CN114402085A - 金属基材涂布用混合物 - Google Patents
金属基材涂布用混合物 Download PDFInfo
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- CN114402085A CN114402085A CN202080058318.9A CN202080058318A CN114402085A CN 114402085 A CN114402085 A CN 114402085A CN 202080058318 A CN202080058318 A CN 202080058318A CN 114402085 A CN114402085 A CN 114402085A
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- Prior art keywords
- mixture
- metal substrate
- clay
- silicate
- oxide ceramic
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- 239000000203 mixture Substances 0.000 title claims abstract description 177
- 229910052751 metal Inorganic materials 0.000 title claims abstract description 103
- 239000002184 metal Substances 0.000 title claims abstract description 103
- 239000000758 substrate Substances 0.000 title claims abstract description 102
- 239000011248 coating agent Substances 0.000 title claims abstract description 41
- 238000000576 coating method Methods 0.000 title claims abstract description 41
- 229910052574 oxide ceramic Inorganic materials 0.000 claims abstract description 42
- 229910001579 aluminosilicate mineral Inorganic materials 0.000 claims abstract description 41
- 230000015572 biosynthetic process Effects 0.000 claims abstract description 41
- 229910052910 alkali metal silicate Inorganic materials 0.000 claims abstract description 40
- 239000011521 glass Substances 0.000 claims abstract description 39
- 239000004927 clay Substances 0.000 claims abstract description 34
- 238000000034 method Methods 0.000 claims description 33
- 239000002002 slurry Substances 0.000 claims description 22
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 21
- 239000006254 rheological additive Substances 0.000 claims description 13
- 239000004111 Potassium silicate Substances 0.000 claims description 5
- 229910052913 potassium silicate Inorganic materials 0.000 claims description 5
- NNHHDJVEYQHLHG-UHFFFAOYSA-N potassium silicate Chemical compound [K+].[K+].[O-][Si]([O-])=O NNHHDJVEYQHLHG-UHFFFAOYSA-N 0.000 claims description 5
- 235000019353 potassium silicate Nutrition 0.000 claims description 5
- 239000004115 Sodium Silicate Substances 0.000 claims description 4
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 4
