Wear-resistant steel pipe Manufacturers

What are the commonly used substrates and lining materials for wear-resistant steel pipes?

In industrial transportation systems, especially in high-wear and high-impact working environments such as mining, electricity, metallurgy, and cement, wear-resistant steel pipes play a vital role. Its core function is to significantly extend the life of the pipeline, reduce the frequency of replacement, and reduce operating costs when conveying solid particles, fly ash, slurry, sand and gravel and other media. The performance of wear-resistant steel pipes depends largely on the scientific selection and manufacturing quality of their substrates and lining materials.
As an excellent supplier of wear-resistant and heat-resistant materials in the heat treatment, metallurgy and petrochemical industries in Jiangsu Province, Wuxi Dongmingguan Special Metal Manufacturing Co., Ltd. has long focused on the research and development and manufacturing of wear-resistant steel pipes and high-alloy centrifugal casting pipes, and has accumulated rich engineering experience, especially in the aspect of material selection, forming its own mature technical system.
Choice of substrate for wear-resistant steel pipes
The substrate of wear-resistant steel pipes mainly bears the role of mechanical support, and its strength, plasticity and welding performance determine the structural stability of the entire pipeline system. Common base materials include:
1. Carbon structural steel (such as Q235, Q345)
This is the most common structural steel type, with good weldability, moderate strength, low cost, and is widely used in conventional industrial transportation occasions. Suitable for coating ceramic lining or as a cladding base pipe.
2. Alloy structural steel (such as 20#, 16Mn, CrMo series)
It is used in working conditions with certain requirements for high temperature or corrosive environment, and has higher tensile strength and temperature resistance.
3. High temperature alloy steel (such as HK, HP, HT series)
In high temperature and highly corrosive environment, ordinary carbon steel is difficult to cope with, and high temperature high alloy base materials are required at this time. For example, the high chromium nickel alloy materials such as HP40, HK30, IN519 used by Wuxi Dongmingguan have achieved excellent thermal stability and structural density through centrifugal casting process, and are widely used in high temperature pipeline systems in petrochemical cracking furnaces and heat treatment equipment.
Wuxi Dongmingguan has an annual production capacity of 5,000 tons of castings, equipped with multiple heat treatment furnaces and precision processing equipment. It can tailor high-performance substrate solutions according to customer working conditions and effectively match the structural requirements of various complex transportation occasions.
Lining material types and selection of wear-resistant steel pipes
The lining material determines the wear resistance, impact resistance and corrosion resistance of the pipeline. According to the characteristics of the conveying medium, the operating temperature and the wear mode, the common lining materials include:
1. Overlay wear-resistant layer (alloy overlay)
This is the most widely used method at present. By overlaying high chromium alloys (such as Cr7C3, Cr13, etc.) on the inner wall of the steel pipe to form a dense wear-resistant layer, the hardness can reach HRC 60~65. Suitable for medium and high impact wear environments such as fly ash and coal powder.
Wuxi Dongmingguan has advanced overlay equipment and EPC precision casting technology, which can realize multi-layer overlay and composite overlay technology, greatly improving the bonding strength and service life of the overlay layer.
2. Ceramic lining (alumina/zirconia ceramic sheet/ceramic ring)
Ceramics have extremely high hardness (HV 1000~1800) and excellent corrosion resistance, and are suitable for high wear and low impact environments. They are often used in ash pipelines in coal-fired power plants and slurry conveying systems in mines.
Wuxi Dongmingguan has successfully integrated ceramic patch/ceramic embedded pipe technology into carbon steel structure pipelines through cooperation with ceramic technology suppliers, effectively solving the problem of short life of high-wear pipe sections and gaining high praise from users.
3. Self-propagating composite lining (SHS pipe)
Self-propagating high-temperature synthesis technology (SHS) is a relatively advanced technology in recent years. It forms a dense wear-resistant inner layer through high-temperature instantaneous reaction, has strong bonding force, and is suitable for occasions where both wear resistance and corrosion resistance are important.
4. Centrifugally cast high chromium alloy lining
For high temperature abrasive occasions (such as heat treatment furnaces, cracking tubes), Wuxi Dongmingguan uses high chromium nickel alloys (such as HP, IN519) for centrifugal casting to form thick-walled, high-density alloy pipe bodies, which have extremely high resistance to thermal fatigue and thermal wear. It is the preferred solution for many domestic and foreign equipment manufacturers (such as Epson, Aixie Lin, Fengdong) for long-term matching.

