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Large furnace riveted and welded components

I. Introduction to Riveted and Welded Components for Large Furnaces

Large furnace riveted and welded components refer to enclosed or semi-enclosed thermal equipment used in industrial production for high-temperature processes such as smelting, heating, heat treatment, sintering, etc. These components typically consist of a steel-structure shell, fire-resistant lining, heating system, temperature-control system, and more. They are characterized by their large dimensions—often exceeding 10 meters in length—and significant weight, ranging from hundreds to thousands of tons, while also boasting exceptional heat resistance, capable of withstanding temperatures between 800°C and 1,800°C.

II. Common Materials Used for Furnace Bodies

The material must meet requirements for high-temperature resistance (800–1600℃), thermal fatigue resistance, and excellent corrosion resistance (to oxidation, sulfidation, and carburization), as well as high strength.

Classified by component:

Component	Commonly Used Materials	Characteristics and Applicable Temperature
Furnace Shell Steel Structure	Q235B/Q345R	Ambient temperature ~ 350°C (supporting frame, low cost)
High-temperature furnace shell/liner板	S30408 (304H), S31008 (310S)	800–1100°C (Austenitic stainless steel, oxidation-resistant)
Radiation Tube/Burner	0Cr25Ni20(310S), Inconel 600	1100~1300℃ (high-nickel alloy, carburization-resistant)
Furnace Rollers/Guides	253MA(S30815), Cr28Ni48W5	1200℃+ (High-chromium nickel heat-resistant steel, resistant to deformation)
Fire-resistant anchor fittings	0Cr25Ni20(310S), RA330	Resistant to high-temperature corrosion, securing refractory materials
Insulation layer	Ceramic Fiber Modules / Lightweight Firebricks	Thermal insulation (density only 200–500 kg/m³)

Welding Method Selection

Method	Applicable Scenarios	Advantages
Gas Tungsten Arc Welding (GTAW)	Thin plates (≤6mm), root welds for pipes, precision components	High quality, minimal deformation
Flux-Cored Arc Welding (FCAW)	Structural welds for medium-to-thick plates (6–50 mm), on-site installation	High efficiency, strong wind resistance
Submerged Arc Welding (SAW)	Thick plates (>20mm) with straight, long welds (furnace bottom plates/shells)	Large penetration, no spatter

III. Key Processes in Welding Technology

Pre-weld preparation: material cutting, forming, and beveling (with precision control).

Strict cleaning: Remove oil, rust, water, oxide scale, and other contaminants from the bevel and surrounding areas on both sides.

Assembly tack welding: Use the same welding materials and processes as for the final welds, ensuring high-quality tack welds with appropriate length and spacing. Also, inspect for assembly gaps and misalignment.

Preheating (if required): Heat evenly to the specified temperature, and monitor and record accordingly.

Welding process:

Weld strictly according to the WPS and welding sequence.

Control interlayer temperature (monitor and record).

When performing multi-pass, multi-layer welding, carefully clean away interlayer slag and spatter. Ensure proper fusion of the weld beads to prevent defects.

Monitor key parameters (current, voltage, speed, gas flow rate, etc.).

Key Process Control

Preheating and Interpass Temperature: Stainless Steel/High-Alloy Steel: Preheat to 100–150°C (to prevent cold cracks), with an interpass temperature ≤150°C (to avoid intergranular corrosion). Carbon Steel (Q345R): For thick plates, preheating is required at 80–120°C.

Welding Material Compatibility: 310S Stainless Steel → ER310 Welding Wire (high nickel-chromium content, resistant to hot cracking).

Inconel 600 → ERNiCr-3 Welding Wire (specifically for nickel-based alloys).

Deformation Control: Employ a "skip welding + symmetrical welding" sequence, and pre-set reverse deformation (1–2 mm/m) during the welding of the furnace bottom plate.

The large furnace shell is fabricated using modular, segmented welding—each segment is welded and then straightened before final assembly.

Post-weld treatment: Austenitic stainless steel: No heat treatment required (to avoid σ-phase embrittlement), but pickling and passivation are necessary (to enhance corrosion resistance). Carbon steel/low-alloy steel: Stress-relief annealing at 600°C (to prevent deformation and cracking).

3. Sealing Performance Assurance

The furnace body welds undergo 100% helium leak testing or penetrant testing (PT) to ensure airtightness—particularly for protective atmosphere furnaces.

Continuous welds avoid interruptions, and fillet welds feature a full-penetration design.