- 229910052911 sodium silicate Inorganic materials 0.000 claims description 4
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 claims description 4
- GFQYVLUOOAAOGM-UHFFFAOYSA-N zirconium(iv) silicate Chemical compound [Zr+4].[O-][Si]([O-])([O-])[O-] GFQYVLUOOAAOGM-UHFFFAOYSA-N 0.000 claims description 4
- PAZHGORSDKKUPI-UHFFFAOYSA-N lithium metasilicate Chemical compound [Li+].[Li+].[O-][Si]([O-])=O PAZHGORSDKKUPI-UHFFFAOYSA-N 0.000 claims description 3
- 229910052912 lithium silicate Inorganic materials 0.000 claims description 3
- 239000000126 substance Substances 0.000 claims description 3
- 239000010427 ball clay Substances 0.000 claims description 2
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 claims description 2
- 239000010445 mica Substances 0.000 claims description 2
- 229910052618 mica group Inorganic materials 0.000 claims description 2
- 230000004888 barrier function Effects 0.000 description 31
- 230000008569 process Effects 0.000 description 12
- 238000003303 reheating Methods 0.000 description 11
- 229910000831 Steel Inorganic materials 0.000 description 8
- 239000010959 steel Substances 0.000 description 8
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 6
- 238000010438 heat treatment Methods 0.000 description 6
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N Iron oxide Chemical compound [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 4
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 4
- 239000000416 hydrocolloid Substances 0.000 description 4
- 229910052760 oxygen Inorganic materials 0.000 description 4
- 239000001301 oxygen Substances 0.000 description 4
- 238000005507 spraying Methods 0.000 description 4
- 230000004927 fusion Effects 0.000 description 3
- 238000005098 hot rolling Methods 0.000 description 3
- 229910052742 iron Inorganic materials 0.000 description 3
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 2
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- 239000011230 binding agent Substances 0.000 description 2
- 230000008859 change Effects 0.000 description 2
- 239000007795 chemical reaction product Substances 0.000 description 2
- 238000009472 formulation Methods 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 229920002545 silicone oil Polymers 0.000 description 2
