CN109648768B - 一种钢衬四氟笼箍等钢复合工艺 - Google Patents
一种钢衬四氟笼箍等钢复合工艺 Download PDFInfo
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- 239000010959 steel Substances 0.000 title claims abstract description 65
- 238000000034 method Methods 0.000 title claims abstract description 20
- 238000013329 compounding Methods 0.000 title claims abstract description 6
- 229920001343 polytetrafluoroethylene Polymers 0.000 claims abstract description 55
- 239000004810 polytetrafluoroethylene Substances 0.000 claims abstract description 55
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- 239000000523 sample Substances 0.000 claims description 6
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- 238000012797 qualification Methods 0.000 claims 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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- F16L58/00—Protection of pipes or pipe fittings against corrosion or incrustation
- F16L58/18—Protection of pipes or pipe fittings against corrosion or incrustation specially adapted for pipe fittings
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract
本发明属于钢衬四氟笼箍等钢复合工艺技术领域,尤其是一种钢衬四氟笼箍等钢复合工艺,针对现有的PTFE衬层脱落、起鼓吸瘪、膨胀变形问题,其包括以下工艺步骤,模压,再通过水压接口向工件壳体内加压注水,使压力达到设定的最高值,并压力要保持3‑4小时;膨胀填充物,再将聚四氟乙烯粉料注入S6中的缝隙间;烧结,装炉烧结;炉中预热6小时,使聚四氟乙烯层与金属件达到同步热变系数,在进行逐步升温,升温过程要缓慢有序进行,最后达到385摄氏度,保温6小时,而后慢慢分阶段的降温,烧结全过程36小时。本发明通过等钢复合工艺制作的钢衬四氟笼箍管道设备,耐腐蚀效果好,复合效果好,不会自动脱落,更不会起鼓吸瘪、膨胀变形。
Description
技术领域
本发明涉及钢衬四氟笼箍等钢复合工艺技术领域,尤其涉及一种钢衬四氟笼箍等钢复合工艺。
背景技术
强腐蚀、高低温及负压领域特制的管道,需要耐腐蚀、耐高温性能的管道,现有的管道一体性较差,内部耐腐蚀层吸附能力弱;聚四氟乙烯(简写为PTFE),一般称作“不粘涂层”或“易清洁物料”。这种材料具有抗酸抗碱、抗各种有机溶剂的特点,几乎不溶于所有的溶剂。同时,聚四氟乙烯具有耐高温的特点,它的摩擦系数极低,所以可作润滑作用之余,亦成为了易清洁水管内层的理想涂料。
如何将聚四氟乙烯衬在钢管的内壁上,还能适应在正负压、高温度、强腐蚀、骤冷骤热或冷热交替的恶劣环境下使用,不会导致PTFE衬层脱落、起鼓吸瘪、膨胀变形等现象,本发明提出在模压的基础上实施等钢复合,通过内部结构处理,增强附着力,衬里结构增加钢带,使其在等钢复合的同时,大大提高了钢塑附着强度,为此,本发明提出一种钢衬四氟笼箍等钢复合工艺。
