Thermische spanning:
Het interne mengvat handhaaft de temperatuur rond de 175°C terwijl het wordt gevuld met aggregaten die door wrijving extra warmte genereren. Deze thermische cycli – herhaaldelijk verwarmen en afkoelen – veroorzaken materiaaldegradatie, maatveranderingen en versnelde oxidatie die de structurele integriteit in de loop van de tijd verzwakt.
Slijtage van schurende deeltjes:
Het mengproces combineert hoog-chroomaggregaten, mineralen, zand en bitumineus bindmiddel met hoge snelheid. Deeltjes raken voortdurend het oppervlak van de voering onder hoeken variërend van loodrechte impact tot tangentieel glijdend contact, waardoor multidirectionele schurende slijtagepatronen ontstaan die veel complexer zijn dan eenvoudige glijdende wrijving.
Chemische corrosie:
Moderne asfaltformuleringen bevatten additieven, waaronder rubberpolymeren, verjongingsmiddelen, antistripmiddelen en prestatiemodificatoren. Deze chemicaliën, gecombineerd met geoxideerde bitumenresten en minerale fijne deeltjes, creëren een corrosieve omgeving die conventionele staaloppervlakken aantast en zinkgebaseerde coatings aantast.
Mechanische impactbelasting:
Plotselinge wijzigingen in de belasting van apparatuur, onjuiste materiaalstortsequenties en batchovergangen veroorzaken schokbelastingen die worden doorgegeven aan de voering. Deze impactgebeurtenissen, die honderden keren per dag voorkomen, overschrijden de statische ontwerpbelastingen en veroorzaken microscheurtjes die zich voortplanten in catastrofale storingen.
Impact van vervangingsfrequentie:
Traditionele liners van lage kwaliteit moeten mogelijk elke 6 tot 12 maanden bij continu gebruik worden vervangen. Premium liners die de levensduur verlengen tot 24-36 maanden, elimineren 50-75% van de met vervangingen samenhangende stilstand.
Implicaties voor veiligheid en kwaliteit:
Door verslechterende bekledingen kan asfalt rechtstreeks in contact komen met het scheepsstaal, waardoor het mengsel mogelijk wordt verontreinigd met roestdeeltjes die de bindmiddeleigenschappen en de kwaliteit van de bestrating aantasten. De integriteit van de voering houdt rechtstreeks verband met de kwaliteit van het afgewerkte asfaltmengsel en de duurzaamheid van het wegdek op lange termijn.
Verspreiding van hardmetaal:
Chroom combineert met koolstof om chroomcarbiden (Cr₇C₃ en Cr₂₃C₆) te vormen, die door de hele ijzermatrix neerslaan. Deze carbidekristallen vertonen hardheidswaarden van 1400-1600 HV – vergelijkbaar met industriële diamanten – terwijl de omringende ijzermatrix voor taaiheid en slagvastheid zorgt. Deze tweefasenstructuur lost de traditionele uitdaging op het gebied van materiaaltechniek op, namelijk het bereiken van gelijktijdige hardheid en taaiheid.
Specificatie oppervlaktehardheid:
De asfaltfabriekbekledingen van Haïti bereiken een oppervlaktehardheid van 58-62 HRC (Rockwell Hardness Scale), gemeten volgens de ASTM E18-normen. Dit hardheidsniveau zorgt voor een extreme weerstand tegen het binnendringen van deeltjes, terwijl er voldoende elasticiteit behouden blijft om plaatselijke schokken te absorberen zonder brosse breuk.
Warmtebehandelingsverwerking:
Haïtiaan maakt gebruik van gecontroleerde afschrik- en ontlaatprocessen met behulp van geautomatiseerde warmtebehandelingsovens op aardgas. Het proces omvat:
Verwarmen tot 950°C-1050°C om legeringselementen in de ijzermatrix op te lossen
Snelle koeling (afschrikken) in gecontroleerde oliebaden om een martensietfase te creëren
Tempereren bij 350°C-450°C om de afschrikspanningen te verlichten terwijl de hardheid behouden blijft
Dit uit meerdere stappen bestaande proces bereikt de precieze hardheid-taaiheidsbalans die nodig is voor een levensduur van 24-36+ maanden in asfaltomgevingen.
