CN114232050B - 一种高耐蚀轻质储油容器的制作方法 - Google Patents
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Abstract
本发明针对大呼吸量储油容器吸入盐雾、腐蚀性大气后内壁易腐蚀的问题,提出了一种高耐蚀轻质储油容器的制作方法,采用高强度、易焊接的铝合金制作储油容器,容器整体进行阳极氧化处理,外壁涂覆油漆,内壁进行疏水处理并灌注油液,具有长期耐受海洋环境高湿热、高盐雾和工业污染区腐蚀大气的效果。本发明提出的储油容器的制作方法,相对不锈钢容器减重60%~70%,并增强了储油容器的腐蚀防护能力,提升了产品的环境适应性。在部分应用场合下,储油容器的最大呼吸量达容积的50%~80%。
Description
技术领域
本发明涉及一种储油容器的制作方法,具体涉及一种高耐蚀轻质储油容器的制作方法。
背景技术
储油容器在化工、机械、电子、船舶、航空和航天等行业普遍采用,在容器储满油液或进行油漆涂装后其内壁一般不易腐蚀,但在特殊储油容器中,其内壁不能进行涂装且不能长期保持油液储满。如在液压油箱中,由于液压机构对多余物的控制要求非常严格,油箱内壁不宜采用油漆涂装处理,开放式油箱在工作过程中液位升降吸入外部大气,在恶劣海洋环境和工业污染区域使用时存在内壁腐蚀的风险。一般来说,浸润油液的内壁不易发生腐蚀,但部分装备需长期保持固定的姿态使得液压油液位低,待表面油液流失后,内壁仍容易发生腐蚀,内壁腐蚀产物可能对液压系统的安全性产生威胁。
现有技术中采用不锈钢材质可以解决储油容器耐蚀性问题,但是不锈钢容器存在质量大、焊接工艺要求高的问题。
发明内容
本发明针对大呼吸量储油容器吸入盐雾、腐蚀性大气后内壁易腐蚀的问题,提出了一种高耐蚀轻质储油容器的制作方法,采用高强度、易焊接的铝合金制作储油容器,容器整体进行阳极氧化处理,外壁涂覆油漆,内壁进行疏水处理并灌注油液,具有长期耐受海洋环境高湿热、高盐雾和工业污染区腐蚀大气的效果。
为实现发明目的,本发明的技术方案如下:
一种高耐蚀轻质储油容器的制作方法,储油容器采用铝合金制作,制作方法包括以下步骤:储油容器成形、除油、碱洗、内壁蚀刻、出光、阳极氧化、热水封闭、内壁修饰、外壁油漆、内壁灌注、检验和包装。
进一步的,在除油步骤中,采用酸性、碱性或有机溶剂除油,去除工件表面油脂。
进一步的,在碱洗步骤中,工件用浓度50g/L~85g/L的NaOH溶液浸泡0.5 min ~1.5min,溶液温度为50℃~70℃,清洗至表面水膜连续,然后用去离子水清洗干净。
进一步的,在内壁蚀刻步骤中,工件的内壁用含NaOH浓度 40 g/L ~60g/L、Na3PO4浓度15 g/L ~20g/L、NaF浓度15 g/L ~25g/L、砂面剂浓度50 g/L ~70g/L的溶液浸泡30min~10min,溶液温度为20℃~60℃,然后用去离子水清洗干净。
进一步的,在出光步骤中,工件用浓度400mL/L~600mL/L的硝酸溶液浸泡0.5 min~1.5min,然后用去离子水清洗干净。
进一步的,在阳极氧化步骤中,工件用浓度70mL/L~110mL/L的硫酸溶液进行阳极氧化,氧化温度10℃~20℃,氧化时间20 min ~60min,电流密度为0.5 A/dm2~1A/dm2,氧化结束后工件用去离子水清洗,然后在1%~2%的氨水溶液中浸泡5s~20s,然后再用去离子水清洗干净。
进一步的,在热水封闭步骤中,用稀醋酸和氢氧化钠溶液调节水的pH为5.5~7.0并将水升温至90℃~96℃,将工件在水中浸泡15min ~40min,然后用去离子水清洗干净。
进一步的,在内壁修饰步骤中,工件的内壁用浓度0.5%~2%的氟硅烷乙醇溶液浸泡30 min ~90min,清除氟硅烷乙醇溶液后,用乙醇清洗内壁。
