CN114345970A - High-strength corrosion-resistant aluminum alloy drill rod and preparation method thereof - Google Patents
High-strength corrosion-resistant aluminum alloy drill rod and preparation method thereof Download PDFInfo
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Abstract
The invention discloses a high-strength corrosion-resistant aluminum alloy drill rod and a preparation method thereof, wherein the preparation method comprises the following steps: (1) refining the aluminum alloy cast ingot to remove oxides and impurities; pouring the refined aluminum alloy molten metal into a crucible and preserving heat; (2) atomizing the aluminum alloy metal liquid in the crucible, spraying the aluminum alloy metal liquid at high pressure, uniformly depositing the aluminum alloy metal liquid and quickly solidifying the aluminum alloy metal liquid to form an aluminum alloy billet on the material bearing plate; (3) heating the aluminum alloy billet to be in a semi-solid state, performing densification treatment and seamless aluminum alloy pipe extrusion forming by using a double-acting reverse extrusion process; (4) pickling the aluminum alloy pipe, and then spraying sand; (5) ultrasonically cleaning an aluminum alloy pipe; (6) carrying out supersonic flame thermal spraying on the aluminum alloy pipe; (7) carrying out heat treatment after spraying; (8) and heating the aluminum alloy pipe, and impregnating the aluminum alloy pipe in a resin solution to seal holes to obtain the high-strength corrosion-resistant aluminum alloy drill rod. The preparation method is simple, the production efficiency is high, and the prepared drill rod has the characteristics of high strength, high hardness, salt spray corrosion resistance and the like.
Description
Technical Field
The invention relates to the technical field of petroleum drill pipes, in particular to a high-strength corrosion-resistant aluminum alloy drill pipe and a preparation method thereof.
Background
With the development of oil and gas gradually developing to the depth, the exploration and development difficulty is gradually increased due to the occurrence of deep wells, ultra-deep wells and high-pressure wells, and the core of a series of well completion problems is the material selection of a well completion string. Because the high-temperature high-pressure well and the ultrahigh-pressure high-temperature well generally have harsh bottom temperature, pressure and CO content2、H2S and Cl-And the high-strength corrosion-resistant petroleum pipe is urgently needed under complex corrosion working conditions. The aluminum alloy drill pipe has the advantages of low density, high specific strength, acid corrosion resistance, long fatigue life and the like, is one of main structural materials for solving the problems of safe and efficient drilling of ultra-deep wells, extended reach wells, high-sulfur-content complex wells and the like, has wide application prospect in the field of petroleum exploration drilling, and is a hotspot of the current high-performance oil well pipe material research.
Aluminum alloy drill pipes are applied to the drilling field of a few developed countries such as the United states, Russia and the like for decades, however, the petroleum industry and the geological industry of China are developed after being built, although a plurality of large oil fields are developed, the geological exploration industry is greatly improved, the drill pipes used for drilling almost all adopt steel drill pipes, the research of the aluminum alloy drill pipes starts late, and the research and development time is still short. The existing aluminum alloy drill rod mainly depends on import, which greatly limits the development of the drilling and mining industry in China, so that the realization of independently researching and developing the high-strength corrosion-resistant aluminum alloy drill rod has important significance for guaranteeing the high efficiency, safety and sustainability of the exploration and development of oil and gas resources in China.
Disclosure of Invention
The invention aims to solve the problems of low hardness, poor wear resistance and poor Cl resistance of the existing aluminum alloy drill rod-The high-strength corrosion-resistant aluminum alloy drill rod prepared by the method has the characteristics of high strength, high hardness, salt spray corrosion resistance and the like.
The invention is realized by the following technical scheme:
a preparation method of a high-strength corrosion-resistant aluminum alloy drill rod comprises the following steps:
(1) refining and pouring the aluminum alloy: refining the 7xxx series aluminum alloy cast ingot to remove oxides and impurities in the cast ingot; then, quickly pouring the refined aluminum alloy molten metal into a crucible for spray forming and preserving heat; refining the 7xxx series aluminum alloy cast ingot by a vacuum smelting furnace;
(2) and (3) spray forming: forming an aluminum alloy billet with fine grains on a material bearing plate by atomizing the aluminum alloy metal liquid in the crucible, spraying the aluminum alloy metal liquid at high pressure, uniformly depositing the aluminum alloy metal liquid and quickly solidifying the aluminum alloy metal liquid;
(3) double-acting reverse extrusion: heating the aluminum alloy billet to be in a semi-solid state, and then performing densification treatment and seamless aluminum alloy pipe extrusion forming by adopting a double-acting reverse extrusion process;
(4) surface pickling and sand blasting: pickling the aluminum alloy pipe to remove surface oxide skin, and then carrying out sand blasting treatment to roughen the surface;
(5) ultrasonic cleaning: carrying out ultrasonic cleaning on the aluminum alloy pipe with the roughened surface to remove surface impurities;
(6) supersonic flame thermal spraying: carrying out supersonic flame thermal spraying on the aluminum alloy pipe subjected to ultrasonic cleaning to form a thermal spraying coating;
(7) and (3) heat treatment: carrying out T6 heat treatment on the aluminum alloy pipe forming the hot spraying coating;
(8) hole sealing treatment: and heating the aluminum alloy pipe after the heat treatment, and then impregnating the aluminum alloy pipe in a resin solution for hole sealing to obtain the high-strength corrosion-resistant aluminum alloy drill rod.
