CN114481130A - Overcurrent component and manufacturing method thereof - Google Patents
Overcurrent component and manufacturing method thereof Download PDFInfo
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- CN114481130A CN114481130A CN202210095950.1A CN202210095950A CN114481130A CN 114481130 A CN114481130 A CN 114481130A CN 202210095950 A CN202210095950 A CN 202210095950A CN 114481130 A CN114481130 A CN 114481130A
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- C23C28/02—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material
- C23C28/027—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material including at least one metal matrix material comprising a mixture of at least two metals or metal phases or metal matrix composites, e.g. metal matrix with embedded inorganic hard particles, CERMET, MMC.
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/06—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the coating material
- C23C14/14—Metallic material, boron or silicon
- C23C14/16—Metallic material, boron or silicon on metallic substrates or on substrates of boron or silicon
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/22—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
- C23C14/24—Vacuum evaporation
- C23C14/32—Vacuum evaporation by explosion; by evaporation and subsequent ionisation of the vapours, e.g. ion-plating
- C23C14/325—Electric arc evaporation
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/02—Pretreatment of the material to be coated, e.g. for coating on selected surface areas
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
- C23C4/06—Metallic material
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
- C23C4/06—Metallic material
- C23C4/08—Metallic material containing only metal elements
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
- C23C4/129—Flame spraying
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
- C23C4/134—Plasma spraying
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
- F03B—MACHINES OR ENGINES FOR LIQUIDS
- F03B11/00—Parts or details not provided for in, or of interest apart from, the preceding groups, e.g. wear-protection couplings, between turbine and generator
- F03B11/02—Casings
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
- F03B—MACHINES OR ENGINES FOR LIQUIDS
- F03B3/00—Machines or engines of reaction type; Parts or details peculiar thereto
- F03B3/16—Stators
- F03B3/18—Stator blades; Guide conduits or vanes, e.g. adjustable
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/20—Hydro energy
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Abstract
The invention discloses a flow passage component and a manufacturing method thereof. The overcurrent component comprises: the composite coating comprises a metal bonding layer and a metal ceramic coating, wherein the metal bonding layer is a chromium coating formed on the surface of the flow passage component substrate, and the metal ceramic coating is formed on the surface of the metal bonding layer and comprises tungsten carbide and chromium carbide. The flow passage component provided by the embodiment of the invention has the advantages of good abrasion resistance and cavitation resistance, long service life and the like.
Description
Technical Field
The present invention relates to a flow passage component and a method of manufacturing the flow passage component, and particularly to a flow passage component having excellent abrasion and cavitation resistance and a method of manufacturing the flow passage component.
Background
In the process of hydroelectric power generation, the flow passage components of the water turbine, which are in contact with fluid, can be damaged by silt abrasion and cavitation, so that the service life of the water turbine is influenced, and further the benefit of a power station and the safe operation of the power station are influenced. Therefore, improving the erosion and cavitation damage resistance of the water turbine flow passage component becomes an important research and development subject in the hydroelectric power generation technology.
Disclosure of Invention
The present invention is based on the discovery and recognition by the inventors of the following facts and problems:
the related technology provides a technology for repairing cavitation defects of a water turbine flow passage component, which comprises the step of sequentially coating a ceramic repairing layer, an epoxy bonding bottom coating, a high-toughness polyurethane transition intermediate layer and a polyurethane elastomer surface coating on the defect part of the flow passage component. However, through research, the inventor of the application finds that the technology adopts the organic coating to coat the defective part of the flow passage component, the bonding strength between the coatings is as low as 10-20MPa, the abrasion resistance and the corrosion resistance are poor, and the repaired flow passage component is easy to be rapidly damaged when being used again.
The related technology also provides the treatment of the cavitation part of the water turbine by using the modified polyurethane elastomer coating, wherein a vacuum pouring technology is adopted to extract doped air in the resin mixing process, so that air bubbles are reduced, the internal defects of the coating are effectively reduced, and the comprehensive performance of the coating is improved.
The related art also proposes that a tungsten carbide coating is sprayed on the surface of the flow passage component to improve the wear resistance and the cavitation resistance of the flow passage component, however, the invention of the application discovers that the problem of low bonding strength still exists between the tungsten carbide coating and the flow passage component through research, thereby influencing the wear resistance and the cavitation resistance.
