CN110760781A - Gradient sealing coating structure resistant to gas corrosion and preparation method thereof - Google Patents

Gradient sealing coating structure resistant to gas corrosion and preparation method thereof Download PDF

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Publication number
CN110760781A
CN110760781A CN201910931383.7A CN201910931383A CN110760781A CN 110760781 A CN110760781 A CN 110760781A CN 201910931383 A CN201910931383 A CN 201910931383A CN 110760781 A CN110760781 A CN 110760781A
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aluminum
nickel
percent
silicon
corrosion
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刘刚锋
欧阳德刚
粟伟明
冯乾鸿
田维汉
杜娜
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Wuhan Iron and Steel Co Ltd
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Wuhan Iron and Steel 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
    • C23C4/134—Plasma 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
    • C23C4/04—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
    • C23C4/18—After-treatment

Abstract

The invention discloses a gradient sealing coating structure resisting gas corrosion, which comprises: a substrate; a bottom layer disposed over the base; the surface layer is arranged above the bottom layer; wherein the matrix is Cr which can prevent corrosion of tar, naphthalene, benzene and sulfide17Ni4Cu4Nb corrosion resistant steel; the matrix material is Cr17Ni4Cu4The chromium of the Nb corrosion-resistant steel can perform oxidation reaction with the oxidizing medium in the coal gas to form a chromium-rich oxide film to prevent the oxidizing medium from permeating inwards through the metal surface, and can be automatically recovered to realize corrosion resistance, and meanwhile, the plasma of chromium and molybdenum in the matrix material can automatically supplement sulfur ions for involutionThe space formed by the point corrosion of the gold steel forms a compact protective layer, prevents the point corrosion from developing to the depth direction, has the functions of corrosion resistance and corrosion resistance, meets the requirement that a gas compressor matrix prevents the gas pollutant from being corroded, and improves the compressor efficiency of a compressor and the generating efficiency of a CCPP generating set.

Description

Gradient sealing coating structure resistant to gas corrosion and preparation method thereof
Technical Field
The invention belongs to the technical field of sealing coatings in the steel industry, and particularly relates to a gradient sealing coating structure resistant to gas corrosion and a preparation method thereof.
Background
With the increasing development of aviation technology and the increasing shortage of energy sources, higher and higher requirements are put on the efficiency of the engine. According to the introduction of data, in a high-pressure turbine, when the clearance between a blade and a shell is reduced by 0.13-0.25 mm, the oil consumption can be reduced by 0.5-1.0%, and the efficiency of the engine can be improved by about 2%. However, during the manufacture and operation of the engine, the engine is not free of engine fouling due to: thermal expansion of engine components and thermal deformation of the shaft; the rotor rotates at high speed, and blades extend due to centrifugal force; tolerances in part machining and engine assembly; the clearance cannot be controlled to be substantially zero due to vibration caused by acceleration/deceleration of the engine, landing of the aircraft, and the like, displacement of components caused by vibration, and the like. Thus, in the design and manufacture of aircraft engines, a clearance of 2-3mm must be provided between the blade tip and the casing, but excessive clearance will necessitate substantial leakage of gas, resulting in reduced engine efficiency, while the presence of the abradable composite coating will help to minimize the clearance. An ideal abradable composite coating should have both sufficient strength to resist erosion by the compressed media and some abradability such that the coating is scraped away from damage to the blade when the blade is rubbed against the coating by frictional impact.
At present, the composite gradient sealing coating is mainly applied to the field of military aviation, the compression medium of the composite gradient sealing coating is mainly clean air, the CCPP gas compressor compression medium of the steel enterprise is mainly blast furnace and coke oven gas which are byproducts of the steel enterprise, the gas contains a large amount of corrosive pollutants such as hydrogen sulfide tar, naphthalene, benzene, sulfide, water vapor, solid particles and the like, the pollutants such as the hydrogen sulfide enter a gas compressor flow channel to form acidic strong corrosive substances with water separated out in the cooling process of the compressor, the sealing layer is damaged and falls off through chemical corrosion, and the service life of the sealing coating is shortened. Therefore, the development and research of a medium-low temperature sealing coating suitable for CCPP gas compressors in the domestic steel industry are urgently needed.
