CN111020447A - Hot spraying rare earth alloy coating reinforcing steel bar - Google Patents
Hot spraying rare earth alloy coating reinforcing steel bar Download PDFInfo
- Publication number
- CN111020447A CN111020447A CN201911135085.3A CN201911135085A CN111020447A CN 111020447 A CN111020447 A CN 111020447A CN 201911135085 A CN201911135085 A CN 201911135085A CN 111020447 A CN111020447 A CN 111020447A
- Authority
- CN
- China
- Prior art keywords
- rare earth
- steel bar
- earth alloy
- thermal spraying
- coating
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 238000000576 coating method Methods 0.000 title claims abstract description 184
- 229910045601 alloy Inorganic materials 0.000 title claims abstract description 182
- 239000000956 alloy Substances 0.000 title claims abstract description 182
- 239000011248 coating agent Substances 0.000 title claims abstract description 177
- 229910052761 rare earth metal Inorganic materials 0.000 title claims abstract description 163
- 150000002910 rare earth metals Chemical class 0.000 title claims abstract description 163
- 238000005507 spraying Methods 0.000 title claims abstract description 62
- 229910001294 Reinforcing steel Inorganic materials 0.000 title claims abstract description 60
- 229910000831 Steel Inorganic materials 0.000 claims abstract description 172
- 239000010959 steel Substances 0.000 claims abstract description 172
- 238000007751 thermal spraying Methods 0.000 claims abstract description 118
- 238000004519 manufacturing process Methods 0.000 claims abstract description 32
- 239000003973 paint Substances 0.000 claims abstract description 18
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 claims abstract description 15
- 229910052725 zinc Inorganic materials 0.000 claims abstract description 11
- 229910052802 copper Inorganic materials 0.000 claims abstract description 8
- 229910052720 vanadium Inorganic materials 0.000 claims abstract description 8
- 229910052726 zirconium Inorganic materials 0.000 claims abstract description 8
- 229910052796 boron Inorganic materials 0.000 claims abstract description 7
- 229910052748 manganese Inorganic materials 0.000 claims abstract description 7
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 6
- 229910052719 titanium Inorganic materials 0.000 claims abstract description 6
- 239000011159 matrix material Substances 0.000 claims abstract description 3
- 239000004814 polyurethane Substances 0.000 claims description 52
- 229920002635 polyurethane Polymers 0.000 claims description 52
- 239000007921 spray Substances 0.000 claims description 44
- 239000003795 chemical substances by application Substances 0.000 claims description 38
- 238000007789 sealing Methods 0.000 claims description 37
- 239000011701 zinc Substances 0.000 claims description 19
- 238000010891 electric arc Methods 0.000 claims description 17
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 17
- 239000000047 product Substances 0.000 claims description 16
- 239000000463 material Substances 0.000 claims description 15
- 238000002360 preparation method Methods 0.000 claims description 13
- RTZKZFJDLAIYFH-UHFFFAOYSA-N Diethyl ether Chemical compound CCOCC RTZKZFJDLAIYFH-UHFFFAOYSA-N 0.000 claims description 12
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 claims description 11
- 238000000034 method Methods 0.000 claims description 11
- 238000003723 Smelting Methods 0.000 claims description 10
- 238000013461 design Methods 0.000 claims description 10
- 239000000758 substrate Substances 0.000 claims description 10
- 239000010949 copper Substances 0.000 claims description 9
- 239000010936 titanium Substances 0.000 claims description 9
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 8
- 239000005002 finish coating Substances 0.000 claims description 8
- 239000011572 manganese Substances 0.000 claims description 8
- 238000004806 packaging method and process Methods 0.000 claims description 8
- 239000012535 impurity Substances 0.000 claims description 7
- 239000011777 magnesium Substances 0.000 claims description 7
- 239000002994 raw material Substances 0.000 claims description 7
- 230000003746 surface roughness Effects 0.000 claims description 7
- 238000000137 annealing Methods 0.000 claims description 6
- 238000005422 blasting Methods 0.000 claims description 6
- 238000005266 casting Methods 0.000 claims description 6
- 230000003749 cleanliness Effects 0.000 claims description 6
- 239000000428 dust Substances 0.000 claims description 6
- 239000002245 particle Substances 0.000 claims description 6
- 239000000565 sealant Substances 0.000 claims description 6
- 229910052744 lithium Inorganic materials 0.000 claims description 5
- 229910052749 magnesium Inorganic materials 0.000 claims description 5
- 239000012466 permeate Substances 0.000 claims description 5
- 238000003756 stirring Methods 0.000 claims description 5
- 239000003963 antioxidant agent Substances 0.000 claims description 4
- 230000003078 antioxidant effect Effects 0.000 claims description 4
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- 238000010285 flame spraying Methods 0.000 claims description 4
- 239000000203 mixture Substances 0.000 claims description 4
- 238000012545 processing Methods 0.000 claims description 4
- 238000007670 refining Methods 0.000 claims description 4
- 229910052710 silicon Inorganic materials 0.000 claims description 4
- 229910052684 Cerium Inorganic materials 0.000 claims description 3
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 claims description 3
- 229910052779 Neodymium Inorganic materials 0.000 claims description 3
- 229910052777 Praseodymium Inorganic materials 0.000 claims description 3
- 239000002318 adhesion promoter Substances 0.000 claims description 3
- 239000002518 antifoaming agent Substances 0.000 claims description 3
- 239000012752 auxiliary agent Substances 0.000 claims description 3
- 229910052797 bismuth Inorganic materials 0.000 claims description 3
- 238000009835 boiling Methods 0.000 claims description 3
- GWXLDORMOJMVQZ-UHFFFAOYSA-N cerium Chemical compound [Ce] GWXLDORMOJMVQZ-UHFFFAOYSA-N 0.000 claims description 3
- 239000008367 deionised water Substances 0.000 claims description 3
- 229910021641 deionized water Inorganic materials 0.000 claims description 3
- 239000002270 dispersing agent Substances 0.000 claims description 3
- JBTWLSYIZRCDFO-UHFFFAOYSA-N ethyl methyl carbonate Chemical compound CCOC(=O)OC JBTWLSYIZRCDFO-UHFFFAOYSA-N 0.000 claims description 3
- 238000010438 heat treatment Methods 0.000 claims description 3
- 125000002887 hydroxy group Chemical group [H]O* 0.000 claims description 3
- 230000006698 induction Effects 0.000 claims description 3
- 229910052746 lanthanum Inorganic materials 0.000 claims description 3
- FZLIPJUXYLNCLC-UHFFFAOYSA-N lanthanum atom Chemical compound [La] FZLIPJUXYLNCLC-UHFFFAOYSA-N 0.000 claims description 3
- 238000002156 mixing Methods 0.000 claims description 3
- QEFYFXOXNSNQGX-UHFFFAOYSA-N neodymium atom Chemical compound [Nd] QEFYFXOXNSNQGX-UHFFFAOYSA-N 0.000 claims description 3
- 230000000149 penetrating effect Effects 0.000 claims description 3
- 229920000058 polyacrylate Polymers 0.000 claims description 3
- 229920001228 polyisocyanate Polymers 0.000 claims description 3
- 239000005056 polyisocyanate Substances 0.000 claims description 3
- PUDIUYLPXJFUGB-UHFFFAOYSA-N praseodymium atom Chemical compound [Pr] PUDIUYLPXJFUGB-UHFFFAOYSA-N 0.000 claims description 3
- 238000007665 sagging Methods 0.000 claims description 3
- 239000002904 solvent Substances 0.000 claims description 3
- 239000002562 thickening agent Substances 0.000 claims description 3
- 239000006097 ultraviolet radiation absorber Substances 0.000 claims description 3
- 238000009736 wetting Methods 0.000 claims description 3
- 239000000080 wetting agent Substances 0.000 claims description 3
- 238000005491 wire drawing Methods 0.000 claims description 3
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 claims description 2
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 2
- WHXSMMKQMYFTQS-UHFFFAOYSA-N Lithium Chemical compound [Li] WHXSMMKQMYFTQS-UHFFFAOYSA-N 0.000 claims description 2
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 claims description 2
- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 claims description 2
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims description 2
