CN111424228A - Flame spraying construction method for micro-melting ceramic coating - Google Patents
Flame spraying construction method for micro-melting ceramic coating Download PDFInfo
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- CN111424228A CN111424228A CN202010249076.3A CN202010249076A CN111424228A CN 111424228 A CN111424228 A CN 111424228A CN 202010249076 A CN202010249076 A CN 202010249076A CN 111424228 A CN111424228 A CN 111424228A
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
- C23C4/129—Flame spraying
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
- C23C4/06—Metallic material
- C23C4/08—Metallic material containing only metal elements
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
- C23C4/10—Oxides, borides, carbides, nitrides or silicides; Mixtures thereof
- C23C4/11—Oxides
Abstract
The invention relates to a flame spraying construction method of a micro-melting ceramic coating, which comprises the steps of firstly spraying a nickel-aluminum priming layer on the surface of a heat exchanger by using a flame spraying gun, then spraying spherical alumina powder to the nickel-aluminum priming layer by using the flame spraying gun to obtain an alumina layer, then carrying out surface treatment on the alumina layer, then spraying the micro-melting ceramic powder to the treated alumina layer by using the flame spraying gun, and finally forming a composite ceramic protective layer on the surface of the heat exchanger. The composite ceramic protective layer obtained by constructing the surface of the heat exchanger by adopting the micro-melting ceramic coating flame spraying construction method has strong bonding force with the surface of the heat exchanger and low porosity, the composite ceramic protective layer is not easy to fall off, and the adhesion capability of the composite ceramic protective layer is obviously improved, thereby being beneficial to prolonging the service life of the heat exchanger.
Description
Technical Field
The invention relates to a flame spraying construction method of a micro-melting ceramic coating, belonging to the technical field of surface treatment.
Background
At present, in the field of high-temperature corrosion and wear resistant treatment of heat exchangers, ceramic powder is generally sprayed on the surface of the heat exchanger by a flame spraying method to finally form a protective layer. However, the above-mentioned operation method has the following drawbacks: the porosity of the coating is high, corrosive media are easy to permeate, and the protective layer is easy to fall off after high temperature; if the adhesion is measured by a tensile method, the adhesion strength (bonding strength) is usually 35 to 45 MPa; this limits further improvement of the performance of the heat exchanger surface protective layer.
Disclosure of Invention
Aiming at the defects in the prior art, the invention provides a flame spraying construction method of a micro-melting ceramic coating, which has the following specific technical scheme:
the flame spraying construction method of the micro-melting ceramic coating comprises the following steps: firstly spraying a nickel-aluminum priming layer on the surface of the heat exchanger by using a flame spraying gun, then spraying spherical alumina powder to the nickel-aluminum priming layer by using the flame spraying gun to obtain an alumina layer, then carrying out surface treatment on the alumina layer, then spraying the micro-melting ceramic powder to the treated alumina layer by using the flame spraying gun, and finally forming a composite ceramic protective layer on the surface of the heat exchanger.
According to the further optimization of the technical scheme, the particle size of the spherical alumina powder is 1-50 microns.
According to the further optimization of the technical scheme, the surface treatment step of the aluminum oxide layer is as follows:
step one, coating 1 layer of sodium hydroxide solution on the surface of an aluminum oxide layer, and preserving heat for 15-17min in an incubator at the temperature of 35.6-37.1 ℃; then taking out the mixture from the heat preservation box, putting the mixture into an ultrasonic cleaner, and cleaning the mixture for 5 to 8 times by using clean water;
and step two, after repeating the step one for 3 to 5 times, drying at 55 to 70 ℃ to finish the surface treatment operation of the aluminum oxide layer.
According to the further optimization of the technical scheme, the micro-melting ceramic powder is prepared by mixing alumina powder and glass powder according to the mass ratio of 1 (2.2-2.6), wherein the particle size of the alumina powder is 1-50 mu m, and the particle size of the glass powder is 1-50 mu m.
According to the further optimization of the technical scheme, the flame spraying gun adopts oxyacetylene flame spraying, the micro-melting ceramic powder is thermally sprayed by the flame spraying gun, the spraying temperature of the flame spraying gun is 550-650 ℃, and the acetylene pressure is 0.03 MPa.
According to the further optimization of the technical scheme, the mass fraction of the sodium hydroxide solution is 32.58-33.06%.
