CN101939161A - 压缩机抗腐蚀保护涂层 - Google Patents
压缩机抗腐蚀保护涂层 Download PDFInfo
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Abstract
抗腐蚀和抗磨损的多层涂层保护在海洋环境中操作的压缩机。涂层包含热喷涂的金属陶瓷层和有机物质基密封剂层。
Description
背景
本发明一般涉及压缩机。本发明尤其涉及抗磨损的防腐蚀保护涂层。
压缩机在海洋环境中的防腐蚀是严重的和关键性的问题。压缩机典型地由平常的碳钢或铸铁制备，并对生锈和其它形式的腐蚀性产品高度敏感，尤其在充满盐的海洋环境的空气中。腐蚀降低了压缩机部件的结构完整性，且那些压缩机部件不能包含高压流体，可以导致个人的身体伤害以及昂贵的破坏和修复。
在海洋环境中防腐蚀的先有技术压缩机涂层包括油漆、静电粉末涂层或火焰或电弧喷涂的金属涂层。油漆的表面制备包括洗涤、接着底部涂层施加、接着顶部涂层施加。静电粉末涂层的表面制备包括喷砂、洗涤、用磷酸盐处理、电沉积涂层和固化。油漆的和粉末涂覆的表面的主要缺点是：涂层薄弱且易于被任何尖锐的物体刺穿。甚至针孔就引发腐蚀，可以导致最后的渗透和部件故障。含油漆的金属填充剂也用于防腐蚀。通常的填充剂是锌，因为按电流的感觉锌对铁和钢具有牺牲性，且锌将在侵蚀腐蚀区域邻近的任何铁或钢之前腐蚀。
火焰喷涂的或电弧喷涂的金属涂层显著优于油漆的涂层。铝是优选的涂层，因为按电流的感觉铝对铁和钢具有牺牲性，且铝将在侵蚀腐蚀区域邻近的任何铁或钢之前腐蚀。在该过程中，将铝火焰喷涂到表面，至最高达0.015英寸的厚度，接着是有机密封涂层。表面制备包括任选的化学清除接着喷砂处理。粗糙的喷砂处理的表面有助于铝涂层的机械粘附。如果铝涂层足够厚，那么保护表面避免碰撞和划痕，因为铝将变形并保留在表面上。通常给予火焰喷涂的和电弧喷涂的铝涂层有机密封涂层，因为涂层典型地包含多孔结构。
在压缩机中提高的温度有问题。某些部件(例如压缩机头部和排放外壳)在超过300°F时操作。有机涂层需要抵抗这些温度。
虽然火焰喷涂的和电弧喷涂的铝涂层对海洋环境中的铸铁和钢压缩机部件提供防腐蚀，但是涂层可以通过碰撞或磨损被穿透，假如力足够大。
概述
本发明的示例性实施方案包括有保护性涂层的压缩机和保护压缩机外壳免受腐蚀性海洋环境损坏的方法。保护性涂层包括在压缩机外表面上的金属陶瓷层和在金属陶瓷层上的有机物质基密封剂层。在该方法中，将金属陶瓷层施加至压缩机的外表面，并在金属陶瓷层上施加有机物质基密封剂层。
附图简述
图1是压缩机体的示意图，显示施加金属陶瓷涂层的热喷涂喷嘴。
图2是多层防腐蚀涂层的横切面示意图。
详述
假如在腐蚀性环境中，在电化学系列中金属涂层是铁或钢的阳极，那么金属将在基底金属之前首先腐蚀。换句话说，涂层对基底金属具有牺牲性。铝和锌是对铁和钢具有牺牲性的涂层的两个实例。具有牺牲性的先有技术涂层实例是含锌的油漆和火焰喷涂的铝。假如通过用尖锐的物体碰撞或磨损而去除部分涂层，那么丧失保护，且在那些区域的基底金属将腐蚀。压缩机上的先有技术防腐蚀涂层在海洋环境中的抗磨损将有益于增加抗磨损性。某些压缩机部件可达到影响聚合物涂层的操作温度。具有改善的抗磨损性和提高的温度稳定性的压缩机的抗腐蚀涂层形成本发明的基础。
金属陶瓷是由在金属基质中的陶瓷颗粒构成的复合材料。陶瓷给予结构抗磨损性，而金属贡献延展性。金属陶瓷的抗磨损性和提高的抗温冲击强度(temperature impact strength)通常优于金属本身的那些。可以使用陶瓷粉末和金属粉末作为原料，通过热喷涂施加金属陶瓷涂层。火焰喷涂、电弧喷涂和等离子体喷涂可以用于施加金属陶瓷涂层。在海洋环境中用作压缩机防腐蚀涂层的喷涂的金属陶瓷涂层优选为优选通过等离子体喷涂沉积的铝/氧化铝金属陶瓷。铝基质提供具有牺牲性的防腐蚀以及抗碰撞性，而氧化铝提供抗磨损性和提高的温度强度。也可以使用其它的金属/陶瓷组合。实例包括但不限于氧化铝、氧化锆的组合或与铝和/或锌组合的硅酸铝。
图1显示压缩机外壳10和热喷涂喷嘴40的示意图。压缩机外壳10包括圆柱体20和圆顶30。可以包括但在图中未显示外壳10的其它形状，包括矩形、管道接头、电子外壳等。显示在涂层施加过程中，热喷涂喷嘴40将热喷涂粉末50引向压缩机外壳10。涂层为多层涂层。
