CN114250462A - Preparation method of alloy cladding layer for prolonging wear-resistant and corrosion-resistant life of steel structural member in ocean total immersion area - Google Patents
Preparation method of alloy cladding layer for prolonging wear-resistant and corrosion-resistant life of steel structural member in ocean total immersion area Download PDFInfo
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Abstract
The invention discloses a preparation method of an alloy cladding layer for prolonging the wear-resistant and corrosion-resistant life of a steel structural member in an ocean total immersion area. The raw materials of the carbide ceramic particle alloy material comprise the following components in parts by mass: 18-22 wt.% Cr; 16-24wt.% Ti; 8-12wt.% Al; 0.5-3wt.% Si; the total amount of other impurity elements is required to be less than or equal to 0.15 wt.%; ni for the rest; WC 10-15 wt.%. Adding Al, Si and Ti after the Ni and the Cr are completely melted, and preserving the heat of the melted alloy powder to obtain a melted alloy solution; atomizing to prepare powder to obtain Ni-Cr-Ti-Al-Si alloy powder material; placing the alloy powder and WC particles in a planetary ball mill, ball-milling and uniformly mixing, and screening after ball-milling is finished to obtain a powder material for cladding; and preparing a cladding layer by adopting a multi-pass lap cladding method. The invention can effectively solve the problems of uniform corrosion and local corrosion of the steel structural member in the ocean total immersion area caused by corrosion and abrasion.
Description
Technical Field
The invention relates to the technical fields of corrosion and wear protection technology, surface engineering technology and metal materials, in particular to a preparation method of an alloy cladding layer for prolonging the wear-resistant and corrosion-resistant life of a steel structural member in an ocean total immersion area.
Background
With the proposal of the national 'ocean strong national strategy', the development of offshore wind power as an important component part of the offshore wind power has continuously achieved breakthrough progress and innovative achievements. However, with the further development of offshore wind power from offshore to deep open sea and the accelerated promotion of the national subsidy of the 'hill-withdrawing' policy on the electricity price of renewable energy power generation, the offshore wind power industry faces brand new challenges, and technical innovation, cost reduction and efficiency improvement are imminent. It is estimated that the later operation and maintenance cost of the offshore wind farm is 7 times of the construction cost, wherein the loss caused by the corrosion and abrasion of materials and components is serious. Therefore, the method has great significance for reducing the cost of the wind power plant and improving the benefit of the wind power plant.
Compared to inland, the ocean is a very harsh and complex corrosive environment. Factors such as dissolved oxygen in seawater, sea wave impact, alternation of wetting and drying, sunshine duration, silt impact, biological adhesion and the like can accelerate corrosion of a steel structure, and the corrosion degree is also influenced by salt content, pH value and Cl of seawater-Ion concentration, temperature variation, etc. Therefore, the problem of corrosion prevention in ocean engineering should be highly regarded. However, at present, the corrosion prevention measures for offshore wind power engineering infrastructure and wind turbines mainly come from corrosion prevention experiences in offshore oil platforms, icebreakers, submarine pipelines and the like, researches on corrosion and protection of offshore wind power are few, and related experiences are poor.
The ocean total immersion area is the part which is immersed by seawater all the year round until the surface layer of ocean soil. Due to high concentration of Cl-Due to the existence of ions, the steel is difficult to passivate, and even if the steel is stainless steel, the stability of a passivation film is also reduced, so that pitting corrosion is easy to occur. The average corrosion rate of the full immersion area can reach 0.05-0.13mm/a generally, and the maximum corrosion rate can reach 2-3 times of the average value. The shallow water area of the full-immersion area has the phenomena of flushing impact of floating objects on the sea, biological pollution, chemical pollution and the like, and has high oxygen content and high temperature, so the shallow water area has high oxygen content and high temperatureThe water area is more corrosive, and the corrosion rate is faster.
At present, the full immersion area adopts a combined anticorrosion technology of coating and cathodic protection. The use must be of impermeable coatings and have good resistance to electrical and alkaline. The paint is generally prepared by combining a primer, a middle paint and a finish paint, and mainly comprises water-based inorganic zinc-rich paint (about 40 mu m), epoxy resin paint (about 300 mu m) and chlorinated rubber paint (about 20 mu m). Although the anticorrosive paint is simple in construction, the limitation is large: (1) the bonding strength is not high. The coating is easy to peel off under the conditions of long-term scouring, impact and the like of the silt and loses the protection effect; (2) local corrosion is easy to cause, and the potential safety hazard is large. In a seawater full-immersion area, due to poor electrical insulation of the coating, the cathodic protection is easy to generate an over-protection phenomenon, and the coating is easy to strip and bubble under the damage of hydrogen evolution and alkaline degradation under the over-protection condition, so that local corrosion is caused, and the overall corrosion prevention effect is reduced; (3) it is difficult to solve the problem of biofouling. The coating needs to meet the requirement of no toxicity to the environment, but marine organisms are easy to attach to the surface of the coating to cause fouling and damage phenomena. Therefore, in the current coating and cathodic protection combined anticorrosion technology aiming at the ocean full immersion area, the coating is difficult to meet the anticorrosion requirement and protect the driving of the cathodic protection technology.
