CN109161846A - 一种铝制工件表面的复合涂层及其应用 - Google Patents
一种铝制工件表面的复合涂层及其应用 Download PDFInfo
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- CN109161846A CN109161846A CN201811246414.7A CN201811246414A CN109161846A CN 109161846 A CN109161846 A CN 109161846A CN 201811246414 A CN201811246414 A CN 201811246414A CN 109161846 A CN109161846 A CN 109161846A
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- 238000000576 coating method Methods 0.000 title claims abstract description 76
- 239000011248 coating agent Substances 0.000 title claims abstract description 70
- 239000002131 composite material Substances 0.000 title claims abstract description 55
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- 229910052782 aluminium Inorganic materials 0.000 title claims abstract description 21
- 239000000919 ceramic Substances 0.000 claims abstract description 24
- ITRNXVSDJBHYNJ-UHFFFAOYSA-N tungsten disulfide Chemical compound S=[W]=S ITRNXVSDJBHYNJ-UHFFFAOYSA-N 0.000 claims abstract description 20
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims abstract description 13
- 238000000034 method Methods 0.000 claims description 31
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 claims description 30
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- 239000010937 tungsten Substances 0.000 claims description 30
- 230000003647 oxidation Effects 0.000 claims description 16
- 238000007254 oxidation reaction Methods 0.000 claims description 16
- 238000007743 anodising Methods 0.000 claims description 10
- 239000003795 chemical substances by application Substances 0.000 claims description 10
- XNGIFLGASWRNHJ-UHFFFAOYSA-N phthalic acid group Chemical group C(C=1C(C(=O)O)=CC=CC1)(=O)O XNGIFLGASWRNHJ-UHFFFAOYSA-N 0.000 claims description 10
- -1 polytetrafluoroethylene Polymers 0.000 claims description 10
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- IRIAEXORFWYRCZ-UHFFFAOYSA-N Butylbenzyl phthalate Chemical compound CCCCOC(=O)C1=CC=CC=C1C(=O)OCC1=CC=CC=C1 IRIAEXORFWYRCZ-UHFFFAOYSA-N 0.000 claims description 8
