CN110724900A - Thermal spraying test system and method - Google Patents

Thermal spraying test system and method Download PDF

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Publication number
CN110724900A
CN110724900A CN201910986806.5A CN201910986806A CN110724900A CN 110724900 A CN110724900 A CN 110724900A CN 201910986806 A CN201910986806 A CN 201910986806A CN 110724900 A CN110724900 A CN 110724900A
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powder
spray
substrate
spraying
cabin
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CN201910986806.5A
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CN110724900B (en
Inventor
于月光
刘建明
沈婕
章德铭
卢晓亮
刘通
黄凌峰
候伟骜
王帅
郭丹
石长江
原慷
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Bgrimm Advanced Materials Science & Technology Co Ltd
BGRIMM Technology Group Co Ltd
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Bgrimm Advanced Materials Science & Technology Co Ltd
BGRIMM Technology Group Co Ltd
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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
    • 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
    • C23C4/129—Flame 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
    • C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
    • 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

Abstract

The present disclosure relates to a thermal spray testing system and method. The thermal spray test system comprises: the inner wall of the powder collecting cabin forms a hollow inner cavity, and the outer wall of the powder collecting cabin is provided with a window (11) which is communicated with the outside of the powder collecting cabin and the hollow inner cavity and is used for a spray head of a spray gun to enter and a heat dissipation opening (12) which is communicated with the outside of the powder collecting cabin and the hollow inner cavity; the spraying substrate (70) is arranged on the inner wall of the powder receiving cabin, and the orthographic projection of the plane where the window (11) is located is at least partially located in the window (11); the weighing device is used for respectively weighing the powder scattered in the thermal spraying process collected in the powder collecting cabin and the coating formed on the thermal-sprayed substrate (70); and the data processing device is used for determining burning loss data of the spraying material in the thermal spraying process according to the quality of the coating formed on the spraying substrate (70) and the collected powder quality.

Description

Thermal spraying test system and method
Technical Field
The disclosure relates to the technical field of thermal spraying, in particular to a thermal spraying test system and method.
Background
The thermal spraying technology is a surface engineering technology which heats and accelerates materials by means of flame, plasma and the like and sprays the materials to the surface of a substrate to form a coating. In order to improve the quality of the coating and optimize the thermal spraying process, the prior art mainly tests the properties of the coating such as micro-hardness, porosity, surface roughness, deposition efficiency and the like on the coating formed after thermal spraying, observes the microstructure of the coating, and performs phase analysis, component analysis and the like on the coating.
Disclosure of Invention
In one aspect of the present disclosure, there is provided a thermal spray testing system comprising:
the inner wall of the powder receiving cabin forms a hollow inner cavity, and the outer wall of the powder receiving cabin is provided with a window which is communicated with the outside of the powder receiving cabin and the hollow inner cavity and is used for a spray head of a spray gun to enter and a heat dissipation opening which is communicated with the outside of the powder receiving cabin and the hollow inner cavity;
the spraying substrate is arranged on the inner wall of the powder receiving cabin, and the orthographic projection of the plane where the window is located is at least partially positioned in the window;
the weighing device is used for respectively weighing the powder scattered in the thermal spraying process collected in the powder collecting cabin and the coating formed on the spraying substrate after the thermal spraying;
and the data processing device is used for determining burning loss data of the spraying material in the thermal spraying process according to the quality of the coating formed on the spraying substrate and the collected powder quality.
In some embodiments, the heat dissipation opening is located at the top of the powder collecting cabin and is used for upwards discharging heat inside the powder collecting cabin in the thermal spraying process.
In some embodiments, the distance H1 from the heat dissipation opening to the center of the spray substrate is 0.8-1.5 m.
In some embodiments, the powder collecting cabin comprises: the spraying substrate comprises a hollow cylinder and a hollow cone located on the lower side of the hollow cylinder, the top surface of the hollow cylinder is open to form the heat dissipation opening, the bottom surface of the hollow cylinder is connected with the bottom surface of the hollow cone, the hollow cylinder is communicated with the hollow part of the hollow cone to form the hollow inner cavity, the spraying substrate is arranged on the inner wall of the hollow cylinder, and the window is arranged on the outer wall of the hollow cylinder.
In some embodiments, the total height h of the powder collecting cabin is 1.8-3 m, and the width W of the hollow column is 1.8-3 m; and/or the width W of the hollow cylinder is 1.8-3 m; and/or the thickness T of the hollow column body is 30-50 cm; and/or the taper angle a of the hollow cone is not less than 110 °.
In some embodiments, the inner wall of the hollow cylinder has a rectangular parallelepiped shape, the inner wall of the hollow cone has a quadrangular pyramid shape, and the bottom surface of the rectangular parallelepiped shape has the same shape and size as the top surface of the quadrangular pyramid shape.
