CN101353797B - High-power arc spraying zinc aluminum pseudo-alloy protecting film and spraying method thereof - Google Patents
High-power arc spraying zinc aluminum pseudo-alloy protecting film and spraying method thereof Download PDFInfo
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- CN101353797B CN101353797B CN2008100427995A CN200810042799A CN101353797B CN 101353797 B CN101353797 B CN 101353797B CN 2008100427995 A CN2008100427995 A CN 2008100427995A CN 200810042799 A CN200810042799 A CN 200810042799A CN 101353797 B CN101353797 B CN 101353797B
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Abstract
The invention relates to a zinc-aluminum pseudo-alloy protecting film of steel member anti-corrosion products and a spraying method thereof, in particular to a high-power arc-spray zinc-aluminum pseudo-alloy protecting film which is mainly applicable to the anti-corrosion products, such as bridge steel structures, offshore platforms and other offshore steel structures and the spraying method thereof. The equipment of the invention comprises a spraying system combined by a high-power spraying power source, a refrigerated air dryer, a high-power arc-spray machine and a secondary atomized spray nozzle, which produces the zinc-aluminum pseudo-alloy protecting film. The method of the invention adopts zinc wire and aluminum metal wire as arcs to spray the pseudo alloy protecting film on a workpiece or a steel surface; the method mainly solves the technical problem of how to obtain premium protecting films by adjusting equipment and technology process and the like. The invention has the beneficial effects that: the aluminum content in the zinc-aluminum pseudo-alloy protecting film surface is improved, the performance of the protecting film is enhanced, and the service lifetime of the steel structures is prolonged, thereby having the advantages of reducing cost and improving efficiency.
Description
Technical field
The present invention relates to a kind of spraying method of zinc aluminum pseudo-alloy protecting film of steel member aseptic production, especially refer to a kind of aseptic production that mainly is applicable to other ocean steel constructions such as bridge steel structure, boats and ships, harbour, petroleum storage tank and marine platform, and be not subjected to the influence of element structure, can play the effect of long life anti corrosion, be a kind of product innovation that prolongs steel member work-ing life and the spraying method of zinc aluminum pseudo-alloy protecting film.
Background technology
At present the anticorrosion with painting etching method that uses has a lot, as sprays pure zinc, spray fine aluminium, aluminium-plated and spray aluminium zinc etc. behind the spray zinc earlier, all is applicable to the protection against corrosion of steel member.But these all respectively have its weak point, as:
Spray pure zinc: can produce a large amount of ZnOn stink cloud when spraying pure spelter coating, thereby make the operator get occupational illness easily, so improved the requirement of labour protection measures.And ZnOn stink cloud also has bigger pollution to environment.
The spray fine aluminium: aluminum coating has the performance of long life anti corrosion equally, its surperficial roughness 50～100 μ m, and higher hardness and strong shock resistance are arranged.(1) surface treatment: during the spraying aluminum coating base material purity is required relatively harshness, need reach the Sa3.0 level, general working-yard is difficult to reach.When spraying application, aluminum coating should not be too thick, because pitting corrosion and foaming phenomenon appear in thick aluminium coating easily, reduces the protection effect of coating.(2) sticking power: aluminum coating is coated with floor height for the sticking power of base material not as zinc aluminium false alloy.So also reduced the protection effect of coating for base material.
Earlier aluminium-plated behind the spray zinc: as from whole technological process, to need to divide two steps finish the metallize coating, and then carry out operation such as coating sealing.Whole technological process is more loaded down with trivial details, and can increase the consumption of resource, manpower etc.
The spraying aluminium zinc: Shenyang University of Technology etc. are with a pure zinc silk and a fine aluminium silk; the pseudo-alloy of electric arc spraying has the 13N/mm2 cohesive force; spray voltage is used 150V; the electric pressure of electric arc atomization reaches 0.6Mpa; but further do not improve the composition and the structure of coating, do not have to utilize the material that is coated with up to obtain best protective value.
The achievement in research of Beijing Non-Ferrous Metal Research General Academy: the mass content of aluminium also only has 20% in the aluminium zinc.Though the aluminium zinc coating also can reach Corrosion Protection, there is the theoretical metal worker to point out: when the aluminium mass content reaches 30%, can obtain preferable Corrosion Protection in the zinc aluminium false alloy.Spraying the aluminium zinc coating in addition at first needs zinc and aluminium are made the alloy silk, could use then, when secondary processing, has not only increased cost, has strengthened a series of wastes such as artificial, machinery, the energy, also causes second environmental pollution.
The coating that belongs to these metal sprayings can both play than traditional non-metallic coating steel member anti-corrosion protection and better act on, but other metallic coatings such as the pure zinc of spray, spray fine aluminium and low aluminum content zinc aluminium false alloy are longer than in the protection against corrosion of high-power arc spraying zinc aluminum pseudo-alloy coating working life.In addition, when making the zinc aluminium false alloy coating environmental pollution less, the consumption of resources such as goods and materials, manpower is less.
