CN102162077B - 传动系统中使用的钢丝绳及保护该钢丝绳中的钢丝的方法 - Google Patents
传动系统中使用的钢丝绳及保护该钢丝绳中的钢丝的方法 Download PDFInfo
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- CN102162077B CN102162077B CN2011100460425A CN201110046042A CN102162077B CN 102162077 B CN102162077 B CN 102162077B CN 2011100460425 A CN2011100460425 A CN 2011100460425A CN 201110046042 A CN201110046042 A CN 201110046042A CN 102162077 B CN102162077 B CN 102162077B
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- steel wire
- zinc
- coating
- magnesium oxide
- wireline
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- 229910000831 Steel Inorganic materials 0.000 title claims abstract description 82
- 239000010959 steel Substances 0.000 title claims abstract description 82
- 238000000034 method Methods 0.000 title abstract description 17
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 claims abstract description 52
- 239000000395 magnesium oxide Substances 0.000 claims abstract description 50
- 239000011248 coating agent Substances 0.000 claims abstract description 48
- 238000000576 coating method Methods 0.000 claims abstract description 48
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 claims abstract description 47
- 238000005260 corrosion Methods 0.000 claims abstract description 45
- 230000007797 corrosion Effects 0.000 claims abstract description 45
- 239000011701 zinc Substances 0.000 claims abstract description 26
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 claims abstract description 25
- 229910001297 Zn alloy Inorganic materials 0.000 claims abstract description 24
- 229910052725 zinc Inorganic materials 0.000 claims abstract description 17
- 239000007788 liquid Substances 0.000 claims abstract description 13
- 239000002245 particle Substances 0.000 claims abstract description 13
- 125000001931 aliphatic group Chemical group 0.000 claims abstract description 5
- 239000002480 mineral oil Substances 0.000 claims abstract description 5
- 235000010446 mineral oil Nutrition 0.000 claims abstract description 5
- 239000003112 inhibitor Substances 0.000 claims description 21
- 230000005540 biological transmission Effects 0.000 claims description 17
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 claims description 8
- 229910010271 silicon carbide Inorganic materials 0.000 claims description 6
- 239000000843 powder Substances 0.000 claims description 5
- 239000000314 lubricant Substances 0.000 abstract description 6
- 238000012360 testing method Methods 0.000 description 16
- 229910000635 Spelter Inorganic materials 0.000 description 13
- 230000000694 effects Effects 0.000 description 9
- 239000000203 mixture Substances 0.000 description 9
