CN111205676A

CN111205676A - Method and system for forming quasi-crystal coating and pot

Info

Publication number: CN111205676A
Application number: CN201811299238.3A
Authority: CN
Inventors: 曹达华; 陈炜杰; 黄宇华; 万鹏
Original assignee: Foshan Shunde Midea Electrical Heating Appliances Manufacturing Co Ltd
Current assignee: Foshan Shunde Midea Electrical Heating Appliances Manufacturing Co Ltd
Priority date: 2018-11-02
Filing date: 2018-11-02
Publication date: 2020-05-29
Anticipated expiration: 2038-11-02
Also published as: CN111205676B; CN113956689B; CN113956689A

Abstract

The invention discloses a method and a system for forming a quasi-crystal coating and a pot. The method for forming the quasicrystalline coating comprises the following steps: (1) carrying out powder making treatment on the quasicrystal alloy ingot so as to obtain quasicrystal powder; (2) annealing the quasicrystal powder to obtain annealed powder; (3) and forming a quasicrystalline coating on the substrate based on the annealed powder. According to the method for forming the quasicrystal coating, the quasicrystal coating is formed by utilizing the annealed quasicrystal powder, so that the surface performance of the quasicrystal coating can be effectively improved.

Description

Method and system for forming quasi-crystal coating and pot

Technical Field

The invention relates to the field of material science, in particular to a method and a system for forming a quasi-crystal coating and a pot tool.

Background

Common non-stick coatings comprise PTFE coatings, PFA coatings, PEEK coatings, ceramic coatings and the like, and organic coatings such as PEEK, PTFE, PFA coatings and the like are widely applied to the surfaces of cookers and rice cooker liners and various easy-to-clean occasions due to excellent chemical thermal stability and self-lubricating (non-stick) performance.

However, existing non-stick coatings remain to be improved.

Disclosure of Invention

The present invention is based on the discovery of the following facts and problems:

the inventors found that, in the research on the non-stick coating, the conventional organic coating such as PTFE or PFA has defects such as low hardness and low adhesion, and is very likely to be scratched by a hard substance to scratch the coating, thereby exposing the substrate originally covered by the coating, and causing the harmful metal (for example, aluminum) in the substrate to escape during use, thus impairing the physical health of the user. While ceramic coatings are susceptible to hydrolysis, the non-stick properties of the coatings tend to decrease with increasing use times.

The quasicrystal material is a material with low surface energy characteristics, and has the characteristics of high hardness, low friction coefficient, wear resistance, corrosion resistance and the like, so that the quasicrystal material has the potential of replacing the existing non-stick coating. Especially Al-Cu-Fe system quasi-crystal alloy, the surface energy is between stainless steel and polytetrafluoroethylene, slightly larger than about 25% of polytetrafluoroethylene; and after elements such as Cr, Ti and the like are added into the quasicrystal alloy, the intergranular corrosion tendency of the quasicrystal alloy can be further reduced, so that the corrosion resistance of the quasicrystal alloy is further improved. However, the preparation cost of the quasicrystal block is high, and the method of spraying the quasicrystal powder on the surface of the base material to form the quasicrystal coating has important economic benefits and cost advantages.

In view of the above, the present invention provides a method and system for forming a quasi-crystal coating and a pot. According to the method for forming the quasicrystal coating, the quasicrystal coating is formed by utilizing the annealed quasicrystal powder, so that the surface performance of the quasicrystal coating can be effectively improved.

In one aspect of the invention, a method of forming a quasicrystalline coating is presented. According to an embodiment of the invention, the method comprises: (1) carrying out powder making treatment on the quasicrystal alloy ingot so as to obtain quasicrystal powder; (2) annealing the quasicrystal powder to obtain annealed powder; (3) and forming a quasicrystalline coating on the substrate based on the annealed powder.

According to the method for forming the quasicrystal coating, provided by the embodiment of the invention, the quasicrystal powder is prepared by using the quasicrystal alloy ingot, and annealing treatment is performed on the quasicrystal powder, so that the quasicrystal content in the quasicrystal powder can be increased, and the quasicrystal coating is formed on the substrate by using the annealed powder. The quasicrystal coating formed by the annealed powder has excellent surface properties such as high hardness, low friction coefficient, wear resistance, corrosion resistance and the like, and has the advantage of low preparation cost; in addition, the quasi-crystal coating is formed by adopting the annealed powder, so that the quasi-crystal content in the quasi-crystal coating can be ensured to be higher, the selectivity of the forming process of the quasi-crystal coating is increased, the annealed powder can be formed on the substrate in a hot spraying, cold spraying or physical vapor deposition mode, the quasi-crystal content in the finally formed quasi-crystal coating cannot be influenced by different preparation processes, the quasi-crystal coating with high quasi-crystal content is obtained, and the non-stick performance, the corrosion resistance and the hardness of the quasi-crystal coating are further increased.

In addition, the method for forming the quasicrystalline coating according to the above embodiment of the present invention may further have the following additional technical features:

in some embodiments of the present invention, in the step (2), the powder in the annealed powder is completely quasicrystal-formed by annealing the quasicrystal powder.

In some embodiments of the present invention, step (3) is preceded by: and (3) selecting a first powder and a second powder from the annealed powders, wherein the particle size of the first powder particle is smaller than that of the second powder particle, and the first powder is used in the step (3).

In some embodiments of the present invention, at least 90% of the particles in the first powder have a particle size no greater than 80 μm, and at least 90% of the particles in the second powder have a particle size greater than 80 μm.

In some embodiments of the present invention, the quasicrystalline alloy ingot is formed by subjecting a mixture containing at least one of an aluminum material, a copper material, an iron material, and a chromium material to a melting process.