In some embodiments, the spray baseThe plate is square or rectangular, the length of a single side is not less than 20cm, and the area is not less than 400cm2(ii) a And/or the difference between the width W1 of the window and the width of the sprayed substrate is 30-40 cm; and/or the difference between the height H1 of the window and the height of the spraying substrate is 30-40 cm; and/or the distance from the center of the window to the bottom surface of the inner wall of the powder collecting cabin is 1-1.5 m.
In some embodiments, all the intersecting positions of the planes in the inner wall of the powder collecting cabin are subjected to arc transition treatment, and the radius of the arc transition section is 1.5-5 cm.
In some embodiments, the inner wall finish of the powder collecting cabin is less than or equal to 3.2 μm.
In some embodiments, the thermal spray testing system further comprises: and the air hammer vibrator is arranged on the outer wall of the powder collecting cabin.
In some embodiments, the thermal spray testing system further comprises:
the first temperature control device is used for controlling the temperature of the spraying substrate;
and the second temperature control device is used for controlling the temperature of the cabin body of the powder collecting cabin.
In some embodiments, the first temperature control device comprises:
the air cooling device is positioned outside the powder collecting cabin and close to one side of the spraying substrate, and carries out air cooling heat dissipation on the spraying substrate through compressed air;
the second temperature control device includes:
and the radiating fins are arranged on the outer wall of the powder collecting cabin and are used for radiating the powder collecting cabin.
In some embodiments, the inner wall of the powder collecting cabin is provided with a through hole embedded in the spraying substrate corresponding to the arrangement position of the spraying substrate, and the compressed air outlet is directed to the surface of the spraying substrate on the side far away from the spray gun.
In one aspect of the present disclosure, there is provided a testing method based on the aforementioned thermal spray testing system, including:
extending a spray head of a spray gun into a window of the powder collecting cabin;
enabling the spray gun to move according to set parameters, and spraying the spraying substrate so as to form a coating on the spraying substrate;
after the thermal spraying is finished, collecting powder scattered in the powder collecting cabin in the thermal spraying process, and weighing the collected powder and the coating by the weighing device;
through data processing device, according to the spray material that the spray gun used, the quality of coating and receive the quality calculation of the powder of collecting in the powder cabin thermal spraying in-process the quality of the material that the spray material was burnt and is lost.
In some embodiments, the distance from the heat dissipation opening to the center of the spray substrate is less than 0.8m, and the mass m of the burned-out material is calculated by the following formula3：
m3＝m-m1-(m2/(1-p)) (1)
Where m is the total mass of spray material used by the spray gun, m1Is the mass of the coating, m2Is the mass of the powder collected in the powder collecting cabin, and p is the ratio of the area of the heat dissipation opening to the total surface area of the powder collecting cabin.
In some embodiments, the assay method further comprises:
determining the mass content C of elements or components in the powder collected in the powder collecting cabin by adopting a chemical analysis method2And the mass content C of the elements or components in the coating1；
Calculating the mass content C of the element or component in the burnt material by the following formula3：
Wherein C is the mass content of the element or component in the spray coating material, C1Is the mass content of an element or component in the coating, C2Is in the powder collected in said powder-collecting chamberMass content.
In some embodiments, the distance from the heat dissipation opening to the center of the spray substrate is 0.8-1.5 m, and the burned material mass m is calculated by the following formula3：
m3＝m-m1-m2； (3)
Wherein m is the total mass of the spray material used by the spray gun, m1Is the mass of the coating, m2Is the mass of the powder collected in the powder collecting cabin.
In some embodiments, the assay method further comprises:
determining the mass content C of elements or components in the powder collected in the powder collecting cabin by adopting a chemical analysis method2And the mass content C of the elements or components in the coating1；
Calculating the mass content C of the element or component in the burnt material by the following formula3：
Figure BDA0002236945910000041
Wherein C is the mass content of the element or component in the spray coating material.
Drawings
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the disclosure and together with the description, serve to explain the principles of the disclosure.
The present disclosure may be more clearly understood from the following detailed description, taken with reference to the accompanying drawings, in which:
fig. 1 and 2 are schematic structural views of an embodiment of a thermal spray testing system according to the present disclosure at different perspective perspectives, respectively;
fig. 3-5 are schematic structural views at a front view angle, a top view angle, and a left view angle, respectively, of an embodiment of a thermal spray testing system according to the present disclosure;
FIG. 6 is a schematic flow chart diagram of one embodiment of an assay method according to the present disclosure.
It should be understood that the dimensions of the various parts shown in the figures are not drawn to scale. Further, the same or similar reference numerals denote the same or similar components.
Detailed Description
Various exemplary embodiments of the present disclosure will now be described in detail with reference to the accompanying drawings. The description of the exemplary embodiments is merely illustrative and is in no way intended to limit the disclosure, its application, or uses. The present disclosure may be embodied in many different forms and is not limited to the embodiments described herein. These embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. It should be noted that: the relative arrangement of parts and steps, the composition of materials, numerical expressions and numerical values set forth in these embodiments are to be construed as merely illustrative, and not as limitative, unless specifically stated otherwise.
