CN114908309B - 一种抗腐蚀耐磨损复合涂层及其在钢管内表面形成涂层的工艺 - Google Patents
一种抗腐蚀耐磨损复合涂层及其在钢管内表面形成涂层的工艺 Download PDFInfo
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- 239000003822 epoxy resin Substances 0.000 claims description 33
- 229920000647 polyepoxide Polymers 0.000 claims description 33
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- 229910052782 aluminium Inorganic materials 0.000 claims description 23
- 229920000642 polymer Polymers 0.000 claims description 18
- 238000006243 chemical reaction Methods 0.000 claims description 16
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- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 14
- 238000001035 drying Methods 0.000 claims description 12
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- 150000001412 amines Chemical class 0.000 claims description 7
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- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 claims description 6
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- 239000002184 metal Substances 0.000 abstract 1
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- FAPWRFPIFSIZLT-UHFFFAOYSA-M Sodium chloride Chemical compound [Na+].[Cl-] FAPWRFPIFSIZLT-UHFFFAOYSA-M 0.000 description 15
- 238000005406 washing Methods 0.000 description 8
- 238000005516 engineering process Methods 0.000 description 7
- 238000011835 investigation Methods 0.000 description 6
- 239000011780 sodium chloride Substances 0.000 description 6
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- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 2
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 2
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- HPALAKNZSZLMCH-UHFFFAOYSA-M sodium;chloride;hydrate Chemical compound O.[Na+].[Cl-] HPALAKNZSZLMCH-UHFFFAOYSA-M 0.000 description 2
