CN104379817B - 用于防止腐蚀的方法以及通过这种方法得到的部件 - Google Patents

用于防止腐蚀的方法以及通过这种方法得到的部件 Download PDF

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CN104379817B
CN104379817B CN201380019338.5A CN201380019338A CN104379817B CN 104379817 B CN104379817 B CN 104379817B CN 201380019338 A CN201380019338 A CN 201380019338A CN 104379817 B CN104379817 B CN 104379817B
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CN104379817A (zh
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M.吉亚诺兹
R.保勒蒂
M.罗马内利
M.安塞尔米
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Nuovo Pignone Technologie SRL
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    • C23C18/16—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by reduction or substitution, e.g. electroless plating
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Abstract

本发明提供一种方法(100)，所述方法用于防止具有由碳钢、低合金钢或不锈钢制成的金属基底(5)的涡轮机的部件(1)发生腐蚀，所述方法包括：‑第一沉积步骤(110)，即通过电镀将第一金属层(2a)沉积在所述基底(5)上；‑第二沉积步骤(120)，即通过无电敷镀将至少镍合金的第二层(2b)沉积在所述第一层(2a)上；‑在所述沉积步骤(110、120)之后的至少一个热处理(140)步骤，实施所述热处理(140)的温度(T)和时间(t)取决于所述层(2a、2b)的总厚度，所述温度(T)的值与所述厚度成正比，所述时间(t)的值与所述温度(T)成反比。

