CN104530945B - 一种用于动车车头的涂层组合 - Google Patents
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Abstract
本发明涉及一种用于动车车头的抗冲蚀涂层组合,所述涂层组合是车头尖端喷涂改性聚氨酯树脂复合涂层,斜面喷涂硬质陶瓷涂层。本发明将车头尖端喷涂高韧性涂层,有效提高其抗正面冲蚀能力;斜面喷涂高硬度涂层,有效提高其抗划擦能力,本发明的车头涂层组合能够保证车头尖端及斜面位置涂层在运行时的寿命基本相同,适合统一更换;与现有的涂层相比,车头涂层使用寿命提高3倍以上。
Description
技术领域
本发明属于涂层技术领域,具体涉及一种用于动车车头的抗冲蚀涂层组合。
背景技术
随着现代列车的普遍提速,动车组的速度高达300km/h,加之运行环境复杂(扬沙、浮尘等),冲蚀磨损已成为车头涂层主要破坏与损伤模式。
现有车头出于抗冲蚀及美观等因素,采用统一喷涂方式,在车头制备聚氨酯面漆/中漆/聚酯腻子/环氧树脂底漆系复合涂层。
但实际情况是车头的不同部位,如车头尖端、斜面,受冲蚀角度相差较大,导致动车运行时涂层冲蚀磨损机制不同,以车头为例,车头尖端主要受正面撞击,因此容易产生变形及裂纹而磨损,而斜面主要受粒子划擦而造成磨损。目前的车头的涂层不能满足现有的要求,统一喷涂的聚氨酯面漆/中漆/聚酯腻子/环氧树脂底漆系涂层在运行过程中涂层磨损严重,需要统一更换涂层,因此运营成本较高。
因此需要对车头不同位置的涂层进行设计,使得其运营时寿命接近,减少因某些部位磨损程度严重,必须将车头涂层统一更换造成的浪费。
针对这一现状,本发明提出一种用于车头不同部位的抗冲蚀涂层组合。
发明内容
本发明的目的是提供一种用于动车车头表面的涂层组合。所述涂层组合相比原有涂层体系,冲蚀磨损率降为原有的1/3,涂层整体使用寿命提高了3倍左右。
具体的说,所述用于动车车头表面的涂层组合包括位于车头尖端部位的改性聚氨酯树脂复合涂层,以及位于车头斜面部位的硬质陶瓷涂层。
其中,所述车头尖端部位为车头前端可拆卸部分,如图1所示,一般是车头最尖端为起点,向车身方向延伸约1米的范围;
所述改性聚氨酯树脂复合涂层的厚度为60-500μm,优选100-300μm。
所述的车头斜面部位为除前端可拆卸部分以外的其他迎风面部位,如图1所示,基本上其入射角度在45°以下(不包括45°);
所述改性聚氨酯树脂复合涂层是一类高韧性涂层,其特点是对正面冲击不敏感,对斜面冲击非常敏感,发明人经过研究发现,车头承受正面冲击位置的部位可采用这种涂层,所述的改性聚氨酯树脂复合涂层可选用现有的聚氨酯/聚酯腻子/环氧底漆系复合涂层,更优选改性聚氨酯/聚氨酯/环氧底漆系复合涂层。
具体的说,现有的聚氨酯/聚酯腻子/环氧底漆系复合涂层,其具体为双组分聚氨酯面漆60um+双组分聚氨酯中漆30um+不饱和聚酯腻子1-2mm+双组分环氧底漆60um。
发明优选的改性聚氨酯复合涂层的厚度优选为150-250μm。
所述改性聚氨酯复合涂层由下述涂层组成,各涂层的厚度以干膜厚度计:80-120μm厚度的改性聚氨酯面漆,20-40μm厚度的双组份聚氨酯中漆和50-80μm的双组分环氧树脂底漆。
更优选的,所述改性聚氨酯复合涂层由下述涂层组成:100μm厚度的改性聚氨酯面漆,30μm厚度的双组份聚氨酯中漆和60μm(干膜厚度)的双组分环氧树脂底漆。