The use of "first," "second," and similar terms in this disclosure is not intended to indicate any order, quantity, or importance, but rather are used to distinguish one element from another. The word "comprising" or "comprises", and the like, means that the element preceding the word covers the element listed after the word, and does not exclude the possibility that other elements are also covered. "upper", "lower", "left", "right", and the like are used merely to indicate relative positional relationships, and when the absolute position of the object being described is changed, the relative positional relationships may also be changed accordingly.
In the present disclosure, when a specific device is described as being located between a first device and a second device, there may or may not be intervening devices between the specific device and the first device or the second device. When a particular device is described as being coupled to other devices, that particular device may be directly coupled to the other devices without intervening devices or may be directly coupled to the other devices with intervening devices.
All terms (including technical or scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs unless specifically defined otherwise. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
Techniques, methods, and apparatus known to those of ordinary skill in the relevant art may not be discussed in detail but are intended to be part of the specification where appropriate.
The inventor researches and analyzes that the main research object of the optimization of the thermal spraying process at present is the coating, the spraying material needs to be heated and accelerated in the thermal spraying process, and the spraying process mostly occurs in the atmospheric environment, so that the loss of easily burnt and decomposed components in the spraying material can be caused, the great difference is generated between the components of the coating and the spraying material, and the quality of the coating is not easy to control. If the loss data of each component in the spray material can be clarified to optimize the spray material and the thermal spraying process, the quality stability of the thermal spraying coating can be improved. However, there is currently a lack of a solution for quantifying the loss data of material composition during thermal spray coating, leading researchers in the field to have insufficient knowledge of the associated problems.
In view of the above, the present disclosure provides a thermal spraying test system and method, which can quantitatively determine the component loss condition of a spraying material during a thermal spraying process.
As shown in fig. 1 and 2, are schematic structural views of an embodiment of a thermal spray testing system according to the present disclosure at different perspective perspectives, respectively. Referring to fig. 1 and 2, in conjunction with fig. 3-5, in some embodiments, a thermal spray testing system includes: a powder collecting cabin, a spraying substrate 70, a weighing device and a data processing device. The inner wall of the powder collecting cabin forms a hollow inner cavity, and the outer wall of the powder collecting cabin is provided with a window 11 and a heat dissipation opening 12. The powder collecting cabin can be fixed on the ground or on a fixed or movable platform through a bracket 30. The bracket 30 can be used for supporting the powder receiving cabin, adjusting the height position of the spray gun and the window 11, and the like.
The window 11 is communicated with the outside of the powder receiving cabin and the hollow inner cavity and is used for a spray head of a spray gun to enter. The spray gun is movable within the window 11 to effect overall spraying of the spray substrate 70. The heat dissipation opening 12 is communicated with the outside of the powder collection cabin and the hollow inner cavity, so that the heat in the hollow inner cavity of the powder collection cabin can be released outwards.
The spraying substrate 70 is arranged on the inner wall of the powder collecting cabin, and the orthographic projection of the plane of the window 11 is at least partially positioned in the window 11. This facilitates the projection of the spray head of the spray gun from the window 11 and as far as possible against the surface of the spray substrate 70.
The weighing device is used for weighing the powder scattered in the thermal spraying process collected in the powder collecting cabin and the coating formed on the thermal sprayed substrate 70. The weighing process realized by the weighing device can be carried out after the thermal spraying is finished, the coating can be weighed after the coating is completely peeled off from the sprayed substrate, or the coating can be directly weighed on the sprayed substrate with the coating, and the weight of the sprayed substrate is subtracted to indirectly obtain the coating.
The data processing device is used for determining the burning loss data of the spraying material in the thermal spraying process according to the quality of the coating formed on the spraying substrate 70 and the collected powder quality. Burnout data may include the mass of the material being burned out, or the mass content of one or some elements or components in the material being burned out, etc. The data processing device can be in signal connection with the weighing device and can acquire weighing data from the weighing device, and can also receive relevant data input by workers, such as the mass of a sprayed substrate without a coating, the relevant mass content of elements or components and the like.
The inventor researches and discovers that the loss of easily burnt and decomposed components in the spraying material is not considered in the related technology, and the loss mainly lies in that the flame flow temperature of thermal spraying is very high, for example, the plasma spraying flame flow temperature is as high as 20000-40000 ℃, the flame spraying temperature is as high as 3000-4000 ℃, and if the powder scattered in the thermal spraying process is collected, the powder scattered in the powder scattering process is in a large range, so that the complete collection is difficult, and the temperature of a collecting device is increased too fast, so that the spray gun is damaged, and the like. If the coating material is sprayed into water for collection, the powder collected in this way has a large difference in material composition and the like from the powder under normal spraying conditions, and is of no reference value.
