CN114351078B - Plasma arc spraying method using current-carrying wire - Google Patents
Plasma arc spraying method using current-carrying wire Download PDFInfo
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Abstract
The invention discloses a plasma arc spraying method using current-carrying wires, 1, generating an electric arc between a tungsten cathode and an anode wire, and melting the anode wire to form a metal molten drop; 2. guiding a plasma gas through a plasma nozzle to generate a plasma jet; 3. under the synergistic effect of the arc accelerating gas and the pulse current which are coaxial with the anode wire, the metal molten drops are atomized and form fine particles to enter the plasma jet; 4. the compressed air nozzle is arranged at the periphery of the plasma nozzle and concentric with the plasma nozzle and is used for supplying compressed air, and the air flow of the compressed air is converged around the end part of the anode wire to compress and accelerate the plasma jet; 5. the high-speed plasma jet jets fine particles to the surface of the workpiece to form a coating. The method is suitable for manufacturing the wear-resistant and corrosion-resistant coating on the surface of the workpiece, and the anode wire can be selected from solid wires and flux-cored wires. Compared with the traditional method, the coating prepared by the method has the advantages that the porosity is reduced by 50-70%, the interfacial adhesion strength is increased by 20-30%, in addition, the low porosity and high adhesion strength of the coating can be ensured when the spraying thickness is 1mm or more, and the method is suitable for application in the industrial field.
Description
Technical Field
The invention belongs to the technical field of plasma spraying, and particularly relates to a plasma arc spraying method using a current-carrying wire.
Background
Comparison technique 1: plasma wire transfer arc thermal spray system [ patent EP2236211B1, inventor: hauser, A.Schwenk, ford-Wacker Co., ltd., B05B7/22, 2015/37, 9/2015. The plasma wire transfer arc thermal spray system includes a wire feed section (for delivering a first electrode), a plasma source (providing a plasma jet), a nozzle (directing the plasma jet to the wire end), and a second electrode (located at a center of the nozzle). The nozzle is made of an electrically insulating material and comprises a plurality of coaxial holes surrounding a central hole of the nozzle, the coaxial holes being supplied with a secondary gas by a plasma jet provided around the central hole. The nozzle may be made in the form of a laval nozzle. The first and second electrodes are energized with high voltage for generating direct current, alternating current or high frequency current.
The disadvantage of the comparative technique 1 is that the atomization effect of the first electrode wire melting to form droplets cannot be ensured, and the uniform spraying effect of the product surface cannot be ensured.
Comparison technique 2: nanomaterial feedstock for thermal spray systems, method of manufacture, and coatings made thereof [ patent US20030077398A1, inventors: p.r.strutt, b.h.kerr, r.f.boland, C23C4/06, 24 months 2003 ]. The invention proposes a method for producing high quality nanostructured coatings using a liquid suspension of nanoparticles in conventional thermal spraying. The method uses ultrasonic waves to shake up agglomerated particles, uniformly disperses the nano particles in a liquid medium, and performs ultrasonic atomization.
A disadvantage of comparative technique 2 is the need to use a liquid suspension, which limits the ability to apply a functional coating to the working surface of a part by this technique.
Comparison technique 3: wire alloy for plasma transferred wire arc spray process [ patent US20150060413A1, inventors: T.Smith, marle International Inc., B23K10/027, 5/3/2015 ]. Aiming at a plasma wire arc thermal spraying (PTWA) process for preparing a corrosion-resistant coating on the surface of a diesel internal combustion engine cylinder, a stainless steel flux-cored wire is provided, and the flux-cored wire is as follows: metal oxide powder or powder containing 100% chromium carbide.
The disadvantage of comparative technique 3 is that the spray material can only use a flux-cored wire, but not a solid wire.