In order to solve the problem of long-acting corrosion protection of the steel structure in the ocean total immersion area, a wear-resistant corrosion-resistant cladding layer with good metallurgical bonding is prepared on the surface of the steel structure by utilizing a high-speed laser cladding technology, so that the wear-resistant corrosion-resistant service life of the steel structure is greatly prolonged, and the purposes of cost reduction and efficiency improvement are achieved. The high-speed laser cladding technology is one of the most advanced cladding layer preparation technologies in the world at present, has the characteristics of high energy density, low dilution, small thermal deformation of a workpiece and the like, and can greatly improve the surface performance of a structural member on the premise of not influencing the mechanical property of the structural member. The cladding layer prepared by the laser cladding technology has compact structure, less internal pore cracks, metallurgical bonding with the matrix, and far higher bonding strength than the coating, and can effectively solve the problem that the coating is easy to wear and peel off when being impacted. Meanwhile, the cladding layer greatly improves the surface hardness and seawater corrosion resistance of the steel member by utilizing a fine grain strengthening principle, an alloying principle, a solid solution strengthening principle and a second-phase particle dispersion strengthening principle, so that the problems that an anti-corrosion coating is easy to strip, wear and local corrosion are effectively solved, the cathodic protection technology is assisted, and the long-acting protection of the steel member in the offshore full-immersion area can be realized.
At present, the full immersion area adopts a combined anticorrosion technology of coating and cathodic protection. The use must be of impermeable coatings and have good resistance to electrical and alkaline. The paint is generally prepared by combining a primer, a middle paint and a finish paint, and mainly comprises water-based inorganic zinc-rich paint (about 40 mu m), epoxy resin paint (about 300 mu m) and chlorinated rubber paint (about 20 mu m). Although the anticorrosive paint is simple in construction, the limitation is large: (1) the bonding strength is not high. The coating is easy to peel off under the conditions of long-term scouring, impact and the like of the silt and loses the protection effect; (2) local corrosion is easy to cause, and the potential safety hazard is large. In a seawater full-immersion area, due to poor electrical insulation of the coating, the cathodic protection is easy to generate an over-protection phenomenon, and the coating is easy to strip and bubble under the damage of hydrogen evolution and alkaline degradation under the over-protection condition, so that local corrosion is caused, and the overall corrosion prevention effect is reduced; (3) it is difficult to solve the problem of biofouling. The coating needs to meet the requirement of no toxicity to the environment, but marine organisms are easy to attach to the surface of the coating to cause fouling and damage phenomena. Therefore, in the current coating and cathodic protection combined anticorrosion technology aiming at the ocean full immersion area, the coating is difficult to meet the anticorrosion requirement and protect the driving of the cathodic protection technology.
Disclosure of Invention
The invention provides a preparation method of an alloy cladding layer for prolonging the wear-resistant and corrosion-resistant life of a steel structural member in an ocean total immersion area.
The technical scheme of the invention is as follows:
a carbide ceramic particle alloy material for improving the wear-resistant and corrosion-resistant life of a steel structural member in an ocean total immersion area,
carbide ceramic particle alloy material raw materials (also called powder materials for cladding, the powder materials for cladding are composed of alloy powder materials and WC particles, the alloy powder materials are obtained by using atomization powder preparation, and the powder materials for cladding are obtained by uniformly ball-milling the materials after the atomization powder preparation and the WC particles in a ball mill) comprise alloy powder and WC particles (tungsten carbide particles);
the raw materials of the carbide ceramic particle alloy material comprise the following components in parts by mass:
18-22 wt.% Cr; 16-24wt.% Ti; 8-12wt.% Al; 0.5-3wt.% Si; the total amount of other impurity elements is required to be less than or equal to 0.15 wt.%; ni for the rest;
WC：10-15wt.%。
preferably, the WC particle size requires 200-400 mesh.
Preferably, the mass ratio of Ti to Al in the carbide ceramic particle alloy material raw material is controlled in the range of 1.8 to 3, and if the mass ratio of Ti to Al is higher than 3, the strength of the cladding layer is lowered.
Preferably, the content of Si element in the raw material of the alloy powder is 3wt% or less. Experiments have shown that an excess of Si (> 3 wt.%) causes large through cracks in the cladding layer samples.