The invention has the beneficial effects that:
the protective layer obtained by constructing the surface of the heat exchanger by adopting the flame spraying construction method of the micro-melting ceramic coating has strong bonding force with the surface of the heat exchanger, is not easy to fall off, and has low porosity of the coating and strong anti-corrosion capability. The adhesive capacity of the protective layer is evaluated by adopting a stretching method, and the adhesive force can reach 68-73 MPa. The invention effectively solves the technical defects of the prior art, further improves the adhesive force of the surface protective layer of the heat exchanger, thereby being beneficial to prolonging the service life of the radiator, and has good implementation effect and high application value.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is further described in detail with reference to the following embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.
Example 1
Firstly, spraying nickel-aluminum powder on the surface of a heat exchanger by utilizing a flame spraying process to form a nickel-aluminum priming coat; and then, spraying spherical alumina powder against the nickel-aluminum priming layer by using a flame spraying gun to obtain an alumina layer, performing surface treatment on the alumina layer, spraying the micro-melting ceramic powder against the treated alumina layer by using the flame spraying gun, and finally forming a composite ceramic protective layer on the surface of the heat exchanger.
The surface treatment step of the aluminum oxide layer is as follows:
step one, coating 1 layer of sodium hydroxide solution on the surface of an aluminum oxide layer, and preserving heat for 17min in an incubator at the temperature of 35.6 ℃; then taking out the mixture from the heat preservation box, putting the mixture into an ultrasonic cleaner, and cleaning the mixture for 5 to 8 times by using clean water;
and step two, after repeating the step one for 3 to 5 times, drying at 55 to 70 ℃ to finish the surface treatment operation of the aluminum oxide priming coat.
The flame spraying gun is used for spraying oxyacetylene flame, and the micro-melting ceramic powder is thermally sprayed by the flame spraying gun, wherein the spraying temperature of the flame spraying gun is 550-650 ℃, and the acetylene pressure is 0.03 MPa.
The micro-melting ceramic powder is prepared by mixing alumina powder and glass powder according to the mass ratio of 1:2.2, wherein the particle size of the alumina powder is 1-50 mu m, and the particle size of the glass powder is 1-50 mu m.
The particle size of the spherical alumina powder is 1-50 mu m. The mass fraction of the sodium hydroxide solution is 32.58%.
Wherein the average porosity of the alumina layer is 2.1%, the average porosity of the alumina layer treated by the sodium hydroxide solution is 36.9%, and the average porosity of the composite ceramic protective layer is 1%. The adhesive capacity of the composite ceramic protective layer was measured by a tensile method, and the bonding strength was 68 MPa.
Example 2
Firstly, spraying nickel-aluminum powder on the surface of a heat exchanger by utilizing a flame spraying process to form a nickel-aluminum priming coat; and then, spraying spherical alumina powder against the nickel-aluminum priming layer by using a flame spraying gun to obtain an alumina layer, performing surface treatment on the alumina layer, spraying the micro-melting ceramic powder against the treated alumina layer by using the flame spraying gun, and finally forming a composite ceramic protective layer on the surface of the heat exchanger.
The surface treatment step of the aluminum oxide layer is as follows:
step one, coating 1 layer of sodium hydroxide solution on the surface of an aluminum oxide priming layer, and preserving heat for 16min in an incubator at the temperature of 36.3 ℃; then taking out the mixture from the heat preservation box, putting the mixture into an ultrasonic cleaner, and cleaning the mixture for 5 to 8 times by using clean water;
and step two, after repeating the step one for 3 to 5 times, drying at 55 to 70 ℃ to finish the surface treatment operation of the aluminum oxide priming coat.
The flame spraying gun is used for spraying oxyacetylene flame, and the micro-melting ceramic powder is thermally sprayed by the flame spraying gun, wherein the spraying temperature of the flame spraying gun is 600 ℃, and the acetylene pressure is 0.03 MPa.
The micro-melting ceramic powder is prepared by mixing alumina powder and glass powder according to the mass ratio of 1:2.5, wherein the particle size of the alumina powder is 1-50 mu m, and the particle size of the glass powder is 1-50 mu m.
The particle size of the spherical alumina powder is 1-50 mu m. The mass fraction of the sodium hydroxide solution is 32.91%.