Therefore, a gradient sealing coating structure resistant to gas corrosion is provided.
Disclosure of Invention
The invention aims to provide a gradient sealing coating structure resisting gas corrosion so as to solve the problems in the background technology.
In order to achieve the purpose, the invention adopts the following technical scheme: a gas corrosion resistant gradient seal coating structure comprising:
a substrate;
a bottom layer disposed over the base;
the surface layer is arranged above the bottom layer;
wherein the matrix is selected from tar, naphthalene, benzene,
Sulfide-corroded Cr17Ni4Cu4The Nb corrosion-resistant steel is prepared from the following raw materials in percentage by mass: manganese: 0 to 1 percent; chromium: 15.5 to 17.5 percent; silicon: 0 to 1 percent; nickel: 3 to 5 percent; copper: 3 to 5 percent; niobium: 0.15 to 0.45 percent; the balance being iron;
the bottom layer is nickel-aluminum mixed powder with complete cladding and good tissue uniformity, and the nickel-aluminum mixed powder is prepared from the following raw materials in percentage by mass: the mass percent of nickel is 75-85%, and the mass percent of aluminum is 15-25%;
the surface layer is aluminum-silicon-graphite composed of silicon and graphite, the aluminum-silicon-graphite is divided into a high-pressure sealing layer and a low-pressure sealing layer, and the high-pressure sealing layer is prepared from the following raw materials in percentage by mass: the low-pressure sealing layer is prepared from the following raw materials in percentage by mass: 30-50% of aluminum and silicon, 50-60% of graphite and 0-15% of molybdenum.
The present invention is further preferred: the core of the bottom layer is nickel, and a layer of aluminum metal particles is wrapped on the surface of the nickel.
The present invention is further preferred: the thickness of the surface layer is 1.5-2 mm.
The present invention is further preferred: the thickness of the bottom layer is 0.2-0.25 mm.
The invention also provides a preparation method of the gradient sealing coating structure resisting gas corrosion, which comprises the following steps:
s1, preparing a matrix: mixing manganese, chromium, silicon, nickel, copper, niobium and iron according to a certain proportion, smelting and cooling to obtain the Cr capable of preventing corrosion of tar, naphthalene, benzene and sulfide17Ni4Cu4The Nb corrosion-resistant steel is prepared from the following raw materials in percentage by mass: manganese: 0 to 1 percent; chromium: 15.5 to 17.5 percent; silicon: 0 to 1 percent; nickel: 3 to 5 percent; copper: 3 to 5 percent; niobium: 0.15 to 0.45 percent; the balance being iron;
s2, preparing a bottom layer: coating a layer of aluminum metal particles on the surface of nickel to prepare nickel-aluminum mixed powder with complete coating and good tissue uniformity, wherein the nickel and the aluminum in the nickel-aluminum mixed powder are as follows by mass percent: the mass percent of nickel is 75-85%, and the mass percent of aluminum is 15-25%;
s3, preparing a surface layer: mixing aluminum, silicon and graphite, and cooling to obtain aluminum-silicon graphite, wherein the aluminum-silicon graphite is divided into a high-pressure sealing layer and a low-pressure sealing layer, and the high-pressure sealing layer is prepared from the following raw materials in percentage by mass: the low-pressure sealing layer is prepared from the following raw materials in percentage by mass: 30-50% of aluminum and silicon, 50-60% of graphite and 0-15% of molybdenum;
and S4, rolling the bottom layer on the substrate, and then rolling the surface layer on the bottom layer to obtain the gradient sealing coating resistant to gas corrosion.
The present invention is further preferred: in S1, the temperature is 1500-1600 ℃ when the manganese, the chromium, the silicon, the nickel, the copper, the niobium and the iron are mixed and smelted according to the proportion.
The present invention is further preferred: mixing and smelting manganese, chromium, silicon, nickel, copper, niobium and iron according to a proportion, and cooling for later use.
The present invention is further preferred: in S3, the coating mass structure distribution is achieved by controlling the plasma torch flow rate while mixing the aluminum, silicon, and graphite.
