Regarding ceramic installation
Our company uses a dovetail groove inlay structure combined with a strong adhesive to fix the wear-resistant ceramic. Although this process is more difficult, it allows for the connection of ceramic pieces with tiny gaps along the dovetail groove direction. Since product development, there have been no instances of more than four ceramic pieces detaching from the same blade (detachment is mostly caused by the wire rope accidentally snagging the blade during impeller hoisting). Furthermore, the ceramic piece design takes into account both size and weight, so even if individual ceramic pieces are damaged, it will not affect the overall dynamic balance of the impeller.
How to Solve the Problem of Heavy Wear?
Wear-resistant ceramics, as a high-wear-resistant material in the industrial field, owe their wear resistance to the precise control of three core factors: raw material selection, powder preparation, and sintering process.
Raw Material Selection: High-purity α-alumina and crystal growth inhibitors are used.
Powder Preparation: Advanced processes are used to produce uniformly distributed, highly fluid granulated powder.
Sintering Process: Strict control of sintering parameters and temperature effectively inhibits excessive crystal growth, reduces internal porosity, and forms a highly dense sintered structure.
The impact of adding wear-resistant ceramics on the overall performance of the impeller
The total weight of all ceramic blocks is about 60 kg. After deducting the weight of metal reduced during the impeller metal processing, the final overall weight of the impeller is only about 5-6 kg more than the original impeller. Since the addition of ceramics does not change the original structural shape of the fan, the impact on the fan flow rate is negligible.
How to solve the problem of ceramic detachment at high temperatures?
Fan impellers operate in environments with temperatures exceeding 200℃ for extended periods. Traditional epoxy resin adhesives are not heat-resistant and prone to aging, making them unsuitable for long-term use (even with dovetail grooves or spot welding, the adhesive still easily becomes brittle and crumbles at high temperatures).
Our company employs a dual fixing solution of "adhesive bonding + dovetail grooves," using a high-temperature resistant inorganic adhesive. This adhesive exhibits excellent adhesion, processability, and thixotropy to both steel and ceramics, can cure at room temperature, and possesses high strength, high toughness, and resistance to high temperatures and aging. Within a temperature range of -50℃ to 500℃, the liner can operate stably for a long time without aging or detachment.
How to solve the problem of ceramic detachment caused by wind turbine vibration and transportation?
Wind turbine impellers vibrate intensely during operation, requiring adhesives to possess both high shear strength and seismic resistance. Our adhesives have a shear strength of 2.5 MPa, effectively ensuring the stability of ceramics under strong vibration environments and significantly reducing the risk of detachment.
How to address the impact of sudden heating and cooling on ceramics during start-up or shutdown?
In the rapid heating and cooling environment during unit start-up and shutdown, the difference in thermal expansion coefficients between ceramics and steel, along with the brittleness of organic adhesives, can easily lead to the detachment of entire ceramic sheets. We have improved the formulation of our inorganic adhesive, ensuring its thermal expansion coefficient (9×10⁻⁶ m/m·K) falls between that of steel and ceramics. Simultaneously, we utilize the microfiber structure of the adhesive to buffer the compressive stress caused by the difference in thermal expansion, ensuring the long-term reliable operation of the ceramics under extreme temperature variations.
How to solve the problem of ceramic gaps?
By using mature technology to control the ceramic gap to ≤1mm, and by using a staggered bonding method perpendicular to the wind direction, we can avoid the formation of continuous gaps along the wind direction, reduce the erosion of the gaps by airflow, and achieve precise docking of the tiny gaps in the ceramic pieces.
يجب أن تكون رسالتك بين 20-3000 حرف!
