CN112159947A - Electric arc spraying method - Google Patents
Electric arc spraying method Download PDFInfo
- Publication number
- CN112159947A CN112159947A CN202011210920.8A CN202011210920A CN112159947A CN 112159947 A CN112159947 A CN 112159947A CN 202011210920 A CN202011210920 A CN 202011210920A CN 112159947 A CN112159947 A CN 112159947A
- Authority
- CN
- China
- Prior art keywords
- spraying
- workpiece
- electric arc
- metal wire
- sand blasting
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 238000005507 spraying Methods 0.000 title claims abstract description 141
- 238000010891 electric arc Methods 0.000 title claims abstract description 54
- 239000002184 metal Substances 0.000 claims abstract description 58
- 229910052751 metal Inorganic materials 0.000 claims abstract description 58
- 238000005488 sandblasting Methods 0.000 claims abstract description 49
- 239000011248 coating agent Substances 0.000 claims abstract description 39
- 238000000576 coating method Methods 0.000 claims abstract description 39
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 claims abstract description 13
- 238000007789 sealing Methods 0.000 claims abstract description 13
- 238000005260 corrosion Methods 0.000 claims abstract description 9
- 230000007797 corrosion Effects 0.000 claims abstract description 9
- 238000004140 cleaning Methods 0.000 claims abstract description 8
- 238000007689 inspection Methods 0.000 claims abstract description 6
- 238000010276 construction Methods 0.000 claims abstract description 4
- 238000001035 drying Methods 0.000 claims abstract description 4
- 238000005498 polishing Methods 0.000 claims abstract description 4
- 238000002360 preparation method Methods 0.000 claims abstract description 4
- 238000000034 method Methods 0.000 claims description 32
- 230000008569 process Effects 0.000 claims description 26
- 239000007921 spray Substances 0.000 claims description 22
- 239000010410 layer Substances 0.000 claims description 16
- 238000011179 visual inspection Methods 0.000 claims description 14
- 239000000463 material Substances 0.000 claims description 13
- 239000002245 particle Substances 0.000 claims description 12
- 239000000853 adhesive Substances 0.000 claims description 9
- 230000001070 adhesive effect Effects 0.000 claims description 9
- 239000011521 glass Substances 0.000 claims description 7
- 239000002131 composite material Substances 0.000 claims description 6
- 239000012535 impurity Substances 0.000 claims description 6
- 239000002932 luster Substances 0.000 claims description 6
- 239000011241 protective layer Substances 0.000 claims description 6
- 239000004576 sand Substances 0.000 claims description 6
- 239000000126 substance Substances 0.000 claims description 6
- 230000007704 transition Effects 0.000 claims description 5
- 239000000428 dust Substances 0.000 claims description 4
- 239000000956 alloy Substances 0.000 claims description 3
- 229910045601 alloy Inorganic materials 0.000 claims description 3
- 239000003795 chemical substances by application Substances 0.000 claims description 3
- 229910052593 corundum Inorganic materials 0.000 claims description 3
- 239000010431 corundum Substances 0.000 claims description 3
- 238000007667 floating Methods 0.000 claims description 3
- 239000011148 porous material Substances 0.000 claims description 3
- 238000007781 pre-processing Methods 0.000 claims description 2
- 239000011159 matrix material Substances 0.000 abstract description 14
- 230000005587 bubbling Effects 0.000 abstract description 6
- 238000005336 cracking Methods 0.000 abstract description 5
- 230000000694 effects Effects 0.000 description 17
- 239000000758 substrate Substances 0.000 description 12
- 230000009286 beneficial effect Effects 0.000 description 7
- 239000002923 metal particle Substances 0.000 description 7
- 238000001179 sorption measurement Methods 0.000 description 6
- 230000007547 defect Effects 0.000 description 4
- 230000004913 activation Effects 0.000 description 3
- 238000006243 chemical reaction Methods 0.000 description 3
- 230000003749 cleanliness Effects 0.000 description 3
- 239000013078 crystal Substances 0.000 description 3
- 238000009792 diffusion process Methods 0.000 description 3
- 239000003344 environmental pollutant Substances 0.000 description 3
- 239000004519 grease Substances 0.000 description 3
- 231100000719 pollutant Toxicity 0.000 description 3
- 230000037452 priming Effects 0.000 description 3
- 230000035882 stress Effects 0.000 description 3
- 230000008646 thermal stress Effects 0.000 description 3
- 230000007613 environmental effect Effects 0.000 description 2
- 230000002349 favourable effect Effects 0.000 description 2
- 230000002035 prolonged effect Effects 0.000 description 2
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- 238000009825 accumulation Methods 0.000 description 1
- 239000011247 coating layer Substances 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000005265 energy consumption Methods 0.000 description 1