Wherein the average porosity of the alumina layer is 2.1%, the average porosity of the alumina layer treated by the sodium hydroxide solution is 36.9%, and the average porosity of the composite ceramic protective layer is 0.8%. The adhesive capacity of the composite ceramic protective layer was measured by a tensile method, and the bond strength was 70 MPa.
Example 3
Firstly, spraying nickel-aluminum powder on the surface of a heat exchanger by utilizing a flame spraying process to form a nickel-aluminum priming coat; and then, spraying spherical alumina powder against the nickel-aluminum priming layer by using a flame spraying gun to obtain an alumina layer, performing surface treatment on the alumina layer, spraying the micro-melting ceramic powder against the treated alumina layer by using the flame spraying gun, and finally forming a composite ceramic protective layer on the surface of the heat exchanger.
The surface treatment step of the aluminum oxide layer is as follows:
step one, coating 1 layer of sodium hydroxide solution on the surface of an aluminum oxide priming layer, and preserving heat for 15min in an incubator at the temperature of 37.1 ℃; then taking out the mixture from the heat preservation box, putting the mixture into an ultrasonic cleaner, and cleaning the mixture for 5 to 8 times by using clean water;
and step two, after repeating the step one for 3 to 5 times, drying at 55 to 70 ℃ to finish the surface treatment operation of the aluminum oxide priming coat.
The flame spraying gun is used for spraying oxyacetylene flame, and the micro-melting ceramic powder is thermally sprayed by the flame spraying gun, wherein the spraying temperature of the flame spraying gun is 650 ℃, and the acetylene pressure is 0.03 MPa.
The micro-melting ceramic powder is prepared by mixing alumina powder and glass powder according to the mass ratio of 1:2.6, wherein the particle size of the alumina powder is 1-50 mu m, and the particle size of the glass powder is 1-50 mu m.
The particle size of the spherical alumina powder is 1-50 mu m. The mass fraction of the sodium hydroxide solution is 33.06%.
Wherein the average porosity of the alumina layer is 1.9%, the average porosity of the alumina layer treated by the sodium hydroxide solution is 37.1%, and the average porosity of the composite ceramic protective layer is 0.5%. The adhesive capacity of the composite ceramic protective layer was measured by a tensile method, and the bonding strength was 73 MPa.
Comparative example 1
Firstly, spraying nickel-aluminum powder on the surface of a heat exchanger by utilizing a flame spraying process to form a nickel-aluminum priming coat; and then, spraying the columnar alumina powder against the nickel-aluminum priming coat by using a flame spraying gun to obtain an alumina contrast layer A, and then carrying out surface treatment on the alumina contrast layer A to obtain an alumina treatment layer B.
The surface treatment procedure for the alumina control layer a was as follows:
step one, brushing 1 layer of sodium hydroxide solution with the mass fraction of 32.91% on the surface of an alumina contrast layer A, and preserving heat for 16min in an incubator at the temperature of 36.3 ℃; then taking out the mixture from the heat preservation box, putting the mixture into an ultrasonic cleaner, and cleaning the mixture for 5 to 8 times by using clean water;
and step two, after repeating the step one for 3 to 5 times, drying at 55 to 70 ℃ to finish the surface treatment operation of the alumina contrast layer A.
Wherein the average porosity of the alumina control layer A is 4.7%, and the average porosity of the front surface of the alumina treatment layer B is 25.1%.
Comparative example 2
Firstly, spraying nickel-aluminum powder on the surface of a heat exchanger by utilizing a flame spraying process to form a nickel-aluminum priming coat; and then, spraying spherical alumina powder to the nickel-aluminum priming layer by using a flame spraying gun to obtain an alumina layer, performing surface treatment on the alumina layer, spraying glass powder to the treated alumina layer by using the flame spraying gun, and finally forming a composite contrast layer C on the surface of the heat exchanger.
The surface treatment step of the aluminum oxide layer is as follows:
step one, coating 1 layer of sodium hydroxide solution on the surface of an aluminum oxide priming layer, and preserving heat for 16min in an incubator at the temperature of 36.3 ℃; then taking out the mixture from the heat preservation box, putting the mixture into an ultrasonic cleaner, and cleaning the mixture for 5 to 8 times by using clean water;
and step two, after repeating the step one for 3 to 5 times, drying at 55 to 70 ℃ to finish the surface treatment operation of the aluminum oxide priming coat.