- 239000007921 spray Substances 0.000 description 8
- 230000008569 process Effects 0.000 description 7
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 6
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 description 6
- 210000000689 upper leg Anatomy 0.000 description 6
- 238000004519 manufacturing process Methods 0.000 description 5
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 4
- 239000012267 brine Substances 0.000 description 4
- 229910052799 carbon Inorganic materials 0.000 description 4
- 239000006185 dispersion Substances 0.000 description 4
- 238000005516 engineering process Methods 0.000 description 4
- 230000003628 erosive effect Effects 0.000 description 4
- 239000000344 soap Substances 0.000 description 4
- HPALAKNZSZLMCH-UHFFFAOYSA-M sodium;chloride;hydrate Chemical compound O.[Na+].[Cl-] HPALAKNZSZLMCH-UHFFFAOYSA-M 0.000 description 4
- 239000007787 solid Substances 0.000 description 4
- 229930040373 Paraformaldehyde Natural products 0.000 description 3
- 238000013459 approach Methods 0.000 description 3
- 150000001875 compounds Chemical class 0.000 description 3
- 230000002349 favourable effect Effects 0.000 description 3
- 229910052742 iron Inorganic materials 0.000 description 3
- 239000011777 magnesium Substances 0.000 description 3
- 230000003647 oxidation Effects 0.000 description 3
- 238000007254 oxidation reaction Methods 0.000 description 3
- 229920006324 polyoxymethylene Polymers 0.000 description 3
- 239000000243 solution Substances 0.000 description 3
- 238000010186 staining Methods 0.000 description 3
- 239000000126 substance Substances 0.000 description 3
- 150000003751 zinc Chemical class 0.000 description 3
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 2
- 229910000640 Fe alloy Inorganic materials 0.000 description 2
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 2
- FAPWRFPIFSIZLT-UHFFFAOYSA-M Sodium chloride Chemical compound [Na+].[Cl-] FAPWRFPIFSIZLT-UHFFFAOYSA-M 0.000 description 2
- 238000005299 abrasion Methods 0.000 description 2
- 239000006061 abrasive grain Substances 0.000 description 2
- 229910045601 alloy Inorganic materials 0.000 description 2
- 239000000956 alloy Substances 0.000 description 2
- 238000005275 alloying Methods 0.000 description 2
- 239000003795 chemical substances by application Substances 0.000 description 2
- 238000009826 distribution Methods 0.000 description 2
- 238000005538 encapsulation Methods 0.000 description 2
- KFZAUHNPPZCSCR-UHFFFAOYSA-N iron zinc Chemical compound [Fe].[Zn] KFZAUHNPPZCSCR-UHFFFAOYSA-N 0.000 description 2
- 229910052749 magnesium Inorganic materials 0.000 description 2
- 239000001095 magnesium carbonate Substances 0.000 description 2