The preparation method of the nickel-chromium alloy cladding layer of the carbide ceramic particle alloy material for improving the wear resistance and corrosion resistance life of the steel structural member in the ocean total immersion zone comprises the following steps:
(1) smelting alloy powder: firstly, putting metal powder Ni into a vacuum medium-frequency induction furnace to be heated, adding Cr after Ni is completely melted, adding Al, Si and Ti after Ni and Cr are completely melted, and preserving the heat of the melted alloy powder to obtain a melted alloy solution; only adding metal powder and not adding WC particles when smelting alloy powder;
(2) atomizing to prepare powder: preparing an alloy powder material by using a nitrogen protection atomization powder preparation technology, wherein the required atomization medium is nitrogen, pouring the molten alloy solution in the step (1) into a crucible of an atomization rapid condensation device, and carrying out atomization powder preparation by using the device to obtain a Ni-Cr-Ti-Al-Si alloy powder material;
(3) screening to obtain a finished alloy powder material: and (3) screening the Ni-Cr-Ti-Al-Si alloy powder material prepared in the step (2), wherein the granularity of the screened Ni-Cr-Ti-Al-Si alloy powder material is within the range of 200-400 meshes, and obtaining the alloy powder.
Preferably, in the smelting process of the alloy powder in the step (1), the metal powder Ni is firstly placed in a vacuum medium frequency induction furnace for heating, Cr is added after Ni is completely melted, and other alloy elements are added after the two elements are in a molten state.
Preferably, in the smelting process of the alloy powder in the step (1), the molten alloy powder is kept at the temperature of 1100-1300 ℃ for 30-60 min; in the step (2), atomization powder preparation is carried out: the flow rate of the molten alloy solution is 0.6kg/min to 1 kg/min.
Further preferably, the preparation method of the nickel-chromium alloy cladding layer comprises the following steps:
s1: placing the alloy powder and WC particles in a planetary ball mill for ball milling and uniformly mixing, and screening after ball milling is finished, wherein the granularity of the alloy powder and the WC particles is within the range of 200-400 meshes, so as to obtain a powder material for cladding;
s2: the fiber laser is used as a heat source for cladding, a pneumatic synchronous powder feeder is used for feeding powder materials for cladding, nitrogen is used for feeding the powder materials for cladding, and argon is used for protecting a molten pool;
s3: and preparing a cladding layer by adopting a multi-pass lap cladding method.
More preferably, in the step S1, the rotation speed of the ball mill is 150r/min to 200r/min, and the ball milling time is 10h to 12 h; the screening particle size is 200-400 meshes.
More preferably, in step S2, a high-power fiber laser with a power of 3 to 4kW is used as a heat source for cladding, a focal spot of the laser beam is 1.5 to 3.5mm, a pneumatic synchronous powder feeder is used to feed the powder material for cladding, the powder feeding amount is 1.5 to 5kg/h, the powder feeder uses nitrogen to feed the powder material for cladding, the gas feeding amount is 12 to 24L/min, argon is used to protect the molten pool, and the gas feeding amount is 10 to 20L/min;
still further preferably, the step S3: the relative speed of the laser beam and the workpiece is 4-22cm/s, the cladding layers are prepared by adopting a multi-pass overlapping cladding method, the overlapping rate of two adjacent cladding layers is 40-60% during single cladding, and the thickness of the cladding layer formed by single-layer cladding can be selected within the range of 200-1000 mu m.
The invention has the following beneficial effects:
sea full immersion area, steel structural member, sea water corrosion resistance, silt erosion resistance, wear resistance, corrosion resistance, high bonding strength, laser cladding layer and optimized preparation process parameters.
The invention aims to effectively solve the problems of uniform corrosion, local corrosion and the like of a steel structural member in an ocean total immersion area caused by seawater erosion and silt abrasion.
The invention provides a preparation method of a carbide ceramic particle reinforced nickel-chromium alloy cladding layer for prolonging the wear-resistant and corrosion-resistant life of a steel structural member in an ocean total immersion area. The wear-resistant corrosion-resistant cladding layer is prepared on the surface of the steel structure by using a laser cladding technology, and the thickness of the prepared cladding layer is adjustable within the range of 300-1600 mu m by using a multilayer overlapping process. The bonding strength of the cladding layer and the substrate is obviously higher than that of the coating, and the wear resistance and corrosion resistance of the cladding layer are obviously superior to those of a steel plate and traditional anticorrosive paint. The invention can effectively solve the problems of uniform corrosion and local corrosion of the steel structural member in the ocean total immersion area caused by corrosion and abrasion.
The invention utilizes the laser cladding technology to prepare the wear-resistant and corrosion-resistant cladding layer on the surface of the steel structural member in the marine full-immersion area serving as the service environment, and the components of the cladding layer are uniformly metallurgically bonded with the matrix. The invention can solve the corrosion problem caused by low bonding strength and easy falling of the anticorrosive coating and the matrix, can effectively improve the corrosion resistance and wear resistance of the steel structural member, and reduce the annual corrosion rate and the local pitting corrosion tendency, thereby obviously improving the safety performance of the steel structural member and reducing the later operation and maintenance cost.