Description

用于防止腐蚀的方法以及通过这种方法得到的部件
技术领域
本发明涉及一种用于防止海底或陆上或海上部件发生腐蚀的方法。本发明的方法可以有利地用于防止海底或陆上或海上涡轮机的部件发生腐蚀。
背景技术
构建在海底或陆上或海上环境中运行的部件时，通常使用碳钢、低合金钢和不锈钢等材料。如果此类环境包括潮湿的二氧化碳(CO2)，则碳钢和低合金钢将受到腐蚀损坏的影响。此外，如果此类环境包括氯化物，则不锈钢将受到点状腐蚀损坏的影响。
发明内容
因此，本发明的一个目标是提供一种改进的制造方法来防止腐蚀，所述制造方法能够通过以下方法来避免上述不便之处：
-有效地解决含有氯化物、CO2和硫化氢(H2S)等侵蚀性污染物的多数潮湿环境中的防腐问题，同时
-使用成本较低的材料。
本发明的另一个目标是提供一种改进的制造方法来防止形状复杂的海底或陆上或海上部件，例如电动压缩机的外壳的内外表面发生腐蚀。
为实现上述目标，本发明提供了一种用于防止涡轮机的部件发生腐蚀的方法，所述涡轮机包括由碳钢、低合金钢或不锈钢制成的金属基底，其中所述方法包括：
-第一沉积步骤，即通过电镀将第一金属层沉积在所述基底上；
-第二沉积步骤，即通过无电敷镀将至少镍合金的第二层沉积在所述第一层上；
-在所述沉积步骤之后的至少一个热处理步骤，实施所述热处理的温度和时间取决于所述层的总厚度，所述温度的值与所述厚度成正比，所述时间的值与所述温度成反比。
根据第一实施例的另一有利特征，所述方法进一步包括：第三沉积步骤，即通过电镀将第三金属层沉积在所述第二层上；以及第四沉积步骤，即通过无电敷镀将第四层所述镍合金沉积在所述第三层上。
根据第一实施例的另一有利特征，所述层的所述总厚度的值介于70μm与300μm之间。
通过提供由镍基涂层构成并且具有以上指定厚度的多层涂层，本发明的解决方案能够有效保护核心金属基底。所述方法中包括的热处理能够获得耐久且结构均匀的涂层，所述涂层具有最佳延展度值(ε□＝1.000％到(ε□＝1.025％)和硬度值(HV100＝600 toHV100＝650)。
通过提供成本低于不锈钢和更昂贵合金(例如，诸如铬镍铁合金625、铬镍铁合金718等镍基合金)的防腐涂层并且允许将成本较低材料用于核心金属基底中，例如，碳或低合金钢中，所述无电镀镍过程能够节省成本。
无电敷镀过程可以易于施加到任何形状的部件，尤其是复杂形状的部件中。
本发明还通过一种涡轮机来实现上述目标，所述涡轮机包括部件，所述部件包括由碳钢、低合金钢或不锈钢制成的金属基底以及涂层，所述涂层包含位于所述基底上的镍，所述涂层包括通过电镀沉积的至少第一金属层、通过无电敷镀沉积的至少镍合金的第二层、通过电镀沉积的第三金属层以及通过无电敷镀沉积的镍合金的第四层，所述涂层的厚度介于约70μm与300μm之间，所述涂层具有介于600HV100与650HV100之间的硬度值以及介于1.000％与1.025％之间的延展度值。
具体但不排他地来说，本发明的涡轮机包括电动压缩机，所述电动压缩机包括外壳，所述外壳的内表面和/或外表面上具有使用本发明方法获得的涂层。
此外，本发明还通过一种用于提取液态和/或气态烃类混合物的设备来实现以上目标，所述设备包括井口、管道和上述涡轮机，其中所述管道将所述涡轮机直接连接到所述井口。由于根据本发明的涡轮机用于防腐性，因此能够避免在涡轮机的上游使用洗涤器和过滤系统，从而防止腐蚀性物质到达涡轮机。
附图说明
结合附图阅读本发明实施例的以下描述可清楚地了解本发明的其他目标特征和优点，其中：
图1a到图1b是两个框图，其示意性地分别示出了根据本发明的一种防腐方法的第一实施例和第二实施例；
图2是根据本发明的一种海底涡轮机的部件的轴测法视图；
图3是图2中所示的部件的截面图；
图4是根据本发明的一种用于陆上或海上应用中的离心式涡轮压缩机的部件的截面图；
图5是图3和图4中所示的细节V的放大图；
图6是与本发明不同实施例对应的图3和图4中所示的细节V的放大图；
图7a是一种用于从贮槽中提取气体的现有技术设备的示意图；
图7b是一种从贮槽中提取气体的设备的示意图，所述设备包括根据本发明的涡轮机的部件。
具体实施方式
参照附图，其中示出了一种用于在涡轮机201的部件1中进行防腐的方法，其整体用100表示。部件1具有金属基底5，所述金属基底由碳钢、低合金钢或不锈钢制成。
在图2和图3所示的实施例中，海底部件1是海底压缩机的外壳。
根据图4所示的实施例，本发明的方法适用于在陆上或海上运行的电动压缩机的外壳。
具体但不排他地说，本发明的方法可以成功地应用于海底应用或者在其他类型的潮湿环境中运行的其他部件，尤其存在二氧化碳(CO2)和/或硫化氢(H2S)和/或氯化物时，前提是所述方法100包括至少第一沉积步骤110、第二沉积步骤120和最终热处理步骤140，如下详述。
第一沉积步骤110包括通过电镀将第一金属镍层2a沉积在金属基底5上。
第一层2a在所属领域中已知为镍触击，并且具有介于1到10μm之间的厚度，从而为接下来的第二步骤120提供活化作用。