The related art also proposes forming a chromium-plated layer on the surface of the flow passage member of the water turbine, and then forming tungsten carbide or a chromium carbide layer on the chromium-plated layer. However, the inventors of the present application found through studies that a chromized layer is formed on the surface of the flow passage component, the bonding strength between the tungsten carbide layer or the chromium carbide layer and the chromized layer is still low, and the tungsten carbide layer or the chromium carbide layer is still in contact with the surface of the flow passage component such as stainless steel, thereby affecting the properties of wear resistance and cavitation erosion.
In addition, the inventor of the present application also found through research that the composition, thickness, dimension and forming method of the coating layer have an influence on the bonding strength, porosity, and further on the abrasion and cavitation resistance.
The present invention is directed to solving, at least to some extent, one of the technical problems in the related art. To this end, embodiments of the present invention propose a flow passage component having excellent wear and cavitation resistance.
The overcurrent component according to the embodiment of the invention comprises: the composite coating comprises a metal bonding layer and a metal ceramic coating, wherein the metal bonding layer is a chromium coating formed on the surface of the flow passage component substrate, and the metal ceramic coating is formed on the surface of the metal bonding layer and comprises tungsten carbide and chromium carbide.
The flow passage component provided by the embodiment of the invention has the advantages of good abrasion resistance and cavitation resistance and long service life.
Optionally, the chromium coating is formed on the surface of the flow passage component substrate by supersonic flame spraying, multi-arc ion plating or plasma spraying, and the cermet coating is formed on the surface of the chromium coating by supersonic flame spraying.
Optionally, the metal bonding layer has a thickness of 50 microns to 80 microns, and the cermet coating has a thickness of 100 microns to 400 microns.
Optionally, the cermet coating is formed on the surface of the metallic bond coat by supersonic flame spraying a mixed powder comprising chromium carbide powder and multi-scale tungsten carbide powder.
Optionally, the dimensions of the tungsten carbide powder include a first dimension greater than or equal to 10 nanometers and less than or equal to 200 nanometers, a second dimension greater than 0.2 micrometers and less than or equal to 1 micrometer, and a third dimension greater than 1.2 micrometers and less than or equal to 10 micrometers.
Optionally, the weight ratio of the tungsten carbide powder of the first scale, the tungsten carbide powder of the second scale, and the tungsten carbide powder of the third scale is 1: (1-3): (0.5-1).
Optionally, the composite coating comprises 20 wt% to 70 wt% tungsten carbide and 10 wt% to 60 wt% chromium carbide and 15 wt% to 25 wt% metallic binder.
Optionally, the flow passage component is a turbine blade.
The embodiment of the invention also provides a manufacturing method of the overcurrent component.
The method for manufacturing the overcurrent component comprises the following steps:
cleaning, derusting and drying the surface of the flow passage component substrate, and performing sand blasting and roughening to ensure that the surface roughness Ra of the flow passage component substrate is 5-20 micrometers;
spraying a chromium coating on the surface of the filter component substrate by supersonic flame spraying, multi-arc ion plating or plasma spraying;
stirring and mixing chromium carbide powder and tungsten carbide powder, then carrying out spray drying granulation, sintering, crushing and grading to obtain mixed powder;
spraying the mixed powder on the surface of the chromium coating by supersonic flame spraying to form a cermet coating.
Optionally, the conditions of the mixed powder spraying are as follows: the gas flow is 50-90 liters/minute, the oxygen flow is 100-500 liters/minute, the compressed air flow is 150-600 liters/minute, the powder feeding carrier gas flow is 5-30 liters/minute, the powder feeding speed is 20-100 g/minute, the spraying distance is 100-400 mm, and the linear speed of spraying is 20-500 m/minute.
Drawings
Fig. 1 is a partial structural schematic diagram of a flow passage component according to an embodiment of the invention.
Fig. 2 is a flow chart of a method of manufacturing a flow passage component according to an embodiment of the invention.
Detailed Description
Reference will now be made in detail to embodiments of the present invention, examples of which are illustrated in the accompanying drawings. The embodiments described below with reference to the drawings are illustrative and intended to be illustrative of the invention and are not to be construed as limiting the invention.