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- BJQHLKABXJIVAM-UHFFFAOYSA-N bis(2-ethylhexyl) phthalate Chemical compound CCCCC(CC)COC(=O)C1=CC=CC=C1C(=O)OCC(CC)CCCC BJQHLKABXJIVAM-UHFFFAOYSA-N 0.000 claims description 3
- 229910002804 graphite Inorganic materials 0.000 claims description 3
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- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 claims description 2
- SIXWIUJQBBANGK-UHFFFAOYSA-N 4-(4-fluorophenyl)-1h-pyrazol-5-amine Chemical compound N1N=CC(C=2C=CC(F)=CC=2)=C1N SIXWIUJQBBANGK-UHFFFAOYSA-N 0.000 claims description 2
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 2
- MQIUGAXCHLFZKX-UHFFFAOYSA-N Di-n-octyl phthalate Natural products CCCCCCCCOC(=O)C1=CC=CC=C1C(=O)OCCCCCCCC MQIUGAXCHLFZKX-UHFFFAOYSA-N 0.000 claims description 2
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- GOOHAUXETOMSMM-UHFFFAOYSA-N Propylene oxide Chemical compound CC1CO1 GOOHAUXETOMSMM-UHFFFAOYSA-N 0.000 claims description 2
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- RLSSMJSEOOYNOY-UHFFFAOYSA-N m-cresol Chemical compound CC1=CC=CC(O)=C1 RLSSMJSEOOYNOY-UHFFFAOYSA-N 0.000 claims description 2
- 229940100630 metacresol Drugs 0.000 claims description 2
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Natural products C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 claims description 2
- 229920001778 nylon Polymers 0.000 claims description 2
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- 239000005011 phenolic resin Substances 0.000 claims description 2
- 150000002989 phenols Chemical class 0.000 claims description 2
- 125000001997 phenyl group Chemical group [H]C1=C([H])C([H])=C(*)C([H])=C1[H] 0.000 claims description 2
- XNGIFLGASWRNHJ-UHFFFAOYSA-L phthalate(2-) Chemical compound [O-]C(=O)C1=CC=CC=C1C([O-])=O XNGIFLGASWRNHJ-UHFFFAOYSA-L 0.000 claims description 2
- 239000009719 polyimide resin Substances 0.000 claims description 2
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- 239000000377 silicon dioxide Substances 0.000 claims description 2
- 238000004544 sputter deposition Methods 0.000 claims description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 2
