CN112176341A - Composite coating of metal substrate and construction method thereof - Google Patents
Composite coating of metal substrate and construction method thereof Download PDFInfo
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- CN112176341A CN112176341A CN202011204051.8A CN202011204051A CN112176341A CN 112176341 A CN112176341 A CN 112176341A CN 202011204051 A CN202011204051 A CN 202011204051A CN 112176341 A CN112176341 A CN 112176341A
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- metal
- spraying
- composite coating
- coating
- binder
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- 229910052751 metal Inorganic materials 0.000 title claims abstract description 85
- 239000002184 metal Substances 0.000 title claims abstract description 85
- 238000000576 coating method Methods 0.000 title claims abstract description 63
- 239000011248 coating agent Substances 0.000 title claims abstract description 61
- 239000002131 composite material Substances 0.000 title claims abstract description 28
- 239000000758 substrate Substances 0.000 title claims abstract description 25
- 238000010276 construction Methods 0.000 title claims description 7
- 239000000463 material Substances 0.000 claims abstract description 40
- 239000010410 layer Substances 0.000 claims abstract description 38
- 239000002344 surface layer Substances 0.000 claims abstract description 27
- 239000011230 binding agent Substances 0.000 claims abstract description 26
- 239000000843 powder Substances 0.000 claims abstract description 25
- 239000000919 ceramic Substances 0.000 claims abstract description 8
- 239000002694 phosphate binding agent Substances 0.000 claims abstract description 7
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical group [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 claims abstract description 6
- 238000013329 compounding Methods 0.000 claims abstract description 4
- 238000005507 spraying Methods 0.000 claims description 42
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 22
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 17
- 239000011651 chromium Substances 0.000 claims description 15
- 229910052804 chromium Inorganic materials 0.000 claims description 14
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims description 13
- 239000000203 mixture Substances 0.000 claims description 12
- 229910052759 nickel Inorganic materials 0.000 claims description 11
- 238000010285 flame spraying Methods 0.000 claims description 10
- 238000000034 method Methods 0.000 claims description 10
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 claims description 9
- 229910052782 aluminium Inorganic materials 0.000 claims description 9
- 229910052719 titanium Inorganic materials 0.000 claims description 9
- 239000010936 titanium Substances 0.000 claims description 9
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 8
- 229910052742 iron Inorganic materials 0.000 claims description 8
- 238000007751 thermal spraying Methods 0.000 claims description 7
- 238000004140 cleaning Methods 0.000 claims description 6
- 238000005488 sandblasting Methods 0.000 claims description 6
- 238000007664 blowing Methods 0.000 claims description 4
- 229910052758 niobium Inorganic materials 0.000 claims description 4
- 239000010955 niobium Substances 0.000 claims description 4
- GUCVJGMIXFAOAE-UHFFFAOYSA-N niobium atom Chemical compound [Nb] GUCVJGMIXFAOAE-UHFFFAOYSA-N 0.000 claims description 4
- 239000011701 zinc Substances 0.000 claims description 4
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 3
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 claims description 3
- 239000002253 acid Substances 0.000 claims description 3
- 230000001680 brushing effect Effects 0.000 claims description 3
- 238000010288 cold spraying Methods 0.000 claims description 3
- 229910052802 copper Inorganic materials 0.000 claims description 3
- 239000010949 copper Substances 0.000 claims description 3
- 238000004880 explosion Methods 0.000 claims description 3
- 238000000227 grinding Methods 0.000 claims description 3
- 238000007750 plasma spraying Methods 0.000 claims description 3
- 238000005096 rolling process Methods 0.000 claims description 3
- 229910052725 zinc Inorganic materials 0.000 claims description 3
- 230000007797 corrosion Effects 0.000 abstract description 20
- 238000005260 corrosion Methods 0.000 abstract description 20
- 238000005524 ceramic coating Methods 0.000 abstract description 19
- 230000000694 effects Effects 0.000 abstract description 6
- 238000005461 lubrication Methods 0.000 abstract description 6
- 238000005516 engineering process Methods 0.000 abstract description 4
- 239000011148 porous material Substances 0.000 abstract description 3