But present arc spraying technology still exists following defective:
The first, the wire material of use often carries out electric arc spraying for the metal wire material of identical material.The thickness of general single silk material spraying is thicker, and the rot-resistant time limit is shorter, substrate surface treatment is required harsh;
The second, the electric arc spraying equipment of use, power is little, and working efficiency is lower, and when coating 100 μ m thickness, existing efficient only is 5～8m
2
The 3rd, the structure difference of the spraying equipment of employing, the fogging degree of spray gun is poor; Factors such as wire feed dynamics deficiency are not suitable for big area and long site operation job requirements apart from wire feed.
Summary of the invention
In order to overcome above-mentioned weak point, main purpose of the present invention aims to provide and a kind ofly is combined into an integral spray system by high-power spraying source, high-power arc spraying machine, air compressor machine, cooling driers and secondary-atomizing jet head sets, reach zinc aluminum pseudo-alloy protecting film via this system's thermospray output, this product neither is subjected to the influence of element structure, both had than higher sticking power, the extexine of high aluminium content and high aluminium sesquioxide content is arranged again, is the zinc aluminum pseudo-alloy protecting film that one deck has the long life anti corrosion function.
Another object of the present invention aims to provide a kind of by improving original spraying equipment; improve technical process; adopt spraying methods such as coatingsurface sealing treatment and surperficial finish paint application; make it both to have improved the aluminium component that contains of pseudo-alloy protecting film, improved the spraying method of high-power arc spraying zinc aluminum pseudo-alloy protecting film of the chemoproection performance of protective film again.
The technical problem to be solved in the present invention is: mainly solve the problem that how obtains the high-quality protective film by change equipment and technical process; Solve plant issues such as how selecting high-power spraying source, high-power arc spraying machine, air compressor machine, cooling driers and secondary-atomizing shower nozzle; Solve and how the primary atomization spray gun is improved to the secondary-atomizing spray gun, how about secondary-atomizing shower nozzle after the improvement is by the secondary-atomizing air-flow, be applied to the metal drop that had atomized that the secondary-atomizing air-flow of electric arc back will melt and smash and atomizing once more, be ejected into the problem of workpiece surface; Solve the aluminium content that how to improve in the zinc aluminum pseudo-alloy protecting film, thereby improve the relevant technologies problems such as solidity to corrosion of protective film.
The technical solution adopted for the present invention to solve the technical problems is:
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A kind of spraying method of high-power arc spraying zinc aluminum pseudo-alloy protecting film, this method is combined into the overall thermal paint finishing by selecting high-power spraying source, high-power arc spraying machine, air compressor machine and cooling driers for use, employing zinc, aluminum metal silk to workpiece, carry out pseudo-alloy protecting film spraying to steel surface as arc; Spray gun by secondary-atomizing structure and above-mentioned spraying equipment system adopt the secondary-atomizing shower nozzle, and it is applied to the secondary-atomizing air-flow of electric arc back, the metal drop that had atomized of fusing is smashed and atomizing once more, is ejected into workpiece surface; The zinc aluminum pseudo-alloy protecting film of this system's thermospray output and the surface adhesion of steel substrate are together; The follow-up metal drop that had atomized is smashed by the secondary-atomizing air-flow, is ejected into the drop back of front, forms pseudo-alloy mechanical bond, up to required thick; This spraying method mainly comprises following algorithm:
The production preparation module comprises: structure, environment, project scale are investigated, carried out the preparation work of the subsidiary machine material of various material allotments and necessaries, device and production;
The surface treatment of step 2. steel substrate
After executing the production preparation module, then enter steel substrate surface treatment module, remove oxide compound, grease, dirt and the paint dirt settling of matrix surface;
The inspection of step 3. matrix surface
After executing the matrix surface processing module, then enter matrix surface and check module, matrix surface checks that module comprises: degree of cleaning reach the Sa2.5 level, and matrix surface should not have oil, drying; Roughness reaches Rz35～75 μ m; If passed examination then enters the application module of spraying zinc aluminum pseudo-alloy protecting film; If inspection is defective, then return steel substrate surface treatment module;
The application of step 4. spraying zinc aluminum pseudo-alloy protecting film
The matrix surface passed examination then enters the application module of zinc aluminum pseudo-alloy protecting film, the application of finishing zinc aluminum pseudo-alloy protecting film comprises: spraying requires with the silk material: the aluminium wire aluminum content is 99.5%, zinc silk zinc content is 99.99%, and require wire do not have oil, rustless, do not have dirty, bright and clean, must not have and be difficult to align the restorative plastic bending; Spraying equipment: electric arc spraying equipment adopts the spraying machine of the above inversion large power of 400A, by the wire drive feeder that improves equipment, makes traditional push-wire-type into plug-type wire feed, has enlarged the lower limit of the zinc-aluminium silk material diameter that uses; Adopt the secondary-atomizing shower nozzle, increase at least 8 pores in the secondary air duct in the shower nozzle cavity, make drop reach better fogging degree, spraying source has good level and smooth " volt-ampere characteristic ", and is stable to guarantee arc burning; Wherein: large power electric arc, electric current reaches 400A; Electric pressure＞0.7MPa atomizes; Be coated with the measurable temperature of rete≤60 ° after the secondary-atomizing film forming;
The inspection of step 5. protective film
After executing the application module of spraying zinc aluminum pseudo-alloy protecting film, then enter protective film and check module, the protective film inspection comprises: outward appearance: with 5～10 times of lens examinations, coating is even, densification, no peeling, falls defective such as piece at bubbling, big molten drop, macrobead, crackle; Thickness: adopt thickness tester to check that obtain the uniform coating of thickness, mean thickness is: design thickness-10 μ m≤mean thickness≤design thickness+15 μ m; If passed examination then enters the sealing of hole processing module; If inspection is defective, then return the application module of spraying zinc aluminum pseudo-alloy protecting film;
Step 6. sealing of hole is handled
The protective film passed examination then enters the sealing of hole processing module, and the sealing of hole processing module comprises: carry out sealing of hole according to design; With its obstruction, fill up protective film pit and space in the space of sealing paint infiltration zinc aluminum pseudo-alloy protecting film, finish sealing of hole work;
Step 7. completion
After executing the sealing of hole processing module, then enter the completion module, power cut-off.
