CN113416436B - 一种轨道防腐涂层及其涂覆工艺 - Google Patents

一种轨道防腐涂层及其涂覆工艺 Download PDF

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CN113416436B
CN113416436B CN202110715926.9A CN202110715926A CN113416436B CN 113416436 B CN113416436 B CN 113416436B CN 202110715926 A CN202110715926 A CN 202110715926A CN 113416436 B CN113416436 B CN 113416436B
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代启宏
陈齐嵘
杨连杰
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Jiangsu Ruizhong Rail Transportation Equipment Co ltd
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Abstract

本发明提供一种轨道防腐涂层及其涂覆工艺，涉及一种对轨道表面形成多层防腐的涂层结构及其涂覆工艺，属于金属加工领域。提拱了一种结合强度高，内部结构致密的多层轨道防腐涂层，包括基层、底涂层、面涂层，基层置于金属基材表面，底涂、面涂层依次附着于基层上，基层采用热浸锌工艺在金属表面附着锌层，底涂层采用纳米级片状锌片、纳米级片状铝片、无机钛酸盐、硅酸盐混合制备成无机钛腐蚀剂，面涂层采用纳米复合材料，采用片状结构进行错位堆叠，结构紧密，间隙小，能够增加外部介质接触基材的路径行程。

Description

一种轨道防腐涂层及其涂覆工艺
技术领域
本发明提供一种轨道防腐涂层及其涂覆工艺，涉及一种对轨道表面形成多层防腐的涂层结构及其涂覆工艺，属于材料工程领域。
背景技术
目前，轨道交通运用广泛，地铁、高铁等，工作环境多样性，要求耐候性强，现有的轨道仅仅通过单一的热浸锌进行表面分防腐，利用电化学形成防腐，由于轨道工作过程中，载荷为动态，对表面的热浸锌层容易出现磨损，结合外部环境影响，容易出现锈蚀的情况，因此，仅仅通过单一的热浸锌防腐性能单一，热浸锌在基材表面一球状分布，分布不紧密，间隙大，颗粒间结构面积小，电导率低，电化学防腐效率低。
公告号CN109606402B公开了一种轨道车辆碳钢车体防腐工艺及车体，所述防腐工艺包括如下步骤：S1、在车体的基材上整体喷涂改性环氧树脂底漆，然后在车体顶部和端部喷涂面漆；其中改性环氧树脂底漆的喷涂厚度至少为100 um；S2、采用密封胶对车体间断焊缝、边角部位进行密封防腐处理；S3、通过工艺孔对车体的腔体内壁面喷涂防腐蜡涂层，上述工艺通过采用物料附着结构进行防护，将内部结构和外部隔绝形成防腐，但仅仅涂刷防腐蜡等容易脱落影响内部防腐，且单一的防腐结构，耐磨损性能差，在承托荷载时，容易脱落，和基材形成电化学腐蚀。
公开号CN213013709U公开了一种玻璃钢轨道，包括第一轨道、第二轨道,所述第一轨道与所述第二轨道的结构大小、形状一致，所述第一轨道上设有玻璃钢，所述玻璃钢固定安装在第一轨道外壁，所述第一轨道上端外壁玻璃钢设有贯穿孔，所述第一轨道下端安装有固定座，所述第一轨道上端面设有安装孔，所述安装孔内安装有辅助移动装置，其本质是在轨道表面上添加防护结构，且和基材结合强度差，两相分界清晰，容易脱落分离。
发明内容
为解决上述技术问题，本发明一种轨道防腐涂层，提供了一种结合强度高，内部结构致密的多层轨道防腐涂层及其涂覆工艺，耐蚀性好，使用寿命高。
本发明一种轨道防腐涂层包括基层、底涂层、面涂层；
基层置于金属基材表面，底涂、面涂层依次附着于基层上；
基层采用热浸锌工艺在金属表面附着锌层；
底涂层采用纳米级片状锌片、纳米级片状铝片、无机钛酸盐、硅酸盐混合制备成无机钛腐蚀剂；
面涂层采用纳米复合材料；
所述无机钛腐蚀剂制备工艺如下：
