What is Wear Resistant Tube
Wear Resistant Tube is a steel pipe made of steel plate or steel strip after crimping and welding. The production process of the wear-resistant pipe is simple, the production efficiency is high, the variety and specifications are many, and the equipment capital is low, but the general strength is lower than that of the seamless steel pipe. Since the 1930s, the quality of welds has been continuously improved, and the varieties and specifications of wear-resistant pipes have been increasing, and have replaced seamless steel pipes in some fields. Wear-resistant pipes are divided into SSAW steel pipes and LSAW steel pipes according to the form of welds.
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Benefits of Wear Resistant Tube
High wear resistance
The thickness of the wear-resistant layer of the wear-resistant pipe is 3-12 mm, and the hardness of the wear-resistant layer can reach HRC58-62. The wear resistance is more than 15-20 times that of ordinary steel pipes, and the wear resistance is much higher than that of spray welding and thermal spraying.
Better impact performance
The wear-resistant pipe is a double-layer metal structure. The wear-resistant layer and the base material are metallurgically bonded. The bonding strength is high. It can absorb energy during the impact process, and the wear-resistant layer will not fall off.It can be applied to the working conditions with strong vibration and shock.
Good temperature resistance
The alloy carbide of wear-resistant pipe has strong stability at high temperature, and the wear-resistant steel plate can be used within 500°C and can be used within 1200°C.
Strong connection performance
The base material of wear-resistant steel pipe is ordinary Q235 steel plate, which ensures that the wear-resistant steel plate has toughness and plasticity, provides strength against external force, and can be connected with other structures by welding, plug welding, bolt connection, etc.The connection is firm, not easy to fall off, and there are more connection methods than other materials.
Good choice performance
For wear-resistant pipes, choose base materials of different thicknesses, and surfacing alloy wear-resistant layers of different layers and thicknesses to obtain steel pipes of different thicknesses and different uses, and the maximum thickness can reach more than 30mm;
Good processing performance
Wear-resistant pipes can be processed into different specifications and sizes according to requirements, and can be processed, cold-formed, welded, bent, etc., which are convenient to use; they can be tailored and welded on site, making maintenance and replacement work time-saving, convenient, and greatly reducing work intensity.
What are the Applications of Wear Resistant Tube
Mining industry
In the material conveying, pulp conveying and pulp conveying systems of mines, due to the high-speed flow of materials and various acid and alkali corrosion in the water, carbon steel pipes are easily worn and lead to downtime for replacement. &The excellent wear resistance and acid and alkali resistance of zirconium-aluminum composite ceramics and wear-resistant ceramic lined pipes have been widely used in mine transportation systems and have won unanimous praise.
Coal power plant industry
Wear resistant tube are widely used in coal-fired power plants, coal mill outlet elbows, coarse and fine powder separator conveying pipes, coal powder conveying pipes and dust removal, desulfurization pipes, etc.
Cement industry
Wear resistant tube are widely used in vertical mill outlet elbows, dust removal pipes, humidification tower inlet and outlet elbows, cyclone separator inlet and outlet elbows and coal powder conveying pipes in cement plants.
Steel industry
Wear resistant tube are widely used in steel mill dust removal pipes, limestone conveying pipes, pulverized coal pipes, desulfurization pipes and blast furnace slag removal pipes.
Lithium battery industry
Wear resistant tube are widely used in straight pipes and elbows for pneumatic conveying of lithium battery cathode material powder.
Construction machinery industry
Wear resistant tube are widely used in pump truck boom concrete conveying straight pipes and elbows.
How to Choose Wear Resistant Tube
Strength and Durability
Strength and durability are the most critical factors when selecting the steel type for your project area. Your project requirements will dictate the level of strength and durability that your steel must possess to withstand the intended conditions of use.To determine the appropriate level of grading systems, several factors must be considered: the expected load-bearing capacity of the steel, the environmental conditions the steel will be exposed to, and the lifespan of the finished product.
Corrosion Resistance
You must consider the level of anti-corrosive property, especially if it will be exposed to harsh environmental conditions. Corrosion can cause structural damage, reduce the product’s lifespan, and increase maintenance costs. The level of rust-proof quality required will be determined by factors like moisture, salt water, and chemicals.Galvanized steel is another option for corrosion resistance. It is coated with a layer of zinc that acts as a barrier against rust and corrosion. However, galvanized steel may not be suitable for products exposed to extremely corrosive environments.