发明内容
本发明提出的一种钢衬四氟笼箍等钢复合工艺,解决了现有PTFE衬层脱落、起鼓吸瘪、膨胀变形问题。
为了实现上述目的,本发明采用了如下技术方案:
一种钢衬四氟笼箍等钢复合工艺,包括以下工艺步骤,
S1,外壳制作,按照工件的几何形状,制作工件壳体、橡皮内膜和定性内模;
S2,制作笼箍,准备与工件壳体内壁相吻合的环状钢板,在环状钢板的周向表面等距离开设有开孔;
S3,将多个环状钢板等距离焊接在工件壳体的内壁上;
S4,第一次检验,焊接按照高压容器制作标准,严格控制生产过程;
S5,喷砂,任何壳体和需衬氟的部件,都必须在衬氟前,对金属表面进行喷砂处理,除净所有金属表面上的油脂,氧化皮、锈蚀产物及一切杂物,达到金属表面无任何可见残留物,呈现均一的金属本色,并带有粗糙度,应达到HGJ34-90中的的技术要求标准,金属壳体方能达到衬里施工要求;
S6,组装,将工件壳体、橡皮内膜和定性内模组装一起,再和工件整体组装起来,根据厚度需求计算,工件壳体和工件之间有间距,向缝隙间中均匀加入聚四氟乙烯粉料;
S7,模压,再通过水压接口向工件壳体内加压注水,压力分阶段进行,要使聚四氟乙烯粉料内的气体逐渐排出,使压力达到设定的最高值,并压力要保持3-4小时;
S8,第二次半成品检验,泄压后对半成品进行检验,包括密度、厚度及电火花测漏检验,再装入橡皮内膜和定性内模;
S9,膨胀填充物,再将聚四氟乙烯粉料注入S6中的缝隙间;
S10,烧结,装炉烧结;炉中预热6小时,使聚四氟乙烯层与金属件达到同步热变系数,在进行逐步升温,升温过程要缓慢有序进行,最后达到385摄氏度,保温6小时,而后慢慢分阶段的降温,烧结全过程36小时;
S11,车削密封面,拆除模具,再进行成品表层处理、法兰密封面聚四氟乙烯层车削,用电火花检测仪对衬里层进行微孔检测,检测质量缺陷,根据聚四氟乙烯衬里厚度输出电压20kV-30kV,探头在防腐衬里层上面移动速度不超过100mm/s探测,以不击穿为合格,检验合格的产品进行金属外壳喷漆处理,再由质量部门对成品进行检验,成品合格的进行包装入库。
优选的,所述S3中,将环状钢板的开孔中预先填充有四氟粉料,形成聚四氟乙烯附层。
优选的,所述S7中,使用水压机加压注水,使内部橡皮内膜膨胀,压力至10MPa-22MPa;在压力作用下,使达到2.16-2.27g/cm3的密度而成型。
优选的,所述S11中,根据四氟衬里厚度输出电压25kV,探头在防腐衬里层上面移动速度50mm/s探测。
优选的,所述S7中,使用水压机加压注水,使内部橡皮内膜膨胀,压力至18MPa;在压力作用下,使达到2.20g/cm3的密度而成型。
一种钢衬四氟笼箍管道设备,包括管道设备主体,所述管道设备主体的两端外壁上均焊接有连接法兰,所述管道设备主体包括不锈钢钢管,沿管道设备主体的长度方向且位于不锈钢钢管的内壁上等距离焊接有多个笼箍钢带,且笼箍钢带呈环状带状结构,所述笼箍钢带的内壁周向等距离设有开孔,所述开孔中填充有聚四氟乙烯附层,位于聚四氟乙烯附层和笼箍钢带表面的不锈钢钢管的内壁上设置有聚四氟乙烯衬层。
优选的,所述笼箍钢带与不锈钢钢管的中心轴线处于同一条中心轴线上,笼箍钢带的外壁焊接在不锈钢钢管的内壁上。
优选的,所述管道设备主体的外壁两侧焊接有鞍座。
优选的,所述管道设备主体的外壁中部通过螺钉固定有铭牌。
优选的,所述连接法兰的外壁周向等距离设有安装孔。
与现有技术相比,本发明的有益效果是:利用几何原理制作模具,留出需要衬里厚度的间隙,将PTFE粉料均布投入,使用水压机加压,使内部橡皮模具膨胀,压力至10MPa-22MPa。在压力作用下,使PTFE粉料中的气体排出,并达到2.16-2.27/m3的密度而成型,从而能够优越达到抗渗透、高温和高压的效果;在高温的作用下,使PTFE分子结构紧密结合;高温下橡皮内膜自动膨胀,同时结合PTFE自身的反膨胀力,工件衬层二次受压,同时高温中的PTFE处于熔融状态,使处于熔融状态的PTFE分子结构紧密结合,同时和环状钢板复合在一起,从而达到钢塑一体化的效果,使PTFE与壳体更加紧密复合,从而达到耐高温全真空的效果,通过等钢复合工艺制作的钢衬四氟笼箍管道设备,耐腐蚀效果好,复合效果好,不会自动脱落,更不会起鼓吸瘪、膨胀变形。