In the powder material for cladding, the ceramic particles and each metal element have the following specific functions: (1) the WC ceramic particles have stable chemical properties and high hardness, are similar to diamond, and are good conductors of electricity and heat. Proper amount of WC particles are added into the powder material for cladding, so that the integral hardness of the cladding layer can be effectively improved, and the wear resistance of the cladding layer is improved. (2) The melting point of Ni is lower, so that the wettability between the substrate and the cladding layer can be improved, the thermal expansion coefficient can be reduced, the occurrence of cracks and holes in the cladding layer can be reduced, and the possibility of local corrosion can be reduced. (3) The addition of Cr can form (Ni, Cr) ss solid solution with Ni, reduce the electrode potential of the cladding layer and improve the crystal resistance of the cladding layerThe method has the advantages of high intercross corrosion capability, easy passivation of Cr and high film forming capability, and can form a very thin passivation film in a corrosion environment to improve the uniform corrosion resistance of a cladding layer. (4) On one hand, the addition of Ti improves the nucleation rate, reduces the grain size, refines the solid solution structure and the network structure in the cladding layer and improves the hardness of the cladding layer by utilizing the fine grain strengthening principle; on the other hand, when the mass ratio of Ti to Al is in the range of 1.8 to 3, Ti to Al forms a stable intermediate phase Al along the grain boundary between the network structure and the solid solution phase3Ti, the hardness of the cladding layer is improved by utilizing a second phase strengthening principle; the last aspect is that the addition of Ti can reduce the brittleness of WC and reduce the possibility of cracking of the cladding layer. (5) The addition of Si is used as a deoxidizer, so that the fluidity and slagging capacity of the cladding layer are improved, the number of holes of the cladding layer is reduced, and the performance of the cladding layer is optimized in a preparation process; and on the other hand, when the element Si is seriously corroded, silicate is easily formed, and a film is formed through an adsorption mechanism, so that the base material is protected from further corrosion. The Si element content in the raw materials of the alloy powder is less than or equal to 3 wt%. Experiments show that there is an excess of Si: (>3 wt%) caused large through cracks in the cladding samples.
As mentioned above, the WC ceramic particle reinforced nickel-chromium laser cladding layer formed by the laser cladding technology has the characteristics of uniform matrix organization structure components and regular and non-agglomeration ceramic particle distribution. Compared with a cladding layer without WC ceramic particles, the method has the advantages that the WC particles obviously improve the wear resistance of the cladding layer, and can realize the wear resistance and corrosion resistance protection of the steel structural member in the ocean total immersion area under the conditions of silt erosion and seawater erosion.
The invention has the following specific beneficial effects:
(1) the component design scheme of the tungsten carbide ceramic particle reinforced nickel-chromium alloy cladding layer is provided, the preparation of the cladding layer can be realized in a process angle by the component design, the prepared cladding layer has uniform tissue and no obvious holes or cracks, and the problem of the increase of the cracks of the cladding layer caused by the additional particles is solved; (2) the prepared cladding layer has higher hardness and can resist the abrasion of seawater erosion and silt erosion on the steel structural member; the open circuit potential is higher, and the seawater corrosion resistance of the steel structural member can be improved; has higher bonding strength, and can solve the problems of coating shedding, local corrosion and the like of the common coating and the thermal spraying coating under the action of external force.
Drawings
FIG. 1 is a microstructure diagram of a cross section of a tungsten carbide ceramic particle-reinforced nickel-chromium alloy cladding layer in example 1.
FIG. 2 is a graph showing the hardness change of the W-carbide ceramic particles-reinforced Ni-Cr alloy cladding layer in example 1.
FIG. 3 is a displacement-force curve of the compression test of the W carbide ceramic particles reinforced NiCr alloy cladding layer of example 1.
FIG. 4 is a graph showing the hardness change of the W-carbide ceramic particles-reinforced NiCr alloy cladding layer in example 3.
Fig. 5 is a diagram showing the tungsten carbide ceramic particles-reinforced nickel-chromium alloy cladding layer of example 4 after being treated with a color developer.
FIG. 6 is a surface schematic representation of a tungsten carbide ceramic particle reinforced nickel chromium alloy cladding layer in example 5.
FIG. 7 is a photograph showing the color-developer-treated surface of the W-carbide ceramic particles-reinforced Ni-Cr alloy cladding layer in example 5.
Example 1 preparation method of a deep sea wind farm steel pipe pile foundation surface carbide ceramic particle reinforced nickel-chromium alloy wear-resistant corrosion-resistant cladding layer.
Component design and preparation of powder material for cladding
1. Designing the components of the alloy powder material:
the mass percentages of the metal powder and the ceramic particles in the powder material are as follows:
20wt.% Cr; 20wt.% Ti; 10wt.% Al; 1wt.% Si; 10wt.% WC; ni for the rest; the total amount of other impurity elements is required to be less than or equal to 0.15 wt.%; the WC granularity is 200-400 meshes.