The following describes the flow passage component 1 according to an embodiment of the present invention with reference to the drawings. As shown in fig. 1, a flow element 1 according to an embodiment of the present invention includes a flow element base 10 and a composite coating 20, and the composite coating 20 is formed on a surface of the flow element base 10. The composite coating 20 includes a metal bonding layer 21 and a cermet coating 22, the metal bonding layer 21 is a chromium coating formed on the surface of the flow passage component substrate 10, and the cermet coating 22 is formed on the surface of the metal bonding layer 21 and includes tungsten carbide and chromium carbide. That is, the metallic bond layer 21 is located between the flow component substrate 10 and the cermet coating 22.
The flow component 1 according to the embodiment of the invention has the advantages that the composite coating layer 20 comprises the metal bonding layer 21 formed on the surface of the flow component base body 10, so that the combination between the metal bonding layer 21 and the flow component base body 10 can be metallurgically bonded, namely the combination between the composite coating layer 20 and the flow component base body 10, and the bonding performance of the metal ceramic coating layer 22 and the metal bonding layer 21 can be higher than that of the metal ceramic coating layer 22 and the flow component base body 10.
Therefore, the metal bonding layer 21 is introduced (namely, the metal bonding layer 21 is arranged between the flow passage component substrate 10 and the metal ceramic coating 22), so that the problem of stress cracking caused by mismatching of lattice parameters and difference of thermal expansion coefficients of the metal ceramic coating 22 and the flow passage component substrate 10 (metal substrate) can be solved, the combination between the metal ceramic coating 22 and the flow passage component substrate 10 is tighter, and the composite coating 20 is not easy to fall off integrally. Further, the abrasion resistance and cavitation resistance of the composite coating 20 and the flow passage member 1 are greatly improved. The composite coating 20 and the flow passage component base body 10 have the bonding strength of more than or equal to 80MPa, and compared with the flow passage component without the composite coating 20, the service life of the flow passage component 1 with the composite coating 20 can be prolonged by 10-30 times.
Therefore, the flow passage component 1 according to the embodiment of the invention has the advantages of good abrasion and cavitation resistance, long service life and the like.
The flow passage component 1 according to the embodiment of the invention can be not only hydraulic machinery such as a water turbine blade, a rotating wheel and the like, but also flow passage components of fluid machinery such as a ship propeller, a water pump, a valve, a rudder blade, a water turbine impeller and the like, and can also be various fan blades in the fields of metallurgy, electric power and the like.
As shown in fig. 1, the flow component 1 according to the embodiment of the present invention includes a flow component base 10 and a composite coating 20, and the composite coating 20 includes a metal bonding layer 21 and a cermet coating 22. The metal bonding layer 21 is a chromium coating formed on the surface of the flow component substrate 10, and the cermet coating 22 is formed on the surface of the metal bonding layer 21 and includes tungsten carbide and chromium carbide.
Optionally, the thickness of the metal bonding layer 21 is 50 microns to 80 microns and the thickness of the cermet coating 22 is 100 microns to 400 microns. Therefore, the thickness of the metal bonding layer 21 and the metal ceramic coating 22 can be reduced, the thickness and the material amount of the composite coating 20 can be reduced, and the manufacturing cost of the flow passage component 1 can be reduced under the condition that the bonding strength of the composite coating 20 and the flow passage component substrate 10 and the abrasion resistance and cavitation resistance of the flow passage component 1 are ensured.
Optionally, the thickness of the metal bond layer 21 is 60 microns to 70 microns and the thickness of the cermet coating 22 is 200 microns to 300 microns. Therefore, the thickness and the material consumption of the composite coating 20 can be reduced so as to reduce the manufacturing cost of the flow passage component 1, and the increase of the manufacturing difficulty caused by the excessively small thicknesses of the metal bonding layer 21 and the metal ceramic coating 22 can be avoided.
Alternatively, the thickness of the metal bond layer 21 is 66 microns to 68 microns and the thickness of the cermet coating 22 is 210 microns to 230 microns. Therefore, the thickness and the material consumption of the composite coating 20 can be reduced so as to reduce the manufacturing cost of the flow passage component 1, and the increase of the manufacturing difficulty caused by the excessively small thicknesses of the metal bonding layer 21 and the metal ceramic coating 22 can be avoided.
