CN112065768A - 一种基于hvof工艺的水泵叶轮及其制造方法 - Google Patents
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- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 title claims abstract description 26
- 230000008569 process Effects 0.000 title claims abstract description 21
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 11
- 238000007749 high velocity oxygen fuel spraying Methods 0.000 title claims abstract 8
- 238000003672 processing method Methods 0.000 title description 2
- 238000000034 method Methods 0.000 claims abstract description 23
- 238000005507 spraying Methods 0.000 claims abstract description 15
- 238000000576 coating method Methods 0.000 claims abstract description 10
- 239000011248 coating agent Substances 0.000 claims abstract description 9
- 239000007921 spray Substances 0.000 claims description 7
- 238000007789 sealing Methods 0.000 claims description 6
- 239000011347 resin Substances 0.000 claims description 4
- 229920005989 resin Polymers 0.000 claims description 4
- 238000004140 cleaning Methods 0.000 claims description 3
- 229910003460 diamond Inorganic materials 0.000 claims description 3
- 239000010432 diamond Substances 0.000 claims description 3
- 238000007689 inspection Methods 0.000 claims description 3
- 239000007788 liquid Substances 0.000 claims description 3
- 239000000463 material Substances 0.000 claims description 3
- 238000005498 polishing Methods 0.000 claims description 3
- 238000012423 maintenance Methods 0.000 abstract description 9
- 238000005299 abrasion Methods 0.000 abstract description 4
- 229910009043 WC-Co Inorganic materials 0.000 abstract description 2
- 239000000956 alloy Substances 0.000 abstract description 2
- 229910045601 alloy Inorganic materials 0.000 abstract description 2
- 238000000354 decomposition reaction Methods 0.000 abstract description 2
- 230000002035 prolonged effect Effects 0.000 abstract description 2
- 238000003466 welding Methods 0.000 description 9
- 230000008901 benefit Effects 0.000 description 6
- 239000012530 fluid Substances 0.000 description 3
- 239000012535 impurity Substances 0.000 description 3
- 238000004080 punching Methods 0.000 description 3
- 230000007547 defect Effects 0.000 description 2
- 238000010285 flame spraying Methods 0.000 description 2
- 230000006870 function Effects 0.000 description 2
- 230000006872 improvement Effects 0.000 description 2
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 239000013065 commercial product Substances 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000003912 environmental pollution Methods 0.000 description 1
