CN115159981A - 一种等离子喷涂用陶瓷造粒粉的制备方法 - Google Patents
一种等离子喷涂用陶瓷造粒粉的制备方法 Download PDFInfo
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Abstract
本发明提出的一种等离子喷涂用陶瓷造粒粉的制备方法为：将陶瓷微粉、分散剂、丙烯酰胺、交联剂、催化剂、引发剂、消泡剂均分的分散到去离子水中，制备出稳定的陶瓷浆料；然后先后将乳化剂和陶瓷浆料加入油相中，以一定转速搅拌制备出含陶瓷浆料微球的乳状液；乳化剂与陶瓷浆料的质量比为1:40~500；油相和陶瓷浆料的体积比为1:0.1~5；将所得到的乳状液放入微波干燥箱中保温一段时间以促进陶瓷浆料微球中的丙烯酰胺交联固化；用过滤的方式就可将固化后的陶瓷湿球和油相分离；湿球烘干后即可得到所需的球形陶瓷造粒粉。本发明所制备的粉体球形度高、纯度好、流动性较佳。本制备适用于工业化大规模生产，在热喷涂等领域极具前景。
Description
技术领域
本发明属于热喷涂技术领域，具体涉及一种等离子喷涂用陶瓷造粒粉的制备方法。
背景技术
等离子喷涂是采用压缩电弧作热源，连续的工作气体(氩气、氮气、氢气等)穿过压缩电弧而电离，成为高温高速的等离子焰流，喷涂材料通过等离子焰流加热到熔化或半熔化状态，并随同等离子焰流以高速喷射并沉积在经过粗化的洁净基材表面上，经淬冷凝固后形成喷涂层；使用等离子喷涂的方法在金属基体上制备陶瓷涂层，将金属材料良好的力学性能和陶瓷材料耐高温、耐磨损、耐腐蚀性能相结合，使其满足材料在工作时的机械性能和环境性能，得到完全符合工作需要的材料；等离子喷涂技术是目前制备陶瓷涂层的主要方法之一，已在国民经济的各个领域包括航天航空、钢铁冶金、石油化工、机械制造、能源技术等领域获得了广泛的应用。
合适的陶瓷粉末是等离子喷涂制备陶瓷涂层技术的关键；为保证喷涂过程中粉体的半熔化状态，喷涂粉的粒度要适中；为保证喷涂的效率，粉体的流动性要好，粉体的球形度要高、粒度不可以过小；纳米级和亚微米级粉末不能直接用于热喷涂，需要进行粉末颗粒的尺寸增大处理，即通过二次造粒改善粉末物性后用于等离子喷涂；各种二次造粒方法中，喷雾造粒法是最常用的方法之一；该法具有成本低、适用性广、成分与粒度易于控制的特点，可满足热喷涂粉末对物性的要求。
但是，喷雾造粒法制备等离子喷涂用陶瓷造粒粉存在如下问题：第一、粉体收得率低，喷雾造粒过程中有大量的粉体体粘结到造粒罐的罐壁上，难以被回收，严重影响粉体的利用率；第二、对设备要求较高，造粒粉体的质量很大程度上决定于喷雾干燥机；第三、喷雾造粒工艺较为复杂；针对纳米级和亚微米级粉末的新型二次造粒技术有待开发。
发明内容
针对现有技术存在的不足，本发明的目的在于提供一种等离子喷涂用陶瓷造粒粉的制备方法。
本发明为完成上述目的采用如下技术方案：
一种等离子喷涂用陶瓷造粒粉的制备方法，制备方法为：将陶瓷微粉、分散剂、丙烯酰胺、交联剂、催化剂、引发剂、消泡剂均分的分散到去离子水中，制备出稳定的陶瓷浆料；然后先后将乳化剂和陶瓷浆料加入油相中，以一定转速搅拌制备出含陶瓷浆料微球的乳状液；所述乳化剂与陶瓷浆料的质量比为1:40~500；所述油相和陶瓷浆料的体积比为1:0.1~5；将所得到的乳状液放入微波干燥箱中保温一段时间以促进陶瓷浆料微球中的丙烯酰胺交联固化；用过滤的方式就可将固化后的陶瓷湿球和油相分离；湿球烘干后即可得到所需的球形陶瓷造粒粉。
所述陶瓷微粉为ZrO2、Al2O3、YTaO4、Y2O3中的一种。
所述分散剂为聚乙二醇、Isobam-104、聚丙烯酸铵中的一种或多种。
所述交联剂、催化剂和引发剂分别为N,N’-亚甲基双丙烯酰胺、N,N,N,’N’-四甲基乙二胺和过硫酸铵。
所述消泡剂为正辛醇、二异丁基甲醇和二硬脂酰乙二胺中的一种或多种。