进一步的,在外壁油漆步骤中,对工件的内壁进行遮蔽保护,对工件的外壁进行涂装前处理,然后外壁涂装油漆,工件在60℃~100℃温度下烘干1.5 h ~5h。
进一步的,在内壁灌注步骤中,工件的内壁用油液浸润2h ~24h,然后容器工件倒扣放置,于50℃~80℃温度下烘干0.5h~3h。
进一步的,在内壁修饰步骤中,氟硅烷选用十七氟癸基三乙氧基硅烷、十七氟癸基三甲氧基硅烷、十七氟癸基三氯硅烷、十三氟辛基三乙氧基硅烷、十三氟辛基三甲氧基硅烷、十三氟辛基三氯硅烷的任意一种。
进一步的,在内壁灌注步骤中,油液选用全氟聚醚、甲基硅油、矿物油、液压油中的任意一种。
进一步的,在检验和包装步骤中,检验工件外壁油漆质量和内壁处理质量,检验合格后将工件进行包装。
本发明提出的高耐蚀轻质储油容器的制作方法,可采用高强度、易焊接的铝合金替代不锈钢材料制作耐蚀储油容器。针对大呼吸量储油容器吸入盐雾、腐蚀性大气后内壁易腐蚀的问题,经本发明所述的方法处理后,储油容器整体进行阳极氧化处理,外壁涂覆油漆,内壁进行疏水处理并灌注油液,具有长期耐受海洋环境高湿热、高盐雾和工业污染区腐蚀大气的效果。本发明提出的储油容器的制作方法,相对不锈钢容器减重60%~70%,并增强了储油容器的腐蚀防护能力,提升了产品的环境适应性。在部分应用场合下,储油容器的最大呼吸量达容积的50%~80%。
具体实施方式
下面详细描述本发明的具体实施方式。
本文的材料、方法和实施例均是示例性的,并且除非特别说明,不应理解为限制性的。
一种高耐蚀轻质储油容器的制作方法,储油容器采用铝合金制作,制作方法包括以下步骤:储油容器成形、除油、碱洗、内壁蚀刻、出光、阳极氧化、热水封闭、内壁修饰、外壁油漆、内壁灌注、检验和包装。在除油步骤中,采用酸性、碱性或有机溶剂除油,去除工件表面油脂。在碱洗步骤中,工件用浓度50g/L~85g/L的NaOH溶液浸泡0.5 min ~1.5min,溶液温度为50℃~70℃,清洗至表面水膜连续,然后用去离子水清洗干净。在内壁蚀刻步骤中,工件的内壁用含NaOH浓度 40 g/L ~60g/L、Na3PO4浓度15 g/L ~20g/L、NaF浓度15 g/L ~25g/L、砂面剂浓度50 g/L ~70g/L的溶液浸泡30min ~10min,溶液温度为20℃~60℃,然后用去离子水清洗干净。在出光步骤中,工件用浓度400mL/L~600mL/L的硝酸溶液浸泡0.5 min ~1.5min,然后用去离子水清洗干净。在阳极氧化步骤中,工件用浓度70mL/L~110mL/L的硫酸溶液进行阳极氧化,氧化温度10℃~20℃,氧化时间20 min ~60min,电流密度为0.5 A/dm2~1A/dm2,氧化结束后工件用去离子水清洗,然后在1%~2%的氨水溶液中浸泡5s~20s,然后再用去离子水清洗干净。在热水封闭步骤中,用稀醋酸和氢氧化钠溶液调节水的pH为5.5~7.0并将水升温至90℃~96℃,将工件在水中浸泡15min ~40min,然后用去离子水清洗干净。在内壁修饰步骤中,工件的内壁用浓度0.5%~2%的氟硅烷乙醇溶液浸泡30 min ~90min,清除氟硅烷乙醇溶液后,用乙醇清洗内壁。在外壁油漆步骤中,对工件的内壁进行遮蔽保护,对工件的外壁进行涂装前处理,然后外壁涂装油漆,工件在60℃~100℃温度下烘干1.5 h ~5h。在内壁灌注步骤中,工件的内壁用油液浸润2h ~24h,然后容器工件倒扣放置,于50℃~80℃温度下烘干0.5h~3h。在内壁修饰步骤中,氟硅烷选用十七氟癸基三乙氧基硅烷、十七氟癸基三甲氧基硅烷、十七氟癸基三氯硅烷、十三氟辛基三乙氧基硅烷、十三氟辛基三甲氧基硅烷、十三氟辛基三氯硅烷的任意一种。在内壁灌注步骤中,油液选用全氟聚醚、甲基硅油、矿物油、液压油中的任意一种。在检验和包装步骤中,检验工件外壁油漆质量和内壁处理质量,检验合格后将工件进行包装。