Therefore, in the embodiment, the spraying substrate is arranged in the powder receiving cabin, and the hollow inner cavity of the powder receiving cabin is communicated with the outside through the window and the heat dissipation opening, wherein the spray gun is received through the window, so that the spray head of the spray gun can extend into the hollow inner cavity, and the powder scattered in the flame flow sprayed by the spray head of the spray gun is contained in the hollow inner cavity; and the heat accumulated in the hollow inner cavity of the powder collecting cabin is dissipated outwards through the heat dissipation opening, so that the damage of the test device caused by overhigh temperature in the powder collecting cabin is avoided. The powder collected in the coating and the powder collecting cabin is weighed, and the data in the aspect of burning loss can be obtained by calculating according to the mass conservation law, so that the quantitative determination of the component loss condition of the spraying material in the thermal spraying process is realized.
Referring to fig. 1 and 2, in some embodiments, the heat dissipation opening 12 is located at the top of the powder collection chamber so that heat can be dissipated upwards through the heat dissipation opening 12 during the thermal spraying process. Since the thermal spraying process needs to be continued for a certain time (for example, more than 10 minutes) to collect a sufficient amount of scattered powder, the heat accumulated in the thermal spraying process can float up with the hot air and flow out from the heat dissipation opening 12 to the outside, and the cold air is supplemented into the powder collecting chamber with the outside, so that a gas flow circulation is formed, and the temperature in the powder collecting chamber is ensured not to be too high.
On the other hand, the heat dissipation opening 12 is arranged at the top of the powder collecting cabin, so that the collection of scattered powder is facilitated. When the spray gun sprays high-temperature flame flow, the powder scatters to the periphery, the powder scattered to the left and right directions of the powder collecting cabin and the powder scattered below can be completely collected through the gathering effect of the hollow inner cavity of the powder collecting cabin, and at least part of the powder scattered above can fall back to the powder collecting cabin under the action of gravity, so that the scattered powder is fully collected as much as possible.
Referring to FIG. 3, in some embodiments, the distance H1 from the heat dissipation opening 12 to the center of the spray substrate 70 is 0.8-1.5 m. Experiments prove that when the distance H1 between the heat dissipation opening 12 at the top and the spray substrate 70 reaches 0.8m, most of the upward scattered powder loses kinetic energy in the process of flying to the heat dissipation opening 12 and falls back to the hollow inner cavity of the powder collection cabin, so that the amount of scattered powder which escapes and cannot be collected is effectively reduced. If the top of the powder collecting chamber is short or the heat dissipation opening 12 is disposed at the front side, the rear side or the left and right sides of the powder collecting chamber, so that the distance H1 from the heat dissipation opening 12 to the center of the spray substrate 70 is small, for example, less than 0.8m, then it can be approximately considered that the scattered powder is randomly ejected and distributed to the whole space during spraying, and therefore, the mass of the powder scattered in the whole spraying process can be estimated according to the ratio of the mass of the powder of the actual mobile phone and the total surface area of the powder collecting chamber to the area of the heat dissipation opening 12. On the other hand, considering that if the heat dissipation opening 12 is too far from the spray substrate 70, it is difficult for the air heated by the high-temperature flame flow to be dissipated to the outside through the heat dissipation opening 12 as quickly as possible, thereby affecting the heat dissipation performance of the powder collecting compartment, it is preferable that the distance H1 is not more than 1.5 m.
The powder collecting chamber can be made of metal or alloy, for example, formed by welding galvanized sheet steel. The inner wall of the powder collecting chamber needs to have higher smoothness so as to fully collect the powder, and accordingly, the smoothness of the inner wall of the powder collecting chamber is preferably less than or equal to 3.2 mu m. In addition, in order to avoid the difficulty in collection caused by powder remaining at the intersection of different planes in the inner wall of the powder collecting cabin, the intersection of all the planes in the inner wall of the powder collecting cabin is preferably subjected to arc transition treatment, and the radius of an arc transition section is 1.5-5 cm.
Referring to fig. 1-5, in some embodiments, an air hammer vibrator 60 may also be provided on the outer wall of the bin. The air hammer vibrator 60 may be turned on for a period of time (e.g., 10 to 30 minutes) after the thermal spraying is completed, and may apply vibration to the outer wall to urge the powder attached to the inner wall of the hollow cavity to fall off the inner wall. This also eliminates the labor of collecting the powder adhered to the inner wall by the brush. In fig. 3, six air hammer vibrators 60 are provided on the outer wall of the powder collecting compartment, two are provided on the front outer wall of the powder collecting compartment, two are provided on the left and right outer walls of the powder collecting compartment, and two are provided on the lower outer wall of the powder collecting compartment, so that more sufficient powder collection can be ensured.
Referring to FIG. 3, in some embodiments, the spray substrate 70 may be made of a metal or alloy, such as by usingStainless steel with a thickness of not less than 3 mm. The spray substrate 70 may be square or rectangular, with a single side length of no less than 20cm and an area of no less than 400cm2. The arrangement of the substrate 70 with a large area is beneficial to the fact that the spray gun can spray according to the gun moving speed and the gun moving path in the actual production process, so that the test process is consistent with the actual production conditions as much as possible. The surface of the spray substrate 70 may be subjected to a grit blasting process prior to spraying to remove rust and scale from the substrate surface while adding an adsorptive force to the surface-roughening thermal spray coating.