Alternatively, the thickness of the metal bonding layer 21 may be, for example, but not limited to, 60 micrometers, 61 micrometers, 62 micrometers, 63 micrometers, 64 micrometers, 65 micrometers, 66 micrometers, 67 micrometers, 68 micrometers, 69 micrometers, or 70 micrometers. The thickness of the cermet coating 22 may be, for example, but not limited to, 210 microns, 211 microns, 212 microns, 213 microns, 214 microns, 215 microns, 216 microns, 217 microns, 218 microns, 219 microns, 220 microns, 221 microns, 222 microns, 223 microns, 224 microns, 225 microns, 226 microns, 227 microns, 228 microns, 229 microns, or 230 microns.
The chromium coating (metal bonding layer 21) may be formed on the surface of the flow passage member base body 10 by supersonic flame spraying, multi-arc ion plating, or plasma spraying, and the cermet coating 22 is formed on the surface of the chromium coating (metal bonding layer 21) by supersonic flame spraying. Therefore, the composite coating 20 has a smaller self-corrosion potential and self-corrosion current density, and the composite coating 20 has larger microhardness, bonding strength and porosity, so that the composite coating 20 has high strength, high hardness, high toughness, low porosity and strong corrosion resistance, the abrasion resistance and cavitation resistance of the overcurrent component 1 can be obviously improved, the service life of the overcurrent component 1 is further prolonged, the maintenance cost is reduced, and the economic benefit is improved.
Wherein the microhardness of the composite coating 20 is more than 1300HV0.2, the porosity of the composite coating 20 is less than 0.5%, and the bonding strength of the composite coating 20 is more than or equal to 80 Mpa. The erosion weight loss of the composite coating 20 in the sand-containing running water is only 3% -8% of that of the high-strength stainless steel. The cavitation weight loss is 10-30% of that of the high-strength stainless steel. The porosity can be measured using image gray scale and the microhardness can be measured using a microhardness meter.
The composite coating 20 may include 20 wt% to 70 wt% tungsten carbide (WC) and 10 wt% to 60 wt% chromium carbide (Cr2C3) and 15 wt% to 25 wt% metallic binder.
Alternatively, the cermet coating 22 is formed on the surface of the metallic bond layer 21 by spraying a mixed powder including chromium carbide powder and multi-scale tungsten carbide powder by a supersonic flame. By using the multi-scale tungsten carbide powder to manufacture the metal ceramic coating 22, the composite coating 20 can have larger microhardness and bonding strength and smaller porosity, and particularly, the bonding strength between the composite coating 20 and the flow passage component substrate 10 can be effectively improved, and the porosity of the composite coating 20 can be reduced, so that the wear resistance and cavitation resistance of the flow passage component 1 can be obviously improved, the service life of the flow passage component 1 can be further prolonged, the maintenance cost can be reduced, and the economic benefit can be improved.
The dimensions of the tungsten carbide powder include a first dimension, a second dimension, and a third dimension. In other words, the raw materials from which the cermet coating 22 is made include chromium carbide powder, a metal binder, tungsten carbide powder of a first dimension, tungsten carbide powder of a second dimension, and tungsten carbide powder of a third dimension. The first scale is larger than or equal to 10 nanometers and smaller than or equal to 200 nanometers, the second scale is larger than 0.2 micrometer and smaller than or equal to 1 micrometer, and the third scale is larger than 1.2 micrometer and smaller than or equal to 10 micrometers.
That is, the tungsten carbide powder includes a first scale of tungsten carbide powder, a second scale of tungsten carbide powder, and a third scale of tungsten carbide powder. The weight ratio of the tungsten carbide powder with the first size, the tungsten carbide powder with the second size and the tungsten carbide powder with the third size is 1: (1-3): (0.5-1). Therefore, the composite coating 20 has higher microhardness and bonding strength and smaller porosity, and particularly, the bonding strength between the composite coating 20 and the flow passage component substrate 10 can be effectively improved, and the porosity of the composite coating 20 can be reduced, so that the wear resistance and cavitation resistance of the flow passage component 1 can be obviously improved, the service life of the flow passage component 1 can be further prolonged, the maintenance cost can be reduced, and the economic benefit can be improved.