所述陶瓷微粉、分散剂、丙烯酰胺、交联剂、催化剂、引发剂、消泡剂和去离子水的质量比比例为 100、0.1~0.5、8~18、0.8~0.18、0.2~0.3、1~3、0.01~0.1和20~100。
所述是乳化剂为司班80。
所述的油相为氢聚硅氧烷、四甲基－四乙烯基－环四硅氧烷的一种或两种的混合。
所述微波加热的温度和时间60~80℃保温0.5~5 h。
本发明提出的一种等离子喷涂用陶瓷造粒粉的制备方法，所制备造粒粉球形度高、纯度好、粒度分布较为集中、流动性较佳、满足等离子喷涂对陶瓷粉末物性的要求；该方法操作简单，对设备要求低，收得率高（接近100 %），便于工业化大规模生产，在热喷涂领域极具前景。
附图说明
图1为本实施例3所制得的氧化铝等离子喷涂用造粒粉。
具体实施方式
结合附图和具体实施例对本发明作进一步描述：
实施例一：
一种等离子喷涂用陶瓷造粒粉的新型制备方法:
1.陶瓷浆料制备：以平均粒径为1 μm的1Kg钇稳定氧化锆为主要原料，加入200 g的去离子水、2 g的 Isobam-104，0.2 g的正辛醇球磨3小时；继续加入100 g的丙烯酰胺和10 g的N,N’-亚甲基双丙烯酰胺，2 g的N,N,N,’N’-四甲基乙二胺和20 g的过硫酸铵,球磨3小时等到稳定的陶瓷浆料。
2.油相混合液制备：量取氢聚硅氧烷的体积为陶瓷浆料体积的5倍，加入乳化剂司班80（体积分数为陶瓷浆料的1/100），以500 r/min的转速一边加热一边搅拌，加热到80 ℃保温30 min。
3.乳化造粒：将油相混合液放入微波干燥箱中，温度设备为80 ℃，在以500 r/min搅拌过程中逐滴加入陶瓷浆料，通过乳化的方式制备陶瓷浆料微球。继续加热2 h，促进陶瓷浆料微球固化。
4.过滤：通过过滤的方式将固化后的陶瓷微球分离出来。
5.干燥：110 ℃干燥至恒重，得到等离子喷涂用氧化锆造粒粉。
本实施例所得等离子喷涂用氧化锆造粒粉，球形度较好，粒径为30~110 μm，流动性较佳，可到35s/50g以下。
实施例二：
一种等离子喷涂用陶瓷造粒粉的新型制备方法:
1.陶瓷浆料制备：以平均粒径为0.8 μm的1Kg氧化钇为主要原料，加入280 g去离子水、3 g的聚丙烯酸铵，0.3 g的正辛醇球磨3小时；继续加入110 g的丙烯酰胺，11 g的N,N’-亚甲基双丙烯酰胺，2 g的N,N,N,’N’-四甲基乙二胺和15 g的过硫酸铵,球磨3小时等到稳定的陶瓷浆料。
2.油相混合液制备：量取氢聚硅氧烷的体积为陶瓷浆料体积的4倍，加入乳化剂司班80（体积分数为陶瓷浆料的1/200），以500 r/min的转速一边加热一边搅拌，加热到80 ℃保温30 min。
3.乳化造粒：将油相混合液放入微波干燥箱中，温度设备为80 ℃，在以500 r/min搅拌过程中逐滴加入陶瓷浆料，通过乳化的方式制备陶瓷浆料微球。继续加热2 h，促进陶瓷浆料微球固化。
4.过滤：通过过滤的方式将固化后的陶瓷微球分离出来。
5.干燥：110 ℃干燥至恒重，得到等离子喷涂用氧化钇造粒粉。
本实施例所得等离子喷涂用氧化钇造粒粉，球形度较好，粒径为20~120 μm，流动性较佳，可到40s/50g以下。
实施例三：
一种等离子喷涂用陶瓷造粒粉的新型制备方法:
1.陶瓷浆料制备：以平均粒径为1.1 μm的1Kg氧化铝为主要原料，加入200 g去离子水、2 g的Isobam-104，0.3 g的正辛醇球磨3小时；继续加入120 g的丙烯酰胺，12 g的N,N’-亚甲基双丙烯酰胺，2 g的N,N,N,’N’-四甲基乙二胺和12 g的过硫酸铵,球磨3小时等到稳定的陶瓷浆料。
2.油相混合液制备：量取氢聚硅氧烷的体积为陶瓷浆料体积的6倍，加入乳化剂司班80（体积分数为陶瓷浆料的1/150），以500 r/min的转速一边加热一边搅拌，加热到80 ℃保温30 min。