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 claims description 2
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 claims description 2
- JCXGWMGPZLAOME-UHFFFAOYSA-N bismuth atom Chemical compound [Bi] JCXGWMGPZLAOME-UHFFFAOYSA-N 0.000 claims description 2
- 230000005587 bubbling Effects 0.000 claims description 2
- 238000004140 cleaning Methods 0.000 claims description 2
- 238000005488 sandblasting Methods 0.000 claims description 2
- 239000010703 silicon Substances 0.000 claims description 2
- 239000002893 slag Substances 0.000 claims description 2
- 239000004567 concrete Substances 0.000 abstract description 35
- 229920006334 epoxy coating Polymers 0.000 abstract description 30
- 230000007797 corrosion Effects 0.000 abstract description 21
- 238000005260 corrosion Methods 0.000 abstract description 21
- 229910000611 Zinc aluminium Inorganic materials 0.000 abstract description 12
- HXFVOUUOTHJFPX-UHFFFAOYSA-N alumane;zinc Chemical compound [AlH3].[Zn] HXFVOUUOTHJFPX-UHFFFAOYSA-N 0.000 abstract description 12
- 239000011247 coating layer Substances 0.000 abstract description 10
- 238000004873 anchoring Methods 0.000 abstract description 9
- 230000008439 repair process Effects 0.000 abstract description 5
- 229910052751 metal Inorganic materials 0.000 abstract description 4
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- 230000000694 effects Effects 0.000 description 8
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- 238000010586 diagram Methods 0.000 description 3
- 238000005498 polishing Methods 0.000 description 3
- 238000003860 storage Methods 0.000 description 3
- 229910001335 Galvanized steel Inorganic materials 0.000 description 2
- 239000000853 adhesive Substances 0.000 description 2
- 239000010953 base metal Substances 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 2
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- 230000006872 improvement Effects 0.000 description 2
- 238000001179 sorption measurement Methods 0.000 description 2
- VEXZGXHMUGYJMC-UHFFFAOYSA-M Chloride anion Chemical compound [Cl-] VEXZGXHMUGYJMC-UHFFFAOYSA-M 0.000 description 1
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 1
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 1
- 230000002745 absorbent Effects 0.000 description 1
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- 230000009471 action Effects 0.000 description 1
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- 229910052804 chromium Inorganic materials 0.000 description 1
- 239000011651 chromium Substances 0.000 description 1
- 238000003618 dip coating Methods 0.000 description 1
- 238000007590 electrostatic spraying Methods 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 229910052739 hydrogen Inorganic materials 0.000 description 1
- 239000001257 hydrogen Substances 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 229910001092 metal group alloy Inorganic materials 0.000 description 1
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- 239000002699 waste material Substances 0.000 description 1
- 238000003466 welding Methods 0.000 description 1
- 229910052724 xenon Inorganic materials 0.000 description 1
Images
Classifications
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D175/00—Coating compositions based on polyureas or polyurethanes; Coating compositions based on derivatives of such polymers
- C09D175/04—Polyurethanes
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
- C09D5/002—Priming paints
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
- C09D5/08—Anti-corrosive paints
- C09D5/10—Anti-corrosive paints containing metal dust
- C09D5/103—Anti-corrosive paints containing metal dust containing Al
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
- C09D5/08—Anti-corrosive paints
- C09D5/10—Anti-corrosive paints containing metal dust
- C09D5/106—Anti-corrosive paints containing metal dust containing Zn
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
- C09D5/24—Electrically-conducting paints
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D7/00—Features of coating compositions, not provided for in group C09D5/00; Processes for incorporating ingredients in coating compositions
- C09D7/40—Additives
- C09D7/48—Stabilisers against degradation by oxygen, light or heat
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C18/00—Alloys based on zinc
- C22C18/04—Alloys based on zinc with aluminium as the next major constituent
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C30/00—Alloys containing less than 50% by weight of each constituent
- C22C30/02—Alloys containing less than 50% by weight of each constituent containing copper
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C30/00—Alloys containing less than 50% by weight of each constituent
- C22C30/06—Alloys containing less than 50% by weight of each constituent containing zinc
-
- 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
- C23C4/02—Pretreatment of the material to be coated, e.g. for coating on selected surface areas
-
- 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
-
- 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
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/02—Elements
- C08K3/08—Metals
- C08K2003/0812—Aluminium
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/02—Elements
- C08K3/08—Metals
- C08K2003/0893—Zinc
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L2205/00—Polymer mixtures characterised by other features
- C08L2205/02—Polymer mixtures characterised by other features containing two or more polymers of the same C08L -group
- C08L2205/025—Polymer mixtures characterised by other features containing two or more polymers of the same C08L -group containing two or more polymers of the same hierarchy C08L, and differing only in parameters such as density, comonomer content, molecular weight, structure
Abstract
The invention discloses a thermal spraying rare earth alloy coating reinforcing steel bar, which is prepared by adopting a thermal spraying mode and spraying rare earth alloy wires on the surface of a reinforcing steel bar matrix through the steps of mechanical rust removal, thermal spraying, post treatment and the like, wherein the rare earth alloy wires take Zn and Al as main components, Si, Li, Cu, Zr, V, Ti, B, Mn, rare earth metals and the like are added in a balanced manner, and the hardness, plasticity and toughness of an alloy and a coating and the shielding and cathode protection performance of a metal thermal spraying coating layer are optimized; the surface of the concrete is easy to be compatibly bonded by adopting a two-component waterborne polyurethane sealant and finish paint; the production efficiency is improved by adopting the production lines with the structures of ten, x, meter and the like. The invention solves the common technical problems that the relative bonding strength of the epoxy coating steel bar and the zinc-aluminum coating steel bar with concrete is greatly reduced, the anchoring length of the steel bar is increased by 25 percent, the corrosion resistance and durability are insufficient, the cut and the damaged part are difficult to repair on site and the like in the prior art, and has good application prospect.
Description
Technical Field
The invention relates to a coated steel bar technology, in particular to a hot-sprayed rare earth alloy coated steel bar, belonging to the technical field of application and protection of constructional engineering steel.
Background
In order to prolong the service life of reinforced concrete engineering in severe corrosive environment and meet the design requirement of long service life of reinforced concrete structural engineering such as harbor wharfs, cross-sea bridges, tunnels, offshore oil production platforms and the like, the research of optimizing epoxy resin coating reinforcing steel bars for Bin-West Faneya bridges in 1973 is the leading research to solve the problem of reinforcing steel bar corrosion and obtain good effect, and then the epoxy resin coating reinforcing steel bar technology is widely adopted in countries and regions such as America, Japan, Europe, middle east and the like. Since the last 80 th century, after the technology is tried and put forward in China, the technology of epoxy resin coating reinforcing steel bars is popularized and put forward in China at present, and positive effects are achieved.
