CN115449792B - Metal fiber felt-based self-fluxing alloy and aluminized composite protective layer for heating surface of boiler pipe - Google Patents
Metal fiber felt-based self-fluxing alloy and aluminized composite protective layer for heating surface of boiler pipe Download PDFInfo
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- CN115449792B CN115449792B CN202211039835.9A CN202211039835A CN115449792B CN 115449792 B CN115449792 B CN 115449792B CN 202211039835 A CN202211039835 A CN 202211039835A CN 115449792 B CN115449792 B CN 115449792B
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- XEEYBQQBJWHFJM-UHFFFAOYSA-N iron Substances [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims abstract description 167
- 229910052742 iron Inorganic materials 0.000 claims abstract description 93
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Classifications
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- C23C28/02—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material
- C23C28/021—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material including at least one metal alloy layer
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/06—Ferrous alloys, e.g. steel alloys containing aluminium
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
- C22C38/34—Ferrous alloys, e.g. steel alloys containing chromium with more than 1.5% by weight of silicon
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
- C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
- C22C38/54—Ferrous alloys, e.g. steel alloys containing chromium with nickel with boron
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C24/00—Coating starting from inorganic powder
- C23C24/02—Coating starting from inorganic powder by application of pressure only
- C23C24/04—Impact or kinetic deposition of particles
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C24/00—Coating starting from inorganic powder
- C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
- C23C24/10—Coating starting from inorganic powder by application of heat or pressure and heat with intermediate formation of a liquid phase in the layer
- C23C24/103—Coating with metallic material, i.e. metals or metal alloys, optionally comprising hard particles, e.g. oxides, carbides or nitrides
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
- C23C4/06—Metallic material
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
- C23C4/129—Flame spraying
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
- C23C4/131—Wire arc spraying
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23M—CASINGS, LININGS, WALLS OR DOORS SPECIALLY ADAPTED FOR COMBUSTION CHAMBERS, e.g. FIREBRIDGES; DEVICES FOR DEFLECTING AIR, FLAMES OR COMBUSTION PRODUCTS IN COMBUSTION CHAMBERS; SAFETY ARRANGEMENTS SPECIALLY ADAPTED FOR COMBUSTION APPARATUS; DETAILS OF COMBUSTION CHAMBERS, NOT OTHERWISE PROVIDED FOR
- F23M5/00—Casings; Linings; Walls
- F23M5/08—Cooling thereof; Tube walls
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E20/00—Combustion technologies with mitigation potential
- Y02E20/12—Heat utilisation in combustion or incineration of waste
Abstract
The invention relates to a metal fiber felt base self-fluxing alloy and aluminized composite protective layer for a heating surface of a boiler tube, which comprises a metal fiber felt base-iron base self-fluxing alloy composite layer and a metal fiber felt base aluminized composite layer. The protective layer has high strength, strong toughness and high temperature resistance, and can effectively prevent the heated surface from high temperature corrosion and thinning or even bursting, thereby further prolonging the service life. The invention also relates to a preparation method of the protective layer, which adopts a metal fiber felt aluminizing and induction cladding composite technology, has simple operation, low cost and high production efficiency, and is expected to develop into a novel long-acting protective technology suitable for high-temperature corrosion of the heating surface of the garbage boiler.
Description
Technical Field
The invention belongs to the technical field of protection of thermal pipelines, and relates to a metal fiber felt-based self-fluxing alloy and aluminized composite protective layer for a heating surface of a boiler pipe and a preparation method thereof.
Background
With the acceleration of the national development of new energy strategy, the domestic waste incineration power generation industry has rapidly developed in recent years. However, for a long time, the bottleneck problem of the technical development of the waste incineration power generation is that the boiler four pipes (water cooling wall, superheater, reheater and economizer) are severely corroded at high temperature. Particularly, under the great background of the development of high-parameter boilers in recent years, the main parameters of the boilers are improved to cause more serious high-temperature corrosion, so that the phenomenon of pipe explosion is frequently caused by rapid thinning of a heating surface of a pipeline, and the enterprise is subjected to non-regular shutdown maintenance, thereby bringing about great potential safety hazard and further increasing the economic burden of the enterprise.
At present, the method commonly adopted for high-temperature corrosion protection of four-pipe heating surfaces of the waste incineration boiler in China comprises about 60% of surfacing, about 25% of induction fusion welding, and the balance of about 15% of thermal spraying, high-temperature ceramic coating and the like, namely, surfacing and induction fusion welding are taken as main stream technologies, and the method basically takes the place of market control. Although the overall application of these two technologies is better, problems have also begun to be exposed in recent years, such as the gradual exposure of overlay welding to short plates with high Wen Fuyi life, which are affected by high dilution rates, and low production efficiency, high cost, etc. existing in itself; induction fusion welding also has the problems of further improving service life, long-term stability of the coating and the like under the condition of high parameters due to the fact that the coating existing in the technology is thinner (< 0.5 mm). Therefore, development of a new protection technology with excellent protection performance and long service life and more competitive production efficiency and preparation cost has become an urgent task for technological personnel in the high-temperature corrosion prevention field in China.
Disclosure of Invention
Aiming at the problems of surfacing and induction fusion welding in the prior art, the invention provides the metal fiber felt-based self-fluxing alloy and aluminized composite protective layer for the heating surface of the boiler pipe, which has high strength, strong toughness and high temperature resistance, and can effectively prevent the heating surface from being corroded, thinned and even blown out at high temperature, thereby further prolonging the service life.
The invention also provides a preparation method of the metal fiber felt-based self-fluxing alloy and aluminizing composite protective layer for the heating surface of the boiler pipe, and the method adopts a metal fiber felt aluminizing and induction cladding composite technology, is simple to operate, and is expected to develop into a novel long-acting protective technology suitable for high-temperature corrosion of the heating surface of the garbage boiler.
To this end, a first aspect of the present invention provides a metal fiber felt based self-fluxing alloy and aluminizing composite protective layer for a heating surface of a boiler tube, comprising a metal fiber felt based-iron based self-fluxing alloy composite layer and a metal fiber felt based aluminizing composite layer.