Welding Process	Application scenarios
Material preparation process	Flame cutting (CNC cutting), plasma cutting, laser cutting, shearing, and sawing. High-precision bevel machining (such as edge milling and bevel cutting machines).
Forming process adopted	Rolling (cylindrical and conical sections), bending (using a bending machine), pressure forming (with large-scale presses), and roll forming.
Assembly and Alignment	Using large-scale tooling fixtures and platforms—such as welding positioners and roller stands—ensures the precise positioning and dimensions of each component. This is a critical step in quality control.
Common Welding Methods	Application scenarios
Submerged Arc Welding	Suitable for long straight welds and circumferential seams (such as longitudinal and circumferential seams of cylindrical shells).
Gas-shielded welding	MAG (CO2 or mixed gas), MIG (inert gas). Widely used and highly versatile (manual, semi-automatic, automatic), suitable for various positions and joint types.
Shielded Metal Arc Welding	Suitable for positions that are difficult to automate, short welds, and repair welding. It is less efficient and relies heavily on the welder's skill.
Electroslag Welding	Vertical welding for extra-thick plates (such as box-beam diaphragms).
Narrow-Gap Welding	Designed for butt welding of ultra-thick plates, it offers high efficiency and minimal deformation.
Post-weld treatment
Stress	Large components generally require post-weld heat treatment—either overall or localized (typically stress relief annealing)—to remove weld slag and spatter, followed by grinding of the weld seam and its surrounding areas. This process helps relieve residual welding stresses, preventing deformation and cracking while enhancing toughness.
Orthopedic	Flame straightening, mechanical straightening (using a press), to control welding deformation.
Mechanical Processing	Perform precision machining operations such as milling, boring, and drilling on critical mating surfaces and hole locations.

We will conduct non-destructive testing, inspection, and testing on the products:

Visual Inspection	Surface defects (cracks, undercut appearance inspection (VT), porosity, arc craters, etc.).
Ultrasonic Testing (UT)	Detecting internal defects (such as lack of fusion, incomplete penetration, slag inclusions, and cracks) is especially critical for thick plates.
Radiographic Testing (RT)	Intuitively displays internal defects and is commonly used for critical butt joints.
Magnetic Particle Testing (MT)	Detection of Surface and Near-Surface Defects (Ferromagnetic Materials)
Penetrant Testing (PT)	Detecting surface opening defects (non-magnetic materials).
Destructive Testing (Sampling)	Such as tensile testing, bending tests, impact tests, hardness tests, and metallographic analysis (typically conducted during process qualification or random inspections).
Dimensional Inspection	Check whether the overall structural dimensions and key component dimensions meet the drawing requirements.
Pressure/Leak Test (if required)	Such as hydraulic tests, pneumatic tests, and air-tightness tests.

IV. Specification Range

Large furnace bodies vary significantly in weight, primarily depending on their size, the thickness of the refractory materials, and the material grade.

Typical Furnace Type Weight Reference

Furnace Type	Dimensions (Length × Width × Height)	Weight range	Structural Features
Car-type heat treatment furnace	5m × 3m × 2.5m	50 to 80 tons	Steel structures account for 70%, with a relatively thin fire-resistant layer.
Large aluminum melting furnace	10m × 6m × 4m	150 to 250 tons	Heavy-duty refractory bricks + high-alloy lining (accounting for 40% by weight)
Steel Rolling Heating Furnace	30m × 15m × 5m	800 to 1200 tons	The fire-resistant layer is 500mm thick (accounting for over 60% by weight).
Glass melting furnace	20m × 10m × 3m	2000 to 3000 tons	Specialty Zirconia-Alumina Bricks (Density > 3.5 g/cm³)

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Large furnace riveted and welded components

Large furnace riveted and welded components are used in industrial production for high-temperature processes (such as smelting and heating) in either fully or semi-enclosed thermal equipment. Typically, these components consist of a steel structural shell, refractory lining, heating system, temperature-control system, and more. The materials must withstand extreme temperatures ranging from 800°C to 1600°C. Commonly used welding methods include argon arc welding, flux-cored wire gas-shielded welding, and submerged arc welding. These components find applications in large-scale aluminum melting furnaces and steel rolling heating furnaces.

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TOP

I. Introduction to Riveted and Welded Components for Large Furnaces

II. Common Materials Used for Furnace Bodies

III. Key Processes in Welding Technology

Key Process Control

IV. Specification Range

Large furnace riveted and welded components

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