Comparative technique 4 (prototype technique) is the technique closest in nature to the method described in this patent, and is a high-efficiency thermal spray technique using a plasma wire transfer arc. [ patent US6372298B1, inventors: D.R. Marantz, K.A. Kowalsky, D.J. Cook, L.G. Gargo Global technology Co., ltd., B05B7/224,2002, 4/16). This technique creates a plasma transferred arc between the cathode and the melt electrode wire. The energy of the plasma and the arc melts the wire and forms atomized metal droplets, which are surrounded by an accelerating gas that promotes the plasma to fuse the metal particles to the workpiece surface. The accelerating gas flow is 28-56L/min, acts on the tail end of the melting electrode wire, accelerates the plasma with metal molten drops and completes spraying, and finally prepares a compact metal coating on the surface of the workpiece. The technical system comprises a cathode, a nozzle (sleeved around the cathode, (1) provided with a central hole for providing plasma gas, (2) provided with a plurality of coaxial air holes around the central hole of the nozzle for providing acceleration gas), a wire feeding mechanism (for guiding the melting electrode wire to a plasma arc), a power supply (for burning between the cathode and the melting electrode wire) and the like.
The disadvantage of comparative technique 4 (prototype technique) is that pores are formed when the spray thickness exceeds 1mm and the adhesion strength of the coating to the substrate is not high.
Disclosure of Invention
The invention relates to a plasma arc spraying method using current-carrying wires, which aims to overcome the defects in the prior art, and the method comprises the steps of spraying a wear-resistant and corrosion-resistant coating with the thickness of 1mm or more on the surfaces of parts and structures, ensuring the low porosity and high adhesive strength of the coating, and achieving the purposes by adopting the following technical scheme:
1) The anode wire is fed through the conducting nozzle by means of the wire feeding mechanism, and an electric arc is generated between the tungsten cathode and the anode wire, so that the anode wire is melted to form metal molten drops;
2) Guiding a plasma gas through a plasma nozzle to generate a plasma jet;
3) Providing arc acceleration gas through an arc acceleration nozzle coaxial with the anode wire, atomizing the metal molten drops and forming fine particles to enter a plasma jet under the action of the arc acceleration gas and pulse current;
4) The compressed air nozzle is arranged at the periphery of the plasma nozzle and concentric with the plasma nozzle and is used for supplying compressed air, and the air flow of the compressed air is converged around the end part of the anode wire to compress and accelerate the plasma jet;
5) The high-speed plasma jet jets fine particles to the surface of the workpiece to form a coating.
As a preferable scheme of the invention, the anode wire is a solid wire or a flux-cored wire, the diameter is 0.6-3.0mm, and the wire feeding speed of the wire in the spraying process is 1-20m/min.
As a preferable scheme of the invention, the current between the tungsten cathode and the anode wires is in a two-stage rectangular pulse modulation mode, the frequency is 20-400Hz, the range is 60-600A, the current of the first stage is increased from 60A to 200A, the current of the second stage is increased from 200A to 600A, and the duration of the second stage is shortened by 50% -67% compared with the duration of the first stage.
As a preferable scheme of the invention, the plasma gas is argon, helium or a mixed gas of argon and helium, and the gas flow is 5-50L/min.
In a preferred embodiment of the present invention, the arc accelerating gas is argon gas, helium gas, or a mixed gas of argon gas and helium gas.
As a preferable mode of the invention, the arc accelerating gas is supplied at a pulse frequency of 1-10Hz, the maximum gas flow is 20-60L/min, the minimum gas flow is 2-6L/min, and the ratio of the maximum gas flow to the minimum duration is 1:1.
As a preferable scheme of the invention, water is injected into the arc acceleration gas, and the water flow is 0.03-0.06L/min.
As a preferable mode of the present invention, hydrocarbon gas is added to the arc acceleration gas, the hydrocarbon gas is methane or propane, and the flow rate of the added hydrocarbon gas is not more than 10% of the total flow rate of the arc acceleration gas. .
As a preferable mode of the present invention, hydrogen is added to the arc acceleration gas, and the flow rate of the added hydrogen is not more than 10% of the total flow rate of the arc acceleration gas.