Epoxy resin coating reinforcing steel bar is under the factory production condition, adopts the electrostatic spraying method to spray epoxy resin powder on reinforcing steel bar surface and makes, and epoxy resin coating reinforcing steel bar must have its own defect. Firstly, the existing epoxy coating has high hardness and large brittleness, is easy to cause local damage, such as easy damage of the epoxy coating in storage, transportation, bending and construction, increases the product repair investment, influences the engineering application and construction, and causes numerous hidden dangers to the engineering anticorrosion service life, safe operation and the like; secondly, the surface of the epoxy coating is smooth, and the epoxy coating is adhered to the concrete mainly by virtue of a horizontal component force of an occlusion effect, so that the bonding strength of the coating steel bar and the concrete is greatly lower than that of a common steel bar, and the bonding strength of the coating steel bar and the concrete is reduced by 13%, therefore, the anchoring length of the epoxy coating steel bar needs to be increased by 25% compared with that of the common steel bar, and the engineering investment is increased; thirdly, the epoxy coating does not have self-repairing capability, and once the epoxy coating is damaged or invaded by a corrosive medium, the corrosion resistance of the epoxy coating is rapidly reduced, so that the service life of a building is directly influenced; fourthly, the epoxy coating has shielding insulativity, so that the epoxy coating steel bar cannot be used together with an impressed current cathodic protection system of engineering, and the performance of the protection effect of a related system is influenced; fifthly, the existing epoxy coating steel bar is found in engineering application, after the epoxy coating steel bar purchased in engineering enters a field, the surface of the epoxy coating appears discoloration and even pulverization after being placed for a few months, the bonding strength of the epoxy coating steel bar and concrete is greatly influenced, and the self corrosion protection capability of the epoxy coating steel bar is also rapidly reduced.
Aiming at the problems of epoxy coating steel bars, galvanized steel bars or zinc-aluminum alloy and other coating steel bars are introduced in the industry, the problems that the epoxy coating is easy to damage, has no self-repairing capability and cannot be used together with an impressed current cathode protection system are solved, the steel bars are popular in the market, the aluminum content in the coating of the coating steel bars is 0.05-0.5% or 4.2-6.2% (GB/T32968-2016 (Zinc-aluminum alloy coating steel bars for reinforced concrete), the corrosion resistance is obviously insufficient in the case of heavy corrosion protection environments, particularly in the case of ocean chloride ion environments, the industrial research and the engineering practical application show that the bonding strength of the coating steel bars and the concrete is obviously reduced and can reach 13% in the severe cases, in addition, the hot dip coating process has hydrogen embrittlement potential, the practical application shows that the fatigue strength of the coating steel bars is generally reduced, cracks are gradually continued from the coating to the steel bars, the industry therefore requires that the anchoring length of galvanized steel bars must also be increased by 25%. The Chinese patent 201310150992.1 'zinc and epoxy double-coating steel bar' proposes a zinc and epoxy double-coating steel bar and a processing method thereof, wherein a zinc layer is thermally sprayed on the surface of the steel bar, an epoxy coating is electrostatically sprayed on the zinc layer, and the double-coating structure overcomes the bad problems caused by coating damage and coating omission of micropores, but the steel bar has the problems that the relative bonding strength with concrete is greatly reduced and the length of an anchoring end is increased by 25% as with a zinc-aluminum coating layer, an epoxy coating composite coating steel bar, an epoxy coating steel bar and the like, and the steel bar can not be used together with an engineering impressed current cathodic protection system.
Chinese patent 201810981069.5 proposes an amorphous protective corrosion-resistant steel bar and a preparation method thereof, wherein an amorphous coating is prepared by adopting a supersonic electric arc spraying technology, and hole sealing treatment is adopted, so that the coating has high bonding strength and low porosity, and a new way is provided for steel bar protection. The self detection result shows that the corrosion potential of the amorphous coating steel bar in the concrete simulated pore liquid is about-460 mV, although the corrosion potential is higher than that of a chromium coating layer (-554mV), the corrosion potential is obviously different from that of zinc, zinc-aluminum alloy and even aluminum, in addition, the amorphous coating does not have a cathode protection effect, the defect on corrosion protection is obvious, and the amorphous coating and an engineering impressed current cathode protection system are difficult to effectively combine to play a role.
Disclosure of Invention
The invention aims to provide a hot spraying rare earth alloy coating reinforcing steel bar, which has the advantages of simple processing and manufacturing process, low product cost, excellent cost performance, no reduction or even improvement of the relative bonding strength with concrete, balanced components of the used rare earth alloy wire, simple and convenient preparation, good corrosion resistance of a coating, balanced cathode protection effect, high adhesion strength with a substrate and the like; the longitudinal step arrangement is adopted during the hot spraying preparation of the reinforcing steel bars, so that the hot spraying consumption is reduced, the productivity is ensured, and the manufacturing cost is reduced. The invention solves the common technical problems that the relative bonding strength of the epoxy coating steel bar and the zinc-aluminum coating steel bar with concrete is greatly reduced, the anchoring length of the steel bar is increased by 25%, the corrosion resistance and durability are insufficient, the cut and the damaged part are difficult to repair on site and the like, and also solves the technical problems that the epoxy coating steel bar (containing the epoxy zinc-plated steel bar) and the zinc-aluminum coating steel bar are respectively subjected to corrosion resistance and solarization and aging resistance.
The invention is realized by the following technical scheme: a thermal spraying rare earth alloy coating steel bar adopts a thermal spraying mode, rare earth alloy wires are sprayed on a steel bar substrate with a cleaned surface to form a thermal spraying rare earth alloy coating, and the specific steps are as follows:
step 1: the mechanical rust removal adopts a sand blasting or shot blasting mechanical rust removal method to remove dust, impurities, oxide skin and rusty materials attached to the surface of the steel bar, the surface cleanliness of the steel bar base material after the mechanical rust removal treatment reaches Sa2.5 grade and above, and the surface roughness reaches Rz60-100 mu m;
step 2: within 0.5h after the mechanical rust removal by thermal spraying, immediately spraying a rare earth alloy wire to the surface of the steel bar matrix qualified in the mechanical rust removal by a thermal spraying spray gun to form a thermal spraying rare earth alloy coating, wherein the thickness of the thermal spraying rare earth alloy coating is 50-200 mu m, the surface of the coating needs to be fine and uniform in particles, and the defects of peeling, bubbling, large molten drop, flow, crack, peeling and the like are not allowed;
and step 3: the post-treatment can be carried out according to the design requirements of the hot-sprayed rare earth alloy coating steel bar product, and the steel bar after the hot-sprayed treatment can be further treated, such as surface protection of the hot-sprayed rare earth alloy coating, fixed-length cutting of the steel bar, notch repairing protection, finished product packaging protection and the like;
the rare earth alloy wire comprises the following components in percentage by weight: 15 to 40 percent of aluminum Al; rare earth metals: 0.01 to 0.02 percent; silicon Si: 3% -6%; copper Cu: 0.05% -2%; zirconium Zr: 0.01 to 0.2 percent; magnesium Mg: 0.02% -0.03%; v, V: 0.01 to 0.5 percent; lithium Li: 0.01 to 1.0 percent; titanium Ti: 0.01 to 0.2 percent; 0.01 to 0.2 percent of boron B; bismuth Bi: 0.01 to 0.2 percent; manganese Mn: 0.05 percent to 0.2 percent; the balance of zinc, Zn and inevitable impurities;
the preparation method of the rare earth alloy wire comprises the following steps: comprises the following components in percentage by weight: rare earth metals: 0.01 to 0.02 percent; si: 3% -6%, Cu: 0.05-2%, Zr: 0.01-0.2%, Mg: 0.02% -0.03%, V: 0.01% -0.5%, Li: 0.01 to 1.0 percent, Ti: 0.01-0.2%, B0.01-0.2%, Bi: 0.01 to 0.2 percent of Mn: 0.05% -0.2%, Zn: 20-30% of the raw materials are mixed and smelted in a hollow induction furnace to prepare an intermediate alloy for later use; then putting 15-40% of Al and the rest Zn into a smelting furnace for smelting at the smelting temperature of 750 +/-10 ℃, refining after the Al and the Zn are completely molten, then adding the prepared intermediate alloy, fully stirring to be molten, standing for 0.5-2 h, removing slag, and casting into a bar; then putting the bar into an electric furnace at 400 +/-20 ℃ for heat treatment for 3-6 h, and horizontally continuously casting to obtain an alloy rough blank with the diameter of 4-8 mm; annealing the rough blank in a vacuum annealing furnace at 200 +/-20 ℃ for 1-2 h, and then reducing the diameter of the rough blank by a wire drawing machine for 3-8 times, and drawing to prepare a rare earth alloy wire with the diameter of 3mm or 2 mm; the drawing speed is controlled to be 20 +/-5 mm/min, and the drawing environment temperature is controlled to be 25 +/-2 ℃;
the rare earth metal is any one of or any two or more of cerium Ce, praseodymium Pr, lanthanum La and neodymium Nd in any ratio.