Temperature and Pressure
Consider the ability to withstand the temperature and pressure requirements of the application. Different steel grades have varying melting points and yield strengths, which can affect their performance in high-temperature or high-pressure environments.For example, if you’re working on a project involving boilers, pressure vessels, or piping systems, you must choose a steel grade with high-temperature and high-pressure capabilities. Alloy and stainless steels are often used in these applications due to their excellent strength and durability at elevated temperatures.
Cost Considerations
When choosing the suitable steel grade for your project, raw material costs are a factor. Different steel grades have varying raw material costs based on their composition and availability.High-strength steel grades with alloying elements such as chromium, nickel, or molybdenum tend to be more expensive due to the cost of these materials. On the other hand, lower-strength steel grades with lower alloying elements tend to be more cost-effective.Another factor that can impact raw material costs is the demand and availability of the steel grade. If a particular steel grade is in high demand, its raw material costs may be higher due to supply and demand.
To create wear-resistant pipes, a unique heating and quenching process alters the microstructure of the steel, resulting in an ideal induction-hardened pipe profile with outstanding inner abrasion resistance and outer wall ductility for the most mission-critical applications.
First, we begin with steel pipe rolled and formed using our proprietary steel chemistry. Next, we use our specific induction hardening process, which includes induction heating of the pipe. To cool the pipe, the inner pipe wall is water quenched. Sudden cooling of the pipe’s hot surface creates a martensitic microstructure within the pipe, toughening the pipe for superior abrasion resistance. The pipe’s outer surface cools more slowly, increasing ductility and tensile strength up to 90 KSI. Finally, the product is complete. The results are an abrasion-resistant pipe with an outer wall that is ductile enough to accommodate high-pressure service and welding stresses, and an inner wall that resists abrasive slurries and the toughest conveyance materials.
Types of Wear Resistant Tube
Hardfacing Wear Resistance CCO Steel Pipe
Hardfacing Wear Resistance CCO Steel Pipe using wear-resistant pipe surfacing machine, adopting open-arc self-protection automatic surfacing welding technology on the inner wall (above 300mm in diameter) or outer wall (unlimited diameter) of seamless steel pipe (Comply with GB / T8163-1999), a layer of high wear-resistant or high corrosion-resistant alloy material is automatically and seamlessly welded by the CNC to form chromium carbide alloy wear-resistant pipe.
Wear Resistant Ceramic Pipe
Wear-resistant pipes are widely used in mines with serious wear, mineral fines and tailings transportation, coal-fired power plants for powder feeding, slag removal, ash conveying and other wear-resistant pipes are also very suitable.
Weld Clad Tubes
The weld clad tubes are welded with alloy wear-resistant layers on low-carbon steel plates.It has high wear resistance and good impact performance. It can be cut, bent, welded and can be connected with other structures by welding, plug welding, bolt connection.The alloy wear-resistant layers are generally 1/3 to 1/2 of the total thickness. During use, the pipeline can resist the comprehensive performance of external force, such as strength, toughness and plasticity, and the alloy wear-resistant layer provides wear-resistant performance that meets the requirements of specified working conditions.
Alumina Wear Resistant Ceramic Composite Pipes
Alumina Wear Resistant Ceramic Composite Pipes using the principle of ceramic metal composite production technology, through bonding, welding, inlaid, riveting and sleeve technology, Various wear resistant ceramic sheets, plates, and bricks are composited on the wear surface of the pipe fittings to form a smooth wear resistant surface layer, and the composite pipe fittings of ordinary metal materials are still used for the matrix.Compared with traditional all metal alloy pipe fittings, the composite pipe fittings have higher wear resistance, which can increase the overall wear resistant and anti-corrosion service life of pipe fittings by more than tens of times.
How to Maintain Wear Resistant Tube
Proper Material Selection: Choosing the suitable material for wear resistant tube is of paramount importance. Stainless steel, due to its resistance to corrosion, and corrosion-resistant alloys are ideal for industries with a high corrosion risk. These materials offer long-lasting protection against the chemical reactions responsible for corrosion.