Preferably, the metal fiber mat is a high density iron chromium aluminum fiber mat having a porosity of < 30%.
In some embodiments of the invention, the metal fiber felt base-iron based self-fluxing alloy composite layer has a thickness of 2mm±0.02mm.
In other embodiments of the invention, the metal fiber blanket has a thickness of 0.3 to 5 mm.+ -. 0.02mm, preferably 2 to 3 mm.+ -. 0.02mm.
In still other embodiments of the present invention, the aluminized composite layer has a thickness of 0.3-0.5mm + -0.05 mm.
In the invention, the thickness of the metal fiber felt base self-fluxing alloy and aluminized composite protective layer is more than or equal to 3mm.
According to a second aspect of the invention, there is provided a method for preparing a composite protective layer of a metal fiber felt-based self-fluxing alloy and aluminizing for a heating surface of a boiler tube according to the first aspect of the invention, comprising:
step A, respectively and independently carrying out sand blasting roughening and dirt cleaning treatment on two surfaces of a heating surface of a water wall tube row and a metal fiber felt to obtain a clean water wall tube row with roughened heating surfaces and a clean metal fiber felt with roughened two surfaces;
step B, cold spraying or brushing an iron-based self-fluxing alloy coating on the roughened heating surface of the clean water wall tube row to obtain a water wall tube row with the iron-based self-fluxing alloy coating on the heating surface;
step C, the metal fiber felt is paved on a heating surface of a water wall tube row with an iron-based self-fluxing alloy coating on the heating surface to be tightly pressed, and the metal fiber felt is tightly attached to the heating surface of the tube row through the iron-based self-fluxing alloy coating, so that the water wall tube row with the iron-based self-fluxing alloy coating and the metal fiber felt attached to the heating surface is obtained;
step D, starting a transmission chain and a high-frequency induction coil for conveying the water wall tube row, enabling the water wall tube row with the iron-based self-fluxing alloy coating and the metal fiber felt adhered on the heated surface to be automatically fed, heating the water wall tube with the iron-based self-fluxing alloy coating and the metal fiber felt adhered on the heated surface through the fixed induction coil, controlling the automatic feeding speed to enable the adhesive to be completely dried, and obtaining the water wall tube row with the heated surface provided with the iron-based self-fluxing alloy coating-metal fiber felt bottom layer, wherein the coating is not melted;
e, reversely moving a water wall tube bank with an iron-based self-fluxing alloy coating-metal fiber felt bottom coating on a heating surface, controlling an automatic feeding speed, and finishing induction cladding of the iron-based self-fluxing alloy coating on the tube bank heating surface, so that the iron-chromium-aluminum fiber felt and the tube bank heating surfaces respectively positioned on two sides of the iron-based self-fluxing alloy coating are fixedly connected by means of the melting-recrystallization process of the iron-based self-fluxing alloy coating, and the cold wall tube bank with the metal fiber felt-iron-based self-fluxing alloy composite cladding coating on the heating surface is obtained;
and F, when the cold-wall tube bank with the metal fiber felt-iron-based self-fluxing alloy composite cladding coating on the cladding heating surface is just out of the induction coil, and the surface of the tube bank is still in a red hot state, spraying an aluminum alloy coating on the surface of the cladding coating by using electric arc or flame, and under the dual high temperature effects of the induction cladding residual temperature and the thermal spraying, penetrating the aluminum alloy coating into pores on the surface of the metal fiber felt to seal the surface of the metal fiber felt, thereby obtaining the metal fiber felt-based self-fluxing alloy and aluminized composite protective layer on the heating surface of the water-wall tube bank.
According to the method, in the step F, when a cold-wall tube row with a metal fiber felt-iron-based self-fluxing alloy composite cladding coating on a heating surface after cladding is positioned in a region of 300-500mm from an induction coil, an aluminum alloy coating is sprayed on the surface of the cladding coating by using an electric arc or flame under the condition that the surface of the tube row is in a red heat state of 650-800 ℃.
In some embodiments of the invention, the metal fiber mat comprises 1Cr13Al4, 1Cr21Al4, 0Cr21Al6, 0Cr23Al5, 0Cr25Al5, 0Cr21Al6Nb, 0Cr27Al7Mo2.
Preferably, the iron-based self-fluxing alloy material consists of an iron-based self-fluxing alloy and a binder, wherein the composition of the iron-based self-fluxing alloy material is as follows:
in some embodiments of the invention, in step D, the speed of the automatic feed is 10-30mm/s.
In other embodiments of the invention, in step E, the speed of the automatic feed is 0.5-1.5mm/s.
According to some modes of the invention, the method further comprises a step G after the step F, and the quality of the metal fiber felt-based self-fluxing alloy and aluminized composite protective layer used for the heating surface of the boiler pipe is detected.
In a third aspect, the invention provides a boiler tube with a metal fiber felt based self-fluxing alloy and aluminized composite protective layer for a boiler tube heating surface according to the first aspect of the invention or prepared by the method according to the second aspect of the invention.
The metal fiber felt-based self-fluxing alloy and aluminized composite protective layer for the heating surface of the boiler pipe provided by the invention has high strength, strong toughness and high temperature resistance, and can effectively prevent the heating surface from high temperature corrosion and thinning and even pipe explosion, thereby further prolonging the service life. Compared with the induction fusion welding thickness of about 0.5mm and the surfacing welding thickness of 2.5mm, the total thickness of the protective layer is more than 3mm, so the protective life should be longer; the cost of the coating is reduced by more than 60% compared with the surfacing welding and more than 20% compared with the induction welding coating.
The preparation method of the protective layer provided by the invention adopts a metal fiber felt aluminizing and induction cladding composite technology, and has the advantages of simple operation and low cost; compared with the surfacing, the invention has the advantages that the heat input amount of the surfacing on the surface of the tube bank is larger, so that the problems of dilution rate and heat deformation control of the tube bank are solved, and the invention has no two problems, so that the production efficiency is higher, and the invention is expected to develop a novel long-acting protection technology suitable for high-temperature corrosion of the heating surface of the garbage boiler.