- 239000000446 fuel Substances 0.000 description 1
- 238000002347 injection Methods 0.000 description 1
- 239000007924 injection Substances 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 238000009991 scouring Methods 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04D—NON-POSITIVE-DISPLACEMENT PUMPS
- F04D29/00—Details, component parts, or accessories
- F04D29/18—Rotors
- F04D29/22—Rotors specially for centrifugal pumps
- F04D29/2205—Conventional flow pattern
- F04D29/2222—Construction and assembly
- F04D29/2227—Construction and assembly for special materials
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C29/00—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides
- C22C29/02—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides
- C22C29/06—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides based on carbides, but not containing other metal compounds
- C22C29/067—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides based on carbides, but not containing other metal compounds comprising a particular metallic binder
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C29/00—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides
- C22C29/02—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides
- C22C29/06—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides based on carbides, but not containing other metal compounds
- C22C29/08—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides based on carbides, but not containing other metal compounds based on tungsten carbide
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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
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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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Abstract
本发明提供了一种基于HVOF工艺的水泵叶轮及其制造方法,该技术方案基于对以往叶轮磨损情况的分析,确定叶片进口、叶片出口、滑动部位为最容易发生磨损的位置;在此基础上,利用HVOF喷涂工艺对三处部位进行表面硬化处理。HVOF喷涂可以获得结合强度高、致密的高质量涂层。超音速火焰的速度很快,但温度相对较低,对于WC‑Co硬质合金可以有效地抑制WC在喷涂过程中的分解,涂层不仅结合强度高,且致密,耐磨性能优越。且HVOF喷涂工艺操作简单、成本低,在叶轮的易磨损部位进行HVOF喷涂,极大限度的延长了叶轮的寿命,降低了零部件的更换频率,降低了维修成本,可节约资源。同时降低了水泵停机维护的频率,提高水泵运行效率。
Description
技术领域
本发明涉及水泵技术领域,进一步涉及对水泵叶轮及其制造工艺的改进,具体涉及一种基于HVOF工艺的水泵叶轮及其制造方法。
背景技术
在水泵运行过程中,流体中的杂质对叶轮的使用寿命具有直接影响。以江水、黄河水为例,由于其中含有大量的泥沙等颗粒状杂质,因此在流经水泵时会对水泵造成严重的冲刷性磨损,尤其对高速旋转的叶轮,这种磨损尤为严重。
叶轮使用寿命短造成水泵维修频繁。停机维修对工程的影响是巨大的,而且频繁地更换叶轮造成维修工作量大,维修费用高,水泵的利用率降低。因此,如何延长叶轮的使用寿命,提高水泵利用率,最大限度发挥工程的经济效益、社会效益和生态效益,是急需解决的问题。