- ZLNQQNXFFQJAID-UHFFFAOYSA-L magnesium carbonate Chemical compound [Mg+2].[O-]C([O-])=O ZLNQQNXFFQJAID-UHFFFAOYSA-L 0.000 description 2
- 235000014380 magnesium carbonate Nutrition 0.000 description 2
- 229910000021 magnesium carbonate Inorganic materials 0.000 description 2
- 229910052759 nickel Inorganic materials 0.000 description 2
- 239000012188 paraffin wax Substances 0.000 description 2
- 230000008092 positive effect Effects 0.000 description 2
- 230000002829 reductive effect Effects 0.000 description 2
- 150000003839 salts Chemical class 0.000 description 2
- 238000004088 simulation Methods 0.000 description 2
- 239000010935 stainless steel Substances 0.000 description 2
- 229910001220 stainless steel Inorganic materials 0.000 description 2
- 238000005728 strengthening Methods 0.000 description 2
- LEEDMQGKBNGPDN-UHFFFAOYSA-N 2-methylnonadecane Chemical compound CCCCCCCCCCCCCCCCCC(C)C LEEDMQGKBNGPDN-UHFFFAOYSA-N 0.000 description 1
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 1
- 229910052684 Cerium Inorganic materials 0.000 description 1
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 1
- 241000060350 Citronella moorei Species 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 229910000677 High-carbon steel Inorganic materials 0.000 description 1
- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 description 1
- 229910001122 Mischmetal Inorganic materials 0.000 description 1
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 description 1
- 241000475481 Nebula Species 0.000 description 1
- 229920002292 Nylon 6 Polymers 0.000 description 1
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 description 1
- 229910001128 Sn alloy Inorganic materials 0.000 description 1
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 1
- 239000005864 Sulphur Substances 0.000 description 1
- 230000004913 activation Effects 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- HXFVOUUOTHJFPX-UHFFFAOYSA-N alumane;zinc Chemical compound [AlH3].[Zn] HXFVOUUOTHJFPX-UHFFFAOYSA-N 0.000 description 1
- 239000004411 aluminium Substances 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 150000001408 amides Chemical class 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 230000008901 benefit Effects 0.000 description 1
- 229910052796 boron Inorganic materials 0.000 description 1
- 238000001354 calcination Methods 0.000 description 1
- 238000010349 cathodic reaction Methods 0.000 description 1
- 239000003518 caustics Substances 0.000 description 1
- ZMIGMASIKSOYAM-UHFFFAOYSA-N cerium Chemical compound [Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce] ZMIGMASIKSOYAM-UHFFFAOYSA-N 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 229910052804 chromium Inorganic materials 0.000 description 1