- 230000007774 longterm Effects 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 230000008439 repair process Effects 0.000 description 1
Images
Classifications
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
- C23C4/131—Wire arc spraying
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24C—ABRASIVE OR RELATED BLASTING WITH PARTICULATE MATERIAL
- B24C1/00—Methods for use of abrasive blasting for producing particular effects; Use of auxiliary equipment in connection with such methods
- B24C1/06—Methods for use of abrasive blasting for producing particular effects; Use of auxiliary equipment in connection with such methods for producing matt surfaces, e.g. on plastic materials, on glass
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24C—ABRASIVE OR RELATED BLASTING WITH PARTICULATE MATERIAL
- B24C1/00—Methods for use of abrasive blasting for producing particular effects; Use of auxiliary equipment in connection with such methods
- B24C1/08—Methods for use of abrasive blasting for producing particular effects; Use of auxiliary equipment in connection with such methods for polishing surfaces, e.g. smoothing a surface by making use of liquid-borne abrasives
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/02—Pretreatment of the material to be coated, e.g. for coating on selected surface areas
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
- C23C4/14—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying for coating elongate material
- C23C4/16—Wires; Tubes
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/18—After-treatment
-
- C—CHEMISTRY; METALLURGY
- 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
- C23G—CLEANING OR DE-GREASING OF METALLIC MATERIAL BY CHEMICAL METHODS OTHER THAN ELECTROLYSIS
- C23G1/00—Cleaning or pickling metallic material with solutions or molten salts
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Physics & Mathematics (AREA)
- Plasma & Fusion (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Materials Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- General Chemical & Material Sciences (AREA)
- Coating By Spraying Or Casting (AREA)
Abstract
The invention relates to an electric arc spraying method, which comprises the following steps: s1: construction preparation; s2: performing surface pretreatment to be sprayed, and performing sand blasting treatment on the surface of the workpiece by adopting pneumatically controlled sand blasting equipment to ensure that the roughness of the workpiece reaches 90-120 um; s3, pretreating the metal wire, cleaning the metal wire by using a rust remover, straightening the metal wire by using a straightening machine after cleaning and drying, and polishing the metal wire to make the surface of the metal wire smooth after straightening; s4, arc spraying; s5, sealing holes of the coating; s6: and (5) coating inspection, wherein the appearance surface after spraying is inspected. The metal wire is cleaned, dried, straightened and polished before spraying, so that the outer surface of the sprayed workpiece is smooth, the coating is uniform, flat and compact, the coating and a matrix are well combined, and the phenomena of bubbling, cracking, pitted surface and peeling are avoided, thereby improving the corrosion resistance and the structural strength of the workpiece.
Description
Technical Field
The invention relates to the technical field of electric arc spraying, in particular to an electric arc spraying method.
Background
Arc spraying is a technique of melting metal by burning an electric arc between two continuously fed wires, atomizing the molten metal with a high-speed gas flow, and accelerating the atomized metal particles to spray them toward a workpiece to form a coating layer.
In the prior art, a proper metal wire needs to be selected as a raw material before spraying, but the metal wire can form an oxide layer on the surface of the metal wire due to long-term exposure in air, and the metal wire is easily stained with oil stains and dust. After the metal wire is used for spraying, the phenomena of unevenness, bubbling, peeling and pitted surface of an electric arc spraying layer on the surface of a workpiece can be caused, the electric arc spraying effect is reduced, and the surface repair of a part with large-area corrosion resistance and abrasion or processing errors is not facilitated.
Disclosure of Invention
Aiming at the defects in the prior art, the invention aims to provide an electric arc spraying method, which is characterized in that after a metal wire is cleaned, dried, straightened and polished before spraying, the outer surface of a sprayed workpiece is smooth, the coating is uniform, flat and compact, the coating is well combined with a matrix, and the phenomena of bubbling, cracking, pitted surface and peeling are avoided, so that the corrosion resistance and the structural strength of the workpiece are improved.