2. Preparation of alloy powder material
(1) Melting of alloy powder
Mixing metal powder Ni, Cr, Ti, Al, Si and ceramic particles WC according to the following mass fraction: 20wt.% Cr; 20wt.% Ti; 10wt.% Al; 1wt.% Si; 10wt.% WC; 39wt.% of Ni. The purities of the metal powder and the ceramic particles are both more than or equal to 99.9 percent. Firstly, putting metal powder Ni into a vacuum intermediate frequency induction furnace to be heated, adding Cr after Ni is completely melted, adding Al, Si and Ti after Ni and Cr are completely melted, and preserving the heat of the melted alloy powder for 50min at the temperature of 1200 ℃. When the alloy powder is smelted, only the metal powder is added, and the WC particles are not added.
(2) Atomized powder
The alloy powder material is prepared by using a nitrogen protection atomization powder preparation technology, wherein the required atomization medium is nitrogen, and the flow rate of an alloy solution is 0.8 kg/min. Pouring the molten alloy solution in the step (1) into a crucible of an atomization rapid condensation device, and carrying out atomization powder preparation by using the device to obtain the Ni-Cr-Ti-Al-Si alloy powder material.
(3) Screening to obtain finished alloy powder material
Sieving the alloy powder material prepared in the step (2), wherein the granularity of the alloy powder material is within the range of 200-400 meshes.
3. Preparation of powder material for cladding
And (3) placing the finished alloy powder material obtained in the step (3) of preparing the alloy powder material in the step (2) and WC ceramic particles in the component design of the alloy powder material in the step (1) into a planetary ball mill for ball milling and uniformly mixing. The rotating speed of the ball mill is 160r/min, and the ball milling time is 10 h. And (3) repeating the step (3) in the preparation of the alloy powder material in the step (2) after the ball milling is finished, and screening to obtain the powder material for cladding, wherein the granularity of the powder material is within the range of 200-400 meshes.
Preparation method of particle-reinforced nickel-chromium alloy cladding layer
The steel pipe pile with the diameter of 6.5m is selected for cladding, the steel pipe pile is mainly made of DH36, part of the steel pipe pile is made of DH36-Z35, and the thickness between the inner wall and the outer wall of the steel pipe pile is 80 mm. The area to be cladded is the outer surface of the steel pipe pile. By utilizing a high-speed laser cladding technology, according to the specific powder material components for cladding designed in the step one, adjusting laser cladding process parameters, and preparing a tungsten carbide particle reinforced nickel-chromium alloy cladding layer on the outer surface of the steel pipe pile, the specific steps are as follows:
(1) and uniformly thinning the surface of the steel pipe pile by machining to 400 mu m. And (4) carrying out oil removal cleaning treatment on the surface of the thinned steel pipe pile by using acetone, and fixing the steel pipe pile on a cladding worktable.
(2) And (3) filling the powder material for cladding prepared in the step I, the step II of designing and preparing the components of the powder material for cladding into a powder storage container of a pneumatic powder feeder, and preparing the seawater corrosion resistant cladding layer by adopting a mode that the steel pipe pile is relatively static, the laser head moves relatively and a plurality of times of lap joints are carried out. Argon is used as shielding gas in the cladding process, and the gas delivery amount is 17L/min; nitrogen is used as powder feeding gas, and the gas feeding amount is 18L/min; the powder is fed by a pneumatic synchronous powder feeder, and the powder feeding amount is 3 kg/h. The main parameters of laser cladding are as follows: the output power of the fiber laser is 3kW, the diameter of a laser beam focus spot is 1.6mm, and the relative movement speed of the laser beam focus spot and a workpiece is 11 cm/s; the overlapping ratio of two adjacent cladding layers is 50%, and the thickness of the formed cladding layer is about 600 μm.
(3) Machining the surface of the steel pipe pile with the tungsten carbide particle reinforced nickel-chromium alloy cladding layer, thinning the cladding layer prepared in the step (2) by 200 microns, recovering the original size of the steel pipe pile, and polishing the steel pipe pile until the steel pipe pile is bright. And the thickness of the cladding layer on the surface of the final steel pipe pile is 400 mu m.
As can be seen from FIG. 1, no obvious voids or cracks are formed in the cladding layer and at the interface joint, which indicates that the component design can realize the cladding layer without obvious defects in the preparation process. Meanwhile, the cladding layer and the substrate are in good metallurgical bonding, and the problem that the bonding strength of the traditional anticorrosive coating and the substrate is not high is solved.
As can be seen from FIG. 2, the hardness of the cladding layer is greatly improved compared with that of the base material, the cladding layer can obviously improve the wear resistance of the base material, and the problem of poor wear resistance of the traditional anticorrosive paint in the full-immersion area is solved.