- 230000007547 defect Effects 0.000 abstract description 2
- 230000009286 beneficial effect Effects 0.000 description 14
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 13
- 235000019353 potassium silicate Nutrition 0.000 description 8
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 description 8
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 7
- 239000002994 raw material Substances 0.000 description 6
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 6
- 229910010271 silicon carbide Inorganic materials 0.000 description 6
- 239000000126 substance Substances 0.000 description 6
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 5
- 238000004939 coking Methods 0.000 description 5
- 239000007769 metal material Substances 0.000 description 5
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 4
- 238000005299 abrasion Methods 0.000 description 4
- 239000000446 fuel Substances 0.000 description 4
- UONOETXJSWQNOL-UHFFFAOYSA-N tungsten carbide Chemical compound [W+]#[C-] UONOETXJSWQNOL-UHFFFAOYSA-N 0.000 description 4
- 229910000975 Carbon steel Inorganic materials 0.000 description 3
- 239000006087 Silane Coupling Agent Substances 0.000 description 3
- 239000010962 carbon steel Substances 0.000 description 3
- 229910000420 cerium oxide Inorganic materials 0.000 description 3
- 238000012512 characterization method Methods 0.000 description 3
- 230000008021 deposition Effects 0.000 description 3
- QDOXWKRWXJOMAK-UHFFFAOYSA-N dichromium trioxide Chemical compound O=[Cr]O[Cr]=O QDOXWKRWXJOMAK-UHFFFAOYSA-N 0.000 description 3
- 239000000428 dust Substances 0.000 description 3
- 238000010891 electric arc Methods 0.000 description 3
- BMMGVYCKOGBVEV-UHFFFAOYSA-N oxo(oxoceriooxy)cerium Chemical compound [Ce]=O.O=[Ce]=O BMMGVYCKOGBVEV-UHFFFAOYSA-N 0.000 description 3
- RVTZCBVAJQQJTK-UHFFFAOYSA-N oxygen(2-);zirconium(4+) Chemical compound [O-2].[O-2].[Zr+4] RVTZCBVAJQQJTK-UHFFFAOYSA-N 0.000 description 3
- 239000002245 particle Substances 0.000 description 3
- 229910052761 rare earth metal Inorganic materials 0.000 description 3
- 150000002910 rare earth metals Chemical class 0.000 description 3
- 229910052710 silicon Inorganic materials 0.000 description 3
- 239000000377 silicon dioxide Substances 0.000 description 3
- 238000001228 spectrum Methods 0.000 description 3
- 238000003756 stirring Methods 0.000 description 3
- 229910052717 sulfur Inorganic materials 0.000 description 3
- 238000005303 weighing Methods 0.000 description 3
- 229910001928 zirconium oxide Inorganic materials 0.000 description 3
- 229910000851 Alloy steel Inorganic materials 0.000 description 2
- 239000004111 Potassium silicate Substances 0.000 description 2
- 239000004115 Sodium Silicate Substances 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 2
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 2
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 description 2
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 2
- 229910045601 alloy Inorganic materials 0.000 description 2
- 239000000956 alloy Substances 0.000 description 2
- 229910052593 corundum Inorganic materials 0.000 description 2
- RGPUVZXXZFNFBF-UHFFFAOYSA-K diphosphonooxyalumanyl dihydrogen phosphate Chemical compound [Al+3].OP(O)([O-])=O.OP(O)([O-])=O.OP(O)([O-])=O RGPUVZXXZFNFBF-UHFFFAOYSA-K 0.000 description 2
- 239000000839 emulsion Substances 0.000 description 2
- 229910052500 inorganic mineral Inorganic materials 0.000 description 2
- PAZHGORSDKKUPI-UHFFFAOYSA-N lithium metasilicate Chemical compound [Li+].[Li+].[O-][Si]([O-])=O PAZHGORSDKKUPI-UHFFFAOYSA-N 0.000 description 2
- 229910052912 lithium silicate Inorganic materials 0.000 description 2
- QQFLQYOOQVLGTQ-UHFFFAOYSA-L magnesium;dihydrogen phosphate Chemical compound [Mg+2].OP(O)([O-])=O.OP(O)([O-])=O QQFLQYOOQVLGTQ-UHFFFAOYSA-L 0.000 description 2
- 239000011707 mineral Substances 0.000 description 2
- 229910000401 monomagnesium phosphate Inorganic materials 0.000 description 2
- 235000019785 monomagnesium phosphate Nutrition 0.000 description 2
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 2
- 239000000049 pigment Substances 0.000 description 2
- 229910052913 potassium silicate Inorganic materials 0.000 description 2
- NNHHDJVEYQHLHG-UHFFFAOYSA-N potassium silicate Chemical compound [K+].[K+].[O-][Si]([O-])=O NNHHDJVEYQHLHG-UHFFFAOYSA-N 0.000 description 2
- 230000008569 process Effects 0.000 description 2
- 239000011253 protective coating Substances 0.000 description 2
- 238000010926 purge Methods 0.000 description 2
- 239000011347 resin Substances 0.000 description 2
- 229920005989 resin Polymers 0.000 description 2