Drawings
The invention will be described below with reference to the accompanying drawings.
FIG. 1 is a schematic diagram of a process for induction cladding and aluminum spraying of a water wall tube array.
The reference numerals of fig. 1 have the following meanings; 13 fins; 21 pipe curved surface coating; 22 tube root and fin coating; 50 aluminium spraying (here aluminium spraying operation); a 60 coil support; 70 drive chain rollers; 80 high frequency induction remelting coil (rectangular copper tube).
Detailed Description
In order that the invention may be readily understood, the invention will be described in detail below with reference to the accompanying drawings. Before the present invention is described in detail, it is to be understood that this invention is not limited to particular embodiments described. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting.
Unless defined otherwise, all terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. Although any methods and materials similar or equivalent to those described herein can also be used in the practice or testing of the present invention, the preferred methods and materials are now described.
The terms "about," "substantially," and "primarily" as used herein in connection with a range of an element, concentration, temperature, or other physical or chemical property or characteristic, cover a variation that may exist in the upper and/or lower limit of the range of the property or characteristic, including, for example, variations caused by rounding off, measurement methods, or other statistical variation. As used herein, a numerical value associated with an amount, weight, etc., is defined as "about" all values of each particular value plus or minus 1%. For example, the term "about 10%" should be interpreted as "9% to 11%".
I, terminology
The term "waterwall" as used herein is also referred to as a "waterwall" or "waterwall tube". The steel pipes are normally vertically paved on the inner wall surface of the boiler wall and are mainly used for absorbing heat released by flame and high-temperature flue gas in the boiler.
The term "boiler four tubes" and "boiler tubes" as used herein may be used interchangeably and include water walls, superheaters, reheaters, and economizers.
II, embodiment
Aiming at the problems of surfacing and induction fusion welding, the invention adopts a metal fiber felt aluminizing and induction fusion welding composite technology so as to develop a novel long-acting protection technology suitable for high-temperature corrosion of the heating surface of the garbage boiler.
The invention abandons the idea of directly preparing a coating on the surface of a pipeline by the traditional protective layer, adopts a prefabricated metal fiber mat as the protective layer, is connected with the pipeline, and finally seals the technical path of the pore. The method has the advantages that the preparation of the protective layer is not influenced by the structural shape of the pipeline and the environmental conditions, the process design can be more flexible, and the production efficiency is improved and the cost is reduced. Similar methods have been used in the past, such as mounting ceramic patches on the heated surfaces of water walls. Although the method has a certain protection effect, the method is not applied in large batches later, and the main reason is that: due to the inherent brittle nature of ceramic materials, once an individual patch cracks or peels off corrosive gas into the pipe surface, rapid failure of the integral protective layer can result; the ceramic material has low heat conductivity, effectively blocks heat energy conduction, reduces energy conversion efficiency, and blocks heat conduction to raise the temperature of gas in the furnace, so that the hot corrosion of other components on the gas passage is increased; the ceramic patch connection is not tightly sealed, and becomes an inlet of corrosive gas.
Thus, in a first aspect of the present invention, a metal fiber felt-based self-fluxing alloy and aluminizing composite protective layer for a heating surface of a tube for a boiler is constituted by a main body of a metal fiber felt newly developed over 20 years as a protective layer, the composite protective layer comprising a metal fiber felt-based iron-based self-fluxing alloy composite layer and a metal fiber felt-based aluminizing composite layer.
In the invention, the metal fiber felt is a high-density iron-chromium-aluminum fiber felt, and the porosity is less than 30%.
In some embodiments of the invention, in the metal fiber felt base-iron based self-fluxing alloy composite layer, the thickness of the iron based self-fluxing alloy layer is 2mm±0.02mm; the thickness of the metal fiber felt is 0.3-5mm plus or minus 0.02mm, preferably 2-3mm plus or minus 0.02mm; the thickness of the aluminized composite layer is 0.3-0.5mm plus or minus 0.05mm; the thickness of the metal fiber felt base self-fluxing alloy and aluminized composite protective layer is more than or equal to 3mm.
It will be appreciated by those skilled in the art that in practice, the metal fiber felt based self-fluxing alloy and aluminized composite protective layer for the heating surface of the boiler tube provided by the present invention naturally forms a very thin Al layer on the outer surface of the metal fiber felt based aluminized composite layer 2 O 3 The ceramic film has a thickness less than or equal to 0.01mm and has a certain reinforcing effect on the metal fiber felt-based self-fluxing alloy and the aluminized composite protective layer.