- KFZMGEQAYNKOFK-UHFFFAOYSA-N Isopropanol Chemical compound CC(C)O KFZMGEQAYNKOFK-UHFFFAOYSA-N 0.000 claims 2
- BDAGIHXWWSANSR-UHFFFAOYSA-N methanoic acid Natural products OC=O BDAGIHXWWSANSR-UHFFFAOYSA-N 0.000 claims 2
- OSWFIVFLDKOXQC-UHFFFAOYSA-N 4-(3-methoxyphenyl)aniline Chemical compound COC1=CC=CC(C=2C=CC(N)=CC=2)=C1 OSWFIVFLDKOXQC-UHFFFAOYSA-N 0.000 claims 1
- VOWAEIGWURALJQ-UHFFFAOYSA-N Dicyclohexyl phthalate Chemical compound C=1C=CC=C(C(=O)OC2CCCCC2)C=1C(=O)OC1CCCCC1 VOWAEIGWURALJQ-UHFFFAOYSA-N 0.000 claims 1
- 239000004593 Epoxy Substances 0.000 claims 1
- ZSDJVGXBJDDOCD-UHFFFAOYSA-N benzene dioctyl benzene-1,2-dicarboxylate Chemical group C(C=1C(C(=O)OCCCCCCCC)=CC=CC1)(=O)OCCCCCCCC.C1=CC=CC=C1 ZSDJVGXBJDDOCD-UHFFFAOYSA-N 0.000 claims 1
- 235000019253 formic acid Nutrition 0.000 claims 1
- 125000005498 phthalate group Chemical group 0.000 claims 1
- 229920000058 polyacrylate Polymers 0.000 claims 1
- 229920005989 resin Polymers 0.000 claims 1
- 239000011347 resin Substances 0.000 claims 1
- DCKVNWZUADLDEH-UHFFFAOYSA-N sec-butyl acetate Chemical compound CCC(C)OC(C)=O DCKVNWZUADLDEH-UHFFFAOYSA-N 0.000 claims 1
- 239000004408 titanium dioxide Substances 0.000 claims 1
- 239000000178 monomer Substances 0.000 abstract description 13
- 230000006835 compression Effects 0.000 abstract description 9
- 238000007906 compression Methods 0.000 abstract description 9
- 230000001050 lubricating effect Effects 0.000 abstract 4
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- 239000000314 lubricant Substances 0.000 description 9
- 238000012360 testing method Methods 0.000 description 7
- 239000000853 adhesive Substances 0.000 description 4
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- 238000001755 magnetron sputter deposition Methods 0.000 description 4
- 239000000463 material Substances 0.000 description 4
- 238000001816 cooling Methods 0.000 description 3
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- 239000002253 acid Substances 0.000 description 2
- 238000000151 deposition Methods 0.000 description 2
