CN115386840A - Corrosion-resistant wear-resistant ZnNiAl coating and spraying method thereof - Google Patents
Corrosion-resistant wear-resistant ZnNiAl coating and spraying method thereof Download PDFInfo
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- 238000000576 coating method Methods 0.000 title claims abstract description 153
- 239000011248 coating agent Substances 0.000 title claims abstract description 147
- 238000005507 spraying Methods 0.000 title claims abstract description 133
- 238000005260 corrosion Methods 0.000 title claims abstract description 85
- 230000007797 corrosion Effects 0.000 title claims abstract description 81
- 229910000831 Steel Inorganic materials 0.000 claims description 75
- 239000010959 steel Substances 0.000 claims description 75
- 239000007921 spray Substances 0.000 claims description 57
- 239000000463 material Substances 0.000 claims description 50
- 238000010891 electric arc Methods 0.000 claims description 34
- 238000000034 method Methods 0.000 claims description 29
- 239000002344 surface layer Substances 0.000 claims description 22
- 229910003310 Ni-Al Inorganic materials 0.000 claims description 17
- 239000010410 layer Substances 0.000 claims description 11
- 238000005488 sandblasting Methods 0.000 claims description 11
- 230000037452 priming Effects 0.000 claims description 10
- 238000010438 heat treatment Methods 0.000 claims description 9
- 229910052725 zinc Inorganic materials 0.000 claims description 8
- 238000005422 blasting Methods 0.000 claims description 4
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 2
- 230000009286 beneficial effect Effects 0.000 abstract description 4
- 229910000765 intermetallic Inorganic materials 0.000 abstract description 3
- 230000000052 comparative effect Effects 0.000 description 17
- 150000003839 salts Chemical class 0.000 description 17
- 238000007655 standard test method Methods 0.000 description 8
- 238000001514 detection method Methods 0.000 description 7
- 229910045601 alloy Inorganic materials 0.000 description 5
- 239000000956 alloy Substances 0.000 description 5
- 230000003750 conditioning effect Effects 0.000 description 5
- 229910007570 Zn-Al Inorganic materials 0.000 description 3
- 239000002923 metal particle Substances 0.000 description 3
- 239000011148 porous material Substances 0.000 description 3
- 239000000758 substrate Substances 0.000 description 3
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 230000001105 regulatory effect Effects 0.000 description 2
- 238000007789 sealing Methods 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 229910000943 NiAl Inorganic materials 0.000 description 1
- NPXOKRUENSOPAO-UHFFFAOYSA-N Raney nickel Chemical compound [Al].[Ni] NPXOKRUENSOPAO-UHFFFAOYSA-N 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 239000003153 chemical reaction reagent Substances 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 230000001276 controlling effect Effects 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000009792 diffusion process Methods 0.000 description 1
- 238000007598 dipping method Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 238000005554 pickling Methods 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 230000002035 prolonged effect Effects 0.000 description 1
- 238000005728 strengthening Methods 0.000 description 1
- 230000009466 transformation Effects 0.000 description 1
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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
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C18/00—Alloys based on zinc
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C18/00—Alloys based on zinc
- C22C18/04—Alloys based on zinc with aluminium as the next major constituent
-
- 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
- C23C14/02—Pretreatment of the material to be coated
- C23C14/021—Cleaning or etching treatments
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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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Abstract
The invention discloses a corrosion-resistant wear-resistant ZnNiAl coating and a spraying method thereof. The intermetallic compound formed between the Ni and the Al is beneficial to improving the wear resistance of the coating while not improving the corrosion rate and reducing the density of the coating.
Description
Technical Field
The invention relates to the technical field of metal surface corrosion and protection, in particular to a corrosion-resistant and wear-resistant ZnNiAl coating and a spraying method thereof.
Background
At present, the electric arc spraying technology is successfully applied to steel structure bridges, television towers, power transmission and transformation iron towers, underground cable pipelines and low-temperature reaction chemical equipment in China, the anti-corrosion requirement is met through electric arc or plasma coatings, the service life of steel components is greatly prolonged, the electrode potentials of Al and Zn are lower than that of steel materials, and even if the porosity of the coatings is high or a medium is locally damaged, the Al and Zn serve as sacrificial anodes to provide corrosion protection for the steel materials (cathodes). In addition, al and Zn coatings also have a "self-healing" property of the pores-corrosion products can further fill the pores to heal the pores and further hinder the progress of the corrosion reaction. Therefore, znAl alloy is the most commonly used steel structure anticorrosion coating material. The ZnAl alloy coating prepared by adopting the electric arc spraying method avoids the pollution of hot dipping, is suitable for preparing the anticorrosive coating of a large-scale steel structure and is convenient for field construction. In the production, the ZnAl alloy coating is prepared by an electric arc spraying method to improve the corrosion resistance of a steel structure.