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Abstract
本发明涉及一种抗腐蚀耐磨损复合涂层及其在钢管内表面形成涂层的工艺,属于金属(高温合金)材料表面改性技术领域,本发明通过热浸镀+自蔓延合成技术+离心沉积技术在金属管道内表面制备Al过渡层‑以Al203+ZrO2为主,含少量CrB4的陶瓷中间层‑环氧树脂内层,以改善钢管的抗腐蚀耐磨损性能差的技术难题,所获得的涂层具有结合力好、组织均匀致密的特点,同时,该制备工艺具备简单稳定、操作方便、效率高、成本低廉、易于实现等特点。实验表明:有涂层钢管在相同工况条件下,抗腐蚀性能较无涂层钢管提高了8‑10倍,耐冲蚀性能提高了9‑12倍。
Description
技术领域
本发明属于钢管(高温合金)材料表面改性,具体涉及一种抗腐蚀耐磨损复合涂层及其在钢管内表面形成涂层的工艺。
背景技术
抗腐蚀耐磨损管道的开发一直是工程技术领域研发的重点和长期关注的问题,并且随着当前国民经济的发展和对更多资源的开发利用,对管道的服役条件提出了更高的要求,不但要承受Cl-、SO2等腐蚀介质的侵蚀,同时还要抗冲刷耐磨损,这对钢管的抗腐蚀耐磨损性提出新的要求。
为提高钢管的上述性能,常用两种方式:1)整体合金化,添加Ni、Cr等各种合金元素,设计新的钢管体系,如G3合金钢管,N80钢管等,该方法虽能改善钢管的上述性能,但会显著增加钢管的使用成本,同时由于材料的腐蚀及磨损大多发生于材料表面,因此提高材料的表面性能显得更加重要;2)钢管表面改性技术,通过研究钢管的失效机理及失效机制,合理设计钢管表面改性层的成分,在提高其抗腐蚀耐磨损性能的同时使钢管的成本在可控范围内。
研究发现,自蔓延高温合成技术(SHS技术)具有工艺简单、反应速度快、能耗低、投资少等系列优点,所制备的陶瓷涂层具有较高的机械强度,良好的耐高温、耐腐蚀、抗磨损等特点,成为目前研究的热点,但单一的陶瓷涂层脆性大,孔隙较多,因此需要对其改性,本发明将在涂层涂层和钢管基体之间引入过渡层,同时利用高分子材料来密封陶瓷涂层的孔隙了裂纹,形成三元复合涂层。
发明内容
本发明的目的在于提供一种抗腐蚀耐磨损复合涂层及其在钢管内表面形成涂层的工艺,该涂层包括Al过渡层,以Al203+ZrO2为主、含少量CrB4的陶瓷中间层,以及环氧树脂+Al2O3内层,结合力好,组织均匀且致密,在钢管表面形成后可有效提高钢管的抗腐蚀耐磨损性能。
本发明解决上述技术问题的技术方案如下。
一种钢管内表面抗腐蚀耐磨损复合涂层,包括:Al过渡层、陶瓷中间层和环氧树脂层;所述陶瓷中间层由含有Al、Zr、B、Cr的铝热剂通过自蔓延反应形成;所述环氧树脂层中按照每1L环氧树脂中加入20-30g Al2O3。
进一步地,所述铝热剂按照重量百分比计,包括:20%~25% Al粉,3%~5% Zr粉,1%~2% B粉,3%~6% Cr2O3粉,其余为Fe2O3粉。
进一步地,所述环氧树脂层中Al2O3的粒度≤300目。
进一步地,所述环氧树脂层中含有环氧树脂质量 10-15%的固化剂。
优选地,所述固化剂为T-31改性胺。
本发明还提供一种在钢管内表面形成涂层的工艺,包括如下步骤:
(1)将钢管内表面进行热浸镀铝,形成Al过渡层;
(2)在Al过渡层上通过自蔓延反应制备陶瓷中间层;
(3)在陶瓷中间层上通过离心法制备Al2O3增强的环氧树脂内层。
进一步地,所述步骤(1)具体包括如下步骤:
1-1.将钢管内表面进行除尘、除锈处理;
1-2.将钢管加热至500-550℃;
1-3.在钢管内部通入660-700℃的铝液,并使铝液均匀覆盖整个内壁,形成Al过渡层。
进一步地,所述步骤(2)具体包括如下步骤:
2-1.将形成Al过渡层的钢管使用流动水冲洗,吹干;
2-2.配制铝热剂粉料;
2-3.将铝热剂粉料在球磨机中混合3-4h;
2-4.将铝热剂粉料均匀填充到钢管内表面,填料密度为1.2-1.5g/cm3;
2-5.将填充好铝热剂粉料的钢管预热至温度130-170℃;
2-6.将钢管固定在离心机上,启动离心设备,使钢管离心力保持在50-100g;
