CN107190260B - A kind of anti-corrosion heat insulating coat system and preparation method thereof - Google Patents

A kind of anti-corrosion heat insulating coat system and preparation method thereof Download PDF

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CN107190260B
CN107190260B CN201710372358.0A CN201710372358A CN107190260B CN 107190260 B CN107190260 B CN 107190260B CN 201710372358 A CN201710372358 A CN 201710372358A CN 107190260 B CN107190260 B CN 107190260B
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powder
insulation layer
compound
coating
spraying
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CN107190260A (en
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黄国胜
胡旋烨
李相波
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725th Research Institute of CSIC
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725th Research Institute of CSIC
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    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • 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
    • C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
    • C23C28/32—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer
    • C23C28/321—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer with at least one metal alloy layer
    • C23C28/3215—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer with at least one metal alloy layer at least one MCrAlX layer
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • 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
    • C23C24/00—Coating starting from inorganic powder
    • C23C24/02—Coating starting from inorganic powder by application of pressure only
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • 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
    • C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
    • C23C28/34—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates
    • C23C28/345—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates with at least one oxide layer
    • C23C28/3455—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates with at least one oxide layer with a refractory ceramic layer, e.g. refractory metal oxide, ZrO2, rare earth oxides or a thermal barrier system comprising at least one refractory oxide layer
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • 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
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
    • C23C4/06—Metallic material
    • C23C4/073—Metallic material containing MCrAl or MCrAlY alloys, where M is nickel, cobalt or iron, with or without non-metal elements
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • 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
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
    • C23C4/06—Metallic material
    • C23C4/08—Metallic material containing only metal elements
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • 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
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
    • C23C4/10—Oxides, borides, carbides, nitrides or silicides; Mixtures thereof
    • C23C4/11—Oxides
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • 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
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • 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
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
    • C23C4/134—Plasma spraying
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T50/00—Aeronautics or air transport
    • Y02T50/60—Efficient propulsion technologies, e.g. for aircraft

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  • Chemical & Material Sciences (AREA)
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  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Inorganic Chemistry (AREA)
  • Ceramic Engineering (AREA)
  • Coating By Spraying Or Casting (AREA)

Abstract

The invention belongs to the anti-corrosion heat-barrier material technical fields of Surface Engineering, more particularly to a kind of anti-corrosion heat insulating coat system and preparation method thereof, the main structure of anti-corrosion heat insulating coat system includes compound prime coat, erosion resistant coating, thermal insulation layer and confining bed, the specific embodiment of anti-corrosion heat insulating coat system preparation method includes pretreatment matrix, prepare compound prime coat, prepare erosion resistant coating, it prepares thermal insulation layer and prepares confining bed totally five steps, it is pre-processed first on aluminum substrate surface, recycle low pressure cold spraying preparation bonding erosion resistant coating, then the excessive layer of gradient/gradual change bonding is prepared using high pressure cold spraying method, finally ceramic coating is prepared using plasma spraying method；Its is anti-corrosion, and heat insulating coat architecture is simple, anti-corrosion good heat-insulation effect, and use environment is friendly, life cycle is long, and preparation method is easy to operate, and scientific in principle is reliable, safety and environmental protection improves the bond strength of coating system interlayer, strengthens the corrosion compatibility of coating system and matrix.

Description

A kind of anti-corrosion heat insulating coat system and preparation method thereof
Technical field:
The invention belongs to the anti-corrosion heat-barrier material technical fields of Surface Engineering, and in particular to a kind of anti-corrosion heat insulating coat system and Preparation method sprays anti-corrosion heat insulating coat in aluminum alloy surface, so that the component of aluminum alloy material obtains in marine environment It is widely applied.