- RMAQACBXLXPBSY-UHFFFAOYSA-N silicic acid Chemical compound O[Si](O)(O)O RMAQACBXLXPBSY-UHFFFAOYSA-N 0.000 description 2
- 229910052814 silicon oxide Inorganic materials 0.000 description 2
- 239000001488 sodium phosphate Substances 0.000 description 2
- 229910000162 sodium phosphate Inorganic materials 0.000 description 2
- 229910052911 sodium silicate Inorganic materials 0.000 description 2
- 239000010959 steel Substances 0.000 description 2
- 239000011593 sulfur Substances 0.000 description 2
- RYFMWSXOAZQYPI-UHFFFAOYSA-K trisodium phosphate Chemical compound [Na+].[Na+].[Na+].[O-]P([O-])([O-])=O RYFMWSXOAZQYPI-UHFFFAOYSA-K 0.000 description 2
- MFXMOUUKFMDYLM-UHFFFAOYSA-L zinc;dihydrogen phosphate Chemical compound [Zn+2].OP(O)([O-])=O.OP(O)([O-])=O MFXMOUUKFMDYLM-UHFFFAOYSA-L 0.000 description 2
- 229910052726 zirconium Inorganic materials 0.000 description 2
- 239000005995 Aluminium silicate Substances 0.000 description 1
- 229910052684 Cerium Inorganic materials 0.000 description 1
- VEXZGXHMUGYJMC-UHFFFAOYSA-M Chloride anion Chemical compound [Cl-] VEXZGXHMUGYJMC-UHFFFAOYSA-M 0.000 description 1
- MBMLMWLHJBBADN-UHFFFAOYSA-N Ferrous sulfide Chemical class [Fe]=S MBMLMWLHJBBADN-UHFFFAOYSA-N 0.000 description 1
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 description 1
- 229910052581 Si3N4 Inorganic materials 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- UCKMPCXJQFINFW-UHFFFAOYSA-N Sulphide Chemical compound [S-2] UCKMPCXJQFINFW-UHFFFAOYSA-N 0.000 description 1
- HSFWRNGVRCDJHI-UHFFFAOYSA-N alpha-acetylene Natural products C#C HSFWRNGVRCDJHI-UHFFFAOYSA-N 0.000 description 1
- 235000012211 aluminium silicate Nutrition 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 229910002110 ceramic alloy Inorganic materials 0.000 description 1
- 229910010293 ceramic material Inorganic materials 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 238000005253 cladding Methods 0.000 description 1
- 229910052681 coesite Inorganic materials 0.000 description 1
- 238000002485 combustion reaction Methods 0.000 description 1
- 239000010431 corundum Substances 0.000 description 1
- 229910052906 cristobalite Inorganic materials 0.000 description 1
- 125000002534 ethynyl group Chemical group [H]C#C* 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 description 1
- 230000001050 lubricating effect Effects 0.000 description 1
- 239000002905 metal composite material Substances 0.000 description 1
- 239000010445 mica Substances 0.000 description 1
- 229910052618 mica group Inorganic materials 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229910052750 molybdenum Inorganic materials 0.000 description 1
- 239000011733 molybdenum Substances 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- 230000000750 progressive effect Effects 0.000 description 1
- 230000001681 protective effect Effects 0.000 description 1
- 238000000550 scanning electron microscopy energy dispersive X-ray spectroscopy Methods 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- HQVNEWCFYHHQES-UHFFFAOYSA-N silicon nitride Chemical compound N12[Si]34N5[Si]62N3[Si]51N64 HQVNEWCFYHHQES-UHFFFAOYSA-N 0.000 description 1
- 239000007921 spray Substances 0.000 description 1
- 229910052682 stishovite Inorganic materials 0.000 description 1
- 239000002562 thickening agent Substances 0.000 description 1
- 229910052905 tridymite Inorganic materials 0.000 description 1
- 229910052720 vanadium Inorganic materials 0.000 description 1
- LEONUFNNVUYDNQ-UHFFFAOYSA-N vanadium atom Chemical compound [V] LEONUFNNVUYDNQ-UHFFFAOYSA-N 0.000 description 1
- 238000003466 welding Methods 0.000 description 1
- 229910001845 yogo sapphire Inorganic materials 0.000 description 1
Images
Classifications
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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
- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
-
- 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
- C23C24/00—Coating starting from inorganic powder
- C23C24/02—Coating starting from inorganic powder by application of pressure only
- C23C24/04—Impact or kinetic deposition of particles
-
- 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
- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
- C23C28/34—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates
-
- 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
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Inorganic Chemistry (AREA)
- Physics & Mathematics (AREA)
- Plasma & Fusion (AREA)
- Coating By Spraying Or Casting (AREA)
Abstract