- 229920001285 xanthan gum Polymers 0.000 description 2
- 229940082509 xanthan gum Drugs 0.000 description 2
- 235000010493 xanthan gum Nutrition 0.000 description 2
- 239000000230 xanthan gum Substances 0.000 description 2
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 description 1
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
- 229910000323 aluminium silicate Inorganic materials 0.000 description 1
- 238000000498 ball milling Methods 0.000 description 1
- 230000001680 brushing effect Effects 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 229910002092 carbon dioxide Inorganic materials 0.000 description 1
- 239000001569 carbon dioxide Substances 0.000 description 1
- 238000005266 casting Methods 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000009749 continuous casting Methods 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 238000007598 dipping method Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000007590 electrostatic spraying Methods 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 238000005242 forging Methods 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 229920000876 geopolymer Polymers 0.000 description 1
- 229910052500 inorganic mineral Inorganic materials 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 239000011707 mineral Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 239000000047 product Substances 0.000 description 1
- 238000004064 recycling Methods 0.000 description 1
- -1 steel substrates) Chemical compound 0.000 description 1
- 239000010936 titanium Substances 0.000 description 1
- 229910052719 titanium Inorganic materials 0.000 description 1
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
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- C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
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- C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
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Abstract
一种用于涂布金属基材以防止或限制氧化皮形成的混合物。该混合物包含20至90重量%的以下中的至少一种:氧化物陶瓷材料、铝硅酸盐矿物或玻璃料。所述混合物进一步包含1至20重量%的粘土和3至70重量%的碱金属硅酸盐。
Description
技术领域
本发明的实施例涉及涂布金属基材以防止或限制氧化皮形成的混合物,以及防止或限制金属基材上氧化皮形成的方法。
背景技术