The surface protection of the thermal spraying rare earth alloy coating is to brush coat a polyurethane primer sealant on the surface of the thermal spraying rare earth alloy coating, wherein the sealant permeates into the interior of the thermal spraying rare earth alloy coating and does not count the thickness. When the sealant brush coating design is performed on the thermal spraying rare earth alloy coating, the thickness of the thermal spraying rare earth alloy coating can be properly adjusted according to engineering requirements, and is preferably 80-120 μm, 100-160 μm, 100-200 μm and the like.
The polyurethane primer sealing agent is preferably water-based and two-component; the polyurethane primer sealing agent comprises a main agent part and a primer part, wherein the main agent part comprises the following raw materials in percentage by weight: 30-35% of hydroxyl-containing polyacrylate dispersoid, 20-25% of aqueous elastic polyurethane dispersoid, 3-5% of alcohol ether solvent, 1.5-2.0% of wetting dispersant, 0.2-0.5% of wetting agent, 0.2-0.6% of defoaming agent, 0.2-0.6% of flatting agent, 0.3-1.0% of thickening agent, 5-10% of flaky zinc powder or aluminum powder, 0.5-1.0% of anti-settling agent, 0.2-4% of anti-sagging auxiliary agent, 0.3-1.5% of adhesion promoter, 0.1-0.5% of antioxidant, 0.1-1% of ultraviolet absorber and the balance of deionized water; the curing agent part comprises the following raw materials: 60-80% of water dispersible polyisocyanate and 20-40% of high boiling point ether ester solvent. Adding flaky zinc powder or aluminum powder to increase the shielding corrosion resistance and conductivity of the closed area, adding an antioxidant and an ultraviolet absorbent to further improve the anti-exposure performance of the closed exposed surface, and ensuring that the steel bar can be exposed for a long time without aging, oxidation and the like in an engineering field even if the steel bar is simply closed and is coated with the rare earth alloy. When the polyurethane primer sealing agent is used, the main agent and the curing agent are mixed according to the mass mixing ratio of 5:1, and the polyurethane primer sealing agent can be used after being uniformly stirred.
In addition, the surface protection of the thermal spraying rare earth alloy coating can be directly coated with polyurethane finish; the polyurethane finish paint is aqueous and double-component; the thickness of the polyurethane finish coating on the upper part of the surface of the thermal spraying rare earth alloy coating is 10-20 mu m, except for the thickness of the polyurethane finish coating penetrating into the thermal spraying rare earth alloy coating. When the thermal spraying rare earth alloy coating is designed by a polyurethane finish brush, the thickness of the thermal spraying rare earth alloy coating can be properly adjusted according to engineering requirements, and is preferably 80-120 μm, 80-160 μm, 100-200 μm and the like.
The surface protection of the thermal spraying rare earth alloy coating can also be realized by brushing a polyurethane primer sealant on the surface of the thermal spraying rare earth alloy coating and then brushing a polyurethane finish, wherein the polyurethane primer sealant permeates into the interior of the thermal spraying rare earth alloy coating without counting the thickness, and the thickness of the polyurethane finish is 20-30 mu m. When the sealer + polyurethane finish composite coating brush coating design is carried out on the thermal spraying rare earth alloy coating, the thickness of the thermal spraying rare earth alloy coating can be properly adjusted according to engineering requirements, and preferably 50-120 μm, 80-160 μm, 100-200 μm and the like.
When the rare earth alloy coating reinforcing steel bars are thermally sprayed, the reinforcing steel bars are laid as follows: the steel bars are in a longitudinal assembly line walking mode overall, and are in a thermal spraying mode of being staggered and arranged in a stepped manner in sequence transversely, the requirements of the horizontal projection and the vertical projection of the steel bars are not overlapped, the horizontal or vertical projection gap between two adjacent steel bars is less than or equal to 5mm, and the tool conditions can be optimized to 3mm or less to 0mm when being met, so that the spraying deposition rate is improved to the maximum degree, and the consumption is reduced; the thermal spraying spray guns are arranged on the periphery of the longitudinal assembly line surrounding the reinforcing steel bars, and are fixedly arranged in at least four positions in a staggered mode along the longitudinal direction of the reinforcing steel bars so as to ensure that spray jets of the spray guns do not interfere with each other. If each reinforcing steel bar on the production line is sprayed from 4 directions of upper, lower, left and right during operation, the cross-shaped cross section of the spray gun along the step-shaped cross section of the reinforcing steel bar production line is in a cross structure; the distance between each spray gun and the surface of the steel bar closest to the spray gun is not less than 150mm, and the distance between each spray gun and the surface of the steel bar farthest from the spray gun is not more than 350mm, so that the optimal spraying distance between each spray gun and the steel bar is ensured, the effect is improved, and the uniform and non-leakage spraying of the rare earth alloy coating on the surface of the steel bar during operation can be ensured.
When the process design needs, if the diameter of the steel bar is larger, the running speed of the steel bar production line is accelerated or the rare earth alloy coating is required to be sprayed more uniformly, the thermal spraying guns can be arranged in 6 or 8 directions around the outer periphery of the longitudinal steel bar production line, and the spraying guns are respectively in a star-shaped or m-shaped structure along the stepped cross section of the steel bar production line, so that the rare earth alloy coating sprayed on the surface of the steel bar is uniform and has no leakage spraying.
The hot spraying mode comprises modes of flame spraying, conventional electric arc spraying, supersonic electric arc spraying, high-power multi-atomization electric arc spraying, double-atomization electric arc spraying, supersonic flame spraying and the like, spray guns can be sequentially arranged along the longitudinal direction of the steel bar, the reliable and uniform spraying of a coating layer in each direction of the steel bar is ensured, the interference among different spray gun jet flows is reduced, the spraying distance from the spray guns to the steel bar and the spacing distance among the spray guns are designed to be optimal, the spraying quality and the spraying efficiency can be remarkably improved, and the spraying consumption is reduced to the greatest extent. The position of the thermal spraying spray gun can be in a fixed state after being laid, the steel bar production line moves forwards, the fixed thermal spraying spray gun realizes stable spraying on the steel bar after adjusting the angle according to the concrete laying condition of the steel bar production line, and the stable quality of a spraying coating can be ensured. When required, the thermal spraying spray gun can be designed to be in a movable working state so as to meet the actual requirements of the operation of the steel bar production line.
The thickness of the thermal spraying alloy coating on the surface of the thermal spraying rare earth alloy coating steel bar is 50-200 mu m, the thermal spraying alloy coating can be preferably 50-120 mu m, 80-160 mu m, 100-200 mu m and the like according to different engineering design actual requirements and corrosion environment conditions, and the minimum thickness of single points of the thermal spraying rare earth alloy coating is not less than 50 mu m. The shielding and cathode protection performance of the thermal spraying rare earth alloy coating is too poor due to the fact that the thermal spraying rare earth alloy coating is too thin, the processing cost of the steel bar is increased due to the fact that the thermal spraying rare earth alloy coating is too thick, and the surface form and the mechanical property of the steel bar and the bonding effect of the steel bar and concrete can be affected.