Background technique:
Aluminium alloy is with its specific strength and specific stiffness height and damping good series of advantages in Aeronautics and Astronautics, automobile, electricity The industries such as son and household electrical appliances have extremely important application value and wide application prospect, but because of the chemical property of aluminium alloy Vivaciously, it is low to be subject to burn into hardness, not wear-resisting, fusing point is low, heat resistance is poor, limits aluminium alloy grinding in heat resistanceheat resistant environment Study carefully slow with application development；Surface treatment can be efficiently modified the surface propertys of various aluminium alloys, improve corrosion-resistant, abrasion performance and resistance to Hot property, most popular means of defence are that thermal barrier coating is sprayed on alloy matrix aluminum, the preparation method packet of thermal barrier coating Include electro beam physics vapour deposition method (EB-PVD), flame-spraying, plasma spraying (APS), supersonic flame spraying (HVOF) With detonation flame spraying etc., wherein plasma spraying, powder flame spraying, supersonic flame spraying and detonation flame spraying belong to thermal jet Painting technology, difference are that melting particle in the spray gun of different structure is sprayed, thermal spraying The principle of technology is to be fused into blow after molten state or semi-molten state by air-flow by dusty spray using Combustion Energy or electric energy to make It is atomized, and is ejected into matrix surface at a high speed and forms spray coating；It is main between particle between spray coating and matrix and in spray coating It is followed by pass through microcell metallurgical bonding and chemical bonds by the mechanical types connection such as inlaying, being engaged or clog.Coating The middle material as working lining is mainly Al2O3(aluminium oxide) or ZrO2The ceramics of (zirconium dioxide) contour performance, low thermal conductivity Material；The introducing of composite coating makes the cohesive strength of coating and the bond strength of coating and matrix all be significantly improved, and And the thermal stress in coating is eased, to enhance the thermal shock resistance and service life of coating.Currently, thermal boundary applies Layer is with MCrAlY (adhesive layer)+ZrO2For Main System, wherein M (metal) is the mixing group of Co (cobalt) or Ni (nickel) or both Part, adhesive coating and matrix and overstress can be played the role of, ZrO2By adding YO2(yttrium oxide) plays heat-insulated and steady Determine the effect of volume, the Al (aluminium) in MCrAlY is by generating Al2O3(the thermally grown layer of TGO), which plays, prevents oxygen diffusible oxydation base The effect of body.
Since heat spraying method is the operation carried out at high temperature, so the thermal damage to matrix is big, and thermal spraying side The coating porosity of method preparation is higher, and coating is chronically in marine environment inevitably by the corrosion of marine environment； In salt mist environment, salt fog reaches the adhesive layer and matrix of matrix along hole, equally will cause adhesive layer and matrix by ocean The corrosion of environment, corrosion product, which will lead to the decline of insulating ceramic layer binding force, makes coating finally fall off failure；Meanwhile MCrAlY+ZrO2Coating system shows that its corrosion resisting property (non-heat erosion) is poor in many application examples, is not suitable for ocean ring The corrosion protection in border, thus, designing new suitable marine environment corrosion-resistant coating system becomes urgent need, related patents text Sintering thermal expansion coating in offering be in Al alloys andMg alloys and its composite material surface, first pass through silicate and phosphate system etc. from Daughter electrolyte makes Al alloys andMg alloys and its composite material surface electrolytic oxidation filming medium, then in plasma electrolysis oxidation film base With the electrophoretic deposition of electrophoretic deposition electrolyte on plinth, Al alloys andMg alloys and its composite material surface thermal barrier coating is made, still not It can solve the big problem of the coefficient of expansion, do not promoted the use of.Therefore, R & D design one kind is for aluminium alloy in marine environment Anti-corrosion heat insulating coat system and preparation method thereof improves the performance of aluminum alloy surface coating based on cold spray technique, has good Social and economic benefit.
Summary of the invention:
It is an object of the invention to overcome in the prior art aluminum alloy surface have the shortcomings that thermal barrier coating antiseptic property is poor, Heat insulating coat system and preparation method thereof that a kind of aluminium alloy of R & D design is anti-corrosion, processability is good resistance on alloy matrix aluminum Hot coating keeps matrix excessively steady to the physical parameter of coating, and the corruption of splashing seawater can be resisted when using in marine environment Erosion and thermal shock destroy.