The preparation method of the high-strength corrosion-resistant aluminum alloy drill pipe provided by the invention is simple in preparation process and high in production efficiency, and the prepared aluminum alloy drill pipe is high in yield strength and tensile strength and has obvious corrosion resistance in a salt spray environment. The invention relates to a high-strength corrosion-resistant aluminum alloy drill rod with 600 MPa-level yield strength.
Further, the preparation method of the high-strength corrosion-resistant aluminum alloy drill rod comprises the following steps: step (1) refining and pouring of aluminum alloy: refining the 7xxx series aluminum alloy cast ingot, and removing oxides and impurities in the cast ingot by adopting aluminum-yttrium alloy as a refining agent; then, rapidly pouring the refined aluminum alloy molten metal into crucible equipment for spray forming and preserving heat at 650-750 ℃; wherein the 7xxx series aluminum alloy is 7075 or 7055.
Further, the preparation method of the high-strength corrosion-resistant aluminum alloy drill rod comprises the following steps: step (2) spray forming: the high-pressure injection adopts 1-2MPa inert gas, the deposition rate is 10-50Kg/h, and the grain diameter of the aluminum alloy billet is 10-15 mu m.
Further, the preparation method of the high-strength corrosion-resistant aluminum alloy drill rod comprises the following steps: the double-acting reverse extrusion process in the step (3): the extrusion temperature is 550-650 ℃, the extrusion pressure is 1500-3000MPa, the extrusion ratio is 15-25, and the extrusion speed is 8-20 mm/s.
Further, the preparation method of the high-strength corrosion-resistant aluminum alloy drill rod comprises the following steps: and (4) surface pickling and sand blasting: adopting pickling solution to carry out pickling on the aluminum alloy pipe, removing surface oxide skin, then carrying out sand blasting treatment,texturing the surface; wherein the pickling solution is prepared from HCl, HNO3The aluminum alloy pipe is prepared according to the mass ratio of 2:3, and the pickling is stopped when bubbles begin to be generated on the surface of the aluminum alloy pipe; the surface roughness of the aluminum alloy pipe after sand blasting treatment is 3-5 mu m.
Further, the preparation method of the high-strength corrosion-resistant aluminum alloy drill rod comprises the following steps: ultrasonic cleaning: placing the aluminum alloy pipe in ethanol for ultrasonic cleaning to remove surface impurities; wherein the ultrasonic frequency is 100-200Hz, and the ultrasonic cleaning time is 15-20 minutes.
Further, the preparation method of the high-strength corrosion-resistant aluminum alloy drill rod comprises the following steps: and (6) supersonic flame thermal spraying: carrying out supersonic flame thermal spraying on the aluminum alloy pipe subjected to ultrasonic cleaning to form a thermal spraying coating; wherein the volume ratio of propane to oxygen is 2:3, the spraying distance is 200-240mm, the spraying powder is Ni60, the particle size of the powder is 10-40 μm, the powder feeding amount is 25-50g/min, and the thickness of the obtained Ni60 coating is 0.3-0.5 mm.
Further, the preparation method of the high-strength corrosion-resistant aluminum alloy drill rod comprises the following steps: step (7) heat treatment: and carrying out T6 heat treatment on the aluminum alloy pipe for forming the thermal spraying coating, wherein the heat treatment temperature is 450-500 ℃, and the heat treatment time is 2-5 hours.
Further, the preparation method of the high-strength corrosion-resistant aluminum alloy drill rod comprises the following steps: and (8) hole sealing treatment: and after the heat treatment, heating the aluminum alloy pipe to the temperature of 100-150 ℃, and then impregnating the aluminum alloy pipe in a phenolic resin solution for 1-2 hours to perform hole sealing, thereby obtaining the high-strength corrosion-resistant aluminum alloy drill pipe.