The above object of the present invention is achieved by the following technical solutions:
an electric arc spraying method comprising the steps of:
s1: construction preparation, namely removing dust and impurities on the surface of a workpiece, and carrying out quality inspection on the whole part of the workpiece subjected to spraying;
s2: performing surface pretreatment to be sprayed, and performing sand blasting treatment on the surface of the workpiece by adopting pneumatically controlled sand blasting equipment to ensure that the roughness of the workpiece reaches 90-120 um;
s3, preprocessing a metal wire, cleaning the metal wire by using a rust remover, straightening the metal wire by using a straightening machine after cleaning and drying, and polishing the metal wire to make the surface of the metal wire smooth after straightening;
s4, performing electric arc spraying, namely respectively connecting an air compressor and a spray gun with an electric arc spraying power supply, installing a wire feeder between the spray gun and the electric arc spraying power supply, connecting one end of the metal wire into the wire feeder, and turning on equipment to spray the workpiece;
s5, sealing holes of the coating, namely, spraying and sealing the holes by using the special sealing agent for high-temperature corrosion resistance and wear resistance within 5-8 hours after spraying is finished, sealing capillary pores, and forming a composite coating together with the metal coating;
s6: and (3) inspecting the coating, namely inspecting the total thickness of the coating by adopting a hanging piece mode, wherein the total thickness of the composite coating is 0.8-0.9mm, and inspecting the appearance surface after spraying.
Compared with the traditional electric arc spraying, the technical scheme has the advantages that the process of surface pretreatment to be sprayed is added before the electric arc spraying, namely, the surface of the workpiece is subjected to sand blasting, the surface activity of the workpiece can be improved by sand blasting, the adsorption force between spraying particles and the surface of the workpiece can be increased, and the metallurgical bonding force between the spraying particles and a matrix can be improved. After repeated impact of sand grains, the surface of the workpiece forms certain residual compressive stress, which is beneficial to improving the overall fatigue strength of the workpiece; while also being beneficial in eliminating residual thermal stresses formed during the spray coating process.
Meanwhile, a pretreatment procedure for the metal wire is added before the electric arc spraying, even if the surface of the metal wire placed for a long time is rusted, impurities on the metal wire are removed after the metal wire is cleaned, dried, straightened and polished, so that the purity of atomized metal particles is improved, and the metal particles can be uniformly attached to the surface of a workpiece. The sprayed workpiece has smooth outer surface, even, flat and compact coating, good combination of the coating and the matrix, no bubbling, cracking, pitted surface and peeling, and the corrosion resistance and the structural strength of the workpiece are improved.
The present invention in a preferred example may be further configured to: in S2, the surface to be sprayed is pretreated by the following steps:
s2 a: carrying out primary sand blasting, selecting 15-16 meshes of corundum sand to carry out coarse sand blasting on the surface of the workpiece, and removing floating ash, hard ash and rust layers on the surface, particularly adhesive substances in small pits until the metallic luster is completely exposed;
s2 b: and secondary sand blasting, namely, sand blasting the derusted surface again to roughen the surface of the workpiece so as to improve the bonding strength.
Through the technical scheme, the purpose of the primary sand blasting process is to purify the surface of a workpiece and remove various pollutants on the sprayed surface, particularly grease, dirt, oxide skin, rust layer and the like, so that the surface of the workpiece shows uniform metal luster, the adhesion and the bonding (mechanical occlusion and metallurgical micro-diffusion) of a priming material and the active surface of a matrix are facilitated, the bonding strength is improved, and the cleanliness of the working surface reaches grade Sa 3.
The purpose of the secondary sand blasting process is to roughen the surface of the workpiece, and the combination of the thermal spray coating and the substrate is mainly combined mechanically, so that the pretreatment of the substrate needs to remove oil and rust and roughen the surface so that the surface has certain roughness. The secondary sand blasting increases the contact area of the spraying layer material and the matrix, and improves the adhesive adsorption force of the joint surface. Meanwhile, the filling embedding and pinning occlusion effects of the coating material and the surface of the substrate are increased, so that the adhesive force of the coating and the substrate is enhanced.
The present invention in a preferred example may be further configured to: before the primary sand blasting process, shielding and protecting the non-spraying surface of the workpiece by adopting a shielding belt and a baffle object to form a protective layer, and reserving a transition area 210mm at the edge of the protective layer;
in the sand blasting process, the arc voltage is set to be 36-37V, the distance between the spray gun and the workpiece surface is kept at 350-400mm, the spraying moving speed is kept between 0.9m/min and 1.1m/min during spraying, and the spraying temperature rise T is controlled to be less than 100 ℃.
Through above-mentioned technical scheme, guaranteed that the work piece in the sandblast process, the surface can form smooth transition. And arc voltage, jet distance, spraying moving speed and spraying temperature rise are adjusted to be in proper ranges, so that rough pits which are uniformly distributed can be formed on the surface of the workpiece, micro-metallurgical bonding is generated on a bonding surface, and the bonding force is improved.
The present invention in a preferred example may be further configured to: the interval between the sand blasting process and the electric arc spraying process is less than 3 hours.