As shown in FIG. 3, the maximum force value was 17.76kN, and the bonding area of the experimental clad layer was 1cm2The calculated bonding strength of the cladding layer was 177 MPa. High bondingThe strength ensures that the cladding layer is not easy to fall off under the action of external force, and the problem of low bonding strength of the traditional anticorrosive paint is solved.
Example 2: preparation method of carbide ceramic particle reinforced nickel-chromium alloy wear-resistant and corrosion-resistant cladding layer of steel pipe pile of cross-sea bridge
Component design and preparation of powder material for cladding
1. Designing the components of the alloy powder material:
the mass percentages of the metal powder and the ceramic particles in the powder material are as follows:
18wt.% Cr; 16wt.% Ti; 8wt.% Al; 2wt.% Si; 12wt.% WC; the balance of Ni and the total amount of other impurity elements are required to be less than or equal to 0.15 wt.%; the WC granularity is 200-400 meshes.
2. Preparation of alloy powder material
(1) Melting of alloy powder
Mixing metal powder Ni, Cr, Ti, Al, Si and ceramic particles WC according to the following mass fraction: 18wt.% Cr; 16wt.% Ti; 8wt.% Al; 2wt.% Si; 12wt.% WC; ni:44 wt.%. The purities of the metal powder and the ceramic particles are both more than or equal to 99.9 percent. Firstly, putting metal powder Ni into a vacuum medium-frequency induction furnace to be heated, adding Cr after Ni is completely melted, adding Al, Si and Ti after Ni and Cr are completely melted, and preserving the heat of the melted alloy powder for 40min at the temperature of 1100 ℃. When the alloy powder is smelted, only the metal powder is added, and the WC particles are not added.
(2) Atomized powder
The alloy powder material is prepared by using a nitrogen protection atomization powder preparation technology, wherein the required atomization medium is nitrogen, and the flow rate of an alloy solution is 0.9 kg/min. Pouring the molten alloy solution in the step (1) into a crucible of an atomization rapid condensation device, and carrying out atomization powder preparation by using the device to obtain the Ni-Cr-Ti-Al-Si alloy powder material.
(3) Screening to obtain finished alloy powder material
Sieving the alloy powder material prepared in the step (2), wherein the granularity of the alloy powder material is within the range of 200-400 meshes.
3. Preparation of powder material for cladding
And (3) putting the finished alloy powder material in the step (3) and the WC ceramic particles in the step (1) into a planetary ball mill, and ball-milling and uniformly mixing. The rotating speed of the ball mill is 200r/min, and the ball milling time is 10 h. And (3) repeating the step (3) in the preparation of the alloy powder material in the step (2) after the ball milling is finished, and screening to obtain the powder material for cladding, wherein the granularity of the powder material is within the range of 200-400 meshes.
Preparation method of particle-reinforced nickel-chromium alloy cladding layer
The workpiece to be cladded is a sea-crossing bridge steel pipe pile foundation, the diameter of the workpiece is 1.6m, and the region to be cladded is the outer surface of the steel pipe pile. Preparing a tungsten carbide particle reinforced nickel-chromium alloy cladding layer on the outer surface of the steel pipe pile by using a high-speed laser cladding technology, and specifically comprising the following steps of:
(1) and uniformly thinning the surface of the steel pipe pile by machining to 750 mu m. And (3) removing oil on the surface of the thinned steel pipe pile by using acetone and absolute ethyl alcohol, cleaning and fixing the surface on a cladding worktable.
(2) And (3) filling the powder material for cladding prepared in the step I, the step II of designing and preparing the components of the powder material for cladding into a powder storage container of a pneumatic powder feeder, and preparing the seawater corrosion resistant cladding layer by adopting a mode that the steel pipe pile is relatively static, the laser head moves relatively and a plurality of times of lap joints are carried out. Argon is used as shielding gas in the cladding process, and the gas delivery amount is 12L/min; nitrogen is used as powder feeding gas, and the gas feeding amount is 15L/min; the powder is fed by a pneumatic synchronous powder feeder, and the powder feeding amount is 1.5 kg/h. The main parameters of laser cladding are as follows: the output power of the fiber laser is 3kW, the diameter of a laser beam focus spot is 2mm, and the relative movement speed of the laser beam focus spot and a workpiece is 16 cm/s; the overlapping ratio of two adjacent cladding layers is 50%, and the thickness of the formed cladding layer is about 300 mu m.
(3) Repeating the step (2) of the second preparation method of the particle reinforced nickel-chromium alloy cladding layer three times in the same area to prepare the seawater corrosion resistant cladding layer with the average thickness of about 900 mu m.
(4) And (2) machining the surface of the steel pipe pile with the tungsten carbide particle reinforced nickel-chromium alloy cladding layer prepared in the step (3), uniformly thinning by 150 microns and polishing to enable the surface to reach the original design size.