- 239000011651 chromium Substances 0.000 description 1
- 238000005253 cladding Methods 0.000 description 1
- 239000008199 coating composition Substances 0.000 description 1
- 229910017052 cobalt Inorganic materials 0.000 description 1
- 239000010941 cobalt Substances 0.000 description 1
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 238000012937 correction Methods 0.000 description 1
- 238000005536 corrosion prevention Methods 0.000 description 1
- 230000001186 cumulative effect Effects 0.000 description 1
- 125000004122 cyclic group Chemical group 0.000 description 1
- 238000005238 degreasing Methods 0.000 description 1
- 229910003460 diamond Inorganic materials 0.000 description 1
- 239000010432 diamond Substances 0.000 description 1
- 238000003618 dip coating Methods 0.000 description 1
- 238000007598 dipping method Methods 0.000 description 1
- 238000006073 displacement reaction Methods 0.000 description 1
- 238000010891 electric arc Methods 0.000 description 1
- 230000002708 enhancing effect Effects 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 230000003203 everyday effect Effects 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 239000000835 fiber Substances 0.000 description 1
- 238000005246 galvanizing Methods 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 239000004519 grease Substances 0.000 description 1
- 238000000227 grinding Methods 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 230000005764 inhibitory process Effects 0.000 description 1
- 229910052500 inorganic mineral Inorganic materials 0.000 description 1
- 238000009533 lab test Methods 0.000 description 1
- 229910052746 lanthanum Inorganic materials 0.000 description 1
- FZLIPJUXYLNCLC-UHFFFAOYSA-N lanthanum atom Chemical compound [La] FZLIPJUXYLNCLC-UHFFFAOYSA-N 0.000 description 1
- 229960001708 magnesium carbonate Drugs 0.000 description 1
- 229910052748 manganese Inorganic materials 0.000 description 1
- 239000011572 manganese Substances 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 235000010755 mineral Nutrition 0.000 description 1
- 239000011707 mineral Substances 0.000 description 1
- 229910052750 molybdenum Inorganic materials 0.000 description 1
- 239000011733 molybdenum Substances 0.000 description 1
- 238000012544 monitoring process Methods 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 239000003921 oil Substances 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 239000003973 paint Substances 0.000 description 1
- 238000002161 passivation Methods 0.000 description 1