The existing research shows that the bonding strength between the reinforcing steel bar and the concrete is mainly reflected on the bonding and anchoring between the surface of the reinforcing steel bar and the concrete, namely, the physical adsorption between the concrete and the surface of the reinforcing steel bar, the frictional resistance between the reinforcing steel bar and the reinforcing steel bar when the reinforcing steel bar is pulled, and the mechanical engaging force between the reinforcing steel bar and the reinforcing steel bar. Compared with untreated steel bars, the surface physical adsorption force, the frictional resistance and the mechanical engaging force of the epoxy coating steel bars and the plated steel bars are greatly reduced, and the bonding strength of the epoxy coating steel bars and the plated steel bars and the concrete is realized mainly by the horizontal component force of the engaging action, so that the bonding strength is obviously greatly reduced.
The invention has the beneficial effects that:
the invention adopts the thermal spraying technology to form a layer of thermal spraying rare earth alloy coating on the surface of a steel bar parent metal, so that the surface state of the steel bar is obviously improved while the corrosion resistance is endowed, when concrete is poured, concrete slurry can penetrate into the thermal spraying rare earth alloy coating and even reach the steel bar base body part, therefore, the concrete is tightly and firmly combined with the thermal spraying rare earth alloy coating steel bar into a whole after being gelled, the bonding strength of the thermal spraying rare earth alloy coating steel bar and the concrete generally reaches more than 14MPa, the relative bonding strength reaches 114 percent, even after the coating is closed and finished, the surface of the thermal spraying rare earth alloy coating steel bar has enough roughness, the relative bonding strength between the thermal spraying rare earth alloy coating steel bar and the concrete respectively reaches 105 percent and 98 percent, and the relative bonding strength is not obviously reduced after the corrosion resistance test, and the engineering uses the invention, no 25% increase in length is required at the anchorage ends of the rebars.
The rare earth alloy wire takes Zn and Al as main components, Si, Li, Cu, Zr, V, Ti, B and Mn are added in a balanced manner to optimize the hardness, plasticity and toughness of the alloy and the coating; the composite Mg, Bi and rare earth metals and Si, Li, Cu, Zr, V, Ti, B and Mn have synergistic effect, so that the refining of alloy grains is realized, the intergranular corrosion is prevented, the wear resistance is improved, the excellent corrosion resistance and durability and the good self-adhesive strength of the thermal spraying rare earth alloy coating are ensured through the optimization, the stability and the improvement of the performance of the metal alloy, and the stable, reliable and excellent adhesive capacity of the thermal spraying rare earth alloy coating reinforcing steel bar prepared by using the thermal spraying rare earth alloy wire material and concrete is realized.
The hot spraying repair operation can be conveniently carried out on the notch, the welding point, the mechanical connection part, the damaged part in the transportation and processing process and the like by adopting the hot spraying tool in the production field and the engineering application field of the steel bar, the repaired part is ensured to be integrated with the original hot spraying coating, and the engineering hidden trouble caused by the existing steel bar product repair technology is completely solved.
Aiming at the problems of large thermal spraying loss and low deposition rate, the invention optimizes the thermal spraying mode, innovatively designs the layout of a steel bar production line, and the steel bars longitudinally travel, but do not adopt a plane mode of the traditional production line, but are mutually staggered in a step shape, the horizontal and vertical projection intervals between the steel bars are controlled to be 0, and the thermal spraying spray guns are also easy to layout and position, the design furthest reduces the invalid area of the front spraying components of the fixed thermal spraying guns, such as the upper part, the lower part, the left part, the right part and the like of the production line so as to improve the effective spraying area and avoid the process waste; meanwhile, the steel bars can be ensured to stably move along the production line, and the peripheral surfaces of the steel bars can be completely, uniformly and reliably sprayed with metal coatings.
Aiming at the project with proper requirement on durability, the invention provides a series of designs of thermal spraying and sealing or + finish paint or + sealing and finish paint, the prior art shows that the corrosion resistance of the thermal spraying alloy coating is obviously improved after the coating is sealed, the invention adopts polyurethane primer as the sealing agent, has good weather resistance and durability, does not have the problems of discoloration, light loss and aging of epoxy reinforcing steel bars during site storage, does not have the problem of surface oxidation of galvanized reinforcing steel bars, and the sealing agent is a water-based environment-friendly product, can completely permeate into the alloy coating, ensures that the surface of the closed thermal spraying alloy coating also has good roughness and affinity with concrete slurry, so that the concrete slurry is difficult to permeate into the alloy coating during pouring, but the surface of the total coating still can maintain good bonding capability with concrete, and the bonding strength is slightly higher than that of the untreated steel bar base material.
The invention adopts finish paint coating to further improve the cost performance of products and is beneficial to the popularization and use of small and medium-sized projects, the thickness of the finish paint is controlled below 30 mu m, namely, in order to ensure that the surface of a thermal spraying rare earth alloy coating after finish paint coating can keep certain surface roughness formed by an alloy coating and ensure that the surface of the alloy coating after finish paint coating can still maintain good bonding capability with concrete, the adoption of the water-based finish paint responds to the national environmental protection policy, and the water-based finish paint surface is more easily compatible and adsorbed with concrete slurry, actual tests show that the bonding strength of a steel bar of the thermal spraying rare earth alloy coating after finish paint coating and the concrete is not equal to that of an untreated steel bar base material, and the length of a steel bar anchoring end does not need to be increased by.
Drawings
FIG. 1 is a schematic diagram of the layout of a cross-shaped steel bar production line in a thermal spraying mode.
FIG. 2 is a schematic representation of the coating structure prepared in example 6 of the present invention.
FIG. 3 is a schematic representation of the coating structure prepared in example 7 of the present invention.
FIG. 4 is a schematic representation of the coating structure prepared in example 8 of the present invention.
Fig. 5 is a schematic diagram of the layout of a herringbone reinforcing steel bar production line in the thermal spraying mode.
FIG. 6 is a schematic diagram of the layout of a thermal spraying type steel bar production line shaped like a Chinese character 'mi'.
In the figure, 1-a thermal spraying spray gun, 2-a steel bar substrate, 3-a thermal spraying rare earth alloy coating, 4-a sealing coating and 5-a finish coating.
Detailed Description
The invention is further described with reference to the following figures and examples.
Example 1 to example 3
Rare earth alloy wire materials were prepared having the compositions in weight percent shown in table 1.
Smelting Si, Cu, Zr, Mg, V, Li, Ti, B, Bi, Mn, rare earth metal and the like contained in the components and 20-30% of Zn in a hollow induction furnace to prepare an intermediate alloy for later use;
then putting Al and the rest Zn into a smelting furnace for smelting, wherein the smelting temperature is 750 +/-10 ℃, refining after the Al and the Zn are completely molten, then adding the prepared intermediate alloy, fully stirring until the intermediate alloy is molten, standing for 0.5-2 h, slagging off, and casting into a bar material;
putting the bar into an electric furnace at 400 +/-20 ℃ for heat treatment for 3-6 h, and horizontally continuously casting to obtain an alloy rough blank with the diameter of 4-8 mm; annealing the rough blank in a vacuum annealing furnace at 200 +/-20 ℃ for 1-2 h, and then reducing the diameter of the rough blank by a wire drawing machine for 3-8 times, and drawing to prepare a hot spraying special wire with the diameter of 2mm or 3 mm; the drawing speed is controlled to be 20 +/-5 mm/min, and the drawing environment temperature is controlled to be 25 +/-2 ℃.