How to effectively control deformation and cracking of wear-resistant steel pipes during the manufacturing process

Today, with the increasingly complex high-wear working conditions, wear-resistant steel pipes are widely used in mining, power, cement, metallurgy, petrochemical and other industries due to their excellent wear resistance. However, in the manufacturing process, deformation and cracking problems have always been technical difficulties in quality control, especially in the centrifugal casting and surfacing processes of large-diameter, long-size or high-alloy steels. How to effectively control these two key defects that affect life and safety at the source has become a topic that manufacturing companies must overcome.
Material source control: the first line of defense for chemical composition and organizational structure
The performance of wear-resistant steel pipes begins with the reasonable design of materials and strict quality control. At Wuxi Dongmingguan, the company uses direct reading spectrometers, handheld spectrometers and crystal phase analyzers to ensure that the composition of raw materials meets the process setting requirements. In response to the wear-resistant requirements of different working conditions, high-temperature wear-resistant materials such as Cr-Ni high alloy steel, Cr-Mo alloy steel, HP, HK, etc. are often used.
In addition, the company uses crystal phase control to avoid segregation structure or hard and brittle phase in castings, and prevents stress concentration cracking of materials during subsequent heat treatment and surfacing.
Process optimization: multi-dimensional control of casting, cooling and heat treatment
When producing high-alloy centrifugal cast pipes or composite wear-resistant steel pipes, the optimization of casting temperature, cooling rate and heat treatment process is particularly critical. Wuxi Dongmingguan takes the following measures in actual operation:
1. Dynamic balance control during centrifugal casting
The company uses high-precision frequency conversion control centrifugal equipment to maintain uniform speed and temperature gradient during the pouring process, so as to achieve dense arrangement of molten metal on the inner wall of the pipe, and effectively avoid uneven thickness or stress accumulation caused by "metal fluctuation".
2. Stress relief during heat treatment
Equipped with multiple programmable heat treatment furnaces, it can accurately implement heat treatment processes such as annealing, solutionizing, normalizing, and tempering. Through step-by-step heating and slow cooling, it can fully release internal stress and effectively prevent cracks in cast pipes or cladding layers during later processing or service.
The heat treatment process is combined with ABAQUS finite element simulation software to analyze stress fields, predict deformation trends, and make structural design and process parameter adjustments in advance.
Thermal stress control technology in welding cladding stage
For composite pipe structures that require cladding wear-resistant layers, heat-affected zone control during welding is particularly important. Based on many years of cladding experience, Dongmingguan has formed the following key control points:
1. Layered multi-pass cladding
Adopting a multi-pass welding strategy with low current and low heat input, layered cladding is uniformly performed to effectively reduce the temperature peak of a single layer and reduce the risk of thermal cracks.
2. Preheating and post-heat treatment
For high-carbon and high-chromium cladding alloys, preheating (150-350℃) and post-heating insulation processes are implemented to alleviate microcracks caused by uneven tissue shrinkage during cooling.
3. Automatic welding equipment stabilizes cladding quality
Introducing intelligent welding robots to control cladding speed and posture, combined with weld tracking systems to maintain weld consistency, and reduce human factors from interfering with quality.
Equal emphasis on geometric tolerance control and non-destructive testing methods
To ensure the overall geometric dimensions of the pipeline and the absence of potential microcracks, the company uses multiple sets of high-precision testing methods:
3D scanner (GEOMAGIC CON): real-time comparison with the CAD model to control the deformation within ±1mm;
Ultrasonic flaw detector, magnetic particle flaw detector: used to detect hidden defects such as internal shrinkage, slag inclusions and microcracks;
Brinell hardness tester and tensile impact tester: comprehensive evaluation of whether the mechanical properties meet the standard requirements.
These high-standard testing procedures run through the three stages of raw materials, semi-finished products and finished products, providing a solid guarantee for the stability and traceability of the products.

