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Our Solution:
To tackle this challenge, our R&D team has successfully developed a high-performance austenitic stainless steel sheet based on years of practical experience. This product is specifically designed to meet the performance requirements of membranes under harsh working conditions, including high cycling, fatigue resistance, and corrosion resistance.
Rigorous R&D and Manufacturing Processes:
1. Precise Material Design: Scientifically determined the key chemical components of the thin sheet to ensure excellent substrate performance.
2. Comprehensive Process Optimization: Collaborated with experts in smelting, rolling, and heat treatment to thoroughly discuss and establish:
Smelting Process: Ensures material purity and compositional uniformity.
Rolling Process: Achieves precise thickness control and excellent plate shape.
Heat Treatment Process: Optimizes microstructure and enhances overall mechanical properties.
Strengthening Treatment Process: Specifically improves the material's fatigue strength and surface hardness.
Surface TR Treatment Process: Effectively improves surface condition, enhancing wear resistance and corrosion resistance.
3. Dedicated Equipment Assurance: Key processes are equipped with specialized equipment to ensure stable execution of processes and product consistency.
4. Standardized Production Process: Ultimately formed a complete and standardized production process and specific procedural guidelines, ensuring the reliability and traceability of product quality.
Practical Application Verification and Effects:
This high-performance stainless steel sheet has been successfully applied to various models of diaphragm compressor diaphragms. Verification of actual usage data: The diaphragms made from this material have significantly improved their service life, effectively meeting design requirements and usage expectations, bringing tangible benefits to customers.
Conclusion:
This high-performance austenitic stainless steel sheet is a professional solution provided by our company to address the lifespan challenges of diaphragm compressor diaphragms. It embodies a deep integration of materials science, process engineering, and practical application, aiming to offer more reliable and longer-lasting core component material choices for the diaphragm compressor industry.
Order code: 177T
The maximum diameter of the membrane with a thickness of 0.4mm can reach Ф600mm.
The maximum diameter of the membrane with a thickness of 0.5mm can reach Ф1200mm.
Our company offers two thicknesses of diaphragms that are compatible with multiple brands of diaphragm compressors.
Maximum diameter available | Advantages | ||
Φ600*0.4 | Short replenishment cycle | Life expectancy greatly enhanced. | Improve economic efficiency Reduce labor intensity |
Φ1200*0.5 | |||
177T has unparalleled comprehensive mechanical properties; its austenitic structure not only withstands corrosion from various media but also serves as an excellent material resistant to hydrogen gas corrosion, playing a significant role in carbon neutrality and hydrogen energy.
Order Instructions
Our company only provides diaphragms made of 177T material.
We do not guarantee the lifespan of the diaphragms; we only compare their lifespan with those not provided by our company.
The buyer must provide CAD cutting drawings, which will take effect after confirmation by the seller, who will provide the specifications of the original sheet material.
Recommendations:
For diaphragms with a diameter ≤ Ф600mm, use sheet material with a thickness of 0.4mm.
For diaphragms with Ф600mm < diameter ≤ Ф1200mm, use sheet material with a thickness of 0.5mm.
A minimum order of 4 sets is required for each specification of diaphragm.
The delivery period is within 2 weeks after full payment is received.
The lifespan of the diaphragm is the main design basis for diaphragm compressors. When the mechanical design, pressure, and volume of the compressor meet the requirements, the lifespan of the metal diaphragm will determine the reliability of the compressor. A reliable diaphragm will reduce maintenance costs and increase output. The key factors affecting diaphragm damage are as follows:
About the diaphragm
1. Mechanical properties: A high-quality diaphragm must possess excellent mechanical properties such as high tensile strength and HV hardness.
2. Diaphragm material: The material of the diaphragm should be elastic, allowing for a longer resistance to metal fatigue.
3. Chemical corrosion: Different gases require complex adjustments of trace elements to address corrosiveness.
About diaphragm compressors
1. Sealing structure: Different manufacturers have different sealing structures, which can lead to additional stress on the diaphragm due to poor sealing, shortening its lifespan.
2. Oil pressure: The piston pressure pushes hydraulic oil to the diaphragm; it is important to ensure that this pressure is not excessively high.
3. Diaphragm chamber curve: An excellent diaphragm chamber curve must perfectly match the performance of the diaphragm. If the match is not perfect, it can hinder the diaphragm's performance or lead to premature failure.
4. Operating temperature: For diaphragm compressors used in hydrogen stations, the exhaust temperature must not exceed the standard of 135 degrees; otherwise, phenomena such as hydrogen embrittlement and corrosion may occur.
Quality of the gas
1. Gas purity: Currently, there are different types of hydrogen, including gray hydrogen, blue hydrogen, and green hydrogen. Gray and blue hydrogen are industrial by-products, and the impurities in the gas vary depending on the source. In the compression stage, foreign objects can impact the gas side of the diaphragm, causing premature damage.
2. The moisture content in the gas can significantly damage the diaphragm.
Please operate according to the manufacturer's standard operating manual, as incorrect operating procedures can easily lead to various issues, resulting in diaphragm damage and shutdown alarms.
1. Diaphragm Materials:
(1) Mechanical Properties of the Material: Tongxin Company uses specially treated 177T as the diaphragm material, which has good mechanical properties.
(2) Surface Finish of the Diaphragm: Roughness on the diaphragm surface can cause stress concentration and significantly affect the stress distribution of the diaphragm. The 177T diaphragm is processed with cold rolling and polishing to achieve a smooth surface without impurities.
(3) Thickness of the Diaphragm: The thickness of the material also affects stress. The thickness of the diaphragm is inversely proportional to stress. Tongxin's standard thickness is 0.4mm/0.5mm. When the thickness is less than 0.4mm, the material becomes difficult to handle and is prone to deformation; additionally, overly thin diaphragms are prone to breakage.
2. Diaphragm Stress:
(1) Curvature of the Chamber: The greatest factor affecting diaphragm stress is the shape of the chamber's curvature. Currently, the domestic curves include single exponential, double exponential, and triple exponential curves.
(2) Torque: The rubber "O" ring seal has a small tightening torque, which reduces diaphragm stress and extends diaphragm life.
3. On-Site Operations:
(1) Compressed Gases: Corrosive gases will reduce diaphragm life. The 177T material includes trace elements that provide corrosion resistance.
(2) Cleanliness of the Gas: Any small particles mixed in the gas, once they enter the chamber, will eventually accumulate at the chamber edges (close to the sealing surface), leading to increased stress that severely affects diaphragm life.
(3) Friction Corrosion: This type of corrosion occurs between two objects under pressure. Relative displacement will cause stress concentration. To reduce this wear, lubricate both sides of the intermediate plate evenly with 1-2 drops of oil. The 177T diaphragm has a Vickers hardness of HV400/600, completely eliminating wear corrosion between diaphragms, thus extending diaphragm life.
(4) Temperature: High temperatures will also affect diaphragm stress, causing thermal stress in the diaphragm. High compression ratios will generate heat, and the effects vary with different compressed gases. In summary, it is necessary to lower the temperature to extend diaphragm life.
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