Through the technical scheme, organic dirt and oxide layers on the surface of the workpiece can be removed through sand blasting, plastic deformation of metal surface crystal grains is increased, lattice defects are increased, the surface is in a state of easy chemical reaction, and the physical and chemical combination between spraying particles and the metal surface is facilitated. Therefore, after sand blasting, spraying should be carried out as soon as possible, and the shorter the time, the better the surface activation effect is, and the higher the bonding quality of the coating is. The interval time is controlled within 3 hours, the effect of electric arc spraying can be ensured, and the spraying quality is improved.
The present invention in a preferred example may be further configured to: in the step S4, the air pressure of the air compressor during working is kept above 0.6MPa, the ambient temperature during the electric arc spraying is between-10 ℃ and +40 ℃, and the altitude is not more than 1400 m;
the voltage of the electric arc spraying is 28V-35V, the current is 160A-200A, the spraying material is L-302 and CP-302A alloy wire with the diameter of 2.0mm, the spraying distance is 200mm-300mm, the spraying angle is 45-75 degrees, and the particle spraying speed is more than 400 m/s.
Through the technical scheme, the environmental parameters and the working parameters of the electric arc spraying equipment are adjusted, so that the electric arc spraying equipment can work normally, the spraying quality is improved to the maximum extent, and the service life of the electric arc spraying equipment is prolonged.
The present invention in a preferred example may be further configured to: the spraying mode of the electric arc spraying adopts a well-shaped spraying mode, the operation is carried out in a layered and partitioned mode, and the local area is moved to other areas after reaching the process design thickness.
Through above-mentioned technical scheme, so set up the thickness that can ensure the spraying layer even, prevent to appear leaking and spout the phenomenon.
The present invention in a preferred example may be further configured to: in S6, visually inspecting the surface of the workpiece, and inspecting the sprayed appearance surface of the workpiece by using a visual inspection system, wherein the visual inspection system includes a magnifying glass, a camera and a display screen;
the camera slides and is arranged above the magnifying glass, and the camera is connected with the display screen through a data line.
Through the technical scheme, the workpiece surface is detected by special quality inspection personnel in visual inspection, the image on the workpiece surface is amplified by the magnifier, and the amplified image is collected and transmitted to the display screen by the camera, so that the visual inspection is convenient to observe, and is safe and reliable. The surface of the sprayed workpiece is detected by adopting a visual inspection and visual inspection system, so that the effect of electric arc spraying can be accurately detected, and the practicability is improved.
In summary, the invention includes at least one of the following beneficial technical effects:
1. compared with the traditional electric arc spraying, the invention adds the step of surface pretreatment to be sprayed before the electric arc spraying, namely, the surface of the workpiece is subjected to sand blasting treatment, and the sand blasting can improve the surface activity of the workpiece, is favorable for increasing the adsorption force between the sprayed particles and the surface of the workpiece, and improves the metallurgical bonding force between the sprayed particles and a matrix. After repeated impact of sand grains, the surface of the workpiece forms certain residual compressive stress, which is beneficial to improving the overall fatigue strength of the workpiece; while also being beneficial in eliminating residual thermal stresses formed during the spray coating process.
Meanwhile, a pretreatment procedure for the metal wire is added before the electric arc spraying, even if the surface of the metal wire placed for a long time is rusted, impurities on the metal wire are removed after the metal wire is cleaned, dried, straightened and polished, so that the purity of atomized metal particles is improved, and the metal particles can be uniformly attached to the surface of a workpiece. The sprayed workpiece has smooth outer surface, even, flat and compact coating, good combination of the coating and the matrix, no bubbling, cracking, pitted surface and peeling, and the corrosion resistance and the structural strength of the workpiece are improved.
2. The primary sand blasting process aims to purify the surface of a workpiece and remove various pollutants on the sprayed surface, particularly grease, dirt, oxide skin, rust layer and the like, so that the surface of the workpiece shows uniform metal luster, adhesion bonding (mechanical occlusion and metallurgical micro-diffusion) of a priming material and the active surface of a matrix is facilitated, the bonding strength is improved, and the cleanliness of a working surface reaches grade Sa 3.
The purpose of the secondary sand blasting process is to roughen the surface of the workpiece, and the combination of the thermal spray coating and the substrate is mainly combined mechanically, so that the pretreatment of the substrate needs to remove oil and rust and roughen the surface so that the surface has certain roughness. The secondary sand blasting increases the contact area of the spraying layer material and the matrix, and improves the adhesive adsorption force of the joint surface. Meanwhile, the filling embedding and pinning occlusion effects of the coating material and the surface of the substrate are increased, so that the adhesive force of the coating and the substrate is enhanced.
3. The sand blasting can remove organic dirt and oxide layers on the surface of the workpiece, increase the plastic deformation of metal surface crystal grains and increase lattice defects, so that the surface is in a state of easy chemical reaction, and the physical and chemical combination between the sprayed particles and the metal surface is promoted. Therefore, after sand blasting, spraying should be carried out as soon as possible, and the shorter the time, the better the surface activation effect is, and the higher the bonding quality of the coating is. The interval time is controlled within 3 hours, the effect of electric arc spraying can be ensured, and the spraying quality is improved.