2-7.点燃铝热剂粉料进行自蔓延反应,待自蔓延反应完成,钢管温度冷却后,关闭离心机,取下钢管。
进一步地,所述铝热剂按照重量百分比计,包括:20%~25% Al粉,3%~5% Zr粉,1%~2% B粉,3%~6% Cr2O3粉,其余为Fe2O3粉。
进一步地,所述步骤(3)具体包括如下步骤:
3-1.将形成陶瓷中间层的钢管使用流动水冲洗,吹干;
3-2.配制颗粒增强环氧树脂涂料,并将该涂料超声搅拌1h,使其均匀化;
3-3.将钢管固定在离心机上,将颗粒增强环氧树脂涂料注入钢管内部,加入量以可在钢管内壁形成1-1.5mm厚的环氧树脂层为宜;
3-4.启动离心设备,使钢管离心力保持在5-10g;
3-5.待高分子涂层固化后关闭离心机,取出钢管结束。
进一步地,所述颗粒增强环氧树脂涂料是在每1L环氧树脂中加入20-30g Al2O3。
进一步地,所述Al2O3的粒度≤300目。
进一步地,所述环氧树脂层中含有环氧树脂质量 10-15%的固化剂。
优选地,所述固化剂为T-31改性胺。
本发明采用上述技术方案,其有益效果在于:本发明通过热浸镀+自蔓延扩散法在钢管表面制备了多元复合涂层,解决了钢管抗腐蚀耐磨损性能差的技术难题。
所获得的涂层具有结合力好、组织均匀致密的特点,使得钢管在相同工况条件下,抗腐蚀性能较无涂层钢管提高了8-10倍,耐冲蚀性能提高了9-12倍,同时,该制备工艺具备简单稳定、操作方便、效率高、成本低廉、易于实现等特点。
且目前,通过热浸镀+自蔓延扩散法在钢管表面制备抗腐蚀耐磨损多元复合涂层的技术尚属空白,因此,针对该多元复合涂层制备技术的研究和实现对提高镍钢管抗腐蚀耐磨损的应用具有重要意义。
附图说明
图1为钢管表面多元复合涂层的制备工艺流程图;
图2为采用本发明实施例1所获得的多元复合涂层截面形貌图;
图3为采用本发明实施例2所获得的多元复合涂层截面形貌图;
图4为采用本发明实施例3所获得的多元复合涂层截面形貌图。
具体实施方式
参照图1,一种钢管内表面制备抗腐蚀耐磨损多元复合涂层的工艺流程,包括以下步骤:
(1)准备钢管:将钢管内表面进行除尘、除锈处理;
(2)将钢管加热至500-550℃;
(3)在钢管内部通入660-700℃铝液,并使铝液均匀覆盖整个内壁,形成Al过渡层;
(4)将经过热浸镀铝的钢管使用流动水冲洗,吹干;
(5)配制自蔓延反应铝热剂粉料,按照重量百分比计,包括20%~25% Al粉,3%~5%Zr粉,1%~2% B粉,3%~6% Cr2O3粉,其余为Fe2O3粉;将铝热剂粉料在球磨机中混合4h;
(6)将铝热剂粉料均匀的填充到钢管的内表面,填料密度为1.2-1.5g/cm3;
(7)将填充好铝热剂粉料的钢管预热至温度130-170℃;
(8)将钢管固定在离心机上,启动离心设备,使钢管离心力保持在50-100g;
(9)点燃铝热剂粉料,待自蔓延反应完成,钢管温度冷却后,关闭离心机;
(10)将经过前期处理的钢管使用流动水冲洗,吹干;
(11)配制颗粒增强高分子涂料,每1L环氧树脂中加入20-30g Al2O3,要求Al2O3的粒度≤300目,加入质量为环氧树脂质量 10-15%的固化剂(T-31改性胺),并将该涂料超声搅拌1h,使其均匀化;
(12)将钢管固定在离心机上,将颗粒增强高分子涂料注入钢管内部,加入量以可在钢管内壁形成1-1.5mm厚的颗粒增强高分子涂层为宜;
(13)启动离心设备,使钢管离心力保持在5-10g;
(14)待高分子涂层固化后关闭离心机;
(15)取出钢管结束。
实施例1:
参见图2,采用本发明技术方案的方法流程为:(1)准备钢管:将钢管内表面进行除尘、除锈处理;(2)将钢管加热至530℃;(3)在钢管内部通入680℃铝液,并使铝液均匀覆盖整个内壁,形成Al过渡层;(4)将经过热浸镀铝的钢管使用流动水冲洗,吹干;(5)配制自蔓延反应铝热剂粉料,按照重量百分比计,包括23% Al粉,3% Zr粉,1%B粉,3%Cr2O3粉,其余为Fe2O3粉。