Examples 1-3 main performance test data of the rare earth alloy wire and the thermal spraying rare earth alloy coating thereof are shown in table 1, and the comparative sample 1 is ZnAl15, and the comparative sample 2 is Al, which both meet the requirements of GB/T12608-.
Table 1 shows the rare earth alloy wire compositions, properties and thermal spray rare earth alloy coating properties of the rare earth alloy wires of examples 1, 2 and 3
The comparison of the data in the table 1 shows that the cathodic protection performance of the rare earth alloy wire is not obviously reduced by the increase of the Al content, the hardness and the adhesion strength of the metal coating are obviously improved, and the effect is good.
Example 4-example 5
The preparation of the water-based two-component polyurethane primer sealing agent comprises the following components in percentage by weight shown in Table 2
The preparation method of the main agent part comprises the following steps: adding an alcohol ether solvent, a wetting dispersant, a wetting agent, a leveling agent, an anti-settling agent, an adhesion promoter, an antioxidant and an ultraviolet absorber into deionized water according to the weight percentage in the table 2, stirring and dispersing until the fineness is below 30 mu m, adding a hydroxyl-containing polyacrylate dispersoid, a water-based elastic polyurethane dispersoid, flaky zinc powder or aluminum powder, a defoaming agent, a thickening agent and an anti-sagging auxiliary agent, stirring and dispersing for 30min, and then discharging and packaging.
The curing agent part comprises the following raw materials: 60-80% of water dispersible polyisocyanate and 20-40% of high boiling point ether ester solvent, uniformly mixing and dispersing the two according to the weight percentage in the table 2, discharging and packaging.
Examples 4-5 the polyurethane primer sealer primary performance test data is shown in table 2.
TABLE 2 Main Performance test data of aqueous two-component polyurethane primer sealer
Example 6
As shown in FIGS. 1 and 2;
the preparation method of the thermal spraying rare earth alloy coating reinforcing steel bar comprises the following steps: the preparation method of the thermal spraying rare earth alloy coating reinforcing steel bar comprises the following steps: the steel bar production line is arranged in a mode shown in figure 1, and the thermal spraying spray gun 1 is arranged on the periphery of the longitudinal cross section of the steel bar production line 2 and is in a cross-shaped structure.
Step 1: the mechanical rust removal is carried out by a shot blasting machine, dust, impurities, oxide skin and rusty materials attached to the surface of the steel bar are removed, the surface cleanliness of the steel bar substrate reaches grade Sa3, and the surface roughness reaches Rz60-100 mu m;
step 2: after the hot spraying machine derusts the rust, the rare earth alloy wire prepared in the example 1 is sprayed on the surface of the steel bar substrate 2 qualified in derusting by adopting an electric arc spray gun, the traveling speed of the steel bar and the parameters of the hot spraying process are regulated and controlled, the thickness of a hot spraying rare earth alloy coating 3 is 100-200 mu m, and the particles on the surface of the hot spraying rare earth alloy coating are fine and uniform;
and step 3: and after the post-processed reinforcing steel bars are cut to fixed length, manually polishing the notches and the corners smoothly by using an angle grinder, spraying rare earth alloy coatings on the notches and the corners by using a thermal spraying spray gun and the rare earth alloy wires in the embodiment 1 after the requirements of St3 level are met, wherein the thicknesses of the notches and the corners reach 150-200 mu m, and then packaging and warehousing the finished coated reinforcing steel bars by using plastic films or soft cloth.
Example 6 the main performance data for thermally sprayed rare earth alloy coated steel bars are shown in table 3.
Example 7
As shown in fig. 1 and 3;
the preparation method of the thermal spraying rare earth alloy coating reinforcing steel bar comprises the following steps:
step 1: the mechanical derusting shot blasting machine derusts, removes dust, impurities, oxide skin and rusty materials attached to the surface of the steel bar 2, the surface cleanliness of the steel bar base material reaches Sa2.5 grade, and the surface roughness reaches Rz60-100 mu m;
step 2: after the hot spraying machine derusts, the rare earth alloy wire prepared in the example 2 is sprayed on the surface of the steel bar substrate 2 qualified for derusting by using an electric arc spray gun 1, the thickness of a hot spraying rare earth alloy coating 3 is 100-160 mu m, and the surface particles of the hot spraying rare earth alloy coating are fine and uniform.
And step 3: the surface of the thermal spraying rare earth alloy coating 3 is coated with the aqueous bi-component polyurethane primer sealing agent in the embodiment 4, and the coating amount and the coating process are controlled to ensure that the polyurethane primer sealing agent is completely impregnated into the thermal spraying rare earth alloy coating to form the sealing coating 4. The thickness of the sealing coating 4 on the surface of the thermal spraying rare earth alloy coating 3 is not counted, namely, the primer sealing agent is reduced to the greatest extent above the surface of the thermal spraying rare earth alloy coating 3 after the sealing treatment, so that the surface of the thermal spraying rare earth alloy coating 3 on the surface of the steel bar after the sealing treatment can still have good roughness.
In the sealing treatment, in order to ensure that the sealing agent remains on the surface of the hot spraying rare earth alloy coating 3 as little as possible after the coating is sealed, the dosage of the sealing agent is selected and controlled to be 60-90 percent of that of the sealing agent in normal sealing, and the specific method comprises the following steps: firstly, carrying out a plot experiment, selecting a thermal spraying rare earth alloy coating with the same thickness of 1-2m2Sealing coating is carried out according to the conventional sealing requirement, and the dosage M of the sealing agent on unit area is calculated0In the practice of the invention, according to M060-90% of the amount of the rare earth alloy is used for the sealing operation of the thermal spraying rare earth alloy coating.
After the steel bars are cut to a fixed length, the notches and the corners of the notches are smoothly polished manually by an angle grinder, after St 3-level requirements are met, the notches and the corners of the notches are sprayed with rare earth alloy coating layers by using an electric arc spray gun through rare earth alloy wires in example 2, the thickness of the rare earth alloy coating layers reaches 120-180 mu m, then a water-based double-component polyurethane primer sealing agent is adopted and is coated on the surface of the thermal spraying rare earth alloy coating layer 3, the coating amount and the coating process are controlled, the polyurethane primer sealing agent is guaranteed to be completely impregnated into the thermal spraying rare earth alloy coating layers, and the thickness of the sealing agent above the; and finally, packaging and warehousing the finished product of the coated reinforcing steel bar by adopting a plastic film or soft cloth.
Example 7 the main performance data for thermally sprayed rare earth alloy coated steel bars are shown in table 3.
Example 8
As shown in fig. 4 and 5;
the preparation method of the thermal spraying rare earth alloy coating reinforcing steel bar comprises the following steps: the rebar flow line is laid in a "+" fashion as shown in figure 5,
step 1: the mechanical rust removal is carried out by a shot blasting machine, dust, impurities, oxide skin and rusty materials attached to the surface of the steel bar 2 are removed, the surface cleanliness of the steel bar base material reaches Sa2.5 grade, and the surface roughness reaches Rz60-100 mu m;
step 2: after the hot spraying machine derusts, the rare earth alloy wire prepared in the example 2 is sprayed on the surface of the steel bar substrate 2 qualified for derusting by using an electric arc spray gun 1, the thickness of a hot spraying rare earth alloy coating 3 is 80-160 mu m, and the surface particles of the hot spraying rare earth alloy coating are fine and uniform.