目前,在国内市场上,输送泥沙含量高的介质的水泵叶轮通常使用冲压焊接工艺来制作。但是由于冲压焊接叶轮的设计理论还不成熟,还存在许多问题,如叶轮盖板冲压后变形比较大;叶轮盖板与叶片采用电阻点焊,焊接后二者不能很好地结合,导致流道间串流;焊点容易脱落,导致叶轮损伤;焊接后叶轮盖板变形等。与一次成型的铸造叶轮相比,由于冲压焊接叶轮的焊接量大,也造成了制做难度大,环境污染严重等问题。
发明内容
本发明旨在针对现有技术的技术缺陷,提供一种基于HVOF工艺的水泵叶轮及其制造方法,以解决常规叶轮在输送高杂质含量的流体时,磨损较为严重的技术问题。
本发明要解决的另一技术问题是,采用冲压焊接工艺制造耐磨性叶轮,不仅工艺难度大,而且存在叶轮盖板变形较大、焊点易脱落等缺陷。
本发明要解决的再一技术问题是,如何提升水泵叶轮的耐磨性,以满足对高杂质含量流体的输送要求。
为实现以上技术目的,本发明采用以下技术方案:
一种基于HVOF工艺的水泵叶轮,该叶轮具有叶片入口和叶片出口,叶轮顶面的边缘位置为滑动部位;其中,在叶片入口、叶片出口、滑动部位处分别具有由HVOF工艺喷涂的、材质为WC-10Co-4Cr的涂层。
在以上技术方案的基础上,本发明进一步提供了上述水泵叶轮的制造方法,包括以下步骤:
1)以叶片入口、叶片出口、滑动部位作为待喷涂部位;将待喷涂部位表面的油污、毛刺清理干净;
2)对不喷涂的部位做好防护;
3)使用JP-5000喷枪对所述待喷涂部位进行喷涂,喷涂的材质为WC-10Co-4Cr;
4)使用金刚石对喷涂部位进行打磨,打磨后涂层的厚度在0.2~0.3mm;
5)进行封孔处理。
作为优选,步骤5)所述的封孔处理,是用毛刷在表面涂覆树脂。
作为优选,还包括以下步骤6):对喷涂部位进行液体渗透探伤。
在以上技术方案中,所述HVOF工艺,是指超音速火焰喷涂方法。所述JP-5000喷枪,是指型号为JP-5000的超音速火焰喷涂系统的喷枪,该设备为常规市售产品,可自市面购得。
本发明根据以往叶轮的磨损及维修情况,确定叶片进口、叶片出口、滑动部位为最容易发生磨损的位置;在此基础上,利用HVOF喷涂工艺对三处部位进行表面硬化处理。
HVOF喷涂可以获得结合强度高、致密的高质量涂层。超音速火焰的速度很快,但温度相对较低,对于WC-Co硬质合金可以有效地抑制WC在喷涂过程中的分解,涂层不仅结合强度高,且致密,耐磨性能优越。且HVOF喷涂工艺操作简单、成本低,在叶轮的易磨损部位进行HVOF喷涂,极大限度的延长了叶轮的寿命,降低了零部件的更换频率,降低了维修成本,可节约资源。同时降低了水泵停机维护的频率,提高水泵运行效率,最大限度发挥工程的经济效益、社会效益和生态效益。
附图说明
图1是本发明的结构示意图;
图中:
1、叶片入口 2、叶片出口 3、滑动部位。
具体实施方式
以下将对本发明的具体实施方式进行详细描述。为了避免过多不必要的细节,在以下实施例中对属于公知的结构或功能将不进行详细描述。以下实施例中所使用的近似性语言可用于定量表述,表明在不改变基本功能的情况下可允许数量有一定的变动。除有定义外,以下实施例中所用的技术和科学术语具有与本发明所属领域技术人员普遍理解的相同含义。
一种基于HVOF工艺的水泵叶轮,如图1所示,该叶轮具有叶片入口1和叶片出口2,叶轮顶面的边缘位置为滑动部位3;其中,在叶片入口1、叶片出口2、滑动部位3处分别具有由HVOF工艺喷涂的、材质为WC-10Co-4Cr的涂层。
该水泵叶轮的具体制造方法如下:
(1)以叶片入口1、叶片出口2、滑动部位3作为待喷涂部位,将待喷涂部位加工至喷涂前尺寸,并将表面油污毛刺清理干净;
(2)将不喷涂的部位做好防护;
(3)使用JP-5000喷枪对叶轮进行喷涂,喷涂的材质为WC-10Co-4Cr;
(4)使用金刚石对喷涂部位进行打磨,打磨后涂层的厚度在0.2~0.3mm左右;
(5)进行封孔处理。封孔处理是指用毛刷在表面涂一层树脂,这样更加不易被腐蚀;
(6)对喷涂部位进行液体渗透探伤。
以上对本发明的实施例进行了详细说明,但所述内容仅为本发明的较佳实施例,并不用以限制本发明。凡在本发明的申请范围内所做的任何修改、等同替换和改进等,均应包含在本发明的保护范围之内。
Claims (4)
1.一种基于HVOF工艺的水泵叶轮,该叶轮具有叶片入口(1)和叶片出口(2),叶轮顶面的边缘位置为滑动部位(3);其特征在于,在叶片入口(1)、叶片出口(2)、滑动部位(3)处分别具有由HVOF工艺喷涂的、材质为WC-10Co-4Cr的涂层。
2.权利要求1所述的水泵叶轮的制造方法,其特征在于,包括以下步骤:
1)以叶片入口(1)、叶片出口(2)、滑动部位(3)作为待喷涂部位;将待喷涂部位表面的油污、毛刺清理干净;
2)对不喷涂的部位做好防护;
3)使用JP-5000喷枪对所述待喷涂部位进行喷涂,喷涂的材质为WC-10Co-4Cr;
4)使用金刚石对喷涂部位进行打磨,打磨后涂层的厚度在0.2~0.3mm;
5)进行封孔处理。
3.根据权利要求2所述的制造方法,其特征在于,步骤5)所述的封孔处理,是用毛刷在表面涂覆树脂。
4.根据权利要求2所述的制造方法,其特征在于,还包括以下步骤6):对喷涂部位进行液体渗透探伤。
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CN113025944A (zh) * | 2021-03-04 | 2021-06-25 | 哈动国家水力发电设备工程技术研究中心有限公司 | 一种海水水泵水轮机活动导叶的腐蚀防护方法 |
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CN113025944A (zh) * | 2021-03-04 | 2021-06-25 | 哈动国家水力发电设备工程技术研究中心有限公司 | 一种海水水泵水轮机活动导叶的腐蚀防护方法 |
CN113025944B (zh) * | 2021-03-04 | 2023-01-13 | 哈动国家水力发电设备工程技术研究中心有限公司 | 一种海水水泵水轮机活动导叶的腐蚀防护方法 |
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