PROCESS OF MANUFACTURE OF BASALTIC ANTIABRASIVE HYBRID PLATES

Abstract

PROCESS OF MANUFACTURE OF BASALTIC ANTIABRASIVE HYBRID PLATES it's a process of manufacture of plates with basalt coating that will be applied to elements in contact with highly abrasive products for a higher resistance to abrasion wear, thus increasing useful life and as a result reducing industrial processes that stand still, with expressive increase in productivity, with applications in mining industries, steel mill, chutes, stock houses, silos, machines and transport systems, storage and motion subject to abrasive action through contact between intake or product with motion surface and/or storage, therefore it will be composed by steel plate SAC 50 (1); special glue cement (2); steel screen (3); basalt plates (4); and screws (5) forming a basaltic coating hybrid plate which resist traction and corrosion.

Claims

1. PROCESS OF MANUFACTURE OF BASALTIC ANTIABRASIVE HYBRID PLATES is featured by making possible through plate hybride, the manufacture of a plate that has antiabrasive characteristics, or resistive properties to abrasion, stress and corrosion; having a steel plate SAC 50 (1) composes the first layer of hybrid plate, and next it will be applied a glue cement (2) that will involve a steel screen (3) in such a way that will let the union of the steel plate SAC 50 (1) to the plates of cast basalt (4); the steel plate SAC 50 (1) will be fixed by screws (5) standard DIN in yours diverses gauges that will allow the fixation of hybrid plate in the equipment where will be applied, or too, the steel plate SAC 50 (1) can come without screws (5) being fixed by anchoring forming a set of basaltic coating on the elements in contact with products highly abrasives.

Description

[0008] The manufacturing process of basaltic antiabrasive hybrid plates will be better understood through of he detailed description in line with the following figures attached, where:

[0009] FIG. 01 Presents a view in perspective from hybrid plate of process from manufacturing of hybrid plates antiabrasives basaltics with folded edge.

[0010] FIG. 02 Presents a side view from hybrid plate of process from manufacturing of hybrid plates antiabrasives basaltics with folded edge.

[0011] FIG. 03 Presents a front view from hybrid plate of process from manufacturing of hybrid plates antiabrasives basaltics with folded edge.

[0012] FIG. 04 Presents an upper view from hybrid plate of process from manufacturing of hybrid plates antiabrasives basaltics with folded edge.

[0013] FIG. 05 Presents an exploded perspective view of process from manufacturing of hybrid plates antiabrasives basaltics with screws.

[0014] FIG. 06 Presents a view in perspective from hybrid plate of process from manufacturing of hybrid plates antiabrasives basaltics with screws.

[0015] FIG. 07 Presents an upper view from hybrid plate of process from manufacturing of hybrid plates antiabrasives basaltics with screws.

[0016] FIG. 08 Presents an upper view from hybrid plate of process from manufacturing of hybrid plates antiabrasives basaltics with screws.

[0017] FIG. 09 Presents a view in perspective approximate from hybrid plate of process from manufacturing of hybrid plates antiabrasives basaltics with screws.

[0018] With reference to these figures can observe that the process from manufacturing of hybrid plates antiabrasives basaltics is understood as a product that will be offered to the industries of mining, steel mills and any others that have yours facilities subject to high levels of abrasion.

[0019] The basaltic plate here described refers to a hybrid plate made of steel plate SAC 50 (1) in yours diverses gauges which will be the face for support of the plate, soon will be aggregated a special glue cement (2), jointly with steel screen (3); and by end will be fixed the basaltic plates (4) comprising thus the other face of plate for abrasion resistance.

[0020] The steel plate SAC 50 (1) will may consist in screws (5). DIN standard in the diverses gauges, allowing that the hybrid plates fix in the surfaces that will be implanted. Or too, which still allow the not utilization of screws (5); being fixed through Anchorage.

[0021] The special glue cement (2) comprises in a mixture that will involve the steel screen (3) in such way that this set will allow the property from shock absorber of impact thus as to unite the steel plate SAC 50 (1) to the basaltic plates (4). Such as, being a mixture that will result in an alloy, it will allow still the functionality of flexibility, compression and compressibility.

[0022] Such hybrid plates still will may receive galvanizing treatment, aiming to ensure still more the protection against the rust.