Optionally, the weight ratio of the tungsten carbide powder of the first scale, the tungsten carbide powder of the second scale and the tungsten carbide powder of the third scale is 1: (2-3): (0.5-0.7). Therefore, the composite coating 20 has higher microhardness and bonding strength and smaller porosity, and particularly, the bonding strength between the composite coating 20 and the flow passage component substrate 10 can be effectively improved, and the porosity of the composite coating 20 can be reduced, so that the wear resistance and cavitation resistance of the flow passage component 1 can be obviously improved, the service life of the flow passage component 1 can be further prolonged, the maintenance cost can be reduced, and the economic benefit can be improved.
Optionally, the weight ratio of the tungsten carbide powder of the first scale, the tungsten carbide powder of the second scale and the tungsten carbide powder of the third scale is 1: (2.6-2.7): (0.56-0.58). Therefore, the composite coating 20 has higher microhardness and bonding strength and smaller porosity, and particularly, the bonding strength between the composite coating 20 and the flow passage component substrate 10 can be effectively improved, and the porosity of the composite coating 20 can be reduced, so that the wear resistance and cavitation resistance of the flow passage component 1 can be obviously improved, the service life of the flow passage component 1 can be further prolonged, the maintenance cost can be reduced, and the economic benefit can be improved.
Optionally, the weight ratio of the tungsten carbide powder of the first scale, the tungsten carbide powder of the second scale, and the tungsten carbide powder of the third scale is 1: 2.68: 0.57. therefore, the composite coating 20 has higher microhardness and bonding strength and smaller porosity, and particularly, the bonding strength between the composite coating 20 and the flow passage component substrate 10 can be effectively improved, and the porosity of the composite coating 20 can be reduced, so that the wear resistance and cavitation resistance of the flow passage component 1 can be obviously improved, the service life of the flow passage component 1 can be further prolonged, the maintenance cost can be reduced, and the economic benefit can be improved.
Optionally, the first dimension is greater than or equal to 50 nm and less than or equal to 150 nm, the second dimension is greater than 0.3 micron and less than or equal to 0.8 micron, and the third dimension is greater than 3 microns and less than or equal to 8 microns. Therefore, the composite coating 20 has higher microhardness and bonding strength and smaller porosity, and particularly, the bonding strength between the composite coating 20 and the flow passage component substrate 10 can be effectively improved, and the porosity of the composite coating 20 can be reduced, so that the wear resistance and cavitation resistance of the flow passage component 1 can be obviously improved, the service life of the flow passage component 1 can be further prolonged, the maintenance cost can be reduced, and the economic benefit can be improved.
Optionally, the first dimension is greater than or equal to 70 nm and less than or equal to 90 nm, the second dimension is greater than 0.4 micron and less than or equal to 0.6 micron, and the third dimension is greater than 5 microns and less than or equal to 7 microns. Therefore, the composite coating 20 has higher microhardness and bonding strength and smaller porosity, and particularly, the bonding strength between the composite coating 20 and the flow passage component substrate 10 can be effectively improved, and the porosity of the composite coating 20 can be reduced, so that the wear resistance and cavitation resistance of the flow passage component 1 can be obviously improved, the service life of the flow passage component 1 can be further prolonged, the maintenance cost can be reduced, and the economic benefit can be improved.
Alternatively, the first dimension may be, for example, but not limited to, 70 nanometers, 71 nanometers, 72 nanometers, 73 nanometers, 74 nanometers, 75 nanometers, 76 nanometers, 77 nanometers, 78 nanometers, 79 nanometers, 80 nanometers, 81 nanometers, 82 nanometers, 83 nanometers, 84 nanometers, 85 nanometers, 86 nanometers, 87 nanometers, 88 nanometers, 89 nanometers, or 90 nanometers.
Alternatively, the second dimension may be, for example, but not limited to, 0.4 microns, 0.41 microns, 0.42 microns, 0.43 microns, 0.44 microns, 0.45 microns, 0.46 microns, 0.47 microns, 0.48 microns, 0.49 microns, 0.5 microns, 0.51 microns, 0.52 microns, 0.53 microns, 0.54 microns, 0.55 microns, 0.56 microns, 0.57 microns, 0.58 microns, 0.59 microns, or 0.6 microns.