1）每平米取纳米级片状铝片10-25g；
纳米级片状锌片重量为纳米级片状铝片的1.2-1.5倍
无机钛酸盐40-60g；
硅酸盐20-30g；
2）将纳米级片状锌片和纳米级片状铝片混合形成混合物，将无机钛酸盐、硅酸盐加入混合物内进行混合，制备得到无机钛腐蚀剂；
所述步骤2）中纳米级片状锌片和纳米级片状铝片的混合采用混搅器进行混合，混搅转速40-50转/min，混搅时间15-20min，混搅温度200℃-300℃；
所述步骤2）中，无机钛酸盐和硅酸盐同步加入，混搅器转速降为30-40转/min，持续时间20-25min，温度保持100℃-150℃；
面涂层采用镍锌金属粉末混合物熔覆形成。
本发明中一种轨道防腐涂层的涂覆工艺如下：
1）将基材酸洗，表面清洁干燥；
2）将基材进行热浸锌处理，在表面形成基底；
3）将无机钛腐蚀剂涂在基材表面，通过高温加压固化使得无机钛腐蚀剂固化；
所述高温温度为350℃-420℃，加热时间30-40min，表面施压1-1.5Mpa，，真空度为80-100；
所述无机钛腐蚀剂厚度10-50μm；
4）将面涂层涂覆在基材表面；
所述面涂层采用镍锌混合比1：（0.5-0.8）；
所述粉末粒度3-10μm；
面涂层采用激光熔覆进行涂覆。
有益效果：
一、采用片状结构进行错位堆叠，结构紧密，间隙小，能够增加外部介质接触基材的路径行程；
二、层片状错位分布，能够形成补足，对局部破损区域通过片状错位进行修复；
三、面涂层采用镍锌合金粉末，提高了整体面涂层的硬度，且锌和底涂层内的锌片结合，提高了整体的结合强度；
四、基底的热浸锌形成球状颗粒结构，和底面层的片状结构穿插形成结合；
五、底面层固化过程中，对基底的热浸锌形成了钝化，增加了基底的耐腐蚀性能。
附图说明
图1为本发明一种轨道防腐涂层结构示意图。
图2为目前单一热镀锌涂层的微观结构示意图。
图3为本发明一种轨道防腐涂层底涂层的微观结构示意图。
图4为本发明一种轨道防腐涂层各层分布结构示意图。
附图中
1、基材；2、基层；3、面涂层；4、底涂层。
具体实施方式
实施例1
无机钛腐蚀剂制备取纳米级片状铝片20g；
纳米级片状锌片25g
无机钛酸盐50g；
硅酸盐25g；
通过混搅机将纳米级片状锌片和纳米级片状铝片混合，混搅机转速48±5转/min；
加入无机钛酸盐、硅酸盐，混胶机转速为35±5转/min；
涂刷厚度20μm，所述高温温度为400℃，加热时间35min，真空度为85。
实施例2
无机钛腐蚀剂制备取纳米级片状铝片10g；
纳米级片状锌片15g
无机钛酸盐40g；
硅酸盐20；
涂刷厚度15μm，所述高温温度为380℃，加热时间30min，真空度为85；
针对实施例1和实施例2中的底涂层4的工艺方法，进行盐雾试验，与单一的进行热浸锌的防腐形式进行数据对比：
Figure DEST_PATH_IMAGE001
GB9286 － 1998 涂膜附着力测定法；
GB1731 － 1993 漆膜柔韧性测定法；
GB1732－ 1993 漆膜耐冲击测定法；
GB1763 － 1993 漆膜耐化学试剂性测定法的规定要求。
实施例3
对面涂层3的施工工艺如下：
取锌50g、镍100g，粒度5微米；
将底面层4清洁干净，清除表面的氧化物、油膜，通过激光熔覆机熔覆在底面层上。
实施例4
对面涂层3的施工工艺如下：
取锌50g、镍100g，粒度5微米；
将底面层4清洁干净，清除表面的氧化物、油膜，将钎焊膏用喷枪或刷涂方法均匀地涂在干净的底面层表面，涂层厚度设计为1.5mm，钎膏涂层厚度3.5 mm；将钢板通过传送机构水平送入可控气氛钎焊炉，在保护气氛下经过预热加热区，钎焊区，冷却区完成钎涂熔覆。
Figure 543462DEST_PATH_IMAGE003
实施例5
面涂层3采用陶瓷涂层，耐酸耐碱、不导电，结构致密，适用于带电导轨的防腐。
以上对本发明及其实施方式进行了描述，这种描述没有限制性，附图中所示的也只是本发明的实施方式之一，实际的结构并不局限于此。总而言之如果本领域的普通技术人员受其启示，在不脱离本发明创造宗旨的情况下，不经创造性的设计出与该技术方案相似的结构方式及实施例，均应属于本发明的保护范围。

