High temperature abrasion in sinter plants and their cost efficient wear protection

Markus Varga

High temperature abrasion in sinter plants and their cost efficient wear protection

Titel in Übersetzung: Hochtemperatur-Abrasion in Sinteranlagen und deren wirtschaftlicher Verschleißschutz

Markus Varga

Lehrstuhl für Allgemeinen Maschinenbau (140)

Publikation: Thesis / Studienabschlussarbeiten und Habilitationsschriften › Dissertation

525 Downloads (Pure)

Abstract

Abrasion bei Hochtemperatur (HT) ist ein kritischer Verschleißmechanismus in vielen industriellen Anwendungen. In dieser Arbeit wurden am Beispiel von Eisenerz-Sinteranlagen Instandhaltungstätigkeiten analysiert und Abrasion zeigte sich als der häufigste tribologische Schadensmechanismus. Kernkomponenten wie die Roststäbe am Sinterband, der Sinterbrecher und das Heißsieb werden durch verschiedene Formen von Abrasion bei HT geschädigt. Schadensanalysen zeigten Hochlast-Abrasion, Schlagabrasion und Erosion als Hauptlast, daher wurden diese Abrasionsformen im Detail bei Temperaturen bis zu 550°C-700°C erforscht. Der Einfluss dieser verschiedenen Abrasionsformen auf unterschiedliche verschleißbeständige HT Werkstoffe wurde untersucht. Relativ weiche Gusswerkstoffe mit geringem Hartphasenanteil (40 %) und hohe Härte bei Anwendungstemperatur als unerlässlich um Schlagabrasion zu widerstehen: Werkstoffe mit geringem Hartphasenanteil zeigten bis zu 17× höheren Verschleiß. MML Bildung ist stark abhängig von der Mikrostruktur des Werkstoffes: Hartauftragungen mit über 40 % Hartphasenanteil bilden keine signifikante MML aus. Materialerweichung durch steigende Temperatur und abrasives Hochlastregime begünstigen die Ausbildung dicker MML bei Werkstoffen mit geringem Hartphasenanteil. Der Verschleißschutz durch in-situ Bildung von MML war besonders bei Hochtemperatur ausgeprägt. Ein linearer Zusammenhang zwischen den Verschleißraten und der Warmhärte ist besonders bei Hochlast-Abrasion und 30° Erosion zu finden. Weiters folgt das Verhältnis aus 90° und 30°-Erosion einem linearen Zusammenhang mit der Warmhärte bei nahezu alle getesteten Werkstoffen und Temperaturen.

Titel in Übersetzung	Hochtemperatur-Abrasion in Sinteranlagen und deren wirtschaftlicher Verschleißschutz
Originalsprache	Englisch
Qualifikation	Dr.mont.
Betreuer/-in / Berater/-in	Danzer, Robert, Beurteiler B (intern) Grün, Florian, Beurteiler A (intern)
Publikationsstatus	Veröffentlicht - 2016

Bibliographische Notiz

nicht gesperrt

Schlagwörter

Tribologie
Abrasion
Hochtemperatur
Hartauftragung
Sinteranlage
Instandhaltung

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title = "High temperature abrasion in sinter plants and their cost efficient wear protection",

abstract = "Abrasive wear at high temperatures (HT) is a serious issue in many industrial applications. Within this work, on the example of an iron ore sinter plant, maintenance tasks were analysed and abrasive wear was found to be the most frequent tribological failure. Core components like the grate bars of the sinter belt, the sinter crusher system and the hot sieve suffer from abrasion at HT, with various forms of abrasion present. Failure analysis pointed out that high-stress abrasion, impact-abrasion and erosion are of major concern, hence these abrasion modes were studied in detail at temperatures up to 550°C-700°C. The influence of the various forms of abrasion on prospective HT wear-resistant materials was investigated. Relative soft cast materials with low amount of hardphases (40 %) and high hardness at application temperature are necessary to withstand impact-abrasion, because low hardphase containing materials showed up to 17× higher wear loss. MML formation is strongly dependent on the microstructure of the material: hardfacings with more than 40 % hardphases do not show significant MML formation. Temperature-induced material softening and severe abrasive contact encourage massive MML formation on low hardphase containing materials. In this case, wear protection of in-situ formation of MML was pronounced at HT. Linear correlation of abrasive wear rates with hot hardness was especially evident at high-stress abrasion and oblique erosion (30°). Further, the ratio of normal and oblique erosion follows a linear relationship with the hot hardness for nearly all materials and temperatures investigated.",

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N2 - Abrasive wear at high temperatures (HT) is a serious issue in many industrial applications. Within this work, on the example of an iron ore sinter plant, maintenance tasks were analysed and abrasive wear was found to be the most frequent tribological failure. Core components like the grate bars of the sinter belt, the sinter crusher system and the hot sieve suffer from abrasion at HT, with various forms of abrasion present. Failure analysis pointed out that high-stress abrasion, impact-abrasion and erosion are of major concern, hence these abrasion modes were studied in detail at temperatures up to 550°C-700°C. The influence of the various forms of abrasion on prospective HT wear-resistant materials was investigated. Relative soft cast materials with low amount of hardphases (40 %) and high hardness at application temperature are necessary to withstand impact-abrasion, because low hardphase containing materials showed up to 17× higher wear loss. MML formation is strongly dependent on the microstructure of the material: hardfacings with more than 40 % hardphases do not show significant MML formation. Temperature-induced material softening and severe abrasive contact encourage massive MML formation on low hardphase containing materials. In this case, wear protection of in-situ formation of MML was pronounced at HT. Linear correlation of abrasive wear rates with hot hardness was especially evident at high-stress abrasion and oblique erosion (30°). Further, the ratio of normal and oblique erosion follows a linear relationship with the hot hardness for nearly all materials and temperatures investigated.

AB - Abrasive wear at high temperatures (HT) is a serious issue in many industrial applications. Within this work, on the example of an iron ore sinter plant, maintenance tasks were analysed and abrasive wear was found to be the most frequent tribological failure. Core components like the grate bars of the sinter belt, the sinter crusher system and the hot sieve suffer from abrasion at HT, with various forms of abrasion present. Failure analysis pointed out that high-stress abrasion, impact-abrasion and erosion are of major concern, hence these abrasion modes were studied in detail at temperatures up to 550°C-700°C. The influence of the various forms of abrasion on prospective HT wear-resistant materials was investigated. Relative soft cast materials with low amount of hardphases (40 %) and high hardness at application temperature are necessary to withstand impact-abrasion, because low hardphase containing materials showed up to 17× higher wear loss. MML formation is strongly dependent on the microstructure of the material: hardfacings with more than 40 % hardphases do not show significant MML formation. Temperature-induced material softening and severe abrasive contact encourage massive MML formation on low hardphase containing materials. In this case, wear protection of in-situ formation of MML was pronounced at HT. Linear correlation of abrasive wear rates with hot hardness was especially evident at high-stress abrasion and oblique erosion (30°). Further, the ratio of normal and oblique erosion follows a linear relationship with the hot hardness for nearly all materials and temperatures investigated.

KW - tribology

KW - abrasion

KW - high temperature

KW - hardfacing

KW - sinter plant

KW - maintenance

KW - Tribologie

KW - Abrasion

KW - Hochtemperatur

KW - Hartauftragung

KW - Sinteranlage

KW - Instandhaltung

M3 - Doctoral Thesis

ER -