As a preferable scheme of the invention, the compressed air nozzle is positioned around the plasma nozzle and concentric with the plasma nozzle, the included angle between the air outlet direction of the compressed air nozzle and the axis of the plasma nozzle is 5-15 degrees, and the ratio of the air outlet cross section area of the compressed air nozzle to the air outlet cross section area of the plasma nozzle is 5-50.
As a preferable scheme of the invention, the gas flow rate of the compressed air is 300-1300L/min.
As a preferred version of the invention, the compressed air is provided at supersonic speed by a compressed air nozzle concentric with the plasma nozzle and shaped like a laval nozzle.
The invention has the technical effects that:
1. the invention has simple structure and ingenious design, a plasma transfer arc is generated between the cathode and the melting electrode wire, the wire is melted and atomized into metal particles by the energy of the plasma transfer arc, the periphery of the plasma transfer arc is surrounded by compressed air, and the compressed air flow promotes the plasma with metal molten drops to be sprayed onto the surface of a product.
2. Under the combined action of the arc accelerating gas and the pulse current, the anode wire is melted into molten drops and further atomized to a great extent into fine particles, the atomized fine particles are sprayed on the surface of a product to form a coating, so that the low porosity of the coating is ensured, and compared with a prototype method, the method provided by the invention can reduce the porosity of the coating by 50-70%.
3. The compressed air supplied by the compressed air nozzle can effectively compress and accelerate the plasma jet containing atomized metal particles, the jet speed can reach 50-200m/s, the high-speed jet spraying acts on the surface of a product, the adhesion between a coating and the product interface is ensured, and compared with a prototype method, the method provided by the invention can increase the adhesion strength of the coating interface by 20-30%.
4. The wear-resistant and corrosion-resistant coating with the thickness of 1mm or more is sprayed on the surfaces of parts and structures, and the low porosity and high adhesive strength of the coating can still be ensured.
The technical effect makes the method provided by the invention very suitable for application in the industrial field.
Drawings
Fig. 1 is a schematic diagram of a plasma arc spraying method using a current-carrying wire according to the present invention.
FIG. 2 is a schematic illustration of a test verification system of the method of the present invention, 2 a) being a spray booth; 2b) Is a power supply and air supply system with a mobile control panel; 2c) Is a PLAZER-30 plasma accelerator with an anode wire and a wire feed mechanism.
FIG. 3 is a comparison of porosity and interfacial adhesion for a coating of thickness 1mm or less (solid wire: AISI304 stainless steel, diameter. Phi. 1.6 mm) sprayed by the inventive technique and by the prototype technique, wherein FIG. 3a is the coating obtained by the prototype technique and FIG. 3b is the coating obtained by the inventive technique.
FIG. 4 is a comparison of porosity and interfacial adhesion for a coating of > 1mm thickness sprayed by the inventive technique and by the prototype technique (flux core wire: Q235 steel pharmaceutical core wire filled with WC powder, diameter. Phi. 3.0 mm), wherein FIG. 4a is the coating obtained by the prototype technique and FIG. 4b is the coating obtained by the inventive technique.
In the accompanying drawings
1. An anode wire; 2. a contact tip; 3. a tungsten cathode; 4. an arc; 5. a plasma gas; a 6 plasma nozzle; 7, plasma jet; 8. compressed air; 9. a compressed air nozzle; 10. arc accelerating gas; 11. an arc acceleration nozzle; 12. metal droplets; 13. fine particles; 14. a workpiece; 15. and (3) coating.
