangement, sectional forming according to customer requirement.

Claims (4)

1. a hydrogenation reactor cylinder electric smelting manufacturing process, it is characterised in that:
The method is the high energy thermal source using arc heat, resistance heat, electroslag heat to be composited, the metal of fusing conveying continuously Raw material thread material, on base material, Layer by layer solidification stack shaping manufactures hardware;
Electric smelting head and base material are connected to two poles, and during shaping, raw metal silk material delivers to base via conveying mechanism and electric smelting head Material surface, under the accumulation of graininess auxiliary material is protected, produces electric arc between raw material thread material and base material, melt portions heap applies auxiliary material Forming melted slag bath, electric current flows through raw material thread material and melted auxiliary material slag bath forms resistance heat and electroslag heat, at arc heat, electricity Make raw material thread material melt under thermal resistance, electroslag three kinds of hot composite high-energy Sources of heat, form molten bath, local at substrate surface, Continue transferring raw material silk material and auxiliary material, according to the hierarchy slicing data of formed parts, adopt computerized control electric smelting head and base The relative movement of material, it is achieved molten bath is quickly cooling Layer by layer solidification accumulation on base material, final shaping hydrogenation reactor cylinder;
Raw material thread material is low-alloy steel material, raw material thread material diameter 2-8mm, C content 0.08-0.12%, workpiece C after shaping Content 0.04-0.08%, workpiece grain size 7-9 level;
Substrate material is 309 stainless steels or ordinary carbon steel or other steel alloy, when for 309 stainless steel, after component shaping Base material is retained as a Forming Workpiece part, when for ordinary carbon steel or other steel alloy, and can be in follow-up machining Remove;
According to Forming Workpiece requirement, base material or deposit are heated or cooled, control base material or deposit layer Surface temperature is 120~450 DEG C.
Hydrogenation reactor cylinder electric smelting manufacturing process the most according to claim 1, it is characterised in that:
According to hydrogenation reactor equipment and efficiency requirements, shape barrel diameter 2-7m, length 2-18m.
Hydrogenation reactor cylinder electric smelting manufacturing process the most according to claim 1, it is characterised in that:
Different according to silk material diameter, the electric current in power parameter is 200A~3000A, and voltage is 20V~60V, and power supply is Direct current or AC power, when using dc source, electric smelting head connects negative or positive electrode.
Hydrogenation reactor cylinder electric smelting manufacturing process the most according to claim 1, it is characterised in that:
According to reactor shell formed parts size and forming efficiency requirement, the quantity set of electric smelting head is 1~100, During the arrangement of many electric smelting head, adjacent electric smelting head spacing is 50~500mm.
CN201410617459.6A 2014-11-04 2014-11-04 Hydrogenation reactor cylinder electric smelting manufacturing process Active CN104526167B (en)

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CN104526171B (en) * 2014-11-04 2016-10-12 南方增材科技有限公司 Hardware electric smelting manufacturing process
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CN106956003B (en) * 2017-03-23 2019-07-26 南方增材科技有限公司 A kind of metal cylinder electric smelting increasing material manufacturing system
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CN112792433B (en) * 2021-01-15 2022-04-12 南方增材科技有限公司 Preparation method of high-toughness low-alloy steel member and high-toughness low-alloy steel member

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Patentee before: Wang Jun

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