English (UK) 
简体中文 Why does your deflector wear through after half a year of use? The inner wall of the pipeline is always pitted by the material? Today, we will break open the crumbs to say through - from the material selection to the installation of positioning, to teach you to make the life of the deflector plate to last more than 5 years!
First, the basis of the article: the deflector by virtue of what can carry ten million times the impact?
1. Material is lifeblood, don't save money on alloys
- Rare earth wear-resistant alloys(ZG15Cr22Ni7Mn4NRE): temperature resistance of 1250 ℃ +, tensile strength ≥ 560Mpa. a power plant used it, 6 years only to wear off 0.1mm
- Cemented carbide round bar inlayTungsten carbide round bar embedded in ordinary steel plate, hardness soared to HRA89, life expectancy increased by 5 times.
- Ceramic Composite Layer: Aluminium oxide ceramic sheet on the inside wall, 20 times harder than hardened steel, but don't glue it - it's easy to crumble at high temperatures! Spot welding + mechanical self-locking is the only way to be reliable
2. If the inner wall of the pipe is not well protected, the deflector plate is no matter how strong it is.
The material picks out the soft targets! Once the inner wall is worn through, the high-speed particles hit the deflector plate directly:
- Corundum ceramic lining: Centrifugally cast AL₂O₃ ceramic layer, Mohs hardness class 9, preferred for pulverised coal pipelines
- Wear-resistant cladding: Surface welded tungsten carbide, thickness from 3mm - a steel plant to save this step, three months leakage of a ground iron ore powder!
Second, the actual combat: the installation of the wrong 1 mm, life less than three years
Scenario 1: How do you weld without cracking?
- Preheat! Preheat! Preheat!: Heating to 300°C before welding, holding and slow cooling after welding
- Segmented skip welding: Stop at 50mm per section and continue when the temperature drops - straight through? Waiting to crack into a tortoise shell!
Scenario 2: What is the most wear-resistant angle setting?
| take | Golden Angle | Overturning cases |
|---|---|---|
| Dust collector deflector | 15-30° | ＞45°? The airflow is messing up the filter bag. |
| Boiler dense phase zone infusion | 25-35° | <20°? Mountains of material |
| Pneumatic grey pipe | 30-40° | Vertical? Pipe walls wear through in six months. |
Scenario 3: How does the locator god work?
Shandong Nuclear Power's tooling is well tested:
- Mandrel through the rib plate, L-shaped positioning stopper jamming position (error <3mm)
- Clamping baffle spinning bolts firmly, hand shaking is considered qualified
- The turntable is turned 90° to weld the cross brace - standing up is stronger than lying down 20%!
Third, the protection chapter: pipe wall strengthening three strokes to save lives
Trick 1: How come the ceramic patch doesn't come off?
- surface roughening: Blasted to Sa3, roughness Ra≥50μm
- Adhesive + mechanical locking: High-temperature resistant adhesive coated + spot welding ceramic cap - a cement factory saved the cap, a year off 30% ceramic tiles!
Tip 2: How to strengthen the blockage-prone area?
The elbow is most afraid of grinding through! Three tricks to save your life:
- Thickened ceramic layer: 5mm for straight pipes, 8mm for elbows.
- Deflector coverage up to 80%Material Drilling
- Outlet extension 50cm: The deflector is half a metre longer than the material flow and cushions the impact force.
IV. Operation and maintenance: monitoring techniques to keep the deflector board alive for 5 more years
Pit 1: Visual inspection = going through the motions
A power plant fiasco: the surface looks intact, but when you hit it, it crumbles - the internal corrosion has rotted through! That's the way to find out:
- Monthly thickness measurements: Critical elbow cloth 8 measurement points, the thickness of the drop 30% immediate warning
- thermal imaging scan: Sudden change in deflector temperature >50°C? Internal crack alarm!
Pit 2: Violent dismantling for dust removal
High-pressure air guns dislike blowing? The ceramic layer crumbles for you! Correct posture:
- 0.6MPa compressed air blowing at an angle of 45°.
- Blow the frame before clearing the panel
- Soak the bolts in WD-40 for two hours and retighten them.
V. Self-inspection: three major death operations should not be touched
Death 1: Use of ordinary steel in wet environments
Tears of blood in the seaside power plant: 304 stainless steel deflector plate with 6 years, carbon steel rusted to slag only lasted 1 year! Keep in mind:
- Stainless steel or PP plastic deflector is required for humidity > 60%.
- Rusted? Spray zinc-based paint immediately after sandpapering.
Death 2: The deflector plate is welded shut and won't move.
What should I do if the material is too much or too little? Learn from the mine's god operation:
- Articulated base + tension spring: Automatic press-bending and expansion of more material, less material popping back to the original position
- Laser flow sensor linkageMobile phone alarm in seconds!
Deadly 3: Wear-resistant layer is saved on the knife's edge
A factory's "money-saving" car flip-flop:
- Spray ordinary paint where tungsten carbide should be overlaid - wear through in half a year
- The ceramic piece saves caps - two years of repairs is enough to buy three new sets of plates!
Let's end on a positive note.
Don't buy into the "leave it alone" myth! Wear-resistant deflector want to use ten years? Remember the twelve words of truth.Hard material, accurate installation, diligent inspection, bufferingThe welding on the ignore the factory every year to lose hundreds of thousands of dollars. The factories that weld on and ignore it lose hundreds of thousands of dollars a year just by shutting down and changing boards - doesn't it smell good to save that money and give the employees bonuses?