将铝热剂粉料在球磨机中混合4h;(6)将铝热剂粉料均匀的填充到钢管的内表面,填料密度为1.2g/cm3;(7)将填充好铝热剂粉料的钢管预热至温度130℃;(8)将钢管固定在离心机上,启动离心设备,使钢管离心力保持在50g;(9)点燃铝热剂粉料,待自蔓延反应完成,钢管温度冷却后,关闭离心机;(10)将经过前期处理的钢管使用流动水冲洗,吹干;(11)配制颗粒增强高分子涂料,每1L环氧树脂中加入20g Al2O3,要求Al2O3的粒度≤300目,加入质量为环氧树脂质量 10%的固化剂(T-31改性胺),并将该涂料超声搅拌1h,使其均匀化;(12)将钢管固定在离心机上,将颗粒增强高分子涂料注入钢管内部,加入量以可在钢管内壁形成1mm厚的颗粒增强高分子涂层;(13)启动离心设备,使钢管离心力保持在5g;(14)待高分子涂层固化后关闭离心机;(15)取出钢管结束。
参见图2为采用本发明实施例1所获得的多元复合涂层截面形貌图。另:采用该工艺所制备的涂层与无涂层的钢管在4.5%NaCl盐水溶液中浸泡200h,利用失重法测得其抗腐蚀性能较无涂层钢管提高了8-9倍(多批次考察结果);采用该工艺所制备的涂层与无涂层的钢管在4.5%NaCl盐水溶液中(加入质量分数为15%的Al2O3刚玉颗粒,粒径为300-500 μm。实验温度保持在25℃,冲击攻角为90°,流速为0.4m/s)冲蚀100h,利用失重法测得其耐冲蚀性能提高了9-10倍(多批次考察结果)。
实施例2
参见图3,采用本发明技术方案的方法流程为:(1)准备钢管:将钢管内表面进行除尘、除锈处理;(2)将钢管加热至530℃;(3)在钢管内部通入680℃铝液,并使铝液均匀覆盖整个内壁,形成Al过渡层;(4)将经过热浸镀铝的钢管使用流动水冲洗,吹干;(5)配制自蔓延反应铝热剂粉料,按照重量百分比计,包括20% Al粉,4% Zr粉,1.5%B粉,5%Cr2O3粉,其余为Fe2O3粉。将铝热剂粉料在球磨机中混合4h;(6)将铝热剂粉料均匀的填充到钢管的内表面,填料密度为1.4g/cm3;(7)将填充好铝热剂粉料的钢管预热至温度150℃;(8)将钢管固定在离心机上,启动离心设备,使钢管离心力保持在75g;(9)点燃铝热剂粉料,待自蔓延反应完成,钢管温度冷却后,关闭离心机;(10)将经过前期处理的钢管使用流动水冲洗,吹干;(11)配制颗粒增强高分子涂料,每1L环氧树脂中加入25g Al2O3,要求Al2O3的粒度≤300目,加入质量为环氧树脂质量 12%的固化剂(T-31改性胺),并将该涂料超声搅拌1h,使其均匀化;(12)将钢管固定在离心机上,将颗粒增强高分子涂料注入钢管内部,加入量以可在钢管内壁形成1.3mm厚的颗粒增强高分子涂层;(13)启动离心设备,使钢管离心力保持在8g;(14)待高分子涂层固化后关闭离心机;(15)取出钢管结束。
参见图3为采用本发明实施例2所获得的多元复合涂层截面形貌图。另:采用该工艺所制备的涂层与无涂层的钢管在4.5%NaCl盐水溶液中浸泡200h,利用失重法测得其抗腐蚀性能较无涂层钢管提高了9-10倍(多批次考察结果);采用该工艺所制备的涂层与无涂层的钢管在4.5%NaCl盐水溶液中(加入质量分数为15%的Al2O3刚玉颗粒,粒径为300-500 μm。实验温度保持在25℃,冲击攻角为90°,流速为0.4m/s)冲蚀100h,利用失重法测得其耐冲蚀性能提高了10-12倍(多批次考察结果)。
实施例3
参见图4,采用本发明技术方案的方法流程为:(1)准备钢管:将钢管内表面进行除尘、除锈处理;(2)将钢管加热至550℃;(3)在钢管内部通入700℃铝液,并使铝液均匀覆盖整个内壁,形成Al过渡层;(4)将经过热浸镀铝的钢管使用流动水冲洗,吹干;(5)配制自蔓延反应铝热剂粉料,按照重量百分比计,包括25% Al粉,5% Zr粉,2%B粉,6%Cr2O3粉,其余为Fe2O3粉。将铝热剂粉料在球磨机中混合4h;(6)将铝热剂粉料均匀的填充到钢管的内表面,填料密度为1.5g/cm3;(7)将填充好铝热剂粉料的钢管预热至温度170℃;(8)将钢管固定在离心机上,启动离心设备,使钢管离心力保持在100g;(9)点燃铝热剂粉料,待自蔓延反应完成,钢管温度冷却后,关闭离心机;(10)将经过前期处理的钢管使用流动水冲洗,吹干;(11)配制颗粒增强高分子涂料,每1L环氧树脂中加入30g Al2O3,要求Al2O3的粒度≤300目,加入质量为环氧树脂质量 15%的固化剂(T-31改性胺),并将该涂料超声搅拌1h,使其均匀化;(12)将钢管固定在离心机上,将颗粒增强高分子涂料注入钢管内部,加入量以可在钢管内壁形成1.5mm厚的颗粒增强高分子涂层;(13)启动离心设备,使钢管离心力保持在10g;(14)待高分子涂层固化后关闭离心机;(15)取出钢管结束。