图2是在压缩机外壳体60上的多层防腐蚀涂层70的横切面2-2的示意图。防腐蚀涂层70包括第一层80、第二层90和第三层100。第一层80是等离子体喷涂的金属/陶瓷金属陶瓷。金属陶瓷层80的厚度为约0.005英寸-约0.020英寸；优选层厚为约0.015英寸。优选，金属陶瓷层80是铝/氧化铝金属陶瓷。
金属陶瓷层80用密封剂层90覆盖。密封剂层90可以是通过喷涂或刷涂施加的有机物质基保护层，该保护层含溶剂和其它无机材料，或它可以是通过静电喷涂施加的有机物质基粉末层。优选密封剂层90是静电热固性聚酯粉末层。热固性聚酯粉末包括但不限于异氰尿酸三缩水甘油酯(TGIC)、羟基烷基酰胺、二缩水甘油醚(digyclidal)环氧树脂和甲基化的TGIC。特别优选异氰尿酸三缩水甘油酯(TGIC)聚酯粉末涂层。
为了附加的保护和/或为了美观，可以包括任选的顶部涂层100。顶部涂层100可以是聚氨酯聚合物、氨酯基丙烯酸、环氧聚酰胺或其它聚合物涂层。顶部涂层100通过喷涂、刷涂或粉末涂覆来施加。
在涂布压缩机外壳10之前，需要彻底地清洗和去除油污。可以使用含水碱性工业清洗液。假如压缩机部件是铸铁，那么可能必需另外的表面制备，以去除将抑制涂层粘附的表面上的任何石墨。许多公司提供从铸铁表面去除石墨的清洗技术。例如在工业中已知的Kolene电解盐法。
为了去除另外的表面污染物并暴露新鲜的钢或铁，可通过磨料喷砂来处理压缩机外壳。喷砂也用于使金属陶瓷涂层机械锚定至基体。喷砂应该满足SSPC SP 5或NACE 1“白色金属”的表面完成要求。优选的砂砾介质是约16-30筛目尺寸的氧化铝。当基体具有由角形粗砂颗粒形成的无规表面质地时，导致改善的金属陶瓷的粘附。优选在喷砂之后产生的基体表面完成具有通过ASTM D 4417方法A、B或C测得的约0.0015英寸-约0.0025英寸的表面特性的基牙图案。优选在金属陶瓷涂层的沉积之前清洁100％的金属化的表面。
应该掩蔽压缩机外壳10的不喷砂区域。这样的部件的实例是电连接、观察镜或内部的耦合丝。
为了避免将否则抑制金属陶瓷的粘附的闪锈或其它形式表面污染的形成，压缩机外壳10应该无水分。喷涂可以发生在室温，但待喷涂区域的局部加热是有益的。作为替代，可在等离子体喷涂之前，将压缩机外壳10置于250°F的烘箱内，以消除任何表面水分。在任何情况下，空气温度将最低在露点之上约5°F。等离子体喷涂应该发生在干燥之后的4小时内，以获得最大的涂层粘附。在喷涂之前铁基体的表面质量优选为SSPC SP 5“白色金属”。最优选的金属陶瓷原料组合物为纯铝(最低纯度99.9％)粉末和纯氧化铝粉末。金属陶瓷涂层的组成为铝约35-约85％体积和氧化铝约15-约65％体积。尤其优选约75％体积的铝和约25％体积的氧化铝。金属陶瓷的涂层厚度为约0.005英寸-约0.025英寸，并特别优选约0.015英寸。
金属陶瓷涂层可以是粉末火焰喷涂的、金属丝火焰喷涂的、电弧金属丝喷涂的或等离子体弧喷涂的，并且优选等离子体弧喷涂技术。等离子体弧喷涂使用热-等离子体，并为通用的热喷涂方法。热-等离子体，密集的高度电离的气体，具有足够高的热焓密度，以熔化和沉积粉末，事实上为任何金属合金或陶瓷。DC(直流电)热-等离子体喷涂可以在高速下喷涂粉末，产生可能接近理论密度的高涂层密度。等离子体喷涂导致细的、基本上等轴的颗粒。通过稳定连续弧形排出的流动惰性气体(一般为氩)加上小百分比的提高热焓的二原子气体例如氢气，来维持等离子体火焰。通过惰性气体将原料粉末(粒度直径约0.0005英寸-约0.003英寸)运载至出现的等离子体火焰内。使在运输中熔化而没有过分蒸发的颗粒加速并碰撞在基体上，在此处它们变平，并按与在快速凝固过程中达到的那些相似的冷却速度凝固。当它们击中压缩机体时，小滴的动能引起金属陶瓷颗粒变形和变平，在钢或铁表面上形成铝/氧化铝金属陶瓷的均匀层。因为该沉积方法的性质，所以可在铝与氧化铝的颗粒之间形成少量的空隙。连接基体与外部大气的互联的孔隙是不能接受的。金属陶瓷涂层优选应该充分厚，以防止互联的孔隙。
