CN106967991A - 铁丝脱脂、去杂的方法及其在镀锌生产工艺中的应用 - Google Patents
铁丝脱脂、去杂的方法及其在镀锌生产工艺中的应用 Download PDFInfo
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Abstract
本发明公开了一种铁丝脱脂、去杂的方法,经过拉丝工序后,在高温无氧的环境下,对铁丝进行脱脂、去杂,该方法简单易于控制,安全、易于操作,处理效率高,处理后的铁丝光亮,过程环保、无污染。本发明还提供了一种应用上述铁丝脱脂、去杂的方法进行铁丝镀锌的生产工艺,包括依次进行的拉丝工序、前置工序、冷却工序、镀锌工序、干燥工序等,生产的镀锌铁丝镀层牢固、平整、光亮、寿命长,相对于传统的镀锌工艺,该过程节约了水资源,实现了污染物零排放,过程环保且易于操作,整体设备占地面积小,运营成本低。本发明适用于金属制品的表面镀锌处理。
Description
技术领域
本发明属于金属表面处理领域,涉及一种铁丝脱脂、去杂及镀锌的生产工艺,具体地说是一种铁丝脱脂、去杂的方法及其在镀锌生产工艺中的应用。
背景技术
金属材料长期存放或者使用容易锈蚀,为了延长金属工件的使用寿命,常用的方法之一是对其表面进行镀锌处理。锌层不仅可以防止金属工件氧化,延长其使用寿命,而且还可使金属表面美化,扩大其应用范围。
工件镀锌之前先要脱脂、去杂,使得工件表面平整,无杂质,以保证工件镀锌后镀层接着层牢固,光亮平整,经久耐用,因此工件镀锌的前处理步骤为镀锌的关键步骤之一,决定着镀锌工件的质量好坏。目前,工件的脱脂、去杂方法主要是通过酸洗、碱洗来实现的,这种方法虽然在一定程度上解决了该问题,但是酸洗或者碱洗的操作要求苛刻,存在如下诸多问题:
①液体的温度、冲洗的时间不易控制,液体的温度偏低,则脱脂、去杂效果不好,影响镀锌工件的镀层质量;冲洗时间短,则脱脂、去杂效果不明显,时间长,则工件自身也会受到酸液或者碱液的腐蚀,导致镀锌件的次品率提高;
②酸洗或者碱洗后还需要反复水洗去除工件表面的酸液或者碱液,这一过程不仅浪费了大量的水资源,洗液还需进行污水处理后才能达标排放,这一过程增加了生产成本,加重了环境污染,同时也使操作流程复杂;
③酸洗、碱洗或水洗等,需要设置各种设备池,占地面积大,不利于节约成本。
发明内容
本发明要解决的技术问题,是提供一种铁丝脱脂、去杂的方法,在高温无氧的环境下,通入还原性气体后对铁丝进行脱脂、去杂,该方法简单易于控制,安全、易于操作,处理效率高,处理后的铁丝光亮,过程环保、无污染。
本发明的另外一个目的,是提供了一种应用上述铁丝脱脂、去杂的方法进行铁丝镀锌的生产工艺,包括依次进行的拉丝工序、前置工序、冷却工序、镀锌工序、干燥工序等,生产的镀锌工件镀层牢固、平整、光亮、寿命长,相对于传统的镀锌工艺,该过程节约了水资源,实现了污染物零排放,过程环保且易于操作,整体设备占地面积小,运营成本低。
为解决上述技术问题,本发明所采取的技术方案是:
一种铁丝脱脂、去杂的方法,铁丝通过拉丝油进行拉拔后,置于无氧的高温炉内,不断通入还原性气体,对铁丝进行脱脂、去杂。
作为本发明的限定:
步骤(1)中,所述的拉丝油按照重量份数计包含如下组分:
石蜡油40-55份、棕榈油90-100份、单油酸甘油酯10-15份、氧化锌0.1-0.7份、对羟基苯甲酸丁酯3-5份、硅烷偶联剂KH550 0.3份、三乙醇胺0.7-1.5份、咪唑啉0.5份、N,N’—二亚水杨丙二胺3份、硫辛酸1.5-2份、助剂2份;
所述的高温炉先依次经过升温阶段,由室温加热至550℃,保温3min,再经过降温阶段降温至430℃,保温5min,最后自然冷却至室温。
温度对铁丝的力学性能及脱脂、去杂的效果有显著的影响,热处理可以改变工件的内部组织结构,从而改善其工艺性能和使用性能,充分挖掘工件的潜力,延长零件的使用寿命,提高产品质量,节约材料和能源;正确的热处理还可以消除工件经铸造、锻造、焊接等热加工工艺造成的各种缺陷,细化晶粒、消除偏析、降低内应力,使组织和性能更加均匀;
