CN113174286A - 一种风电螺纹防卡润滑脂及其制备方法 - Google Patents

一种风电螺纹防卡润滑脂及其制备方法 Download PDF

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CN113174286A
CN113174286A CN202110460405.3A CN202110460405A CN113174286A CN 113174286 A CN113174286 A CN 113174286A CN 202110460405 A CN202110460405 A CN 202110460405A CN 113174286 A CN113174286 A CN 113174286A
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于延晨
张利
陈绿峰
王超
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Qingdao Lubemater Lubrication Materials Technology Co ltd
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Abstract

本发明提供的一种风电螺纹防卡润滑脂组合物，以润滑脂组合物的重量为基准，包括以下组分：基础油55份、固体润滑剂45份、外加活性膨润土粉末2‑4份、亚磷酸二正丁酯1‑2份、聚异丁烯1.5‑5份、硫化异丁烯1‑2份、癸二酸钠0.5‑1.5份、环烷酸铋0.5‑1份、丙酮0.5‑1份、抗氧剂0.5‑1份；所述固体润滑剂45份具体组成为：二硫化钼5份、胶体石墨5份、纳米碳酸钙20份、300目电解铜粉15份。本发明提供的螺纹防卡脂采用全合成基础油配方，活性膨润土作为稠化剂，高低温性能优异；采用特定配比的固体润滑剂组合保证乏油润滑下仍具有优异的承载能力，并且摩擦系数极低、具有修复螺纹防止粘扣损伤的作用。本发明提供的风电螺纹防卡润滑脂制备方法中原料配比、加料顺序、后处理工艺合理高效。

Description

一种风电螺纹防卡润滑脂及其制备方法
技术领域
本发明属于润滑脂技术领域，具体涉及一种风电螺纹防卡润滑脂及其制备方法。
技术背景
近年来，我国风电行业尤其是大容量的兆瓦级别大型风力发电机组得到快速发展，风电设备用的高强度紧固件由于长期野外服役，环境恶劣，维修条件差，所以要求风机稳定性强。正常连续工作情况下，风电设备紧固件要求必须保证10年以上的使用寿命。
螺栓作为风电机组的主要连接方式之一，应用在齿轮箱、叶片连接等诸多关键部位，螺栓的安全关系到整个风电机组的安全可靠运行。润滑脂摩擦学性能和防腐蚀性能达不到要求的情况下，设备运行时间过长会导致紧固螺栓过早损坏或螺纹粘扣损伤，损伤后风机维修困难，维护成本高并且影响设备的使用寿命。
发明内容
本发明的目的是提供一种适用于风电风机紧固件的螺纹防卡润滑脂。另外，本发明还提供了该润滑脂的制备方法。
本发明提供的一种风电螺纹防卡润滑脂组合物，以润滑脂组合物的重量为基准，包括以下组分：基础油55份、固体润滑剂45份、外加活性膨润土粉末2-4份、亚磷酸二正丁酯1-2份、聚异丁烯1.5-5份、硫化异丁烯1-2份、癸二酸钠0.5-1.5份、环烷酸铋0.5-1份、丙酮0.5-1份、抗氧剂0.5-1份；
所述固体润滑剂45份具体组成为：二硫化钼5份、胶体石墨5份、纳米碳酸钙20份、300目电解铜粉15份。
所述基础油为复酯Ar 9200和PAO4的组合；
所述抗氧剂为苯基-β-萘胺、二苯胺、丁基/辛基二苯胺中的一种或几种；
所述丙酮的添加量为活性膨润土粉末质量分数的10％-20％；
本发明所述一种风电螺纹防卡润滑脂的制备方法，具体步骤为：
1)将基础油加热至65-70℃，向基础油中依次分批加入二硫化钼、胶体石墨、纳米碳酸钙、电解铜粉加入基础油中搅拌分散，充分稀释和润湿各种固体添加剂原料，防止固体剂团聚。
2)加入活性膨润土粉末同时以200ml/min的速度滴加丙酮，边搅拌边升温至90℃，在90℃稠化2h,丙酮帮助膨润土粉末快速均匀分散。
3)稠化2h后等待丙酮完全挥发，加入聚异丁烯、硫化异丁烯、亚磷酸二正丁酯、癸二酸钠、环烷酸铋、抗氧剂，搅拌1h后研磨均质出釜。
本发明的技术特点及有益效果：
本发明的螺纹防卡润滑脂，具备优异的摩擦学性能、防腐蚀性能、高低温性能、抗水性和抗氧化性能。采用特定添加剂配比的固体润滑剂保证乏油润滑下仍具有优异的承载能力(四球烧结PD值)，并且摩擦系数极低、具有修复螺纹防止粘扣损伤的作用；采用特定添加剂配比的固体润滑剂使得300目电解铜粉达到纳米铜粉的摩擦学性能水平，显著降低成本。另外，本发明还提供了该种防卡润滑脂的制备方法，该制备方法中原料配比、加料顺序、后处理工艺合理高效。
本发明制备的风电螺纹防卡润滑脂摩擦学性能优异，四球机实验无卡咬负荷PD值为7840N，四球长磨实验摩擦系数0.06，磨斑直径0.47mm；抗水性和防腐蚀性强，水淋实验损失量0.8％，铜片腐蚀等级1a；胶体安定性好，100℃钢网分油1.6％。耐高温性好，180℃高温损失量2.6％；低温性能好，-40℃启动扭矩300mN·m，电解铜粉的加入可以修复螺纹损伤部位，起到增强密封和抗螺纹粘扣损伤的作用。
具体实施方式
下面的实施例可以使本专业的技术人员更全面地理解本发明，但并不因此将本发明限制在所述的实施例范围之中。
实施例1：
先将100kg的复酯Ar 9200(40℃粘度2400mm2/s，100℃粘度200mm2/s)和450kg的PAO 4基础油加入调和釜中加热至65℃，随后依次分批加入200kg纳米碳酸钙、50kg二硫化钼、50kg胶体石墨、150kg 300目电解铜粉充分搅拌分散1h。
随后加入40kg活性膨润土并同时以200ml/min的速度滴加4kg丙酮，边搅拌边升温至90℃，90℃稠化2h。稠化2h后等待丙酮完全挥发，加入15kg聚异丁烯、10kg硫化异丁烯、20kg亚磷酸二正丁酯、10kg癸二酸钠、10kg环烷酸铋、10kg二苯胺，搅拌1h后研磨均质出釜。
对比例1：
先将100kg的复酯Ar 9200和450kg的PAO4基础油加入调和釜中加热至65℃，随后依次分批加入50kg纳米碳酸钙、50kg二硫化钼、100kg胶体石墨、250kg300目电解铜粉充分搅拌分散1h。
随后加入40kg活性膨润土并同时以200ml/min的速度滴加4kg丙酮，边搅拌边升温至90℃，90℃稠化2h。稠化2h后等待丙酮完全挥发，加入15kg聚异丁烯、10kg硫化异丁烯、20kg亚磷酸二正丁酯、10kg癸二酸钠、10kg环烷酸铋、10kg二苯胺，搅拌1h后研磨均质出釜。
对比例2：
先将100kg的复酯Ar 9200和450kg的PAO 4基础油加入调和釜中加热至65℃，随后依次分批加入100kg纳米碳酸钙、50kg二硫化钼、150kg胶体石墨、150kg 300目电解铜粉充分搅拌分散1h。
随后加入40kg活性膨润土并同时以200ml/min的速度滴加4kg丙酮，边搅拌边升温至90℃，90℃稠化2h。稠化2h后等待丙酮完全挥发，加入15kg聚异丁烯、10kg硫化异丁烯、20kg亚磷酸二正丁酯、10kg癸二酸钠、10kg环烷酸铋、10kg二苯胺，搅拌1h后研磨均质出釜。
对比例3：
先将100kg的150BS和450kg的500N基础油加入调和釜中加热至65℃，随后依次分批加入200kg纳米碳酸钙、50kg二硫化钼、50kg胶体石墨、150kg 300目电解铜粉充分搅拌分散1h。
随后加入40kg活性膨润土并同时以200ml/min的速度滴加4kg丙酮，边搅拌边升温至90℃，90℃稠化2h。稠化2h后等待丙酮完全挥发，加入15kg聚异丁烯、10kg硫化异丁烯、20kg亚磷酸二正丁酯、10kg癸二酸钠、10kg环烷酸铋、10kg二苯胺，搅拌1h后研磨均质出釜。
表1：实施例、对比例的结果分析表
Figure BDA0003042045700000041
从表1的分析结果中可以看出大量的电解铜粉导致摩擦系数变大，抗磨性能变差，通过优化固体剂配比在保证电解铜粉添加量的同时摩擦学性能达到超细纳米铜粉的性能水平；全合成基础油配方在高温蒸发损失、抗水淋性和低温扭矩方面表现优异。实施例1制备所得的风电螺纹防卡润滑脂具有优异的极压性能、抗磨性能、抗水淋性、分油性能和低温性能。本发明提供的风电螺纹防卡润滑脂制备方法中原料配比、加料顺序、后处理工艺合理高效。
上述实施例对本发明进行示例性描述其目的在于让熟悉此项技术的相关技术人员能够了解本发明的内容并据以实施，并不能以此限制本发明的保护范围。凡根据本发明的方法构思和技术方案进行非实质改进，或未经改进将发明的构思和技术方案直接应用于其他场合的，均在本发明的保护范围之内。

