Special process for wear-resistant elbows

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According to the power industry standard DL/T680-1999 \"Technical Requirements for Wear-Resistant Pipes,\" ceramic tile-type wear-resistant pipes (TC-G) exhibit good wear resistance. The drawback of these products is the issue of detachment; the original manufacturing methods involved using ordinary adhesives for bonding or employing an arch-shaped design for fitting. However, the ordinary bonding method often leads to detachment, and the adhesives tend to age over time. Additionally, the fitting method requires a certain thickness of the ceramic tiles, resulting in high costs. Our company has addressed the issue of peeling by combining a new three-in-one wear-resistant composite technology with a bonding medium layer; moreover, the thickness can be chosen arbitrarily, making the ceramic tile wear-resistant pipeline (TC-G) product an excellent solution for coal powder pipelines and mineral powder transmission pipelines in power plants. Manufacturing process for ceramic wear-resistant elbows: 1. Surface treatment of the workpiece – Metal surfaces develop a layer of rust over time as a result of prolonged use. Before applying the ceramic tiles, the surface must be polished and rust removed using sandblasting and grinding machines. If the surface is not cleaned properly before applying the ceramic tiles, this will be the main reason for a decrease in the adhesion strength of the ceramic tiles. During the grinding and polishing process carried out by workers, oil or dust inevitably remains on the metal surface; if the surface is not cleaned thoroughly with a specialized cleaning agent before ceramic tiles are applied, this can result in the tiles not adhering firmly enough and falling off. 2. Strictly adhere to the mixing ratio for the adhesive; the ceramic adhesive must be prepared in a 1/2 ratio as specified, and mixed thoroughly to ensure that all components are well combined. The ambient temperature should be maintained between 5 and 40°C; if the temperature is too low, it should be raised to within this range. Construction should also be avoided in conditions of direct sunlight and strong winds, to prevent deformation caused by the thermal expansion and contraction of the ceramic tiles leading to mutual compression; moreover, strong winds can significantly reduce the bonding strength of the ceramic adhesive due to dust generation. The surface should be smooth, with even filler application and no bubbles; there should be no protruding wear-resistant ceramic pieces, as these can affect flow rate and reduce wear resistance. 3. Quality inspection: The company’s dedicated inspectors must examine each ceramic wear-resistant elbow individually, checking aspects such as its appearance, angle, and flatness, to ensure that all products leave the factory meeting quality standards. A special manufacturing process is used: wear-resistant ceramic elbows and pipes are created by attaching aluminum oxide ceramic sheets with holes in them to the inner wall of the pipe using high-temperature adhesives, combined with spot welding; the ceramic material is then firmly welded to the inner wall of the steel pipe through these holes. To protect the solder joint, screw on the ceramic cover. The production process for welding ceramic wear-resistant elbows is relatively complex; welding combined with bonding provides dual-layer reinforcement, preventing the ceramic tiles from falling off. Such elbows are often used in pipelines that are subject to high impact forces and require high wear resistance.