CN107937856A - 一种耐磨疏水涂层的制备方法 - Google Patents
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Abstract
一种耐磨疏水涂层的制备方法，基体除油和喷砂毛化处理；用大气等离子喷涂方法，采用AT:PFA=1:3的混合粉末，喷涂距离90～120mm，电流600～650A，Ar流量40～60L/min，H2流量8～12L/min，送粉量 20～35g/min喷涂制备AT‑PFA底层；然后用超音速火焰喷涂方法，采用AT:PFA=3:1混合粉末，汽油流量10～15L/min，氧气流量700～900L/min，送粉量30～50g/min喷涂制备AT‑PFA面层。本发明方法充分利用AT材料和PFA材料的优点，发挥大气等离子喷涂方法和超音速火焰喷涂方法的优势制备的涂层能兼顾高耐磨性和高疏水性，效率高、成本低，能工业化生产。
Description
技术领域
本发明涉及一种金属基体表面功能涂层的制备方法。
背景技术
以荷叶为代表的表面自清洁效应，被称为“荷叶效应”，是由粗糙表面上微米-纳米复合结构的乳突以及低表面能的蜡状物质共同引起的。这些自清洁表面具有很好的疏水性能，以及较强的抗污能力，即表面污染物，如灰尘等可以被滚落的水滴带走而不留下任何痕迹。自清洁涂层具有节水、节能、防结冰等功能，是目前材料学科研究的热点之一。
基于“荷叶效应”的疏水表面，其制备途径包括利用疏水材料来构建表面粗糙结构以及在粗糙表面上修饰低表面能物质。疏水材料在国防、工农业生产和人们的日常生活中有着非常广阔的应用前景，如在卫星天线和雷达的表面清洁、潜艇水体的减阻，以及石油化工领域内管壁修饰等方面具有非常高的应用价值。
目前制备疏水表面或疏水涂层的方法有很多，总的可归纳为以下两类：一是使用低表面能物质修饰粗糙表面，二是对疏水表面进行粗糙化处理。制备疏水表面或涂层方法众多，包括激光刻蚀、静电喷涂、化学沉积、电沉积等，其中以上方法获得的疏水涂层耐磨性较差，这也是制约疏水涂层在日常生活和工业生产中难推广的主要原因。
发明内容
针对现有疏水涂层耐磨性差等缺点，本发明提供一种耐磨疏水涂层的制备方法。
所述耐磨疏水涂层的制备方法步骤如下：依次用煤油、酒精、丙酮对基体进行除油处理，然后用46号刚玉砂对基体进行喷砂毛化；采用AT(Al2O3-40wt%TiO2):PFA(可溶性聚四氟乙烯)=1:3混合粉末，喷涂距离90～120mm，电流600～650A，Ar流量40～60L/min，H2流量8～12L/min，送粉量 20～35g/min大气等离子喷涂方法喷涂底层，厚度88～96μm；然后，采用AT:PFA=3:1混合粉末，汽油流量10～15L/min，氧气流量700～900L/min，送粉量30～50g/min超音速火焰喷涂方法喷涂面层，厚度19～27μm。
本发明用大气等离子以AT:PFA=1:3混合粉末喷涂底层，然后用超音速火焰喷涂以AT:PFA=3:1混合粉末喷涂面层，发挥AT和PFA两种材料的优势，其中AT具有耐磨、耐高温、耐腐蚀等一系列优点，PFA具有表面能低以及突出的疏水性和极佳的化学稳定性。尽管PFA可单独作为疏水涂层，但因其材质较软，耐磨性和与基体结合性较差，在一定程度上限制了其应用。为了改善纯PFA涂层的耐磨性能，提高涂层与基体间的结合强度，在PFA涂层中引入AT涂层，通过大气等离子喷涂和超音速火焰喷涂的方法，可获得粗糙度较大的AT-PFA涂层(粗糙度> 6微米)，从而使涂层既有良好的疏水性、高耐磨性以及高结合强度。本发明涂层可应用于不同苛刻服役环境领域如高铁牵引机头雷达外皮防冰涂层、锂离子电池电极轧辊等。本发明所使用的喷涂技术中，大气等离子喷涂焰流温度高(等离子焰流中心温度>8000℃)可使得所有无机材料熔融，因此，采用本发明可获得高熔点陶瓷材料涂层，当喷涂AT-PFA混合粉末时，AT粉末由于密度较重，在载气的作用下可射入等离子焰流中心，使得粉末发生熔融，而PFA粉末由于密度较小，不能进入焰流中心而停留于外焰，其也会熔融，最终两熔融粉末可均匀沉积在基体表面形成耐磨疏水涂层，但等离子喷涂焰流速度低，所获涂层致密度和耐磨性有待于进一步提高。为进一步提高涂层的耐磨性能，需采用超音速火焰喷涂以高氧化铝粉末配比的混合粉末进行喷涂，目的如下：一是超音速火焰喷涂焰流温度较低(约3200℃)，不能使AT粉末熔融形成有效沉积，但能使粉末能达到超音速，对已大气等离子喷涂沉积的涂层进行夯实致密化，使得涂层更加致密。此外混合粉末中的低熔点PFA粉末则会发生熔融，并以较高的速度沉积在涂层表面，获得致密薄涂层。如果单纯采用超音速火焰喷涂沉积AT-PFA涂层，由于AT熔点较高，在基体表面不能形成扁平粒子，涂层沉积效率极低。采用本发明方法制备的AT-PFA耐磨疏水涂层如图1所示，图2为涂层的疏水性能润湿角测试，测得的润湿角为148.9°，图3为涂层的耐磨性能测试结果(对磨件为Si3N4钢球，直径为Φ4mm，摩擦半径为5mm，旋转角速度为382rpm，载荷10N，测试时间为2h)，磨痕宽度为1.14mm，表现出良好的耐磨性能。