The invention has the technical effects and advantages that: compared with the prior art, the gradient sealing coating structure resistant to gas corrosion provided by the invention has the following advantages:
firstly, the matrix material is Cr17Ni4Cu4Chromium of the Nb corrosion-resistant steel can perform oxidation reaction with an oxidizing medium in coal gas to form a chromium-rich oxide film to prevent the oxidizing medium from permeating inwards through the metal surface, and can be automatically recovered to realize corrosion resistance and corrosion resistance;
the bottom layer material of the sealing coating is nickel-aluminum mixed powder coated with nickel by nano-scale aluminum powder with smaller particles and better tissue uniformity, aluminum and nickel can fully react to generate exothermic reaction during plasma spraying, so that the powder is in micro-metallurgical bonding with the surface of a matrix, the bonding strength of the coating is increased, molybdenum element is added into the coating, molybdenum and aluminum also generate exothermic reaction to produce molybdenum aluminide intermetallic compounds besides aluminum and nickel generate exothermic reaction to generate nickel aluminide compounds during plasma spraying, the thickness and the bonding performance of the coating are improved, the porosity is reduced, the sealing coating is prevented from being peeled and lost, and the compressor efficiency of a compressor and the electricity generation efficiency of a CCPP (cyclic propylene glycol terephthalate) generator set are improved;
the aluminum-silicon-graphite mixing mass percentage in the surface layer material can be properly adjusted according to different requirements of the CCPP gas compressor on the abradability and the erosion resistance, the requirement on the erosion resistance of a high-pressure-level balance hub part is higher, and the aluminum-silicon mass percentage can be increased to enhance the erosion resistance of the sealing coating; the low-pressure part has higher requirement on the abradability, can increase the mass percentage of graphite with the lubricating effect, and reduce the damage to the rotor caused by mechanical collision of the sealing coating and the rotor, so that the high-efficiency sealing and the service cycle extension can be realized according to different parts.
Drawings
FIG. 1 is a schematic structural view of the present invention;
FIG. 2 is a schematic diagram of the chemical structure of the aluminum-silicon graphite of the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. The specific embodiments described herein are merely illustrative of the invention and do not delimit the invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
In order to solve the technical problems, the principle of the technical scheme in the embodiment of the application is as follows:
the invention provides a gas corrosion resistant gradient sealing coating structure as shown in figure 1, which comprises:
a substrate;
a bottom layer disposed over the base;
the surface layer is arranged above the bottom layer;
wherein the matrix is Cr which can prevent corrosion of tar, naphthalene, benzene and sulfide17Ni4Cu4The Nb corrosion-resistant steel is prepared from the following raw materials in percentage by mass: manganese: 0 to 1 percent; chromium: 15.5 to 17.5 percent; silicon: 0 to 1 percent; nickel: 3 to 5 percent; copper: 3 to 5 percent; niobium: 0.15 to 0.45 percent(ii) a The balance being iron; the matrix material is Cr17Ni4Cu4Chromium and nickel in the Nb corrosion-resistant steel can be subjected to oxidation reaction with oxygen in the coal gas to form a protective film to realize corrosion resistance, and the matrix material is Cr17Ni4Cu4The plasma of chromium and molybdenum in the Nb corrosion-resistant steel can automatically supplement a space formed by the spot corrosion of sulfide ions on the alloy steel to form a compact protective layer, so that the spot corrosion is prevented from developing in the depth direction, the corrosion-resistant and corrosion-resistant functions are realized, and the service life of a matrix is prolonged;
the bottom layer is nickel-aluminum mixed powder with complete cladding and good tissue uniformity, and the nickel-aluminum mixed powder is prepared from the following raw materials in percentage by mass: the mass percent of nickel is 75-85%, and the mass percent of aluminum is 15-25%; the bottom layer adopts nickel-aluminum mixed powder, nickel and aluminum can both generate oxidation reaction with oxygen in coal gas to form a protective film to realize corrosion resistance, and meanwhile, the material of the bottom layer of the sealing coating is nano-grade aluminum powder coated with nickel, the particles of the nickel-aluminum powder are smaller, the tissue uniformity of the nickel-aluminum powder is better, and the aluminum and the nickel can fully react to generate exothermic reaction during plasma spraying so as to form intermetallic compounds on the surfaces of the powder and the matrix to realize micro-metallurgical bonding, thereby increasing the bonding strength of the coating;