In some embodiments of the invention, the atomic percentages of aluminum, copper, iron, and chromium in the mixture are: 60-70% of aluminum, 10-25% of copper, 5-15% of iron and 5-15% of chromium.

In some embodiments of the present invention, the aluminum material is pure aluminum, the copper material is pure copper, the iron material is pure iron, and the chromium material is pure chromium or a chromium-titanium alloy.

In some embodiments of the present invention, the method of forming a quasicrystalline coating further comprises using the second powder for preparing the quasicrystalline alloy ingot.

In some embodiments of the invention, the milling is performed by an atomized milling process.

In some embodiments of the present invention, in the step (2), the annealing treatment is performed in an inert gas atmosphere or under vacuum, and the temperature of the annealing treatment is 700 to 900 ℃.

In some embodiments of the present invention, the oxygen content in the quasicrystalline coating layer is not higher than 10 at%, and preferably, the oxygen content in the quasicrystalline coating layer is 4 to 7 at%.

In some embodiments of the invention, the annealing treatment conditions are: the temperature rising rate is 5-100 ℃/min, the heat preservation time is 0.5-6 h, the temperature reduction rate is 5-100 ℃/min, the temperature is reduced to 200-300 ℃, and the temperature is cooled to the room temperature along with the furnace.

In some embodiments of the present invention, at least 90% of the particles in the first powder have a particle size of not less than 20 μm, and at least 90% of the particles in the second powder have a particle size of not more than 150 μm.

In some embodiments of the present invention, step (3) further comprises: (3-1) forming a first sub-coating layer on the substrate based on the second powder; and (3-2) forming the second sub-coating on the surface of the first sub-coating, which is far away from the substrate, based on the first powder, so as to obtain the quasicrystal coating comprising the first sub-coating and the second sub-coating.

In some embodiments of the present invention, the first sub-coating layer and the second sub-coating layer are formed by a spray coating method.

In some embodiments of the present invention, the first sub-coating layer and the second sub-coating layer are formed by a plasma spraying method.

In some embodiments of the invention, the conditions of the plasma spray process include: the arc power is 25-50 kW, and the arc voltage is 40-50V.

In some embodiments of the present invention, step (3) is followed by polishing the quasicrystalline coating.

In yet another aspect of the invention, the invention provides a system for implementing the method for forming a quasicrystalline coating of the above embodiment. According to an embodiment of the invention, the system comprises: the powder making device is suitable for making powder from the quasi-crystal alloy ingot so as to obtain quasi-crystal powder; the annealing device is connected with the powder making device and is suitable for annealing the quasicrystal powder so as to obtain annealed powder; and the spraying device is connected with the annealing device and is suitable for forming a quasicrystal coating on the substrate based on the annealed powder.

According to the system for forming the quasicrystal coating, the quasicrystal alloy ingot is prepared into the quasicrystal powder by the powder making device, the annealing device is used for annealing the quasicrystal powder, so that the quasicrystal content of the quasicrystal powder can be increased, and the annealed powder is sprayed on the substrate by the spraying device to form the quasicrystal coating. The quasicrystal coating formed by the annealed powder has excellent surface properties such as high hardness, low friction coefficient, wear resistance, corrosion resistance and the like. Therefore, the system for forming the quasicrystal coating can effectively form the quasicrystal coating with the advantages, and has the advantage of low preparation cost; in addition, the quasi-crystal coating is formed by adopting the annealed powder, so that the quasi-crystal content in the quasi-crystal coating can be ensured to be higher, the selectivity of the forming process of the quasi-crystal coating is increased, the annealed powder can be formed on the substrate in a hot spraying, cold spraying or physical vapor deposition mode, the quasi-crystal content in the finally formed quasi-crystal coating cannot be influenced by different preparation processes, the quasi-crystal coating with high quasi-crystal content is obtained, and the non-stick performance, the corrosion resistance and the hardness of the quasi-crystal coating are further increased.

In addition, the system for forming the quasicrystalline coating according to the above embodiment of the present invention may further have the following additional technical features:

in some embodiments of the invention, the system for forming a quasicrystalline coating further comprises: and the screening device is connected with the annealing device and the spraying device and is suitable for screening the annealed powder so as to obtain first powder and second powder, wherein the particle size of at least 90% of particles in the first powder is not more than 80 micrometers, and the particle size of at least 90% of particles in the second powder is more than 80 micrometers.

In some embodiments of the present invention, the spray coating device is adapted to form the quasicrystalline coating on the substrate based on the first powder.

In some embodiments of the invention, the system for forming a quasicrystalline coating further comprises: and the smelting device is connected with the powder making device and is suitable for smelting a mixture containing at least one of aluminum materials, copper materials, iron materials and chromium materials so as to obtain a quasicrystal alloy ingot.

In some embodiments of the present invention, the screening device comprises a first screening unit having a 700 mesh screen disposed therein, a second screening unit having a 180 mesh screen disposed therein, and a third screening unit having a 100 mesh screen disposed therein.

In some embodiments of the present invention, the spray coating device includes a first sub-coating spray coating unit and a second sub-coating spray coating unit, the first sub-coating spray coating unit is adapted to form a first sub-coating on a substrate using the second powder; the second sub-coating spraying unit is suitable for forming a second sub-coating on the surface, far away from the base body, of the first sub-coating by using the first powder.

In some embodiments of the invention, the screening device is connected to the smelting device.

In some embodiments of the invention, the system for forming a quasicrystalline coating further comprises: and the polishing device is connected with the spraying device and is suitable for polishing the quasicrystal coating.