Alternatively, the third dimension may be, for example, but not limited to, 5 microns, 5.1 microns, 5.2 microns, 5.3 microns, 5.4 microns, 5.5 microns, 5.6 microns, 5.7 microns, 5.8 microns, 5.9 microns, 6 microns, 6.1 microns, 6.2 microns, 6.3 microns, 6.4 microns, 6.5 microns, 6.6 microns, 6.7 microns, 6.8 microns, 6.9 microns, or 7 microns.
The application also provides a manufacturing method of the flow passage component 1 according to the embodiment of the invention. As shown in fig. 2, a method for manufacturing the overcurrent component 1 according to the embodiment of the invention includes the following steps:
the surface of the flow passage component base body 10 is cleaned, derusted, dried and sandblasted and roughened so that the surface roughness Ra of the flow passage component base body 10 is 5-20 micrometers.
The chromium coating (metal bonding layer 21) is formed by spraying on the surface of the flow passage component substrate 10 by supersonic flame spraying, multi-arc ion plating or plasma spraying.
And stirring and mixing the chromium carbide powder and the tungsten carbide powder, then carrying out spray drying granulation, sintering, crushing and grading to obtain mixed powder.
The mixed powder was sprayed on the surface of the chromium coating by supersonic flame spraying to form a cermet coating 22.
Alternatively, the chromium carbide powder and the tungsten carbide powder are mixed for 15 to 72 hours by a powder mixer or a ball mill.
Optionally, the conditions of the mixed powder spraying are: the flow rate of fuel gas (such as propane) is 50-90 liters/minute, the flow rate of oxygen is 100-500 liters/minute, the flow rate of compressed air is 150-600 liters/minute, the flow rate of powder conveying and carrying gas is 5-30 liters/minute, the powder conveying speed is 20-100 g/minute, the spraying distance is 100-400 mm, and the linear speed of spraying is 20-500 m/minute.
Example 1
Tungsten carbide (WC), chromium carbide (Cr2C3) and a metal binder are mixed according to the weight ratio of the tungsten carbide (WC): 40 wt%, chromium carbide (Cr2C 3): 40 wt%, metal binder Co: 20 wt% was prepared. Adding alcohol and polyethylene glycol into the prepared formula raw materials, and fully mixing in a ball mill for 40 hours. Then spray drying granulation, sintering, crushing and grading are carried out.
The tungsten carbide (WC) comprises tungsten carbide powder of a first scale, tungsten carbide powder of a second scale and tungsten carbide powder of a third scale, wherein the weight ratio of the tungsten carbide powder of the first scale, the tungsten carbide powder of the second scale and the tungsten carbide powder of the third scale is 1: 3: 0.5, the first dimension is 10 nanometers, the second dimension is 0.2 micrometers, and the third dimension is 1.2 micrometers.
Cleaning, derusting and drying the surface of the base material of the water turbine blade, and blasting sand to roughen the surface of the base material of the water turbine blade, wherein the roughness of the surface after sand blasting is 5 mu m.
A metallic chromium bonding layer (chromium coating) is prepared on the surface of a base material of the hydraulic turbine blade by a supersonic flame spraying method, and the thickness of the metallic chromium bonding layer is 80 mu m.
And (3) spraying the composite powder of the chromium carbide, the tungsten carbide and the metal binder on the prepared turbine blades by adopting supersonic flame spraying equipment to form the cavitation erosion resistant micro-nano chromium carbide and tungsten carbide composite coating (the metal ceramic coating 22).
The spraying process parameters are controlled as follows: the cavitation erosion resistant composite coating is obtained by adopting the propane flow rate of 60L/min, the oxygen flow rate of 150L/min, the compressed air flow rate of 200L/min, the powder feeding carrier gas flow rate of 15L/min, the powder feeding speed of 80g/min, the spraying distance of 150mm and the linear speed of 100 m/min.
Example 2
Tungsten carbide (WC), chromium carbide (Cr2C3) and a metal binder are mixed according to the weight ratio of the tungsten carbide (WC): 60 wt%, chromium carbide (Cr2C 3): 20 wt%, metal binder Co: 20 wt% was prepared. Adding alcohol and polyethylene glycol into the prepared formula raw materials, and fully mixing for 50 hours in a ball mill. Then spray drying granulation, sintering, crushing and grading are carried out.