To achieve the goals above, the main structure of anti-corrosion heat insulating coat system of the present invention includes compound bottoming Layer, erosion resistant coating, thermal insulation layer and confining bed；The upper surface of alloy matrix aluminum is coated with compound prime coat, the surface of compound prime coat It is coated with erosion resistant coating, the surface of erosion resistant coating is coated with thermal insulation layer, and the surface of thermal insulation layer is coated with confining bed；Compound prime coat be by What Ni powder was prepared after mixing with Al powder using the upper surface that low pressure cold spray process is sprayed on alloy matrix aluminum, wherein The weight percent of Ni is 10-20%, so that the thermal expansion coefficient phase of the thermal expansion coefficient of compound prime coat and alloy matrix aluminum Closely, compound prime coat with a thickness of 50-200 μm；Erosion resistant coating is after mixing Zn powder with Ni powder using cold spraying or thermal jet What the surface that painting technique is sprayed on compound prime coat was prepared, wherein the weight percent of Ni is 20-30%, the painting of erosion resistant coating With a thickness of 80-120 μm, erosion resistant coating has the function of that alloy matrix aluminum and external environment is isolated layer；Thermal insulation layer is compound by 4-8 layers Thermal insulation layer is constituted, and compound heat-insulation layer is by the mixed-powder and Al of M powder, Cr powder and Al powder2O3Or ZrO2After powder mixing It is prepared using the surface that high pressure cold spray process is sprayed on erosion resistant coating, wherein M powder is Co powder or Ni powder or Co The mixing powder of powder and Ni powder, from 80% to 0% transition of weight percent of the MCrAl powder in thermal insulation layer, every interlayer Amount of transition less than 30%, the Al on most surface layer2O3Powder or ZrO2Powder is sprayed using plasma spray coating process, compound heat-insulation layer With a thickness of 50-80 μm, thermal insulation layer with a thickness of 200-640 μm, thermal insulation layer covers gradient and single composition variation；Closing Layer is by Al2O3Powder or ZrO2Powder mixed with sealer after using hot-spraying technique be sprayed on thermal insulation layer surface preparation and At, wherein Al2O3Powder or ZrO2The weight percent of powder be 20-60%, confining bed with a thickness of 200-300 μm, closing Layer has the function of for the heat in environment and corroding being isolated with alloy matrix aluminum.
The specific embodiment of anti-corrosion heat insulating coat system preparation method of the present invention includes pretreatment matrix, preparation Compound prime coat prepares erosion resistant coating, prepares thermal insulation layer and prepares confining bed totally five steps:
(1) it pre-processes matrix: spray will be passed through by the compressed air that the pressure of oil water separator and surge tank is 0.6MPa Rifle carries out sandblasting activation derusting using surface of the Brown Alundum to alloy matrix aluminum, and the roughness of alloy matrix aluminum is 20-80um, The surface appearance uniform for estimating alloy matrix aluminum is consistent, without visible grease, dirt, oxide skin, hole, sharpened surface, gap After the attachment of painting layer, processing is dusted using surface of the dust catcher to alloy matrix aluminum, completes the pre- place of matrix Reason；
(2) compound prime coat is prepared: in workshop or the place of compound sets requirement by step (1) pretreated aluminium alloy For substrate preheating to 90-120 DEG C, using low pressure cold spray process by partial size is 10-30 μm for 5-20 μm of Ni powder and partial size The powder spray that mixes of Al powder forms the compound prime coat with a thickness of 50-80 μm in the upper surface of alloy matrix aluminum, spray coated Spraying temperature in journey is 350-550 DEG C, and the linear distance between spray gun and alloy matrix aluminum is 5-50mm, spray gun and aluminium alloy The angle of angle is 60-90 ° between matrix, and the powder feeding rate of spray gun is less than 2.5g/s, and the movement speed of spray gun is matched with powder feeding rate, In spraying process using pressure greater than the compressed air of 0.7MPa, nitrogen, helium or more than several gases mixture to aluminium Alloy substrate is sprayed, and the preparation of compound prime coat is completed；
(3) it prepares erosion resistant coating: checking the appearance of compound prime coat, it is ensured that compound prime coat is without hole, sharpened surface and seam The alloy matrix aluminum for being coated with compound prime coat is preheating to 90-120 DEG C, using flame-spraying, electric arc spraying or cold spraying by gap The mixing powder spray of Zn powder and Ni powder is formed ZnNi composite coating or ZnNi by technique on the surface of compound prime coat Alloy coat, in spraying process, the angle of angle is 60-90 ° between spray gun and alloy matrix aluminum, completes the preparation of erosion resistant coating；