What connection methods should be paid attention to when installing wear-resistant steel pipes on site

The connection methods of wear-resistant steel pipes are mainly selected based on their working pressure, temperature, installation environment, maintenance convenience and other factors. The following are several common connection methods and their characteristics:
1. Welded Joint
Welding is currently the most solid and best-sealed connection method, suitable for high temperature, high pressure or occasions where regular disassembly is not possible. Its main advantages are strong integrity and not easy to leak; its disadvantages are high installation technical requirements and difficulty in later disassembly.
Dongmingguan's suggestion: In the transportation of high-temperature and high-pressure media or in limited space (such as high-temperature radiation tubes, heating furnace circulation pipelines), it is recommended to use a fully welded structure, and automatic welding or argon arc welding is used to improve quality stability.
2. Flanged Joint
Flanged joints are easy to install and disassemble and repair, and are often used in systems with medium and low pressure or pipe sections that require regular maintenance and replacement. Dongmingguan provides prefabricated flange docking ports and ensures the accuracy of the sealing surface through mechanical processing.
Note during installation: The flange end face should be perpendicular to the pipe axis, and the gasket selection needs to consider the corrosiveness and temperature of the medium. Metal wound gaskets or high-strength flexible graphite gaskets are recommended.
3. Clamp Coupling
Suitable for fast loading and unloading and mobile pipeline systems, commonly used in mining transportation systems. Clamp connections achieve end face sealing through external fastening rings and are generally used in low-pressure situations.
Dongmingguan customizes the external expansion reinforcement structure at both ends of the high-alloy centrifugal casting pipe, and cooperates with the high-strength clamp to lock and seal, which improves the connection stability.
4. Sleeve/Threaded Joint
It is suitable for small-diameter or low-flow scenarios, and is generally used for auxiliary pipelines. However, for high-hardness wear-resistant pipes, due to the difficulty of thread processing and lack of impact resistance, they are rarely used in practice.
Technical details that should be paid special attention to during installation
In order to ensure the long-term and stable operation of the wear-resistant steel pipe system, Wuxi Dongmingguan emphasizes that the following key technical points should be paid attention to during on-site installation:
1. Pipeline axial centering control
Any form of misaligned, skewed or misaligned connection will cause local wear and even leakage of the joint. The company recommends using a three-dimensional laser scanner for on-site measurement and positioning to ensure accurate docking of each section of the pipeline.
2. Thermal expansion and contraction gap reservation
Wear-resistant steel pipes are often used in high-temperature occasions (>600℃), and thermal expansion compensation needs to be considered. It is recommended to set expansion joints between each section, or design bellows expansion joints and sliding brackets to avoid deformation or cracking of the connection section due to thermal expansion.
3. Control of the heat affected zone of welding installation
If welding connection is adopted, the welding heat input must be controlled at the construction site to avoid embrittlement of the parent material structure due to overheating. Dongmingguan recommends the use of multi-pass low heat input welding process and local annealing after welding to release welding residual stress.
Customized connection services supported by Dongmingguan
As a professional manufacturer integrating design, manufacturing, processing and testing, Wuxi Dongmingguan Special Metal Manufacturing Co., Ltd. not only provides standard wear-resistant pipe products, but also provides one-stop connection structure optimization design services:
Customized pre-installed welding end face or flange structure for customers;
Welding positioning and overall pre-installation can be completed before leaving the factory, saving on-site installation time;
Provide strength analysis and thermal stress simulation (ABAQUS) of the connection structure to ensure safe operation;
Provide technical support services at the installation site, including process guidance and testing services.