附图说明
图1为本发明提出的一种钢衬四氟笼箍等钢复合工艺的工装构造图;
图2为本发明提出的一种钢衬四氟笼箍管道设备的结构示意图;
图3为图2中A部分的放大图;
图4为本发明提出的一种钢衬四氟笼箍管道设备中笼箍钢带的结构示意图。
具体实施方式
下面将结合本发明实施例中的附图,对本发明实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例仅仅是本发明一部分实施例,而不是全部的实施例。
参照图1-4,一种钢衬四氟笼箍等钢复合工艺,包括以下工艺步骤,
S1,外壳制作,按照工件的几何形状,制作工件壳体、橡皮内膜和定性内模;
S2,制作笼箍,准备与工件壳体内壁相吻合的环状钢板,在环状钢板的周向表面等距离开设有开孔;
S3,将多个环状钢板等距离焊接在工件壳体的内壁上;
S4,第一次检验,焊接按照高压容器制作标准,严格控制生产过程;
S5,喷砂,任何壳体和需衬氟的部件,都必须在衬氟前,对金属表面进行喷砂处理,除净所有金属表面上的油脂,氧化皮、锈蚀产物及一切杂物,达到金属表面无任何可见残留物,呈现均一的金属本色,并带有粗糙度,应达到HGJ34-90中的的技术要求标准,金属壳体方能达到衬里施工要求;
S6,组装,将工件壳体、橡皮内膜和定性内模组装一起,再和工件整体组装起来,根据厚度需求计算,工件壳体和工件之间有间距,向缝隙间中均匀加入聚四氟乙烯粉料;
S7,模压,再通过水压接口向工件壳体内加压注水,压力分阶段进行,要使聚四氟乙烯粉料内的气体逐渐排出,使压力达到设定的最高值,并压力要保持3-4小时;
S8,第二次半成品检验,泄压后对半成品进行检验,包括密度、厚度及电火花测漏检验,再装入橡皮内膜和定性内模;
S9,膨胀填充物,再将聚四氟乙烯粉料注入S6中的缝隙间;
S10,烧结,装炉烧结;炉中预热6小时,使聚四氟乙烯层与金属件达到同步热变系数,在进行逐步升温,升温过程要缓慢有序进行,最后达到385摄氏度,保温6小时,而后慢慢分阶段的降温,烧结全过程36小时;
S11,车削密封面,拆除模具,再进行成品表层处理、法兰密封面聚四氟乙烯层车削,用电火花检测仪对衬里层进行微孔检测,检测质量缺陷,根据聚四氟乙烯衬里厚度输出电压20kV-30kV,探头在防腐衬里层上面移动速度不超过100mm/s探测,以不击穿为合格,检验合格的产品进行金属外壳喷漆处理,再由质量部门对成品进行检验,成品合格的进行包装入库。
本实施方式中,所述S3中,将环状钢板的开孔中预先填充有四氟粉料,形成聚四氟乙烯附层。
本实施方式中,所述S7中,使用水压机加压注水,使内部橡皮内膜膨胀,压力至10MPa-22MPa;在压力作用下,使达到2.16-2.27g/cm3的密度而成型。
本实施方式中,所述S11中,根据四氟衬里厚度输出电压25kV,探头在防腐衬里层上面移动速度50mm/s探测。
本实施方式中,所述S7中,使用水压机加压注水,使内部橡皮内膜膨胀,压力至18MPa;在压力作用下,使达到2.20g/cm3的密度而成型。
一种钢衬四氟笼箍管道设备,包括管道设备主体1,所述管道设备主体1的两端外壁上均焊接有连接法兰2,所述管道设备主体1包括不锈钢钢管101,沿管道设备主体1的长度方向且位于不锈钢钢管101的内壁上等距离焊接有多个笼箍钢带102,且笼箍钢带102呈环状带状结构,所述笼箍钢带102的内壁周向等距离设有开孔103,所述开孔103中填充有聚四氟乙烯附层104,位于聚四氟乙烯附层104和笼箍钢带102表面的不锈钢钢管101的内壁上设置有聚四氟乙烯衬层105。
本实施方式中,所述笼箍钢带102与不锈钢钢管101的中心轴线处于同一条中心轴线上,笼箍钢带102的外壁焊接在不锈钢钢管101的内壁上。
本实施方式中,所述管道设备主体1的外壁两侧焊接有鞍座3。