The invention relates to a preparation method of a metal fiber felt-based self-fluxing alloy and aluminized composite protective layer for a heating surface of a boiler tube, which comprises the following steps:
step A, pretreatment: respectively and independently carrying out sand blasting roughening and dirt cleaning treatment on the two surfaces of the heating surface of the water wall tube row and the metal fiber felt to obtain a clean water wall tube row with the roughened heating surface and a clean metal fiber felt with the roughened two surfaces;
step B, manufacturing an iron-based self-fluxing alloy coating: cold spraying or brushing an iron-based self-fluxing alloy coating on the roughened clean water wall tube row heating surface to obtain a water wall tube row with the iron-based self-fluxing alloy coating on the heating surface;
and C, compacting and adhering: the metal fiber felt is paved on the heating surface of a water wall tube row with the iron-based self-fluxing alloy coating on the heating surface to be tightly pressed, and the metal fiber felt is tightly attached to the heating surface of the tube row through the iron-based self-fluxing alloy coating, so that the water wall tube row with the iron-based self-fluxing alloy coating and the metal fiber felt attached to the heating surface is obtained;
step D, drying the binder: starting a transmission chain and a high-frequency induction coil for conveying the water wall tube row, enabling the water wall tube row with the iron-based self-fluxing alloy coating and the metal fiber felt adhered on the heating surface to automatically feed, heating the water wall tube with the iron-based self-fluxing alloy coating and the metal fiber felt adhered on the heating surface through the fixed induction coil, controlling the automatic feeding speed to be 10-30mm/s, controlling the heating speed so as to enable the adhesive to be completely dried, and obtaining the water wall tube row with the heating surface provided with the iron-based self-fluxing alloy coating-metal fiber felt bottom layer, wherein the coating is not melted;
step E, cladding: the water wall tube bank with the iron-based self-fluxing alloy coating-metal fiber felt bottom coating on the heating surface is reversely moved, the automatic feeding speed is controlled to be 0.5-1.5mm/s, and the induction cladding of the iron-based self-fluxing alloy coating on the tube bank heating surface is completed, so that the iron-chromium-aluminum fiber felt and the tube bank heating surfaces respectively positioned on the two sides of the iron-based self-fluxing alloy coating are fixedly connected by virtue of the melting-recrystallization process of the iron-based self-fluxing alloy coating, and the cold wall tube bank with the metal fiber felt base-iron-based self-fluxing alloy composite cladding coating on the heating surface is obtained;
step F, aluminum spraying: when the cold-wall tube bank with the metal fiber felt-iron-based self-fluxing alloy composite cladding coating on the cladding heating surface is just out of the induction coil, and the surface of the tube bank is still in a red-hot state, spraying an aluminum alloy coating on the surface of the cladding coating by using electric arc or flame, and under the dual high temperature effects of the induction cladding residual temperature and the thermal spraying, the aluminum alloy coating permeates into pores on the surface of the metal fiber felt to seal the surface of the metal fiber felt, so that the metal fiber felt-based self-fluxing alloy and aluminized composite protective layer is obtained on the heating surface of the water-wall tube bank.
According to the method, in the step F, when a cold-wall tube row with a metal fiber felt-iron-based self-fluxing alloy composite cladding coating on a heating surface after cladding is positioned in a region of 300-500mm from an induction coil, an aluminum alloy coating is sprayed on the surface of the cladding coating by using an electric arc or flame under the condition that the surface of the tube row is in a red heat state of 650-800 ℃.
According to some modes of the invention, the method further comprises a step G after the step F, and the quality of the metal fiber felt-based self-fluxing alloy and aluminized composite protective layer used for the heating surface of the boiler pipe is detected.
The method can also be understood as a method for manufacturing a boiler tube with a metal fiber felt based self-fluxing alloy and aluminized composite protective layer on the heated surface, comprising the steps of:
(1) Pretreatment: respectively and independently carrying out sand blasting roughening and dirt cleaning treatment on the two surfaces of the heating surface of the water wall tube row and the metal fiber felt to obtain a clean water wall tube row with the roughened heating surface and a clean metal fiber felt with the roughened two surfaces;
(2) Manufacturing an iron-based self-fluxing alloy coating: cold spraying or brushing an iron-based self-fluxing alloy coating on the roughened clean water wall tube row heating surface to obtain a water wall tube row with the iron-based self-fluxing alloy coating on the heating surface;
(3) And (3) compacting and adhering: the metal fiber felt is paved on the heating surface of a water wall tube row with the iron-based self-fluxing alloy coating on the heating surface to be tightly pressed, and the metal fiber felt is tightly attached to the heating surface of the tube row through the iron-based self-fluxing alloy coating, so that the water wall tube row with the iron-based self-fluxing alloy coating and the metal fiber felt attached to the heating surface is obtained;
(4) Drying the binder: and starting a transmission chain and a high-frequency induction coil for conveying the water wall tube row, so that the water wall tube row with the iron-based self-fluxing alloy coating and the metal fiber felt adhered on the heating surface is automatically fed, heating the water wall tube with the iron-based self-fluxing alloy coating and the metal fiber felt adhered on the heating surface through the fixed induction coil, and controlling the automatic feeding speed to be 10-30mm/s, thereby controlling the heating speed to ensure that the adhesive is completely dried, but the coating is not melted, and obtaining the water wall tube row with the iron-based self-fluxing alloy coating-metal fiber felt bottom layer on the heating surface.
(5) Cladding: the water wall tube bank with the iron-based self-fluxing alloy coating-metal fiber felt bottom coating on the heating surface is reversely moved, the automatic feeding speed is controlled to be 0.5-1.5mm/s, and the induction cladding of the iron-based self-fluxing alloy coating on the tube bank heating surface is completed, so that the iron-chromium-aluminum fiber felt and the tube bank heating surfaces respectively positioned on the two sides of the iron-based self-fluxing alloy coating are fixedly connected by virtue of the melting-recrystallization process of the iron-based self-fluxing alloy coating, and the cold wall tube bank with the metal fiber felt base-iron-based self-fluxing alloy composite cladding coating on the heating surface is obtained;
(6) Spraying aluminum: when the cold-wall tube row with the metal fiber felt-iron-based self-fluxing alloy composite cladding coating on the cladding surface is just out of the induction coil and the tube row surface is still in a red hot state, spraying an aluminum alloy coating on the cladding coating surface by using electric arc or flame, and penetrating the aluminum alloy coating into pores on the metal fiber felt surface under the dual high temperature effects of the induction cladding residual temperature and the thermal spraying to seal the hole on the metal fiber felt surface, wherein the heating surface is provided with the boiler tube with the metal fiber felt-based self-fluxing alloy and the aluminized composite protective layer.
According to the method of the invention, in the step (6), when the cold-wall tube row with the metal fiber felt-iron-based self-fluxing alloy composite cladding coating on the heated surface after cladding is positioned in a region of 300-500mm from the induction coil, the aluminum alloy coating is sprayed on the cladding coating surface by using electric arc or flame under the condition that the surface of the tube row is in a red heat state of 650-800 ℃.
According to some embodiments of the invention, the method further comprises a step (7) after the step (6), wherein the quality of the metal fiber felt-based self-melting alloy and aluminized composite protective layer used for the heating surface of the boiler pipe is detected.