In fig. 3, the difference between the width W1 of the window 11 and the width of the spray substrate 70 is preferably 30 to 40cm, and/or the difference between the height H1 of the window 11 and the height of the spray substrate 70 is also preferably 30 to 40 cm. The movement space of the spray gun in the horizontal direction and/or the vertical direction after the spray gun extends into the window is facilitated, and the influence on the thermal spraying range due to interference between the spray gun and the window is avoided. In addition, the distance between the center of the window 11 and the bottom surface of the inner wall of the powder receiving cabin is preferably 1-1.5 m so as to meet the moving range limitation of a spraying manipulator connected with a spray gun.
For the thermal spray testing system of the present disclosure, different shapes of the powder collection chamber, such as cylindrical, spherical, prismatic, may be used in different embodiments. Referring to fig. 1 and 2, in some embodiments, the powder collection bin comprises: a hollow cylinder 10 and a hollow cone 20 at the lower side of the hollow cylinder 10. The top surface of the hollow cylinder 10 is open to form the heat dissipation opening 12, the bottom surface of the hollow cylinder 10 is connected with the bottom surface of the hollow cone 20, and the hollow cylinder 10 is communicated with the hollow part of the hollow cone 20 to form the hollow inner cavity.
The spraying substrate 70 is disposed on the inner wall of the hollow cylinder 10, and the window 11 is disposed on the outer wall of the hollow cylinder 10. The relatively wide inner cavity formed by the hollow cylinder 10 is beneficial to outward dissipation of heat of flame flow ejected by the spray gun, excessive temperature caused by heat accumulation is avoided, and the hollow cone 20 can utilize the conical inner wall of the hollow cone to downwards gather the hollow cylinder 10 and powder scattered in the thermal spraying process received by the hollow cone 20. A collecting box 21 can be arranged below the hollow cone 20, and after the collection is finished, the collecting box 21 can be taken out for further weighing.
For convenience of manufacture and design, referring to fig. 1 and 2, it is preferable that the inner wall of the hollow cylinder 10 has a rectangular parallelepiped shape, the inner wall of the hollow cone 20 has a quadrangular pyramid shape, and the bottom surface of the rectangular parallelepiped shape has the same shape and size as the top surface of the quadrangular pyramid shape. The hammer vibrators 60 may be provided on the outer walls of the hollow cylinder 10 and the hollow cone 20, respectively.
Referring to fig. 3 and 5, in some embodiments, the total height h of the powder collecting cabin is preferably 1.8-3 m. Therefore, the powder collecting cabin can be ensured to collect the scattered powder during thermal spraying as fully as possible, a channel for the heat in the hollow cavity to be scattered outwards can be formed, and the height of the powder collecting cabin exceeding the space height of a room where a thermal spraying test system is located is avoided.
In some embodiments, the width W of the hollow cylinder 10 is preferably 1.8-3 m to reduce secondary bounce of the scattered powder and escape from the hollow cavity. In some embodiments, the thickness T of the hollow cylinder 10 is preferably 30-50 cm, so as to reduce the influence of secondary rebound of the scattered powder on the shape of the powder. Specifically, when the thickness T is not less than 30cm, the flying distance of the particles rebounded on the substrate is attenuated to 0.5m/s or less because the flying distance is more than 30cm, so that the deformation is not enough because of small kinetic energy, and the thickness is not more than 50cm, so that the dust accumulation and pollution caused by the fact that the cable of the accessory of the spray gun penetrates into the cabin body too much can be reduced. In some embodiments, the taper angle α of the hollow cone 20 is preferably not less than 110 ° so as not to occupy a large space height.
In order to maintain the thermal spray test process consistent with the conditions involved in actual production, it is preferable to have independent temperature control of the spray substrate 70 and the chamber body of the powder collection chamber in the thermal spray test system. In some embodiments, the thermal spray testing system further comprises: a first temperature control device and a second temperature control device. The first temperature control device is used for controlling the temperature of the spraying substrate 70, and the temperature of the first temperature control device can be controlled to be 50-200 ℃. The second temperature control device is used for controlling the temperature of the powder collecting cabin, and the temperature can be controlled below 30 ℃.
Referring to fig. 2, in some embodiments, the first temperature control device may include: and the air cooling device 40 is positioned at one side of the powder collecting cabin, which is adjacent to the spraying substrate 70, and is used for cooling and radiating the spraying substrate 70 through compressed air. If the spray substrate 70 is attached to the inner wall of the powder receiving chamber, the air cooling device 40 may blow the compressed air with a relatively low temperature toward the outer wall region corresponding to the spray substrate 70 by the air pump to cool the region, thereby indirectly cooling the spray substrate 70. In fig. 2, the inner wall of the powder collecting chamber may be provided with a through hole into which the spray substrate 70 is inserted, corresponding to the position where the spray substrate 70 is provided. And the compressed air outlet of the air cooling device 40 is directed to the surface of the side of the spray substrate 70 away from the spray gun, so that the compressed air can be directly blown to the back side of the spray substrate 70, so as to more fully cool the spray substrate 70.