Drawings
FIG. 1 is a schematic flow diagram of the present invention.
Detailed Description
The present invention will be described in further detail with reference to the accompanying drawings.
Referring to fig. 1, the arc spraying method disclosed by the invention comprises the following steps:
s1: construction preparation, namely removing dust and impurities on the surface of a workpiece, and carrying out all-around quality inspection on the part of the workpiece subjected to spraying;
s2: performing surface pretreatment to be sprayed, and performing sand blasting treatment on the surface of the workpiece by adopting pneumatically controlled sand blasting equipment to ensure that the roughness of the workpiece reaches 90-120 um;
s3, pretreating the metal wire, cleaning the metal wire by using a rust remover, straightening the metal wire by using a straightening machine after cleaning and drying, and polishing the metal wire to make the surface of the metal wire smooth after straightening;
s4, electric arc spraying, wherein the air compressor and the spray gun are respectively connected with an electric arc spraying power supply, a wire feeder is arranged between the spray gun and the electric arc spraying power supply, one end of a metal wire is connected into the wire feeder, and the equipment is turned on to spray the workpiece;
s5, sealing holes of the coating, namely, spraying and sealing the holes by using the special sealing agent for high-temperature corrosion resistance and wear resistance within 5-8 hours after spraying is finished, sealing capillary pores, and forming a composite coating together with the metal coating;
s6: and (4) inspecting the coating, namely inspecting the total thickness of the coating by adopting a hanging piece mode, wherein the total thickness of the composite coating is 0.8-0.9mm, and inspecting the appearance surface after spraying.
Before carrying out a sandblast process, adopt to shield area, baffle article to shield the protection and form the protective layer to work piece non-spraying surface, reserve transition region 210mm at the protective layer edge, so set up and guaranteed that the work piece can form smooth transition at the sandblast in-process, surface.
Wherein, in S2, the surface to be sprayed is pretreated by the following steps:
s2 a: carrying out primary sand blasting, selecting 15-16 meshes of corundum sand to carry out coarse sand blasting on the surface of the workpiece, and removing floating ash, hard ash and rust layers on the surface, particularly adhesive substances in small pits until the metallic luster is completely exposed;
s2 b: and secondary sand blasting, namely, carrying out secondary sand blasting on the derusted surface to roughen the surface of the workpiece so as to improve the bonding strength.
The primary sand blasting process aims to purify the surface of a workpiece and remove various pollutants on the sprayed surface, particularly grease, dirt, oxide skin, rust layer and the like, so that the surface of the workpiece shows uniform metal luster, adhesion bonding (mechanical occlusion and metallurgical micro-diffusion) of a priming material and the active surface of a matrix is facilitated, the bonding strength is improved, and the cleanliness of a working surface reaches grade Sa 3.
The purpose of the secondary sand blasting process is to roughen the surface of the workpiece, and the combination of the thermal spray coating and the substrate is mainly combined mechanically, so that the pretreatment of the substrate needs to remove oil and rust and roughen the surface so that the surface has certain roughness. The secondary sand blasting increases the contact area of the spraying layer material and the matrix, and improves the adhesive adsorption force of the joint surface. Meanwhile, the filling embedding and pinning occlusion effects of the coating material and the surface of the substrate are increased, so that the adhesive force of the coating and the substrate is enhanced.
In the sand blasting process, the arc voltage is set to be 36-37V, the distance between the spray gun and the surface of the workpiece is kept at 350-400mm, the spraying moving speed is kept between 0.9m/min and 1.1m/min during spraying, and the spraying temperature rise T is controlled to be less than 100 ℃. The arc voltage, the spraying distance, the spraying moving speed and the spraying temperature rise are adjusted to be in a proper range, so that rough pits which are uniformly distributed can be formed on the surface of the workpiece, the bonding surface is enabled to generate micro-metallurgical bonding, and the bonding force is improved.
Referring to fig. 1, in S4, the air pressure of the air compressor is maintained at 0.6MPa or more, the ambient temperature of the arc spraying is-10 to +40 ℃, and the altitude is not more than 1400 m. The voltage of electric arc spraying is 28V-35V, the current is 160A-200A, the spraying material is L-302 and CP-302A alloy wire with phi of 2.0mm, the spraying distance is 200mm-300mm, the spraying angle is 45-75 degrees, and the particle spraying speed is more than 400 m/s.