In some embodiments of the present invention, in the step C or the step (3), the fiber felt and the heat-receiving surface of the tube bank may be tightly adhered by using a wooden hammer, a rubber hammer or a copper hammer to repeatedly tap, so as to achieve the purpose of adhering the composite coating to the water-cooled wall.
In the present invention, the metal fiber felt is produced by weaving metal fiber with micron level diameter into sheet with certain thickness of 0.3-5mm, non-woven spreading, overlapping and high temperature sintering. While commercial metal fiber mats are of a wide variety, the inventor researches and discovers that the metal fiber mats which are really applicable to the garbage boiler can only be iron-chromium-aluminum fiber mats and stainless steel fiber mats, and the iron-chromium-aluminum fiber mats have relative advantages. Table 1 shows the overall properties of the iron-chromium-aluminum fiber mats. As can be seen from Table 1, the main mechanical properties of the Fe-Cr-Al fiber are better than the coating properties of the same material.
TABLE 1 Properties of FeCrAl fibers
As can be seen from table 1, the metal fiber mat has the following characteristics:
(1) High strength and toughness
Because of the traction effect among the fibers, the strength of the felt is much higher than that of a coating with the same material and thickness, and meanwhile, the toughness is high, so that the fatigue strength is high, fatigue cracks are not easy to generate, and even if microcracks exist, the fatigue cracks are not easy to expand; and the strength is high, the abrasion resistance is high enough to resist the thinning caused by the erosion abrasion of fly ash particles in high-temperature flue gas.
(2) High temperature resistance
The service temperature of the stainless steel fiber is less than 600 ℃, the temperature of iron, chromium and aluminum is less than 1000 ℃, the stainless steel fiber can resist high-temperature oxidation and severe corrosion of headache chlorides in a garbage furnace, and the capability of preventing high-temperature corrosion is superior to that of a coating with the same material and thickness, so that the stainless steel fiber is an ideal high-temperature corrosion protection material.
(3) The metal fiber felt has good heat conductivity, does not influence the heat exchange performance of the boiler system, and also has a thermal expansion coefficient very close to that of pipeline metal, so that the felt is not easy to fall off as long as the felt is fixed with the pipe wall.
(4) The metal fiber felt has a foldable flexible structure, is very suitable for being attached to special-shaped surfaces such as water-cooled walls or various pipelines, and the thickness of the metal fiber felt can be optionally selected according to the needs.
(5) Low cost
As currently commercially available iron-chromium-aluminum fiber mats with a thickness of 2-3mm are below 2200 yuan/m 2 Stainless steel fiber felt lower than 3500 yuan/m 2 Even if other surface treatments are added, the total price is not more than 5500 yuan/m 2 Not only compared with surfacing welding>13000 yuan/m 2 ) Much lower than induction fusion welding>8000 yuan/m 2 ) And is also low.
However, the metal fiber felt cannot be directly applied to the high-temperature corrosion protection of the heating surface of the boiler because the short plates are also very prominent, and mainly has two problems:
(1) Because the metal fibers are mutually overlapped and woven in the weaving process, a large number of pores are necessarily present, and the metal fiber felt has the characteristic of high porosity (30-80%). The industry has utilized fiber mat labyrinth-like microporous channels for use in fine filtration materials. The size of the pores is generally related to the thickness of the fibers, the finer the fibers, the smaller the pores. The pore diameter (0.05-0.3 mm) and distribution among the fibers are very uniform, which also provides a good foundation for our experimental research of hole sealing technology. Therefore, how to reduce the ultra-high porosity to below 3-5% is the first problem to be solved.
(2) And the metal fiber felt can be tightly combined with the outer wall of the pipeline, and the metal fiber felt cannot fall off under the long-term service condition.
Aiming at the two problems, the invention takes the preparation of a metal fiber felt protective layer on the surface of a water-cooled wall as an example, and the corresponding strategies are as follows:
(1) First, a high density iron-chromium-aluminum fiber mat (porosity < 30%) was selected as the protective layer body. Secondly, cold spraying or brushing a layer (the thickness is about 2 mm) of iron-based self-fluxing alloy mixed with an adhesive on the heating surface of the water wall tube bank, paving a fiber felt on the surface of the tube bank, rolling by a self-made automatic feeding profiling roller press, and tightly attaching the fiber felt and the heating surface of the tube bank through the iron-based self-fluxing alloy adhesive layer.
(2) And (3) automatically feeding the water wall tube bank, and finishing the cladding of the iron-based self-fluxing alloy coating on the heating surface of the tube bank through a fixed induction coil. And (3) realizing the fixation of the iron-chromium-aluminum fiber felt and the heating surface of the tube bank after natural cooling by means of the melting-recrystallization process of the coating remelting.
(3) By means of the high temperature of the induction cladding waste heat, aluminum alloy (aluminum is more than 85%, the balance is chromium, nickel, silicon and the like) is sprayed on the surface of the metal fiber felt, the thickness of the coating is about 0.3-0.5mm, and the purposes of covering the pores on the upper surface of the fiber felt and penetrating into the pores of the fiber felt as much as possible by means of the high-permeability aluminum alloy are achieved.
The invention has the advantages that:
(1) The invention aims to create a novel long-acting high-temperature corrosion protection technology with comprehensive performance and service life not lower than that of surfacing welding and induction fusion welding and lower cost than those of surfacing welding and induction fusion welding. The metal fiber felt is a new material developed at home and abroad after 2000, and is mainly applied to filters in coal, petroleum and chemical industries. Through searching, no report on the method for protecting the surface corrosion of the boiler pipeline is seen at home and abroad, so the method belongs to the integration innovation of the transplanting technology.
(2) The invention abandons the idea of directly preparing the coating on the surface of the pipeline by the traditional protective layer, adopts the prefabricated metal fiber mat as the protective layer, is connected with the pipeline firstly, and finally seals the technical path of the pores on the surface of the metal fiber mat. The method has the advantages that the preparation process of the prefabricated protective layer is not limited by the structural shape of the pipeline and the environmental conditions, only connection with the pipe row is considered, and the process is simple.