The invention has the beneficial effects as follows: the aluminium content in the zinc aluminum pseudo-alloy protecting film improves, helps high-caliber corrosion proof function greatly, and the zinc-aluminium volume percent is 50: 50; Be that weight percent is the zinc aluminum pseudo-alloy protecting film of aluminium/zinc=30.0/70.0; Use the spraying machine of the above inversion large power of 400A, and by spray gun with secondary-atomizing and spray gun with 8 apertures, improve zinc aluminum pseudo-alloy protecting film surface aluminum content and reach 70% volume, and protective film is at the matrix surface uniform distribution, improved the performance of protective film, prolong the work-ing life of steel member, thereby reduced the maintenance times in the operation process, and the relevant expense that produces, resource etc.; 16000 hours proofs of salt fog accelerated test are anticorrosion effectively, are equivalent to use 80 years.The present invention reaches raising protective film erosion resistance and has improved working efficiency simultaneously by improving its spraying coating process equipment.
Description of drawings
The present invention is further described below in conjunction with drawings and Examples.
Accompanying drawing 1 is the laminate structure synoptic diagram of zinc aluminum pseudo-alloy protecting film of the present invention;
Accompanying drawing 2 is the structural representation of secondary-atomizing shower nozzle of the present invention;
Accompanying drawing 3 is a process flow diagram of the present invention;
Accompanying drawing 4 is a spraying schematic diagram of the present invention;
Accompanying drawing 5 is the protective film laminate structure synoptic diagram of one of embodiment of the invention;
Accompanying drawing 6 is synoptic diagram of electron microscope scanning picture * 100 of protective film of the present invention;
Accompanying drawing 7 is electronic spectrum synoptic diagram of protective film of the present invention;
Label declaration in the accompanying drawing:
The 1-steel substrate; 21-produces preparation;
2-bottom zinc aluminium false alloy; The surface treatment of 22-steel substrate;
3-top layer zinc aluminium false alloy; The 23-matrix surface is checked;
The anodal aluminium wire of 4-; The application of 24-spraying zinc aluminum pseudo-alloy protecting film;
5-negative pole zinc silk; The 25-protective film is checked;
Air channel of 6-; The 26-sealing of hole is handled;
The 7-secondary air duct; The 27-application;
8-rapid fluid joint; The 28-inspection of filming;
The 9-shell; The 29-completion;
The 10-insulator cone; 30-zinc;
The 11-zinc aluminum pseudo-alloy protecting film; 31-zinc oxide;
The 12-thread eye; The 32-aluminum oxide;
13-shower nozzle bottom surface; 33-aluminium;
14-secondary-atomizing shower nozzle; The 34-aluminium zinc;
35-aluminum oxide, zinc oxide;
Embodiment
See also shown in the accompanying drawing 1,2,3, the present invention forms the overall thermal paint finishing by selecting high-power arc spraying machine, air compressor machine and cooling driers for use, and employing zinc, aluminum metal silk to workpiece, carry out pseudo-alloy protecting film spraying to the surface as arc.
Product of the present invention comprises: primary atomization spray gun, power supply, air compressor machine, spraying machine coating and coating, it is characterized in that also comprising: high-power spraying source, cooling driers, high-power arc spraying machine and secondary-atomizing shower nozzle 14 are combined as an integral spray system, reach zinc aluminum pseudo-alloy protecting film 11 via this system's thermospray output, wherein:
One zinc aluminum pseudo-alloy protecting film 11 is provided with the laminate structure that steel substrate 1, bottom zinc aluminium false alloy 2 and top layer zinc aluminium false alloy 3 are combined into a combined integrate pseudo-alloy protecting film from bottom to top successively, and the aluminium sesquioxide protective membrane of one deck densification is arranged in this pseudo-alloy protecting film outside; Mechanically be connected between described bottom zinc aluminium false alloy 2 and the top layer zinc aluminium false alloy 3, both combine bottom zinc aluminium false alloy 2 and top layer zinc aluminium false alloy 3 back and are sprayed on the surface of steel substrate 1 with the form of mechanical mixture, and bond together.