In fig. 2, the second temperature control device may include: and the radiating fins 50 are arranged on the outer wall of the powder receiving cabin and are used for radiating the powder receiving cabin. The heat sink 50 can increase the heat dissipation area of the powder collecting chamber and improve the heat dissipation efficiency. Considering that the inner wall of the rear side of the powder receiving chamber has a higher temperature under the action of the flame flow, the heat sink fins 50 may be arranged at a plurality of positions on the rear side of the powder receiving chamber, for example, three sets of heat sink fins 50 are arranged on the upper and lower sides of the rear side of the hollow cylindrical body 10 in fig. 2.
In addition, the first temperature control device and the second temperature control device can respectively comprise a temperature sensor and a controller, the temperature of the temperature control objects can be detected through the temperature sensors, and the spray power of the spray gun, the compressed air pressure and the flow of the air cooling device and the like can be controlled through the controller, so that the temperature of the cabin body for spraying the substrate and receiving the powder cabin can be kept consistent with that in actual production, and the risk of equipment damage in the test process can be reduced.
Based on the thermal spraying test system, the disclosure also provides a corresponding test method embodiment. FIG. 6 is a schematic flow chart diagram illustrating one embodiment of an assay method according to the present disclosure.
Referring to FIG. 6, in some embodiments, a testing method based on the aforementioned thermal spray testing system embodiments includes steps 100-400. In step 100, a nozzle of a spray gun is extended into the window 11 of the powder collecting cabin. In step 200, the spray gun is moved according to the set parameters, and the spray substrate 70 is sprayed, so as to form a coating layer on the spray substrate 70. In step 300, after the thermal spraying is completed, collecting powder scattered in the powder collecting cabin during the thermal spraying, and weighing the collected powder and the coating by the weighing device. In step 400, calculating, by the data processing device, a mass of a material burned out of the spray material during thermal spraying according to the spray material used by the spray gun, the mass of the coating, and the mass of the powder collected in the powder collecting chamber.
For a thermal spray test system in which the distance from the heat dissipation opening 12 to the center of the spray substrate 70 is less than 0.8m, powder that escapes from the powder collection chamber without being collected needs to be considered in calculating the mass of the burned material. And the mass ratio of the powder that is not collected to the whole powder scattered at the time of thermal spraying can be approximately equal to the ratio of the area passing through the heat dissipation opening 12 to the total surface area of the powder collecting chamber. Accordingly, the burned-out material mass m can be calculated by the following formula3：
m3＝m-m1-(m2/(1-p)) (1)
Where m is the total mass of spray material used by the spray gun, m1Is the mass of the coating, m2Is the mass of the powder collected in the powder collecting chamber, and p is the ratio of the area of the heat dissipation opening 12 to the total surface area of the powder collecting chamber.
In order to further determine the mass content of one or some elements or components in the material burnt during the thermal spraying process, the mass content C of the elements or components in the powder collected in the powder collecting cabin can be respectively determined by adopting a chemical analysis method2And the mass content C of the elements or components in the coating1And calculating the mass content C of the element or component in the burnt material by the following formula3：
Figure BDA0002236945910000121
Wherein C is the mass content of the element or component in the spray coating material, C1Is the mass content of an element or component in the coating, C2Is the mass content of the element or component in the powder collected in the powder collecting cabin.
For the thermal spraying test system with the distance from the heat dissipation opening 12 to the center of the spraying substrate 70 being 0.8-1.5 m, most of the upward scattered powder can return to the powder collecting cabin under the action of gravity, and the mass ratio of the powder which escapes without being collected to the whole powder scattered during thermal spraying is small, and is ignored here for the sake of convenience of calculation. Accordingly, the burned-out material mass m can be calculated by the following formula3：
m3＝m-m1-m2； (3)
Wherein m is the total mass of the spray material used by the spray gun, m1Is the mass of the coating, m2Is the mass of the powder collected in the powder collecting cabin.
In order to further determine the mass content of one or some elements or components in the material burnt during the thermal spraying process, the mass content C of the elements or components in the powder collected in the powder collecting cabin can be determined by chemical analysis2And the mass content C of the elements or components in the coating1And calculating the mass content C of the element or component in the burnt material by the following formula3：
Figure BDA0002236945910000122
Wherein C is the mass content of the element or component in the spray coating material.
The following is an example of a process of plasma spraying an alumino-silicate powder on a stainless steel spray substrate.
The spraying parameters include: the spraying power is 30kW, the powder feeding rate is 20g/min, the spraying distance is 90mm, the gun moving speed is 1mm/s, the gun moving width is 40mm, and the spraying time is 10 min. Assuming that the heat dissipation openings 12 are located at the top and the front side of the powder collecting chamber and the distance from the center of the spray substrate 70 is less than 0.8m, p is 15.1% determined by the ratio of the area of the heat dissipation openings to the total surface area of the powder collecting chamber. The total mass m of the spray material used by the spray gun can be calculated by the following formula:
M＝Fr×t (5)
and Fr is the powder feeding rate of the spray gun, t is the spraying time, the moment when the flame flow of the spray gun moves to the sprayed substrate after being stabilized is taken as the beginning, and the moment when the flame flow moves out of the sprayed substrate is taken as the end.