- 229910052698 phosphorus Inorganic materials 0.000 description 1
- 239000011574 phosphorus Substances 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- -1 polyoxymethylene Polymers 0.000 description 1
- 229920001296 polysiloxane Polymers 0.000 description 1
- 230000002335 preservative effect Effects 0.000 description 1
- 239000011253 protective coating Substances 0.000 description 1
- 239000010453 quartz Substances 0.000 description 1
- 229910002059 quaternary alloy Inorganic materials 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 230000002441 reversible effect Effects 0.000 description 1
- 239000012266 salt solution Substances 0.000 description 1
- 230000035807 sensation Effects 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N silicon dioxide Inorganic materials O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 1
- 239000002002 slurry Substances 0.000 description 1
- 239000011780 sodium chloride Substances 0.000 description 1
- 239000012086 standard solution Substances 0.000 description 1
- 230000003068 static effect Effects 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
- 239000000375 suspending agent Substances 0.000 description 1
- GZCWPZJOEIAXRU-UHFFFAOYSA-N tin zinc Chemical compound [Zn].[Sn] GZCWPZJOEIAXRU-UHFFFAOYSA-N 0.000 description 1
- 230000007704 transition Effects 0.000 description 1
- 229910052720 vanadium Inorganic materials 0.000 description 1
- GPPXJZIENCGNKB-UHFFFAOYSA-N vanadium Chemical compound [V]#[V] GPPXJZIENCGNKB-UHFFFAOYSA-N 0.000 description 1
- 230000000007 visual effect Effects 0.000 description 1
- 238000011179 visual inspection Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 238000005491 wire drawing Methods 0.000 description 1
Classifications
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- C—CHEMISTRY; METALLURGY
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- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C30/00—Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
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Abstract
本发明涉及一种在传动系统中使用的钢丝绳及保护该钢丝绳中的钢丝的方法,其可以在滑动车辆门或窗户升降机中使用。该钢绳的特别之处在于其具有显著的耐腐蚀性,该耐腐蚀性通过将氧化镁颗粒分散在涂覆锌或锌合金的钢丝上并使这些颗粒与涂层接触而得到。该分散和接触可以借助液体载体如脂肪族矿物油获得,该脂肪族矿物油常常作为所述钢丝绳的润滑剂使用。氧化镁确保了甚至在减少了锌涂层的厚度的情况下相等或者更好的耐腐蚀性。在保持钢绳的直径的情况下,减少锌涂层的厚度增加了钢丝绳的强度。
Description
本申请是申请日为2006年12月11日,申请号为200680048997.1,发明名称为“传动系统中使用的钢丝绳及保护该钢丝绳中的钢丝的方法”的发明专利申请的分案申请。
技术领域
本发明涉及钢丝绳领域,特别是在操作过程中必须具有耐腐蚀环境性能的钢丝绳。可以在许多传动系统中发现所述钢丝绳,仅举几个例子,如:汽车门中的窗升降器,或者横向活动拉门的传动系统,或者帆布篷驱动系统,或者车库门开关驱动系统,或者起重钢绳。本发明提供了一种在保持好的疲劳性能和改善的磨擦性能的同时,具有更好的耐腐蚀性能的钢丝绳。
背景技术