Claims (6)

1.一种轨道防腐涂层，其特征在于：包括基层（2）、底涂层（4）、面涂层（3）；
基层（2）置于金属基材（1）表面，底涂层（4）、面涂层（3）依次附着于基层（2）上；
所述基层（2）为热浸锌；
所述底涂层（4）采用纳米级片状锌片、纳米级片状铝片、无机钛酸盐、硅酸盐混合制备成无机钛腐蚀剂，通过高温加压工艺和基层（2）结合；
所述高温温度为350℃-420℃，加热时间30-40min，表面施压1-1.5Mpa，真空度为80-100；
所述无机钛腐蚀剂厚度10-50μm；
所述面涂层（3）采用镍锌金属粉末混合物熔覆形成。
2.根据权利要求1所述的一种轨道防腐涂层，其特征在于：所述无机钛腐蚀剂制备工艺如下：
1）每平米取纳米级片状铝片10-25g；
纳米级片状锌片重量为纳米级片状铝片的1.2-1.5倍；
无机钛酸盐40-60g；
硅酸盐20-30g；
2）将纳米级片状锌片和纳米级片状铝片混合形成混合物，将无机钛酸盐、硅酸盐加入混合物内进行混合，制备得到无机钛腐蚀剂；
所述步骤2）中纳米级片状锌片和纳米级片状铝片的混合采用混搅器进行混合，混搅转速40-50转/min，混搅时间15-20min，混搅温度200℃-300℃；
所述步骤2）中，无机钛酸盐和硅酸盐同步加入，混搅器转速降为30-40转/min，持续时间20-25min，温度保持100℃-150℃。
3.根据权利要求2所述的一种轨道防腐涂层，其特征在于：所述步骤2）中，采用喷雾混合，将纳米级片状锌片和纳米级片状铝片通过高压气流相对射入容器内进行混合，同步添加无机钛酸盐和硅酸盐。
4.根据权利要求1所述的一种轨道防腐涂层，其特征在于：一种轨道防腐涂层的涂覆工艺如下：
1）将基材（1）酸洗，表面清洁干燥；
2）将基材（1）进行热浸锌处理，在表面形成基底；
3）将无机钛腐蚀剂涂在基材（1）表面，通过高温加压固化使得无机钛腐蚀剂固化；
所述高温温度为350℃-420℃，加热时间30-40min，表面施压1-1.5Mpa，真空度为80-100；
所述无机钛腐蚀剂厚度10-50μm；
4）将面涂层（3）涂覆在基材（1）表面；
所述面涂层（3）采用镍锌混合比1：（0.5-0.8）；
所述镍锌粉末粒度3-10μm；
面涂层（3）采用激光熔覆进行附着。
5.根据权利要求1所述的一种轨道防腐涂层，其特征在于：所述面涂层（3）涂覆工艺如下：
将钎焊膏用喷枪或刷涂方法均匀地涂在干净的底面层表面，涂层厚度设计为1.5mm，钎膏涂层厚度3.5 mm；
将钢板通过传送机构水平送入可控气氛钎焊炉，在保护气氛下经过预热加热区，钎焊区，冷却区完成钎涂熔覆。
6.根据权利要求1所述的一种轨道防腐涂层，其特征在于：所述面涂层（3）采用陶瓷涂层，所述陶瓷涂层采用气相沉积进行制备。
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