- 230000008021 deposition Effects 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- DOIRQSBPFJWKBE-UHFFFAOYSA-N dibutyl phthalate Chemical compound CCCCOC(=O)C1=CC=CC=C1C(=O)OCCCC DOIRQSBPFJWKBE-UHFFFAOYSA-N 0.000 description 2
- FLKPEMZONWLCSK-UHFFFAOYSA-N diethyl phthalate Chemical compound CCOC(=O)C1=CC=CC=C1C(=O)OCC FLKPEMZONWLCSK-UHFFFAOYSA-N 0.000 description 2
- 238000010790 dilution Methods 0.000 description 2
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- 239000007788 liquid Substances 0.000 description 2
- 239000012528 membrane Substances 0.000 description 2
- CWQXQMHSOZUFJS-UHFFFAOYSA-N molybdenum disulfide Chemical compound S=[Mo]=S CWQXQMHSOZUFJS-UHFFFAOYSA-N 0.000 description 2
- 229910052982 molybdenum disulfide Inorganic materials 0.000 description 2
- 238000007745 plasma electrolytic oxidation reaction Methods 0.000 description 2
- 229920000647 polyepoxide Polymers 0.000 description 2
- 239000003507 refrigerant Substances 0.000 description 2
- 229910052710 silicon Inorganic materials 0.000 description 2
- 239000010703 silicon Substances 0.000 description 2
- 239000000243 solution Substances 0.000 description 2
- 230000003746 surface roughness Effects 0.000 description 2
- 238000010998 test method Methods 0.000 description 2
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 1
- 239000005864 Sulphur Substances 0.000 description 1
- 238000004378 air conditioning Methods 0.000 description 1
- 150000001336 alkenes Chemical class 0.000 description 1
- 239000010407 anodic oxide Substances 0.000 description 1
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- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 229910052961 molybdenite Inorganic materials 0.000 description 1
- JRZJOMJEPLMPRA-UHFFFAOYSA-N olefin Natural products CCCCCCCC=C JRZJOMJEPLMPRA-UHFFFAOYSA-N 0.000 description 1
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
- 235000013324 preserved food Nutrition 0.000 description 1
- 238000013000 roll bending Methods 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
- 239000002344 surface layer Substances 0.000 description 1
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- 238000013519 translation Methods 0.000 description 1
Classifications