本发明中的铁丝在应用时,需要保持一定的硬度,又需要具有一定的弯折度,实现铁丝反复弯折的功能,当温度高于550℃时,铁丝的晶相结构不稳定,工件容易粘连,不利于保持工件原本的形状,工件的硬度偏大,而弯折度偏低;当温度低于450℃时,还原性气体扩散、吸附于工件表面的速率变慢,因工件表面温度低于气体的温度,还原性气体附着于工件表面后,还原性气体的温度降低,气体的活化分子数降低,反应的活化能垒升高,直接降低了工件脱脂、除杂效果,另外,温度低时工件的硬度偏大,工件的硬度和弯折度不能同时达到最佳;
所述步骤(1)中,还原性气体为CO或H2中的一种;
所述步骤(1)中,还原性气体为CO和H2的混合气体;
作为本发明的进一步限定:
所述的升温阶段包含两个阶段,
第一阶段由室温升温至300℃;
第二阶段由300℃升温至500℃,保温3min。
升温阶段直接影响到工件组织结构和脱脂的效果,升温阶段不按照上述两个阶段进行时,工件的组织性能不均匀,应力消除效果不佳,晶粒细化程度差,脱脂不完全,工件表面易发黑;
本发明还提供了一种应用上述铁丝脱脂、去杂的方法的铁丝镀锌生产工艺,该生产工艺按照如下的步骤顺序依次进行:
⑴拉丝工序
铁丝工件经过拉丝油拉拔后,得A;
⑵前置工序
将A置于无氧高温炉内,不断通入还原性气体,脱脂、去杂后,得B;
⑶冷却工序
在无氧环境下,通过水冷或者自然冷却的方式,将B温度降至室温,得C;
降温的方式直接影响工件的力学性能和显微结构,在步骤⑵中,工件处于高温状态,通过冷却,保证工件相应的组织转变,使工件尺寸和性能稳定;另外,工件通过冷却,提高了自身的热性和塑性,水冷或者自然冷却能够获得硬度、强度、塑性或韧性的最佳配合,同时满足工件弯折和硬度的性能要求。
⑷镀锌工序
将C置于镀锌池中,镀锌后工件出池,得D;
⑸干燥工序
将D进行干燥后,得镀锌后的铁丝成品。
上述铁丝无酸洗镀锌的生产工艺作为一个整体,操作流程简单,易于控制,脱脂、去杂效果佳,镀锌工件的质量高,整个过程环保无污染,占地面积小,适于工业化生产。
由于采用了上述的技术方案,本发明与现有技术相比,所取得的技术进步在于:
本发明所提供的铁丝脱脂、去杂的方法,是在高温无氧的环境下,通过还原性气体对铁丝的还原作用对铁丝进行脱脂、去杂,该方法简单易于控制,安全、易于操作,处理效率高,处理后的铁丝光亮,过程环保、无污染;
本发明还提供了应用上述铁丝脱脂、去杂的方法进行镀锌的生产工艺,具有如下优点:
(1)脱脂、去杂效果佳,生产的镀锌工件镀层牢固,均匀、平整、光亮,寿命长;
(2)该过程节约了水资源,无污染物排放,过程环保且易于操作;
(3)整体设备占地面积小,运营成本低,适于工业化生产。
本发明适用于金属制品的表面脱脂、去杂及镀锌处理。
本发明下面将结合具体实施例作进一步详细说明。
具体实施方式
下述实施例中所用的实验方法,如无特殊说明,均为常规的实验方法,所用的试剂,如无特殊说明,均可从商业渠道得到。
实施例1 铁丝脱脂、去杂的方法及应用其镀锌的生产工艺
本实施例为一种铁丝无酸洗镀锌的生产工艺,按照如下的步骤顺序进行:
(11)拉丝工序
将拉丝液倒入拉丝机中,把模具按顺序放好,尾模具放在拉丝机的铁壁上,拉拔后得A1;
上述所用的拉丝油,
石蜡油40g、棕榈油90 g、单油酸甘油酯15 g、氧化锌0.5g、对羟基苯甲酸丁酯3g、硅烷偶联剂KH550 0.3g、三乙醇胺1.5g、咪唑啉0.5g、N,N’—二亚水杨丙二胺3g、硫辛酸2g、助剂2;
(12)前置工序
将体积比为3:1的H2和N2的混合气体,不断通入平式高温炉内,将炉内的空气置换完全后,将A置于高温炉内,高温炉先依次经过两段升温阶段,第一升温阶段由室温加热至300℃,保温3min,第二升温阶段由300℃升温至550℃,保温3min,再经过降温阶段降温至450℃,保温5min,铁丝脱脂、去杂后,得B1;
(12)冷却工序
在无氧环境下,利用水冷方式将B1温度降至室温,得C1;
(13)镀锌工序
将C1置于镀锌池中,镀锌后工件出池,镀锌过程以及镀锌中所使用的试剂、镀锌方法均应用现有的试剂、镀锌方法;