| Materiaaltype | Samenstelling | Hardheid (HRC) | Levensduur | Thermische prestaties | Corrosieweerstand | Toepassingsgeschiktheid | Kostenprofiel |
| Standaard koolstofstaal | ASTM A36 | 30-35 | 3-6 maanden | Slecht (mislukt >300°C) | Minimaal | Budgetoperaties | Laag |
| Gegoten staal met hoog mangaangehalte | ZGMn13-5 (Mn 11-15%) | 40-48 | 8-12 maanden | Redelijk (voldoende tot 350°C) | Gematigd | Algemene dienst | Medium |
| Medium chroom (18Cr) | 18Cr2Ni4W | 50-55 | 12-18 maanden | Goed (stabiel tot 400°C) | Goed | Standaard dienstvoeringen | Middelhoog |
| Hoog chroomgehalte 26Cr (Haïtiaanse standaard) | Cr26 met Ni/Mo-toevoegingen | 58-62 | 24-36 maanden | Uitstekend (hoger dan 450°C) | Uitstekend | Premium voeringen | Hoog |
| Keramische composiet overlay | Cr26-basis + keramische deeltjes | 62-65 | 36-48 maanden | Uitstekend (behoudt hardheid tot 500°C) | Uitstekend | Extreme slijtageservice | Premie |
Oppervlakteafwerking Ra 3,2-6,3 μm, waardoor de insluiting van deeltjes wordt geminimaliseerd
Dimensionale tolerantie ±1-2 mm op kritische interfaces
Vlakheidsafwijking <2 mm over afmetingen van 500 mm
Consistente kernhardheid gedurende het hele gietstuk zonder variatie in de hardheid van het oppervlak en de ondergrond
DISA 250-C-335 verticale vormlijn:
Dit door Denemarken ontworpen geautomatiseerde systeem produceert 355 mallen per uur met een uitzonderlijke maatvastheid. De geautomatiseerde zandverdichtings- en kernplaatsingsmechanismen van de machine zorgen voor een herhaalbare productkwaliteit die handmatig gieten niet kan bereiken, en leveren de nauwe toleranties die vereist zijn voor nauwkeurig passende liners.
Verloren schuimgietvermogen:
Voor complexe voeringgeometrieën met interne verstevigingsribben of aangepaste montagefuncties gebruikt Haitian de verloren-schuimgiettechnologie. Dit proces elimineert de traditionele beperkingen bij het maken van kernen, waardoor ontwerpinnovaties mogelijk zijn die de prestaties van de voering verbeteren en tegelijkertijd de productiekosten verlagen.
Innovatie in 3D-zandprinten:
Recentelijk ingezette 3D-zandprinters brengen de ontwikkeling van prototypen terug van traditionele cycli van 45 dagen naar 15-20 dagen. Deze versnelde ontwikkelingstijdlijn maakt snelle aanpassingen mogelijk voor groothandelspartners die aanpassingen nodig hebben om te passen bij eigen apparatuurontwerpen.
Middenfrequente inductieovens (3750 kW, 300 Hz):
Acht geautomatiseerde smeltovens met geïntegreerde laad- en overdrachtsystemen zorgen batch na batch voor een nauwkeurige legeringssamenstelling. Het middenfrequente ontwerp zorgt voor een superieure verwarmingsefficiëntie in vergelijking met alternatieven met een lagere frequentie, waardoor het energieverbruik met 20-30% wordt verminderd en de metaalkwaliteit wordt verbeterd.
Warmtebehandelingssystemen:
Volledig geautomatiseerde warmtebehandelingsovens op aardgas met intelligente temperatuurregeling (PID-systemen) en meerpuntsthermokoppelbewaking zorgen voor een consistente hardheid en microstructuur in alle productie-eenheden. Deze consistentie elimineert de prestatievariaties die vaak voorkomen bij handmatige warmtebehandelingen.
Materiaalanalyse:
Direct afleesbare spectrometrie (ARL 2460 spectrometer) verifieert het chroomgehalte, de nikkeltoevoegingen en de samenstelling van sporenelementen met een nauwkeurigheid van ±0,1%, zodat elke voering voldoet aan de gespecificeerde materiaalsamenstelling.
Hardheid testen:
Meerdere hardheidsmetingen per voering met behulp van Brinell (HB) en Rockwell (HRC) schalen verifiëren de oppervlaktehardheid binnen het specificatiebereik van ±2 HRC. Uit productiegegevens blijkt dat het bereik van 58-62 HRC consistent wordt bereikt met een conformiteitspercentage van >99%.
Metallografische analyse:
Periodiek metallografisch onderzoek bevestigt de juiste microstructuur en carbidedistributie bij de afschriktemper, waarbij eventuele afwijkingen worden geïdentificeerd die kunnen wijzen op problemen met de ovencontrole of problemen met de materiaalbatch.
Niet-destructief testen:
Ultrasone foutdetectie volgens GB/T 7233.1-2009 klasse II-normen identificeert interne porositeit of materiaalfouten. Alle liners die een Graad II-acceptatie behalen, voldoen aan de inspectiedekking van 100%.
Dimensionale verificatie:
Coördinatenmeetmachines (CMM) verifiëren alle kritische afmetingen aan de hand van specificaties. Het testen van de pasvorm van de montage garandeert een goed interfacecontact met de montageoppervlakken.
100% eindinspectie:
Elke voering wordt vóór verzending aan een uitgebreide dimensionale en visuele inspectie onderworpen. Het bedrijf houdt inspectiedocumentatie bij voor elke productiebatch, waardoor volledige traceerbaarheid wordt geboden.