以下通过几个实施例和对比例详细说明本发明高耐蚀轻质储油容器的制作方法。
实施例1
采用6063(T6)铝合金制作储油容器,然后依次进行:
1)碱性除油;
2)容器用浓度80g/L的NaOH溶液浸泡0.5min,溶液温度50℃,然后用去离子水清洗干净;
3)封堵容器开孔,容器的内壁用含NaOH浓度60g/L、Na3PO4浓度18g/L、NaF浓度20g/L、砂面剂浓度60g/L的溶液浸泡6min,溶液温度40℃。然后用去离子水清洗干净。
4)容器用浓度500mL/L的硝酸溶液浸泡1min,然后用去离子水清洗干净。
5)容器用浓度100mL/L的硫酸溶液进行阳极氧化,氧化温度18℃,氧化时间30min,电流密度为0.8A/dm2。氧化结束后容器用去离子水清洗,然后在1.5%的氨水溶液中浸泡10s,然后再用去离子水清洗干净。
6)调节水的pH并将水升温至92℃,将容器工件在水中浸泡40min,然后用去离子水清洗干净。
7)封堵容器开孔,容器的内壁用浓度1.5%的十七氟癸基三乙氧基硅烷乙醇溶液浸泡45min,清除十七氟癸基三乙氧基硅烷乙醇溶液后,用乙醇清洗内壁。
8)对容器的内壁进行遮蔽保护,对容器的外壁进行涂装前处理,然后外壁涂装环氧底漆和氟碳面漆。容器工件在100℃温度下烘干1.5h。
9)容器的内壁用Krytox GPL105油液浸润8h,然后容器工件倒扣放置,于70℃温度下烘干2h,然后擦除容器上的少量残余油液。
10)检验容器外壁油漆外观、厚度和附着力,检验容器内壁阳极氧化膜质量,然后将零件进行包装。
另外,按相同铝合金材质和加工工艺,制作油漆样板,记为1#样板;制作修饰及注油处理样板,记为2#样板。
实施例2
采用7050(T7451)铝合金制作储油容器,然后依次进行:
1)有机溶剂除油;
2)容器用浓度60g/L的NaOH溶液浸泡1min,溶液温度60℃,然后用去离子水清洗干净;
3)封堵容器开孔,容器的内壁用含NaOH浓度40g/L、Na3PO4浓度15g/L、NaF浓度15g/L、砂面剂浓度50g/L的溶液浸泡10min,溶液温度60℃。然后用去离子水清洗干净。
4)容器用浓度400mL/L的硝酸溶液浸泡1.5min,然后用去离子水清洗干净。
5)容器用浓度80mL/L的硫酸溶液进行阳极氧化,氧化温度13℃,氧化时间60min,电流密度为0.6A/dm2。氧化结束后容器用去离子水清洗,然后在0.5%的氨水溶液中浸泡20s,然后再用去离子水清洗干净。
6)调节水的pH并将水升温至95℃,将容器工件在水中浸泡20min,然后用去离子水清洗干净。
7)封堵容器开孔,容器的内壁用浓度1%的十三氟辛基三氯硅烷乙醇溶液浸泡60min,清除十三氟辛基三氯硅烷乙醇溶液后,用乙醇清洗内壁。
8)对容器的内壁进行遮蔽保护,对容器的外壁进行涂装前处理,然后外壁涂装聚氨酯底漆和氟碳面漆。容器工件在70℃温度下烘干4h。
9)容器的内壁用15号航空液压油浸润24h,然后容器工件倒扣放置,于60℃温度下烘干1h,然后擦除容器上的少量残余油液。
10)检验容器外壁油漆外观、厚度和附着力,检验容器内壁阳极氧化膜质量,然后将零件进行包装。
另外,按相同铝合金材质和加工工艺,制作油漆样板,记为3#样板;制作修饰及注油处理样板,记为4#样板。
对比例1
制作6063(T6)和7050(T7451)硫酸阳极氧化样板,氧化膜厚度18μm,采用热水封闭,分别记为5#样板和6#样板。制作06Cr19Ni10不锈钢样板,经钝化处理,记为7#样板。
实施例3