CHARACTERISTICS OF MEANS

Basalt: Physical Characteristics of Molten Basalt

[0023]

TABLE-US-00001 Category Property Density 3 g/cm.sup.3 Compressive resistance 300 MPa Bending resistance ?60 MPa Impact resistance 1.76 KJ/m.sup.2 Abrasion resistance 0.07 g/cm.sup.2 Vickers hardness scale ?720 kg/mm.sup.2 Modulus of elasticity 1.67 ? 10 MPa Coefficient of expansion 8.92 ? 10.sup.?6 Chemical attack resistance 95%-98% H2SO4 ?98% 20% H2SO4 ?94% 20% NaOH ?98%

CHARACTERISTICS OF STEEL SAC 50

General Characteristics of Thick Plates

[0024]

TABLE-US-00002 Resistance to Current Previous Flow limit atmospheric Fire generation generation (MPa) corrosion resistance USI-CIVIL-300 ASTM-A36MGM ? Min 300 ? ? USI-CIVIL-350 ASTM-A572-50-1 v Min 350 ? ? USI-SAC-300 USI-SAC-41-MG ? Min 300 v ? USI-SAC-350 USI-SAC-50 v Min 350 v ? USI-FIRE-350 USI-FIRE-490 v Min 325 v v (Room Temperature) Min 217 (600? C.) *Legends: ? - low, ? - m?dium, v - high

Similarity to the Thick Plates

[0025]

TABLE-US-00003 Similar Rules Quality ASTM EM JIS NBR Mercosul USI- ASTM-A-36 10025- G3101- 6650- 02-131- CIVIL-300 S235J0 SS400 CF26 ED24 USI- ASTM- 10025- G3101- 5000 02-102-MCF- CIVIL-350 A572-50-1 S35530 SS490 5004 345 02-101-MCG- 360 USI- SAC- A709W- 10155- G3114- 5921-CFR- 02-103-GRAU- 41 GR36 S235J0 SMA400 400 400 5008-CGR- 400 USI- SAC- A709W- 5921-CFR- NM-140-98- 41MG GR50 400 GRAU-400 5008-CGR- 400 USI- SAC- A588 (CG) 10155- G3114- 5921-CFR- NM-140-98- 50 A606-2 (TQ) S355J0W SMA490 500 GRAU-500 5008-CGR- 500 USI- SAC- A242-1 (CG) 10155- G3125- 350 A606-4 (TQ) S355J0WP SPA-H

Characterization of Steels Regarding Their Chemical Systems

[0026]

TABLE-US-00004 DU Application Nomenclature Chemical system Structural ASTM-A-36-MG C e Mn ASTM-A-36 ASTM-A-572-50-1 USI-CIVIL-300 USI-CIVIL-350 Corrosion USI-SAC-300 Si, P, Cu e Cr resistance USI-SAC-350 Fire resistance USI-FIRE-300, Mo e Cu USI-FIRE-350

Specified Chemical Compound (% in Mass)Thick Plates

[0027]

TABLE-US-00005 Steel Thickness C Mn Si P S Nb ASTM- 6.0 to 0.26 0.80 to 0.15 to 0.04 0.05 A36-MG 75.00 1.35 0.30 ASTM- 6.0 to 0.25 0.4 A36 19.1 0.80 to max 19.1 to 0.26 1.20 0.15 to 38.1 0.27 0.4 38.1 to 63.5 63.5 to 101.6 ASTM- until 9.53 0.23 0.50 to 0.4 0.005 to A572- 9.53 to 0.2 1.35 max. 0.050 50-1 38.10 0.80 to 0.15 to 38.1 to 1.50 0.40 50.00

Specified Mechanical Properties

[0028]