Environmental parameters and self working parameters during arc spraying are adjusted, so that the arc spraying equipment can work normally, the spraying quality is improved to the maximum extent, and the service life of the arc spraying equipment is prolonged. Furthermore, the spraying mode of electric arc spraying adopts a well-shaped spraying mode, layered and partitioned operation is carried out, a local area reaches the process design thickness and then is shifted to other areas, the thickness uniformity of a spraying layer can be ensured by the arrangement, and the phenomenon of spray leakage is prevented.
The interval between the sand blasting process and the electric arc spraying process is less than 3 hours, organic dirt and oxide layers on the surface of the workpiece can be removed by sand blasting, plastic deformation of metal surface crystal grains is increased, lattice defects are increased, the surface is in a state of easy chemical reaction, and physical and chemical combination between sprayed particles and the metal surface is facilitated. Therefore, after sand blasting, spraying should be carried out as soon as possible, and the shorter the time, the better the surface activation effect is, and the higher the bonding quality of the coating is. The interval time is controlled within 3 hours, the effect of electric arc spraying can be ensured, and the spraying quality is improved.
Further, in S6, the surface of the workpiece is visually inspected, and then the appearance surface of the workpiece after being sprayed is inspected by using a visual inspection system, wherein the visual inspection system includes a magnifying glass, a camera and a display screen. The camera slides and sets up in the top of magnifying glass, and the camera passes through the data line with the display screen and is connected.
The visual inspection is realized by detecting the surface of the workpiece by special quality inspection personnel, the magnifying glass magnifies the image of the surface of the workpiece, and the magnified image is collected and transmitted to the display screen by the camera, so that the visual inspection is convenient to observe, and is safe and reliable. The surface of the sprayed workpiece is detected by adopting a visual inspection and visual inspection system, so that the effect of electric arc spraying can be accurately detected, and the practicability is improved.
In this embodiment, the spray gun is preferably a pull type spray gun, which has the advantages of strong bonding, high efficiency, low energy consumption and less loss, and has several advantages compared with the push type arc spraying. 1. Has a spraying working surface, long distance and large space. If the push type device is only two meters long away from the workpiece, the pull type device can be extended to 30-50 meters. 2. The pull type spray gun can rotate up, down, left and right to spray, while the push type spray gun has unsatisfactory spraying effect when spraying upwards. 3. The pull type spray gun has the advantages that the metal wire is not arranged in the cable, the metal wire cannot cause thermal expansion to block, the short circuit of the spray gun of the equipment is caused, the arc crossing point is good, the spraying work is continuous and normal, and particularly, the zinc wire is sprayed, so that the superiority is further shown. 4. As the pull type spray gun adopts a phi 2mm wire, the material loss rate is far lower than that of a push type spraying device, and the spraying accumulation efficiency is also high.
The implementation principle of the embodiment is as follows: compared with the traditional electric arc spraying, the invention adds the step of surface pretreatment to be sprayed before the electric arc spraying, namely, the surface of the workpiece is subjected to sand blasting treatment, and the sand blasting can improve the surface activity of the workpiece, is favorable for increasing the adsorption force between the sprayed particles and the surface of the workpiece, and improves the metallurgical bonding force between the sprayed particles and a matrix. After repeated impact of sand grains, the surface of the workpiece forms certain residual compressive stress, which is beneficial to improving the overall fatigue strength of the workpiece; while also being beneficial in eliminating residual thermal stresses formed during the spray coating process.
Meanwhile, a pretreatment procedure for the metal wire is added before the electric arc spraying, even if the surface of the metal wire placed for a long time is rusted, impurities on the metal wire are removed after the metal wire is cleaned, dried, straightened and polished, so that the purity of atomized metal particles is improved, and the metal particles can be uniformly attached to the surface of a workpiece. The sprayed workpiece has smooth outer surface, even, flat and compact coating, good combination of the coating and the matrix, no bubbling, cracking, pitted surface and peeling, and the corrosion resistance and the structural strength of the workpiece are improved.
The embodiments of the present invention are preferred embodiments of the present invention, and the scope of the present invention is not limited by these embodiments, so: all equivalent changes made according to the structure, shape and principle of the invention are covered by the protection scope of the invention.