the surface layer is aluminum-silicon-graphite composed of silicon and graphite, the aluminum-silicon-graphite is divided into a high-pressure sealing layer and a low-pressure sealing layer, and the high-pressure sealing layer is prepared from the following raw materials in percentage by mass: the low-pressure sealing layer is prepared from the following raw materials in percentage by mass: 30-50% of aluminum and silicon, 30-50% of graphite and 0-15% of molybdenum; the mixed mass percentage of the alumina silica graphite in the surface layer material can be properly adjusted according to different requirements of a CCPP gas compressor on the abradability and the erosion resistance, the stage balance hub with higher pressure grade is more eroded by particles in a compressed medium, and the amplitude change is less influenced by the centrifugal force and the surge effect of a machine set, so that the mass percentage of aluminum and silicon elements is designed to be 30-60%, the mass percentage of graphite is 10-25%, the mass percentage of Mo is 0-15%, the corresponding low-pressure stage and middle stage parts are more influenced by the centrifugal force and the surge effect of the machine set, the impeller easily collides with a sealing coating, the abradability of the sealing coating of the impeller is higher than the erosion resistance in order to avoid damaging the impeller, the mass ratio of the aluminum and the silicon elements is 30-50%, the mass percentage of the graphite is 30-50%, and the mass percentage of the Mo is 0-15%, SiC is a compound combined by covalent bonds, has stable chemical performance, and is hardly corroded by other acid and alkali except strong oxidizing gas and molten alkali, wherein graphite can play a role in lubrication and acid corrosion resistance, and an aluminum-silicon metal silicon-aluminum phase can effectively ensure that the sealing coating has better scouring resistance; meanwhile, the corrosion-resistant coating can enable the performances of abradability, erosion resistance, corrosion resistance and the like of the sealing coating to be optimal by adjusting the mass percentage of the material.
The invention specifically comprises the following steps: the core of the bottom layer is nickel, and a layer of aluminum metal particles is wrapped on the surface of the nickel.
By adopting the technical scheme, when the nickel-aluminum powder-aluminum-coated nickel is heated to the melting point of aluminum, a violent chemical combination reaction occurs between nickel and aluminum, and simultaneously, a large amount of heat is released to form an intermetallic compound, so that micro-metallurgical bonding is formed between the coating and the matrix, and meanwhile, the heat release interval of the aluminum-coated nickel powder is larger than that of the nickel-coated aluminum powder, so that the aluminum-coated nickel powder and the metal matrix are easier to form micro-metallurgical bonding in the plasma spraying process.
The invention specifically comprises the following steps: the thickness of the surface layer is 1.5-2 mm.
By adopting the technical scheme, the surface layer material is aluminum silicon graphite consisting of a metal phase and silicon carbide, wherein SiC is a compound combined by covalent bonds, the chemical property is stable, strong oxidizing gas and molten alkali are removed, the corrosion of other acid and alkali is hardly caused, the lubricating effect and the acid corrosion resistance can be realized, and the abradability and the corrosion resistance are enhanced; meanwhile, the thickness of the surface layer is 1.5-2.0 mm, so that the surface stress among the bottom layer, the base body and the surface layer can be effectively released, and the impeller and the sealing coating are prevented from mechanical collision in the compression process of the compressor.
The invention specifically comprises the following steps: the thickness of the bottom layer is 0.2-0.25 mm.
By adopting the technical scheme, the bottom layer is used as a transition layer for relieving the interface stress of the substrate and the surface layer, the reaction of aluminum and nickel is insufficient easily in the plasma spraying process when the thickness is too large, the intermetallic compound can not be formed to realize micro-metallurgical bonding, and the bonding strength of the coating is reduced; the interface stress between the surface layer and the base body cannot be effectively relieved due to the fact that the thickness of the bottom layer is too small, the sealing coating is prone to being damaged and peeled off, therefore, the thickness of the bottom layer is set to be 0.2-0.25mm, aluminum and nickel can be fully reacted in the plasma spraying process, intermetallic compounds are formed, micro-metallurgical bonding is achieved, the bonding strength of the coating is improved, and meanwhile, the interface stress between the surface layer and the base body is effectively relieved.