1~6#样板进行酸性盐雾试验和酸性大气试验。酸性盐雾试验按照GJB 150.11A-2009规定的方法进行,盐溶液pH为3.5±0.5, 24h喷盐雾和24h干燥为一个循环,进行4次循环。酸性大气试验按照GJB 150.28-2009规定的方法进行,溶液pH为3.5±0.5,喷雾2h、贮存22h为一个循环,进行3次循环。然后采用GB/T 6461-2002、GB/T 1766-2008对腐蚀试验后的样板进行评级。腐蚀试验结果如下表所示。
表1 酸性盐雾和酸性大气试验结果
可见,本发明提出的高耐蚀轻质储油容器的制作方法,相对不锈钢容器减重60%~70%,并增强了储油容器的腐蚀防护能力,提升了产品的环境适应性。
至此,已经结合优选实施方式描述了本发明的技术方案,但是,本领域技术人员容易理解的是,本发明的保护范围显然不局限于这些具体实施方式。在不偏离本发明的原理的前提下,本领域技术人员可以对相关技术特征作出等同的更改或替换,这些更改或替换之后的技术方案都将落入本发明的保护范围之内。
Claims (4)
1.一种高耐蚀轻质储油容器的制作方法,储油容器采用铝合金制作,制作方法包括以下步骤:储油容器成形、除油、碱洗、内壁蚀刻、出光、阳极氧化、热水封闭、内壁修饰、外壁油漆、内壁灌注、检验和包装;其中:在除油步骤中,采用酸性、碱性或有机溶剂除油,去除工件表面油脂;在碱洗步骤中,工件用浓度50g/L~85g/L的NaOH溶液浸泡0.5 min ~1.5min,溶液温度为50℃~70℃,清洗至表面水膜连续,然后用去离子水清洗干净;在内壁蚀刻步骤中,工件的内壁用含NaOH浓度 40 g/L ~60g/L、Na3PO4浓度15 g/L ~20g/L、NaF浓度15 g/L ~25g/L、砂面剂浓度50 g/L ~70g/L的溶液浸泡30min ~10min,溶液温度为20℃~60℃,然后用去离子水清洗干净;在出光步骤中,工件用浓度400mL/L~600mL/L的硝酸溶液浸泡0.5min ~1.5min,然后用去离子水清洗干净;在阳极氧化步骤中,工件用浓度70mL/L~110mL/L的硫酸溶液进行阳极氧化,氧化温度10℃~20℃,氧化时间20 min ~60min,电流密度为0.5A/dm2~1A/dm2,氧化结束后工件用去离子水清洗,然后在1%~2%的氨水溶液中浸泡5s~20s,然后再用去离子水清洗干净;在热水封闭步骤中,用稀醋酸和氢氧化钠溶液调节水的pH为5.5~7.0并将水升温至90℃~96℃,将工件在水中浸泡15min ~40min,然后用去离子水清洗干净;在内壁修饰步骤中,工件的内壁用浓度0.5%~2%的氟硅烷乙醇溶液浸泡30 min ~90min,清除氟硅烷乙醇溶液后,用乙醇清洗内壁;在外壁油漆步骤中,对工件的内壁进行遮蔽保护,对工件的外壁进行涂装前处理,然后外壁涂装油漆,工件在60℃~100℃温度下烘干1.5 h ~5h;在内壁灌注步骤中,工件的内壁用油液浸润2h ~24h,然后容器工件倒扣放置,于50℃~80℃温度下烘干0.5h~3h。
2.根据权利要求1所述的高耐蚀轻质储油容器的制作方法,其特征在于:在内壁修饰步骤中,氟硅烷选用十七氟癸基三乙氧基硅烷、十七氟癸基三甲氧基硅烷、十七氟癸基三氯硅烷、十三氟辛基三乙氧基硅烷、十三氟辛基三甲氧基硅烷、十三氟辛基三氯硅烷的任意一种。
3.根据权利要求1所述的高耐蚀轻质储油容器的制作方法,其特征在于:在内壁灌注步骤中,油液选用全氟聚醚、甲基硅油、矿物油、液压油中的任意一种。
4.根据权利要求1所述的高耐蚀轻质储油容器的制作方法,其特征在于:在检验和包装步骤中,检验工件外壁油漆质量和内壁处理质量,检验合格后将工件进行包装。
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