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- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
- C25D11/00—Electrolytic coating by surface reaction, i.e. forming conversion layers
- C25D11/02—Anodisation
- C25D11/026—Anodisation with spark discharge
-
- 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
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/06—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the coating material
- C23C14/0623—Sulfides, selenides or tellurides
-
- 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
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/22—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
- C23C14/34—Sputtering
- C23C14/35—Sputtering by application of a magnetic field, e.g. magnetron sputtering
-
- 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
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/58—After-treatment
- C23C14/5806—Thermal treatment
-
- 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
- C23C26/00—Coating not provided for in groups C23C2/00 - C23C24/00
-
- 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
- C23C28/04—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 only coatings of inorganic non-metallic material
-
- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
- C25D11/00—Electrolytic coating by surface reaction, i.e. forming conversion layers
- C25D11/02—Anodisation
- C25D11/04—Anodisation of aluminium or alloys based thereon
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Materials Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Mechanical Engineering (AREA)
- Electrochemistry (AREA)
- Physics & Mathematics (AREA)
- Thermal Sciences (AREA)
- Inorganic Chemistry (AREA)
- Rotary Pumps (AREA)
- Applications Or Details Of Rotary Compressors (AREA)
Abstract
本发明涉及复合涂层技术领域,具体涉及一种铝制工件表面复合涂层及其应用,在铝制工件的表面设置有Al2O3基陶瓷硬质耐磨层,并在其上设置有二硫化钨层。设置本发明的复合涂层,该复合涂层的氧化铝基陶瓷硬质耐磨层的硬度高,粗糙度小,改善了工件的耐磨性能;其二是二硫化钨单体润滑层填充了氧化铝基陶瓷硬质耐磨层的微孔,降低了氧化铝陶瓷硬质耐磨层的粗糙度,摩擦系数小;复合涂层的膜层均匀性好,结合力强,解决了高压重载工况下复合涂层中单体润滑层易失效的问题,其三是二硫化钨单体润滑层膜层薄,减少了涡旋压缩机动涡旋盘和静涡旋盘在工作过程中因复合涂层的单体润滑层磨损后而导致的泄露量,使冷量大幅提升,从而提升压缩机的压缩性能。
Description
技术领域
本发明涉及复合涂层技术领域,具体涉及一种铝制工件表面的复合涂层及其应用。