(4) prepare thermal insulation layer: use plasma spraying, supersonic flame spraying and high pressure cold spray process by partial size for The Al that 10-50 μm of MCrAl powder and partial size is 20-150 μm2O3Powder mixes the MCrAl that powder or partial size are 10-50 μm The ZrO that powder and partial size are 20-150 μm2The mixing powder spray of powder formed on the surface of erosion resistant coating 4-8 layers it is compound every Thermosphere, wherein M is the mixing powder of Co powder or Ni powder or Co powder and Ni powder, the MCrAl powder in compound heat-insulation layer From 80% to 0% transition of weight percent, the amount of transition of every interlayer is less than 30%, the Al on most surface layer2O3Powder or ZrO2Powder It is sprayed using plasma spray coating process, the thickness in monolayer of compound heat-insulation layer is 50-80 μm, and 4-8 layers of compound heat-insulation layer forms thickness The thermal insulation layer that degree is 200-640 μm, completes the preparation of thermal insulation layer；
(5) it prepares confining bed: sealer according to sets requirement rush dilute, to guarantee the permeability of sealer, use Hot-spraying technique is by Al2O3Powder or ZrO2Powder with rush it is dilute after sealer mix after be sprayed on the surface of thermal insulation layer and formed With a thickness of 200-300 μm of confining bed, wherein Al2O3Powder or ZrO2The weight percent of powder is 20-60%, sealer packet The inorganic matter for including asphaltic base aluminium paste, aluminium silicone resin and silicate and chromate completes the preparation of confining bed.
Plasma spray coating process of the present invention is that the particle and distortion particle of melting or semi-molten is stacked in Metal Substrate body surface Face and form coating, particle and distortion particle stack when, it is not completely overlapped, be staggeredly stacked, moreover, particle and distortion particle fly Scanning frequency degree and temperature difference, show the particle being constantly stacked up apparent irregular, cause to stack and deposit between particle In gap, and in coating forming procedure, particle and distortion particle is changed into solid-state from molten state, and temperature constantly declines, and particle and distortion particle is fast Rapid hardening is solid, has little time to escape out of particle heap from the gas being precipitated between molten state particle, forms stomata in the coating, therefore, needs Seal treatment is carried out to the surface of coating；Low pressure cold spray process is that a kind of material surface based on aerodynamic principle changes Property new technology, using 600 DEG C of < low-temperature prewarming high pressure gas carry the scaled type Laval nozzle of powder particle formed it is super The gas-solid two-phase flow of velocity of sound hits matrix with ultrahigh speed under complete solid-state, in the whole process, since spraying temperature is low, particle Holding solid state will not occur chemical reaction and phase transformation, be not susceptible to solids expansion and oxidative phenomena, in knockout process Middle powder particle occurs plastic deformation and is closely linked to form coating, and cold air power spraying and coating can be realized under low-temperature condition Metal coating deposits, small to the heat affecting of matrix in spraying process, material is not undergone phase transition, and coating is fine and close, porosity is low, The defect of plasma spray technology is compensated for, opens new technology road to improve composite coating high temperature resistant and corrosion resistance.
Compared with prior art, the present invention being pre-processed first on aluminum substrate surface, low pressure cold spraying preparation is recycled Erosion resistant coating is bonded, then prepares the excessive layer of gradient/gradual change bonding using high pressure cold spraying method, finally utilizes plasma spraying Method prepares ceramic coating, so that alloy matrix aluminum completely cuts off completely with corrosive environment, improves the durability of alloy matrix aluminum, spray Heat input during painting is small, avoids alloy matrix aluminum and wrecks, and the compression characteristic of cold spray process is able to ascend The resistance to thermal cycling fatigue performance of coating system, to be obviously improved the anti-corrosion and temperature capacity of alloy matrix aluminum, lower layer's coating is complete At upper layer coating is carried out after spraying immediately, spray-coating surface does not have to carry out blasting treatment, and compound prime coat and thermal insulation layer cover gradient Change with single composition；Its is anti-corrosion, and heat insulating coat architecture is simple, anti-corrosion good heat-insulation effect, and use environment is friendly, the service life Period is long, and preparation method is easy to operate, and scientific in principle is reliable, safety and environmental protection, improves the bond strength of coating system interlayer, adds The strong corrosion compatibility of coating system and matrix, has good promotion and application prospect.