In another aspect of the present invention, the present invention provides a pot manufactured by the method or the system of the above embodiment. The pot body of the pot is the base body. Therefore, the inner surface of the pot body has the quasi-crystal coating formed by the method or the system of the embodiment. It should be noted that all the features and advantages of the method for forming a quasi-crystal coating and the system for forming a quasi-crystal coating described above are also applicable to the pot, and are not described in detail herein. In general, the inner surface of the pot has excellent surface properties.

In some embodiments of the invention, the inner surface of the pot body of the pot is pretreated in advance, the pretreatment comprising: stamping, sanding, drying and removing sand.

Additional aspects and advantages of the invention will be set forth in part in the description which follows and, in part, will be obvious from the description, or may be learned by practice of the invention.

Drawings

The above and/or additional aspects and advantages of the present invention will become apparent and readily appreciated from the following description of the embodiments, taken in conjunction with the accompanying drawings of which:

FIG. 1 is a schematic flow diagram of a method of forming a quasicrystalline coating according to one embodiment of the present invention;

FIG. 2 is a schematic flow diagram of a method of forming a quasicrystalline coating according to yet another embodiment of the present invention;

FIG. 3 is a schematic flow diagram of a method of forming a quasicrystalline coating in accordance with yet another embodiment of the present invention;

FIG. 4 is a schematic flow diagram of a method of forming a quasicrystalline coating in accordance with yet another embodiment of the present invention;

FIG. 5 is a schematic diagram of a system for forming a quasicrystalline coating according to one embodiment of the present invention;

FIG. 6 is a schematic diagram of a system for forming a quasicrystalline coating according to yet another embodiment of the present invention;

FIG. 7 is a schematic diagram of a system for forming a quasicrystalline coating according to yet another embodiment of the present invention;

FIG. 8 is a schematic diagram of a system for forming a quasicrystalline coating in accordance with yet another embodiment of the present invention;

FIG. 9 is a schematic diagram of a system for forming a quasicrystalline coating according to yet another embodiment of the present invention;

FIG. 10 is a schematic diagram of a system for forming a quasicrystalline coating according to yet another embodiment of the present invention;

FIG. 11 is a first subcoat surface topography map in accordance with one embodiment of the present invention.

Detailed Description

Reference will now be made in detail to embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like or similar reference numerals refer to the same or similar elements or elements having the same or similar function throughout. The embodiments described below with reference to the drawings are illustrative and intended to be illustrative of the invention and are not to be construed as limiting the invention.

Furthermore, the terms "first", "second", "third" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defined as "first," "second," or "third" may explicitly or implicitly include at least one of the feature. In the description of the present invention, "a plurality" means at least two, e.g., two, three, etc., unless specifically limited otherwise.

In the present invention, unless otherwise expressly specified or limited, the terms "connected" and the like are to be construed broadly, e.g., as meaning either a fixed connection, a removable connection, or an integral part; can be mechanically or electrically connected; they may be directly connected or indirectly connected through intervening media, or they may be connected internally or in any other suitable relationship, unless expressly stated otherwise. The specific meanings of the above terms in the present invention can be understood by those skilled in the art according to specific situations.

In the present invention, unless otherwise expressly stated or limited, the first feature "on" or "under" the second feature may be directly contacting the first and second features or indirectly contacting the first and second features through an intermediate. Also, a first feature "on," "over," and "above" a second feature may be directly or diagonally above the second feature, or may simply indicate that the first feature is at a higher level than the second feature. A first feature being "under," "below," and "beneath" a second feature may be directly under or obliquely under the first feature, or may simply mean that the first feature is at a lesser elevation than the second feature.

The inventor finds that common non-stick coatings comprise PTFE coatings, PFA coatings, PEEK coatings, ceramic coatings and the like in research on the non-stick coatings, and organic coatings such as PEEK, PTFE and PFA coatings have excellent chemical thermal stability and self-lubricating (non-stick) performance, so that the non-stick coatings are widely applied to the surfaces of inner containers of cookers and rice cookers and various easy-to-clean occasions.

However, conventional organic coatings such as PTFE and PFA have disadvantages such as low hardness and low adhesion, and are very likely to be scratched by hard materials, so that the base material originally covered by the coating is exposed, and harmful metals (e.g., aluminum) in the base material are likely to escape during use, thus impairing the health of users. While ceramic coatings are susceptible to hydrolysis, the non-stick properties of the coatings tend to decrease with increasing use times.

In view of this, in one aspect of the invention. The invention provides a method for forming a quasicrystalline coating. According to an embodiment of the invention, with reference to fig. 1, the method comprises: (1) carrying out powder making treatment on the quasicrystal alloy ingot so as to obtain quasicrystal powder; (2) annealing the quasicrystal powder to obtain annealed powder; (3) and forming a quasicrystalline coating on the substrate based on the annealed powder.

The method of forming a quasicrystalline coating according to an embodiment of the present invention is described in detail below with reference to fig. 1 to 4. According to an embodiment of the invention, the method comprises:

s100: powder processing

In the step, the quasicrystal alloy ingot is subjected to powder making treatment so as to obtain quasicrystal powder.

According to an embodiment of the present invention, the quasi-crystal alloy ingot is formed by melting a mixture containing at least one of an aluminum material, a copper material, an iron material, and a chromium material. Therefore, the obtained quasicrystal alloy ingot is more suitable for forming a quasicrystal coating later.

According to an embodiment of the present invention, the atomic percentages of aluminum, copper, iron and chromium in the above mixture are: 60-70% of aluminum, 10-25% of copper, 5-15% of iron and 5-15% of chromium. Therefore, the quasicrystal content in the obtained quasicrystal coating can be higher.