Claims (5)

1.一种适用于风电风机螺纹防卡润滑脂组合物，其特征在于，所述润滑脂组合物按重量百分比包括以下组分：基础油55份、固体润滑剂45份、外加活性膨润土粉末2-4份、亚磷酸二正丁酯1-2份、聚异丁烯1.5-5份、硫化异丁烯1-2份、癸二酸钠0.5-1.5份、环烷酸铋0.5-1份、丙酮0.5-1份、抗氧剂0.5-1份；
所述固体润滑剂45份具体组成为：二硫化钼5份、胶体石墨5份、纳米碳酸钙20份、300目电解铜粉15份。
2.如权利要求1所述一种适用于风电风机螺纹防卡润滑脂组合物，其特征在于，所述基础油为复酯Ar 9200、PAO4的组合。
3.如权利要求1所述一种适用于风电风机螺纹防卡润滑脂组合物，其特征在于，所述抗氧剂为苯基-β-萘胺、二苯胺、丁基/辛基二苯胺中的一种或几种。
4.如权利要求1所述一种适用于风电风机螺纹防卡润滑脂组合物，其特征在于，所述丙酮的添加量为活性膨润土粉末质量分数的10％-20％。
5.如权利要求1～4所述适用于风电风机螺纹防卡润滑脂组合物的制备方法，包括：
1)将基础油加热至65-70℃，向基础油中依次分批加入二硫化钼、胶体石墨、纳米碳酸钙、电解铜粉加入基础油中搅拌分散，充分稀释和润湿各种固体添加剂原料，防止固体剂团聚；
2)加入活性膨润土粉末同时以200ml/min的速度滴加丙酮，边搅拌边升温至90℃，在90℃稠化2h,丙酮帮助膨润土粉末快速均匀分散；
3)稠化2h后等待丙酮完全挥发，加入聚异丁烯、硫化异丁烯、亚磷酸二正丁酯、癸二酸钠、环烷酸铋、抗氧剂，搅拌1h后研磨均质出釜。
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