Detailed Description
The invention aims to spray a wear-resistant and corrosion-resistant coating with a thickness of 1mm and above on the surfaces of parts and structures, and the coating has low porosity and high adhesion strength on the surfaces. The following description of the embodiments of the present invention will be made apparent and fully in view of the accompanying drawings, in which some, but not all embodiments of the invention are shown. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
A plasma arc spraying method using current-carrying wires, as shown in fig. 1, the specific embodiment comprises:
1) The anode wire 1 is fed through the conducting nozzle 2 by a wire feeding mechanism, an electric arc 4 is generated between the tungsten cathode 3 and the anode wire 1, and the anode wire 1 is melted to form a metal molten drop 12;
2) Directing a plasma gas 5 through a plasma nozzle 6 to produce a plasma jet 7;
3) Providing an arc acceleration gas 10 through an arc acceleration nozzle 11 coaxial with the anode wire 1, and atomizing the metal droplets 12 and forming fine particles 13 into the plasma jet 7 under the action of the arc acceleration gas 10 and a pulse current;
4) The compressed air nozzle 9 is arranged at the periphery of the plasma nozzle 6 and concentric with the plasma nozzle, and is used for supplying compressed air 8, and the air flow of the compressed air 8 is converged around the end part of the anode wire 1 to compress and accelerate the plasma jet 7;
5) The high-speed plasma jet 7 sprays fine particles 13 onto the surface of the workpiece 14 to form a coating 15.
Wherein:
the anode wire 1 is a solid wire or a flux-cored wire, the diameter is 0.6-3.0mm, and the wire feeding speed of the anode wire 1 in the spraying process is 1-20m/min.
The current between the tungsten cathode 3 and the anode wire 1 is in a two-stage rectangular pulse modulation mode, the frequency is 20-400Hz, the range is 60-600A, the first-stage pulse current is increased from 60A to 200A, the second-stage pulse current is increased from 200A to 600A, and the duration of the second-stage pulse current is shortened by 50% -67% compared with the duration of the first-stage pulse current.
The plasma gas 5 is argon or helium or a mixed gas of argon and helium, and the gas flow is 5-50L/min.
The arc accelerating gas 10 is argon gas, helium gas, or a mixed gas of argon gas and helium gas.
The arc accelerating gas 10 is supplied at a pulse frequency of 1-10Hz, with a gas flow maximum of 20-60L/min, a gas flow minimum of 2-6L/min, and a ratio of gas flow maximum to minimum duration of 1:1.
Water can be selectively injected into the arc accelerating gas 10, and the water flow is 0.03-0.06L/min.
Optionally, hydrocarbon gas, either methane or propane, may be added to the arc acceleration gas 10 at a flow rate not exceeding 10% of the total flow rate of the arc acceleration gas. .
Optionally, hydrogen is added to the arc acceleration gas 10 at a flow rate not exceeding 10% of the total flow rate of the arc acceleration gas.
The compressed air nozzle 9 is positioned around the plasma nozzle 6 and concentric with the plasma nozzle 6, the included angle between the air outlet direction of the compressed air nozzle and the axis of the plasma nozzle is 5-15 degrees, and the ratio of the air outlet cross-sectional area of the compressed air nozzle to the air outlet cross-sectional area of the plasma nozzle is 5-50.
The gas flow rate of the compressed air 8 is 300-1300L/min.
Compressed air 8 is provided at supersonic speed by a compressed air nozzle 9 concentric with plasma nozzle 6 and shaped like a laval nozzle.
To test the effectiveness of the proposed method, a laboratory system as shown in fig. 2 was created, which includes: a spray booth (fig. 2 a), a power and gas supply system with a moving control panel (operating current no more than 600A, voltage no more than 80V, plasma gas consumption no more than 50L/min) (fig. 2 b), a PLAZER-30 plasma accelerator with anode wire and wire feed mechanism (fig. 2 c).
In the experiment, a solid wire and a flux-cored wire are adopted, wherein the solid wire is an AISI304 type stainless steel welding wire with the diameter phi of 1.6mm, and the flux-cored wire is a Q235 steel pharmaceutical core wire filled with WC powder with the diameter phi of 3.0 mm. The spray substrate used a Q235 steel plate of 100X 10mm in size, and was subjected to shot peening prior to spraying. The prototype method and the method of the invention are adopted for spraying.
The prototype method comprises the following steps: the current for generating the electric arc is 200-250A direct current and the voltage is 40V, and the flow rate of argon coaxially supplied to the anode wire is 40L/min.