(14)干燥工序
将D1进行干燥后,得镀锌后的铁丝成品。
将D1利用镀锌工序的余热通过瓷模具定型、干燥后,得成品。
本实施例工件的脱脂、去杂效果佳,生产的镀锌铁丝成品镀层牢固,均匀、平整、光亮,铁丝的弯折度和硬度适配好,寿命长;该过程节约了水资源,无污染物排放,过程环保且易于操作,整体设备占地面积小,运营成本低,适于工业化生产。
实施例2-6 铁丝脱脂、去杂的方法及应用其镀锌的生产工艺
本实施例分别为一种铁丝脱脂、去杂的方法及应用其镀锌的生产工艺,该生产工艺与实施例1相同,镀锌工序为现有的镀锌技术,不同之处仅在于:生产过程中相应的技术参数不同,具体的技术参数见下表。
实施例2-5中提供的工件的脱脂、去杂方式效果佳,生产的镀锌铁丝成品镀层牢固,均匀、平整、光亮,铁丝的弯折度和硬度适配好,寿命长;该过程节约了水资源,无污染物排放,过程环保且易于操作,整体设备占地面积小,运营成本低,适于工业化生产。
实施例1-5,仅是本发明的较佳实施例而已,并非是对本发明所作的其它形式的限定,任何熟悉本专业的技术人员可能利用上述技术内容作为启示加以变更或改型为等同变化的等效实施例。但凡是未脱离本发明权利要求的技术实质,对以上实施例所作出的简单修改、等同变化与改型,仍属于本发明权利要求保护的范围。
实施例2-5中提供的工件的脱脂、去杂方式效果佳,生产的镀锌铁丝成品镀层牢固,均匀、平整、光亮,铁丝的弯折度和硬度适配好,寿命长;该过程节约了水资源,无污染物排放,过程环保且易于操作,整体设备占地面积小,运营成本低,适于工业化生产。
实施例1-5,仅是本发明的较佳实施例而已,并非是对本发明所作的其它形式的限定,任何熟悉本专业的技术人员可能利用上述技术内容作为启示加以变更或改型为等同变化的等效实施例。但凡是未脱离本发明权利要求的技术实质,对以上实施例所作出的简单修改、等同变化与改型,仍属于本发明权利要求保护的范围。
Claims (8)
1.一种铁丝脱脂、去杂的方法,其特征在于:铁丝通过拉丝油进行拉拔后,置于无氧的高温炉内,不断通入还原性气体,对铁丝进行脱脂、去杂。
2.根据权利要求1所述的铁丝脱脂、去杂的方法,其特征在于步骤(1)中,所述的拉丝油按照重量份数计包含如下成分组成:
石蜡油40-55份、棕榈油90-100份、单油酸甘油酯10-15份、氧化锌0.1-0.7份、对羟基苯甲酸丁酯3-5份、硅烷偶联剂KH550 0.3份、三乙醇胺0.7-1.5份、咪唑啉0.5份、N,N’—二亚水杨丙二胺3份、硫辛酸1.5-2份、助剂2份。
3.根据权利要求1所述的铁丝脱脂、去杂的方法,其特征在于:所述的高温炉先依次经过升温阶段,由室温加热至550℃,保温3min,再经过降温阶段降温至450℃,保温5min,最后自然冷却至室温。
4.根据权利要求3所述的铁丝脱脂、去杂的方法,其特征在于:所述的升温阶段为两个阶段,
第一阶段由室温升温至300℃;
第二阶段由300℃升温至500℃,保温3min。
5.根据权利要求1所述的铁丝脱脂、去杂的方法,其特征在于:所述步骤(1)中,还原性气体为CO或H2中的一种。
6.根据权利要求1所述的铁丝脱脂、去杂的方法,其特征在于:所述步骤(1)中,还原性气体为CO和H2的混合气体。
7.根据权利要求1所述的铁丝脱脂、去杂的方法,其特征在于:所述步骤(1)中,还原性气体是体积比为3:1的H2和N2的混合气体。
8.一种应用1-7中任意一项所述的铁丝脱脂、去杂的方法的铁丝镀锌生产工艺,其特征在于该生产工艺按照如下的步骤顺序依次进行:
⑴拉丝工序
铁丝工件经过拉丝油拉拔后,得A;
⑵前置工序
将A置于无氧高温炉内,不断通入还原性气体,脱脂、去杂后,得B;
⑶冷却工序
在无氧环境下,通过水冷或者自然冷却的方式,将B温度降至室温,得C;
⑷镀锌工序
将C置于镀锌池中,镀锌后工件出池,得D;
⑸干燥工序
将D进行干燥后,得镀锌后的铁丝成品。
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