The invention discloses a composite coating of a metal substrate, which is formed by compounding a bottom layer and a surface layer which are sequentially coated on the metal substrate; the bottom layer is composed of metal wires, metal powder and metal skin wrapping wires; the surface layer is composed of ceramic powder and a binder; the binder is a silicate binder, a phosphate binder or a sol binder. The invention combines the corrosion resistance and wear resistance of the metal coating and the compact lubrication characteristic of the ceramic coating, achieves the effect that 1+1 is more than 2, the metal coating is more easily combined with the metal base material, the combination strength is more than 60Mpa, the defect point pore space or unsmooth surface is compensated by the ceramic coating, and the coating obtained by the integral composite coating technology has the advantages of high temperature resistance, corrosion resistance, wear resistance, high lubrication, long service life and temperature resistance of more than 1600 ℃.
Description
Technical Field
The invention belongs to the technical field of composite coatings, and particularly relates to a composite coating of a metal substrate and a construction method thereof.
Background
In the basic construction of a plurality of fields such as industry, agriculture, navigation, aerospace, military and the like, common metal materials are often selected as the first choice materials due to low price. In the actual use process, common metal materials such as carbon steel, 20G boiler steel, Q235 and #45 steel cannot completely meet the application of various industries, and the materials are easy to wear, seriously corrode and oxidize at high temperature, or cause serious surface adhesion due to the fact that the materials are base materials in heat exchange equipment and the fuel is complex.
At present, a plurality of methods for solving the problems are available, such as spraying protective coatings, such as metal thermal spraying corrosion-resistant and wear-resistant materials, cladding high-wear-resistant and corrosion-resistant materials, spraying high-temperature coatings and the like. However, a single protection scheme cannot effectively solve the above problems.
Therefore, the development of a composite coating with long service life, corrosion resistance, wear resistance and high lubrication suitable for metal substrates is a problem to be solved urgently by those skilled in the art.
Disclosure of Invention
In view of the above, the invention provides a composite coating with long service life, corrosion resistance, wear resistance and high lubrication for metal substrates.
The technical scheme is as follows:
a composite coating of a metal substrate is formed by compounding a bottom layer and a surface layer which are sequentially coated on the metal substrate;
the bottom layer is composed of metal wires, metal powder and metal skin wrapping wires;
the surface layer is composed of ceramic powder and a binder;
the binder is a silicate binder, a phosphate binder or a sol binder.
Further, the thickness of the base layer is 50 to 500. mu.m.
The adoption of the further beneficial effects is as follows: the service life of the compounded coating exceeds 1 year of the bottom layer, the service life of the surface layer is half a year, the comprehensive service life exceeds 2 years, and the anti-coking performance of the coating is improved by 80 percent, and the heat exchange effect is improved by 5 percent.
Further, the thickness of the surface layer is 50-200 μm.
The adoption of the further beneficial effects is as follows: the coating is proper in thickness, covers the bottom layer, fills up pores of the metal coating, and fills up pits of the bottom layer, so that the surface of the whole coating is smoother.
Further, the diameter of the metal wire is 1.2 to 6 mm.
The adoption of the further beneficial effects is as follows: the metal wire with the diameter range is convenient for spraying of the existing spraying equipment.
Further, the metal wire is composed of one or a mixture of more of copper, aluminum, zinc, iron, nickel, chromium, titanium and niobium.
The adoption of the further beneficial effects is as follows: the material selection is convenient, the surface characteristics of the base material can be better changed by the performance characteristics of different metal materials, and further the basic performance of the protective base material is improved, such as the improvement of the corrosion resistance, the wear resistance, the high temperature resistance and the like.
Further, the diameter of the metal skin wrapping wire is 2-6 mm.
The adoption of the further beneficial effects is as follows: the diameter material can better wrap powder metal materials, ceramic materials and the like, and is convenient to spray and use.