The preparation method of the high-strength corrosion-resistant aluminum alloy drill rod provided by the invention adopts a method of quickly solidifying and refining grains by using a spray forming technology, so that the grains are effectively refined to prepare a fine grain ingot blank with the average grain diameter of about 10-15 mu m, the grain boundary interface is clear, and precipitates do not exist on the interface; the injection additive manufacturing blank is precisely formed through semi-solid processing, and the high performance of the injection additive manufacturing blank is kept; the Ni60 coating is thermally sprayed on the surface of the aluminum alloy drill rod, the bonding strength, the corrosion resistance and the wear resistance of the coating and an aluminum alloy matrix are good, the coating is applied to the fields of petroleum and exploration, the urgent need of China for the advanced aluminum alloy drill rod can be fundamentally solved, and a new thought and a new method are provided for designing and manufacturing a novel high-performance ultrahigh-strength 7xxx series aluminum alloy structural material.
A high-strength corrosion-resistant aluminum alloy drill pipe is characterized by being prepared by the preparation method. The invention prepares a high-strength corrosion-resistant aluminum alloy drill rod with 600 MPa-level yield strength; the prepared aluminum alloy drill rod has the advantages of high strength (high yield strength and tensile strength), high hardness, salt spray corrosion resistance (obvious corrosion resistance in a salt spray environment) and the like.
The invention has the beneficial effects that:
(1) the invention provides a preparation method of a high-strength corrosion-resistant aluminum alloy drill pipe with 600 MPa-level yield strength, which adopts spray forming and double-acting backward extrusion technologies, wherein the formed aluminum alloy is a seamless pipe, the yield strength and the tensile strength are high, the problems of low elastic modulus and poor rigidity of the conventional aluminum alloy drill pipe are fundamentally solved, and the requirements of ultra-deep well and inclined well drilling on the mechanical properties of the drill pipe are met.
(2) The invention provides a preparation method of a high-strength corrosion-resistant aluminum alloy drill rod with 600 MPa-level yield strength, wherein a high-strength corrosion-resistant protective layer is established on the surface of the aluminum alloy drill rod by utilizing a supersonic flame thermal spraying process, a coating is firmly combined with an aluminum alloy matrix, and the coating is Cl-doped-The drill rod has remarkable corrosion resistance, solves the problem that the existing aluminum alloy drill rod is not resistant to salt corrosion, and prolongs the service life of the aluminum alloy drill rod.
(3) The preparation method of the high-strength corrosion-resistant aluminum alloy drill rod with 600 MPa-level yield strength, provided by the invention, has the advantages of simple process, high production efficiency, environmental friendliness and small environmental pollution, and overcomes the defects of high cost and large environmental pollution of the aluminum alloy drill rod corrosion prevention technology in the prior art.
(4) The high-strength corrosion-resistant aluminum alloy drill pipe prepared by the invention has the advantages of high strength, high hardness, high wear resistance, corrosion resistance and the like, the tensile strength reaches 692MPa, the yield strength reaches 643MPa, the corrosion potential is-0.4V, and the surface hardness is 750 HV.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings needed to be used in the description of the embodiments will be briefly introduced below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art to obtain other drawings based on these drawings without creative efforts.
FIG. 1 is a SEM image of the cross section of a high-strength corrosion-resistant aluminum alloy drill pipe matrix and a Ni60 coating prepared in example 6 of the invention.
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 a part of the embodiments of the present invention, and not all of the embodiments. The following description of at least one exemplary embodiment is merely illustrative in nature and is in no way intended to limit the invention, its application, or uses. 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.
Example 1
A preparation method of a high-strength corrosion-resistant aluminum alloy drill rod comprises the following steps:
(1) refining and pouring the aluminum alloy: refining the 7055 aluminum alloy cast ingot by a vacuum smelting furnace, and removing oxides and impurities in the cast ingot by using aluminum-yttrium alloy as a refining agent; then, rapidly pouring the refined aluminum alloy molten metal into a crucible for spray forming, and preserving heat at 650 ℃ for later use;
(2) and (3) spray forming: the aluminum alloy metal liquid flowing out of the crucible is atomized, sprayed at high pressure, deposited uniformly and solidified quickly by adopting argon gas with the pressure of 2MPa, the deposition rate is 50Kg/h, and a cylindrical aluminum alloy billet with the grain size of 10-15 mu m is formed on the material bearing plate;
(3) double-acting reverse extrusion: heating the aluminum alloy billet subjected to spray forming to 650 ℃ (semi-solid state), and then performing densification treatment and seamless aluminum alloy pipe extrusion forming by adopting a double-acting reverse extrusion process, wherein the extrusion force is 1500MPa, the extrusion ratio is 15, and the extrusion speed is 8 mm/s;
(4) surface pickling and sand blasting: pickling the aluminum alloy pipe by using a pickling solution to remove surface oxide skin, and then performing sand blasting treatment to roughen the surface; wherein the pickling solution is prepared from HCl, HNO3The aluminum alloy pipe is prepared according to the mass ratio of 2:3, and the pickling is stopped when bubbles begin to be generated on the surface of the aluminum alloy pipe; the surface roughness of the aluminum alloy pipe after sand blasting treatment is 3-5 mu m;
(5) ultrasonic cleaning: placing the aluminum alloy pipe with the roughened surface in ethanol for ultrasonic cleaning to remove surface impurities; wherein the ultrasonic frequency is 100Hz, and the ultrasonic cleaning time is 15 minutes;
(6) supersonic flame thermal spraying: carrying out supersonic flame thermal spraying on the aluminum alloy pipe subjected to ultrasonic cleaning to form a thermal spraying coating; during supersonic flame thermal spraying, the volume ratio of propane to oxygen is 2:3, the spraying distance is 240mm, the spraying powder is Ni60, the particle size of the powder is 20 mu m, the powder feeding amount is 50g/min, and the thickness of the obtained Ni60 coating (namely the thermal spraying coating) is 0.4 mm;
(7) and (3) heat treatment: carrying out T6 heat treatment on the aluminum alloy pipe with the thermal spraying coating, wherein the heat treatment temperature is 460 ℃ and the heat treatment time is 2 hours;
(8) hole sealing treatment: and after heat treatment, heating the aluminum alloy pipe with the thermal spraying coating to 150 ℃, and then impregnating the aluminum alloy pipe in a phenolic resin solution for 2 hours to carry out hole sealing, thus obtaining the high-strength corrosion-resistant aluminum alloy drill rod.
