1. Overview
Our company has developed swirl burners for 600MW, 1000MW subcritical and supercritical boilers, featuring a unique design with high precision requirements. These burners involve a significant amount of welding, particularly between stainless steel (1Cr18Ni9Ti) and carbon steel (Q235-A). The welding joints include various types such as butt joints, corner joints, and lap joints. Due to the large size of the components, numerous welds are concentrated in specific areas, making the welding workload quite extensive. Moreover, the welding process leads to considerable deformation, which is challenging to control. This results in a high correction workload, increasing both the difficulty of manufacturing and overall production costs. To address these challenges, we conducted process tests and implemented a new welding technique—flux-cored wire CO₂ gas shielded welding instead of traditional electrode arc welding. This method not only improves the appearance of the welds but also enhances product quality and production efficiency.
2. Process Testing
(1) **Welding Wire and Metal Performance Test**: We used standard grade E309LT1-1, φ 1.2mm flux-cored stainless steel wire with CO₂ shielding gas. The test plate was made of 1Cr18Ni9Ti, 12mm thick, and the deposited metal's chemical composition met the required standards. The test was performed in different positions—flat, horizontal, and vertical. The wire fed smoothly, the arc was stable, the weld appearance was neat, and slag removal was easy. There was minimal spatter, indicating excellent process performance. (2) **Test Plate Welding**: According to the "Steam Boiler Safety Technical Supervision Regulations," we selected 1Cr18Ni9Ti and Q235-A plates for testing. The test plate dimensions were 400mm × 125mm × 12mm, with a V-groove. The base metal and deposited metal’s chemical composition and mechanical properties are listed in Table 2. The welding sequence involved welding three sides of the groove, cleaning the root, and then welding the opposite side. The welding parameters are shown in Table 3. (3) **Test Plate Evaluation**: The weld on test plate S1 passed 100% RT (Radiographic Testing). The chemical composition of the weld metal is presented in Table 4, while the mechanical properties of the welded joint are detailed in Table 5.
For more detailed information, please refer to the attachment and read the 18th issue of Metalworking (Hot Processing).
19X7 Non-rotating SS Wire Rope
The service life of the steel wire rope is proportional to the fatigue life. According to the approximate price of the steel wire rope market, the price of the manganese-based phosphating Coated Steel Wire Rope is about 1.4-1.6 times that of the smooth steel wire rope, and the service life extension is much higher than the price increase. Therefore, the average daily use cost of phosphating coated steel wire rope is only 30-45% of that of smooth steel wire rope, the use cost is lower, and the cost performance is higher.
Therefore, the phosphating coated steel wire rope has a long service life and a lower cost of use, and the smooth steel wire rope must be completely eliminated. This is the general trend and the development trend of steel wire rope manufacturing technology.
Non Rotating Wire Rope,Rotation Resistant Rope,Anti Rotation Wire Rope,Rotation Resistant Wire Rope
Jiangsu Hongze Stainless Steel Wire Rope Co., Ltd , https://www.hzrope.com