Further, the metal sheath wrapping wire consists of a core wire and a wrapping layer, wherein the core wire is an alloy containing iron, nickel or chromium; the wrapping layer is one or a mixture of more of nickel, chromium, titanium, niobium, zirconium oxide, aluminum oxide, silicon oxide, tungsten carbide and silicon carbide.
The adoption of the further beneficial effects is as follows: the corrosion resistance, wear resistance and high temperature resistance of the coating are improved.
Further, the metal powder is made of nickel, chromium and/or titanium.
The adoption of the further beneficial effects is as follows: the bonding strength of the coating and the base material is improved.
Further, the ceramic powder is composed of one or a mixture of more of zirconia, alumina, silica, tungsten carbide, and silicon carbide.
The adoption of the further beneficial effects is as follows: the corrosion resistance and the wear resistance of the coating are improved.
Further, the silicate binder is composed of one or a mixture of more of sodium silicate, potassium silicate and lithium silicate;
the phosphate binder is composed of one or a mixture of more of sodium phosphate, magnesium dihydrogen phosphate, zinc dihydrogen phosphate and aluminum dihydrogen phosphate;
the sol binder is composed of water glass and sol, the weight ratio of the water glass to the sol is 1-2:1, and the sol is silica sol, aluminum sol or zirconium sol.
Furthermore, the binder is a nano-scale binder, and aggregate in the nano-scale binder is micron-scale aggregate.
The adoption of the further beneficial effects is as follows: provides gradient components for the whole system of the coating and improves the whole wear-resisting, corrosion-resisting and lubricating properties of the coating.
Further, the surface layer also comprises one or a mixture of several of pigment, mineral powder, rare earth material powder or nano-layered material powder.
The adoption of the further beneficial effects is as follows: improve the heat exchange effect and the anti-coking performance of the coating.
Further, the metal base material is carbon steel or alloy steel.
The invention also provides a construction method of the composite coating of the metal base material, which comprises the following steps:
(1) pretreating the surface of a metal base material to enable the surface of the base material to reach more than Sa2.5 grade;
(2) spraying a bottom layer by means of metal thermal spraying;
(3) and after the bottom layer is cooled to room temperature, spraying the surface layer.
Further, in the step (1), the pretreatment mode is one or a combination of several modes of sand blasting, grinding, purging, laser cleaning and acid cleaning.
The adoption of the further beneficial effects is as follows: the bonding strength of the coating is improved.
Further, in the step (2), the metal thermal spraying mode is one or a combination of several modes of electric arc spraying, plasma spraying, supersonic flame spraying, wire flame spraying, cold spraying, explosion spraying and powder flame spraying.
The adoption of the further beneficial effects is as follows: the coating can be sprayed uniformly onto the substrate.
Further, in the step (3), the surface layer is sprayed by one or a combination of air spraying, airless spraying, brushing and rolling.
The adoption of the further beneficial effects is as follows: the coating can be sprayed uniformly onto the substrate.
The invention has the beneficial effects that: the invention can be widely applied to the fields of easy abrasion, oxidation, corrosion, bonding, heat exchange and the like of metal materials, for example, a boiler is a high-temperature heat exchange equipment device, the heated heat exchange surface of the boiler is formed by combining and welding metal pipe fittings, and the water-cooled walls, the superheater, the reheater and the economizer of four pipes of the boiler have common problems of corrosion, coking, abrasion and the like due to different problems caused by fuel diversity and grade change; the invention provides a coating protection method aiming at corrosion, coking and abrasion of a heated heat exchange surface of four pipes of a boiler, the process of the coating protection method comprises a bottom layer and a surface layer, the surface layer can compensate the porosity of the bottom layer after being sprayed, and the integral coating after being compounded forms a high-temperature nano ceramic alloy coating system; the boiler is a high-temperature, high-pressure and complex operation environment, fuel is multiple, the service life of the coating is short at high temperature after the common coating is applied, and the application of the composite coating technology solves the problems of the application and the application effect of the protective coating from the application level.
The ceramic and metal composite coating technology combines the corrosion resistance and wear resistance of the metal coating and the compact lubrication characteristic of the ceramic coating, and has the effect that 1+1 is more than 2; the metal coating and the metal base material are easy to combine, the combination strength is more than 60Mpa, the defect point pores or unsmooth surfaces are made up by the ceramic coating, the coating obtained by the integral composite coating technology is high temperature resistant, corrosion resistant, wear resistant, high in lubrication and long in service life, the temperature resistance is more than 1600 ℃, and a practical solution is provided for the safe operation of a boiler. The reliability is high, the coating does not drop off due to the combustion state changes of boiler load, working condition, atmosphere, fuel factors and the like, and the problems of corrosion, abrasion and coking of four pipes of the boiler can be solved.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to the provided drawings without creative efforts.