The tungsten carbide (WC) comprises tungsten carbide powder of a first scale, tungsten carbide powder of a second scale and tungsten carbide powder of a third scale, wherein the weight ratio of the tungsten carbide powder of the first scale, the tungsten carbide powder of the second scale and the tungsten carbide powder of the third scale is 1: 1: 1, the first dimension is 200 nm, the second dimension is 1 micron, and the third dimension is 10 microns.
Cleaning, derusting and drying the surface of the base material of the water turbine blade, and blasting sand to roughen the surface of the base material of the water turbine blade, wherein the surface roughness is 20 mu m after sand blasting.
Preparing a metal chromium bonding layer on the surface of the base material of the water turbine blade by a multi-arc ion plating method, wherein the thickness of the metal chromium bonding layer is 80 mu m.
And spraying composite powder of chromium carbide, tungsten carbide and metal binder on the prepared turbine blades by adopting supersonic flame spraying equipment to form the cavitation erosion resistant micro-nano chromium carbide and tungsten carbide composite coating.
The spraying process parameters are controlled as follows: the cavitation erosion resistant composite coating is obtained by adopting the propane flow of 50L/min, the oxygen flow of 100L/min, the compressed air flow of 300L/min, the powder feeding carrier gas flow of 20L/min, the powder feeding speed of 60g/min, the spraying distance of 200mm and the linear speed of 200 m/min.
Example 3
Tungsten carbide (WC), chromium carbide (Cr2C3) and a metal binder are mixed according to the weight ratio of the tungsten carbide (WC): 20 wt%, chromium carbide (Cr2C 3): 60 wt%, metal binder Co: 20 wt% was prepared. Adding alcohol and polyethylene glycol into the prepared formula raw materials, and fully mixing in a ball mill for 30 hours. Then spray drying granulation, sintering, crushing and grading are carried out.
The tungsten carbide (WC) comprises tungsten carbide powder of a first scale, tungsten carbide powder of a second scale and tungsten carbide powder of a third scale, wherein the weight ratio of the tungsten carbide powder of the first scale, the tungsten carbide powder of the second scale and the tungsten carbide powder of the third scale is 1: 2.7: 0.57, the first dimension is 100 nanometers, the second dimension is 0.5 micrometers, and the third dimension is 5 micrometers.
Cleaning, derusting and drying the surface of the base material of the water turbine blade, and blasting sand to roughen the surface of the base material of the water turbine blade, wherein the surface roughness is 10 mu m after sand blasting.
A metal chromium bonding layer is prepared on the surface of a base material of the water turbine blade by a plasma spraying method, and the thickness of the metal chromium bonding layer is 60 mu m.
And (3) spraying the composite powder of the chromium carbide, the tungsten carbide and the metal binder on the prepared turbine blades by adopting supersonic flame spraying equipment to form the cavitation erosion resistant micro-nano chromium carbide and tungsten carbide composite coating (the metal ceramic coating 22).
The spraying process parameters are controlled as follows: the cavitation erosion resistant composite coating is obtained by adopting the propane flow rate of 80L/min, the oxygen flow rate of 300L/min, the compressed air flow rate of 400L/min, the powder feeding carrier gas flow rate of 30L/min, the powder feeding speed of 40g/min, the spraying distance of 100mm and the linear velocity of 80 m/min.
In the description of the present invention, it is to be understood that the terms "central," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," "circumferential," and the like are used in the orientations and positional relationships indicated in the drawings for convenience in describing the invention and to simplify the description, and are not intended to indicate or imply that the referenced devices or elements must have a particular orientation, be constructed and operated in a particular orientation, and are therefore not to be considered limiting of the invention.
Furthermore, the terms "first", "second" and "first" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one such feature. In the description of the present invention, "a plurality" means at least two, e.g., two, three, etc., unless specifically limited otherwise.
In the present invention, unless otherwise expressly stated or limited, the terms "mounted," "connected," "secured," and the like are to be construed broadly and can, for example, be fixedly connected, detachably connected, or integrally formed; may be mechanically coupled, may be electrically coupled or may be in communication with each other; they may be directly connected or indirectly connected through intervening media, or they may be connected internally or in any other suitable relationship, unless expressly stated otherwise. The specific meanings of the above terms in the present invention can be understood by those skilled in the art according to specific situations.