The bottom zinc aluminium false alloy 2 and the top layer zinc aluminium false alloy 3 of described high-power arc spraying zinc aluminum pseudo-alloy protecting film is that zinc, aluminium material are formed, and contains the syndeton of the two oxide compound and the two alloy.
The pseudo-alloy protecting film outside surface of described high-power arc spraying zinc aluminum pseudo-alloy protecting film 11 has aluminum content, and this aluminum content is greater than the average aluminum content of pseudo-alloy protecting film.
The pseudo-alloy protecting film internal surface of described high-power arc spraying zinc aluminum pseudo-alloy protecting film 11 has zinc content, and with steel substrate 1 be the direct adhesive structure of spraying.
The volume percent of the aluminium/zinc in the described high-power arc spraying zinc aluminum pseudo-alloy protecting film 11 is 50: 50, and the weight percent of aluminium/zinc is=30.0/70.0.
A kind of spraying method of high-power arc spraying zinc aluminum pseudo-alloy protecting film, this method is combined into the overall thermal paint finishing by selecting high-power spraying source, high-power arc spraying machine, air compressor machine and cooling driers for use, employing zinc, aluminum metal silk to workpiece, carry out pseudo-alloy protecting film spraying to steel surface as arc; Spray gun by secondary-atomizing structure and above-mentioned spraying equipment system adopt secondary-atomizing shower nozzle 14, and it is applied to the secondary-atomizing air-flow of electric arc back, the metal drop that had atomized of fusing is smashed and atomizing once more, is ejected into workpiece surface; The zinc aluminum pseudo-alloy protecting film 11 of this system's thermospray output and the surface adhesion of steel substrate 1 are together; The follow-up metal drop that had atomized is smashed by the secondary-atomizing air-flow, is ejected into the drop back of front, forms pseudo-alloy mechanical bond, till the coating of desired thickness; This spraying method mainly comprises following algorithm:
Producing preparation 21 modules comprises: structure, environment, project scale are investigated, carried out the preparation work of the subsidiary machine material of various material allotments and necessaries, device and production;
After executing production preparation 21 modules, then enter steel substrate surface treatment 22 modules, remove oxide compound, grease, dirt and the paint dirt settling of matrix surface;
Execute after matrix surface handles 22 modules, then enter matrix surface and check 23 modules, matrix surface checks that 23 modules comprise: degree of cleaning reach the Sa2.5 level, and matrix surface should not have oil, drying; Roughness reaches Rz35～75 μ m; If passed examination then enters application 24 modules of spraying zinc aluminum pseudo-alloy protecting film; If inspection is defective, then return steel substrate surface 22 modules;
The application 24 of step 4. spraying zinc aluminum pseudo-alloy protecting film
Matrix surface is checked 23 qualified application 24 modules that then enter zinc aluminum pseudo-alloy protecting film, the application 24 of finishing zinc aluminum pseudo-alloy protecting film comprises: spraying requires with the silk material: the aluminium wire aluminum content is 99.5%, zinc silk zinc content is 99.99%, and require wire do not have oil, rustless, do not have dirty, bright and clean, must not have and be difficult to align the restorative plastic bending; Spraying equipment: electric arc spraying equipment adopts the spraying machine of the above inversion large power of 400A, by the wire drive feeder that improves equipment, makes traditional push-wire-type into plug-type wire feed, has enlarged the lower limit of the zinc-aluminium silk material diameter that uses; Adopt secondary-atomizing shower nozzle 14, increase at least 8 pores in the secondary air duct 7 in the shower nozzle cavity, make drop reach better fogging degree, spraying source has good level and smooth " volt-ampere characteristic ", and is stable to guarantee arc burning; Wherein: large power electric arc, electric current reaches 400A; Electric pressure＞0.7MPa atomizes; Be coated with the measurable temperature of rete≤60 ° after the secondary-atomizing film forming;
Step 5. protective film checks 25
After executing application 24 modules of spraying zinc aluminum pseudo-alloy protecting film, then enter protective film and check 25 modules, protective film inspection 25 comprises: outward appearance: with 5～10 times of lens examinations, coating is even, densification, no peeling, falls defective such as piece at bubbling, big molten drop, macrobead, crackle; Thickness: adopt thickness tester to check that obtain the uniform coating of thickness, mean thickness is: design thickness-10 μ m≤mean thickness≤design thickness+15 μ m; If passed examination then enters sealing of hole place 26 modules; If inspection is defective, then return application 24 modules of spraying zinc aluminum pseudo-alloy protecting film;
Step 6. sealing of hole place 26
Protective film is checked 25 qualified sealing of hole place 26 modules that then enter, and sealing of hole is handled 26 modules and comprised: carry out sealing of hole according to design; With its obstruction, fill up protective film pit and space in the space of sealing paint infiltration zinc aluminum pseudo-alloy protecting film, finish sealing of hole work;
Step 7. completion 27
Execute after sealing of hole handles 26 modules, then enter completion 27 modules, power cut-off.