成型工艺(例如热轧)将固化的金属基材(例如板坯、钢坯或铸锭)转化为可用于制造工业和建筑行业的产品。这种成型工艺在大约1200℃或更高的温度下进行。这需要使用再加热炉将金属基材加热到所需温度。在一些情况下,金属基材在重新加热之前可能处于环境温度。或者,在连续铸造操作中,金属基材在再加热之前可能已经很热,例如在大约800℃。
在再加热过程中,在一些金属基材的表面上,例如在包含铁的金属基材(如钢基材)上,由于金属中的铁氧化为氧化铁,形成了含量明显的氧化皮。在所述成型工艺之前和期间,必须例如,通过高压喷射水流基本上去除氧化皮,从而保持金属的质量。
氧化皮的形成及其随后的去除会导致金属(例如钢)损耗,这在金属工业中是一个重大问题。表面积较大的金属基材的再加热尤其如此。
因此需要减少或防止金属基材再加热期间氧化皮的形成。除非另外说明,否则本说明书中提到的所有比例均以占总组成重量的百分数(%)表示。
发明内容
根据本发明的各种但非全部实例,提供一种用于涂布金属基材以防止或限制氧化皮形成的混合物,其中所述混合物包含:
20至90重量%的以下中的至少一种:氧化物陶瓷材料、铝硅酸盐矿物或玻璃料;所述混合物进一步包含:
1至20重量%的粘土;和
3至70重量%的碱金属硅酸盐。
氧化物陶瓷材料可包括氧化铝或硅酸锆。铝硅酸盐矿物可包括云母。
碱金属硅酸盐可包括以下中的任何一种:硅酸钠、硅酸钾或硅酸锂。粘土可以包括瓷土或球粘土。
混合物可包含30至85重量%的以下中的至少一种:氧化物陶瓷材料、铝硅酸盐矿物或玻璃料,可包含35至80重量%的以下中的至少一种:氧化物陶瓷材料、铝硅酸盐矿物或玻璃料。
混合物可包含3至18重量%的粘土,可包含5至17重量%的粘土。
混合物可包含5至60重量%的碱金属硅酸盐,可包含6至55重量%的碱金属硅酸盐。
混合物可以包含流变改性剂。流变改性剂可包括水胶体(hydrocolloid),或可包括胶。胶可以包括黄原胶。混合物可以包含0.1重量%至1.0重量%的流变改性剂,可以包含0.1重量%至0.8重量%的流变改性剂,可以包含0.2重量%至0.5重量%的流变改性剂。
混合物可以包含水。
玻璃料可以包含多种不同的玻璃料,其中每种玻璃料具有不同的化学组成。每种玻璃料可以具有不同的软化点。玻璃料可包含2至5种不同的玻璃料。玻璃料可包含硅酸盐玻璃料。
根据本发明的各种但非全部实例,提供一种用于涂布金属基材以防止或限制氧化皮形成的混合物,其中所述混合物包含:
氧化物陶瓷材料;
粘土;和
碱金属硅酸盐。
根据本发明的各种但非全部实例,提供一种用于涂布金属基材以防止或限制氧化皮形成的混合物,其中所述混合物包含:
铝硅酸盐矿物;
粘土;和
碱金属硅酸盐。
根据本发明的各种但非全部实例,提供一种用于涂布金属基材以防止或限制氧化皮形成的混合物,其中所述混合物包含:
玻璃料;
粘土;和
碱金属硅酸盐。
根据本发明的各种但非全部实例,提供一种用于涂布金属基材以防止或限制氧化皮形成的混合物,其中所述混合物包含:
氧化物陶瓷材料;
铝硅酸盐矿物;
粘土;和
碱金属硅酸盐。
根据本发明的各种但非全部实例,提供一种用于涂布金属基材以防止或限制氧化皮形成的混合物,其中所述混合物包含:
氧化物陶瓷材料;
玻璃料;
粘土;和
碱金属硅酸盐。
根据本发明的各种但非全部实例,提供一种用于涂布金属基材以防止或限制氧化皮形成的混合物,其中所述混合物包含:
铝硅酸盐矿物;
玻璃料;
粘土;和
碱金属硅酸盐。
根据本发明的各种但非全部实例,提供一种用于涂布金属基材以防止或限制氧化皮形成的混合物,其中所述混合物包含:
氧化物陶瓷材料;
铝硅酸盐矿物;
玻璃料;
粘土;和
碱金属硅酸盐。
根据本发明的各种但非全部实例,提供一种用于涂布金属基材以防止或限制氧化皮形成的浆料,其中所述浆料包含悬浮在水中的混合物,所述混合物包含:
20至90重量%的以下中的至少一种:氧化物陶瓷材料、铝硅酸盐矿物或玻璃料;所述混合物进一步包含:
1至20重量%的粘土;和
3至70重量%的碱金属硅酸盐。
浆料相对于水的密度为1.2至2.2,相对于水的密度为1.5至2。
根据本发明的各种但非全部实例,提供一种屏障以防止或限制金属基材上氧化皮的形成,其中所述屏障是包含以下的混合物的反应产物:
20至90重量%的以下中的至少一种:氧化物陶瓷材料、铝硅酸盐矿物或玻璃料;所述混合物进一步包含:
1至20重量%的粘土;和
3至70重量%的碱金属硅酸盐。
根据本发明的各种但非全部实例,提供一种防止或限制金属基材上氧化皮形成的方法,其中所述方法包括:
采用混合物涂布金属基材;
其中所述混合物包含:20至90重量%的以下中的至少一种:氧化物陶瓷材料、铝硅酸盐矿物或玻璃料;所述混合物进一步包含:1至20重量%的粘土;和3至70重量%的碱金属硅酸盐。
所述方法可以包括采用混合物涂布金属基材,以提供平均厚度为100μm至400μm的层,或平均厚度为200μm至400μm的层,或平均厚度为250μm至300μm的层。
所述方法可以包括通过手动或自动工艺采用混合物涂布金属基材。所述方法可以包括将由混合物形成的浆料喷涂到金属基材上。
或者,所述方法可以包括将混合物通过静电喷涂施加到金属基材上。在这种情况下,根据本发明实例所述的混合物可以包含大约0.5重量%的硅油。
所述方法可以包括当金属基材的温度在环境温度至大约1300℃之间的任何温度时,优选当金属基材的温度在环境温度至大约800℃之间的任何温度时,采用混合物涂布金属基材。例如,环境温度可以在0℃和50℃之间。混合物可以处于环境温度。