其中,所述双组分环氧树脂底漆由环氧树脂,溶剂、助剂、填充剂、分散剂以及聚酰胺固化剂组成;具体为质量分数如下:环氧树脂50-70%,溶剂和助剂10-20%,分散剂1-5%,填充料1-5%,固化剂10-15%等。
其中,所述的环氧树脂可以选择双酚A型环氧树脂;
所述的溶剂可选用本领域常用的溶剂,如乙醇等,本发明选用乙醇。
所述助剂选用催干剂或增韧剂。所述催干剂选用二氧化锰或醋酸铅;所述增韧剂选用邻苯二甲酸二乙酯、邻苯二甲酸二丁酯或邻苯二甲酸二辛酯;
所述分散剂选用适合分散主成分的分散剂,如硅酸盐类(LBCB-1)分散剂。
所述填充料选用本领域常用的填充料,本发明选用钛白粉;
所述的聚酰胺固化剂选用粘度10000-18000mpa.s./40℃的固化剂。
其中,所述双组分聚氨酯中漆可选用聚酯树脂、丙烯酸树脂及相应的助剂以及溶剂调制而成;具体为质量分数如下:聚酯树脂10-30%,丙烯酸树脂20-40%,异佛尔二异氰酸酯15-20%,醋酸丁酯5-10%,分散剂0.1-1%等。
其中,所述的聚酯选用氨基树脂交联固化的饱和聚酯树脂;
所述的丙烯酸树脂选用分子量一般为75000~120000的热塑性丙烯酸树脂;
所述异佛尔二异氰酸酯用作固化剂,可采用本领域常用的异佛尔二异氰酸酯。
所述醋酸丁酯用作溶剂,其能够在涂料涂膜以后迅速挥发。
所述分散剂可选用适合分散主成分的分散剂,如硅酸盐类(LBCB-1)分散剂。
其中改性聚氨酯面漆为在聚氨酯材料中引入长链聚醚、聚酯链段并以此喷涂的面漆,其韧性较原有涂层有极大提高;具体质量分数为:聚酯树脂10-30%,丙烯酸树脂20-40%,己二异氰酸酯15-20%,醋酸丁酯5-10%,长链聚醚树脂3-5%,长链聚酯树脂3-5%等。
其中,各原料的选择均可采用本领域常用的原料,特别是上文中提及的各种原料的选择。
长链聚醚树脂选用碳原子数为500-1000的聚醚树脂;
长链聚酯树脂选用碳原子数为500-1000的聚酯树脂;
所述硬质陶瓷涂层为金属陶瓷涂层,可采用各种硬度高于900Hv的金属陶瓷涂层,如WC-Co、Al2O3-TiO2、WC-CoCr等金属陶瓷;所述金属陶瓷涂层的厚度与复合树脂涂层的厚度一致;涂层方法可选用本领域常用的方法,如热喷涂等;
优选的,所述金属陶瓷涂层的厚度为80-200μm;更优选80-120μm。
本发明所述的硬质陶瓷涂层选用WC-Co金属陶瓷;其中WC-Co金属陶瓷中的WC含量一般为88%;Co含量一般为12%;这样的WC-Co金属陶瓷的硬度大于1000Hv。
所述WC-Co金属陶瓷涂层的厚度为80-200μm;更优选80-120μm。
采用热喷涂方法将WC、Co粉末通过高温熔化后喷射到铝合金基体表面形成金属陶瓷涂层;所述的热喷涂方法可采用本领域常用的超音速火焰喷涂等,具体的方法是将WC粉末和金属Co粉混合物经过高速火焰热喷涂系统,热熔后,金属液体包裹WC颗粒,喷涂在基材上,WC形成陶瓷相,含金属弥散相,得到涂层。
根据动车车头的调研资料(如图1所示),车头尖端部位在运行时受冲蚀的入射角度接近90°,车头斜面部位在运行时受冲蚀的入射角度在30°左右;在此基础上,发明人对改性聚氨酯复合涂层进行了不同入射角度下的冲蚀磨损率的实验,得到复合涂层冲蚀磨率随入射角度的变化曲线(如图2),研究发现随着入射角度的变化,改性聚氨酯涂层的冲蚀磨损有很大的变化,其30°入射的冲蚀磨损最大,冲蚀磨损率为0.25mm3/g,而对于90°入射的正面冲击不敏感,其冲蚀磨损率仅为0.08mm3/g,在30°入射时的是90°入射时(0.08mm3/g)的3倍以上。