See also shown in the accompanying drawing 2, the present invention improves former primary atomization spray gun structure, shell 9 and the insulator cone 10 middle cyclic secondary air ducts 7 of setting up at the primary atomization spray gun, after described ring texture is fixedlyed connected by precision casting with cone and is processed, be combined as the secondary-atomizing spray gun, metal drop behind the secondary-atomizing of this secondary-atomizing lance ejection is a zinc aluminum pseudo-alloy protecting film 11, the surface adhesion of this zinc aluminum pseudo-alloy protecting film 11 and steel substrate 1 together, the spray gun and a zinc aluminum pseudo-alloy protecting film 11 of described secondary-atomizing structure are combined as an integral spray equipment; Be provided with air channel 6 one time at intravital center, spray gun chamber, both sides along an air channel 6 are symmetrical arranged insulator cone 10 respectively, an anodal aluminium wire 4 and a negative pole zinc silk 5 enter respectively in the insulator cone 10, atomization air flow enters from the tapered hole between two one metal wires, after above-mentioned ring texture is all fixedlyed connected by precision casting with cone and is processed, be combined as the spray gun of primary atomization, nearly 13 places, shower nozzle bottom surface set up a rapid fluid joint 8 on the shell 9 of primary atomization spray gun, at shell 9 and insulator cone 10 intermediate formation cyclic secondary air ducts 7, be provided with thread eye 12 in the middle of the insulator cone 10, be the shower nozzle that is combined as secondary-atomizing after fixedly connected therebetween, wherein:
Nozzle housing 9 is processed into one together with interlayer secondary air duct 7 and thread eye 12 by precision casting, boring; Half of rapid fluid joint 8 securely is connected on the shell 9 with welded seal, and air-supply duct is connected on the shell 9 by second half of rapid fluid joint 8; Shower nozzle bottom surface 13 is connected the handgrip of spray gun by fastening piece and draws on the motor; Set up equally distributed at least 8 pores in the spray gun cavity of described secondary-atomizing shower nozzle 14; The secondary air duct 7 of described secondary-atomizing shower nozzle 14 be shaped as the taper air channel;
Principle of work of the present invention and technical characterictic are:
The present invention is by selecting high-power arc spraying machine, air compressor machine, air cooling driers and equipment such as improved wire drive feeder and secondary-atomizing spray gun in addition for use, and thermospray obtains zinc aluminum pseudo-alloy protecting film, and its zinc-aluminium volume percent is 50: 50; Be that weight percent is the zinc aluminum pseudo-alloy protecting film of aluminium/zinc=30.0/70.0.
Use the above inversion large power spraying machine of 400A, shortened the time that expose to the open air on the surface after the sandblast.Use high-power spraying machine when protective film 100 μ m thickness, per hour to reach 20m
2Working efficiency, and solved ineffective technical barrier; By the wire drive feeder that improves equipment, the plug-type push type wire feed that makes into traditional has increased the wire feed dynamics, thereby allows to adapt to big area and long apart from the wire feed in-situ spraying; Change the structure of spray gun in addition, change the spray gun of original primary atomization into the secondary-atomizing structure,, fogging degree is improved reach the purpose that improves coating quality thereby increased secondary-atomizing because the quality of protective film quality depends on the fogging degree of spray gun.The secondary-atomizing spray gun carries out secondary-atomizing to the zinc aluminium false alloy stream of ejection by secondary air, and make the protective film surface be rich in air (oxygen enrichment), zinc aluminum pseudo-alloy protecting film surface aluminum content is greatly enhanced, reach 70% (volume), and in the spray gun cavity, increase by 8 pores and make the secondary-atomizing air communication cross these 8 pores to reach better fogging degree, thereby improve erosion resistance.
By 1. large power electric arc, electric current reaches 400A; Electric pressure＞0.7Mpa atomizes; 2. secondary high-pressure hot gas, because arc temperature can reach 6000 ℃, can be through hot gas with aluminium by being oxidized to aluminum oxide.Because power is big, the zinc-aluminium particle can be broken up with spectroscopic analysis and can draw the rear surface composition, measure the aluminium composition greater than average content and can measure aluminium sesquioxide content, prove that aluminium sesquioxide generates in spraying process.Make the corrosion resisting property of zinc aluminum pseudo-alloy protecting film be improved.
Characteristics of the present invention are the aluminium component in the pseudo-alloy protecting film is brought up near 30%, and the performance that aluminium component improves the back protective film also improves greatly:
1, electro-chemical protection: press the current potential of metal in 3% seawater, zinc is more perishable than aluminium, early sacrifices.The sacrifice of zinc had both protected steel also to protect aluminium, and the intact back of zinc sacrifice aluminium continues to sacrifice, and continues the protection steel, has prolonged total galvanic protection time.