TABLE-US-00006 Traction (cross) Bending (1) Lengthening (2) (Longitudinal) LE LR Thickness BM % Thickness Steel (MPa) (MPa) (min) (min) (min) (mm) Diameter ASTM- Min Min 6.00 to 50 18 Below 19.05 0.5E A36-MG 300 75.00 200 0.18 19.05 to 25.40 1.0E 25.40 to 38.10 1.5E 38.10 to 50.80 2.5E Above 50.80 3.0E ASTM- Min 400 to 6.00 to 200 20 Below 19.05 0.5E A36 250 550 70.00 19.05 to 25.40 1.0E 25.40 to 38.10 1.5E 70.00 to 50 23 38.10 to 50.80 2.5E 101.6 Above 50.80 3.0E ASTM- Min Min <50.00 200 16 Below 19.05 1.0E A572- 345 450 19.05 to 25.40 1.5E 50-1 25.40 to 38.10 2.5E 1 - Carried out when requested by the client. 2 - The lengthening values must be reduced according to the following table;

Quality for General Uses

[0029]

TABLE-US-00007 Thickness Chemical Compound (%) Specification range C Mn Si P S (SAE) (mm) (max) (max.) (max.) (max.) (max.) 1010 5.0 < e ? 0.08- 0.30- 0.35 0.04 0.05 152.4 0.13 0.60 1020 0.17- 0.23 1045 0.42- 0.60- 0.10- 0.50 0.90 0.35

Equipment Needed for Manufacturing:

[0030] Plasma cutting equipment for steel and screen plates; [0031] Equipment for welding type mig; [0032] Bend equipment for steel plate; [0033] Special tables for cutting the molten Basalt; [0034] Press for casting steel and basalt plates.

Stage of Productive Process:

[0035] Basalt casting in order to prepare the pieces: in this stage, the cutting, the shape cutting, the mounting teeth and the cast basalt plates finishing is carried out, according to the dimensions of the steel plate to be coated; [0036] Electrolytic galvanizing of the steel plates: galvanizing of plates on specified measurements (when plates are subjetcted to humidity conditions and/or environmental corrosion); [0037] Doubling of plates: the plate bend in its greater dimension is carried out forming a cross section in L; [0038] Cutting: plasma cutting and punching of steel plates USI SAC 350 (old SAC 50) is carried out; [0039] Cutting on steel screen: cutting on screen in galvanized steel 14 is carried out and it will be scaled on glue cement between the steel plate and the basalt coating; [0040] Preparation of a special glue cement: a proportioning plaster with a mixture of special cement ARI (high initial resistance) is done+granilha+crushed basalt; [0041] Plates casting using hydraulic press: the application of the basalt pieces on the plates, is done mounted among themselves and stuck with a special glue cement; [0042] Painting, finishing and codification of the end product: it is carried out the procedure for final surfacing, serial number with barcode for identifying lot number and date of manufacturing.
Components and characteristics of the products (steel, electrolytic galvanizing, screen, cast basalt, special cement, screws, welding, cuttings): Type of products. [0043] Standard plates; [0044] Hybrid plates; [0045] Formed plates; [0046] Ducts Coating; [0047] Customized plates.
Benefits identified with the use from process of manufacture in basaltic antiabrasive hybrid plates: [0048] Increase of useful life; [0049] Operation without maintenance; [0050] Operation without interruption; [0051] Eliminates production losses; [0052] There is no contamination of the product resulting from abrasion, mixture or corrosion; [0053] Physiologically harmless, because this is indicated to the food industry; [0054] Smooth contact ?rea, that promotes good fluidity and avoiding accumultation of material; [0055] Reduce the pression loss and, consequently decrease the energy consumption.
Afterwards, it will be indicated some areas where can be applied the process: [0056] Cement plants; [0057] Breweries, malt houses; [0058] Chemical industries; [0059] Gas plants; [0060] Foundries; [0061] Glass plants; [0062] Steel mills and rolling mills; [0063] Lime plants, sand and potassium; [0064] Mineral extraction and coal; [0065] Coke plants; [0066] Mills and incineration plants and residual recycling; [0067] Paper plants.

[0068] In this process, we have observed that only in the restriction of temperature in the operational environment must not exceed 350 degrees Celsius and the limitation of straight impacts and sharp charges act directly on the plates surfasse, this is the only disadvantage of the material due to its crystalline structure.

[0069] As it was shown above, the preferential embodiments given to the measurement of hybrid plates, concerning tickness, shapes, and bends on steel plates, so that the application process for transport equipment coating described here are a feasible alternative. All references to antiabrasive hybrid plates, shall not limit the current invention; it may have constructive variants equivalent, but it cannot escape from scope of protection of the invention.