为了进一步保证抗多孔性，施加密封剂涂层。等离子体喷涂的铝/氧化铝金属陶瓷的优选涂层是异氰尿酸三缩水甘油酯(TGIC)聚酯粉末涂层。在静电粉末喷涂时施加涂层，并在约305°F±5°F的金属温度固化约25分钟-在约345°F±5°F固化约15分钟。在约325°F的金属温度下优选的固化时间为约20分钟。密封剂涂层厚度应为约0.005英寸-约0.025英寸。优选约0.015英寸的厚度。美国海军按照MIL Spec.MIL-PRF-24712使用该涂层用于船部件。
为了附加的保护和美观，可以将顶部涂层例如聚氨酯聚合物、氨酯基丙烯酸和环氧聚酰胺施加至金属陶瓷上的聚合物涂层。顶部涂层可以优选包含着色剂。顶部涂层应该薄，例如约0.003英寸-约0.007英寸。
虽然已经参考示例性实施方案描述了本发明，但是本领域的技术人员将理解，可进行各种改变，并可用等同物替代其要素，而不背离本发明的范围。此外，可进行许多修改以适应本发明教导的具体情况或材料，而不背离其基本范围。因此，本发明将不限于所公开的具体实施方案，但是本发明将包括落在权利要求范围内的所有实施方案。
Claims (20)
1.一种在压缩机的外表面上具有保护涂层的压缩机，所述保护涂层包含：
金属陶瓷层，所述金属陶瓷层在所述压缩机的外表面上；和
有机物质基密封剂层，所述密封剂层在所述金属陶瓷层上。
2.权利要求1的压缩机，其中所述金属陶瓷层是等离子体喷涂的层。
3.权利要求1的压缩机，其中所述金属陶瓷层包含铝和氧化铝。
4.权利要求3的压缩机，其中所述金属陶瓷层包含约35％-约85％体积的铝和约15％-约65％体积的氧化铝。
5.权利要求1的压缩机，其中所述金属陶瓷层的厚度为约0.005英寸-约0.025英寸。
6.权利要求1的压缩机，其中所述金属陶瓷层的厚度为约0.015英寸。
7.权利要求1的压缩机，其中所述有机物质基密封剂层包含异氰尿酸三缩水甘油酯聚酯粉末涂层。
8.权利要求7的压缩机，其中所述异氰尿酸三缩水甘油酯聚酯粉末涂层的厚度为约0.005英寸-约0.025英寸。
9.权利要求7的压缩机，其中所述异氰尿酸三缩水甘油酯聚酯粉末涂层的固化温度为约305°F±10°F-约345°F±10°F。
10.权利要求1的压缩机，所述压缩机还包含：
有机物质基顶部涂层，所述顶部涂层在有机物质基表面层上。
11.权利要求10的压缩机，其中所述有机物质基顶部涂层是聚氨酯聚合物、氨酯基丙烯酸或环氧聚酰亚胺。
12.一种保护压缩机外壳免受海洋环境腐蚀的方法，所述方法包括：
将金属陶瓷层施加在所述压缩机的外表面上；和
将有机物质基密封剂层施加在所述金属陶瓷层上。
13.权利要求12的方法，其中通过等离子体喷涂施加所述金属陶瓷层。
14.权利要求13的方法，其中所述金属陶瓷层是粉末等离子体喷涂的层。
15.权利要求12的方法，其中所述金属陶瓷层包含铝和氧化铝。
16.权利要求15的方法，其中所述金属陶瓷层包含约35％-约85％体积的铝和约15％-约65％体积的氧化铝。
17.权利要求12的方法，其中所述金属陶瓷层的厚度为约0.005英寸-约0.020英寸。
18.权利要求12的方法，其中所述有机物质基密封剂层包含异氰尿酸三缩水甘油酯聚酯粉末涂层。
19.权利要求18的方法，所述方法还包括：
使所述异氰尿酸三缩水甘油酯聚酯粉末涂层，在约305°F±10°F-约345°F±10°F下，固化约5分钟-约20分钟。
20.权利要求12的方法，所述方法还包括：
将有机物质基顶部涂层施加在所述有机物质基密封剂层上。
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Also Published As
| Publication number | Publication date |
|---|---|
| US20110256389A1 (en) | 2011-10-20 |
| EP2188122A1 (en) | 2010-05-26 |
| WO2009078842A1 (en) | 2009-06-25 |
| CN101939161B (zh) | 2013-11-06 |
| JP2011509342A (ja) | 2011-03-24 |
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