2, prevent chemical corrosion: after spraying pseudo-alloy, constitute netted hard framework between the aluminium particulate, not only stoped the corrosion product zinc chloride of zinc, the gathering and the bulk of zinc oxide to run off, and the oxide compound of zinc can be blocked the aperture of aluminium the resultant Al of aluminium
2O
3Originally dense, like this, the medium that enters pseudo-alloy layer has been reduced, the zinc corrosion is also few.
3, strengthened aluminium content, improved the fraction of coverage of aluminium on the zinc aluminium false alloy laminar surface, made fine and close Al
2O
3Major part can couple together, and obstruct or minimizing medium pass through, and the zinc layer just is protected, and prolongs the zinc layer life-span.
4, technological advantage: the present invention utilizes two monometallic silks.When aluminum content in the aluminium zinc surpasses 15% weight ratio, the cold difficulty of drawwing wire, and the present invention accomplishes 27.4% Al weight ratio, and promptly volume ratio is to go fifty-fifty, the simple cost of this sampling technology is low, is convenient to construction.
Principle of the present invention is: utilize metal fuse to produce the high pressure heat release between two electrodes and produce electric arc, make wire after high temperature melting, spray to substrate surface by high-speed gas atomization and with atomization particle, form the anticorrosion protective film with super-long-term weather resistance.
Protection against corrosion principle of the present invention is based on following 5 aspects:
1. metallic aluminium: its surface is oxidized easily, forms the aluminium sesquioxide zone of oxidation, the zone of oxidation of this formation, and its surface is fine and closely woven, and water and oxygen are difficult to see through, and corrosion resistance nature is very good.
2. utilize the potential difference between iron and the zinc, sacrificial zinc ionic method prevents that iron atom is oxidized.
3. utilize metallic zinc ionic discharge process and water and oxygen to react, form zinc hydroxide.
4. the zinc hydroxide that reacts and form through metallic zinc ion and hydroxide radical, i.e. white rust is piled up in the gap of steel surface and spray protective film, slowed down reaction speed and play stable effect.
5. metallic aluminium and oxide compound thereof are as the protective layer of metallic zinc, and over oxidation and a large amount of stripping to prevent metallic zinc stop water and oxygen to see through simultaneously, reach the long-term rust-proof effect of metallic zinc.
The protective film of the high aluminum content zinc aluminium false alloy of high-power arc spraying is to use the method for electric arc spraying to obtain, and during electric arc spraying, uses zinc silk and aluminium wire as two consumable electrodes of electric arc, just obtains zinc aluminum pseudo-alloy protecting film after the ejection.
The structure of the protective film of the high aluminum content zinc aluminium false alloy of high-power arc spraying is the mechanical mixture of two kinds of materials, contains a spot of the two alloy sometimes.
The protective film of the high aluminum content zinc aluminium false alloy of high-power arc spraying has the mechanical property of zinc and aluminium and the characteristics of chemical property concurrently.Chemical property is bordering on spelter coating between spelter coating and aluminum coating; Mechanical property is bordering on aluminum coating between spelter coating and aluminum coating.
The protective film of the high aluminum content zinc aluminium false alloy of high-power arc spraying is to adopt simple wire, with equal feed rate wire feed, is 50: 50 and obtain volume percent by the identical zinc silk of two diameters and aluminium wire; Be that weight percent is the zinc aluminum pseudo-alloy protecting film of aluminium/zinc=30.0/70.0.But there is the theoretical metal worker to point out: when the aluminium mass content reaches 30%, can obtain preferable Corrosion Protection in the zinc aluminium false alloy.
The protective film of high-power arc spraying zinc aluminum pseudo-alloy uses the above inversion large power spraying machine spraying of 400A, makes spray efficiency bring up to greatly and per hour reach 20m when protective film 100 μ m thickness
2Working efficiency, reduce the time that matrix exposes after the sandblast.
The protective film of high-power arc spraying zinc aluminum pseudo-alloy uses the spray gun that the secondary-atomizing structure is arranged, zinc aluminium false alloy particle flux to ejection carries out secondary-atomizing, and make the protective film surface be rich in air (oxygen enrichment), make the zinc aluminum pseudo-alloy protecting film surface generate a large amount of fine and close Al
2O
3, and Al
2O
3Play the plug-hole effect to a certain extent, reduce the voidage on protective film surface, form fine and closely woven stratified protective metal film.In addition, the nozzle of spray gun has 8 apertures, zinc aluminium false alloy stream can be sprayed to matrix surface equably, thereby improve the erosion resistance of protective film.
When the protective film of high-power arc spraying zinc aluminum pseudo-alloy sprayed, the air of spraying had been removed impurity such as moisture content and oil content through cooling driers drying and clean, to guarantee to obtain high-quality zinc aluminum pseudo-alloy protecting film.