背景技术
涡旋压缩机由固定的渐开线静涡旋盘和呈偏心回旋平动的渐开线动涡旋盘组成的可变压缩容积的压缩机,动涡旋盘及静涡旋盘作为涡旋压缩机中最重要的摩擦副,两者的材质、结构、表面涂层及啮合精度直接决定着压缩腔的密封性,气体的压缩量受影响最大,进而影响到整机的性能和可靠性。
目前绝大多数涡旋压缩机被应用到车用空调系统和空气压缩机系统中,车用空调压缩机及空气压缩机的工况和使用环境较为恶劣,其中无油润滑涡旋空气压缩机中只能依靠空气来对动涡旋盘和静涡旋盘进行冷却,因此要求动涡旋盘和静涡旋盘能快速降温。为提高泵体耐磨性及可靠性,动、静涡旋盘的材质大多为轻质、高强度、耐磨的高硅铸造或锻造铝合金,为避免摩擦副为相同金属时易产生粘着磨损的情况,为使压缩机的铝合金动、静涡旋盘的磨合期更短、啮合精度更高、耐磨性能更好,需对动、静涡旋盘的局部或全部表面涂覆硬质耐磨润滑复合涂层现有的复合涂层表面的单体润滑层大多为PTFE或MoS2或有机硅,而这些单体润滑层在高温重载下的耐磨性较差,膜层较厚,膜层的均匀性也不好,该单体润滑层脱落后会使涡旋压缩机中动涡旋盘和静涡旋盘的配合间隙加大,进而影响到涡旋压缩机的压缩性能。所以表面复合涂层的类型、表面粗糙度、硬度、结合力、均匀性和耐磨性等都会直接影响到压缩机整机的性能及可靠性。
现有专利申请号为200920106784.0,专利名称为铝制真空泵腔体改进结构的发明专利,公开了一种铝制真空泵腔体改进结构,包括铝制泵腔,所述铝制泵腔的内表面层为硬质阳极氧化铝层和填充设置在所述硬质阳极氧化铝层表面的聚四氟乙烯层,所述硬质阳极氧化铝层表面有多个微孔,其中所述聚四氟乙烯层密封填充设置在所述微孔内。该专利中的润滑涂层聚四氟乙烯在高温重载的工况下的失效比较严重,在预磨期会使冷冻机油发黑,未能使压缩机泵体在运行前期达到预磨的效果。
发明内容
为了解决现有技术中存在的润滑层在高温重载工况下会失效的问题,本发明提出了一种新的铝制工件表面复合涂层及其应用,通过在铝制工件表面设置该复合涂层,降低了涡旋压缩机中涡旋盘磨合初期的摩擦系数,提高了高压重载工况下复合涂层中单体润滑层的稳定性。
本发明的具体技术方案如下:
一种铝制工件表面的复合涂层,其在铝制工件的表面设置有Al2O3基陶瓷硬质耐磨层,并在其上涂覆有上层二硫化钨层。
其中,所述Al2O3基陶瓷硬质耐磨层为硬质阳极氧化或微弧氧化得到。
其中,所述硬质阳极氧化得到的Al2O3基陶瓷硬质耐磨层,其厚度为10μm-50μm,维氏显微硬度为300HV-500HV,粗糙度Ra≤1.5μm。
其中,所述微弧氧化得到的Al2O3基陶瓷硬质耐磨层,其厚度为5μm-30μm,维氏显微硬度为700HV-1500HV,粗糙度Ra≤0.8μm。
其中,所述二硫化钨层的涂覆方法为手动喷涂法、鼓式喷涂法、浸涂法、浸涂-离心法、刷涂法或丝网印刷法中的一种。
其中,所述涂覆法的浸涂液包括二硫化钨、粘结剂、固化剂、添加剂、稀释剂和增塑剂,所述二硫化钨层中二硫化钨的质量百分比为63.5%-78.5%,粘结剂的质量百分比为20%-30%,固化剂的质量百分比为0.5%-10%,添加剂的质量百分比为0.5%-8.0%,稀释剂的质量百分比为0-15%,增塑剂的质量百分比为0.5-10%。
其中,所述粘结剂为醇酸树脂、聚氨酯、环氧树脂、酚醛树脂、聚酰亚胺树脂、聚丙烯酸酯、有机硅树脂或芳香族杂环聚合物中的一种或多种,所述固化剂为芳族多胺化合物、酚醛化合物、脂肪化合物或环氧丙烷丁基醚的其中一种,所述添加剂为石墨、二氧化硅、二氧化钛、铝粉、铜粉、尼龙粉、聚四氟乙烯、聚酰亚胺中的一种或多种,所述稀释剂为丙醇、异丙醇、丙酮、二甲基酰胺、二甲苯、间甲酚、乙醇或纯水中的一种或多种,所述增塑剂为邻苯二甲酸酯类。
其中,所述邻苯二甲酸酯类为邻苯二甲酸二丁酯、邻苯二甲酸辛酯、邻苯二甲酸异辛酯、邻苯二甲酸正辛酸酯、邻苯二甲酸丁苄酯、邻苯二甲酸二仲辛酯、邻苯二甲酸二环己酯、邻苯二甲酸二异丁酯、邻苯二甲酸二甲酯、邻苯二甲酸二乙酯、邻苯二甲酸二异辛酯或邻苯二甲酸二异癸脂中的一种。
其中,所述二硫化钨层的厚度为10μm-20μm,所述二硫化钨的颗粒度为0.2μm-1.5μm。
其中,涂覆结束后,将所述复合涂层在空气中自然干燥,后对二硫化钨层进行加热固化处理,固化温度为150℃-250℃,固化时间为30min-120min。
其中,所述二硫化钨层的涂覆方法为磁控溅射法或射频磁控溅射法中的一种。
其中,所述二硫化钨层的厚度为0.1μm-0.7μm,所述二硫化钨的颗粒度为0.2μm-1.5μm。
其中,涂覆结束后对所述二硫化钨层进行退火处理,退火温度为150℃-450℃。
一种涡旋压缩机,由铸造铝合金或锻造铝合金制成,包括动涡旋盘、静涡旋盘、十字滑环、上支架、活塞、汽缸、滚子以及法兰盘等部件,在其部件上均全部或局部地设置有上述技术方案所述的复合涂层。
有益效果
在铝制工件上涂覆本发明的复合涂层,具有如下优点:
其一是该复合涂层的氧化铝基陶瓷硬质耐磨层的硬度高,微弧氧化层最高硬度可达1500HV,粗糙度小,微弧氧化层的粗糙度可小于0.8μm,改善了工件的耐磨性能。