Protective Coatings: Applying anti-corrosion coatings to wear resistant tube is a vital step. Epoxy, polyethylene, or fusion-bonded epoxy coatings create a formidable barrier between the metal and the surrounding environment. Regular inspections, maintenance, and reapplication of coatings are necessary to ensure their lasting effectiveness. Innovative nanocoatings can provide enhanced protection by creating ultra-thin, impermeable layers.
Cathodic Protection: Implementing a cathodic protection system involves connecting a sacrificial anode, usually made of materials like aluminium or zinc, to the seamless pipe. This anode corrodes instead of the pipe, effectively preventing corrosion. This method is highly effective in protecting buried pipelines and underwater structures, such as those used in offshore oil and gas operations.
Regular Inspection and Maintenance: Regular inspections are the cornerstone of corrosion prevention. These inspections should encompass a range of methods, including visual assessments, corrosion monitoring using techniques like ultrasonic thickness measurement, and non-destructive testing methods like radiography. Timely maintenance and repairs and a robust preventive maintenance plan can prevent further damage.
Corrosion Inhibitors: Chemical corrosion inhibitors can be injected into the pipelines to create a protective film on the inner surface of the wear resistant tube. This film acts as a barrier between the metal and corrosive substances, effectively mitigating the electrochemical reactions that lead to corrosion. Advanced inhibitor formulations can offer extended protection, even in the harshest environments.
Proper Storage and Handling: Proper storage and handling practices are essential to prevent mechanical damage and corrosion during transportation and installation. Pipes should be stored in a dry environment, and handling should be carried out with utmost care to avoid scratches, dents, or damage to protective coatings. Employing innovative handling equipment, such as anti-corrosion cradles, can further enhance protection.
The Correct Way to Store Wear Resistant Tube
Adequate Elevation
Elevating pipes off the ground is crucial to prevent contact with moisture or soil. Using pipe cradles, wooden supports, or specially designed racks can maintain a buffer between the pipes and the ground. This measure is vital for preventing corrosion in steel wear resistant tube, which are more prone to rust.
Ventilation
Ensure proper ventilation in storage areas. Good air circulation helps maintain a stable environment and reduces the risk of condensation. This is especially important for preventing internal corrosion, which can result from moisture accumulation within the pipe.
Categorisation and Labeling
Categorise and label wear resistant tube based on material type, size, and specifications. This organisation simplifies retrieval and minimises handling, which can inadvertently cause damage.
Protection from Physical Damage
Implement protective measures to prevent physical damage during storage. This includes using appropriate padding or cushioning between pipes and securing them with straps or bands to avoid accidental rolling or falling.
Regular Inspection
Periodically inspect stored wear resistant tube for signs of damage or corrosion. Early detection can prevent minor issues from developing into major problems. Corrosion-resistant coatings, if applied, should be examined for integrity and effectiveness.
Handling Equipment
Employ specialised handling equipment like forklifts or cranes to move and stack pipes. This minimises the risk of damage during the handling process, ensuring the pipes remain in optimal condition.
Our Factory
Shandong Qishuai Wear-resistant Equipment Co., Ltd. is a manufacturing enterprise integrating R & D, manufacture and installation. It is an experienced manufacturer specializing in providing wear-resistant technical solutions and supporting wear-resistant products.Our factory is located in zibo city and it covers more than 2500 square meters.Include 2 workshops.Alumina ceramic and wear resistant chromium carbide plates.The factory has advanced processing equipment and experienced technical staff.We adhere to the way”the quality is the first” and we has won praise at home and abroad.
FAQ
Wear resistant tubes include wear resistant chrome carbide tubes,alumina ceramic pipes and ceramic pipes with steel.We have professional engineers team to give you some suggestions according to your application.Different field use different products.Please contact me if you want to know more informations.
All wear resistant tube products are with high tech and cheap price. If you're looking for professional wear resistant pipe, abrasion tube, wear abrasion pipe, wear tube, wear resistant welding tube, abrasion chromium tube, wear resistant ceramic tiles manufacturers and suppliers in China, please rest assured to place orders with Shandong Qishuai.
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