在许多情况下,钢丝绳为优选的工具,用于在低成本下在几米和几千米之间的距离范围下传递力和位移(即功)。通过使用细金属丝直径,该钢丝绳可以被制作得非常柔韧(从而该钢丝绳可以适应小弯曲滑轮)。当由冷成型,冷拉制成的钢丝组合后,钢丝绳的强度得到了增强从而可以传递更大的力。另外,由于其弹性模量与钢的接近,钢绳的延伸率可以被减至最低,从而消除了传动系统的松弛。该钢丝绳可以设计成能经受在传动系统中发生的反复弯曲,扭转或拉伸运动,事实上,由于疲劳极限可以通过模拟钢丝绳的真实使用的测试精确地预测,因此,钢丝绳是可靠的。最后,钢丝绳显示了一个有利的与磨损部件有关的摩擦系数,该性能使得在许多场合允许使用固定导绳器(fixed rope guide)代替弯曲滑轮,从而在传动系统中节省了可观的成本。
遗憾的是,当在增强腐蚀的环境下(如:室外使用、也包括在升降机的内部、或者汽车门的内部),大部分钢趋向于生锈。在这方面腐蚀是有害的,它会显著减少预期的疲劳级别,从而导致过早的、致命的裂缝。该机理在该领域公知为“腐蚀疲劳”,即,当钢绳的动态加载在腐蚀环境中进行时,所发生的疲劳现象。对于本领域技术人员公知的减少这种腐蚀的几种标准解决方案为:
可以使用具有较小腐蚀倾向的不锈钢(如:AISI 306,AISI 314)。遗憾的是,该钢种常常仅在静态腐蚀应用中表现良好,即,不包括动态时。当钢丝绳在滑轮上重复弯曲时,不锈钢上的氧化层被连续磨损掉,导致了钢丝的过度微振磨损和差的疲劳寿命。
可能最早的解决方案是,使用单独涂覆保护性涂层的钢丝,为了不对该钢丝绳的其它性能产生不利影响,该涂层优选为金属的,在这方面最优选是锌或者锌合金涂层,该锌或者锌合金涂层通过热浸镀法施用到钢丝上。在热浸镀过程中形成的中间合金涂层保证了良好的涂层对钢丝的粘附性,上述涂层对钢提供了牺牲阳极腐蚀保护。
在聚合物中钢绳的封装也是一种公知技术,这样的封装必须能经受住传动系统的动态性,这样才能阻止腐蚀气氛接触钢的表面。WO03/044267中描述了这样的钢丝绳。该解决方案在提供了极好的防腐蚀的同时提供了极好的疲劳性能,但是更严格的说,其不具有良好的摩擦性能同时更加昂贵。
使用抑制腐蚀的油、油脂、浆或者凝胶。所述凝胶必须使钢丝绳具有许多的性能,在许多情况下在不同性能之间是一种折衷(成本,环境,疲劳性能等),在US6106741中可以找到其实施例。
因此,现阶段的传动系统钢丝绳的技术状态由用润滑剂浸渍的涂覆锌或锌合金钢丝绳为主导。选择锌或锌合金涂层厚度以在腐蚀环境中经受住若干小时。在本领域内上述腐蚀测试广为公知,如ISO9227标准(国家等同标准为ASTM B117或DIN 50021)。在该测试中,从钢丝绳生产商得到的样品悬挂于一封闭室中,该封闭室充满喷雾剂(nebula)。保持在100%相对湿度和35℃的温度下。室中的气氛通过循环喷射包含5wt%NaCl的水达到饱和,到目前为止如ISO9227标准中所描述的一样。
对腐蚀进程进行有规律(如:每24小时)的可视监测,然后进行等级分类(“浅棕色锈斑”,“浅棕色锈点”,“深棕色锈斑”,“深棕色锈点”和“5%表面覆盖有深棕色锈”)。接下来的数个小时内,在本测试中进行盐水喷雾耐腐蚀直到在试样上产生“深棕色锈斑”,目前钢丝绳在汽车工业中采用之前必须能忍耐最少72小时的盐水喷雾。
选择润滑剂是为了优化疲劳寿命,对疲劳寿命的估计可以通过模拟钢丝绳在传动系统中的真实寿命使用的专用测试程序获得。因此,有许多可用来测定该疲劳寿命的适宜的测试装置,一个公开有效的测试标准是MIL-W-83420标准,其以前(和现在)仍旧广泛使用来测试“航空钢丝绳”。
在工业上,存在一种使用更细的具有相同或更高强度的钢丝绳的稳定的趋势,目的是减少传动系统的尺寸并且提高防腐蚀和疲劳寿命。对于已知的锌或锌合金涂层,人们陷入强度与腐蚀保护的矛盾之中,因为涂层的腐蚀保护与涂层的厚度粗略地成比例,所以,必须保持为了符合耐腐蚀要求的最小涂层厚度。然而,当使用越来越细的钢丝时,涂层占据了越来越多量的钢丝横断面面积,由于涂层并不增加钢丝的强度,因此,较细的钢丝绳与它们较粗的相似之物相比具有较低的强度。
发明内容
因此,本发明的第一个目的就是提供一种能克服过去的这些问题的钢丝绳。更具体的是,本发明的一个目的就是提供一种结合有良好耐腐蚀性而不影响强度的钢丝绳。进一步的目的为提供一种具有改善了的摩擦性的钢丝绳。本发明人已经找到了一种有效的、便宜的、环境友好的和容易施用的特别简单的腐蚀抑制剂,其适合于传动系统中钢丝绳的特殊用途:以上为本发明的另一目的。
根据本发明的第一个方面,提供一种在传动系统中使用的金属丝绳,所述丝绳的直径小于5mm,虽然更优选的尺寸为低于3mm,同时现在普遍使用的尺寸为2mm和1.5mm,但是发明人相信使用更细直径丝绳的趋势将会持续并且预测在可预见的将来使用直径1mm的绳索将成为可能。
所述金属丝绳由涂覆锌或锌合金的钢丝组合而成,由于需要高强度,用于生产这些钢丝的钢是一种高碳钢。所述钢具有根据下述范围的组成:碳含量为0.35-1.15wt.%,优选为0.60-1.00wt.%碳,锰含量为0.30-0.70wt.%,硅含量为0.10-0.60wt.%,硫含量至多为0.05wt.%,磷含量至多为0.05wt.%。采用特殊元素微合金化,例如包括:铬、镍、钒、硼、钴、铜、钼,其量为0.01-0.08wt%,因为该合金化可以有助于达到更高的强度。
特别流行的用于这些钢丝的涂层为:
工业纯净锌的涂层,其中还包含不可避免的杂质;
有意合金化的锌涂层,其中以下特别受到重视:
锌铝合金,例如包括含2-12wt.%铝的那些和稀土金属混合物,例如:铈或镧,余量为锌。其特别优选的是它们的防腐蚀性能(参见如:EP0550005B1);
锌铁合金,例如包含0.3-1.5wt.%铁或者包含15-25wt.%铁、余量为锌的那些。铁可以来自于钢基材本身。
锌锡合金,该涂层具有有利的摩擦性能(参见如:DE19512180A1)
锌镍合金,例如包含20-30wt.%镍,余量为锌的那些。
注意到,钢丝的涂层常常在具有中间直径的钢丝上完成,然后其通过一系列模具被拉成更细的直径,在拉伸过程中,钢丝的抗拉强度逐渐增加,对于具有高碳含量的钢丝来说增加很明显,如本申请中所述的高碳含量钢丝。典型地,钢丝的抗拉强度超过1750N/mm2,典型地超过2500N/mm2,或者更优选超过2750N/mm2,或者甚至超过3000n/mm2。需要这样更高的抗拉强度以便能够进一步减小钢丝绳的直径,这种钢丝绳的钢丝的直径很少大于0.25mm,优选小于0.22,甚至更优选小于0.15mm。使用很多、细直径的钢丝制成的钢丝绳,相比于具有较少的、更粗直径的钢丝的钢丝绳来说,具有更好的抗疲劳性。