See also shown in the accompanying drawing 4, the present invention sprays principle: one time wind enters shower nozzle from afterbody, and in the middle of two one metal wires, the atomization air flow that is applied to the electric arc back atomizes the molten metal molten drop; Secondary air is from middle (outside of cylindrical housing enters), adopt high pressure to penetrate secondary air, and secondary air enters the outer annular air channel from 8 holes, be ejected in the outer bread of electric arc and electric arc, form the air-flow conical surface and wrapping the zinc aluminium false alloy cone of spraying, make molten melt drop further oxidation under the oxygen enrichment state, secondary air is being sprayed zinc aluminium false alloy cone formation high pressure, zinc aluminium false alloy is beaten to the matrix steel plate, and high-pressure blast is given fusion droplet kinetic energy, smashes oxidized surface, liquid metal is directly contacted with the matrix steel plate, it is high to obtain cohesive force, and the surface is rich in the protective film of aluminium sesquioxide, has improved the corrosion resistance nature of protective film.
High-power arc spraying zinc aluminum pseudo-alloy protecting film is entered with equal feed rate by two identical zinc silk and aluminium wires of diameter, use zinc silk and aluminium wire two consumable electrodes as electric arc, secondary-atomizing by spray gun, and the apertures that increase are evenly distributed on the circumference of spray gun more, zinc aluminium false alloy stream can spray to the steel substrate surface equably when making spraying, obtaining protective film is evenly distributed, and it is high to obtain top layer trioxygen-containingization two aluminium, volume percent is 50: 50 pseudo-alloy protecting films, be that weight percent is the zinc aluminum pseudo-alloy protecting film of aluminium/zinc=30.0/70.0, improve the corrosion resistance nature of protective film.
When the protective film of high-power arc spraying zinc aluminum pseudo-alloy sprayed, the air of spraying had been removed impurity such as moisture content and oil content through cooling driers drying and clean, to guarantee to obtain high-quality high aluminum content zinc aluminum pseudo-alloy protecting film.
See also accompanying drawing 4, shown in 5, the outer bread of electric arc of the spray gun ejection of secondary-atomizing structure electric arc, form the air-flow conical surface and wrapping the zinc aluminium false alloy cone of spraying, make molten melt drop further oxidation under the oxygen enrichment state, secondary air is being sprayed zinc aluminium false alloy cone formation high pressure, zinc aluminium false alloy is beaten to the matrix steel plate, high-pressure blast is given fusion droplet kinetic energy, make zinc 30 molten drops and aluminium 33 molten drops surface oxygen enrichment, zinc 30 molten drops form zinc oxide 31, aluminium 33 molten drops form aluminum oxide 32, form zinc oxide at zinc molten drop and aluminium molten drop surface, aluminum oxide 35 is because high-pressure blast kinetic energy is with zinc, the aluminium molten drop is smashed oxidized surface, liquid metal is directly contacted with the matrix steel plate, zinc 30 and aluminium 33 are embedded into the steel substrate surface by high pressure spraying, wherein, and zinc, aluminium, aluminium zinc 34 is with mechanical connection manner, form the protective film that the high surface of cohesive force is rich in aluminium sesquioxide, can beat thicker and thicker, till the coating of desired thickness, improve the corrosion resistance nature of protective film.
See also shown in the accompanying drawing 6,7, the present invention has improved the fraction of coverage of the aluminium on the zinc aluminium false alloy laminar surface, makes fine and close Al
2O
3Major part can couple together, and obstruct or minimizing medium pass through, and the zinc layer just is protected, and prolongs the zinc layer life-span.By legal metrological service this protective film is measured, aluminium and aluminum oxide addition volume reach 71.11%; Weight reaches 42.79%., greater than average content, and can measure aluminium sesquioxide content by aluminium composition in the composition of Fig. 7 data declaration zinc aluminium false alloy surface.
Rear surface of the present invention is as follows with the electronic energy spectrum result of scan-probe analysis of components:
The electronic energy spectrum analytical results of pseudo-alloy coat surface composition
More than be rear surface analysis of components result of the present invention, the second sum is that oxide aggregate and aluminium content sum reach 70.11% in the table.