Example 3 method for preparing a wear-resistant and corrosion-resistant cladding layer of a nichrome alloy reinforced by carbide ceramic particles on the surface of a steel pipe pile foundation in a deep and distant sea wind farm. (example 1 was used as a basis, except that the mass ratio of Ti to Al in the composition of the cladding powder material was increased to 9: 1)
Designing the components of the alloy powder material:
the mass percentages of the metal powder and the ceramic particles in the powder material are as follows:
20wt.% Cr; 27wt.% Ti; 3wt.% Al; 1wt.% Si; 10wt.% WC; the balance of Ni and the total amount of other impurity elements are required to be less than or equal to 0.15 wt.%; the WC granularity is 200-400 meshes.
FIG. 4 is a graph showing the hardness of the W-carbide ceramic particles-reinforced NiCr alloy cladding layer of example 3, showing that the hardness of the cladding layer tends to decrease with this composition.
Example 4 preparation method of wear-resistant and corrosion-resistant cladding layer of nickel-chromium alloy reinforced by carbide ceramic particles on surface of steel pipe. (based on example 1, the other parts in the cladding powder material composition were the same except that the mass fraction of Si in the cladding powder material composition was increased to 5wt.%, and 1wt.% in example 1, and cracks appeared on the cladding layer surface.)
Component design and preparation of powder material for cladding
1. Designing the components of the alloy powder material:
the mass percentages of the metal powder and the ceramic particles in the powder material are as follows:
20wt.% Cr; 20wt.% Ti; 10wt.% Al; 5wt.% Si; 10wt.% WC; the balance of Ni and the total amount of other impurity elements are required to be less than or equal to 0.15 wt.%; the WC granularity is 200-400 meshes.
The specific cladding process and cladding parameters were consistent with those of example 1.
The cladding layer was prepared in exactly the same manner as in example 1. Based on example 1, the difference is that the mass ratio of Si in the components of the cladding powder material is increased to 5 wt.%. As can be seen from fig. 5, the experimental result shows that, on the premise of ensuring inconvenience of other conditions, the Si mass ratio is increased to 5wt.%, a large number of cracks appear on the surface of the cladding layer, and the process quality of the cladding layer is difficult to ensure. Therefore, from the process point of view, the mass fraction of Si in the powder material composition for cladding should be controlled within the scope of claim 1.
Example 5 preparation method of wear-resistant and corrosion-resistant cladding layer of nickel-chromium alloy reinforced by carbide ceramic particles on surface of steel plate sample. (based on example 1, the other parts in the cladding material composition are the same, except that the mass fraction of Si in the cladding powder material composition is increased to 3.5wt.%, 1wt.% in example 1, and a large number of significant cracks are also formed on the cladding layer surface in example 5.)
Component design and preparation of powder material for cladding
1. Designing the components of the alloy powder material:
the mass percentages of the metal powder and the ceramic particles in the powder material are as follows:
20wt.% Cr; 20wt.% Ti; 10wt.% Al; si 3.5 wt.%; 10wt.% WC; the balance of Ni and the total amount of other impurity elements are required to be less than or equal to 0.15 wt.%; the WC granularity is 200-400 meshes.
The specific cladding process and cladding parameters were consistent with those of example 1.
The cladding layer was prepared in exactly the same manner as in example 1. Based on example 1, except that the Si mass ratio in the composition of the cladding powder material was increased to 3.5 wt.%. As can be seen from fig. 6, the experimental results show that, on the premise of ensuring inconvenience of other conditions, the Si mass ratio is increased to 3.5wt.%, and a large number of cracks are visible on the surface of the cladding material object with naked eyes. Fig. 7 is fig. 6 after color developer treatment, and it is strongly demonstrated from fig. 7 that the sample prepared in fig. 6 has a large number of cracks. Therefore, from the process point of view, the mass fraction of Si in the powder material composition for cladding should be controlled within the scope of claim 1.
The technical solutions of the present invention are explained by the above embodiments, but the present invention is not limited to the above embodiments, that is, it is not meant that the present invention must depend on the above specific embodiments to be implemented. Any modification of the invention or equivalent substitution of the materials for the invention chosen by the skilled person is within the scope of protection of the patent.
Claims (10)
1. A carbide ceramic particle alloy material for improving the wear-resisting and corrosion-resisting life of a steel structural member in an ocean total immersion area is characterized in that:
the raw materials of the carbide ceramic particle alloy material comprise the following components in parts by mass:
18-22 wt.% Cr; 16-24wt.% Ti; 8-12wt.% Al; 0.5-3wt.% Si; the total amount of other impurity elements is required to be less than or equal to 0.15 wt.%; ni for the rest;
WC:10-15wt.%。
2. the carbide ceramic particle alloy material for improving the wear resistance and corrosion resistance life of a steel structure in a marine total immersion area according to claim 1, which is characterized in that: the WC granularity is 200-400 meshes.