The weighing device may use scale, etc. to weigh the mass of the scattered powder and the coating respectively and determine the content of elements (e.g. aluminum, silicon) or components (e.g. polyphenyl ester) in the scattered powder and the coating by chemical analysis. The mass of the burnt material and the mass content of the elements or components can be respectively calculated through the formulas (1) and (2), so that the scattering rate, the burning rate and the deposition rate of the polyphenyl ester, aluminum, silicon elements and the like in the spraying material can be more comprehensively obtained, and further, the research and optimization on the aspects of coating materials, spraying process parameters and the like can be carried out through the data.
Thus, various embodiments of the present disclosure have been described in detail. Some details that are well known in the art have not been described in order to avoid obscuring the concepts of the present disclosure. It will be fully apparent to those skilled in the art from the foregoing description how to practice the presently disclosed embodiments.
Although some specific embodiments of the present disclosure have been described in detail by way of example, it should be understood by those skilled in the art that the foregoing examples are for purposes of illustration only and are not intended to limit the scope of the present disclosure. It will be understood by those skilled in the art that various changes may be made in the above embodiments or equivalents may be substituted for elements thereof without departing from the scope and spirit of the present disclosure. The scope of the present disclosure is defined by the appended claims.

Claims (18)

1. A thermal spray testing system comprising:
the inner wall of the powder collecting cabin forms a hollow inner cavity, and the outer wall of the powder collecting cabin is provided with a window (11) which is communicated with the outside of the powder collecting cabin and the hollow inner cavity and is used for a spray head of a spray gun to enter and a heat dissipation opening (12) which is communicated with the outside of the powder collecting cabin and the hollow inner cavity;
the spraying substrate (70) is arranged on the inner wall of the powder receiving cabin, and the orthographic projection of the plane where the window (11) is located is at least partially located in the window (11);
the weighing device is used for respectively weighing the powder scattered in the thermal spraying process collected in the powder collecting cabin and the coating formed on the thermal-sprayed substrate (70);
and the data processing device is used for determining burning loss data of the spraying material in the thermal spraying process according to the quality of the coating formed on the spraying substrate (70) and the collected powder quality.
2. The thermal spray testing system of claim 1, wherein the heat dissipation opening (12) is located at the top of the powder collection chamber for discharging heat upwardly from the interior of the powder collection chamber during thermal spraying.
3. The thermal spray testing system of claim 2, wherein the distance H1 from the heat dissipation opening (12) to the center of the spray substrate (70) is 0.8-1.5 m.
4. The thermal spray testing system of claim 2, wherein the powder collection bin comprises: the heat dissipation device comprises a hollow cylinder (10) and a hollow cone (20) located on the lower side of the hollow cylinder (10), wherein the top surface of the hollow cylinder (10) is open to form the heat dissipation opening (12), the bottom surface of the hollow cylinder (10) is connected with the bottom surface of the hollow cone (20), the hollow cylinder (10) is communicated with the hollow part of the hollow cone (20) to form the hollow inner cavity, the spraying substrate (70) is arranged on the inner wall of the hollow cylinder (10), and the window (11) is arranged on the outer wall of the hollow cylinder (10).
5. The thermal spray test system according to claim 4, wherein the total height h of the powder collecting cabin is 1.8-3 m; and/or the width W of the hollow cylinder (10) is 1.8-3 m; and/or the thickness T of the hollow column (10) is 30-50 cm; and/or the hollow cone (20) has a cone angle alpha not less than 110 deg..
6. The thermal spray test system according to claim 4, wherein the inner wall of the hollow cylinder (10) has a rectangular parallelepiped shape, the inner wall of the hollow cone (20) has a quadrangular pyramid shape, and the bottom surface of the rectangular parallelepiped shape is the same as the top surface of the quadrangular pyramid shape in shape and size.
7. The thermal spray testing system of claim 1, wherein the spray substrate (70) is square or rectangular, with a single side length of no less than 20cm and an area of no less than 400cm2(ii) a And/or the difference between the width W1 of the window (11) and the width of the spraying substrate (70) is 30-40 cm; and/or the difference between the height H1 of the window (11) and the height of the spraying substrate (70) is 30-40 cm; and/or the distance from the center of the window (11) to the bottom surface of the inner wall of the powder collecting cabin is 1-1.5 m.
8. The thermal spraying test system according to claim 1, wherein the intersection of all planes in the inner wall of the powder collecting cabin is subjected to arc transition treatment, and the radius of an arc transition section is 1.5-5 cm.
9. The thermal spray test system according to claim 1, wherein the inner wall finish of the powder collecting chamber is less than or equal to 3.2 μm.