参见图4为采用本发明实施例3所获得的多元复合涂层截面形貌图。另:采用该工艺所制备的涂层与无涂层的钢管在4.5%NaCl盐水溶液中浸泡200h,利用失重法测得其抗腐蚀性能较无涂层钢管提高了9.5-10倍(多批次考察结果);采用该工艺所制备的涂层与无涂层的钢管在4.5%NaCl盐水溶液中(加入质量分数为15%的Al2O3刚玉颗粒,粒径为300-500 μm。实验温度保持在25℃,冲击攻角为90°,流速为0.4m/s)冲蚀100h,利用失重法测得其耐冲蚀性能提高了11-12倍(多批次考察结果)。
以上所揭露的仅为本发明较佳实施例而已,当然不能以此来限定本发明之权利范围,本领域普通技术人员可以理解实现上述实施例的全部或部分流程,并依本发明权利要求所作的等同变化,仍属于发明所涵盖的范围。
Claims (9)
1.一种钢管内表面抗腐蚀耐磨损复合涂层,其特征在于:包括:Al过渡层、陶瓷中间层和环氧树脂层;所述陶瓷中间层由含有Al、Zr、B、Cr的铝热剂通过自蔓延反应形成;所述环氧树脂层中按照每1L环氧树脂中加入20-30g Al2O3;所述铝热剂按照重量百分比计,包括:20%~25% Al粉,3%~5% Zr粉,1%~2% B粉,3%~6% Cr2O3粉,其余为Fe2O3粉。
2.根据权利要求1所述的一种钢管内表面抗腐蚀耐磨损复合涂层,其特征在于:所述环氧树脂层中Al2O3的粒度≤300目。
3.根据权利要求1所述的一种钢管内表面抗腐蚀耐磨损复合涂层,其特征在于:所述环氧树脂层中含有环氧树脂质量 10-15%的固化剂。
4.根据权利要求3所述的一种钢管内表面抗腐蚀耐磨损复合涂层,其特征在于:所述固化剂为T-31改性胺。
5.一种在钢管内表面形成权利要求1~4任一项所述复合涂层的工艺,在特征在于:包括如下步骤:
(1)将钢管内表面进行热浸镀铝,形成Al过渡层;
(2)在Al过渡层上通过自蔓延反应制备陶瓷中间层;
(3)在陶瓷中间层上通过离心法制备Al2O3增强的环氧树脂内层。
6.根据权利要求5所述的一种在钢管内表面形成涂层的工艺,其特征在于:所述步骤(1)具体包括如下步骤:
1-1.将钢管内表面进行除尘、除锈处理;
1-2.将钢管加热至500-550℃;
1-3.在钢管内部通入660-700℃的铝液,并使铝液均匀覆盖整个内壁,形成Al过渡层。
7.根据权利要求5所述的一种在钢管内表面形成涂层的工艺,在特征在于:所述步骤(2)具体包括如下步骤:
2-1.将形成Al过渡层的钢管使用流动水冲洗,吹干;
2-2.配制铝热剂粉料;
2-3.将铝热剂粉料在球磨机中混合3-4h;
2-4.将铝热剂粉料均匀填充到钢管内表面,填料密度为1.2-1.5g/cm3;
2-5.将填充好铝热剂粉料的钢管预热至温度130-170℃;
2-6.将钢管固定在离心机上,启动离心设备,使钢管离心力保持在50-100g;
2-7.点燃铝热剂粉料进行自蔓延反应,待自蔓延反应完成,钢管温度冷却后,关闭离心机,取下钢管。
8.根据权利要求7所述的一种在钢管内表面形成涂层的工艺,在特征在于:所述铝热剂按照重量百分比计,包括:20%~25% Al粉,3%~5% Zr粉,1%~2% B粉,3%~6% Cr2O3粉,其余为Fe2O3粉。
9.根据权利要求5所述的一种在钢管内表面形成涂层的工艺,在特征在于:所述步骤(3)具体包括如下步骤:
3-1.将形成陶瓷中间层的钢管使用流动水冲洗,吹干;
3-2.配制颗粒增强环氧树脂涂料,并将该涂料超声搅拌1h,使其均匀化;
3-3.将钢管固定在离心机上,将颗粒增强环氧树脂涂料注入钢管内部,加入量以可在钢管内壁形成1-1.5mm厚的环氧树脂层为宜;
3-4.启动离心设备,使钢管离心力保持在5-10g;
3-5.待高分子涂层固化后关闭离心机,取出钢管结束。
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