发明人对各种耐蚀涂层进行了各种研究,发现金属陶瓷涂层具有与现有的改性聚氨酯涂层完全不同的冲蚀磨损特点,以WC-Co金属陶瓷为例,通过冲蚀实验得到复合涂层冲蚀磨率随入射角度的变化曲线见图3,其冲蚀磨损随着入射角度的提高而增加,其对斜面冲击不敏感,对正面冲击非常敏感,陶瓷涂层90°入射的正面冲击的冲蚀磨损率高达0.4mm3/g,而在30°入射时的冲蚀磨损率仅为0.083mm3/g,是相同条件下聚氨酯复合涂层冲蚀磨损率的1/3左右。
因此,本发明提出将车头涂层尖端部位保持不变或更换为改性聚氨酯涂层,斜面部位更换为以WC-Co金属陶瓷为代表的硬质陶瓷涂层,这样车头尖端的改性聚氨酯树脂复合涂层的冲蚀磨损率为0.08mm3/g,车头斜面的硬质陶瓷涂层的冲蚀磨损率为0.083mm3/g,整个车头的冲蚀磨损率均在0.08mm3/g左右,相比原有涂层体系,冲蚀磨损率降为原有的1/3,涂层整体使用寿命提高了3倍左右。
本发明将车头尖端喷涂高韧性涂层,有效提高其抗正面冲蚀能力;斜面喷涂高硬度涂层,有效提高其抗划擦能力。本发明的车头涂层组合能够保证车头尖端及斜面位置涂层在运行时的寿命基本相同,适合统一更换;与现有的涂层相比,车头涂层使用寿命提高3倍以上。
附图说明
图1动车组车头示意图;
图2现有聚氨酯涂层冲蚀磨损率随入射角度变化曲线;
图3改性聚氨酯涂层冲蚀磨损率随入射角度变化曲线;
图4金属陶瓷涂层冲蚀磨损率随角度变化曲线。
图5本发明所述的涂层组合的冲蚀磨损率随角度变化曲线。
具体实施方式
所述实施例是为了说明本发明,但不用于限制本发明所要求保护的范围。如没有特别指明,所述的原料都是本领域常用的原料。
测定各种材料的冲蚀性能采用气流喷射式冲蚀试验机。喷砂式冲蚀实验机由4部分组成:压缩空气供给系统、磨粒供给系统、测试室、除尘及回收装置。压缩空气供给系统提供可调气压,高速气流携带磨料粒子冲蚀试样;磨粒供给系统用于储存磨料粒子和精密控制供料速度;测试室用于放置实验样品以及调节冲蚀入射角度;除尘及回收装置用于除尘及回收磨料粒子。该设备符合美国ASTMG76标准,粒子速度在20m/s-100m/s可调,入射角度在15°-90°可调。
实施例1
对现有的聚氨酯复合涂层体系进行冲蚀实验,实验参数设定为:粒子速度100m/s,供料速度为3.00g/min,粒子粒径在100μm左右。
实验结果发现该涂层无论是小角度冲蚀,还是正面冲蚀,冲蚀体积磨损率均在0.30mm3/g以上,具体实验结果见图2。
实施例2
在铝合金基体上喷镀60μm(干膜厚度)的双组分环氧树脂底漆,接着在上面喷涂30μm厚度的双组份聚氨酯中漆和100μm厚度的改性聚氨酯面漆,由此制备试样,进行冲蚀实验。
实验参数设定为:粒子速度100m/s,供料速度为3.00g/min,粒子粒径在100μm左右,变化粒子入射角度,得改性聚氨酯涂层冲蚀磨损率随入射角度变化曲线,如图3所示。
30°入射的冲蚀磨损最大,冲蚀磨损率为0.25mm3/g,90°入射的正面冲击时其冲蚀磨损率仅为0.08mm3/g。
实施例3
采用热喷涂方法在铝合金基体表面制备平均厚度在100μm左右的WC-Co金属陶瓷涂层,进行冲蚀实验。
实验参数设定为:粒子速度100m/s,供料速度为3.00g/min,粒子粒径在100μm左右,变化粒子入射角度,得WC-Co金属陶瓷涂层冲蚀磨损率随入射角度变化曲线,如图4所示。
