回转窑挡轮缺陷焊接修补工艺探讨  

Discussion on Welding Repair Technology for Defects in Rotary Kiln Thrust Rollers

作　　者：杨杰 李新可 王庆柱 YANG Jie;LI Xinke;WANG Qingzhu(CNBM Equipment Group,Xuzhou Sinoma Heavy Machinery Co.,Ltd.,Xuzhou Jiangsu 221131,China)

机构地区：[1]中国建材装备集团有限公司徐州中材装备重型机械有限公司,江苏徐州221131

出　　处：《水泥技术》2025年第2期47-51,共5页Cement Technology

摘　　要：挡轮装置作为水泥回转窑传动设备的关键承载件,对铸钢材料的质量要求较高。然而,在实际加工制造过程中,铸钢件挡轮仍会出现裂纹、气孔、砂眼等铸造缺陷。通过分析ZG42Cr1Mo铸钢件挡轮材料的化学成分和机械性能,选用J507低氢型焊条,并针对挡轮出现的线性缺陷和非线性缺陷,制定相应的修补处理工艺,如钻止裂孔、机加工挖除、打磨去除等。在修补过程中,应严格控制焊前预热、焊条烘干、层间温度等工艺参数,采用多层多道焊方式进行焊接修补,确保焊接质量。焊后应作及时保温与缓冷处理,避免裂纹产生,并进行磁粉探伤和硬度检查。通过该修补方案,有效解决了挡轮质量不稳定问题,提升了产品竞争力,取得了显著的经济效益,具有较高的推广价值。As a critical load-bearing component of the transmission system in cement rotary kilns,the thrust roller device imposes high-quality requirements on cast steel materials.However,casting defects such as cracks,porosity,and sand inclusions still will occur during manufacturing.By analyzing the chemical composition and mechanical properties of the cast steel grade ZG42Cr1Mo used for thrust rollers,the J507 low-hydrogen electrode was selected.Corresponding repair processes,including drilling stop holes,machining excavation,and grinding removal,were developed to address linear and nonlinear defects in the thrust rollers.During the repair process,critical parameters such as preheating temperature,electrode drying,and interpass temperature were strictly controlled.Multi-layer and multi-pass welding techniques were employed to ensure welding quality.Post-weld insulation and slow cooling treatments were implemented to prevent crack formation,followed by magnetic particle inspection and hardness testing.This repair solution effectively resolved quality instability issues in thrust rollers,enhanced product competitiveness,achieved significant economic benefits,and holds high promotional value.

关 键 词：挡轮装置 铸钢材料 焊接工艺 探伤检验 缺陷修补 

分 类 号：TQ172.622[化学工程—水泥工业] TF777[化学工程—硅酸盐工业]