Example 2
A preparation method of a high-strength corrosion-resistant aluminum alloy drill rod comprises the following steps:
(1) refining and pouring the aluminum alloy: refining the 7055 aluminum alloy cast ingot by a vacuum smelting furnace, and removing oxides and impurities in the cast ingot by using aluminum-yttrium alloy as a refining agent; then, rapidly pouring the refined aluminum alloy molten metal into a crucible for spray forming, and preserving heat at 650 ℃ for later use;
(2) and (3) spray forming: the aluminum alloy metal liquid flowing out of the crucible is atomized, sprayed at high pressure, deposited uniformly and solidified quickly by adopting argon gas with the pressure of 2MPa, the deposition rate is 50Kg/h, and a cylindrical aluminum alloy billet with the grain size of 10-15 mu m is formed on the material bearing plate;
(3) double-acting reverse extrusion: heating the aluminum alloy billet subjected to spray forming to 650 ℃ (semi-solid state), and then performing densification treatment and seamless aluminum alloy pipe extrusion forming by adopting a double-acting reverse extrusion process, wherein the extrusion force is 2000MPa, the extrusion ratio is 20, and the extrusion speed is 15 mm/s;
(4) surface pickling and sand blasting: pickling the aluminum alloy pipe by using a pickling solution to remove surface oxide skin, and then performing sand blasting treatment to roughen the surface; wherein the pickling solution is prepared from HCl, HNO3The aluminum alloy pipe is prepared according to the mass ratio of 2:3, and the pickling is stopped when bubbles begin to be generated on the surface of the aluminum alloy pipe; the surface roughness of the aluminum alloy pipe after sand blasting treatment is 3-5 mu m;
(5) ultrasonic cleaning: placing the aluminum alloy pipe with the roughened surface in ethanol for ultrasonic cleaning to remove surface impurities; wherein the ultrasonic frequency is 150Hz, and the ultrasonic cleaning time is 15 minutes;
(6) supersonic flame thermal spraying: carrying out supersonic flame thermal spraying on the aluminum alloy pipe subjected to ultrasonic cleaning to form a thermal spraying coating; during supersonic flame thermal spraying, the volume ratio of propane to oxygen is 2:3, the spraying distance is 220mm, the spraying powder is Ni60, the particle size of the powder is 25 mu m, the powder feeding amount is 35g/min, and the thickness of the obtained Ni60 coating (namely the thermal spraying coating) is 0.4 mm;
(7) and (3) heat treatment: carrying out T6 heat treatment on the aluminum alloy pipe with the thermal spraying coating, wherein the heat treatment temperature is 480 ℃ and the heat treatment time is 2 hours;
(8) hole sealing treatment: and after heat treatment, heating the aluminum alloy pipe with the thermal spraying coating to 150 ℃, and then impregnating the aluminum alloy pipe in a phenolic resin solution for 1 hour to carry out hole sealing, thus obtaining the high-strength corrosion-resistant aluminum alloy drill rod.