Detailed description of the invention:
Fig. 1 is the main structure schematic illustration of anti-corrosion heat insulating coat system of the present invention.
Fig. 2 is the thickness structure figure for the anti-corrosion heat insulating coat system that the embodiment of the present invention 1 is related to.
Fig. 3 is the crystalline phase figure for the anti-corrosion heat insulating coat system that the embodiment of the present invention 1 is related to.
Specific embodiment:
The present invention is described further by way of example and in conjunction with the accompanying drawings.
Embodiment 1:
The main structure for the anti-corrosion heat insulating coat system that the present embodiment is related to includes compound prime coat 2, erosion resistant coating 3, heat-insulated Layer 4 and confining bed 5；The upper surface of alloy matrix aluminum 1 is coated with compound prime coat 2, and the surface of compound prime coat 2 is coated with anti-corrosion Layer 3, the surface of erosion resistant coating 3 is coated with thermal insulation layer 4, and the surface of thermal insulation layer 4 is coated with confining bed 5；Compound prime coat 2 is by Ni powder End uses low pressure cold spray process to be sprayed on what the upper surface of alloy matrix aluminum 1 was prepared after mixing with Al powder, wherein Ni Weight percent be 10-20% so that the thermal expansion coefficient phase of the thermal expansion coefficient of compound prime coat 2 and alloy matrix aluminum 1 Closely, compound prime coat 2 with a thickness of 50-200 μm；Erosion resistant coating 3 is after mixing Zn powder with Ni powder using cold spraying or heat What the surface that spraying process is sprayed on compound prime coat 2 was prepared, wherein the weight percent of Ni is 20-30%, erosion resistant coating 3 Coating layer thickness be 80-120 μm, erosion resistant coating 3 has the function of that alloy matrix aluminum 1 and external environment is isolated；Thermal insulation layer 4 is by 4- 8 layers of compound heat-insulation layer are constituted, and compound heat-insulation layer is by the mixed-powder and Al of M powder, Cr (chromium) powder and Al powder2O3(oxidation Aluminium) or ZrO2It is prepared after powder mixing using the surface that high pressure cold spray process is sprayed on erosion resistant coating 3, wherein M powder For Co powder or the mixing powder of Ni powder or Co powder and Ni powder, the weight percent of the MCrAl powder in thermal insulation layer 4 from 80% to 0% transition, and the amount of transition of every interlayer is less than 30%, the Al on most surface layer2O3Powder or ZrO2Powder uses plasma spraying Technique spraying, compound heat-insulation layer with a thickness of 50-80 μm, thermal insulation layer 4 with a thickness of 200-640 μm, thermal insulation layer 4 covers gradient Change with single composition；Confining bed 5 is by Al2O3Powder or ZrO2Powder is sprayed after mixing with sealer using hot-spraying technique It is coated in what the surface of thermal insulation layer 4 was prepared, wherein Al2O3Powder or ZrO2The weight percent of powder is 20-60%, closing Layer 5 with a thickness of 200-300 μm, confining bed 5 has the function of for the heat in environment and corroding being isolated with alloy matrix aluminum 1.