According to the embodiment of the invention, the aluminum material is pure aluminum, the copper material is pure copper, the iron material is pure iron, and the chromium material is pure chromium or chromium-titanium alloy. When a chromium-titanium alloy is used to form the quasicrystalline alloy ingot, the quasicrystalline alloy ingot correspondingly includes titanium element. The inventor finds that the chromium-titanium alloy is used as a chromium material for preparing the quasicrystal alloy ingot, namely, a proper amount of titanium element is added into quasicrystal, so that the intergranular corrosion tendency of the quasicrystal alloy can be further reduced, and the corrosion resistance of the quasicrystal alloy can be further improved. According to the embodiment of the present invention, the aluminum material, the copper material, the iron material, and the chromium material may be any of conventional products commercially available.

According to the embodiment of the present invention, the processing method for preparing the quasicrystalline alloy ingot into the quasicrystalline powder is not particularly limited, and those skilled in the art can flexibly select the quasicrystalline powder according to actual needs. According to the preferred embodiment of the invention, the quasicrystal alloy ingot can be prepared into quasicrystal powder through an atomization powder preparation method, and the prepared quasicrystal powder is more suitable for being subsequently used for forming a quasicrystal coating.

S200: annealing treatment

In this step, annealing treatment is performed on the crystal powder. The inventors found that preparing a quasicrystalline alloy ingot into a quasicrystalline powder by a powdering process converts at least a portion of the quasicrystalline powder into an amorphous phase. And then, the quasicrystal seed crystal of the quasicrystal powder can be converted into quasicrystal again by annealing the quasicrystal powder, so that the quasicrystal content of the annealed powder is improved. In addition, annealing treatment is carried out by aiming at the crystal powder instead of annealing after spraying the quasi-crystal powder on the substrate, so that the annealing treatment efficiency can be further improved, the time required by the annealing treatment is reduced, and the annealing cost is reduced. This is probably because the process of annealing the powder is simpler and easier than annealing the coating, and the influence of the overhigh annealing temperature on the strength of the coating is not needed to be considered, so that the annealing treatment can be carried out at a higher temperature, thereby improving the efficiency of the annealing treatment; compared with the process of spraying the powder on the substrate and then annealing, the process has the advantages that the influence of the annealing process on the substrate is avoided, the substrate is prevented from being deformed, the internal structure of the substrate is prevented from being changed, the selectivity of the substrate material is increased, and the influence of the annealing temperature on the substrate material is not required to be considered.

According to the embodiment of the invention, oxygen is inevitably doped in the coating in the preparation process or the use process, the content of the oxygen in the coating is not more than 10 at% based on the total amount of elements in the coating, and preferably, the oxygen content in the coating is 4-7 at%. At the moment, because the oxygen content in the coating is lower, the content of metal elements in the coating is increased, and the coating and the substrate are metallurgically bonded, so that the bonding force between the coating and the substrate can be increased; in addition, if the oxygen content is too high, the bonding of oxygen with other metal elements increases, the kind of crystalline phase in the coating layer is changed, and a quasicrystalline phase cannot be formed in the coating layer, so that the non-stick property, corrosion resistance, and hardness of the coating layer are greatly reduced. .

According to the embodiment of the invention, the annealing treatment is carried out in an inert gas atmosphere or vacuum, and the temperature of the annealing treatment is 700-900 ℃. Such as 700 deg.C, 750 deg.C, 800 deg.C, 850 deg.C or 900 deg.C. Thus, annealing within the temperature range can not only convert the amorphous phase converted by powder processing in the quasicrystal powder into quasicrystal again at high temperature, but also enable the quasicrystal crystal seeds in the quasicrystal powder to grow into quasicrystal crystal grains; if the temperature is lower than 700 ℃, the amorphous phase can not be transformed into the quasicrystal phase; if the temperature is higher than 900 ℃, the crystal grains grow faster to form crystal grains with larger grain sizes, so that the surface of the coating is uneven and the surface roughness is overlarge, and water drops are paved on the surface of the coating due to the capillary action of pores, so that the hydrophobic angle is reduced, and the non-adhesiveness of the non-stick coating is reduced; at the same time, the scratch is increased, and the durability of the non-stick coating is reduced. By annealing at the temperature of 700-900 ℃, the quasicrystal grains with the grain size and the dimension meeting the requirements can be formed, the uniformity of the quasicrystal grains is also increased, and the quasicrystal content meeting the requirements is obtained.

According to the embodiment of the invention, since the quasicrystalline powder contains an easily oxidizable metal element (such as aluminum), the annealing treatment is performed under vacuum or a protective atmosphere (such as nitrogen or argon). Therefore, metal elements such as aluminum and the like which are easy to oxidize can be protected from being oxidized in the annealing process, and the content of quasicrystal in the annealed powder is further improved.

According to some embodiments of the invention, after the annealing treatment, the oxygen content in the quasicrystalline coating does not exceed 10 at%, thereby ensuring that the quasicrystalline coating contains a high content of quasicrystal, so that the quasicrystalline coating has good non-adhesiveness; according to some embodiments of the invention, the oxygen content in the quasicrystalline coating is 4 to 7 at%. Therefore, the metal elements in the quasicrystal coating can be further prevented from being oxidized, the quasicrystal content in the quasicrystal coating is increased, if the oxygen content is less than 4 at%, the quasicrystal content is not obviously increased, the difficulty of the preparation process is increased, and the production cost is further increased. In addition, "at%" refers to an atomic percentage.