第二沉积步骤120包括通过无电镀镍(也称为ENP)将第二镍合金层2b沉积在第一层2a上。
根据本发明的一个实施例，方法100的第二沉积步骤120中使用的镍合金包括镍-磷合金。
根据本发明的更多具体实施例，用于第二沉积步骤120中的镍-磷合金包括9％到11％的磷。
根据本发明的其他实施例，使用不同的镍合金，例如，镍硼合金。
根据本发明的一个实施例(图1a和图5)，第二沉积步骤120包括沉积第二层2b的第一部分20b的第一阶段以及沉积第二层2b的第二部分21b的第二阶段。第二层2b的第一部分20b的厚度介于10μm到25μm之间。
第二层2b的第二部分21b的厚度等于或大于第二层的两倍，即，等于或大于20μm。
根据本发明的另一个实施例，方法100包括其他沉积步骤，即通过无电镀镍沉积其他镍合金层的步骤，每层的厚度大于上一层的厚度。
根据本发明的另一个实施例(图1b和图6)，在第二沉积步骤120之后，方法100包括第三沉积步骤130，即通过电镀将第三镍层2c沉积在第二层2b上的步骤，以及第四沉积步骤135，即通过无电敷镀将第四镍合金层2d沉积在第三层2c上的步骤。第三层2c通过脉冲电镀获得并且提供第二ENP层2b与第四ENP层2d之间的附着力。此外，第三层2c能够避免形成针孔孔隙，这种针孔孔隙通常出现在厚度超过100μm的ENP层中。
根据本发明的另一个实施例(其结果未图示)，第三沉积步骤130和第四沉积步骤135可以重复多次，以便获得每个无电敷镀层沉积在相应的电镀镍层上的多层结构。
无电镀镍结束时，可得到位于金属基底5上的镍基涂层2。
如上所述，根据本发明的不同实施例，涂层2可以包括一个或多个ENP层。
在图5所示的实施例中，涂层2由第一层2a和第二层2b构成，所述第二层包括第一部分20b和第二部分21b，这两部分均通过无电镀镍获得。
在图6所示的实施例中，涂层2包括第一层2a、第二层2b、第三层2c和第四层2d。
在所有情况下，涂层2的总厚度介于70μm与300μm之间。
参见图2和图3，涂层2涂覆到海底电动压缩机的外壳的内表面上。参见图4，涂层2涂覆到陆上或海上应用中的电动压缩机的外壳的内表面上。
根据本发明的其他实施例，涂层2也涂覆到外表面上或者同时涂覆到内外表面上。
沉积步骤110、120、130、135之后，方法100包括最终热处理步骤140，该步骤通过在温度T下和时间t中将涂层2暴露于加热环境中，例如，暴露于热处理烘箱中来实施。实施热处理步骤140能够将在电镀过程中被吸入涂层中的氢气解吸出来。此外，通过热处理步骤140，涂层2的各层更加耐久、彼此吸附力更强并且结构上更加均质。
温度数据T的值介于100℃与300℃之间，时间数据t的值介于2h与6h之间。温度值和时间值具体取决于涂层2的整体厚度，所述温度T的值与镍涂层2的厚度成正比，而所述时间t的值与所述温度的厚度成反比。
根据下表，在方法100的一个实施例中，温度T和时间t的值具体取决于镍涂层2的整体厚度值：
涂层2的厚度 热处理时间 热处理温度
150μm 2小时 200℃
120μm 3小时 190℃
100μm 4小时 180℃
以上热处理步骤使得镍基涂层2的硬度值达到600HV100与650HV100之间并且延展度值达到1.000％与1.025％之间。涂层2的硬度提高了对可能在涡轮机201中流动的与涂层2接触的固体颗粒的耐腐蚀性或耐磨损性。
当涂层2的厚度介于150μm与300μm之间时，硬度和延展度结果最佳。
根据本发明的其他实施例，最终热处理步骤被实施了多次，以便涂层2中达到以上性质。
参见图7a，从天然贮槽205中提取液态和/或气态烃类混合物的传统设备200a包括井口202、位于井口202下游的干式或湿式洗涤器207、位于洗涤器207下游的过滤器208以及传统的涡轮机201a，例如传统的离心式压缩机或海底电动压缩机。洗涤器207用于防止污染物以及特定腐蚀性物质，例如(CO2)和/或硫化氢(H2S)和/或氯化物到达涡轮机201a。过滤器208用于防止固体颗粒到达涡轮机201a。参见图7b，根据本发明的用于从天然贮槽205中提取相同烃类混合物的设备200包括管道203和涡轮机201。管道203将本发明的涡轮机201直接连接到井口202。这意味着，由于根据本发明的涡轮机拥有防腐蚀性，因此可避免在涡轮机的上游使用洗涤器和过滤系统。
本发明的所有实施例均能够实现上述目标和优点。
此外，本发明拥有进一步优点。具体来说，上述方法能够避免涂层中存在穿孔。
本说明书使用各个实例来揭示本发明，包括最佳模式，同时也让所属领域的任何技术人员能够实践本发明，包括制造并使用任何器件或系统，以及实施所涵盖的任何方法。本发明的保护范围由权利要求书界定，并可包括所属领域的一般技术人员想出的其他实例。如果其他此类实例的结构要素与权利要求书的字面意义相同，或如果此类实例包括的等效结构要素与权利要求书的字面意义无大体差别，则此类实例也属于权利要求书的范围。