The specific embodiment for the anti-corrosion heat insulating coat system preparation method that the present embodiment is related to includes pretreatment matrix, system Standby compound prime coat 2 prepares erosion resistant coating 3, prepares thermal insulation layer 4 and prepares totally five steps of confining bed 5:
(1) it pre-processes matrix: spray will be passed through by the compressed air that the pressure of oil water separator and surge tank is 0.6MPa Rifle carries out sandblasting activation derusting using surface of the Brown Alundum to alloy matrix aluminum 1, and the roughness of alloy matrix aluminum 1 is 20- 80um, the surface appearance uniform for estimating alloy matrix aluminum 1 is consistent, without visible grease, dirt, oxide skin, hole, sharp table After the attachment in face, gap and painting layer, processing is dusted using surface of the dust catcher to alloy matrix aluminum 1, completes base The pretreatment of body；
(2) it prepares compound prime coat 2: closing the pretreated aluminium of step (1) in workshop or the place of compound sets requirement Auri body 1 is preheating to 90-120 DEG C, and using low pressure cold spray process by partial size is 10-30 μm for 5-20 μm of Ni powder and partial size The powder spray that mixes of Al powder formed in the upper surface of alloy matrix aluminum 1 with a thickness of 50-80 μm of compound prime coat 2, spray Spraying temperature during painting is 350-550 DEG C, and the linear distance between spray gun and alloy matrix aluminum 1 is 5-50mm, spray gun with The angle of angle is 60-90 ° between alloy matrix aluminum 1, and the powder feeding rate of spray gun is less than 2.5g/s, the movement speed and powder feeding of spray gun Rate matching, in spraying process using compressed air of the pressure greater than 0.7MPa, nitrogen, helium or more than several gases mixing Object sprays alloy matrix aluminum 1, completes the preparation of compound prime coat 2；
(3) prepare erosion resistant coating 3: checking the appearance of compound prime coat 2, it is ensured that compound prime coat 2 without hole, sharpened surface and The alloy matrix aluminum 1 for being coated with compound prime coat 2 is preheating to 90-120 DEG C by gap, using flame-spraying, electric arc spraying or cold Spraying process by the mixing powder spray of Zn powder and Ni powder formed on the surface of compound prime coat 2 ZnNi composite coating or ZnNi alloy coat, in spraying process, the angle of angle is 60-90 ° between spray gun and alloy matrix aluminum 1, completes erosion resistant coating 3 Preparation；
(4) prepare thermal insulation layer 4: use plasma spraying, supersonic flame spraying and high pressure cold spray process by partial size for The Al that 10-50 μm of MCrAl powder and partial size is 20-150 μm2O3Powder mixes the MCrAl that powder or partial size are 10-50 μm The ZrO that powder and partial size are 20-150 μm2The mixing powder spray of powder forms 4-8 layers compound on the surface of erosion resistant coating 3 Thermal insulation layer, wherein M is the mixing powder of Co powder or Ni powder or Co powder and Ni powder, the MCrAl powder in compound heat-insulation layer From 80% to 0% transition of weight percent at end, the amount of transition of every interlayer is less than 30%, the Al on most surface layer2O3Powder or ZrO2Powder End is sprayed using plasma spray coating process, and the thickness in monolayer of compound heat-insulation layer is 50-80 μm, and 4-8 layers of compound heat-insulation layer is formed With a thickness of 200-640 μm of thermal insulation layer 4, the preparation of thermal insulation layer 4 is completed；
(5) it prepares confining bed 5: sealer according to sets requirement rush dilute, to guarantee the permeability of sealer, use Hot-spraying technique is by Al2O3Powder or ZrO2Powder with rush it is dilute after sealer mix after be sprayed on the surface of thermal insulation layer 4 and formed With a thickness of 200-300 μm of confining bed 5, wherein Al2O3Powder or ZrO2The weight percent of powder is 20-60%, sealer packet The inorganic matter of asphaltic base aluminium paste, aluminium silicone resin and silicate and chromate is included, the preparation of confining bed 5 is completed.
The plasma spray coating process that the present embodiment is related to is that the particle and distortion particle of melting or semi-molten is stacked in metallic matrix Surface and form coating, particle and distortion particle is not completely overlapped when stacking, and is staggeredly stacked, moreover, particle and distortion particle Flying speed and temperature difference, show the particle being constantly stacked up apparent irregular, cause to stack between particle There are gaps, and in coating forming procedure, particle and distortion particle is changed into solid-state from molten state, and temperature constantly declines, particle and distortion particle Quickly solidification, has little time to escape out of particle heap, forms stomata in the coating from the gas being precipitated between molten state particle, therefore, It needs to carry out Seal treatment to the surface of coating；Low pressure cold spray process is a kind of material surface based on aerodynamic principle Technology for modifying carries the scaled type Laval nozzle of powder particle using 600 DEG C of < of low-temperature prewarming high pressure gas and is formed The gas-solid two-phase flow of supersonic speed hits matrix with ultrahigh speed under complete solid-state, in the whole process, since spraying temperature is low, grain Son holding solid state will not occur chemical reaction and phase transformation, be not susceptible to solids expansion and oxidative phenomena, hit Powder particle occurs to be plastically deformed and is closely linked to form coating in journey, and cold air power spraying and coating can be realized under low-temperature condition Metal coating deposits, small to the heat affecting of matrix in spraying process, material is not undergone phase transition, and coating is fine and close, porosity It is low, the defect of plasma spray technology is compensated for, opens new technology road to improve composite coating high temperature resistant and corrosion resistance.