The method comprises the following steps: the current to generate the arc is a bipolar pulse current of frequency 250Hz and duration 3ms, with the first stage current increasing from 60A to 200A in 2ms and the second stage current increasing from 200A to 600A in 1 ms. The gas supplied to the anode wire was argon with 10% methane added, which was supplied in pulses at a frequency of 5Hz at a flow rate of 5-50L/min.
The quality of the sprayed coating was detected by: 1) Visual appearance; 2) The porosity of the coating was determined by radiography; 3) The adhesion strength of the sprayed coating was tested by using a pin technique, which opens a hole in the surface of the sprayed substrate, inserts a pin before spraying, and pulls out the pin after spraying, and the adhesion strength was determined according to the magnitude of the pin pulling force.
FIG. 3 is a comparison of porosity and interfacial adhesion for a coating of thickness 1mm or less (solid wire: AISI304 stainless steel, diameter. Phi. 1.6 mm) sprayed by the inventive technique and by the prototype technique, wherein FIG. 3a is the coating obtained by the prototype technique and FIG. 3b is the coating obtained by the inventive technique. Through test analysis, the coating obtained according to the prototype method is found to have a porosity of 4-6% and an interfacial adhesion strength of 40-50MPa. The coating obtained by spraying the technology has the porosity of 1-2% and the interfacial adhesion strength of 60-70MPa.
FIG. 4 is a comparison of porosity and interfacial adhesion for a coating of > 1mm thickness sprayed by the inventive technique and by the prototype technique (flux core wire: Q235 steel pharmaceutical core wire filled with WC powder, diameter. Phi. 3.0 mm), wherein FIG. 4a is the coating obtained by the prototype technique and FIG. 4b is the coating obtained by the inventive technique. Through test analysis, the coating obtained according to the prototype method has the porosity of 3-5% and the interfacial adhesion strength of about 40MPa. The coating obtained by the technology has the porosity of 1-2% and the interfacial adhesion strength of about 60MPa.
When coating with a thickness of > 1mm is applied by the prototype method (for example, coating with a thickness of 4mm is applied by AISI304 wire), the coating is peeled off from the substrate, whereas when coating with a thickness of > 1mm is applied by the method according to the invention, the coating is well bonded to the substrate.
Based on the demonstration, compared with a prototype method, the method provided by the invention can reduce the porosity of the coating obtained by spraying by 50-70%, and the interfacial adhesion strength is increased by 20-30%, so that the spraying method provided by the invention is more suitable for meeting the industrial application requirements.
In the description of the present invention, it should be noted that, unless explicitly specified and limited otherwise, the terms "mounted," "connected," and "connected" are to be construed broadly, and may be either fixedly connected, detachably connected, or integrally connected, for example; can be mechanically or electrically connected; can be directly connected or indirectly connected through an intermediate medium, and can be communication between two elements. The specific meaning of the above terms in the present invention will be understood in specific cases by those of ordinary skill in the art.