(3) The iron-based self-fluxing alloy is used as an intermediate carrier for connecting the iron-chromium-aluminum fiber felt and the tube array, and mainly takes the fact that the iron-based self-fluxing alloy is similar to main material elements of the iron-chromium-aluminum fiber felt and a tube array substrate of a water wall, the interface bonding is better than that of the nickel-based self-fluxing alloy, and the cost of the iron-based self-fluxing alloy is low, and the metal fiber felt comprises 1Cr13Al4, 1Cr21Al4, 0Cr21Al6, 0Cr23Al5, 0Cr25Al5, 0Cr21Al6Nb and 0Cr27Al7Mo2. Table 2 shows the chemical composition and main properties of the iron-based self-fluxing alloy, and it can be seen that coating properties such as melting point, hardness, coefficient of thermal expansion, etc. are more advantageous than nickel-based self-fluxing alloys.
TABLE 2 chemical composition and Main Properties of iron-based self-fluxing alloys
(4) By consulting the related literature, the metal fiber felt used as the high-temperature flue gas filter of the coal-fired boiler is found, and in the use process, the coal tar is very easy to block the pores, so that the filtration is invalid and is difficult to clear, and the problem has become a great difficulty puzzled in the industry. Therefore, the method is inspired, and the aluminum alloy coating is selected for hole sealing. Aluminizing of metal surfaces is a relatively common method in industry to improve corrosion resistance of metal materials by protecting the steel substrate due to the negative potential of aluminum and the sacrificial anodic protection of steel. Belongs to a main method with obvious anti-corrosion effect and lower cost, and the aluminum coating is applied to the high-temperature service environment of the incineration of the boiler garbage, and is extremely easy to quickly react to generate compact Al 2 O 3 And (3) an oxide film. Although the film thickness is only on the order of microns, ceramic films have a "one-tenth of a" effect compared to metal coatings for high temperature corrosion protection. And the ceramic film thickness is very thin, so that the heat conduction cannot be influenced.
In order to achieve the ideal aluminizing hole sealing effect, the invention adopts a method of spraying an aluminum alloy coating with the thickness of about 0.3mm on the surface of a cladding layer by using electric arc or flame when the surface of a water wall tube row is still in a red hot state just after cladding, namely, under the dual high temperature effects of the induction cladding residual temperature and the thermal spraying, the liquid aluminum alloy coating is easier to permeate into pores on the surface of a metal fiber felt, thereby achieving the hole sealing effect. Therefore, although the metal fiber felt has high porosity, after double-sided plugging, the corrosion gas can not enter the substrate surface to corrode the pipeline through the pores.
(5) Compared with the induction fusion welding thickness of about 0.5mm and the surfacing welding thickness of 2.5mm, the total thickness of the protective layer is more than 3mm, so the protective life should be longer; the cost of the coating is reduced by more than 60% compared with the surfacing welding, and is reduced by more than 20% compared with the induction fusion welding coating; compared with the surfacing, the invention has the problems of dilution rate and thermal deformation control of the tube bank because the heat input amount of the surfacing on the surface of the tube bank is larger, but the invention has no two problems; the production efficiency must be much higher than the build-up welding.
In a third aspect, the invention provides a boiler tube with a metal fiber felt based self-fluxing alloy and aluminized composite protective layer for a boiler tube heating surface according to the first aspect of the invention or prepared by the method according to the second aspect of the invention.
III, detection method
The porosity of the metal fiber mat based self-fluxing alloy and aluminized composite protective layer of the present invention was monitored according to GB/T l7721-1999 (metal coating porosity test).
The method for measuring the corrosion resistance of the boiler pipe or the protective layer comprises laboratory measurement and field measurement. The laboratory measurement is to introduce corrosion gas (such as one or more of chlorine, sulfur and alkali metal) in a tube furnace in proportion, put a test piece into the tube furnace for acceleration test, and measure the corrosion rate by adopting a metal corrosion test method-a weight method, namely, the change of the weight of the metal sample before and after corrosion (a weight loss method) is utilized for representing the corrosion rate; in the field measurement, the test piece is directly placed in the boiler, for example, the test piece is welded into the boiler by a hanging piece method, and the test piece is detected by corrosion thinning amount.
IV, examples
The invention is illustrated in detail below by means of the figures and specific examples. The experimental methods described below, unless otherwise specified, are all laboratory routine methods. The experimental materials described below, unless otherwise specified, are commercially available.
Example 1:
(1) And (3) respectively carrying out sand blasting roughening and dirt cleaning treatment on the two surfaces of the heating surface of the water wall tube row and the metal fiber mat by an automatic sand blasting machine to obtain a clean water wall tube row with the roughened heating surface and a clean metal fiber mat with the roughened two surfaces.
(2) And (3) carrying out cold spraying/brushing on the heated surface of the water wall tube row with the iron-based self-fluxing alloy coating with the thickness of about 2 mm+/-0.02 mm (the composition is shown in Table 2), so as to obtain the water wall tube row with the iron-based self-fluxing alloy coating on the heated surface.
(3) Spreading an iron-chromium-aluminum fiber felt (1 Cr13Al4, the porosity is less than 30%) with the thickness of about 2mm plus or minus 0.02mm on the surface of the water wall tube row, repeatedly tapping by a wood hammer or a rubber hammer or a copper hammer manually, tightly attaching the fiber felt to the heated surface of the tube row through an iron-based self-fluxing alloy coating, and obtaining the water wall tube row with the heated surface adhered with the iron-based self-fluxing alloy coating and the metal fiber felt.
(4) Quick heating and drying process: and starting a transmission chain and a high-frequency induction coil for conveying the water wall tube row, so that the tube row is fed quickly and automatically, heating the water wall tube row by the fixed induction coil quickly, controlling the heating speed to ensure that the adhesive is completely dried, and obtaining the water wall tube row with the heating surface provided with the iron-based self-melting alloy coating-metal fiber mat bottom layer, wherein the coating is not melted.