In the present invention, unless otherwise expressly stated or limited, the first feature "on" or "under" the second feature may be directly contacting the first and second features or indirectly contacting the first and second features through an intermediate. Also, a first feature "on," "over," and "above" a second feature may be directly or diagonally above the second feature, or may simply indicate that the first feature is at a higher level than the second feature. A first feature being "under," "below," and "beneath" a second feature may be directly under or obliquely under the first feature, or may simply mean that the first feature is at a lesser elevation than the second feature.
In the present disclosure, the terms "one embodiment," "some embodiments," "an example," "a specific example," or "some examples" and the like mean that a specific feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the present disclosure. In this specification, the schematic representations of the terms used above are not necessarily intended to refer to the same embodiment or example. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples. Furthermore, various embodiments or examples and features of different embodiments or examples described in this specification can be combined and combined by one skilled in the art without contradiction.
Although the above embodiments have been shown and described, it should be understood that they are exemplary and should not be construed as limiting the present invention, and that many changes, modifications, substitutions and alterations to the above embodiments may be made by those of ordinary skill in the art without departing from the scope of the present invention.
Claims (10)
1. A flow pass component, comprising: the composite coating comprises a metal bonding layer and a metal ceramic coating, wherein the metal bonding layer is a chromium coating formed on the surface of the flow passage component substrate, and the metal ceramic coating is formed on the surface of the metal bonding layer and comprises tungsten carbide and chromium carbide.
2. The flow component of claim 1, wherein the chromium coating is formed on the surface of the flow component substrate by high velocity flame spraying, multi-arc ion plating, or plasma spraying, and the cermet coating is formed on the surface of the chromium coating by high velocity flame spraying.
3. The flow component of claim 1, wherein the metal bond layer has a thickness of 50 micrometers to 80 micrometers and the cermet coating has a thickness of 100 micrometers to 400 micrometers.
4. The flow component of claim 1, wherein the cermet coating is formed on the surface of the metallic bond layer by supersonic flame spraying a mixed powder comprising chromium carbide powder and multi-scale tungsten carbide powder.
5. The flow component of claim 4, wherein the tungsten carbide powder has dimensions comprising a first dimension greater than or equal to 10 nanometers and less than or equal to 200 nanometers, a second dimension greater than 0.2 micrometers and less than or equal to 1 micrometer, and a third dimension greater than 1.2 micrometers and less than or equal to 10 micrometers.
6. The flow passage component of claim 5, wherein the weight ratio of the first scale tungsten carbide powder, the second scale tungsten carbide powder, and the third scale tungsten carbide powder is 1: (1-3): (0.5-1).
7. The flow component of any one of claims 1-6, wherein the composite coating comprises 20-70 wt% tungsten carbide and 10-60 wt% chromium carbide and 15-25 wt% metallic binder.
8. The flow passage component of claim 1, wherein the flow passage component is a turbine blade.
9. A method of manufacturing a flow passage component according to any one of claims 1 to 8, comprising the steps of:
cleaning, derusting and drying the surface of the flow passage component substrate, and performing sand blasting and roughening to ensure that the surface roughness Ra of the flow passage component substrate is 5-20 micrometers;
spraying a chromium coating on the surface of the filter component substrate by supersonic flame spraying, multi-arc ion plating or plasma spraying;
stirring and mixing chromium carbide powder and tungsten carbide powder, then carrying out spray drying granulation, sintering, crushing and grading to obtain mixed powder;
spraying the mixed powder on the surface of the chromium coating by supersonic flame spraying to form a cermet coating.
10. The method according to claim 9, wherein the conditions for the mixed powder spraying are as follows: the gas flow is 50-90 liters/minute, the oxygen flow is 100-500 liters/minute, the compressed air flow is 150-600 liters/minute, the powder feeding carrier gas flow is 5-30 liters/minute, the powder feeding speed is 20-100 g/minute, the spraying distance is 100-400 mm, and the linear speed of spraying is 20-500 m/minute.
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| CN116162884A (en) * | 2023-03-09 | 2023-05-26 | 昆明理工大学 | Cavitation erosion resistant composite ceramic coating for water turbine and preparation method thereof |
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