钢丝被组合成股,该股可以组合或者不进一步组合成钢丝绳。在本领域常用的典型的构造形式为:7×7,7×19,19+8×7,19W+8×7,7×8,8×7,8×8,19+9×7,1×3+5×7,以上仅仅表示出一部分。例如:公式7×8表示了一钢丝绳由7股组成,每股由8根钢丝组成。每股由一个芯钢丝和围绕芯钢丝的7根外部钢丝组成,外部钢丝以特定捻距螺旋捻制。六根所述股围绕一中心芯股同样以特定的捻距捻制。外部钢丝的直径优选选择为它们能容易地配合在芯钢丝周围。同样地,芯股的直径选择为能够适合于外部股的直径。可以通围绕中间股一层一层地捻钢丝生产绳股,从而形成了一种示例性构造形式,一芯钢丝由6根钢丝包围,然后又由12根钢丝包围,形成了1+6+12的构造形式从而减少到19根钢丝的股。一特殊的例子是,钢丝的直径如此选择使其完美的配合在一起,如同在瓦灵顿(Warrington)结构中(其如在19w+8×7结构的芯中)那样,所有的19根钢丝然后以相同的捻距组合。有时,股绳在绞合之前进行压紧。或者甚至对已完成的缆绳进行压紧。有时采用纤维替换芯钢丝,本申请的发明构思同样合适于所有这些变化。
典型地,钢丝上的涂层量由钢丝表面上的每平方米涂层的克数来表示。由于涂层并不增加钢绳的强度,因此它必须在不损害耐腐蚀性的同时尽量的薄。传统的涂层量是(括号内的数值指对应于具有7.14此/dm3密度的锌涂层的平均厚度)最小30g/m2(4.2μm)。然而,更低的量如低至25g/m2(3.5μm),或低于20g/m2(2.8μm)或甚至低于15g/m2(2.1μm),对本发明的钢丝绳是更优选的。本发明人认为采用以5g/m2(0.7μm)为目标的锌涂层甚至也能得到可以接受的腐蚀结果。
虽然从原则上说用于涂覆这些钢丝的工艺类型并无限制,但是优选热浸镀方法,由于其提供了溶接到钢上的固体涂层。由于热浸镀,在钢和涂层之间会形成一合金层,其会对钢提供额外的保护。从强度和疲劳度的观点看,特别优选如EP1280958B1中所描述的涂层。其中描述了具有低于2微米(每平方米钢丝14.3g锌)的减少厚度的包含锌铁合金层的锌涂层及与之相关的涂覆钢丝的方法。所述钢丝具有减小的锌的厚度,这对获得钢绳更高的断裂载荷是有利的。另外,锌对钢过渡层的粗糙度大大降低,从而导致改善了的疲劳度。遗憾的是,涂层对自身并没有起到足够的腐蚀防护。
然而,本发明人已经发现了可以通过使用腐蚀抑制剂来补偿降低的耐腐蚀性,该腐蚀抑制剂通过液体载体的方法应用。出人意料的是他们发现了一种非常简单的名叫氧化镁(MgO)的化合物非常适合这个目的,氧化镁(MgO)必须细微地分散于载体中,载体仅仅用于将氧化镁均匀地分布在钢丝表面:该颗粒必须与钢丝的涂层紧密接触。液体载体可以保留或者蒸发掉:这种情况下积极的腐蚀抑制作用依然存在。氧化镁使得可以使用更薄的锌涂层,并带来了更高的强度和更好的疲劳度的优势,同时保持甚至改善了耐腐蚀性。已作必要的修正的氧化镁与当前使用的锌涂层一起在钢丝上使用时,赋予了更多的耐腐蚀可靠性。
氧化镁(MgO)是可以通过许多工艺途径获得的常用产品,第一途径是在氧存在下加热菱镁矿(碳酸镁,一种自然矿藏)。第二途径是使用包含MgCl2的盐水,首先通过湿法沉淀将MgCl2转化成Mg(OH)2进行提纯,然后煅烧除去水。更优选采用后者。生成物氧化镁(MgO)可以通过不同的级别进行分类:
1、“熔融氧化镁”是指在高于2750℃度的温度下,在电弧炉中已熔融过的煅烧氧化镁。其在所有类型的氧化镁中是最稳定的和最强固的。
2、“死烧氧化镁”是指已在1500℃-2000℃温度的范围煅烧过,并具有小于0.1m2/g的表面积。
3、“高温焙烧氧化镁”是指已在1000℃-1500℃温度的范围煅烧过,并具有0.1-1.0m2/g的表面积。
4、“轻烧或者苛性氧化镁”是指在700℃-1000℃温度范围加热,并具有1.0-250m2/g的表面积。
最优选为“轻烧”级别,同时“高温焙烧”级别较少优选,“死烧”级别难于分散因而最少优选,“熔融氧化镁”太惰性以至于不是有用的。
作为载体,脂肪族矿物油是最优选的。脂肪族矿物油一般用于在钢丝在滑轮或者磨损件上弯曲时,通过减少钢丝之间的磨擦增强钢丝绳的疲劳寿命。由于无论如何它们要应用到钢丝绳上,它们可以顺便被当作用于氧化镁分散的载体。另一种可能的液体载体是石蜡(paraphenes)和更具体的是异链烷烃(isoparaphenes),其公知为容易蒸发的。
在仅仅应用微小量于锌或者锌合金涂覆的表面时,氧化镁(MgO)的腐蚀保护效果已经非常明显,事实上,在每平方钢丝表面应用100毫克的最少量的MgO,已经鉴定在盐水喷雾测试中其积极效果在数小时的状态下继续存在。与锌涂层的量(典型地为15000-30000mg/m2量)相比,这是惊人的。防腐效果与施用到锌或锌合金涂层上的MgO的量呈线性增长。因此200mg/m2量的MgO是更优选的,更高的量1000mg/m2或2000mg/m2或甚至4000mg/m2MgO仍然导致改进的结果,目前尚未检测到达到平稳的积极效果。申请人的假设之一是(并非被本理论所束缚)在锌涂层上的MgO的存在抑制了腐蚀过程中的阴极反应(即电子消耗反应),由此,MgO成为一增强锌涂层钝化行为的产品。结果腐蚀将仅仅在无MgO的点处发生。以上使得MgO成为阴极抑制剂,其效果随着存在的氧化镁的量增加。
已经发现,为了获得氧化镁絮凝物的均衡分布,氧化镁细微地分布在钢丝表面是非常重要的。最好通过使用具有平均颗粒尺寸在1-100微米之间的,最优选为5-75微米的细研磨氧化镁来获得这样的分布。氧化镁必须与锌或者锌涂层物理接触,否则防腐蚀效果就会降低或者不存在。
为了使更进一步改善上述接触,本发明人在液体载体中添加了与氧化镁颗粒大约相同尺寸(5-50微米平均颗粒尺寸)的磨粒。想法如下,通过添加研磨剂,锌涂层的表面被研磨从而氧化镁颗粒能更好的嵌入。出人意料的是,他们发现添加所述研磨剂会减少驱动系统中聚合物导向零件的磨损。所述导向零件通常由硬聚合物如聚甲醛(POM)或聚酰胺(Nylon 6)制成。测试参考的描述在EP0550005B1,第14页和图13,14-15。申请人假定(并不被此假设束缚)研磨颗粒并不仅仅活化锌涂层,也磨光钢丝的表面使其更加光滑。作为研磨剂,最优选为碳化硅(SiC),因为它便宜并且在所有的晶粒尺寸下均可获得。其它研磨剂(石英、立方硼化氮、金刚石和许多其他的)可能具有同样的功效。值得注意的还有:这些研磨颗粒对钢丝绳的疲劳行为并不产生负面影响。已经发现对每千克钢丝绳在0.1至10克之间,优选0.1至2克的碳化硅已经足够获得积极的效果。