The flame spraying gun is used for spraying oxyacetylene flame, and is used for thermally spraying glass powder, wherein the spraying temperature of the flame spraying gun is 600 ℃, and the acetylene pressure is 0.03 MPa. The particle size of the glass powder is 1-50 μm. The particle size of the spherical alumina powder is 1-50 mu m. The mass fraction of the sodium hydroxide solution is 32.91%.
The adhesion capability of the composite control layer C was measured by a tensile method, and the bonding strength thereof was 56 MPa.
Comparative example 3
Firstly, spraying nickel-aluminum powder on the surface of a heat exchanger by utilizing a flame spraying process to form a nickel-aluminum priming coat; and (3) spraying the micro-melting ceramic powder against the nickel-aluminum priming coat by using a flame spraying gun, and finally forming a composite contrast layer D on the surface of the heat exchanger.
The flame spraying gun is used for spraying oxyacetylene flame, and the micro-melting ceramic powder is thermally sprayed by the flame spraying gun, wherein the spraying temperature of the flame spraying gun is 600 ℃, and the acetylene pressure is 0.03 MPa.
The micro-melting ceramic powder is prepared by mixing alumina powder and glass powder according to the mass ratio of 1:2.5, wherein the particle size of the alumina powder is 1-50 mu m, and the particle size of the glass powder is 1-50 mu m.
Wherein, the adhesive capacity of the composite control layer D is measured by adopting a stretching method, and the bonding strength is 47 MPa.
Comparative example 4
Firstly, spraying nickel-aluminum powder on the surface of a heat exchanger by utilizing a flame spraying process to form a nickel-aluminum priming coat; and then, spraying spherical alumina powder against the nickel-aluminum priming layer by using a flame spraying gun to obtain an alumina layer, spraying the micro-melting ceramic powder against the alumina layer by using the flame spraying gun, and finally forming a composite contrast layer E on the surface of the heat exchanger.
The flame spraying gun is used for spraying oxyacetylene flame, and the micro-melting ceramic powder is thermally sprayed by the flame spraying gun, wherein the spraying temperature of the flame spraying gun is 600 ℃, and the acetylene pressure is 0.03 MPa.
The micro-melting ceramic powder is prepared by mixing alumina powder and glass powder according to the mass ratio of 1:2.5, wherein the particle size of the alumina powder is 1-50 mu m, and the particle size of the glass powder is 1-50 mu m. The particle size of the spherical alumina powder is 1-50 mu m.
Wherein, the adhesive capacity of the composite control layer E is measured by adopting a stretching method, and the bonding strength is 43 MPa.
In the above examples, the adhesion of the composite protective layers in examples 1 to 3 is excellent, and the adhesion capability of the composite ceramic protective layer is measured by a stretching method, so that the bonding strength of the composite ceramic protective layer can reach 68 to 73MPa, which is significantly superior to that in the prior art, and the porosity of the coating is significantly reduced.
In the present invention, the porosity of the aluminum oxide layer is improved by several tens of times after the surface treatment with the sodium hydroxide solution. The sodium hydroxide solution can react with the alumina, and ultrasonic cleaning is adopted, so that the sodium metaaluminate which is a reaction product is favorably washed away, and a residual coating with high porosity is easily obtained finally; in addition, the thickness of the alumina layer cannot be less than 85 μm, otherwise, the alumina layer is easy to generate more (the area exceeds 3 mm) after the surface treatment of the sodium hydroxide solution2) A void. If the reaction is carried out by completely immersing the alumina layer in the sodium hydroxide solution, the solution has enough amount and is very easy to react excessively, so that the alumina layer with large area is reacted, and the etching holes with large area (the area is more than 20 mm)2). After the treatment of the sodium hydroxide solution, the porosity of the coating is increased, so that the subsequent micro-melting glass powder is embedded and the pores are filled, and even in the subsequent high-temperature heating process, the glass particles and the alumina particles are compounded to form the composite coating which is not easy to fall off compared with a pure glass powder coating.
Analysis of example 2 and comparative example 1 shows that spraying with non-spherical alumina makes the pores of the alumina coating larger, which is not favorable for bonding with the nickel-aluminum base coat.