Example 3
A preparation method of a high-strength corrosion-resistant aluminum alloy drill rod comprises the following steps:
(1) refining and pouring the aluminum alloy: refining the 7075 aluminum alloy cast ingot by a vacuum smelting furnace, and removing oxides and impurities in the cast ingot by using aluminum-yttrium alloy as a refining agent; then, rapidly pouring the refined aluminum alloy molten metal into a crucible for spray forming, and preserving heat at 700 ℃ for later use;
(2) and (3) spray forming: the aluminum alloy metal liquid flowing out of the crucible is atomized, sprayed at high pressure, deposited uniformly and solidified quickly by argon gas with the pressure of 2MPa, the deposition rate is 30Kg/h, and cylindrical aluminum alloy billet with the grain size of 10-15 mu m is formed on the material bearing plate;
(3) double-acting reverse extrusion: heating the aluminum alloy billet subjected to spray forming to 650 ℃ (semi-solid state), and then performing densification treatment and seamless aluminum alloy pipe extrusion forming by adopting a double-acting reverse extrusion process, wherein the extrusion force is 3000MPa, the extrusion ratio is 25, and the extrusion speed is 20 mm/s;
(4) surface pickling and sand blasting: pickling the aluminum alloy pipe by using a pickling solution to remove surface oxide skin, and then performing sand blasting treatment to roughen the surface; wherein the pickling solution is prepared from HCl, HNO3The aluminum alloy pipe is prepared according to the mass ratio of 2:3, and the pickling is stopped when bubbles begin to be generated on the surface of the aluminum alloy pipe; the surface roughness of the aluminum alloy pipe after sand blasting treatment is 3-5 mu m;
(5) ultrasonic cleaning: placing the aluminum alloy pipe with the roughened surface in ethanol for ultrasonic cleaning to remove surface impurities; wherein the ultrasonic frequency is 100Hz, and the ultrasonic cleaning time is 20 minutes;
(6) supersonic flame thermal spraying: carrying out supersonic flame thermal spraying on the aluminum alloy pipe subjected to ultrasonic cleaning to form a thermal spraying coating; during supersonic flame thermal spraying, the volume ratio of propane to oxygen is 2:3, the spraying distance is 200mm, the spraying powder is Ni60, the particle size of the powder is 15 mu m, the powder feeding amount is 25g/min, and the thickness of the obtained Ni60 coating (namely the thermal spraying coating) is 0.3 mm;
(7) and (3) heat treatment: carrying out T6 heat treatment on the aluminum alloy pipe with the thermal spraying coating, wherein the heat treatment temperature is 480 ℃ and the heat treatment time is 3 hours;
(8) hole sealing treatment: and after heat treatment, heating the aluminum alloy pipe forming the thermal spraying coating to 120 ℃, and then impregnating the aluminum alloy pipe in a phenolic resin solution for 1.5 hours to carry out hole sealing, thus obtaining the high-strength corrosion-resistant aluminum alloy drill rod.
Example 4
A preparation method of a high-strength corrosion-resistant aluminum alloy drill rod comprises the following steps:
(1) refining and pouring the aluminum alloy: refining the 7055 aluminum alloy cast ingot by a vacuum smelting furnace, and removing oxides and impurities in the cast ingot by using aluminum-yttrium alloy as a refining agent; then, rapidly pouring the refined aluminum alloy molten metal into a crucible for spray forming, and preserving heat at 750 ℃ for later use;
(2) and (3) spray forming: the aluminum alloy metal liquid flowing out of the crucible is atomized, sprayed at high pressure, deposited uniformly and solidified quickly by argon gas with the pressure of 1MPa, the deposition rate is 20Kg/h, and cylindrical aluminum alloy billet with the grain size of 10-15 mu m is formed on the material bearing plate;
(3) double-acting reverse extrusion: heating the aluminum alloy billet subjected to spray forming to 650 ℃ (semi-solid state), and then performing densification treatment and seamless aluminum alloy pipe extrusion forming by adopting a double-acting reverse extrusion process, wherein the extrusion force is 2000MPa, the extrusion ratio is 15, and the extrusion speed is 20 mm/s;
(4) surface pickling and sand blasting: pickling the aluminum alloy pipe by using a pickling solution to remove surface oxide skin, and then performing sand blasting treatment to roughen the surface; wherein the pickling solution is prepared from HCl, HNO3The aluminum alloy pipe is prepared according to the mass ratio of 2:3, and the pickling is stopped when bubbles begin to be generated on the surface of the aluminum alloy pipe; the surface roughness of the aluminum alloy pipe after sand blasting treatment is 3-5 mu m;
(5) ultrasonic cleaning: placing the aluminum alloy pipe with the roughened surface in ethanol for ultrasonic cleaning to remove surface impurities; wherein the ultrasonic frequency is 200Hz, and the ultrasonic cleaning time is 15 minutes;
(6) supersonic flame thermal spraying: carrying out supersonic flame thermal spraying on the aluminum alloy pipe subjected to ultrasonic cleaning to form a thermal spraying coating; during supersonic flame thermal spraying, the volume ratio of propane to oxygen is 2:3, the spraying distance is 230mm, the spraying powder is Ni60, the particle size of the powder is 40 mu m, the powder feeding amount is 30g/min, and the thickness of the obtained Ni60 coating (namely the thermal spraying coating) is 0.5 mm;
(7) and (3) heat treatment: carrying out T6 heat treatment on the aluminum alloy pipe with the thermal spraying coating, wherein the heat treatment temperature is 500 ℃, and the heat treatment time is 4 hours;
(8) hole sealing treatment: and after heat treatment, heating the aluminum alloy pipe forming the thermal spraying coating to 130 ℃, and then impregnating the aluminum alloy pipe in a phenolic resin solution for 1 hour to carry out hole sealing, thus obtaining the high-strength corrosion-resistant aluminum alloy drill rod.