3. The carbide ceramic particle alloy material for improving the wear resistance and corrosion resistance life of a steel structure in a marine total immersion area according to claim 1, which is characterized in that: the mass ratio of Ti to Al in the raw materials of the carbide ceramic particle alloy material is controlled to be 1.8-3.
4. The method for preparing the nickel-chromium alloy cladding layer by using the carbide ceramic granular alloy material of any one of claims 1 to 3 for prolonging the wear-resisting and corrosion-resisting life of the steel structural member in the ocean total immersion zone is characterized by comprising the following steps of: the preparation of the alloy powder comprises the following steps:
(1) smelting alloy powder: firstly, adding Ni and Cr elements for smelting, firstly, placing metal powder Ni in a vacuum medium-frequency induction furnace for heating, adding Cr after Ni is completely molten, adding Al, Si and Ti after Ni and Cr are completely molten, and preserving the heat of the molten alloy powder to obtain a molten alloy solution; only adding metal powder and not adding WC particles when smelting alloy powder;
(2) atomizing to prepare powder: preparing an alloy powder material by using a nitrogen protection atomization powder preparation technology, wherein the required atomization medium is nitrogen, pouring the molten alloy solution in the step (1) into a crucible of an atomization rapid condensation device, and carrying out atomization powder preparation by using the device to obtain a Ni-Cr-Ti-Al-Si alloy powder material;
(3) screening to obtain a finished alloy powder material: and (3) screening the Ni-Cr-Ti-Al-Si alloy powder material prepared in the step (2), wherein the granularity of the screened Ni-Cr-Ti-Al-Si alloy powder material is within the range of 200-400 meshes, and obtaining the alloy powder.
5. The method for preparing the nickel-chromium alloy cladding layer for improving the wear resistance and corrosion resistance life of the steel structure in the ocean total immersion area according to claim 4, wherein in the smelting process of the alloy powder in the step (1), the metal powder Ni is firstly placed in a vacuum intermediate frequency induction furnace to be heated, Cr is added after the Ni is completely melted, and other alloy elements are added after the two elements are in a molten state.
6. The method for preparing the nickel-chromium alloy cladding layer for improving the wear resistance and corrosion resistance life of the steel structure in the ocean total immersion zone according to claim 4, wherein in the smelting process of the alloy powder in the step (1), the molten alloy powder is kept at the temperature of 1100-1300 ℃ for 30-60 min; in the step (2), atomization powder preparation is carried out: the flow rate of the molten alloy solution is 0.6kg/min to 1 kg/min.
7. The method for preparing the nickel-chromium alloy cladding layer for improving the wear-resisting and corrosion-resisting life of the steel structural member in the ocean total immersion area according to any one of claims 4 to 6, which is characterized by comprising the following steps: the preparation method of the nickel-chromium alloy cladding layer comprises the following steps:
s1: placing the alloy powder and WC particles in a planetary ball mill, ball-milling and uniformly mixing, and screening after ball-milling is finished to obtain a powder material for cladding;
s2: the fiber laser is used as a heat source for cladding, a pneumatic synchronous powder feeder is used for feeding powder materials for cladding, nitrogen is used for feeding the powder materials for cladding, and argon is used for protecting a molten pool;
s3: and preparing a cladding layer by adopting a multi-pass lap cladding method.
8. The method for preparing the nickel-chromium alloy cladding layer for improving the wear-resisting and corrosion-resisting life of the steel structure in the ocean total immersion zone according to claim 7, is characterized in that: in the step S1, the rotating speed of the ball mill is 150r/min-200r/min, and the ball milling time is 10h-12 h; the screening particle size is 200-400 meshes.
9. The method for preparing the nickel-chromium alloy cladding layer for improving the wear-resisting and corrosion-resisting life of the steel structure in the ocean total immersion zone according to claim 7, is characterized in that:
in the step S2, a high-power fiber laser with the power of 3-4kW is selected as a heat source for cladding, the focal spot of a laser beam is 1.5-3.5mm, a pneumatic synchronous powder feeder is used for feeding the powder material for cladding, the powder feeding amount is 1.5-5kg/h, the powder feeder is used for feeding the powder material for cladding by using nitrogen, the gas feeding amount is 12-24L/min, a molten pool is protected by using argon, and the gas feeding amount is 10-20L/min.
10. The method for preparing the nickel-chromium alloy cladding layer for improving the wear-resisting and corrosion-resisting life of the steel structure in the ocean total immersion zone according to claim 7, is characterized in that:
the step S3: the relative speed of the laser beam and the workpiece is 4-22cm/s, the cladding layers are prepared by adopting a multi-pass overlapping cladding method, the overlapping rate of two adjacent cladding layers is 40-60% during single cladding, and the thickness of the cladding layer formed by single-layer cladding can be selected within the range of 200-1000 mu m.
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