Claims (7)
1. An electric arc spraying method, characterized in that: the method comprises the following steps:
s1: construction preparation, namely removing dust and impurities on the surface of a workpiece, and carrying out quality inspection on the whole part of the workpiece subjected to spraying;
s2: performing surface pretreatment to be sprayed, and performing sand blasting treatment on the surface of the workpiece by adopting pneumatically controlled sand blasting equipment to ensure that the roughness of the workpiece reaches 90-120 um;
s3, preprocessing a metal wire, cleaning the metal wire by using a rust remover, straightening the metal wire by using a straightening machine after cleaning and drying, and polishing the metal wire to make the surface of the metal wire smooth after straightening;
s4, performing electric arc spraying, namely respectively connecting an air compressor and a spray gun with an electric arc spraying power supply, installing a wire feeder between the spray gun and the electric arc spraying power supply, connecting one end of the metal wire into the wire feeder, and turning on equipment to spray the workpiece;
s5, sealing holes of the coating, namely, spraying and sealing the holes by using the special sealing agent for high-temperature corrosion resistance and wear resistance within 5-8 hours after spraying is finished, sealing capillary pores, and forming a composite coating together with the metal coating;
s6: and (3) inspecting the coating, namely inspecting the total thickness of the coating by adopting a hanging piece mode, wherein the total thickness of the composite coating is 0.8-0.9mm, and inspecting the appearance surface after spraying.
2. An electric arc spraying method according to claim 1, wherein: in S2, the surface to be sprayed is pretreated by the following steps:
s2 a: carrying out primary sand blasting, selecting 15-16 meshes of corundum sand to carry out coarse sand blasting on the surface of the workpiece, and removing floating ash, hard ash and rust layers on the surface, particularly adhesive substances in small pits until the metallic luster is completely exposed;
s2 b: and secondary sand blasting, namely, sand blasting the derusted surface again to roughen the surface of the workpiece so as to improve the bonding strength.
3. An electric arc spraying method according to claim 2, wherein: before the primary sand blasting process, shielding and protecting the non-spraying surface of the workpiece by adopting a shielding belt and a baffle object to form a protective layer, and reserving a transition area 210mm at the edge of the protective layer;
in the sand blasting process, the arc voltage is set to be 36-37V, the distance between the spray gun and the workpiece surface is kept at 350-400mm, the spraying moving speed is kept between 0.9m/min and 1.1m/min during spraying, and the spraying temperature rise T is controlled to be less than 100 ℃.
4. An electric arc spraying method according to claim 1, wherein: the interval between the sand blasting process and the electric arc spraying process is less than 3 hours.
5. An electric arc spraying method according to claim 1, wherein: in the step S4, the air pressure of the air compressor during working is kept above 0.6MPa, the ambient temperature during the electric arc spraying is between-10 ℃ and +40 ℃, and the altitude is not more than 1400 m;
the voltage of the electric arc spraying is 28V-35V, the current is 160A-200A, the spraying material is L-302 and CP-302A alloy wire with the diameter of 2.0mm, the spraying distance is 200mm-300mm, the spraying angle is 45-75 degrees, and the particle spraying speed is more than 400 m/s.
6. An electric arc spraying method according to claim 5, wherein: the spraying mode of the electric arc spraying adopts a well-shaped spraying mode, the operation is carried out in a layered and partitioned mode, and the local area is moved to other areas after reaching the process design thickness.
7. An electric arc spraying method according to claim 1, wherein: in S6, visually inspecting the surface of the workpiece, and inspecting the sprayed appearance surface of the workpiece by using a visual inspection system, wherein the visual inspection system includes a magnifying glass, a camera and a display screen;
the camera slides and is arranged above the magnifying glass, and the camera is connected with the display screen through a data line.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202011210920.8A CN112159947A (en) | 2020-11-03 | 2020-11-03 | Electric arc spraying method |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202011210920.8A CN112159947A (en) | 2020-11-03 | 2020-11-03 | Electric arc spraying method |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN112159947A true CN112159947A (en) | 2021-01-01 |
Family
ID=73865552
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202011210920.8A Pending CN112159947A (en) | 2020-11-03 | 2020-11-03 | Electric arc spraying method |
Country Status (1)
| Country | Link |
|---|---|
| CN (1) | CN112159947A (en) |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN112877638A (en) * | 2021-03-10 | 2021-06-01 | 石河子大学 | Preparation process flow of high-speed electric arc spraying coating |