FIG. 1 is a schematic view of the structure of a composite coating of a metal substrate according to the present invention;
wherein, 1-metal substrate, 2-bottom layer and 3-surface layer;
FIG. 2 is SEM results for waterwall tubes after example 3 was applied;
FIG. 3 is the EDS surface scan energy spectrum of the cross section of the water wall tube in example 3;
FIG. 4 is a graph showing the XRD characterization results of the deposited layer on the surface of the ceramic coating and the ceramic coating in example 3;
FIG. 5 is an XRD result chart of the deposit and ceramic coating on the surface of the water wall tube in example 3.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only some embodiments, not all embodiments, of the present invention 1. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
In the description of the present invention, it is to be understood that the terms "central," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," "circumferential," and the like are used in the orientations and positional relationships indicated in the drawings for convenience in describing the invention and to simplify the description, and are not intended to indicate or imply that the referenced device or element must have a particular orientation, be constructed and operated in a particular orientation, and are not to be considered limiting of the invention.
Furthermore, the terms "first", "second" and "first" 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" or "second" may explicitly or implicitly include at least one such 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 stated or limited, the terms "mounted," "connected," "secured," and the like are to be construed broadly and can, for example, be fixedly connected, detachably connected, or integrally formed; 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.
It will be understood that when an element is referred to as being "secured to" or "disposed on" another element, it can be directly on the other element or intervening elements may also be present. When an element is referred to as being "connected" to another element, it can be directly connected to the other element or intervening elements may also be present. The terms "vertical," "horizontal," "left," "right," and the like as used herein are for illustrative purposes only and do not represent the only embodiments.
A composite coating of a metal substrate is formed by compounding a bottom layer 2 and a surface layer 3 which are sequentially coated on a metal substrate 1;
the bottom layer 2 is composed of metal wires, metal powder and metal skin wrapping wires;
the surface layer 3 is composed of ceramic powder and a binder;
the binder is a silicate binder, a phosphate binder or a sol binder.
In one embodiment, the thickness of the bottom layer 2 is 50-500 μm.
In one embodiment, face layer 3 has a thickness of 50-200 μm.
In one embodiment, the metal wire has a diameter of 1.2-6 mm.
In one embodiment, the metal wire is composed of a mixture of one or more of copper, aluminum, zinc, and iron.
In one embodiment, the diameter of the metal sheath wrapped wire is 2-6 mm.
In one embodiment, the metal sheath wrapping wire consists of a core wire and a wrapping layer, wherein the core wire is an alloy containing iron, nickel or chromium; the wrapping layer is one or a mixture of more of nickel, chromium, titanium, niobium, zirconium oxide, aluminum oxide, silicon oxide, tungsten carbide and silicon carbide.
In one embodiment, the metal powder is comprised of nickel, chromium, and/or titanium.
In one embodiment, the ceramic powder is composed of a mixture of one or more of zirconia, alumina, silica, tungsten carbide, and silicon carbide.
In one embodiment, the silicate binder is composed of one or a mixture of sodium silicate, potassium silicate and lithium silicate;
the phosphate binder is composed of one or a mixture of more of sodium phosphate, magnesium dihydrogen phosphate, zinc dihydrogen phosphate and aluminum dihydrogen phosphate;
the sol binder is composed of water glass and sol, wherein the weight ratio of the water glass to the sol is 1-2:1, and the sol is silica sol, aluminum sol or zirconium sol.
In one embodiment, the binder is a nanoscale binder and the aggregate in the nanoscale binder is a micron-sized aggregate.
In one embodiment, the surface layer 3 further comprises one or more of a pigment, a mineral powder, a rare earth material powder, or a nano-layered material powder.
In one embodiment, the metal substrate 1 is carbon steel or alloy steel.
The invention also provides a construction method of the composite coating of the metal base material 1, which comprises the following steps:
(1) pretreating the surface of the metal base material 1 to enable the surface of the base material to reach more than Sa2.5 grade;
(2) spraying the bottom layer 2 by means of metal thermal spraying;
(3) and after the bottom layer 2 is cooled to room temperature, spraying the surface layer 3.
In one embodiment, in step (1), the pretreatment mode is one or a combination of sand blasting, grinding, purging, laser cleaning and acid cleaning.