The present invention measures this protective film through legal metrological service, and the correlated performance data that obtain protective film are as follows:
Claims (1)
1. the spraying method of a high-power arc spraying zinc aluminum pseudo-alloy protecting film, it is characterized in that: this method is combined into the overall thermal paint finishing by selecting high-power spraying source, high-power arc spraying machine, air compressor machine and cooling driers for use, employing zinc, aluminum metal silk to workpiece, carry out pseudo-alloy protecting film spraying to steel surface as arc; Spray gun by secondary-atomizing structure and above-mentioned spraying equipment system adopt secondary-atomizing shower nozzle (14), and it is applied to the secondary-atomizing air-flow of electric arc back, the metal drop that had atomized of fusing is smashed and atomizing once more, is ejected into workpiece surface; The zinc aluminum pseudo-alloy protecting film (11) of this system's thermospray output and the surface adhesion of steel substrate (1) are together; The follow-up metal drop that had atomized is smashed by the secondary-atomizing air-flow, is ejected into the drop back of front, forms pseudo-alloy mechanical bond; This spraying method mainly comprises following algorithm:
Step 1. is produced and is prepared (21)
Producing preparation (21) module comprises: structure, environment, project scale are investigated, carried out the preparation work of the subsidiary machine material of various material allotments and necessaries, device and production;
Step 2. steel substrate surface treatment (22)
After executing production preparation (21) module, then enter steel substrate surface treatment (22) module, remove oxide compound, grease, dirt and the paint dirt settling of matrix surface;
Step 3. matrix surface inspection (23)
After executing matrix surface processing (22) module, then enter matrix surface inspection (23) module, matrix surface inspection (23) module comprises: degree of cleaning reach the Sa2.5 level, and matrix surface should not have oil, drying; Roughness reaches Rz35～75 μ m; If passed examination then enters application (24) module of spraying zinc aluminum pseudo-alloy protecting film; If inspection is defective, then return steel substrate surface treatment (22) module;
The application (24) of step 4. spraying zinc aluminum pseudo-alloy protecting film
Matrix surface is checked (23) qualified application (24) module that then enters zinc aluminum pseudo-alloy protecting film, the application (24) of finishing zinc aluminum pseudo-alloy protecting film comprising: spraying requires with the silk material: the aluminium wire aluminum content is 99.5%, zinc silk zinc content is 99.99%, and require wire do not have oil, rustless, do not have dirty, bright and clean, must not have and be difficult to align the restorative plastic bending; Spraying equipment: electric arc spraying equipment adopts the spraying machine of the above inversion large power of 400A, by the wire drive feeder that improves equipment, makes traditional push-wire-type into plug-type wire feed, has enlarged the lower limit of the zinc-aluminium silk material diameter that uses; Adopt secondary-atomizing shower nozzle (14), increase at least 8 pores in the secondary air duct in the shower nozzle cavity (7), make drop reach better fogging degree, spraying source has good level and smooth " volt-ampere characteristic ", and is stable to guarantee arc burning; Wherein: large power electric arc, electric current reaches 400A; Electric pressure＞0.7MPa atomizes; Be coated with the measurable temperature of rete≤60 ° after the secondary-atomizing film forming;
Step 5. protective film inspection (25)
After executing application (24) module of spraying zinc aluminum pseudo-alloy protecting film, then enter protective film inspection (25) module, protective film inspection (25) comprising: outward appearance: with 5～10 times of lens examinations, coating is even, densification, no peeling, falls defective such as piece at bubbling, big molten drop, macrobead, crackle; Thickness: adopt thickness tester to check that obtain the uniform coating of thickness, mean thickness is: design thickness-10 μ m≤mean thickness≤design thickness+15 μ m; If passed examination then enters sealing of hole and handles (26) module; If inspection is defective, then return application (24) module of spraying zinc aluminum pseudo-alloy protecting film;
Step 6. sealing of hole is handled (26)
Protective film is checked (25) qualified sealing of hole processing (26) module that then enters, and sealing of hole is handled (26) module and comprised: carry out sealing of hole according to design; With its obstruction, fill up protective film pit and space in the space of sealing paint infiltration zinc aluminum pseudo-alloy protecting film, finish sealing of hole work;
Step 7. completion (27)
After executing sealing of hole processing (26) module, then enter completion (27) module, power cut-off.
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| CN102774114B (en) * | 2011-05-10 | 2015-04-29 | 上海建冶科技工程股份有限公司 | Metal anticorrosion coating and electric arc spraying process thereof |
| CN103373033B (en) * | 2012-04-17 | 2016-03-30 | 新兴铸管股份有限公司 | Zn-Al-Mg-RE pseudo alloy coating and preparation method thereof |
| CN104073757B (en) * | 2014-07-16 | 2015-08-05 | 中国石油大学(华东) | Strengthen the method for ocean structure steel resistance to corrosion fatigue performance |
| CN104164667A (en) * | 2014-09-15 | 2014-11-26 | 赵军军 | Method for preparing heterogeneous metal coating on steel surface by utilizing frictional heat |
| CN105170386B (en) * | 2015-09-22 | 2017-09-15 | 山东龙泉管道工程股份有限公司 | Based on the semi-automatic spray zinc device of heavy caliber steel cylinder pipe faucet of concrete for turning over pipe machine |
| CN109423594A (en) * | 2017-08-24 | 2019-03-05 | 博世汽车柴油系统有限公司 | Oil injector body surface treatment method |
| CN110893065B (en) * | 2018-09-12 | 2023-04-25 | 武汉苏泊尔炊具有限公司 | Pot body, processing method of pot body and cooking utensil |
| CN110911798A (en) * | 2019-12-02 | 2020-03-24 | 武汉凡谷电子技术股份有限公司 | Dielectric filter processing method and device |
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