(5) Low-speed cladding stroke: and the water wall tube row moves reversely, the automatic feeding speed is controlled according to the speed required by induction cladding, and the induction cladding of the iron-based self-fluxing alloy coating on the heating surface of the tube row is completed. And the iron-chromium-aluminum fiber felts positioned on two sides of the coating are fixedly connected with the heating surfaces of the tube row by means of the melting-recrystallization process of the remelting of the coating, so that the cold wall tube row with the metal fiber felt-iron-based self-melting alloy composite cladding coating on the heating surfaces is obtained, and the structure is shown in figure 1.
(6) When the water wall tube row is just out of the induction coil after being clad, and the surface of the tube row is still in a red hot state, an aluminum alloy coating with the thickness of about 0.3mm plus or minus 0.05mm is sprayed on the surface of the cladding layer by using electric arc or flame. Within 500mm of the spray area, i.e. the tube array, coming out of the induction coil, the temperature drops by about 800-650 ℃. Under the dual high temperature effects of induction cladding residual temperature and thermal spraying, the aluminum alloy coating is easier to permeate into pores on the surface of the metal fiber felt, so that the hole sealing effect is achieved.
(7) And (3) quality control: detecting the quality of the surface coating of the tube bank, repairing the local defect, obtaining the metal fiber felt-based self-fluxing alloy and aluminized composite protective layer on the heating surface of the tube bank of the water wall, and measuring the thickness of the protective layer to be more than 3mm.
The corrosion resistance of the coating is measured by a laboratory, corrosion gases (chlorine, sulfur, alkali metal chloride and the like) which are configured in proportion are introduced into a tube furnace, a test piece is put into the tube furnace for an accelerated corrosion test, and then the weight reduction change of the metal test piece before and after corrosion is measured, so that the result shows that the corrosion amount is very small.
The corrosion resistance of the 20G water wall tube row with the novel fiber reinforced composite coating in the embodiment is directly detected by using the actual consumption rate in production, and compared with the corrosion resistance of the 20G water wall tube row with the original coating, the result shows that the corrosion reduction amount of the 20G water wall tube row test piece with the novel fiber reinforced composite coating in the embodiment is less than 0.1 mu m/h, and the 20G water wall tube row with the novel fiber reinforced composite coating in the embodiment has good corrosion resistance, and the service life of the 20G water wall tube row with the novel fiber reinforced composite coating can reach 10 years, and is improved by more than 8 years compared with the service life of the 20G water wall tube row without the coating, and is at least improved by 5 years compared with the 20G water wall tube row with the original coating (common arc spraying corrosion resistant coating).
Example 2:
example 2 a metal fiber felt based self-fluxing alloy and aluminized composite protective layer was obtained on the heated surface of the water wall tube array using the same procedure and procedure as in example 1, except that the thickness of the iron-chromium-aluminum fiber felt used was about 2.5mm + 0.02mm, the thickness of the aluminum alloy coating was about 0.04mm + 0.05mm, and the thickness of the protective layer was 3mm or more.
The corrosion resistance of the coating is measured by a laboratory, corrosion gases (chlorine, sulfur, alkali metal chloride and the like) which are configured in proportion are introduced into a tube furnace, a test piece is put into the tube furnace for an accelerated corrosion test, and then the weight reduction change of the metal test piece before and after corrosion is measured, so that the result shows that the corrosion amount is very small.
The corrosion resistance of the 20G water wall tube row with the novel fiber reinforced composite coating in the embodiment is directly detected by using the actual consumption rate in production, and compared with the corrosion resistance of the 20G water wall tube row with the original coating, the result shows that the corrosion reduction amount of the 20G water wall tube row test piece with the novel fiber reinforced composite coating in the embodiment is less than 0.1 mu m/h, and the 20G water wall tube row with the novel fiber reinforced composite coating in the embodiment has good corrosion resistance, and the service life of the 20G water wall tube row with the novel fiber reinforced composite coating can reach 10 years, and is improved by more than 8 years compared with the service life of the 20G water wall tube row without the coating, and is at least improved by 5 years compared with the 20G water wall tube row with the original coating (common arc spraying corrosion resistant coating).
Example 3:
example 3a metal fiber felt based self-fluxing alloy and aluminized composite protective layer was obtained on the heated surface of the water wall tube array using the same procedure and procedure as in example 1, except that the thickness of the iron-chromium-aluminum fiber felt used was about 3mm + 0.02mm, the thickness of the aluminum alloy coating was about 0.05mm + 0.05mm, and the thickness of the protective layer was 3mm or more.
The corrosion resistance of the coating is measured by a laboratory, corrosion gases (chlorine, sulfur, alkali metal chloride and the like) which are configured in proportion are introduced into a tube furnace, a test piece is put into the tube furnace for an accelerated corrosion test, and then the weight reduction change of the metal test piece before and after corrosion is measured, so that the result shows that the corrosion amount is very small.
The corrosion resistance of the 20G water wall tube row with the novel fiber reinforced composite coating in the embodiment is directly detected by using the actual consumption rate in production, and compared with the corrosion resistance of the 20G water wall tube row with the original coating, the result shows that the corrosion reduction amount of the 20G water wall tube row test piece with the novel fiber reinforced composite coating in the embodiment is less than 0.1 mu m/h, and the 20G water wall tube row with the novel fiber reinforced composite coating in the embodiment has good corrosion resistance, and the service life of the 20G water wall tube row with the novel fiber reinforced composite coating can reach 10 years, and is improved by more than 8 years compared with the service life of the 20G water wall tube row without the coating, and is at least improved by 5 years compared with the 20G water wall tube row with the original coating (common arc spraying corrosion resistant coating).
The results of the tests carried out by adopting the iron-chromium-aluminum fiber mats with other brands show that the corrosion amount of the coating is very small, the service life of the iron-chromium-aluminum fiber mats can reach 10 years, the service life of the iron-chromium-aluminum fiber mats is prolonged by more than 8 years compared with the service life of a 20G water wall tube row without the coating, and the service life of the iron-chromium-aluminum fiber mats is prolonged by at least 5 years compared with the service life of a 20G water wall tube row with the original coating (common arc spraying anti-corrosion coating).