The invention also provides a preparation method of the gradient sealing coating structure resisting gas corrosion, which comprises the following steps:
s1, preparing a matrix: mixing manganese, chromium, silicon, nickel, copper, niobium and iron according to a certain proportion, smelting and cooling to obtain the Cr capable of preventing corrosion of tar, naphthalene, benzene and sulfide17Ni4Cu4The Nb corrosion-resistant steel is prepared from the following raw materials in percentage by mass: manganese: 0 to 1 percent; chromium: 15.5 to 17.5 percent; silicon: 0 to 1 percent; nickel: 3 to 5 percent; copper: 3 to 5 percent; niobium: 0.15 to 0.45 percent; the balance being iron;
s2, preparing a bottom layer: coating a layer of aluminum metal particles on the surface of nickel to prepare nickel-aluminum mixed powder with complete coating and good tissue uniformity, wherein the nickel and the aluminum in the nickel-aluminum mixed powder are as follows by mass percent: the mass percent of nickel is 75-85%, and the mass percent of aluminum is 15-25%;
s3, preparing a surface layer: mixing aluminum, silicon and graphite, and cooling to obtain aluminum-silicon graphite, wherein the aluminum-silicon graphite is divided into a high-pressure sealing layer and a low-pressure sealing layer, and the high-pressure sealing layer is prepared from the following raw materials in percentage by mass: the low-pressure sealing layer is prepared from the following raw materials in percentage by mass: 30-50% of aluminum and silicon, 30-50% of graphite and 0-15% of molybdenum;
and S4, rolling the bottom layer on the substrate, and then rolling the surface layer on the bottom layer to obtain the gradient sealing coating resistant to gas corrosion.
The invention specifically comprises the following steps: in S1, the temperature is 1500-1600 ℃ when the manganese, the chromium, the silicon, the nickel, the copper, the niobium and the iron are mixed and smelted according to the proportion.
By adopting the technical scheme, the method has the advantages that,
the invention specifically comprises the following steps: mixing and smelting manganese, chromium, silicon, nickel, copper, niobium and iron according to a proportion, and cooling for later use.
By adopting the technical scheme, the qualified corrosion-resistant steel is produced by controlling the mixing temperature, time and rotating speed.
The invention specifically comprises the following steps: in S3, the coating mass distribution is achieved by controlling the torch flow rate in the plasma spray process while mixing the aluminum, silicon, and graphite.
By adopting the technical scheme, the mixing temperature, time and rotating speed can be controlled, and the qualified aluminum-silicon graphite can be produced.
The working principle is as follows: the matrix material is Cr17Ni4Cu4Chromium of the Nb corrosion-resistant steel can perform oxidation reaction with an oxidizing medium in coal gas to form a chromium-rich oxide film to prevent the oxidizing medium from permeating inwards through the metal surface, and can be automatically recovered to realize corrosion resistance and corrosion resistance; the bottom layer material of the sealing coating is nickel-aluminum mixed powder of nano-scale aluminum powder coated nickel with smaller particles and better tissue uniformity, aluminum and nickel can fully react to generate exothermic reaction during plasma spraying so as to realize micro-metallurgical bonding between the powder and the surface of a matrix, the bonding strength of the coating is increased, molybdenum element is added into the coating, and molybdenum and aluminum also generate exothermic reaction to produce nickel aluminum compound besides aluminum and nickel generate exothermic reaction to generate nickel aluminum compound during plasma sprayingThe molybdenum aluminide intermetallic compound improves the thickness and the bonding performance of the coating, reduces the porosity, avoids the peeling failure of the sealing coating, and improves the compressor efficiency of a compressor and the power generation efficiency of a CCPP generator set; the aluminum-silicon-graphite mixing mass percentage in the surface layer material can be properly adjusted according to different requirements of the CCPP gas compressor on the abradability and the erosion resistance, the requirement on the erosion resistance of a high-pressure-level balance hub part is higher, and the erosion resistance of the sealing coating can be enhanced by increasing the aluminum-silicon mass percentage; the low-pressure part has higher requirement on the abradability, can increase the mass percentage of graphite with the lubricating effect, and reduce the damage to the rotor caused by mechanical collision of the sealing coating and the rotor, so that the high-efficiency sealing and the service cycle extension can be realized according to different parts.