The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention; thus, the present invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
Claims (5)
1. A plasma arc spraying method using current-carrying wires, characterized in that:
1) the anode wire (1) is fed through the conducting nozzle (2) by a wire feeding mechanism, an electric arc (4) is generated between the tungsten cathode (3) and the anode wire (1), and the anode wire (1) is melted to form a metal molten drop (12);
2) Directing a plasma gas (5) through a plasma nozzle (6) to produce a plasma jet (7);
3) Providing an arc acceleration gas (10) through an arc acceleration nozzle (11) coaxial with the anode wire (1), and atomizing metal droplets (12) and forming fine particles (13) to enter a plasma jet (7) under the action of the arc acceleration gas (10) and pulse current;
4) The compressed air nozzle (9) is arranged at the periphery of the plasma nozzle (6) and concentric with the plasma nozzle, and is used for supplying compressed air (8), and the air flow of the compressed air (8) is converged around the anode wire (1) to compress and accelerate the plasma jet (7);
5) The high-speed plasma jet (7) sprays fine particles (13) onto the surface of a workpiece (14) to form a coating (15);
the compressed air nozzle (9) is positioned around the plasma nozzle (6) and is concentric with the plasma nozzle (6), the included angle between the air outlet direction of the compressed air nozzle (9) and the axis of the plasma nozzle (6) is 5-15 degrees, and the ratio of the air outlet cross section area of the compressed air nozzle (9) to the air outlet cross section area of the plasma nozzle (6) is 5-50; the anode wire (1) is a solid wire or a flux-cored wire, the diameter is 0.6-3.0mm, and the wire feeding speed of the anode wire (1) in the spraying process is 1-20m/min; the current between the tungsten cathode (3) and the anode wire (1) is in a two-stage rectangular pulse modulation mode, the frequency is 20-400Hz, the range is 60-600A, the first-stage current is increased from 60A to 200A, the second-stage current is increased from 200A to 600A, and the duration of the second stage is shortened by 50% -67% compared with the duration of the first stage; the plasma gas (5) is argon or helium or a mixed gas of argon and helium, and the gas flow is 5-50L/min; the arc accelerating gas (10) is argon, helium or a mixed gas of argon and helium; the arc accelerating gas (10) is supplied at a pulse frequency of 1-10Hz, the maximum gas flow is 20-60L/min, the minimum gas flow is 2-6L/min, and the ratio of the maximum gas flow to the minimum duration is 1:1; the gas flow rate of the compressed air (8) is 300-1300L/min.
2. A plasma arc spraying method using a current carrying wire according to claim 1, wherein: water is injected into the arc acceleration gas (10), and the water flow is 0.03-0.06L/min.
3. A plasma arc spraying method using a current carrying wire according to claim 1, wherein: hydrocarbon gas is added to the arc acceleration gas (10), wherein the hydrocarbon gas is methane or propane, and the flow rate of the added hydrocarbon gas is not more than 10% of the total flow rate of the arc acceleration gas (10).
4. A plasma arc spraying method using a current carrying wire according to claim 1, wherein: hydrogen is added to the arc acceleration gas (10) at a flow rate not exceeding 10% of the total flow rate of the arc acceleration gas (10).
5. A plasma arc spraying method using a current carrying wire according to claim 1, wherein: the compressed air (8) is provided at supersonic speed by a compressed air nozzle (9) concentric with the plasma nozzle (6) and shaped like a laval nozzle.
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Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN101440468A (en) * | 2008-12-23 | 2009-05-27 | 上海气焊机厂有限公司 | Method for spraying welder composite coating |
| JP2015063709A (en) * | 2013-09-24 | 2015-04-09 | トヨタ自動車株式会社 | Film deposition method for iron-based spray coating film, and iron-based spray coating film coated member |
| CN107904543A (en) * | 2017-10-23 | 2018-04-13 | 中国人民解放军陆军装甲兵学院 | High densification copper alloy coating and preparation method thereof |
| CN108624837A (en) * | 2018-04-16 | 2018-10-09 | 北京工业大学 | A kind of coating production improving Rail Surface anti-corrosion conductive capability |
| CN113145855A (en) * | 2021-02-24 | 2021-07-23 | 山东大学 | Device and method for preparing high-melting-point alloy powder by electric arc |
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2021
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Patent Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN101440468A (en) * | 2008-12-23 | 2009-05-27 | 上海气焊机厂有限公司 | Method for spraying welder composite coating |
| JP2015063709A (en) * | 2013-09-24 | 2015-04-09 | トヨタ自動車株式会社 | Film deposition method for iron-based spray coating film, and iron-based spray coating film coated member |
| CN107904543A (en) * | 2017-10-23 | 2018-04-13 | 中国人民解放军陆军装甲兵学院 | High densification copper alloy coating and preparation method thereof |
| CN108624837A (en) * | 2018-04-16 | 2018-10-09 | 北京工业大学 | A kind of coating production improving Rail Surface anti-corrosion conductive capability |
| CN113145855A (en) * | 2021-02-24 | 2021-07-23 | 山东大学 | Device and method for preparing high-melting-point alloy powder by electric arc |
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| CN114351078A (en) | 2022-04-15 |
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