其二是二硫化钨单体润滑层填充了氧化铝基陶瓷硬质耐磨层的微孔,降低了氧化铝陶瓷硬质耐磨层的粗糙度,摩擦系数小,摩擦系数只有0.05;复合涂层的膜层均匀性好,其膜层厚度差值只有±0.5μm;复合涂层结合力强,按照ISO2409划格法,附着力级别可达到0级,复合涂层不容易从工件上脱落,解决了高压重载工况下复合涂层中单体润滑层易失效的问题,
其三是二硫化钨单体润滑层膜层薄,减少了涡旋压缩机动涡旋盘和静涡旋盘在工作过程中因复合涂层的单体润滑层磨损后而导致的泄露量,使冷量大幅提升,从而提升压缩机的压缩性能。
附图说明
图1为实施例1中动涡旋盘10设置本申请复合涂层的示意图。
图2为实施例1中静涡旋盘20设置本申请复合涂层的示意图。
其中,10为动涡旋盘,11为复合涂层,11a为动涡旋盘表面Al2O3基陶瓷硬质耐磨层,11b为动涡旋盘二硫化钨层,21a为静涡旋盘表面Al2O3基陶瓷硬质耐磨层,21b为静涡旋盘二硫化钨层。
具体实施方式
如图1、图2所示,在涡旋压缩机运行时,动涡旋盘10按照一定轨迹进行平动,并与静涡旋盘20按照设计好的配合间隙以相对的公转运动形成不断变化的多个月牙形压缩腔,空气或制冷剂气体在该月牙形压缩腔内完成吸气、逐级压缩及排气的过程,进而实现压缩空气或制冷剂气体的目的。所述动涡旋盘10和静涡旋盘20均采用铸造铝合金或锻造铝合金,再经过精加工得到高精度的动涡旋盘10和静涡旋盘20。所述动涡旋盘10表面以及动涡旋卷板12的全部或局部涂覆有动涡盘复合涂层11,静涡旋盘20以及静涡旋卷板22的全部或局部涂覆有静涡盘复合涂层21。
实施例1
如图1所示,对所述动涡旋盘10和静涡旋盘20的全部表面,生成Al2O3基陶瓷硬质耐磨层(11a,21a),所述Al2O3基陶瓷硬质耐磨层(11a,21a),可以由硬质阳极氧化工艺或者微弧氧化工艺得到。本实施例中使用硬质阳极氧化对动涡旋盘10和静涡旋盘20表面进行处理。所述硬质阳极氧化工艺符合《GB/T 19822-2005铝及铝合金硬质阳极氧化膜规范》。使用测厚仪测得所述硬质阳极氧化膜层的厚度为35μm。按照《GB/T 4340.1金属材料维氏硬度试验第1部分:试验方法》所述的测试方法,对所述硬质阳极氧化层上多个测试点进行维氏显微硬度测试,测得所述硬质阳极氧化层的维氏显微硬度在300HV-500HV之间,较铝合金基材的硬度有大幅的提高。用粗糙度测试仪对硬质阳极氧化层进行粗糙度测试,硬质阳极氧化层表面的粗糙度Ra≤1.5μm,进而改善了空气压缩机涡旋盘的耐磨性能。
为了降低涡旋压缩机中涡旋盘磨合初期的摩擦系数并填充阳极氧化层的微孔,在硬质阳极氧化膜层上进一步设置二硫化钨层(11b,21b)。所述二硫化钨层(11b,21b)的涂覆方法可以为手动喷涂法、鼓式喷涂法、浸涂法、浸涂-离心法、刷涂法或丝网印刷法的一种,也可以为磁控溅射法或射频磁控溅射法中的一种。本实施例中使用浸涂-离心法涂覆二硫化钨层(11b,21b)。配置二硫化钨浸涂液,其中颗粒度为0.2-1.5μm的二硫化钨占浸涂液总量的75.5%,粘结剂为环氧树脂占总量的24.15%,固化剂为芳族多胺化合物占总量的1.7%,增塑剂为邻苯二甲酸丁二醇酯占总量的1.74%,所述添加剂为石墨占总量的1.5%;为便于喷涂,使用丙酮作为稀释剂对配置好的二硫化钨浸液做进一步稀释,所述稀释剂占总量的5%。
为了保证二硫化钨层(11b,21b)的厚度为15μm左右,将浸涂中离心电机的转速调节为150r/min~450r/min,本实施例中选择300r/min,所述零部件在二硫化钨浸液中的时间为20min。完成浸涂后,在空气中自然干燥10min后再送入固化炉中进行加热固化处理,或在完成浸涂后直接使用输送装置送入固化炉中进行加热固化处理,固化温度为200℃,固化时间为30-120min。
对本发明的复合涂层进行力学性能测试,测得本申请的复合涂层可在50MPa高压或重载的工况下长期运行,相较普通二硫化钼层只能承受15-20MPa左右的负载有着很大的提升。除此以外,本发明的复合涂层还能在强氧化还原环境,如含有强酸、强碱的环境以及辐射功率高达180W的环境下正常工作。
本申请复合涂层中的二硫化钨层,减少了压缩机磨合初期的磨合时间,磨合时间与普通单一耐磨涂层Al2O3基陶瓷硬质耐磨层(11a,21a)减少了1/2以上。对该复合涂层进行摩擦系数测试,测得摩擦系数只有0.05,相比现有技术降低了5-15倍左右。使用测厚仪对复合涂层进行多点测试,其中厚度差值只有±0.5μm,膜层均匀性良好。本申请的复合涂层,与铝制金属件的结合力很强,通过ISO2409的划格法对复合涂层进行附着力测试,本申请的附着力级别为0级,常规技术方案的附着力级别只有1级。即使该单体二硫化钨层被磨耗掉,但其膜层较薄只有15μm,对压缩机动涡旋盘10和静涡旋盘20的配合间隙影响很小,减少了零部件因配合间隙增大而加大气体的泄露量,使冷量或空气的压缩量提升,以9000w功率压缩机为例,功率可提高600w,提升了压缩机的COP,压缩机的性能及可靠性得到提升。