According to the embodiment of the invention, in order to obtain the annealed powder with the best service performance and high quasicrystal content, the annealing treatment conditions are as follows: the temperature rise rate is 5-100 ℃/min, such as 5 ℃/min, 10 ℃/min, 20 ℃/min, 30 ℃/min, 40 ℃/min, 50 ℃/min, 60 ℃/min, 70 ℃/min, 80 ℃/min, 90 ℃/min or 100 ℃/min, the heat preservation time is 0.5-6 h, such as 0.5h, 1h, 3h, 5h or 6h, the temperature reduction rate is 5-100 ℃/min, such as 5 ℃/min, 10 ℃/min, 20 ℃/min, 30 ℃/min, 40 ℃/min, 50 ℃/min, 60 ℃/min, 70 ℃/min, 80 ℃/min, 90 ℃/min or 100 ℃/min, the temperature is reduced to 200-300 ℃, such as 200 ℃, 230 ℃, 250 ℃, 270 ℃ or 300 ℃, and then the temperature is cooled to room temperature along with the furnace. Therefore, the content of the quasicrystal in the annealed powder can be improved to the greatest extent, and further the non-adhesiveness and other properties of a quasicrystal coating formed by the annealed powder are improved to the greatest extent; if the temperature rising rate or the temperature lowering rate is too fast, the amorphous phase and the seed crystal cannot be converted or grow up; if the holding time is too short, the amorphous phase cannot be fully converted into the quasicrystal or the seed crystal cannot be fully grown into the crystal grain, and the quasicrystal content of the annealed powder is still improved compared with the quasicrystal powder without annealing treatment.

According to the embodiment of the invention, the powder in the annealed powder completely forms the quasicrystal by annealing the aligned crystal powder. By annealing the quasi-crystal powder, each element in the quasi-crystal powder can form quasi-crystal, so that after the powder in the annealed powder completely forms quasi-crystal, the annealed powder is utilized to form a quasi-crystal coating on the substrate, and the quasi-crystal coating has higher quasi-crystal content and better surface performance.

S300: spray coating treatment

In this step, a quasicrystalline coating is formed on the substrate based on the annealed powder. According to embodiments of the present invention, a quasicrystalline coating may be formed on a substrate based on the annealed powder by any method known to those skilled in the art.

According to an embodiment of the present invention, referring to fig. 2, before S300, further comprising:

s400: screening process

In the step, a first powder and a second powder are selected from the annealed powder, wherein the grain diameter of at least 90% of the grains in the first powder is not more than 80 μm, and the grain diameter of at least 90% of the grains in the second powder is more than 80 μm.

According to the embodiment of the invention, the second powder selected from the annealed powder can be used for preparing the quasicrystalline alloy ingot. The inventors found that the larger particle size of the second powder relative to the first powder greatly affects the corrosion resistance of the quasicrystalline coating if the second powder is directly used to form the quasicrystalline coating. And the second powder is recycled for preparing the quasi-crystal alloy ingot, so that the utilization rate of resources can be obviously improved.

Further, according to the embodiment of the present invention, the first powder and the second powder may be further sieved, so that at least 90% of particles in the first powder have a particle size of not less than 20 μm, and at least 90% of particles in the second powder have a particle size of not more than 150 μm. That is, through further sieving the first powder and the second powder, the particle size of at least 90% of the particles in the first powder is not less than 20 μm and not more than 80 μm, and the particle size of at least 90% of the particles in the second powder is more than 80 μm and not more than 150 μm. This can further contribute to classification and utilization of the first powder and the second powder.

According to an embodiment of the present invention, referring to fig. 3, S300 further includes:

s310: forming a first sub-coating layer

In the step, a first sub-coating is formed on the substrate based on the second powder in which at least 90% of the particles have a particle diameter of more than 80 μm and not more than 150 μm.

S320: forming a second sub-coating layer

In the step, a second sub-coating is formed on the surface of the first sub-coating far away from the substrate based on the first powder with at least 90% of the particles having the particle size not less than 20 μm and not more than 80 μm, so that the quasicrystal coating comprising the first sub-coating and the second sub-coating is obtained.

The inventor finds that, for annealed powder (namely, second powder) with larger particle size, although the powder directly used for forming the quasicrystal coating can generate some adverse effects on the coating performance, the second powder is used for forming the first sub-coating on the substrate, and then the annealed powder (namely, the first powder) with smaller particle size is used for forming the outer layer (namely, the second sub-coating) on the first sub-coating, so that the second powder can be effectively utilized on the premise of not influencing the performance of the outer layer quasicrystal coating, and the utilization rate of resources is improved. In addition, the first sub-coating formed based on the second powder has certain porosity, so that the thermal conductivity of the coating can be further reduced, the surface temperature of the substrate with the quasicrystal coating is more uniform, and the non-stick property of the quasicrystal coating is helped. And the density of the second sub-coating formed outside the first sub-coating by utilizing the first powder with smaller granularity is higher, so that the adverse effect on the coating caused by the larger porosity of the first sub-coating can be effectively eliminated. The annealed powder with the grain diameter of less than 20 mu m or more than 150 mu m can be recycled for preparing the quasicrystal alloy ingot.

According to an embodiment of the present invention, the first sub-coat layer and the second sub-coat layer are formed by a spray coating method. In other embodiments, the first sub-coating layer and the second sub-coating layer may also be formed by melt spraying, physical vapor deposition, or the like. Preferably, the first sub-coat layer and the second sub-coat layer are formed by a plasma spraying method. Therefore, the first sub-coating and the second sub-coating can be effectively formed on the substrate, and the method is mature in process, easy to operate and easy for industrial production.

According to an embodiment of the present invention, the conditions of the plasma spraying method include: the arc power is 25-50 kW, and the arc voltage is 40-50V. Thereby, the first sub-coat layer and the second sub-coat layer having better performance can be formed.

According to an embodiment of the present invention, referring to fig. 4, the method of forming a quasicrystalline coating layer of the present invention further includes, after step (3):

s500: polishing treatment

In this step, the alignment crystal coating is subjected to a polishing treatment. According to the embodiment of the invention, the quasi-crystal coating can be polished manually or mechanically, and the finish of the obtained coating is 0.08-1.25 μm in Ra, so that the appearance of the quasi-crystal coating can be further improved.