However, the wear resistance of the ZnAl alloy coating prepared by the electric arc spraying method is relatively low, so that the coating is easy to damage under a wear environment, and the corrosion resistance is lost. But the spraying of the organic sealing coating leads to that the anti-corrosion coating can seal the pores of the hot-sprayed ZnAl coating, thereby improving the anti-corrosion and wear-resistant properties. However, the sealing process significantly increases the material and process costs, and is not suitable for popularization and application.
Therefore, an alloy coating which has strong bonding force and low cost, can resist wear and corrosion is urgently needed to be developed so as to comprehensively improve the comprehensive corrosion and wear resistance of the steel structure.
Disclosure of Invention
The invention aims to solve the technical problem of providing the corrosion-resistant and wear-resistant ZnNiAl coating and the spraying method thereof aiming at the defects of the prior art, the corrosion-resistant and wear-resistant ZnNiAl coating prepared by the spraying method has strong binding force and lower cost, and the intermetallic compound formed between Ni and Al elements in the coating is beneficial to improving the wear resistance of the coating while not improving the corrosion rate and reducing the density of the coating, so that the ZnNiAl coating has the functions of cathode protection and shielding protection at the same time, and the wear resistance and corrosion resistance of a steel structure are improved.
In order to solve the technical problems, the technical scheme adopted by the invention is as follows:
the corrosion-resistant and wear-resistant ZnNiAl coating comprises the following components in percentage by mass: 60-80 wt% of Zn, 10-30 wt% of Ni and 5-15 wt% of Al; the microhardness of the coating is more than or equal to 150HV 0.5 。
Further, the corrosion-resistant wear-resistant ZnNiAl coating comprises the following components in percentage by mass: zn 65wt.% to 80wt.%, ni 10wt.% to 25wt.%, and Al 10wt.% to 15wt.%, wherein the microhardness of the coating is more than or equal to 160HV 0.5 。
The spraying method for preparing the corrosion-resistant wear-resistant ZnNiAl coating comprises the following steps:
s1, pretreating the surface of a steel structure to be more than Sa2.5 grade by adopting a sand blasting method;
and S2, heating the spraying material to a molten state by adopting an electric arc spraying method, and spraying the spraying material to the surface of the steel structure pretreated in the step S1 through a multi-wire inclined electric arc under the action of compressed air to form the corrosion-resistant and wear-resistant ZnNiAl coating.
Further, the blasting method of step S1 is a high-pressure water blasting method.
Further, the multi-wire inclined arc spraying in the step S2 specifically includes: s2.1, spraying a priming coat; s2.2, spraying a surface layer.
Further, the specific step of S2.1 is: the wire material adopts Ni-5-10 wt.% Al, the distance between a spray gun and the surface of a steel structure is 150-300 mm, the spraying angle of the spray gun is 80-90 degrees, the arc voltage is 30-40V, the arc current is 100-150A, the conveying speed of a spraying material is 0.3-1 m/min, and the pressure of compressed air is 0.5-0.9 MPa, so that the Ni-Al priming coat is obtained.
Further, the specific step of S2.2 is: pure Zn or Zn-10-15 wt.% Al wire and Ni-5-10 wt.% Al are adopted as the wire, a double-spray gun is adopted to respectively spray the pure Zn or Zn-10-15 wt.% Al wire and Ni-5-10 wt.% Al, the distance between the double-spray gun and the surface of the steel structure is 150-500 mm, the spraying angle of the double-spray gun is 30-60 degrees, the arc voltage is 20-40V, the arc current is 100-250A, the conveying speed of the spraying material is 0.4-1.5 m/min, the pressure of compressed air is 0.5-0.9 MPa, and the ZnNiAl surface layer is obtained.
