How can wear resistance be improved in steel fabrication?

2025-03-27 14:57:53

In the steel bridge deck pavement project of Sichuan-Tibet Railway, nano-modified steel plate reduces wheel wear by 42%; Bohai Bay wind power pile foundation protection system realizes 20 years of maintenance-free through gradient composite coating; key transmission parts of a mining machinery adopts laser cladding technology, and its service life is extended by 3 times... These practices reveal that modern Steel Structure anti-wear technology is evolving from a single protection to a system solution.

I. Material genome technology to optimize the alloy ratio

The wear-resistant steel material database built on big data has included 23,000 combinations of alloy ratio data from all over the world. The machine learning model developed by a research institute has successfully predicted the Cr-Mo-V-B multivariate microalloying formula, which enhances the surface hardness of Q690 steel to 58 HRC while maintaining the impact work at -40°C ≥ 47 J. In the application of iron ore conveying system in Australia, the wear rate of this material is reduced by 65% compared with that of the traditional steel grades.

Gradient composite steel plate to realize the performance leap. A special vehicle manufacturer using explosive welding technology, 6mm thick tungsten carbide layer and high toughness matrix combination, three-point bending test shows that the interface bond strength of 520MPa, mining bucket service life exceeded 8000 hours mark.

Second, advanced surface modification technology system

Laser cladding technology breaks through the traditional limitations. The coaxial powder feeding system is used to melt and coat Stellite 6 alloy on the surface of steel components, the hardness of which can reach 62 HRC, and the friction coefficient has been reduced to 0.18. The amount of water corrosion and wear of a hydraulic turbine runner blade has been reduced by 82% after treatment, and the overhauling cycle has been extended from 2 to 5 years during the operation of Jinshajiang Power Station.

Plasma metal penetration technology realizes atomic level combination. A hydraulic pillar by double-layer osmosis plating (inner TiN + outer DLC), the surface hardness of 3800HV, in the coal mine underground acidic environment, corrosion and wear rate of the traditional chrome-plated parts is only 1/7.

Third, intelligent processing technology innovation

Controlled shape control rolling technology breakthrough. The introduction of deformation-induced phase change mechanism in the rolling stage, so that the residual austenite content of NM500 wear-resistant steel is accurately controlled at 8%-12%, wear resistance increased by 30% at the same time, the cold bending performance to meet the d = 2a standard. After the application of this technology by a construction machinery manufacturer, the replacement frequency of moving arm structural parts dropped by 60%.

Ultrasonic-assisted cutting technology improves work hardening. In the processing of high manganese steel rutting fork, 20kHz ultrasonic vibration to reduce cutting force by 45%, the surface roughness Ra value from 3.2μm to 0.8μm, the depth of the work-hardening layer is reduced by 70%, and significantly improve the subsequent heat treatment effect.

Fourth, structure bionic design innovation

Shell pearl layer structure reproduction technology. A research institute imitates the “brick-mud” structure of abalone shell, and builds alumina ceramic/epoxy resin interleaved layer on the surface of steel plate, and the impact wear test shows that the energy absorption efficiency is improved by 4 times. The technology has been applied to high-speed rail brake disk protection, so that the thermal crack sprouting cycle extended to three times the traditional materials.

Sharkskin non-smooth surface drag reduction design. Through the laser micro-weaving technology in the steel propeller surface processing 30μm level diamond-shaped pits, water hole test shows that cavitation damage area reduced by 58%, a 10,000-ton cargo ship after the application of the annual maintenance cost reduction of 1.2 million yuan.