In yet another aspect of the invention, the invention provides a system for implementing the method for forming a quasicrystalline coating of the above embodiment. According to an embodiment of the invention, referring to fig. 5, the system comprises: a powder-making device 100, an annealing device 200 and a spraying device 300. The powder making device 100 is suitable for making a quasi-crystal alloy ingot into powder so as to obtain quasi-crystal powder; the annealing device 200 is connected with the powder making device 100 and is suitable for annealing the crystal powder to obtain annealed powder; the spraying device 300 is connected with the annealing device 200 and is suitable for forming a quasicrystalline coating on a substrate based on the annealed powder.

According to the system for forming the quasicrystal coating, the quasicrystal alloy ingot is prepared into the quasicrystal powder by the powder making device, the annealing device is used for annealing the quasicrystal powder, so that the quasicrystal content of the quasicrystal powder can be increased, and the annealed powder is sprayed on the substrate by the spraying device to form the quasicrystal coating. The quasicrystal coating formed by the annealed powder has excellent surface properties such as high hardness, low friction coefficient, wear resistance, corrosion resistance and the like. Therefore, the system for forming the quasicrystalline coating can effectively form the quasicrystalline coating with the advantages, and has the advantage of low preparation cost.

A system for forming a quasicrystalline coating according to an embodiment of the present invention is described in detail below with reference to FIGS. 5 to 10:

according to the embodiment of the invention, the powder making device 100 is suitable for making the quasicrystalline alloy ingot into powder so as to obtain the quasicrystalline powder.

According to the embodiment of the present invention, the type of the pulverizing apparatus 100 is not particularly limited, and those skilled in the art can flexibly select the pulverizing apparatus according to actual needs. According to the preferred embodiment of the present invention, the powder-making device 100 may be an atomized powder-making device, so that the prepared quasicrystalline powder is more suitable for subsequent use in forming quasicrystalline coatings.

According to an embodiment of the present invention, referring to fig. 6, the system for forming a quasicrystalline coating layer of the present invention further comprises: a smelting device 500. The smelting device 500 is connected with the powder making device 100 and is suitable for smelting a mixture containing at least one of aluminum material, copper material, iron material and chromium material so as to obtain a quasi-crystal alloy ingot.

According to an embodiment of the present invention, the smelting device 500 may be a medium frequency induction furnace.

According to an embodiment of the present invention, the annealing apparatus 200 is adapted to anneal the aligned crystal powder, so as to obtain an annealed powder. The inventors found that preparing a quasicrystalline alloy ingot into a quasicrystalline powder by a powdering process converts at least a portion of the quasicrystalline powder into an amorphous phase. And then, the quasicrystal seed crystal of the quasicrystal powder can be converted into quasicrystal again by annealing the quasicrystal powder, so that the quasicrystal content of the annealed powder is improved. In addition, annealing treatment is carried out by aiming at the crystal powder instead of annealing after spraying the quasi-crystal powder on the substrate, so that the annealing treatment efficiency can be further improved, the time required by the annealing treatment is reduced, and the annealing cost is reduced. This is probably because the process of annealing the powder is simpler and easier than annealing the coating, and the influence of the overhigh annealing temperature on the strength of the coating is not needed to be considered, so that the annealing treatment can be carried out at a higher temperature, thereby improving the efficiency of the annealing treatment; compared with the process of spraying the powder on the substrate and then annealing, the process has the advantages that the influence of the annealing process on the substrate is avoided, the substrate is prevented from being deformed, the internal structure of the substrate is prevented from being changed, the selectivity of the substrate material is increased, and the influence of the annealing temperature on the substrate material is not required to be considered.

According to an embodiment of the present invention, referring to fig. 7, the system for forming a quasicrystalline coating layer of the present invention further comprises: a screening device 400. The screening device 400 is connected with the annealing device 200 and the spraying device 300 and is suitable for screening the annealed powder to obtain first powder and second powder, wherein the grain diameter of at least 90% of the first powder is not more than 80 microns, and the grain diameter of at least 90% of the second powder is more than 80 microns. The spraying device is suitable for forming a quasicrystal coating on the substrate based on the first powder. The inventors found that the larger particle size of the second powder relative to the first powder greatly affects the corrosion resistance of the quasicrystalline coating if the second powder is directly used to form the quasicrystalline coating. And the second powder is recycled for preparing the quasi-crystal alloy ingot, so that the utilization rate of resources can be obviously improved.

According to an embodiment of the present invention, referring to fig. 8, the sieving apparatus 400 includes a first sieving unit 410, a second sieving unit 420, and a third sieving unit 430, the first sieving unit 410 having a 700 mesh screen disposed therein, the second sieving unit 420 having a 180 mesh screen disposed therein, and the third sieving unit 430 having a 100 mesh screen disposed therein. Therefore, through the cooperation of the first to third sieving units, the annealed powder can be sieved to obtain a first powder and a second powder, wherein the particle size of at least 90% of particles in the first powder is not less than 20 microns and not more than 80 microns, and the particle size of at least 90% of particles in the second powder is more than 80 microns and not more than 150 microns. Meanwhile, as can be understood by those skilled in the art, by using the first to third sieving units, powder having a particle size of less than 20 μm and a particle size of more than 150 μm can also be sieved.