Embodiment 2:
The main structure for the anti-corrosion heat insulating coat system that the present embodiment is related to includes compound prime coat 2, erosion resistant coating 3, heat-insulated Layer 4 and confining bed 5；The upper surface of alloy matrix aluminum 1 is coated with compound prime coat 2, and the surface of compound prime coat 2 is coated with anti-corrosion Layer 3, the surface of erosion resistant coating 3 is coated with thermal insulation layer 4, and the surface of thermal insulation layer 4 is coated with confining bed 5；Compound prime coat 2 is by Ni powder What end was prepared after mixing with Al powder using the upper surface that low pressure cold spray process is sprayed on alloy matrix aluminum 1；Erosion resistant coating 3 It is to be prepared after mixing Zn powder with Ni powder using the surface that flame spraying process is sprayed on compound prime coat 1；Every Thermosphere 4 be by Co powder, Ni powder, Cr (chromium) powder, Al powder and Y (yttrium) powder mixed-powder and ZrO2According to weight ratio To be sprayed on what the surface of erosion resistant coating 3 was prepared using supersonic flame spraying technique after 1:1 mixing, wherein most surface ZrO2Coating uses plasma spray coating process；Confining bed 5 is ZrO2Powder is sprayed on after mixing with sealer using hot-spraying technique What the surface of thermal insulation layer 4 was prepared；Compound prime coat 2 with a thickness of 120 μm, erosion resistant coating 3 with a thickness of 100 μm, thermal insulation layer 4 With a thickness of 540 μm and confining bed 5 with a thickness of 200 μm, anti-corrosion heat insulating coat system with a thickness of 960 μm.
The anti-corrosion heat insulating coat system that the present embodiment is related to shows between each coating in laboratory progress experimental verification Bond strength be greater than 30MPa, the surfaces of 1500 DEG C of flame thermal ablation 30s rear enclosed layers 5 changes colour without scaling loss, after salt fog 1500h The surface of confining bed 5 is without white rust.

Claims (2)

1. a kind of anti-corrosion heat insulating coat system, it is characterised in that main structure includes compound prime coat, erosion resistant coating, thermal insulation layer and envelope Close layer；The upper surface of alloy matrix aluminum is coated with compound prime coat, and the surface of compound prime coat is coated with erosion resistant coating, erosion resistant coating Surface is coated with thermal insulation layer, and the surface of thermal insulation layer is coated with confining bed；Compound prime coat is after mixing Ni powder with Al powder It is prepared using the upper surface that low pressure cold spray process is sprayed on alloy matrix aluminum, wherein the weight percent of Ni is 10- 20%, so that the similar thermal expansion coefficient of the thermal expansion coefficient of compound prime coat and alloy matrix aluminum, the thickness of compound prime coat It is 50-200 μm；Erosion resistant coating is to be sprayed on compound bottoming using cold spraying or hot-spraying technique after mixing Zn powder with Ni powder What the surface of layer was prepared, wherein the weight percent of Ni is 20-30%, and the coating layer thickness of erosion resistant coating is 80-120 μm, is prevented Rotten layer has the function of that alloy matrix aluminum and external environment is isolated；Thermal insulation layer is made of 4-8 layers of compound heat-insulation layer, compound heat-insulation Layer is by the mixed-powder and Al of M powder, Cr powder and Al powder2O3Or ZrO2High pressure cold spray process is used after powder mixing It is sprayed on what the surface of erosion resistant coating was prepared, wherein M powder is the mixing of Co powder or Ni powder or Co powder and Ni powder Powder, from 80% to 0% transition of weight percent of the MCrAl powder in thermal insulation layer, the amount of transition of every interlayer is less than 30%, most The Al on surface layer2O3Powder or ZrO2Powder using plasma spray coating process spray, compound heat-insulation layer with a thickness of 50-80 μm, it is heat-insulated Layer with a thickness of 200-640 μm, thermal insulation layer covers gradient and single composition variation；Confining bed is by Al2O3Powder or ZrO2 Powder using hot-spraying technique is sprayed on what the surface of thermal insulation layer was prepared after mixing with sealer, wherein Al2O3Powder or ZrO2The weight percent of powder is 20-60%, confining bed with a thickness of 200-300 μm, confining bed has the heat in environment The effect that amount and corrosion are isolated with alloy matrix aluminum；The sealer is asphaltic base aluminium paste, aluminium silicone resin and silicate and chromium The inorganic matter of hydrochlorate.