Example 5
A preparation method of a high-strength corrosion-resistant aluminum alloy drill rod comprises the following steps:
(1) refining and pouring the aluminum alloy: refining the 7055 aluminum alloy cast ingot by a vacuum smelting furnace, and removing oxides and impurities in the cast ingot by using aluminum-yttrium alloy as a refining agent; then, rapidly pouring the refined aluminum alloy molten metal into a crucible for spray forming, and preserving heat at 720 ℃ for later use;
(2) and (3) spray forming: atomizing the aluminum alloy metal liquid flowing out of the crucible by adopting argon gas with the pressure of 1.5MPa, spraying at high pressure, uniformly depositing and quickly solidifying, wherein the deposition rate is 40Kg/h, and a cylindrical aluminum alloy billet with the grain size of 10-15 mu m is formed on the material bearing plate;
(3) double-acting reverse extrusion: heating the aluminum alloy billet subjected to spray forming to 650 ℃ (semi-solid state), and then performing densification treatment and seamless aluminum alloy pipe extrusion forming by adopting a double-acting reverse extrusion process, wherein the extrusion force is 2000MPa, the extrusion ratio is 15, and the extrusion speed is 12 mm/s;
(4) surface pickling and sand blasting: pickling the aluminum alloy pipe by using a pickling solution to remove surface oxide skin, and then performing sand blasting treatment to roughen the surface; wherein the pickling solution is prepared from HCl, HNO3The aluminum alloy pipe is prepared according to the mass ratio of 2:3, and the pickling is stopped when bubbles begin to be generated on the surface of the aluminum alloy pipe; the surface roughness of the aluminum alloy pipe after sand blasting treatment is 3-5 mu m;
(5) ultrasonic cleaning: placing the aluminum alloy pipe with the roughened surface in ethanol for ultrasonic cleaning to remove surface impurities; wherein the ultrasonic frequency is 150Hz, and the ultrasonic cleaning time is 20 minutes;
(6) supersonic flame thermal spraying: carrying out supersonic flame thermal spraying on the aluminum alloy pipe subjected to ultrasonic cleaning to form a thermal spraying coating; during supersonic flame thermal spraying, the volume ratio of propane to oxygen is 2:3, the spraying distance is 210mm, the spraying powder is Ni60, the particle size of the powder is 40 mu m, the powder feeding amount is 45g/min, and the thickness of the obtained Ni60 coating (namely the thermal spraying coating) is 0.4 mm;
(7) and (3) heat treatment: carrying out T6 heat treatment on the aluminum alloy pipe with the thermal spraying coating, wherein the heat treatment temperature is 450 ℃ and the heat treatment time is 5 hours;
(8) hole sealing treatment: and after heat treatment, heating the aluminum alloy pipe forming the thermal spraying coating to 140 ℃, and then impregnating the aluminum alloy pipe in a phenolic resin solution for 1.5 hours to carry out hole sealing, thus obtaining the high-strength corrosion-resistant aluminum alloy drill rod.