According to an embodiment of the present invention, referring to fig. 9, the spraying device 300 includes a first sub-coating spraying unit 310 and a second sub-coating spraying unit 320, the first sub-coating spraying unit 310 is adapted to form a first sub-coating on the substrate by using the second powder; the second sub-coating layer spraying unit 320 is adapted to form a second sub-coating layer on the surface of the first sub-coating layer away from the substrate by using the first powder. The inventor finds that, for annealed powder (namely, second powder) with larger particle size, although the annealed powder directly used for forming the quasicrystal coating can generate some adverse effects on the coating performance, the second powder is used for forming the first sub-coating on the substrate, and then the annealed powder (namely, the first powder) with smaller particle size is used for forming the outer layer (namely, the second sub-coating) on the first sub-coating, so that the second powder can be effectively utilized on the premise of not influencing the performance of the outer layer quasicrystal coating, and the utilization rate of resources is improved. In addition, the first sub-coating formed based on the second powder has certain porosity, so that the thermal conductivity of the coating can be further reduced, the surface temperature of the substrate with the quasicrystal coating is more uniform, and the non-stick property of the quasicrystal coating is helped. The density of the quasi-crystal coating formed by the first powder with smaller granularity outside the first sub-coating is higher, so that the adverse effect of the larger porosity of the first sub-coating on the coating can be effectively eliminated. According to an embodiment of the present invention, the sieving device 400 may be connected to the melting device 500, whereby, for the quasicrystalline powder having a particle size of less than 20 μm or more than 150 μm, it may be recycled for preparing a quasicrystalline alloy ingot.

According to an embodiment of the present invention, the spray coating device 300 may be a plasma spray coating device. Therefore, the plasma spraying device can effectively form the first sub-coating and the second sub-coating on the substrate, and the process is mature, easy to operate and easy for industrial production.

According to an embodiment of the present invention, the operating conditions of the plasma spraying apparatus include: the arc power is 25-50 kW, and the arc voltage is 40-50V. Thereby, the first sub-coat layer and the second sub-coat layer having better performance can be formed.

According to an embodiment of the present invention, referring to fig. 10, the system for forming a quasicrystalline coating layer of the present invention further includes: a polishing apparatus 600. The polishing apparatus 600 is connected to the spray apparatus 300 and is adapted to polish the crystal coating. According to the embodiment of the invention, the polishing device 600 is used for polishing the crystal coating, and the finish degree of the obtained coating is 0.08-1.25 μm at Ra, so that the appearance of the quasi-crystal coating can be further improved. Thereby, the appearance of the quasicrystalline coating can be further improved.

According to an embodiment of the invention, the inner surface of the pot body of the pot is pretreated in advance, and the pretreatment comprises the following steps: stamping, sanding, drying and removing sand. Therefore, the quasicrystal coating is arranged on the inner surface of the pot body and is directly contacted with food, and the performances of non-sticking of the pot body and the like are improved. According to the embodiment of the invention, the pot body can be pretreated through the conventional processes of pot body stamping, sanding, drying and sand removal. Among other things, care needs to be taken to avoid grit residue in the sanding. The residual grit can cause partial loss of the quasicrystalline coating on the substrate, which seriously affects the corrosion resistance of the coating.

The invention will now be described with reference to specific examples, which are intended to be illustrative only and not to be limiting in any way.

Examples

Forming a quasicrystalline coating according to the following steps:

(1) pure aluminum, pure copper, pure iron and pure chromium are used as raw materials, and according to aluminum: 60-70%, copper: 15-25%, iron: 5-15%, chromium: and (3) respectively mixing the materials according to the atomic ratio of 5-15.

(2) And putting the weighed raw materials into a medium-frequency induction furnace for smelting treatment, wherein iron and chromium are placed at the bottom end of the medium-frequency induction furnace. And introducing inert gas as protective gas in the whole smelting process or vacuumizing the furnace, and after the alloy is completely melted and slag is removed, casting to obtain a quasi-crystal alloy ingot.

(3) And supplying the quasicrystal alloy ingot into an atomization powder making device, carrying out atomization powder making, and obtaining quasicrystal powder by adopting inert gas protection or vacuumizing a system in the whole process.

(4) The annealing device is used for carrying out annealing treatment on the crystal powder under the inert gas atmosphere or vacuum, the temperature of the annealing treatment is 700-900 ℃, and the specific conditions are as follows: the temperature rising rate is 5-100 ℃/min, the heat preservation time is 0.5-6 h, the temperature reduction rate is 5-100 ℃/min, the temperature is reduced to 200-300 ℃, and the temperature is cooled to the room temperature along with the furnace.

(5) And feeding the annealed powder into a screening device, and screening by adopting screens of 700 meshes, 180 meshes and 100 meshes respectively to obtain first powder with at least 90 percent of particle sizes not larger than 80 mu m and not smaller than 20 mu m, second powder with at least 90 percent of particle sizes larger than 80 mu m and not larger than 150 mu m and powder with particle sizes smaller than 20 mu m and larger than 150 mu m. And (3) returning the powder with the particle size smaller than 20 microns and larger than 150 microns to the step (2) for preparing the quasicrystal alloy ingot.

(6) And carrying out stamping, sanding, drying and desanding pretreatment on the pot body to be formed with the quasicrystal coating.

(7) Forming a first sub-coating on the inner surface of the pot body by using a plasma spraying device based on the second powder; the working conditions of the plasma spraying device are as follows: the arc power is 25-50 kW, and the arc voltage is 40-50V. The first subcoat morphology is shown in FIG. 11.

(8) Based on the first powder, spraying a quasicrystal second sub-coating on the surface of the first sub-coating, which is far away from the pot body, by using a plasma spraying device; the working conditions of the plasma spraying device are as follows: the arc power is 25-50 kW, and the arc voltage is 40-50V.

(9) And polishing the alignment crystal coating by using a polishing device.

In the description herein, references to the description of the term "one embodiment," "some embodiments," "an example," "a specific example," or "some examples," etc., mean that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the invention. In this specification, the schematic representations of the terms used above are not necessarily intended to refer to the same embodiment or example. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples. Furthermore, various embodiments or examples and features of different embodiments or examples described in this specification can be combined and combined by one skilled in the art without contradiction.

Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention, and that variations, modifications, substitutions and alterations can be made to the above embodiments by those of ordinary skill in the art within the scope of the present invention.

Claims

1. A method of forming a quasicrystalline coating, comprising:

(1) carrying out powder making treatment on the quasicrystal alloy ingot so as to obtain quasicrystal powder;

(2) annealing the quasicrystal powder to obtain annealed powder;

(3) and forming a quasicrystalline coating on the substrate based on the annealed powder.

2. The method according to claim 1, wherein in the step (2), the quasicrystal powder is annealed to completely form quasicrystals in the annealed powder.

3. The method of claim 1 or 2, further comprising, prior to step (3): and (3) selecting a first powder and a second powder from the annealed powders, wherein the particle size of the first powder particle is smaller than that of the second powder particle, and the first powder is used in the step (3).

4. The method of claim 3, wherein at least 90% of the particles in the first powder have a particle size no greater than 80 μm, and wherein at least 90% of the particles in the second powder have a particle size greater than 80 μm.

5. The method according to claim 1, wherein the quasicrystalline alloy ingot is formed by subjecting a mixture containing at least one of an aluminum material, a copper material, an iron material, and a chromium material to a melting process.

6. The method of claim 5, wherein the atomic percentages of aluminum, copper, iron, and chromium in the mixture are: 60-70% of aluminum, 10-25% of copper, 5-15% of iron and 5-15% of chromium.

7. The method of claim 5, wherein the aluminum material is pure aluminum, the copper material is pure copper, the iron material is pure iron, and the chromium material is pure chromium or a chromium titanium alloy.

8. The method of claim 3, further comprising using the second powder for preparing the quasicrystalline alloy ingot.

9. The method of claim 1, wherein said milling is by atomization milling.

10. The method according to claim 1 or 2, wherein in the step (2), the annealing treatment is performed in an inert gas atmosphere or under vacuum, and the temperature of the annealing treatment is 700 to 900 ℃.

11. The method according to claim 10, wherein the quasicrystalline coating layer has an oxygen content of not higher than 10 at%, preferably 4 to 7 at%.

12. The method according to claim 10, wherein the annealing treatment is performed under the following conditions: the temperature rising rate is 5-100 ℃/min, the heat preservation time is 0.5-6 h, the temperature reduction rate is 5-100 ℃/min, the temperature is reduced to 200-300 ℃, and the temperature is cooled to the room temperature along with the furnace.

13. The method of claim 4, wherein at least 90% of the particles in the first powder have a particle size of not less than 20 μm, and wherein at least 90% of the particles in the second powder have a particle size of not more than 150 μm.

14. The method of claim 13, wherein step (3) further comprises:

(3-1) forming a first sub-coating layer on the substrate based on the second powder; and

(3-2) forming the second sub-coating on the surface of the first sub-coating far away from the substrate based on the first powder, thereby obtaining the quasicrystal coating comprising the first sub-coating and the second sub-coating.

15. The method of claim 14, wherein at least one of the first sub-coating and the second sub-coating is formed by a spray coating process; preferably, at least one of the first sub-coating layer and the second sub-coating layer is formed by a plasma spraying method.

16. The method of claim 15, wherein the conditions of the plasma spray process include: the arc power is 25-50 kW, and the arc voltage is 40-50V.

17. The method of any one of claims 1 to 16, further comprising polishing the quasicrystalline coating after step (3).

18. A system for carrying out the method of forming a quasicrystalline coating layer according to any one of claims 1 to 17, comprising:

the powder making device is suitable for making powder from the quasi-crystal alloy ingot so as to obtain quasi-crystal powder;

the annealing device is connected with the powder making device and is suitable for annealing the quasicrystal powder so as to obtain annealed powder;

and the spraying device is connected with the annealing device and is suitable for forming a quasicrystal coating on the substrate based on the annealed powder.

19. The system of claim 18, further comprising:

and the screening device is connected with the annealing device and the spraying device and is suitable for screening the annealed powder so as to obtain first powder and second powder, wherein the particle size of at least 90% of particles in the first powder is not more than 80 micrometers, and the particle size of at least 90% of particles in the second powder is more than 80 micrometers.

20. The system of claim 19, wherein the spray coating device is adapted to form the quasicrystalline coating on the substrate based on the first powder.

21. The system of claim 18, further comprising:

and the smelting device is connected with the powder making device and is suitable for smelting a mixture containing at least one of aluminum materials, copper materials, iron materials and chromium materials so as to obtain a quasicrystal alloy ingot.

22. The system of claim 21, wherein the screening device comprises a first screening unit having a 700 mesh screen disposed therein, a second screening unit having a 180 mesh screen disposed therein, and a third screening unit having a 100 mesh screen disposed therein.

23. The system of claim 22, wherein the spray device comprises a first sub-coating spray unit and a second sub-coating spray unit, the first sub-coating spray unit is adapted to form a first sub-coating on the substrate using the second powder; the second sub-coating spraying unit is suitable for forming a second sub-coating on the surface, far away from the base body, of the first sub-coating by using the first powder.

24. The system of claim 22, wherein the screening device is coupled to the smelting device.

25. The system of any one of claims 18 to 24, further comprising:

and the polishing device is connected with the spraying device and is suitable for polishing the quasicrystal coating.

26. A cookware prepared by the method of any one of claims 1 to 17 or the system of any one of claims 18 to 25, wherein the base is the body of the cookware.

27. The pot according to claim 26, wherein the inner surface of the pot body of the pot is pre-treated, the pre-treatment comprising: stamping, sanding, drying and removing sand.