在一些实例中,不管金属基材的温度是多少,在施加所述混合物之后,施加到金属基材上的涂层马上开始形成屏障,从而限制或防止氧化皮的形成。在其他实例中,施加到金属基材上的涂层可在高温下,例如,500℃以上,或者可能是800℃以上,或者900℃以上(取决于混合物的组成)开始形成屏障,从而限制或防止氧化皮形成。
根据本发明的各种但非全部实例,可以提供如所附权利要求书所要求保护的实例。
具体实施方式
为了更好地理解有助于理解具体实施方式的各种实例,现在将仅通过参考示例的方式进行说明。
本发明的实例提供一种用于涂布金属基材以防止或限制氧化皮形成的混合物。所述混合物包含20至90重量%的以下中的至少一种:氧化物陶瓷材料、铝硅酸盐矿物或玻璃料。
因此,示例性混合物包含氧化物陶瓷材料和/或铝硅酸盐矿物和/或玻璃料。
因此,示例性混合物可以包含以下中的任何一种:
氧化物陶瓷材料;或
铝硅酸盐矿物;或
玻璃料;或
氧化物陶瓷材料和铝硅酸盐矿物;或
氧化物陶瓷材料和玻璃料;或
铝硅酸盐矿物和玻璃料;或
氧化物陶瓷材料、铝硅酸盐矿物和玻璃料。
所述混合物进一步包含1至20重量%的粘土;和3至70重量%的碱金属硅酸盐。
在所示实例中,金属基材是钢。在其他实例中,基材可以是不同的金属,例如包含镍或钛的基材。
下表1提供了本发明的实例。
表1
如表1中详细所述,在一些实例(例如实例1和2)中,混合物包含氧化物陶瓷材料和铝硅酸盐矿物。在这些实例中,氧化物陶瓷材料可包括氧化铝或硅酸锆。
在一些实例中,其中混合物包含氧化物陶瓷材料和铝硅酸盐矿物,混合物包含20至60重量%的氧化物陶瓷材料。优选地,混合物包含25至55重量%的氧化物陶瓷材料。最优选地,混合物包含30至50重量%的氧化物陶瓷材料。
在一些实例中,其中混合物包含氧化物陶瓷材料和铝硅酸盐矿物,混合物包含3至20重量%的铝硅酸盐矿物。优选地,混合物包含5至15重量%的铝硅酸盐矿物。最优选地,混合物包含6至13重量%的铝硅酸盐矿物。
如表1中详细所述,在一些实例(例如实例3)中,混合物包含玻璃料。
在一些实例中,其中混合物包含玻璃料(例如替代氧化物陶瓷材料和铝硅酸盐矿物),混合物包含40至90重量%的玻璃料。优选地,混合物包含60至90重量%的玻璃料。最优选地,混合物包含65至85重量%的玻璃料。
在一些实例中,不需要氧化物陶瓷材料,例如氧化铝或硅酸锆,以及铝硅酸盐矿物,因为所选玻璃料固有地具有玻璃态结构,并且包含铝硅酸盐。因此在一些实例中不需要单独的耐火元素。但是,在其他实例中,除了玻璃料之外,混合物还可以包含氧化物陶瓷材料和/或铝硅酸盐矿物。
在一些实例中,玻璃料包含多种不同的玻璃料,其中每种玻璃料具有不同的化学组成。玻璃料可包含2至5种不同的玻璃料。例如通过湿法或干法球磨,将玻璃料研磨至平均直径小于75μm。
在一些实例中,不管金属基材的温度是多少,在施加所述混合物之后,施加到金属基材上的涂层马上开始形成屏障,从而限制或防止氧化皮的形成。在其他实例中,施加到金属基材上的涂层可在高温下,例如,500℃以上,或者可能是800℃以上,或者900℃以上(取决于混合物的组成)开始形成屏障,从而限制或防止氧化皮形成。
在本发明的实例中,涂层的结晶相和无定形相可以在加热过程中改变,形成屏障以阻止或限制氧化皮形成。混合物的各组分之间也可能存在一定程度的融合。
在包含氧化物陶瓷材料和/或铝硅酸盐矿物的实例中,这些组分可以充当耐火元素。鉴于这些耐火元素在碱金属硅酸盐软化时随机分散,由涂层形成的屏障可能是不均匀的材料。
在包含多种不同玻璃料的实例中,在形成屏障期间,每种玻璃料具有不同的软化点,各种玻璃料在其相应的软化点开始软化,因此玻璃料在较长的时间内软化。在此过程中,尚未软化或仅部分软化的玻璃料可能会在一定程度上溶解到已经软化的玻璃料中,并且混合物的各组分之间可能存在一定程度的融合。
粘土和碱金属硅酸盐
通过组合粘土和碱金属硅酸盐提供了一种矿物基粘合剂体系,它将涂层熔合到金属基材的表面上,特别是当待涂布混合物的金属基材已经处于高温下时,例如高于环境温度,例如高于大约100℃时。在不受理论束缚下,在高温下,粘土和碱金属硅酸盐可在火山灰反应中形成地质聚合物。碱金属硅酸盐可以是,例如硅酸钠、硅酸钾或硅酸锂。硅酸钠和硅酸钾是水溶性的,因此在本发明的一些实例中优选使用。
在本发明的实例中,混合物包含1至20重量%的粘土。优选地,混合物包含3至18重量%的粘土。最优选地,混合物包含5至17重量%的粘土。
在本发明的实例中,混合物包含3至70重量%的碱金属硅酸盐。优选地,混合物包含5至60重量%的碱金属硅酸盐。最优选地,混合物包含6至55重量%的碱金属硅酸盐。
在一些实例中,其中混合物包含氧化物陶瓷材料和铝硅酸盐矿物(例如实例1和实例2),混合物包含1至15重量%的粘土。优选地,混合物包含4至13重量%的粘土。最优选地,混合物包含5至12重量%的粘土。
在一些实例中,其中混合物包含氧化物陶瓷材料和铝硅酸盐矿物(例如实例1和实例2),混合物包含20至70重量%的碱金属硅酸盐。优选地,混合物包含25至60重量%的碱金属硅酸盐。最优选地,混合物包含30至55重量%的碱金属硅酸盐。
在一些实例中,其中混合物包含氧化物陶瓷材料和/或硅铝酸盐矿物,碱金属硅酸盐也可有助于形成屏障以防止或限制氧化皮形成。