本实施方式中,所述管道设备主体1的外壁中部通过螺钉固定有铭牌4。
本实施方式中,所述连接法兰2的外壁周向等距离设有安装孔。
本发明在使用时,利用几何原理制作模具,留出需要衬里厚度的间隙,将PTFE粉料均布投入,使用水压机加压,使内部橡皮模具膨胀,压力至10MPa-22MPa。在压力作用下,使PTFE粉料中的气体排出,并达到2.16-2.27/m3的密度而成型,从而能够优越达到抗渗透、高温和高压的效果;在高温的作用下,使PTFE分子结构紧密结合;高温下橡皮内膜自动膨胀,同时结合PTFE自身的反膨胀力,工件衬层二次受压,同时高温中的PTFE处于熔融状态,使处于熔融状态的PTFE分子结构紧密结合,同时和环状钢板复合在一起,从而达到钢塑一体化的效果,使PTFE与壳体更加紧密复合,从而达到耐高温全真空的效果,通过等钢复合工艺制作的钢衬四氟笼箍管道,耐腐蚀效果好,复合效果好,不会自动脱落,更不会起鼓吸瘪、膨胀变形。
以上所述,仅为本发明较佳的具体实施方式,但本发明的保护范围并不局限于此,任何熟悉本技术领域的技术人员在本发明揭露的技术范围内,根据本发明的技术方案及其发明构思加以等同替换或改变,都应涵盖在本发明的保护范围之内。
Claims (5)
1.一种钢衬四氟笼箍等钢复合工艺,其特征在于,包括以下工艺步骤:
S1、外壳制作:按照产品的几何形状,制作工件壳体、橡皮内膜和定型内模;
S2、制作笼箍:准备与工件壳体内壁相吻合的环状钢板,在环状钢板的周向表面等距离开设有开孔;
S3、将多个环状钢板等距离焊接在工件壳体的内壁上;
S4、第一次检验:焊接按照高压容器制作标准,严格控制生产过程;
S5、喷砂:任何壳体和需衬氟的部件,都必须在衬氟前,对金属表面进行喷砂处理,除净所有金属表面上的油脂,氧化皮、锈蚀产物,达到金属表面无任何可见残留物,呈现均一的金属本色,并带有粗糙度,应达到HGJ34-90中的的技术要求标准,金属壳体方能达到衬里施工要求;
S6、组装:将工件壳体、橡皮内膜和定型内模组装一起,再和工件整体组装起来,根据厚度需求计算,工件壳体和橡皮内膜之间有间距,向间距中均匀加入聚四氟乙烯粉料;
S7、模压:再通过水压接口向工件壳体内加压注水,压力分阶段进行,要使聚四氟乙烯粉料内的气体逐渐排出,使压力达到设定的最高值,并压力要保持3-4小时;
S8、第二次半成品检验:泄压后对半成品进行检验,包括密度、厚度及电火花测漏检验,再装入橡皮内膜和定型内模;
S9、膨胀填充物,再将聚四氟乙烯粉料注入S6中的缝隙间;
S10、烧结:装炉烧结;炉中预热6小时,使聚四氟乙烯层与金属件同步达到热变系数,再进行逐步升温,升温过程要缓慢有序进行,最后达到385摄氏度,保温6小时,而后慢慢分阶段的降温,烧结全过程36小时;
S11、车削密封面,拆除模具,再进行成品表层处理、法兰密封面聚四氟乙烯层车削,用电火花检测仪对衬里层进行微孔检测,检测质量缺陷,根据聚四氟乙烯衬里厚度输出电压20kV-30kV,探头在防腐衬里层上面移动速度不超过100mm/s探测,以不击穿为合格,检验合格的产品进行金属外壳喷漆处理,再由质量部门对成品进行检验,成品合格的进行包装入库。
2.根据权利要求1所述的一种钢衬四氟笼箍等钢复合工艺,其特征在于,所述S3中,将环状钢板的开孔中预先填充有四氟粉料,形成聚四氟乙烯附层。
3.根据权利要求1所述的一种钢衬四氟笼箍等钢复合工艺,其特征在于,所述S7中,使用水压机加压注水,使内部橡皮内膜膨胀,加压至10MPa-22MPa;在压力作用下,使聚四氟乙烯达到2.16-2.27g/cm3的密度而成型。
4.根据权利要求1所述的一种钢衬四氟笼箍等钢复合工艺,其特征在于,所述S11中,根据四氟衬里厚度输出电压25kV,探头在防腐衬里层上面移动速度50mm/s探测。
5.根据权利要求3所述的一种钢衬四氟笼箍等钢复合工艺,其特征在于,所述S7中,使用水压机加压注水,使内部橡皮内膜膨胀,加压至18MPa;在压力作用下,使聚四氟乙烯达到2.20g/cm3的密度而成型。
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