Example one
The CCPP seven-grade gas compressor seal of a certain steel mill is taken as an example: and three sealing coating performance tests of the same structure and structure components of the matrix and the transition layer material and different structure and structure components of the surface layer material are carried out by plasma spraying in the same spraying process.
The matrix base material is corrosion-resistant steel; the bottom layer is nano nickel-aluminum powder with complete cladding and good tissue uniformity, and the aluminum-clad nickel mixed powder takes nickel as a core and is coated with a layer of aluminum metal particles on the surface, wherein the mass percent of nickel is 80 percent, and the mass percent of aluminum is 20 percent;
the surface layer material is composite material aluminum silicon polyphenyl ester, wherein the mass percent of aluminum and silicon elements is 65%, the mass percent of polyphenyl ester is 25%, and the mass percent of Mo is 10%.
Example two
The CCPP seven-grade gas compressor seal of a certain steel mill is taken as an example: and three sealing coating performance tests of the same structure and structure components of the matrix and the transition layer material and different structure and structure components of the surface layer material are carried out by plasma spraying in the same spraying process.
The matrix base material is corrosion-resistant steel; the bottom layer is nano nickel-aluminum powder with complete cladding and good tissue uniformity, and the aluminum-clad nickel mixed powder takes nickel as a core and is coated with a layer of aluminum metal particles on the surface, wherein the mass percent of nickel is 3 percent, and the mass percent of aluminum is 3 percent;
the surface layer material is made of corrosion-resistant material aluminum silicon graphite, wherein the aluminum mass percent is 30%, the silicon mass percent is 35%, and the graphite mass percent is 35%.
EXAMPLE III
The matrix material is corrosion-resistant steel; the bottom layer is nano nickel-aluminum powder with complete cladding and good tissue uniformity, and the aluminum-clad nickel mixed powder takes nickel as a core and is coated with a layer of aluminum metal particles on the surface, wherein the mass percent of nickel is 5 percent, and the mass percent of aluminum is 5 percent;
the surface layer material is made of corrosion-resistant material aluminum silicon graphite, the coating material is adjusted according to different erosion of medium on the sealing coating of different pressure levels, the quality percentage of the components of the coating material is adjusted according to different naphthalene erosion and abradability of the sealing coating, the high-pressure portion of the gas compressor has higher requirements on the erosion and abradability of the coating, and the components are designed as follows: 35 percent of aluminum, 50 percent of silicon and 15 percent of graphite; the low-pressure part has higher requirement on the abradability of the sealing coating, and the component design is as follows: 30 percent of aluminum, 45 percent of silicon and 25 percent of graphite.
The invention also provides a sealing coating prepared by the first embodiment, the second embodiment and the third embodiment, so as to test the performance of the sealing coating, and the test results are shown in Table 1
TABLE 1 results of coating Performance test for different texture Components
Figure BDA0002218144480000071
Finally, it should also be noted that the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.
While preferred embodiments of the present invention have been described, additional variations and modifications in those embodiments may occur to those skilled in the art once they learn of the basic inventive concepts. Therefore, it is intended that the appended claims be interpreted as including preferred embodiments and all such alterations and modifications as fall within the scope of the invention.
It will be apparent to those skilled in the art that various changes and modifications may be made in the present invention without departing from the spirit and scope of the invention. Thus, if such modifications and variations of the present invention fall within the scope of the claims of the present invention and their equivalents, the present invention is also intended to include such modifications and variations.