在一些实例中,其中混合物包含玻璃料(例如替代氧化物陶瓷材料和铝硅酸盐矿物,例如实例3),碱金属硅酸盐(在所述实例中为硅酸钾)主要作为粘合剂(与粘土一起)添加,并且被认为对防止或限制氧化皮形成的屏障的形成没有明显的作用。因此,在其中混合物包含玻璃料替代氧化物陶瓷材料和铝硅酸盐矿物的实例(例如实例3)中,碱金属硅酸盐的含量显著降低。
在一些实例中,其中混合物包含玻璃料(例如替代氧化物陶瓷材料和铝硅酸盐矿物,例如实例3)的一些实例中,混合物包含1至25重量%的粘土。优选地,混合物包含5至25重量%的粘土。最优选地,混合物包含10至20重量%的粘土。
在一些实例中,其中混合物包含玻璃料(例如替代氧化物陶瓷材料和铝硅酸盐矿物,例如实例3)的一些实例中,混合物包含1至20重量%的碱金属硅酸盐。优选地,混合物包含3至20重量%的碱金属硅酸盐。最优选地,混合物包含5至15重量%的碱金属硅酸盐。
流变改性剂
在一些实例中,混合物包含流变改性剂,例如水胶体制剂或胶。合适的水胶体制剂包括Peptapon。用于在低温例如环境温度下涂布金属基材的混合物包含流变改性剂,从而提供由混合物形成的浆料所需的流动行为。
所述胶可以包括黄原胶。在包含流变改性剂的实例中,混合物包含0.1重量%至1.0重量%的流变改性剂。优选地,混合物包含0.1至0.8重量%的流变改性剂。最优选地,混合物包含0.2至0.5重量%的流变改性剂。
本发明的实例还提供一种用于涂布金属基材的浆料。浆料包含悬浮在水中的根据本发明实例所述的混合物。在一些实例中,浆料包含15至65重量%的水,混合物中各组分的相对含量(例如,如表1实例中所列的)相应地按比例调整。优选地,浆料包含20至55重量%的水。
在一些实例中,浆料相对水的密度为1.2至2.2。优选地,浆料相对水的密度为1.5至2。例如,由表1实例1的混合物形成的浆料相对水的密度为1.9。在表1的实例1中,浆料包含30重量%的水,其余各组分的含量相应地按比例调整。
本发明实例所述的浆料可以通过将混合物机械地分散到水中形成,例如使用高剪切混合器。在包含玻璃料的实例中,玻璃料可以是经湿法或干法球磨(至所需尺寸)的玻璃料。在一些实例中,混合物的各组分可以一起湿磨或干磨。
本发明的实例还提供防止或限制金属基材上形成氧化皮的屏障。屏障与金属基材结合。屏障是根据本发明实例所述混合物的反应产物。
在一些实例中,不管金属基材的温度是多少,在施加所述混合物之后,施加到金属基材上的涂层马上开始形成屏障,从而限制或防止氧化皮的形成。在其他实例中,施加到金属基材上的涂层可在高温下,例如,500℃以上,或者可能是800℃以上,或者900℃以上(取决于混合物的组成)开始形成屏障,从而限制或防止氧化皮形成。
在本发明的实例中,涂层的结晶相和无定形相可以在加热过程中改变,形成阻止或限制氧化皮形成的屏障。混合物的各组分之间也可能存在一定程度的融合。
因此,当金属基材被加热时,例如,加热到大约1200℃(或在某些情况下大约1300℃)的温度时,形成了屏障。屏障可以具有玻璃态结构。屏障可以是陶瓷质的。
本发明的实例还提供防止或限制金属基材上氧化皮形成的方法。所述方法包括采用根据本发明实例所述混合物涂布金属基材。
当金属基材被加热时,通常会在金属基材上形成氧化皮。在一些实例中,金属基材在成型工艺期间被重新加热,即基材在例如金属基材成型之前已经被加热至少一次。因此,本发明的实例还提供防止或限制金属基材在加热或再加热期间在金属基材上形成氧化皮的方法。
在一些实例中,金属基材被加热或再加热到大约1200℃,或在某些情况下大约1300℃。
在一些实例中,混合物作为平均厚度为100μm至400μm的层施加。优选地,混合物作为平均厚度为200μm至400μm的层施加。最优选地,混合物作为平均厚度为250μm至350μm的层施加。
所述方法可以包括通过手动或自动工艺采用混合物涂布金属基材。混合物可以作为浆料涂布,其中如上所述混合物包含水。浆料可以通过喷到金属基材上进行涂布。或者,混合物可以通过静电喷涂施加。在这种情况下,根据本发明实例所述的混合物可以包含大约0.5重量%的硅油。
有利的是,由于混合物包含粘合体系(粘土和碱金属硅酸盐),因此,当金属基材的温度在环境温度至大约1300℃之间的任何温度时,优选当金属基材的温度在环境温度至大约800℃之间的任何温度时,可以采用混合物涂布金属基材。在将浆料在环境温度下涂布到金属基材上的实例中,可以通过浸渍、淹没或刷涂施加到金属基材表面上,并且在某些情况下,随后进行晾干。在一些实例中,可以将干混合物直接施加到金属基材的表面上,例如,在金属基材处于环境温度的实例中。
混合物本身在环境温度下施加,即施加之前混合物的温度是环境温度。
在一些实例中,所述方法可以包括在空气中,即在正常大气水平的氧气下加热金属基材。在其他实例中,如果所述方法在低氧气氛中进行,即其中气氛包含小于20体积%的氧,则可以进一步减少氧化皮的形成。
因此,描述了用于涂布金属基材以防止或限制氧化皮形成的混合物、屏障以及防止或限制在金属基材上形成氧化皮的方法,它们具有如上文和下文详述的许多优点。
正如上文所述,在再加热过程中,在金属基材(例如钢基材)的表面上,由于金属中的铁氧化为氧化铁,形成了含量明显的氧化皮。在本发明的实例中,形成的屏障限制或防止在金属基材的加热或再加热期间形成氧化皮。屏障是至少不透水和二氧化碳的物理屏障。