由上面所述可清楚地知道,本发明人已经查找了特殊的简单的化学物质和添加剂。许多商业上可获得的腐蚀抑制剂是为了一般用途的并不特别定向于用于传动系统的钢丝绳。因此,他们包含超过五种组分,这些组分中的许多种是复杂的和并非现成的。发明人有意地查找了一种简单的解决方案,其首先是有效的、便宜的、环境友好的和容易实施的。其组分剩余的数低于五种,其是:液体载体(在施用后可能消失也可能不消失),氧化镁(MgO),碳化硅(SiC)以及可以是可添加的若干种分散剂或悬浮剂(floatant)。
根据本发明的第二方面,限定了一种包括至少一根涂覆锌或锌合金的钢丝的金属丝产品,该钢丝的特殊之处在于,腐蚀抑制剂是以细微分散固体的形式嵌入锌或锌合金涂层中的。优选的是腐蚀抑制剂存在于涂层的外部表面内。甚至更优选的是该固体腐蚀抑制剂压印(emboss)、压入所述涂层的外部表面内,所述腐蚀抑制剂优选为氧化镁(MgO)。
根据本发明的第三个方面,公开了一种保护金属丝产品的方法。该方法从具有锌或锌合金涂层的中间直径的钢丝开始。该钢和涂层组合物与在本发明第一方面中描述的组合物相符。在一个拉丝机上,优选为湿法拉丝机,将钢丝顺序拉伸通过依次缩小的模具,其在本领域为常用技术。本方法的特殊之处在于,钢丝将细微分散的腐蚀抑制剂拖入了拉伸模具之一内,该腐蚀抑制剂通过模具在钢丝上的压缩行为被施加到涂层的外部表面。腐蚀抑制剂可以在一个模具中被施加到钢丝上,如入口模具(即最大的)或者出口模具(即最小的)。或者抑制剂可以通过两个或更多模具,或者整个模具系列中的每个模具被供给钢丝。
可以以粉末形式提供腐蚀抑制剂,如果那样的话,腐蚀抑制剂可以被混合进粉末肥皂(powder soaps)中,该粉末肥皂作为固体润滑剂在钢丝干法拉拔领域中常常用到。所述粉末混合物可以通过引导该钢丝在模具的入口通过肥皂盒与钢丝一起供给模具,或者腐蚀抑制剂可以混入被钢丝拖入模具入口的液体载体。重要的是腐蚀抑制剂与锌或锌合金涂层具有密切的,导电的接触。因此,腐蚀抑制剂不应被拉拔肥皂残余物与锌或锌合金涂层隔开。
优选的腐蚀抑制剂为氧化镁(MgO)。优选的是氧化镁粉末被细研磨从而能够通过74微米的筛孔。
具体实施方式
以下,描述了一系列实验室规模和在生产环境中的测试,其已经在19+8×7类型的直径为1.5mm的涂覆锌的钢丝绳上进行,该钢丝绳用于在玻璃升降机系统中使用。该钢绳采用以下公式制作:
{[(0.15+6×0.14)3.5S+12×0.14]8.5S+8×(0.14++6×0.14)4.8Z}12S
其中不同的括号级别表示了独立的操作,下标表示了捻距(laylengths)和捻向。该钢绳具有9.78g/m的线性质量和33.56m2/km的钢绳的钢丝表面积。如果没有另外相反的说明,该钢丝绳已经进行了热浸镀锌,每千克涂覆的钢丝绳涂覆有大约100克工业级纯锌涂层(即28g/m2或者平均厚度为3.9μm)。
在最初的一系列测试中,许多物质已经在实验室中进行了评价。如在标准生产钢绳上使用的一样。干净的钢绳样品被涂覆上标准脂肪族矿物油与化合物的混合物。每一种的六个试样均悬挂在盐水喷雾测试室中并每天对其进行目视检查。把可以看到第一个深棕色斑点的那天记录下来。在表1中提到的结果是六个试样的平均值(hSS平均),最小值(hSS最小)和最大值(hSS最大)。在混合物中化合物按照所给出的总的混合物的质量百分比表示。在这些测定的基础上,选择MgO进行进一步的研究。
表1
在第二系列的实验室试验中,MgO的影响通过在裸的脱脂的缆绳上施用混合物进行确定,其中在混合物中具有渐增量的氧化镁。同样样品在盐水喷雾室中进行测试,结果归纳于表2。
表2
在第三系列试验中,一系列混合物以工业规模进行测试,对具有两种水平的锌涂层量的钢丝绳进行测试:一种钢丝表面具有28.0g/m2的标准涂层,一种具有24.3g/m2的减少的涂层。同时使用了一种不同种类的液体载体,其名为液体异链烷烃。具有低分子重量的异链烷烃容易挥发。在这种情况下,石蜡仅仅作为氧化镁在缆绳的钢丝表面的分散剂。由结果可以推出氧化镁的积极效果依然保持。
表3
在第四系列试验中,在润滑剂中添加一定量的碳化硅(晶粒尺寸在8-32微米),目的是通过表面的轻微研磨来活化锌涂层表面,活化的目的是为了发挥氧化镁的作用。虽然在盐水喷雾室中测量的耐腐蚀性并没有由于碳化硅的作用而恶化或改善,但是却意外的获得了另一个积极效果。已经发现固定引导零件的切削性磨损事实上消失了,该固定引导零件有时用来替换滑轮:如果正常的磨损水平是100,SiC的影响将其降低至40甚至到25。该测试在120N载荷和7.5m/分钟钢丝绳相对引导零件速度的条件下进行。POM引导零件的曲率直径为15mm,同时钢丝绳覆盖了零件的180°。磨损在5000来回循环(即10000次通过)后进行评价,在循环中,相同的430mm的钢丝绳滑过引导零件。在测试前并未添加润滑剂。
发明人想要强调,本发明同样良好地适合于所有类型结构的钢丝绳,它们的使用并不限于窗户升降机系统,而是适合于所有类型的传动系统(滑动门、滑动屋顶、车库门、窗帘驱动装置、制动索、离合器拉索、门锁系统,非穷举列表)。
Claims (5)
1.一种用于传动系统的金属丝绳,其包含涂覆锌或锌合金的钢丝,所述钢丝进一步包含液体载体涂层,该液体载体涂层包含腐蚀抑制剂,所述腐蚀抑制剂为氧化镁,所述氧化镁细分散在所述液体载体中,其特征在于,所述液体载体进一步包含颗粒尺寸为5-50微米的磨料粉末,其中,所述细分散的氧化镁的平均颗粒尺寸为1-100微米且在所述金属丝绳的每平方米钢丝表面具有至少100毫克的氧化镁。
2.权利要求1所述的金属丝绳,其中,所述液体载体为脂肪族矿物油。
3.权利要求1-2任一项所述的金属丝绳,其中,在所述金属丝绳的每平方米钢丝表面具有至少200毫克的氧化镁。
4.权利要求1所述的金属丝绳,其中,所述磨料粉末为碳化硅。
5.权利要求4所述的金属丝绳,其中,在每千克所述金属丝绳上具有0.1-10克碳化硅。
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