Furthermore, the corrosion-resistant and wear-resistant ZnNiAl coating consists of a bottom layer and a surface layer, and the total thickness is 90-140 microns.
The invention has the beneficial effects that:
1. according to the corrosion-resistant wear-resistant heterogeneous wire material double-spray-gun electric arc spraying ZnNiAl coating, the Ni element is added into the common Zn and Al corrosion-resistant coating elements to serve as a strengthening element, and the intermetallic compound formed between the Ni element and the Al element is beneficial to improving the wear resistance of the coating and realizing the shielding protection function on a steel structure while the corrosion rate is not improved and the density of the coating is not reduced. Therefore, the ZnNiAl provided by the invention has the effects of cathode protection and shielding protection, improves the wear resistance and corrosion resistance of a steel structure, and meets the application requirements of the steel structure in mechanical friction and corrosion environments.
2. The invention relates to a corrosion-resistant wear-resistant dissimilar wire double-spray gun electric arc spraying ZnNiAl coating, which is characterized in that Ni in a spraying material of the ZnNiAl corrosion-resistant wear-resistant coating can absorb oxygen in compressed air, the coating material is atomized under the action of the compressed air to form high-speed metal particle flow without an oxide film on the surface, then the high-speed metal particle flow collides and deposits on the surface of a steel structure to form the coating, so that Ni-Al elements in the coating form tight metal bond combination to form a high-hardness Ni-Al compound,the microhardness of the coating reaches 160HV 0.5 The above.
3. The NiAl coating of the invention can be used as a priming coating and can show good corrosion resistance, impact resistance and good chemical solution resistance. Meanwhile, the coating has excellent bonding strength with the substrate.
4. The wear-resistant and corrosion-resistant ZnNiAl coating is prepared by adopting heterogeneous wire double-spray gun electric arc spraying, so that intermetallic mechanical combination is formed between the coating and a steel structure, and meanwhile, ni-5-10 wt.% of Al wire sprayed by a spray gun on one side in the process of preparing the wear-resistant and corrosion-resistant ZnNiAl coating improves the temperature and the speed of atomized metal particles, so that the diffusion is caused by collision on the surface of the steel structure, the combined action of metallurgical combination and mechanical combination is obtained, the combination strength between the coating and the steel structure is greatly improved, and the combination strength between the coating and the steel structure is larger than 25MPa.
5. The wear-resistant and corrosion-resistant ZnNiAl coating is prepared by adopting double-spray gun electric arc spraying of heterogeneous wires, and because the metallurgical bonding between the coating and the steel structure is tighter, only simple sand blasting pretreatment needs to be carried out on the steel structure, so that the pickling pretreatment process of the steel structure is avoided, the cost is reduced, no pollution is caused to the environment, and the method is safe and environment-friendly.
6. The wear-resistant and corrosion-resistant ZnNiAl coating wire prepared by adopting the heterogeneous wire double-spray gun electric arc spraying not only can adopt the common Zn-Al wire and Ni-Al wire in the market, but also can adopt the pure Zn wire and Ni-Al wire or the pure Ni wire and Zn-Al wire, and has wide source range and convenient use.
7. According to the invention, zn-10-15 wt.% Al wire and Ni-5-10 wt.% Al wire are adopted as the spraying material of the wear-resistant and corrosion-resistant ZnNiAl coating in a double-spray gun electric arc spraying manner, and the spraying distance between each spray gun and a steel structure substrate can be adjusted in the electric arc spraying process according to the corrosion-resistant and wear-resistant requirements of an actual steel structure, so that the component content of the corrosion-resistant and wear-resistant ZnNiAl coating is regulated and controlled, the spraying is flexible and convenient, the Ni-Al wire and the Zn-Al wire react firstly during spraying, a uniform coating structure is formed, and the spraying efficiency and quality of the wear-resistant and corrosion-resistant ZnNiAl coating are improved.
8. The method adopts the heterogeneous wire double-spray gun electric arc spraying to prepare the wear-resistant and corrosion-resistant ZnNiAl coating wire, the spraying wire is common and easily available in the market, the cost is lower, and the electric arc spraying method is mature in process, easy to realize and suitable for popularization.