In one embodiment, in step (2), the metal thermal spraying mode is one or a combination of arc spraying, plasma spraying, supersonic flame spraying, wire flame spraying, cold spraying, explosion spraying and powder flame spraying.
In one embodiment, in step (3), the surface layer 3 is sprayed by one or a combination of air spraying, airless spraying, brushing and rolling.
Example 1
(1) Selecting a corrosion area of a water-cooled wall of a boiler, carrying out sand blasting treatment on the base material to enable the surface of the base material to reach Sa3.0 level, and blowing off dust particles on the surface of the base material by using compressed air;
(2) spraying a metal wire by using an electric arc spraying machine, wherein the metal wire consists of the following metal simple substances in percentage by weight: 45% of chromium, 4% of titanium and 50% of nickel, wherein the diameter of the metal wire is 1.2 mm, the voltage of the arc spraying machine is adjusted to be 32V, the spraying current is 160A, the spraying distance is 25cm, and the flow of compressed air for spraying is 5m3Min, air supply pressure 0.6Mpa, and thickness of the spraying bottom layer 50 μm;
(3) after the bottom layer is cooled to room temperature, spraying a surface layer, weighing the following raw materials in percentage by weight, and uniformly stirring the raw materials, namely 40% of water glass, 20% of alumina ceramic powder, 5% of cerium oxide, 10% of mica, 5% of kaolin, 1% of a silane coupling agent assistant, 3% of pure acrylic emulsion 502 resin, 5% of silicon carbide, 10% of chrome green, 1% of water, and the thickness of the surface layer is 50 microns.
Example 2
(1) Selecting a corrosion area of a water-cooled wall of a boiler, carrying out sand blasting treatment on the base material to enable the surface of the base material to reach Sa2.5 level, and blowing off dust particles on the surface of the base material by using compressed air;
(2) spraying a metal elementary substance wire by using an electric arc spraying machine, wherein the metal wire consists of the following metal elementary substances in percentage by weight: 45% of chromium, 4% of titanium and 50% of nickel, wherein the diameter of the metal wire is 3.0 mm, the voltage of the arc spraying machine is adjusted to be 36V, the spraying current is 190A, the spraying distance is 30cm, and the flow of compressed air for spraying is 5m3Min, air supply pressure is 0.7Mpa, and the thickness of the spraying bottom layer is 200 mu m;
(3) after the bottom layer is cooled to room temperature, spraying the surface layer, weighing the following raw materials in percentage by weight, and uniformly stirring the raw materials, namely 40% of water glass, 25% of alumina ceramic powder, 10% of zirconium oxide, 5% of cerium oxide, 1% of silane coupling agent assistant, 3% of pure acrylic emulsion 2008 resin, 10% of silicon carbide, 5% of chromium green, 1% of water, and the thickness of the surface layer is 100 microns.
Example 3
(1) Selecting a corrosion area of a water-cooled wall of a boiler, carrying out sand blasting treatment on the base material to enable the surface of the base material to reach Sa3.0 level, and blowing off dust particles on the surface of the base material by using compressed air;
(2) spraying a metal elementary substance wire by using a flame spraying gun, wherein the metal wire consists of the following metal elementary substances in percentage by weight: 4% of titanium, 25% of chromium, 5% of aluminum, 2% of molybdenum, 1% of rare earth, 1% of vanadium, 10% of nickel and 52% of iron, wherein the diameter of the metal wire is 6mm, the flow of oxygen is adjusted to be 100L/min, the flow of acetylene is adjusted to be 100L/min, the spraying distance is 40cm, and the thickness of the spraying bottom layer is 500 microns;
(3) after the bottom layer is cooled to room temperature, spraying a surface layer, weighing the following raw materials in percentage by weight, and uniformly stirring the raw materials, namely 40% of phosphate binder, 20% of corundum ceramic powder, 8% of aluminum powder, 5% of cerium oxide, 1% of silane coupling agent assistant, 8% of silicon nitride, 12% of chromium green, 2% of thickening agent, 4% of water, and the thickness of the surface layer is 200 microns.