实施例2
涡旋压缩机中还有十字滑环、上支架、活塞、汽缸、滚子或法兰盘等部件,在上述部件上同样可以设置本发明的复合涂层。可以使用硬质阳极氧化工艺或者微弧氧化工艺,在部件表面设置Al2O3基陶瓷硬质耐磨层。本实施例中对上述部件的表面进行微弧氧化,所述微弧氧化层的厚度为5-30μm,本实施例中上述部件表面氧化层厚度为15μm,微弧氧化层的维氏显微硬度在700HV-1500HV之间,较铝合金基材的硬度有大幅的提高,微弧氧化层表面的粗糙度Ra≤0.8μm,进而改善了空气压缩机涡旋盘的耐磨性能。
在所述微弧氧化层上设置有二硫化钨层,所述二硫化钨层的涂覆方法可以为手动喷涂法、鼓式喷涂法、浸涂法、浸涂-离心法、刷涂法或丝网印刷法的一种,也可以为磁控溅射法或射频磁控溅射法中的一种。本实施例中,所述二硫化钨层通过磁控溅射法或射频磁控溅射法在Al2O3基陶瓷硬质耐磨层表面设置。本实施例中采用磁控溅射法进行将颗粒度为0.2μm-1.5μm的二硫化钨直接沉积到上述部件表面,沉积的厚度为0.5μm,沉积完成后再对二硫化钨层进行退火处理,退火温度为300℃。
本实施例中涂覆的二硫化钨膜层较薄,仅有0.5μm,且该涂覆该二硫化钨层零部件可在-253℃-480℃的温度范围内正常工作,即使单体层二硫化钨层在压缩机或空压机运行过程中被磨损掉,还有部分二硫化钨填充在Al2O3基陶瓷硬质耐磨层硬质阳极氧化层或微弧氧化层的微孔之中,减小动涡旋盘10和静涡旋盘20上Al2O3基陶瓷硬质耐磨层表面的峰形摩擦副对功的损耗,提升压缩机的运行性能及可靠性。
Claims (14)
1.一种铝制工件表面的复合涂层,其特征在于,在铝制工件的表面设置有Al2O3基陶瓷硬质耐磨层,并在其上设置有二硫化钨层。
2.根据权利要求1所述的复合涂层,其特征在于,所述Al2O3基陶瓷硬质耐磨层由硬质阳极氧化得到或由微弧氧化得到。
3.根据权利要求2所述的复合涂层,其特征在于,所述硬质阳极氧化得到的Al2O3基陶瓷硬质耐磨层,其厚度为10μm-50μm,其维氏显微硬度为300HV-500HV,其粗糙度Ra≤1.5μm。
4.根据权利要求2所述的复合涂层,其特征在于,所述微弧氧化得到的Al2O3基陶瓷硬质耐磨层,其厚度为5μm-30μm,其维氏显微硬度为700HV-1500HV,其粗糙度Ra≤0.8μm。
5.根据权利要求1所述的复合涂层,其特征在于,所述二硫化钨层的涂覆方法为手动喷涂法、鼓式喷涂法、浸涂法、浸涂-离心法、刷涂法或丝网印刷法中的一种。
6.根据权利要求5所述的复合涂层,其特征在于,所述涂覆法的浸涂液包括二硫化钨、粘结剂、固化剂、添加剂、稀释剂或增塑剂,所述二硫化钨层中二硫化钨的质量百分比为63.5%-78.5%,粘结剂的质量百分比为20%-30%,固化剂的质量百分比为0.5%-10%,添加剂的质量百分比为0.5%-8.0%,稀释剂的质量百分比为0-15%,增塑剂的质量百分比为0.5-10%。
7.根据权利要求6所述的复合涂层,其特征在于,所述粘结剂为醇酸树脂、聚氨酯、环氧树脂、酚醛树脂、聚酰亚胺树脂、聚丙烯酸酯、有机硅树脂或芳香族杂环聚合物中的一种或多种,所述固化剂为芳族多胺化合物、酚醛化合物、脂肪化合物或环氧丙烷丁基醚的其中一种,所述添加剂为石墨、二氧化硅、二氧化钛、铝粉、铜粉、尼龙粉、聚四氟乙烯、聚酰亚胺中的一种或多种,所述稀释剂为丙醇、异丙醇、丙酮、二甲基酰胺、二甲苯、间甲酚、乙醇或纯水中的一种或多种,所述增塑剂为邻苯二甲酸酯类。
8.根据权利要求7所述的复合涂层,其特征在于,所述邻苯二甲酸酯类为邻苯二甲酸二丁酯、邻苯二甲酸辛酯、邻苯二甲酸异辛酯、邻苯二甲酸正辛酸酯、邻苯二甲酸丁苄酯、邻苯二甲酸二仲辛酯、邻苯二甲酸二环己酯、邻苯二甲酸二异丁酯、邻苯二甲酸二甲酯、邻苯二甲酸二乙酯、邻苯二甲酸二异辛酯或邻苯二甲酸二异癸脂中的一种。
9.根据权利要求5所述的复合涂层,其特征在于,所述二硫化钨层的厚度为10μm-20μm,所述二硫化钨的颗粒度为0.2μm-1.5μm。
10.根据权利要求9所述的复合涂层,其特征在于,涂覆结束后,将所述复合涂层在空气中自然干燥,后对二硫化钨层进行加热固化处理,固化温度为150℃-250℃,固化时间为30min-120min。
11.根据权利要求1所述的复合涂层,其特征在于,所述二硫化钨层的涂覆方法为磁控溅射法或射频磁控溅射法中的一种。
12.根据权利要求11所述的复合涂层,其特征在于,所述二硫化钨层的厚度为0.1μm-0.7μm,所述二硫化钨的颗粒度为0.2μm-1.5μm。
13.根据权利要求12所述的复合涂层,其特征在于,涂覆结束后对所述二硫化钨层进行退火处理,退火温度为150℃-450℃。
14.一种涡旋压缩机,由铸造铝合金或锻造铝合金制成,包括动涡旋盘(10)、静涡旋盘(20)、十字滑环、上支架、活塞、汽缸、滚子以及法兰盘,其特征在于,在前述部件上均全部或局部地设置有上述权利要求所述的复合涂层。
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