Claims (8)

1. A gradient seal coating structure capable of resisting gas corrosion is characterized by comprising:
a substrate;
a bottom layer disposed over the base;
the surface layer is arranged above the bottom layer;
wherein the matrix is Cr which can prevent corrosion of tar, naphthalene, benzene and sulfide17Ni4Cu4The Nb corrosion-resistant steel is prepared from the following raw materials in percentage by mass: manganese: 0 to 1 percent; chromium: 15.5 to 17.5 percent; silicon: 0 to 1 percent; nickel: 3 to 5 percent; copper: 3 to 5 percent; niobium: 0.15 to 0.45 percent; the balance being iron;
the bottom layer is nickel-aluminum mixed powder with complete cladding and good tissue uniformity, and the nickel-aluminum mixed powder is prepared from the following raw materials in percentage by mass: the mass percent of nickel is 75-85%, and the mass percent of aluminum is 15-25%;
the surface layer is aluminum-silicon-graphite composed of silicon and graphite, the aluminum-silicon-graphite is divided into a high-pressure sealing layer and a low-pressure sealing layer, and the high-pressure sealing layer is prepared from the following raw materials in percentage by mass: the low-pressure sealing layer is prepared from the following raw materials in percentage by mass: 30-50% of aluminum and silicon, 35-50% of graphite and 0-15% of molybdenum.
2. The gas corrosion resistant gradient seal coating structure of claim 1, wherein: the core of the bottom layer is nickel, and a layer of aluminum metal particles is wrapped on the surface of the nickel.
3. The gas corrosion resistant gradient seal coating structure of claim 1, wherein: the thickness of the surface layer is 1.5-2 mm.
4. The gas corrosion resistant gradient seal coating structure of claim 1, wherein: the thickness of the bottom layer is 0.2-0.25 mm.
5. A method for preparing a gradient sealing coating resistant to gas corrosion according to claims 1 to 4, characterized by comprising the following steps:
s1, preparing a matrix: mixing manganese, chromium, silicon, nickel, copper, niobium and iron according to a certain proportion, smelting and cooling to obtain the Cr capable of preventing corrosion of tar, naphthalene, benzene and sulfide17Ni4Cu4The Nb corrosion-resistant steel is prepared from the following raw materials in percentage by mass: manganese: 0 to 1 percent; chromium: 15.5 to 17.5 percent; silicon: 0 to 1 percent; nickel: 3 to 5 percent; copper: 3 to 5 percent; niobium: 0.15 to 0.45 percent; the balance being iron;
s2, preparing a bottom layer: coating a layer of aluminum metal particles on the surface of nickel to prepare nickel-aluminum mixed powder with complete coating and good tissue uniformity, wherein the nickel and the aluminum in the nickel-aluminum mixed powder are as follows by mass percent: the mass percent of nickel is 75-85%, and the mass percent of aluminum is 15-25%;
s3, preparing a surface layer: mixing aluminum, silicon and graphite, and cooling to obtain aluminum-silicon graphite, wherein the aluminum-silicon graphite is divided into a high-pressure sealing layer and a low-pressure sealing layer, and the high-pressure sealing layer is prepared from the following raw materials in percentage by mass: the low-pressure sealing layer is prepared from the following raw materials in percentage by mass: 30-50% of aluminum and silicon, 35-50% of graphite and 0-15% of molybdenum;
and S4, rolling the bottom layer on the substrate, and then rolling the surface layer on the bottom layer to obtain the gradient sealing coating resistant to gas corrosion.
6. The method for preparing the gradient sealing coating structure resisting the gas corrosion according to claim 5, wherein the method comprises the following steps: in S1, the temperature is 1500-1600 ℃ when the manganese, the chromium, the silicon, the nickel, the copper, the niobium and the iron are mixed and smelted according to the proportion.
7. The method for preparing the gradient sealing coating structure resisting gas corrosion according to claim 6, wherein the method comprises the following steps: mixing manganese, chromium, silicon, nickel, copper, niobium and iron in proportion and smelting.
8. The method for preparing the gradient sealing coating structure resisting the gas corrosion according to claim 5, wherein the method comprises the following steps: in S3, the composition ratio is controlled by adjusting the plasma spraying process when mixing aluminum, silicon and graphite.
CN201910931383.7A 2019-09-27 2019-09-27 Gradient sealing coating structure resistant to gas corrosion and preparation method thereof Pending CN110760781A (en)

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