Effect test
The composite coating of the boiler water wall after the coating is applied in the example 3 is detected, fig. 2 is a water wall tube SEM result picture after the coating is applied, fig. 3 is a water wall tube cross section EDS surface scanning energy spectrum, fig. 4 is a XRD characterization result picture of a ceramic coating surface deposition layer and a ceramic coating, and by combining the SEM/EDX point scanning results of fig. 2-4 and the picture 5, obvious corrosion of high-temperature sulfide and high-temperature chloride does not occur in the ceramic coating, the ceramic coating mainly comprises oxides of Al, Cr, Ce and Si, and the mass fraction of S in the ceramic coating is only 0.28%, which indicates that the coating successfully prevents corrosive gas from entering the ceramic coating; and the residues on the surface of the base material mainly comprise Al, Si, Fe and S elements, wherein the mass fraction of the S element is 15.78%, and the mass fraction of the Fe element is 65.27%, which indicates that the residues are iron sulfides generated on the surface of the metal base material due to high-temperature corrosion when the coating is not sprayed, and the sulfur-containing substances can still damage the base material through grain boundary penetration.
XRD characterization results of the ceramic coating surface deposition layer and the ceramic coating are shown in figure 4 and table 1, and loose ash deposition points a attached to the surface of the water wall coating can be found to be mainly formed by SiO2FeO, and mixed oxides of iron, silicon and aluminum, and the b-site of the ceramic coating is mainly composed of Al2O3、Cr2O3An oxide film.
TABLE 1 EDS Point scanning energy spectrum result table for cross section of water wall tube after operation
| O | Na | Mg | Al | Si | S | Cr | Fe | Zn | Ce | |
| a | 25.69 | 0.04 | 0.18 | 0.14 | 0.69 | 15.78 | 0.33 | 65.27 | 0.63 | — |
| b | 26.90 | 0.43 | 0.51 | 50.13 | 6.19 | 0.28 | 4.53 | 5.88 | 1.43 | 6.69 |
Table 2 shows XRF results of the deposit on the surface of the water wall tube and the ceramic coating after operation, and compared with the inside of the ceramic coating, the XRF results of the composite coating of the water wall tube in example 3 show that the composite coating has high S content on the surface of the coating, but much lower than the sulfur content in the deposit on the surface, as shown in fig. 5.
TABLE 2 Water wall tube surface deposits and ceramic coating XRF results (wt%) after run
The embodiments are described in a progressive manner in the specification, each embodiment focuses on differences from other embodiments, and the same and similar parts among the embodiments are referred to each other. The device disclosed by the embodiment corresponds to the method disclosed by the embodiment, so that the description is simple, and the relevant points can be referred to the method part for description.
The description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
Claims (10)
1. The composite coating of the metal base material is characterized by being formed by compounding a bottom layer and a surface layer which are sequentially coated on the metal base material;
the bottom layer is composed of metal wires, metal powder and metal skin wrapping wires;
the surface layer is composed of ceramic powder and a binder;
the binder is a silicate binder, a phosphate binder or a sol binder.
2. The composite coating for a metal substrate of claim 1, wherein the primer layer has a thickness of 50 to 500 μm.
3. The composite coating for a metal substrate of claim 1, wherein the thickness of the top layer is 50-200 μm.
4. The composite coating for a metal substrate according to claim 1, wherein the diameter of the metal wire is 1.2-6 mm.
5. The composite coating for metal substrates as claimed in claim 4, wherein the metal wire is composed of a mixture of one or more of copper, aluminum, zinc, iron, nickel, chromium, titanium and niobium.
6. The composite coating for a metal substrate according to claim 1, wherein the diameter of the metal sheath wrapped wire is 2-6 mm.
7. A method of applying a composite coating of a metal substrate as claimed in any one of claims 1 to 6, comprising the steps of:
(1) pretreating the surface of a metal base material to enable the surface of the base material to reach more than Sa2.5 grade;
(2) spraying a bottom layer by means of metal thermal spraying;
(3) and after the bottom layer is cooled to room temperature, spraying the surface layer.
8. The method for constructing the composite coating of the metal substrate as claimed in claim 7, wherein in the step (1), the pretreatment is one or a combination of sand blasting, grinding, blowing, laser cleaning and acid cleaning.
9. The method for constructing the composite coating of the metal substrate according to claim 7, wherein in the step (2), the metal thermal spraying mode is one or a combination of several modes selected from arc spraying, plasma spraying, supersonic flame spraying, wire flame spraying, cold spraying, explosion spraying and powder flame spraying.
10. The construction method of the composite coating of the metal substrate as claimed in claim 7, wherein in the step (3), the surface layer is sprayed by one or a combination of air spraying, airless spraying, brushing and rolling.
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| CN116445018A (en) * | 2023-04-18 | 2023-07-18 | 中国科学院兰州化学物理研究所 | High-temperature oxidation resistant protective coating for titanium alloy surface and preparation method thereof |
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