And step 3: the post-treatment is shown in figure 4, a commercially available aqueous two-component polyurethane finish is adopted, and a layer of polyurethane finish is brushed on the surface of the thermal spraying rare earth alloy coating 3 to form a sealing coating 4; the thickness of the polyurethane finish coating 5 on the upper part of the surface of the thermal spraying rare earth alloy coating is 10-20 mu m, except for the thickness of the polyurethane finish coating penetrating into the thermal spraying rare earth alloy coating.
And (3) carrying out subsequent treatment after the fixed-length cutting of the reinforcing steel bars, manually polishing the notches and the corners by using an angle grinder, spraying rare earth alloy coatings on the notches and the corners by using an electric arc spray gun after the requirements of St3 level are met, wherein the thickness of the rare earth alloy coatings reaches 100-180 mu m, then coating by using a water-based two-component polyurethane finish paint, firstly coating the finish paint to form a closed coating 4, and then coating the finish paint to form a polyurethane finish paint coating 5, wherein the thickness of the polyurethane finish paint coating reaches 10-20 mu m. And finally, packaging the finished product of the coated reinforcing steel bar by using a plastic film or soft cloth and warehousing.
The thickness of the polyurethane finish coat 5 is controlled to be 10-20 mu m, so that the coated steel bar has good weather resistance and durability, and the coated steel bar still has good roughness formed on the surface of the original thermal spraying rare earth alloy coating, thereby ensuring the bonding strength between the coated steel bar and concrete.
Example 8 the main performance data for thermally sprayed rare earth alloy coated steel bars are shown in table 3.
Example 9
As shown in fig. 4 and 6
The preparation method of the thermal spraying rare earth alloy coating reinforcing steel bar comprises the following steps:
the preparation method of the thermal spraying rare earth alloy coating reinforcing steel bar comprises the following steps: the reinforcing steel bar production line is arranged in a mode of a shape like a Chinese character 'mi' as shown in figure 6
Step 1: the mechanical rust removal is carried out by a shot blasting machine, dust, impurities, oxide skin and rusty materials attached to the surface of the steel bar 2 are removed, the surface cleanliness of the steel bar base material reaches Sa2.5 grade, and the surface roughness reaches Rz60-100 mu m;
step 2: after the hot spraying machine derusts, the rare earth alloy wire prepared in the embodiment 3 is sprayed on the surface of the steel bar substrate 2 qualified for derusting by adopting a supersonic speed electric arc spray gun 1, the thickness of a hot spraying rare earth alloy coating 3 is 50-120 mu m, and the surface particles of the hot spraying rare earth alloy coating are fine and uniform.
And step 3: post-treatment
Firstly, the surface of the thermal spraying rare earth alloy coating 3 is coated with the aqueous bi-component polyurethane primer sealing agent in the embodiment 5, the coating amount and the coating process are controlled, the polyurethane primer sealing agent is ensured to be completely impregnated into the thermal spraying rare earth alloy coating to form a sealing coating 4, and the surface of the thermal spraying rare earth alloy coating still has good roughness after sealing treatment.
Then, brushing a layer of polyurethane finish on the surface of the thermal spraying rare earth alloy coating by using a commercially available aqueous two-component polyurethane finish; the thickness of the polyurethane finish coating 5 on the surface of the thermal spraying rare earth alloy coating 4 is 20-30 mu m.
And (3) carrying out subsequent treatment after the fixed-length cutting of the reinforcing steel bars, manually polishing the notches and the corners smoothly by adopting an angle grinder, spraying rare earth alloy coating layers on the notches and the corners by using an electric arc spray gun after the requirements of St3 level are met, wherein the thickness of the rare earth alloy coating layers reaches 80-120 mu m, and then carrying out bottom coating of the water-based double-component polyurethane primer sealing agent and coating of the water-based double-component polyurethane finish paint. And finally, packaging the finished product of the coated reinforcing steel bar by using a plastic film or soft cloth and warehousing.
The thickness of the polyurethane finish coat 5 is controlled to be 10-20 mu m, so that the coated steel bar has good weather resistance and durability, and the coated steel bar still has good roughness formed on the surface of the original thermal spraying rare earth alloy coating, thereby ensuring the bonding strength between the coated steel bar and concrete.
Example 9 the main properties of the thermally sprayed rare earth alloy coated steel bar are shown in table 3.
TABLE 3 data of main performance test of hot sprayed rare earth alloy coated steel bar
Remarking: the comparative sample 3 is a hot sprayed rare earth alloy coated steel bar and uses a base metal steel bar with the same specification and furnace number, which accords with the national steel standard for the relevant reinforced concrete engineering, and the surface of the steel bar is only subjected to simple ash removal cleaning treatment;
the comparison sample 4 is an epoxy coating steel bar prepared from base steel bars with the same specification, and meets the requirements of JG/T502-2016 epoxy resin coating steel bar;
the comparative sample 5 is a zinc-aluminum alloy coated steel bar prepared from base steel bars with the same specification, and meets the requirements of GB/T32968-2016 zinc-aluminum alloy coated steel bar for reinforced concrete, wherein the Al content is 5%;
the comparison sample 6 is a galvanized epoxy coating steel bar prepared from base steel bars with the same specification, and meets the requirements of JG/T502-2016 epoxy resin coating steel bar.
The measurement data in Table 3 show that the hot sprayed rare earth alloy coated steel bar has good bonding strength with concrete, and the relative bonding strength is not obviously reduced; after the artificial accelerated aging-salt spray test, the relative bonding strength of the zinc-aluminum alloy coating reinforcing steel bar and the concrete is obviously reduced and is lower than 85 percent of qualified line, and the product and the epoxy coating reinforcing steel bar have small change; after the artificial accelerated aging-xenon lamp test, the relative bonding strength of the epoxy coating steel bar and the concrete is obviously reduced and is lower than 85 percent of qualified line, and the product and the zinc-aluminum alloy coating steel bar have little change; the aging test data shows that the product solves the problem that the bonding strength of epoxy coating steel bars and zinc-aluminum alloy coating steel bars with concrete is seriously reduced due to insufficient corrosion resistance and insolation resistance in the processes of product storage, transfer and engineering application.
Test and detection data show that the anchoring end of the steel bar with the thermal spraying rare earth alloy coating can not increase the length by 25 percent, the mechanical properties of the steel bar anchoring and related reinforced concrete structures can meet the same performance requirements of the same kind of base metal steel bars, and the method is safe and reliable.
Claims (10)
1. A hot spraying rare earth alloy coated steel bar is prepared by spraying a rare earth alloy wire onto a steel bar substrate subjected to surface cleaning treatment in a hot spraying mode to form a hot spraying rare earth alloy coating, and is characterized by comprising the following steps of:
step 1: mechanically removing rust; removing dust, impurities, oxide skin and rusty materials attached to the surface of the steel bar by adopting a sand blasting or shot blasting mechanical rust removal method, wherein the surface cleanliness of the steel bar substrate after mechanical rust removal treatment reaches Sa2.5 grade or above, and the surface roughness reaches Rz60-100 mu m;
step 2: thermal spraying; within 0.5h after mechanical rust removal, immediately spraying a thermal spraying spray gun to the rare earth alloy wire on the surface of the steel bar matrix qualified in the mechanical rust removal treatment to form a thermal spraying rare earth alloy coating, wherein the thickness of the thermal spraying rare earth alloy coating is 50-200 mu m, the surface particles are fine and uniform, and the defects of peeling, bubbling, large molten drop, flow, crack and peeling are not allowed; the hot spraying rare earth alloy coating reinforcing steel bar is prepared;
and step 3: post-treatment; according to the design and use requirements of the thermal spraying rare earth alloy coating steel bar product, further processing the steel bar after thermal spraying treatment, including surface protection of the thermal spraying rare earth alloy coating, fixed-length cutting and notch repairing protection of the steel bar, and packaging protection of a finished product;
the rare earth alloy wire comprises the following components in percentage by weight: 15 to 40 percent of aluminum Al; rare earth metals: 0.01 to 0.02 percent; silicon Si: 3% -6%; copper Cu: 0.05% -2%; zirconium Zr: 0.01 to 0.2 percent; magnesium Mg: 0.02% -0.03%; v, V: 0.01 to 0.5 percent; lithium Li: 0.01 to 1.0 percent; titanium Ti: 0.01 to 0.2 percent; b, boron B: 0.01 to 0.2 percent; bismuth Bi: 0.01 to 0.2 percent; manganese Mn: 0.05 percent to 0.2 percent; the balance being zinc Zn.