2. a kind of anti-corrosion heat insulating coat system preparation method, it is characterised in that specific embodiment includes pretreatment matrix, preparation Compound prime coat prepares erosion resistant coating, prepares thermal insulation layer and prepares confining bed totally five steps:
(1) it pre-processes matrix: spray gun will be passed through by the compressed air that the pressure of oil water separator and surge tank is 0.6MPa, adopted Sandblasting activation derusting is carried out with surface of the Brown Alundum to alloy matrix aluminum, the roughness of alloy matrix aluminum is 20-80um, estimates aluminium The surface appearance uniform of alloy substrate is consistent, without visible grease, dirt, oxide skin, hole, sharpened surface, gap and paint After the attachment of coating, processing is dusted using surface of the dust catcher to alloy matrix aluminum, completes the pretreatment of matrix；
(2) compound prime coat is prepared: in workshop or the place of compound sets requirement by step (1) pretreated alloy matrix aluminum It is preheating to 90-120 DEG C, uses the Al powder that partial size is 10-30 μm for 5-20 μm of Ni powder and partial size by low pressure cold spray process The powder spray that mixes at end is formed in the upper surface of alloy matrix aluminum with a thickness of 50-80 μm of compound prime coat, in spraying process Spraying temperature be 350-550 DEG C, linear distance between spray gun and alloy matrix aluminum is 5-50mm, spray gun and alloy matrix aluminum Between the angle of angle be 60-90 °, the powder feeding rate of spray gun is less than 2.5g/s, and the movement speed of spray gun is matched with powder feeding rate, spraying In the process using pressure greater than the compressed air of 0.7MPa, nitrogen, helium or more than several gases mixture to aluminium alloy Matrix is sprayed, and the preparation of compound prime coat is completed；
(3) it prepares erosion resistant coating: checking the appearance of compound prime coat, it is ensured that compound prime coat, will without hole, sharpened surface and gap The alloy matrix aluminum for being coated with compound prime coat is preheating to 90-120 DEG C, using flame-spraying, electric arc spraying or cold spray process The mixing powder spray of Zn powder and Ni powder is formed into ZnNi composite coating or ZnNi alloy on the surface of compound prime coat Coating, in spraying process, the angle of angle is 60-90 ° between spray gun and alloy matrix aluminum, completes the preparation of erosion resistant coating；
(4) it prepares thermal insulation layer: using plasma spraying, supersonic flame spraying and high pressure cold spray process by partial size for 10-50 μ The Al that the MCrAl powder and partial size of m is 20-150 μm2O3Powder mix MCrAl powder that powder or partial size are 10-50 μm with The ZrO that partial size is 20-150 μm2The mixing powder spray of powder forms 4-8 layers of compound heat-insulation layer on the surface of erosion resistant coating, Wherein M is the mixing powder of Co powder or Ni powder or Co powder and Ni powder, the weight of the MCrAl powder in compound heat-insulation layer From 80% to 0% transition of percentage, the amount of transition of every interlayer is less than 30%, the Al on most surface layer2O3Powder or ZrO2Powder use etc. The spraying of plasma spray technique, the thickness in monolayer of compound heat-insulation layer are 50-80 μm, 4-8 layer of compound heat-insulation layer formation with a thickness of 200-640 μm of thermal insulation layer completes the preparation of thermal insulation layer；
(5) prepare confining bed: sealer according to sets requirement rush it is dilute, to guarantee the permeability of sealer, using thermal jet Technique is applied by Al2O3Powder or ZrO2Powder with rush it is dilute after sealer mix after be sprayed on the surface of thermal insulation layer and form thickness For 200-300 μm of confining bed, wherein Al2O3Powder or ZrO2The weight percent of powder is 20-60%, and sealer includes drip The inorganic matter of green base aluminium paste, aluminium silicone resin and silicate and chromate, completes the preparation of confining bed.
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