Jaarlijkse productiecapaciteit: meer dan 60.000 ton slijtvaste gietstukken
Dagelijkse DISA-lijncapaciteit: 80+ ton afgewerkte liners
Standaardlevering: 7-10 dagen voor voorraadartikelen die aan de specificaties voldoen
Versnelde levering: 15-20 dagen voor aangepaste geometrieën
Bulkgroothandelcapaciteit: gelijktijdige productie van meer dan 100 eenheden zonder kwaliteitsverlies
Grenzend aan de uitvalswegen Shanghai-Beijing en Nanjing
Nabijheid van de diepwaterhaven van de Yangtze-rivier voor internationale zendingen
Regionaal knooppunt voor leveranciers van componenten en logistieke dienstverleners
Relaties opgebouwd met grote vrachtvervoerders en internationale logistieke bedrijven
Mogelijkheid tot douane-entrepot voor exportconsolidatie
Deze marktpositie weerspiegelt de erkende uitmuntendheid op het gebied van slijtvaste giettechnologie en het vertrouwen van de klant in productkwaliteit en betrouwbaarheid.
2024: Award voor uitstekende particuliere ondernemingen, provincie Anhui
2023: Nationale Intelligent Manufacturing Excellent Scene Award
2021: "Little Giant" onderneming van het Nationale Ministerie van Industrie en Informatietechnologie
2014: Toonaangevende onderneming in de Chinese slijtvaste gieterijsector (toegangscertificering voor de gieterij-industrie)
Deze partnerschappen en onderscheidingen bevestigen de positionering van Haïti als een vertrouwde leveringspartner voor hoogwaardige slijtvaste componenten.
13 Geautoriseerde uitvindingsoctrooien: inclusief gepatenteerde processen voor gieten met hoog chroomgehalte en oppervlaktebehandeling
45 Gebruiksmodeloctrooien: procesinnovaties en verbeteringen aan apparatuur
Deelname aan nationale normen: Primaire tekeneenheid voor 8 nationale normen en 3 industriële normen, waaronder "Anti-Wear White Cast Iron Castings" (GB/T 9437-2009)
| Kostencategorie | Budgetvoeringen | Haïtiaanse premiumvoeringen |
| Individuele voeringkosten | $150 | $195 |
| Levensduur | 8 maanden (25-30 dagen werking) | 24 maanden (75+ dagen werking) |
| Aantal vereist (5 jaar gebruik) | 7-8 eenheden | 2-3 eenheden |
| Materiaalkosten (5 jaar) | $1,050-1,200 | $390-585 |
| Arbeidsinstallatie/verwijdering | ~ $ 150 per vervanging | ~ $ 150 per vervanging |
| Totaal arbeid (5 jaar) | $1,050-1,200 | $300-450 |
| Kosten voor downtime (@$750/uur) | ~8 uur per vervanging × 7 evenementen = 56 uur = $42.000 | ~8 uur per vervanging × 2 evenementen = 16 uur = $ 12.000 |
| Totale kosten over 5 jaar | $44,300-44,800 | $12,800-13,200 |
| Kostenvoordeel | Basislijn | 71% besparing |
Standaardformaten: 500×300 mm, 600×350 mm, 700×400 mm en aangepaste afmetingen
Dikteopties: 30-50 mm, geoptimaliseerd voor de afmetingen van het montageoppervlak
Interfaceontwerp: Compatibiliteit met vastgeschroefde, vastgelaste en clipbevestigingssystemen
Aangepaste geometrie: gevormde voeringen die passen bij specifieke mengkomcontouren of gespecialiseerde apparatuurontwerpen
DISA-stofverwijderingssystemen handhaven een afvoer van ≤1,8 mg/Nm³ (ruim onder de klasse A-bedrijfsnorm van 10 mg/Nm³)
Ovenemissies maken gebruik van moderne baghouse-filtratietechnologie
Afvalwaterzuiveringssystemen zorgen voor naleving van de milieuwetgeving
Middenfrequente inductieovens verminderen het energieverbruik per eenheid met 20-30% vergeleken met oudere technologie
Geautomatiseerde systemen minimaliseren afval door middel van precisieproductie
Recycling van afvalzand vermindert de vereisten voor het afvoeren van stortplaatsen
Het aanbod van asfaltfabrieken van Haitian Casting vertegenwoordigt de optimale keuze voor groothandelspartners die een balans zoeken tussen kwaliteit, kosteneffectiviteit en marktpositionering op de lange termijn. Dankzij twintig jaar toegewijde focus op slijtvaste giettechnologie, voortdurende investeringen in geavanceerde productiemogelijkheden en bewezen expertise in de meest veeleisende industriële markten van China, levert Haitian liners die de klantwaarde maximaliseren en groothandelspartners tot premiumleveranciers maken in concurrerende apparatuurmarkten.
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