2. A thermally sprayed rare earth alloy coated steel bar according to claim 1, wherein: the rare earth metal is any one of cerium Ce, praseodymium Pr, lanthanum La and neodymium Nd, or the rare earth metal consisting of any two or more of the cerium Ce, the praseodymium Pr, the lanthanum La and the neodymium Nd according to any mass ratio.
3. A thermally sprayed rare earth alloy coated steel bar according to claim 1, wherein: the preparation method of the rare earth alloy wire comprises the following steps: comprises the following components in percentage by weight: rare earth metals: 0.01% -0.02%, Si: 3% -6%, Cu: 0.05-2%, Zr: 0.01-0.2%, Mg: 0.02% -0.03%, V: 0.01% -0.5%, Li: 0.01 to 1.0 percent, Ti: 0.01% -0.2%, B: 0.01 to 0.2 percent, Bi: 0.01 to 0.2 percent of Mn: 0.05% -0.2%, Zn: 20% -30% of the raw materials are mixed, and the mixture is smelted in a hollow induction furnace to prepare an intermediate alloy for later use; then putting 15-40% of Al and the rest Zn into a smelting furnace for smelting at the smelting temperature of 750 +/-10 ℃, refining after the Al and the Zn are completely molten, then adding the prepared intermediate alloy, fully stirring to be molten, standing for 0.5-2 h, removing slag, and casting into a bar; then putting the bar into an electric furnace at 400 +/-20 ℃ for heat treatment for 3-6 h, and horizontally continuously casting to obtain an alloy rough blank with the diameter of 4-8 mm; annealing the rough blank in a vacuum annealing furnace at 200 +/-20 ℃ for 1-2 h, and then reducing the diameter of the rough blank by a wire drawing machine for 3-8 times, and drawing to prepare a rare earth alloy wire with the diameter of 3mm or 2 mm; the drawing speed is controlled to be 20 +/-5 mm/min, and the drawing environment temperature is controlled to be 25 +/-2 ℃.
4. A thermally sprayed rare earth alloy coated steel bar according to claim 1, wherein: the surface protection of the thermal spraying rare earth alloy coating is to brush a polyurethane primer sealant on the surface of the thermal spraying rare earth alloy coating; the thickness of the thermal spraying rare earth alloy coating can be preferably 100-200 mu m;
the polyurethane primer sealing agent is water-based and double-component, and comprises the following components in percentage by weight: the main agent part comprises the following raw materials: 30-35% of hydroxyl-containing polyacrylate dispersoid, 20-25% of aqueous elastic polyurethane dispersoid, 3-5% of alcohol ether solvent, 1.5-2.0% of wetting dispersant, 0.2-0.5% of wetting agent, 0.2-0.6% of defoaming agent, 0.2-0.6% of flatting agent, 0.3-1.0% of thickening agent, 5-10% of flaky zinc powder or aluminum powder, 0.5-1.0% of anti-settling agent, 0.2-4% of anti-sagging auxiliary agent, 0.3-1.55% of adhesion promoter, 0.1-0.5% of antioxidant, 0.1-1% of ultraviolet absorber and the balance of deionized water; the curing agent part comprises the following raw materials: 60-80% of water dispersible polyisocyanate and 20-40% of high boiling point ether ester solvent; when in use, the main agent and the curing agent are mixed according to the mass mixing ratio of 5:1, and the mixture can be used after being uniformly stirred.
5. A thermally sprayed rare earth alloy coated steel bar according to claim 1, wherein: the surface protection of the thermal spraying rare earth alloy coating is to brush polyurethane finish on the surface of the thermal spraying rare earth alloy coating; the polyurethane finish paint is aqueous and double-component; the thickness of the polyurethane finish coating penetrating into the thermal spraying rare earth alloy coating is not counted, and the thickness of the polyurethane finish coating on the upper part of the surface of the thermal spraying rare earth alloy coating is 10-20 mu m; the thickness of the thermal spraying rare earth alloy coating can be preferably 80-160 mu m.
6. A thermally sprayed rare earth alloy coated steel bar according to claim 1, wherein: the surface protection of the thermal spraying rare earth alloy coating is to brush a polyurethane primer sealer on the surface of the thermal spraying rare earth alloy coating and then brush a polyurethane finish, wherein the polyurethane primer sealer permeates into the interior of the thermal spraying rare earth alloy coating and does not count the thickness, and the thickness of the polyurethane finish is 20-30 mu m; the thickness of the thermal spraying rare earth alloy coating is preferably 50-120 mu m.
7. A thermally sprayed rare earth alloy coated steel bar according to claim 1, wherein: the hot spraying mode comprises the layout of reinforcing steel bars and the layout of a hot spraying spray gun, wherein:
the arrangement of the reinforcing steel bars is as follows: the whole reinforcing steel bars are in a longitudinal assembly line walking mode, the reinforcing steel bars are transversely staggered in a step shape, the mutual horizontal projection and the vertical projection of the reinforcing steel bars are not overlapped, and the horizontal or vertical projection gap between two adjacent reinforcing steel bars is less than or equal to 5 mm; further preferably: the horizontal or vertical projection gap between two adjacent steel bars is 0 mm;
the hot spraying spray gun is arranged as follows: the thermal spraying spray gun is arranged at the periphery surrounding the longitudinal assembly line of the reinforcing steel bars and is arranged along the longitudinal direction of the reinforcing steel bars in a staggered way, and each reinforcing steel bar on the production line is sprayed from a plurality of directions around the reinforcing steel bar; the distance between each spray gun and the surface of the steel bar closest to the spray gun is not less than 150mm, and the distance between each spray gun and the surface of the steel bar farthest from the spray gun is not more than 350 mm.
8. A thermally sprayed rare earth alloy coated steel bar according to claim 7, wherein: the thermal spraying spray gun is arranged at the periphery surrounding the longitudinal production line of the steel bar, and is arranged at 4 positions of the longitudinal production line of the sprayed steel bar, namely the upper position, the lower position, the left position and the right position, and the cross section is in a cross-shaped structure along the advancing direction of the production line of the steel bar;
further preferably: the thermal spraying spray guns are distributed at 6 positions on the periphery of the longitudinal production line of the sprayed steel bars, and the cross sections of the thermal spraying spray guns along the advancing direction of the steel bar production line are of an 'x' shaped structure;
it is still further preferred that: the thermal spraying spray gun is arranged at 8 positions around the periphery of the longitudinal assembly line of the reinforcing steel bar, and the cross section along the advancing direction of the reinforcing steel bar production line is of a structure shaped like a Chinese character 'mi'.
9. A thermally sprayed rare earth alloy coated steel bar according to claim 1, wherein: the thermal spraying comprises flame spraying, electric arc spraying, supersonic speed electric arc spraying, high-power electric arc spraying, multi-atomization electric arc spraying, double-atomization electric arc spraying and supersonic speed flame spraying.
10. A thermally sprayed rare earth alloy coated steel bar according to claim 1, wherein: the thermal spraying spray gun is preferably arranged in a fixed mode.
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