正如下表2中详细所述,本发明实例已被证明可将金属基材(如钢基材)上氧化皮的产生量减少50%。例如,氧化皮造成的钢损耗可以从3%(金属基材表面未施加混合物涂层时)减少到至少低至1.5%,并且在一些实例中可以减少到忽略不计(金属基材表面施加混合物涂层并形成屏障时)。在大规模操作中,这代表了显著的节约,表面积较大的金属基材加热时尤其如此。
由于实验室规模试验所需的钢坯尺寸(实际上钢的表面将被预氧化),以下试验是在IF级钢材上进行的,所有这些钢材都有切割面。将钢坯加热至100℃,然后喷涂根据本发明实例所述的混合物(参见上表1),并在电窑中在5%氧气的气氛中烧制至1240℃,保持40分钟。一旦冷却至800℃,将钢坯在冷水中淬火,并去除松散的氧化皮。钢坯在涂布前和去除氧化皮后进行称重,并计算金属损耗百分数%,如下表2所示。
表2
此外,金属基材上形成的任何氧化皮(例如采用根据本发明实例所述混合物涂布金属基材之前形成的氧化皮),通过在随后的成型工艺(例如热轧)之前和期间形成屏障,可以很容易地(例如,通过高压水射流)去除。去除的屏障以及任何氧化皮都与现有的回收方法兼容。此外,去除的屏障和氧化皮是兼容的。已经发现,任何形成的氧化皮都非常薄且易碎。形成的任何氧化皮都与屏障结合,因此不能很好地与金属基材结合,因此更容易去除。
本发明的实例具有成本效益,并且正如所指出的那样,实例所述的混合物可以在广泛温度范围内(从环境温度到非常高的温度,如果需要,即高达大约1300℃)施加到金属基材上。因此,无论金属基材在加热之前是冷的还是在先前的工艺中已经很热,混合物都可以施加到金属基材上。因此,金属基材在施加混合物之前不需要冷却,这降低了与冷却工艺相关的能耗和成本。
此外,本发明的实例在金属基材在高湿度气氛中(例如气窑中)加热的情况下是有效的。
根据本发明实例形成的屏障是连续的,即没有裂缝。
尽管前文已经参考各实例描述了本发明的各种实施例,但是应当理解的是,在不脱离如权利要求所述的本发明范围的情况下,可以对所给出的实例进行修改。例如,可以根据需要改变各组分的比例以适合特定的应用,例如,可以配制密度更高的浆料,从而喷涂固定时间时在金属基材上沉积的混合物更多。本发明的实例通过在金属基材上可能形成氧化皮的任何应用(例如,热成型挤压、锻造或铸造应用)中提供屏障来防止或减少氧化皮形成。因此,本发明的实例不限于在成型工艺(如热轧)之前重新加热金属基材的应用。尽管在再加热期间在金属基材上形成了大量的氧化皮,本发明的实例特别适用于在这种再加热应用中防止或限制氧化皮形成。
除了明确描述的组合之外,前面描述中所述的特征都可以组合使用。
尽管已经参考某些特征对功能进行了描述,但是那些功能可以由其他不管是否已描述的特征来执行。
尽管已经参考某些实施例对特征进行了描述,但是那些特征也可以在其他不管是否已描述的实施例中存在。
本发明中使用的术语“包含”具有包含性而非排他性的含义。也就是说,谈到X包含Y表示X可以仅包含一个Y或者可以包含多个Y。如果使用“包含”时旨在具有排他性含义,则将在上下文中提到“仅包含一个……”或使用“由……组成”来明确。
在此简短的描述中,参考了各种实例。与实例相关的特征或功能的描述表示这些特征或功能存在于该实例中。在本发明中使用术语“实例”或“例如”或“可”表示,无论是否明确说明,这些特征或功能至少存在于所描述的实例中,不管是否作为实例描述,它们可以但不一定存在于一些或所有其他实例中。因此,“实例”、“例如”或“可”指一类实例中的特定实例。实例的性能可以仅仅是该实例的性能,也可以该类实例的性能,或者是包含在该类实例中某些实例但非所有实例的子类的性能。因此隐含地公开了,通过参考一个实例但未通过参考另一个实例描述的特征,其可能以在其他实例中使用但不一定必须在其他实例中使用。
虽然在前述说明书中努力提请注意被认为特别重要的本发明的那些特征,但是应当理解的是,申请人要求对上文提及和/或在附图中示出的任何可专利特征或特征的组合进行保护,无论是否对这些特征进行了特别强调。
Claims (21)
1.一种用于涂布金属基材以防止或限制氧化皮形成的混合物,其中所述混合物包含:
20至90重量%的以下中的至少一种:氧化物陶瓷材料、铝硅酸盐矿物或玻璃料;所述混合物进一步包含:
1至20重量%的粘土;和
3至70重量%的碱金属硅酸盐。
2.根据权利要求1所述的混合物,其中所述氧化物陶瓷材料包括氧化铝或硅酸锆。
3.根据权利要求1或2所述的混合物,其中所述铝硅酸盐矿物包括云母。
4.根据前述权利要求中任一项所述的混合物,其中所述碱金属硅酸盐包括以下中的任一种:硅酸钠、硅酸钾或硅酸锂。
5.根据前述权利要求中任一项所述的混合物,其中所述粘土包括瓷土或球粘土。
6.根据前述权利要求中任一项所述的混合物,其中所述混合物包含30至85重量%的以下中的至少一种:氧化物陶瓷材料、铝硅酸盐矿物或玻璃料。
7.根据前述权利要求中任一项所述的混合物,其中所述混合物包含35至80重量%的以下中的至少一种:氧化物陶瓷材料、铝硅酸盐矿物或玻璃料。
8.根据前述权利要求中任一项所述的混合物,其中所述混合物包含3重量%至18重量%的粘土。
9.根据前述权利要求中任一项所述的混合物,其中所述混合物包含5重量%至17重量%的粘土。