Example 6
A preparation method of a high-strength corrosion-resistant aluminum alloy drill rod comprises the following steps:
(1) refining and pouring the aluminum alloy: refining the 7055 aluminum alloy cast ingot by a vacuum smelting furnace, and removing oxides and impurities in the cast ingot by using aluminum-yttrium alloy as a refining agent; then, rapidly pouring the refined aluminum alloy molten metal into a crucible for spray forming, and preserving heat at 650 ℃ for later use;
(2) and (3) spray forming: the aluminum alloy metal liquid flowing out of the crucible is atomized, sprayed at high pressure, deposited uniformly and solidified quickly by adopting argon gas with the pressure of 2MPa, the deposition rate is 50Kg/h, and a cylindrical aluminum alloy billet with the grain size of 10-15 mu m is formed on the material bearing plate;
(3) double-acting reverse extrusion: heating the aluminum alloy billet subjected to spray forming to 650 ℃ (semi-solid state), and then performing densification treatment and seamless aluminum alloy pipe extrusion forming by adopting a double-acting reverse extrusion process, wherein the extrusion force is 2000MPa, the extrusion ratio is 15, and the extrusion speed is 20 mm/s;
(4) surface pickling and sand blasting: pickling the aluminum alloy pipe by using a pickling solution to remove surface oxide skin, and then performing sand blasting treatment to roughen the surface; wherein the pickling solution is prepared from HCl, HNO3Prepared according to the mass ratio of 2:3The pickling time is stopped when bubbles begin to be generated on the surface of the aluminum alloy pipe; the surface roughness of the aluminum alloy pipe after sand blasting treatment is 3-5 mu m;
(5) ultrasonic cleaning: placing the aluminum alloy pipe with the roughened surface in ethanol for ultrasonic cleaning to remove surface impurities; wherein the ultrasonic frequency is 100Hz, and the ultrasonic cleaning time is 15 minutes;
(6) supersonic flame thermal spraying: carrying out supersonic flame thermal spraying on the aluminum alloy pipe subjected to ultrasonic cleaning to form a thermal spraying coating; during supersonic flame thermal spraying, the ratio of propane to oxygen is 2:3, the spraying distance is 240mm, the spraying powder is Ni60, the particle size of the powder is 10 mu m, the powder feeding amount is 50g/min, and the thickness of the obtained Ni60 coating (namely the thermal spraying coating) is 0.4 mm;
(7) and (3) heat treatment: carrying out T6 heat treatment on the aluminum alloy pipe with the thermal spraying coating, wherein the heat treatment temperature is 460 ℃ and the heat treatment time is 2 hours;
(8) hole sealing treatment: and after heat treatment, heating the aluminum alloy pipe with the thermal spraying coating to 150 ℃, and then impregnating the aluminum alloy pipe in a phenolic resin solution for 2 hours to carry out hole sealing, thus obtaining the high-strength corrosion-resistant aluminum alloy drill rod.
And (3) testing: the cross section of the high strength corrosion resistant aluminum alloy drill rod prepared in example 6 was observed by SEM, and the result is shown in fig. 1; as can be seen from figure 1, the high-strength corrosion-resistant aluminum alloy drill rod prepared by the invention has the advantages of uniform coating structure and high density.
The hardness of the high-strength corrosion-resistant aluminum alloy drill rod prepared in the above examples 1 to 6 was tested by using a TI950 nanoindenter, 10 test points at different positions were selected for each sample, and the hardness of the Ni60 thermal spray coating and the hardness of the aluminum alloy drill rod substrate were tested; performing electrochemical test on the high-strength corrosion-resistant aluminum alloy drill pipe prepared in the above examples 1-6 by using an LK1100A type electrochemical workstation, and testing the potential of the thermal spraying layer and the potential of the aluminum alloy drill pipe substrate; the results of the above tests are shown in Table 1.
Table 1 shows the test results of the high-strength corrosion-resistant aluminum alloy drill rods prepared in examples 1 to 6
The test results of the above examples 1-6 show that the high-strength corrosion-resistant aluminum alloy drill pipe prepared by the invention can reach the yield strength of 600 MPa. The preparation method of the invention adopts the method of rapid solidification and refinement of the crystal grains by the spray forming technology, so that the crystal grains are effectively refined to prepare the fine-grain ingot blank with the average grain diameter of about 10-15 mu m, the crystal boundary interface is clear, and no precipitate exists in the interface; the injection additive manufacturing blank is precisely formed through semi-solid processing and the high performance of the injection additive manufacturing blank is maintained; the Ni60 coating is thermally sprayed on the surface of the aluminum alloy drill rod, the bonding strength, the corrosion resistance and the wear resistance of the coating and an aluminum alloy matrix are good, the coating is applied to the fields of petroleum and exploration, the urgent need of China for the advanced aluminum alloy drill rod can be fundamentally solved, and a new thought and a new method are provided for designing and manufacturing a novel high-performance ultrahigh-strength 7xxx series aluminum alloy structural material.
The above-mentioned preferred embodiments of the present invention are provided for illustration only and not for the purpose of limiting the invention. Obvious variations or modifications of the present invention are within the scope of the present invention.