| CN114774832A (en) * | 2022-03-18 | 2022-07-22 | 无锡华金喷涂防腐技术服务有限公司 | Hot spraying Zn-Al-Mg alloy coating and preparation method thereof |
| CN115369350A (en) * | 2022-07-08 | 2022-11-22 | 太原科技大学 | Method for preparing stainless steel precision foil by combining arc spraying and rolling process under argon protection |
Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2005288485A (en) * | 2004-03-31 | 2005-10-20 | Daido Steel Co Ltd | Ti BASED WIRE FOR WELDING |
| CN102154610A (en) * | 2010-02-11 | 2011-08-17 | 上海建冶科技工程股份有限公司 | Construction technology for anticorrosive composite coating of steel structure |
| CN104878344A (en) * | 2015-05-22 | 2015-09-02 | 山西华辉恒源防腐工程有限公司 | Novel spraying technology for corrosion prevention and abrasion prevention of boiler |
| CN110512125A (en) * | 2019-08-30 | 2019-11-29 | 中国航发北京航空材料研究院 | A kind of preparation method of the diameter aluminium lithium alloy silk material for increasing material manufacturing |
-
2020
- 2020-11-03 CN CN202011210920.8A patent/CN112159947A/en active Pending
Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2005288485A (en) * | 2004-03-31 | 2005-10-20 | Daido Steel Co Ltd | Ti BASED WIRE FOR WELDING |
| CN102154610A (en) * | 2010-02-11 | 2011-08-17 | 上海建冶科技工程股份有限公司 | Construction technology for anticorrosive composite coating of steel structure |
| CN104878344A (en) * | 2015-05-22 | 2015-09-02 | 山西华辉恒源防腐工程有限公司 | Novel spraying technology for corrosion prevention and abrasion prevention of boiler |
| CN110512125A (en) * | 2019-08-30 | 2019-11-29 | 中国航发北京航空材料研究院 | A kind of preparation method of the diameter aluminium lithium alloy silk material for increasing material manufacturing |
Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN112877638A (en) * | 2021-03-10 | 2021-06-01 | 石河子大学 | Preparation process flow of high-speed electric arc spraying coating |
| CN114774832A (en) * | 2022-03-18 | 2022-07-22 | 无锡华金喷涂防腐技术服务有限公司 | Hot spraying Zn-Al-Mg alloy coating and preparation method thereof |
| CN114774832B (en) * | 2022-03-18 | 2024-01-30 | 无锡华金喷涂防腐技术服务有限公司 | Hot spraying Zn-Al-Mg alloy coating and preparation method thereof |
| CN115369350A (en) * | 2022-07-08 | 2022-11-22 | 太原科技大学 | Method for preparing stainless steel precision foil by combining arc spraying and rolling process under argon protection |
| CN115369350B (en) * | 2022-07-08 | 2023-07-07 | 太原科技大学 | Method for preparing stainless steel precise foil by combining arc spraying and rolling process under argon protection |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| CN112159947A (en) | Electric arc spraying method | |
| CN104073757B (en) | Strengthen the method for ocean structure steel resistance to corrosion fatigue performance | |
| CN102154610A (en) | Construction technology for anticorrosive composite coating of steel structure | |
| CN103451650A (en) | Laser quick repair process method for large rotary machine bearing bush | |
| EP1679388A1 (en) | Method of thermal spraying | |
| CN109500744A (en) | Large-size stainless steel work piece surface blasting craft | |
| CN109338271A (en) | A kind of aero-engine titanium alloy component seam allowance repairing sizes method | |
| CN105256268A (en) | Construction process for anticorrosion composite coating of steel structure | |
| CN102041465A (en) | Method for repairing crankshaft of diesel engine | |
| CN111188004A (en) | Process method for repairing flap slide rail abrasion by supersonic spraying | |
| CN109112465A (en) | A kind of novel undercarriage Shaft of Titanium Alloy remanufactures repair method | |
| CN102676970A (en) | In-situ spraying reparation method of horizontal aluminum busbar in electrolytic plant | |
| CN111139465A (en) | Manufacturing method for manufacturing composite steel pipe by laser | |
| CN112899605A (en) | Preparation method and application of tungsten carbide coating | |
| CN104353599A (en) | Method using glass beads to treat anti-rust paint layer of steel aviation part | |
| CN111250368A (en) | Preparation process of polyphenyl ester sealing coating for aero-engine case parts | |
| CN107805809A (en) | A kind of automobile die surface coating renovation technique | |
| CN101705842B (en) | Wear-resistance layers on surfaces of inner ring and outer ring of bypass variable mechanism of gas turbine and preparation method thereof | |
| CN106811716A (en) | The construction technology of anticorrosive composite coating of steel structure | |
| CN102211080A (en) | Anticorrosion method of composite coating positioned on surface of steel structure | |
| CN1763248A (en) | Bearing surface anticorrosion treatment process | |
| CN1904125A (en) | Large power electric arc hot spray coating method of zinc aluminium false alloy | |
| CN114559373B (en) | Repair method for through hole damage of aluminum alloy part | |
| CN115044762A (en) | Silicon steel furnace roller and processing method thereof | |
| CN105385976A (en) | Preparation method for sealing coating of machine part |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| PB01 | Publication | ||
| PB01 | Publication | ||
| SE01 | Entry into force of request for substantive examination | ||
| SE01 | Entry into force of request for substantive examination | ||
| RJ01 | Rejection of invention patent application after publication |
Application publication date: 20210101 |
|
| RJ01 | Rejection of invention patent application after publication |