90°入射的正面冲击的冲蚀磨损率最大,为0.4mm3/g,但30°入射冲蚀磨损率仅为0.083mm3/g。
实施例4
在铝合金基体表面热喷涂80μm的WC-Co金属陶瓷涂层,同时在同一铝合金基体的另一侧喷镀60μm(干膜厚度)的双组分环氧树脂底漆,接着在上面喷涂30μm厚度的双组份聚氨酯中漆和100μm厚度的改性聚氨酯面漆,由此制备试样,进行冲蚀实验。
对金属陶瓷涂层的冲蚀实验入射角度在50°以上,对改性聚氨酯树脂复合涂层的入射角度在50°以下,实验结果见图5,基本与图3和图4的曲线拟合结果相同。
Claims (14)
1.一种用于动车车头的抗冲蚀涂层组合,所述涂层组合为车头尖端喷涂改性聚氨酯树脂复合涂层,斜面喷涂金属陶瓷涂层。
2.根据权利要求1 所述的一种用于动车车头的抗冲蚀涂层组合,其特征在于,所述改性聚氨酯树脂复合涂层的厚度为60-500μm。
3.根据权利要求1所述的一种用于动车车头的抗冲蚀涂层组合,其特征在于,所述改性聚氨酯树脂复合涂层的厚度为100-300μm。
4.根据权利要求1所述的一种用于动车车头的抗冲蚀涂层组合,其特征在于,所述改性聚氨酯树脂复合涂层为聚氨酯/ 聚酯腻子/ 环氧底漆系复合涂层。
5.根据权利要求1所述的一种用于动车车头的抗冲蚀涂层组合,其特征在于,所述改性聚氨酯树脂复合涂层为改性聚氨酯/ 聚氨酯/ 环氧底漆系复合涂层。
6.根据权利要求2-5任意一项所述的一种用于动车车头的抗冲蚀涂层组合,其特征在于,所述改性聚氨酯复合涂层的厚度为150-250μm。
7.根据权利要求5所述的一种用于动车车头的抗冲蚀涂层组合,其特征在于,所述改性聚氨酯复合涂层由下述涂层组成,各涂层的厚度以干膜厚度计:80-120μm 厚度的改性聚氨酯面漆,20-40μm 厚度的双组份聚氨酯中漆和50-80μm 的双组分环氧树脂底漆。
8.根据权利要求5所述的一种用于动车车头的抗冲蚀涂层组合,其特征在于,所述改性聚氨酯复合涂层由下述涂层组成,各涂层的厚度以干膜厚度计:100μm 厚度的改性聚氨酯面漆,30μm 厚度的双组份聚氨酯中漆和60μm 的双组分环氧树脂底漆。
9.根据权利要求1 所述的一种用于动车车头的抗冲蚀涂层组合,其特征在于,所述金属陶瓷涂层为硬度高于900Hv 的金属陶瓷涂层,所述金属陶瓷涂层的厚度为60-500μm。
10.根据权利要求1 所述的一种用于动车车头的抗冲蚀涂层组合,其特征在于,所述金属陶瓷涂层的厚度为100-300μm。
11.根据权利要求1 或9所述的一种用于动车车头的抗冲蚀涂层组合,其特征在于,所述金属陶瓷涂层为WC-Co、Al2O3-TiO2或WC-CoCr金属陶瓷;所述金属陶瓷涂层的厚度为80-200μm 。
12.根据权利要求11所述的一种用于动车车头的抗冲蚀涂层组合,其特征在于,所述金属陶瓷涂层的厚度为80-120μm。
13.根据权利要求1 或9所述的一种用于动车车头的抗冲蚀涂层组合,其特征在于,所述金属陶瓷涂层为WC-Co 金属陶瓷;其中WC-Co 金属陶瓷中的WC 含量为88%;Co 含量为12%;所述WC-Co 金属陶瓷涂层的厚度为80-200μm 。
14.根据权利要求13所述的一种用于动车车头的抗冲蚀涂层组合,其特征在于,所述WC-Co 金属陶瓷涂层的厚度为80-120μm。
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