Analysis of example 2 and comparative example 2 revealed that if the flame spraying was performed only with the glass powder instead of the micro-fused ceramic powder (mixture of alumina powder and glass powder) against the treated alumina layer, gaps between particles were filled, which improved some adhesion, but apparently did not follow the flame spraying with the micro-fused ceramic powder with good effect.
Comparative analysis example 2 and comparative example 3 revealed that: the micro-melting ceramic powder is directly sprayed without spraying an aluminum oxide layer and a sodium hydroxide solution, and the finally obtained composite coating has very poor adhesive force.
Comparative analysis example 2 and comparative example 4 revealed that: even if the aluminum oxide layer is prepared by adopting the flame spraying technology, the bonding force between the aluminum oxide layer and the micro-spraying melting ceramic layer is poor because the aluminum oxide layer is not treated by a sodium hydroxide solution.
In the present invention, the use of sodium hydroxide solution is effective to react with the alumina particles. Because the amount of the sodium hydroxide solution coated on the surface of the nickel-aluminum priming layer every time is very small, the reaction time is very short (the single time does not exceed 17 min), and the reaction temperature is very low (does not exceed 37.1 ℃), the sodium hydroxide solution only has a trace amount of the sodium hydroxide solution to react with a tiny part in the nickel-aluminum priming layer even though penetrating through the aluminum oxide layer, and the nickel-aluminum priming layer cannot be corroded in a large area; in addition, the aluminum particles in the nickel-aluminum base coat are mixed nickel particles, so that the corrosion degree of the nickel-aluminum base coat is further reduced. Finally, if the nickel-aluminum primer layer is extensively corroded by the sodium hydroxide solution, the bonding strength of the subsequent composite ceramic protective layer is affected, and obviously, the bonding strength of the composite ceramic protective layer is remarkably improved in the invention. Therefore, in the present invention, the concentration of the sodium hydroxide solution, the reaction temperature, and the reaction time are very important, and strict control is required in the construction.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, and any modifications, equivalents and improvements made within the spirit and principle of the present invention are intended to be included within the scope of the present invention.
Claims (6)
1. The flame spraying construction method of the micro-melting ceramic coating is characterized by comprising the following steps: firstly spraying a nickel-aluminum priming layer on the surface of the heat exchanger by using a flame spraying gun, then spraying spherical alumina powder to the nickel-aluminum priming layer by using the flame spraying gun to obtain an alumina layer, then carrying out surface treatment on the alumina layer, then spraying the micro-melting ceramic powder to the treated alumina layer by using the flame spraying gun, and finally forming a composite ceramic protective layer on the surface of the heat exchanger.
2. The flame spraying construction method of the micro-melting ceramic coating according to claim 1, characterized in that: the particle size of the spherical alumina powder is 1-50 mu m.
3. The flame spraying construction method of the micro-melting ceramic coating according to claim 1, characterized in that: the surface treatment step of the aluminum oxide layer is as follows:
step one, coating 1 layer of sodium hydroxide solution on the surface of an aluminum oxide layer, and preserving heat for 15-17min in an incubator at the temperature of 35.6-37.1 ℃; then taking out the mixture from the heat preservation box, putting the mixture into an ultrasonic cleaner, and cleaning the mixture for 5 to 8 times by using clean water;
and step two, after repeating the step one for 3 to 5 times, drying at 55 to 70 ℃ to finish the surface treatment operation of the aluminum oxide layer.
4. The flame spraying construction method of the micro-melting ceramic coating according to claim 1, characterized in that: the micro-melting ceramic powder is prepared by mixing alumina powder and glass powder according to the mass ratio of 1 (2.2-2.6), wherein the particle size of the alumina powder is 1-50 mu m, and the particle size of the glass powder is 1-50 mu m.
5. The flame spraying construction method of the micro-melting ceramic coating according to claim 1, characterized in that: the flame spraying gun is used for spraying oxyacetylene flame, and the micro-melting ceramic powder is thermally sprayed by the flame spraying gun, wherein the spraying temperature of the flame spraying gun is 550-650 ℃, and the acetylene pressure is 0.03 MPa.
6. The flame spraying construction method of the micro-melting ceramic coating according to claim 3, characterized in that: the mass fraction of the sodium hydroxide solution is 32.58-33.06%.
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Cited By (1)
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| CN112779491A (en) * | 2020-12-31 | 2021-05-11 | 湖北超卓航空科技股份有限公司 | Flame spraying construction method for micro-melting ceramic coating |
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