10.根据前述权利要求中任一项所述的混合物,其中所述混合物包含5重量%至60重量%的碱金属硅酸盐。
11.根据前述权利要求中任一项所述的混合物,其中所述混合物包含6重量%至55重量%的碱金属硅酸盐。
12.根据前述权利要求中任一项所述的混合物,其中所述混合物包含流变改性剂。
13.根据前述权利要求中任一项所述的混合物,其中所述玻璃料包括多种不同的玻璃料,其中每种玻璃料具有不同的化学组成。
14.根据权利要求13所述的混合物,其中每种玻璃料具有不同的软化点。
15.根据权利要求13或14所述的混合物,其中所述玻璃料包括2至5种不同的玻璃料。
16.根据前述权利要求中任一项所述的混合物,其中所述混合物包含水。
17.一种用于涂布金属基材以防止或限制氧化皮形成的浆料,其中所述浆料包含悬浮在水中的混合物,所述混合物包含:
20至90重量%的以下中的至少一种:氧化物陶瓷材料、铝硅酸盐矿物或玻璃料;所述混合物进一步包含:
1至20重量%的粘土;和
3至70重量%的碱金属硅酸盐。
18.根据权利要求17所述的浆料,其中所述浆料相对于水的密度为1.2至2.2。
19.一种防止或限制金属基材上氧化层形成的方法,其中所述方法包括:
采用混合物涂布金属基材;
其中所述混合物包含:20至90重量%的以下中的至少一种:氧化物陶瓷材料、铝硅酸盐矿物或玻璃料;所述混合物进一步包含:1至20重量%的粘土;和3至70重量%的碱金属硅酸盐。
20.根据权利要求19所述的方法,其中所述方法包括采用所述混合物涂布金属基材,以提供平均厚度为100μm至400μm的层。
21.根据权利要求19或20所述的方法,其中所述方法包括当金属基材的温度在环境温度至大约1300℃之间的任何温度时,采用所述混合物涂布金属基材。
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- 2019-07-10 GB GB1909872.2A patent/GB2585663A/en not_active Withdrawn
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2020
- 2020-07-09 WO PCT/GB2020/051651 patent/WO2021005373A1/en unknown
- 2020-07-09 EP EP20742391.4A patent/EP3990416A1/en not_active Withdrawn
- 2020-07-09 CN CN202080058318.9A patent/CN114402085A/zh active Pending
- 2020-07-09 US US17/625,889 patent/US20220259105A1/en active Pending
Patent Citations (6)
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US3415691A (en) * | 1963-11-07 | 1968-12-10 | Foseco Int | Method of protecting metal surfaces during heat treatment |
US4332618A (en) * | 1980-07-25 | 1982-06-01 | Rolls-Royce Limited | Thermal barrier coating |
US20090324919A1 (en) * | 2006-06-16 | 2009-12-31 | Itn Nanovation Ag | Layers or coatings which are stable at high temperatures and composition for producing them |
CN101210121A (zh) * | 2007-12-24 | 2008-07-02 | 淮阴工学院 | 一种利用凹凸棒石粘土制备高温防氧化保护涂料的方法 |
US20170369711A1 (en) * | 2015-01-14 | 2017-12-28 | Calderys France | Precursors for refractory paints and their use |
CN108793929A (zh) * | 2018-06-20 | 2018-11-13 | 深圳陶金材料科技有限公司 | 一种陶瓷合金涂料及涂层 |
Also Published As
Publication number | Publication date |
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GB201909872D0 (en) | 2019-08-21 |
EP3990416A1 (en) | 2022-05-04 |
US20220259105A1 (en) | 2022-08-18 |
WO2021005373A1 (en) | 2021-01-14 |
GB2585663A (en) | 2021-01-20 |
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