附图说明
图1 实施例1的耐磨疏水涂层截面的扫描电子显微镜照片。
图2 实施例1的耐磨疏水涂层的润湿角测试结果。
图3 实施例1的耐磨疏水涂层的耐磨性能测试结果。
具体实施方式
下面结合具体实施例对本发明的制备方法做进一步说明。
实施例1
依次使用煤油、酒精、丙酮对基体进行除油处理，然后采用46号刚玉砂对铝合金基体表面进行喷砂毛化处理以提高涂层结合强度；首先，采用大气等离子喷涂技术，以AT:PFA=1:3混合粉末喷涂底层，喷涂距离110mm，电流630A，Ar流量45L/min，H2流量10L/min，送粉量35g/min，涂层厚度90μm；随后，采用超音速火焰喷涂以AT:PFA=3:1为混合粉末喷涂面层，汽油流量13L/min，氧气流量900L/min，送粉量45g/min，涂层厚度24μm。
实施例2
依次使用煤油、酒精、丙酮对基体进行除油处理，然后采用46号刚玉砂对铝合金基体表面进行喷砂毛化；首先，采用大气等离子喷涂技术，以AT:PFA=1:3混合粉末喷涂底层，喷涂距离90mm，电流600A，Ar流量40L/min，H2流量8L/min，送粉量 20g/min，涂层厚度88μm；随后，采用超音速火焰喷涂以AT:PFA=3:1为混合粉末喷涂面层，汽油流量10L/min，氧气流量700L/min，送粉量30g/min，涂层厚度25μm。
实施例3
依次使用煤油、酒精、丙酮对基体进行除油处理，然后采用46号刚玉砂对不锈钢基体表面进行喷砂毛化；首先，采用大气等离子喷涂技术，以AT:PFA=1:3混合粉末喷涂底层，喷涂距离120mm，电流650A，Ar流量60L/min，H2流量12L/min，送粉量 35g/min，涂层厚度91μm；随后，采用超音速火焰喷涂以AT:PFA=3:1为混合粉末喷涂面层，汽油流量15L/min，氧气流量900L/min，送粉量50g/min，涂层厚度27μm。
实施例4
依次使用煤油、酒精、丙酮对基体进行除油处理，然后采用46号刚玉砂对不锈钢基体表面进行喷砂毛化；首先，采用大气等离子喷涂技术，以AT:PFA=1:3混合粉末喷涂底层，喷涂距离100mm，电流620A，Ar流量50L/min，H2流量9L/min，送粉量 25g/min，涂层厚度93μm；随后，采用超音速火焰喷涂以AT:PFA=3:1为混合粉末喷涂面层，汽油流量11L/min，氧气流量800L/min，送粉量35g/min，涂层厚度22μm。
实施例5
依次使用煤油、酒精、丙酮对基体进行除油处理，然后采用46号刚玉砂对铸铁基体表面进行喷砂毛化；首先，采用大气等离子喷涂技术，以AT:PFA=1:3混合粉末喷涂底层，喷涂距离110mm，电流640A，Ar流量50L/min，H2流量11L/min，送粉量 30g/min，涂层厚度95μm；随后，采用超音速火焰喷涂以AT:PFA=3:1为混合粉末喷涂面层，汽油流量13L/min，氧气流量850L/min，送粉量45g/min，涂层厚度21μm。
实施例6
依次使用煤油、酒精、丙酮对基体进行除油处理，然后采用46号刚玉砂对铸铁基体表面进行喷砂毛化；首先，采用大气等离子喷涂技术，以AT:PFA=1:3混合粉末喷涂底层，喷涂距离120mm，电流650A，Ar流量40L/min，H2流量8L/min，送粉量 35g/min，涂层厚度96μm；随后，采用超音速火焰喷涂以AT:PFA=3:1为混合粉末喷涂面层，汽油流量14L/min，氧气流量750L/min，送粉量30g/min, ，涂层厚度19μm。
Claims (3)
1.一种耐磨疏水涂层的制备方法，其特征在于步骤如下：基体除油和喷砂毛化处理；用大气等离子喷涂技术制备AT-PFA底层；然后用超音速火焰喷涂技术制备AT-PFA面层。
2.根据权利要求1所述的耐磨疏水涂层的制备方法，其特征在于所述的大气等离子喷涂制备AT-PFA底层的条件是：采用AT:PFA=1:3混合粉末，喷涂距离90～120mm，电流600～650A，Ar流量40～60L/min，H2流量8～12L/min，送粉量 20～35g/min。
3.根据权利要求1所述的耐磨疏水涂层的制备方法，其特征在于所述的超音速火焰喷涂条件是：采用AT:PFA=3:1为混合粉末，汽油流量10～15L/min，氧气流量700～900L/min，送粉量30～50g/min。
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| CN115612968A (zh) * | 2022-09-22 | 2023-01-17 | 广东仕诚塑料机械有限公司 | 一种不粘辊复合涂层的制备方法及不粘辊复合涂层 |
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| CN115612968A (zh) * | 2022-09-22 | 2023-01-17 | 广东仕诚塑料机械有限公司 | 一种不粘辊复合涂层的制备方法及不粘辊复合涂层 |
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