Claims (10)
1. The preparation method of the high-strength corrosion-resistant aluminum alloy drill rod is characterized by comprising the following steps of:
(1) refining and pouring the aluminum alloy: refining the 7xxx series aluminum alloy cast ingot to remove oxides and impurities in the cast ingot; then, quickly pouring the refined aluminum alloy molten metal into a crucible for spray forming and preserving heat;
(2) and (3) spray forming: forming an aluminum alloy billet with fine grains on a material bearing plate by atomizing the aluminum alloy metal liquid in the crucible, spraying the aluminum alloy metal liquid at high pressure, uniformly depositing the aluminum alloy metal liquid and quickly solidifying the aluminum alloy metal liquid;
(3) double-acting reverse extrusion: heating the aluminum alloy billet to be in a semi-solid state, and then performing densification treatment and seamless aluminum alloy pipe extrusion forming by adopting a double-acting reverse extrusion process;
(4) surface pickling and sand blasting: pickling the aluminum alloy pipe to remove surface oxide skin, and then carrying out sand blasting treatment to roughen the surface;
(5) ultrasonic cleaning: carrying out ultrasonic cleaning on the aluminum alloy pipe with the roughened surface to remove surface impurities;
(6) supersonic flame thermal spraying: carrying out supersonic flame thermal spraying on the aluminum alloy pipe subjected to ultrasonic cleaning to form a thermal spraying coating;
(7) and (3) heat treatment: carrying out T6 heat treatment on the aluminum alloy pipe forming the hot spraying coating;
(8) hole sealing treatment: and heating the aluminum alloy pipe after the heat treatment, and then impregnating the aluminum alloy pipe in a resin solution for hole sealing to obtain the high-strength corrosion-resistant aluminum alloy drill rod.
2. The preparation method of the high-strength corrosion-resistant aluminum alloy drill rod as claimed in claim 1, wherein the step (1) of refining and casting the aluminum alloy comprises the following steps: refining the 7xxx series aluminum alloy cast ingot, and removing oxides and impurities in the cast ingot by adopting aluminum-yttrium alloy as a refining agent; then, rapidly pouring the refined aluminum alloy molten metal into crucible equipment for spray forming and preserving heat at 650-750 ℃; wherein the 7xxx series aluminum alloy is 7075 or 7055.
3. The preparation method of the high-strength corrosion-resistant aluminum alloy drill pipe as claimed in claim 1, wherein the step (2) of spray forming: the high-pressure injection adopts 1-2MPa inert gas, the deposition rate is 10-50Kg/h, and the grain diameter of the aluminum alloy billet is 10-15 mu m.
4. The preparation method of the high-strength corrosion-resistant aluminum alloy drill rod as claimed in claim 1, wherein the double-acting backward extrusion process in the step (3): the extrusion temperature is 550-650 ℃, the extrusion pressure is 1500-3000MPa, the extrusion ratio is 15-25, and the extrusion speed is 8-20 mm/s.
5. The preparation method of the high-strength corrosion-resistant aluminum alloy drill pipe as recited in claim 1, wherein the surface is subjected to acid pickling and sand blasting in the step (4): pickling the aluminum alloy pipe by using a pickling solution to remove surface oxide skin, and then performing sand blasting treatment to roughen the surface; wherein the pickling solution is prepared from HCl, HNO3The aluminum alloy pipe is prepared according to the mass ratio of 2:3, and the pickling is stopped when bubbles begin to be generated on the surface of the aluminum alloy pipe; the surface roughness of the aluminum alloy pipe after sand blasting treatment is 3-5 mu m.
6. The preparation method of the high-strength corrosion-resistant aluminum alloy drill rod as claimed in claim 1, wherein the ultrasonic cleaning in the step (5): placing the aluminum alloy pipe in ethanol for ultrasonic cleaning to remove surface impurities; wherein the ultrasonic frequency is 100-200Hz, and the ultrasonic cleaning time is 15-20 minutes.
7. The preparation method of the high-strength corrosion-resistant aluminum alloy drill rod as claimed in claim 1, wherein the supersonic flame thermal spraying in the step (6): carrying out supersonic flame thermal spraying on the aluminum alloy pipe subjected to ultrasonic cleaning to form a thermal spraying coating; wherein the volume ratio of propane to oxygen is 2:3, the spraying distance is 200-240mm, the spraying powder is Ni60, the particle size of the powder is 10-40 μm, the powder feeding amount is 25-50g/min, and the thickness of the obtained Ni60 coating is 0.3-0.5 mm.
8. The preparation method of the high-strength corrosion-resistant aluminum alloy drill rod as claimed in claim 1, wherein the heat treatment in the step (7): and carrying out T6 heat treatment on the aluminum alloy pipe for forming the thermal spraying coating, wherein the heat treatment temperature is 450-500 ℃, and the heat treatment time is 2-5 hours.
9. The preparation method of the high-strength corrosion-resistant aluminum alloy drill rod as claimed in claim 1, wherein the hole sealing treatment in the step (8): and after the heat treatment, heating the aluminum alloy pipe to the temperature of 100-150 ℃, and then impregnating the aluminum alloy pipe in a phenolic resin solution for 1-2 hours to perform hole sealing, thereby obtaining the high-strength corrosion-resistant aluminum alloy drill pipe.
10. A high-strength corrosion-resistant aluminum alloy drill pipe, which is characterized by being prepared by the preparation method of any one of claims 1 to 9.
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