Large ladle riveted and welded parts
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  • Large ladle riveted and welded parts

1. Introduction to Ladle

The ladle is a key container in the metallurgical industry for holding, transporting, refining, and pouring high-temperature molten steel (1500~1700℃). It undertakes the transfer of molten steel (from the steelmaking furnace to the refining station/continuous casting machine), secondary refining (argon stirring, alloying, desulfurization), temperature buffering (maintaining steel superheat), and pouring control (adjusting flow through sliding nozzles).

Core structure: outer shell steel plate (load-bearing body (conical or cylindrical)), permanent lining (insulation layer (lightweight refractory bricks/castables), working lining (direct contact with molten steel, magnesia-carbon bricks/aluminum magnesia-carbon bricks).

2. Common Materials for Ladle

Component

Common Materials

Performance Requirements

Outer Shell Steel Plate

SA516Gr70 (American Standard)

Medium temperature pressure vessel steel (strength stable at 350℃)

 

Q345R (Chinese Standard)

Low cost, welding crack control required

Trunnion

34Cr2Ni2Mo forged steel

Ultra-high strength (tensile strength ≥800MPa)

Permeable Brick Seat

ZG35Cr24Ni7SiN (heat-resistant cast steel)

Thermal shock resistance + oxidation resistance

Slag line area

304 stainless steel composite plate

Prevents slag penetration corrosion

Key point: The shell must meet ASME Sec VIII pressure vessel standards, and the trunnion material impact energy ≥40J (-20℃).

3. Selection of Welding Methods

Location

Welding Process

Parameter Examples

Shell longitudinal/circumferential seams

Submerged Arc Welding (SAW)

Current 600~750A, voltage 32~38V

Trunnion and shell

Flux-cored wire gas shielded welding (FCAW-G)

Multi-layer multi-pass, preheat 150℃

Stainless steel composite plate

Transition layer: ER309L

Heat input ≤15kJ/cm (to prevent carbon migration)

。

4. Key Welding Process Steps

Pre-welding preparation: material cutting, forming, groove processing (precision control).

Thorough cleaning: oil, rust, water, scale, etc. on groove and adjacent areas.

Assembly positioning weld: use the same welding materials and process as formal welding to ensure positioning weld quality, with appropriate length and spacing. Check assembly gaps and misalignment.

Preheating (if needed): uniformly heat to specified temperature and monitor/record.

Welding process:

Strictly follow WPS and welding sequence.

Control interpass temperature (monitor and record).

For multi-layer multi-pass welding, carefully clean interpass slag and spatter. Ensure good weld fusion and avoid defects.

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

Key control measures

Preheat and post-heat: SA516Gr70 steel plate: preheat 120~150℃ (plate thickness >30mm), post-weld hydrogen removal at 250~300℃ for 2 hours.

Deformation control: shell assembly uses "internal welding and external straightening" process, preset reverse deformation amount 3~5mm/m.

Groove design: K-type groove (reduces restraint stress).

Non-destructive testing: 100% UT+MT after welding (detect root cracks).

Composite plate welding: weld carbon steel layer first → clean root → weld transition layer → stainless steel overlay (GTAW backing).

Welding Process

Application scenarios

Cutting processes used

Flame cutting (CNC cutting), plasma cutting, laser cutting, shearing, sawing. High-precision groove processing (such as milling edges, groove cutting machines).

Forming processes used

Plate rolling (cylindrical, conical), bending (press brake), pressure forming (large press), rolling.

Assembly and fitting

Use large tooling fixtures, platforms (such as welding manipulators, roller stands) to ensure precise position and dimensions of components. This is a key quality control step.

Common welding methods

Application scenarios

Submerged Arc Welding

Suitable for long straight welds, circumferential welds (such as cylindrical longitudinal and circumferential seams).

Gas Shielded Welding

MAG (CO2 or mixed gas), MIG (inert gas). Most widely used, highly flexible (manual, semi-automatic, automatic), suitable for various positions and joint types.

Shielded Metal Arc Welding

Suitable for locations difficult to automate, short welds, and repair welding. Efficiency is low and depends on welder skills.

Electroslag welding

Used for vertical welding of ultra-thick plates (e.g., box beam diaphragms).

Narrow gap welding

Used for butt welding of ultra-thick plates, high efficiency, minimal deformation.

Post-weld treatment

 

Stress

Large components generally require overall or local post-weld heat treatment (usually stress relief annealing), removal of slag and spatter, grinding of weld seams and surrounding areas to release residual welding stress, prevent deformation and cracking, and improve toughness.

Straightening

Flame straightening, mechanical straightening (press, etc.) to control welding deformation.

Machining

Precision machining such as milling, boring, and drilling on critical mating surfaces and hole positions.

 

We conduct nondestructive testing and inspection of products:

Visual inspection

Surface defects (cracks, undercut appearance inspection (VT), porosity, arc pits, etc.).

Ultrasonic testing (UT)

Detects internal defects (lack of fusion, incomplete penetration, slag inclusion, cracks, etc.), especially important for thick plates.

Radiographic testing (RT)

Visually displays internal defects, commonly used for important butt joints.

Magnetic particle testing (MT)

Detects surface and near-surface defects (ferromagnetic materials).

Penetrant testing (PT)

Detects surface open defects (non-ferromagnetic materials).

Destructive testing (sampling)

Such as tensile, bending, impact, hardness, metallographic tests (usually performed during process evaluation or sampling inspection).

Dimensional inspection

Check whether overall structure dimensions and key part dimensions meet drawing requirements.

Pressure/leakage test (if needed)

Such as hydraulic test, pneumatic test, airtightness test.

5. Specification range

Capacity

Shell steel plate thickness

Working lining thickness

Total weight range

Steel-to-melt ratio (self-weight/load)

100 tons

40~50mm

150~200mm

60~80 tons

0.6~0.8

200 tons

50~60mm

200~250mm

120~150 tons

0.6~0.75

300 tons

60~80mm

250~300mm

200~250 tons

0.67~0.83

Note: The working lining will erode and thin during use; the residual lining weight is 20%~30% lighter than new and requires regular maintenance!

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Large ladle riveted and welded parts
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  • Large ladle riveted and welded parts

Large ladle riveted and welded parts

The ladle is a key container in the metallurgical industry for holding, transporting, refining, and pouring high-temperature molten steel (1500~1700°C). It is responsible for transferring molten steel (from the steelmaking furnace to the refining station/continuous casting machine), secondary refining (argon stirring, alloying, desulfurization), temperature buffering (maintaining the superheat of molten steel), and pouring control (adjusting flow through a sliding nozzle). Common materials include shell steel plates and trunnions, and it is used in industries such as mining and chemical engineering.

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