It should be noted that the above-mentioned embodiments are only preferred embodiments of the present invention, and are used for explaining the present invention, not to be construed as limiting the present invention. The invention has been described with reference to exemplary embodiments, but it is understood that the words which have been used are words of description and illustration, rather than words of limitation. Modifications may be made to the invention as defined in the appended claims, and the invention may be modified without departing from the scope and spirit of the invention. Although the invention is described herein with reference to particular means, materials and embodiments, the invention is not intended to be limited to the particulars disclosed herein, as the invention extends to all other means and applications which perform the same function.
Claims (9)
1. A metal fiber felt base self-fluxing alloy and aluminized composite protective layer for a heating surface of a boiler tube comprises a metal fiber felt base-iron base self-fluxing alloy composite layer and a metal fiber felt base aluminized composite layer;
the metal fiber felt is an iron-chromium-aluminum fiber felt and comprises 1Cr13Al4, 1Cr21Al4, 0Cr21Al6, 0Cr23Al5, 0Cr25Al5, 0Cr21Al6Nb and 0Cr27Al7Mo2;
the iron-based self-fluxing alloy material consists of an iron-based self-fluxing alloy and a binder, wherein the composition of the iron-based self-fluxing alloy material is as follows:
2. the metal fiber felt based self-fluxing alloy and aluminized composite protective layer of claim 1, wherein the metal fiber felt is a high density iron-chromium-aluminum fiber felt having a porosity of < 30%.
3. The metal fiber felt based self-fluxing alloy and aluminized composite protective layer according to claim 1 or 2, wherein in the metal fiber felt based-iron based self-fluxing alloy composite layer, the thickness of the iron based self-fluxing alloy layer is 2mm plus or minus 0.02mm, the thickness of the metal fiber felt is 0.3-5mm plus or minus 0.02mm, the thickness of the aluminized composite layer is 0.3-0.5mm plus or minus 0.05mm, and the thickness of the metal fiber felt based self-fluxing alloy and aluminized composite protective layer is not less than 3mm.
4. A metal fiber blanket based self-fluxing alloy and aluminizing composite protective layer according to claim 3, wherein the thickness of the metal fiber blanket is 2-3mm ± 0.02mm.
5. A method of preparing a metal fiber felt based self-fluxing alloy and aluminizing composite protective layer for a heated surface of a boiler tube as claimed in any one of claims 1 to 4, comprising:
step A, respectively and independently carrying out sand blasting roughening and dirt cleaning treatment on two surfaces of a heating surface of a water wall tube row and a metal fiber felt to obtain a clean water wall tube row with roughened heating surfaces and a clean metal fiber felt with roughened two surfaces;
step B, cold spraying or brushing an iron-based self-fluxing alloy coating on the roughened heating surface of the clean water wall tube row to obtain a water wall tube row with the iron-based self-fluxing alloy coating on the heating surface;
step C, the metal fiber felt is paved on a heating surface of a water wall tube row with an iron-based self-fluxing alloy coating on the heating surface to be tightly pressed, and the metal fiber felt is tightly attached to the heating surface of the tube row through the iron-based self-fluxing alloy coating, so that the water wall tube row with the iron-based self-fluxing alloy coating and the metal fiber felt attached to the heating surface is obtained;
step D, starting a transmission chain and a high-frequency induction coil for conveying the water wall tube row, enabling the water wall tube row with the iron-based self-fluxing alloy coating and the metal fiber felt adhered on the heated surface to be automatically fed, heating the water wall tube with the iron-based self-fluxing alloy coating and the metal fiber felt adhered on the heated surface through the fixed induction coil, controlling the automatic feeding speed to enable the adhesive to be completely dried, and obtaining the water wall tube row with the heated surface provided with the iron-based self-fluxing alloy coating-metal fiber felt bottom layer, wherein the coating is not melted;
e, reversely moving a water wall tube bank with an iron-based self-fluxing alloy coating-metal fiber felt bottom coating on a heating surface, controlling an automatic feeding speed, and finishing induction cladding of the iron-based self-fluxing alloy coating on the tube bank heating surface, so that the iron-chromium-aluminum fiber felt and the tube bank heating surfaces respectively positioned on two sides of the iron-based self-fluxing alloy coating are fixedly connected by means of the melting-recrystallization process of the iron-based self-fluxing alloy coating, and the cold wall tube bank with the metal fiber felt-iron-based self-fluxing alloy composite cladding coating on the heating surface is obtained;
and F, when the cold-wall tube bank with the metal fiber felt-iron-based self-fluxing alloy composite cladding coating on the cladding heating surface is just out of the induction coil, and the surface of the tube bank is still in a red hot state, spraying an aluminum alloy coating on the surface of the cladding coating by using electric arc or flame, and under the dual high temperature effects of the induction cladding residual temperature and the thermal spraying, penetrating the aluminum alloy coating into pores on the surface of the metal fiber felt to seal the surface of the metal fiber felt, thereby obtaining the metal fiber felt-based self-fluxing alloy and aluminized composite protective layer on the heating surface of the water-wall tube bank.
6. The method according to claim 5, wherein in the step F, when the cold-wall tube row having the metal fiber felt-iron-based self-fluxing alloy composite cladding coating on the heated surface is located in a region of 300-500mm from the induction coil, the aluminum alloy coating is sprayed on the cladding coating surface by an arc or flame in a red heat state of 650-800 ℃ on the surface of the tube row.
7. The method according to claim 5, wherein in step D, the automatic feeding speed is 10-30mm/s; and/or, in step E, the speed of the automatic feeding is 0.5-1.5mm/s.
8. The method according to any one of claims 5 to 7, further comprising a step G after the step F, detecting the quality of the metal fiber felt-based self-fluxing alloy and aluminized composite protective layer for the heating surface of the boiler tube.
9. A tube for a boiler having the metal fiber felt based self-fluxing alloy and aluminized composite protective layer for a tube heating surface for a boiler according to any one of claims 1 to 4 or prepared by the method according to any one of claims 5 to 8.
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