10. The thermal spray testing system of claim 1, further comprising: and the air hammer vibrator (60) is arranged on the outer wall of the powder collecting cabin.
11. The thermal spray testing system of any of claims 1-10, further comprising:
a first temperature control device for controlling the temperature of the spray substrate (70);
and the second temperature control device is used for controlling the temperature of the cabin body of the powder collecting cabin.
12. The thermal spray testing system of claim 11, wherein the first temperature control device comprises:
the air cooling device (40) is positioned at one side, adjacent to the spraying substrate (70), of the outer part of the powder collecting cabin and used for cooling and radiating the spraying substrate (70) through compressed air;
the second temperature control device includes:
and the radiating fin (50) is arranged on the outer wall of the powder receiving cabin and used for radiating the powder receiving cabin.
13. The thermal spray test system according to claim 12, wherein a through hole in which the spray substrate (70) is inserted is provided in a position of the inner wall of the powder collecting chamber corresponding to a position where the spray substrate (70) is disposed, and the compressed air outlet is directed to a surface of the spray substrate (70) on a side away from the spray gun.
14. A testing method based on the thermal spray testing system of any one of claims 1 to 13, comprising:
a spray head of the spray gun extends into a window (11) of the powder receiving cabin;
moving the spray gun according to set parameters, and spraying the spraying substrate (70) so as to form a coating on the spraying substrate (70);
after the thermal spraying is finished, collecting powder scattered in the powder collecting cabin in the thermal spraying process, and weighing the collected powder and the coating by the weighing device;
through data processing device, according to the spray material that the spray gun used, the quality of coating and receive the quality calculation of the powder of collecting in the powder cabin thermal spraying in-process the quality of the material that the spray material was burnt and is lost.
15. Testing method according to claim 14, wherein the heat dissipation opening (12)The distance to the center of the spray substrate (70) is less than 0.8m, and the mass m of the burnt material is calculated by the following formula3：
m3＝m-m1-(m2/(1-p)) (1)
Where m is the total mass of spray material used by the spray gun, m1Is the mass of the coating, m2Is the mass of the powder collected in the powder collecting cabin, and p is the ratio of the area of the heat dissipation opening (12) to the total surface area of the powder collecting cabin.
16. The assay of claim 15, further comprising:
determining the mass content C of elements or components in the powder collected in the powder collecting cabin by adopting a chemical analysis method2And the mass content C of the elements or components in the coating1；
Calculating the mass content C of the element or component in the burnt material by the following formula3：
Figure FDA0002236945900000031
Wherein C is the mass content of the element or component in the spray coating material, C1Is the mass content of an element or component in the coating, C2Is the mass content of the element or component in the powder collected in the powder collecting cabin.
17. Test method according to claim 14, wherein the distance of the heat dissipation opening (12) to the center of the spray substrate (70) is 0.8-1.5 m, the burnt-off material mass m being calculated by the following formula3：
m3＝m-m1-m2； (3)
Wherein m is the total mass of the spray material used by the spray gun, m1Is the mass of the coating, m2Is the mass of the powder collected in the powder collecting cabin.
18. The assay of claim 17, further comprising:
determining the mass content C of elements or components in the powder collected in the powder collecting cabin by adopting a chemical analysis method2And the mass content C of the elements or components in the coating1；
Calculating the mass content C of the element or component in the burnt material by the following formula3：
Figure FDA0002236945900000041
Wherein C is the mass content of the element or component in the spray coating material.
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RU2075535C1 (en) * 1995-01-31 1997-03-20 Институт теоретической и прикладной механики СО РАН Plant for application of coating to internal surface of pipe
CN2447070Y (en) * 2000-10-13 2001-09-12 赖松立 Oddments recovery plant for applying powder
CN101942629A (en) * 2010-09-17 2011-01-12 九江学院 Characterization method for quantifying carbide loss in hot spraying preparation of carbide cermet coating
CN104894504A (en) * 2014-03-05 2015-09-09 镇江布尔机电科技有限公司 Auxiliary apparatus for plate part thermal spraying technology
CN104894501A (en) * 2015-05-21 2015-09-09 广东省工业技术研究院(广州有色金属研究院) Powder gathering device for powder feeding amount measurement of thermal spraying
CN209156210U (en) * 2018-10-23 2019-07-26 漳州市万昆工贸有限公司 A kind of coating painting area powder recovering device

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
RU2075535C1 (en) * 1995-01-31 1997-03-20 Институт теоретической и прикладной механики СО РАН Plant for application of coating to internal surface of pipe
CN2447070Y (en) * 2000-10-13 2001-09-12 赖松立 Oddments recovery plant for applying powder
CN101942629A (en) * 2010-09-17 2011-01-12 九江学院 Characterization method for quantifying carbide loss in hot spraying preparation of carbide cermet coating
CN104894504A (en) * 2014-03-05 2015-09-09 镇江布尔机电科技有限公司 Auxiliary apparatus for plate part thermal spraying technology
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