3.乳化造粒：将油相混合液放入微波干燥箱中，温度设备为80 ℃，在以500 r/min搅拌过程中逐滴加入陶瓷浆料，通过乳化的方式制备陶瓷浆料微球。继续加热2 h，促进陶瓷浆料微球固化。
4.过滤：通过过滤的方式将固化后的陶瓷微球分离出来。
5.干燥：110 ℃干燥至恒重，得到等离子喷涂用氧化铝造粒粉。
本实施例所得等离子喷涂用氧化铝造粒粉，球形度较好，粒径为35~90 μm，流动性较佳，可到33s/50g以下。本实施例所制得的氧化锆等离子喷涂用造粒粉的SEM如图1所示。
实施例四：
一种等离子喷涂用陶瓷造粒粉的新型制备方法:
1.陶瓷浆料制备：以平均粒径为1 μm的1Kg钇稳定氧化锆为主要原料，加入180 g的去离子水、5 g的聚乙二醇，0.2 g的正辛醇球磨3小时；继续加入90 g的丙烯酰胺和9 g的N,N’-亚甲基双丙烯酰胺，2 g的N,N,N,’N’-四甲基乙二胺和20 g的过硫酸铵,球磨3小时等到稳定的陶瓷浆料。
2.油相混合液制备：量取氢聚硅氧烷的体积为陶瓷浆料体积的5倍，加入乳化剂司班80（体积分数为陶瓷浆料的1/150），以500 r/min的转速一边加热一边搅拌，加热到80 ℃保温30 min。
3.乳化造粒：将油相混合液放入微波干燥箱中，温度设备为80 ℃，在以500 r/min搅拌过程中逐滴加入陶瓷浆料，通过乳化的方式制备陶瓷浆料微球。继续加热2 h，促进陶瓷浆料微球固化。
4.过滤：通过过滤的方式将固化后的陶瓷微球分离出来。
5.干燥：110 ℃干燥至恒重，得到等离子喷涂用氧化锆造粒粉。
本实施例所得等离子喷涂用氧化锆造粒粉，球形度较好，粒径为20~120 μm，流动性较佳，可到40s/50g以下。
Claims (9)
1.一种等离子喷涂用陶瓷造粒粉的制备方法，制备方法为：将陶瓷微粉、分散剂、丙烯酰胺、交联剂、催化剂、引发剂、消泡剂均分的分散到去离子水中，制备出稳定的陶瓷浆料；其特征在于:然后先后将乳化剂和陶瓷浆料加入油相中，以一定转速搅拌制备出含陶瓷浆料微球的乳状液；所述乳化剂与陶瓷浆料的质量比为1:40~500；所述油相和陶瓷浆料的体积比为1:0.1~5；将所得到的乳状液放入微波干燥箱中保温一段时间以促进陶瓷浆料微球中的丙烯酰胺交联固化；用过滤的方式就可将固化后的陶瓷湿球和油相分离；湿球烘干后即可得到所需的球形陶瓷造粒粉。
2.根据权利要求1所述的一种等离子喷涂用陶瓷造粒粉的制备方法，其特征在于，所述陶瓷粉体包括但不限于ZrO2、Al2O3、YTaO4、Y2O3中的一种。
3.根据权利要求1所述的一种等离子喷涂用陶瓷造粒粉的制备方法，其特征在于，所述分散剂为聚乙二醇、Isobam-104、聚丙烯酸铵中的一种或多种。
4.如权利要求1所述的一种等离子喷涂用陶瓷造粒粉的制备方法，其特征在于：所述交联剂、催化剂和引发剂分别为N,N’-亚甲基双丙烯酰胺、N,N,N,’N’-四甲基乙二胺和过硫酸铵。
5.如权利要求1所述的一种等离子喷涂用陶瓷造粒粉的制备方法，其特征在于：所述消泡剂为正辛醇、二异丁基甲醇和二硬脂酰乙二胺中的一种或多种。
6.如权利要求1所述的一种等离子喷涂用陶瓷造粒粉的制备方法，其特征在于：所述所述陶瓷微粉、分散、丙烯酰胺、交联剂、催化剂、引发剂、消泡剂和去离子水的比例为 100、0.1~0.5、8~18、0.8~0.18、0.2~0.3、1~3、0.01~0.1和20~100。
7.如权利要求1所述的一种等离子喷涂用陶瓷造粒粉的制备方法，其特征在于：所述乳化剂为司班80。
8.如权利要求1所述的一种等离子喷涂用陶瓷造粒粉的制备方法，其特征在于：所述乳化剂和陶瓷浆料的质量比为1:40~500；所述油和陶瓷浆料的体积比为1:0.1~5。
9.如权利要求1所述的一种等离子喷涂用陶瓷造粒粉的制备方法，其特征在于：所述微波加热的温度为50~100℃。
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