Claims (9)

1.一种用于防止具有由碳钢、低合金钢或不锈钢制成的金属基底(5)的涡轮机的部件(1)发生腐蚀的方法(100)，其中所述方法(100)包括：
-第一沉积步骤(110)，即通过电镀将第一层(2a)沉积在所述基底(5)上；
-第二沉积步骤(120)，即通过无电敷镀将至少镍合金的第二层(2b)沉积在所述第一层(2a)上；
-在所述沉积步骤(110、120)之后的至少一个热处(140)步骤，实施所述热处(140)的温度(T)和时间(t)取决于所述层(2a、2b)的总厚度，所述温度(T)的值与所述厚度成正比，所述时间(t)的值与所述温度(T)成反比，其中所述热处理在介于150℃到300℃之间的温度(T)下以及介于2小时到5小时之间的时间(t)中实施。
2.根据权利要求1所述的方法(100)，其中所述方法(100)进一步包括通过电镀将第三层(2c)沉积在所述第二层(2b)上的第三沉积步骤(130)以及通过无电敷镀将所述镍合金的第四层(2d)沉积在所述第三层(2c)上的第四沉积步骤(135)。
3.根据权利要求1或2所述的方法(100)，其中所述层(2a、2b、2c、2d)的所述总厚度介于70μm与300μm之间。
4.根据权利要求1所述的方法(100)，其中根据下表，所述温度(T)和时间(t)的值取决于所述层(2a、2b、2c、2d)的总厚度的值：
5.一种电动压缩机外壳(1)，所述电动压缩机外壳包括由碳钢、低合金钢或不锈钢制成的金属基底(5)以及涂层(2)，所述涂层包括位于所述基底(5)上的镍，所述涂层(2)包括通过电镀沉积的至少第一镍层(2a)以及通过无电镀沉积的至少镍合金的第二层(2b)，所述涂层(2)的厚度介于70μm与300μm之间；其中，所述涂层经过至少一个热处理(140)，所述热处理在介于150℃到300℃之间的温度(T)下以及介于2小时到5小时之间的时间(t)中实施。
6.一种涡轮机，所述涡轮机包括根据权利要求5所述的外壳。
7.一种涡轮机(201)，所述涡轮机包括部件(1)，所述部件包括由碳钢、低合金钢或不锈钢制成的金属基底(5)以及涂层(2)，所述涂层包括位于所述基底(5)上的镍，所述涂层(2)包括通过电镀沉积的至少第一镍层(2a)以及通过无电镀沉积的至少镍合金的第二层(2b)，所述涂层(2)的厚度介于70μm与300μm之间；其中所述涂层(2)具有介于600HV100与650HV100之间的硬度值以及介于1.000％与1.025％之间的延展度值；所述涂层经过至少一个热处理(140)，实施所述热处理(140)的温度(T)和时间(t)取决于所述层(2a、2b)的总厚度，所述温度(T)的值与所述厚度成正比，所述时间(t)的值与所述温度(T)成反比。
8.根据权利要求7所述的涡轮机(201)，其中所述涂层进一步包括通过电镀沉积的第三层(2c)以及通过无电镀沉积的镍合金的第四层(2d)。
9.一种用于提取液态和/或气态烃类混合物的设备(200)，所述设备包括井口(202)、管道(203)以及根据权利要求6到8中的一项权利要求所述的涡轮机(201)，其中所述管道(203)将所述涡轮机(201)连接到所述井口(202)。
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