Drawings
FIG. 1 is a surface photomicrograph of an arc spray coating of example 1 of the invention;
FIG. 2 is a schematic diagram of the surface SEM appearance of the wear-resistant and corrosion-resistant ZnNiAl coating of the invention;
FIG. 3 is the XRD result of the wear-resistant and corrosion-resistant ZnNiAl coating of the invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention. It is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all embodiments, and all other embodiments obtained by those skilled in the art without any inventive work are within the scope of the present invention.
In order to better understand the present invention, the following examples are further provided for illustration, which are only used for explaining the present invention and do not limit the present invention in any way.
The following examples are intended to illustrate the invention but are not intended to limit the scope of the invention. Unless otherwise specified, the technical means used in the examples are conventional means well known to those skilled in the art, and reagents, instruments or equipment of any manufacturer not specified may be commercially available.
Example 1
The components of the corrosion-resistant wear-resistant ZnNiAl coating of the embodiment 1 in percentage by mass are as follows: zn 69.7wt.%, ni 19.1wt.%, al 11.2wt.%.
The spraying method comprises the following steps:
s1: pretreating the surface of the steel structure to Sa2.5 grade by adopting a sand blasting method;
s2: and (3) heating the spraying material to a molten state by adopting an electric arc spraying method, and spraying the spraying material to the surface of the steel structure pretreated in the step (S1) through a multi-wire inclined electric arc under the action of compressed air. Firstly, forming a bottom layer: adopting Ni-5wt.% Al wire, wherein the distance between a spray gun and the surface of a steel structure is 200mm, the spraying angle of the spray gun is 90 degrees, the arc voltage is 38V, the arc current is 150A, the conveying speed of a spraying material is 0.8m/min, and the pressure of compressed air is 0.6MPa, so as to obtain a Ni-Al priming coat;
and then forming a surface layer: adopting Zn-15wt.% Al wire and Ni-5wt.% Al wire, wherein the distance between a double-spray gun and the surface of a steel structure is 200mm, the spraying angles of the spray guns are 45 degrees, the arc voltage is 25V and 38V respectively, the arc current is 120A and 200A, the conveying speed of the spraying material is 1.13 m/min and 0.81m/min respectively, and the pressure of compressed air is 0.6MPa, so as to obtain the ZnNiAl surface layer.
Through detection, the thickness of the ZnNiAl wear-resistant and corrosion-resistant coating prepared by the embodiment is 130 μm, the microhardness is 196HV0.5, and the interface bonding strength between the ZnNiAl coating and a steel structure is 38MPa, so that the ZnNiAl coating prepared by the embodiment has higher hardness and is tightly bonded with the steel structure.
The ZnNiAl coating prepared in the embodiment is detected according to ASTM G133-05 Standard Test Method for Linear conditioning Ball-on-Flat Sliding Wear, and the result shows that the Wear resistance time of the ZnNiAl coating prepared in the embodiment under a normal load of 1.96N (0.2 kilogram force) is 4050s, which shows that the ZnNiAl coating prepared in the embodiment has better Wear resistance.
The ZnNiAl coating prepared in the embodiment is detected according to GB/T10125-1997 salt spray test for artificial atmosphere corrosion test, and the result shows that the salt spray resistance time of the ZnNiAl coating prepared in the embodiment is 1580h, which indicates that the ZnNiAl coating prepared in the embodiment has better corrosion resistance.
Example 2
The corrosion-resistant and wear-resistant ZnNiAl coating of the embodiment 2 comprises the following components in percentage by mass: zn 75.1wt.%, ni 12.5wt.%, al 12.4wt.%.
The spraying method comprises the following steps:
s1: pretreating the surface of the steel structure to Sa2.5 grade by adopting a sand blasting method;
s2: heating the spraying material to a molten state by adopting an electric arc spraying method, spraying the spraying material to the surface of the steel structure pretreated in the step S1 through a multi-wire inclined electric arc under the action of compressed air, and firstly forming a priming layer: adopting Ni-8wt.% Al wire, wherein the distance between a spray gun and the surface of a steel structure is 200mm, the spraying angle of the spray gun is 85 degrees, the arc voltage is 37V, the arc current is 130A, the conveying speed of the spraying material is 0.7m/min, and the pressure of compressed air is 0.7MPa, so as to obtain the Ni-Al priming coat.
And then forming a surface layer, wherein the surface layer forming process comprises the following steps: zn-12wt.% Al wire and Ni-7 wt.% Al are adopted, the distances between a double-spraying gun and the surface of a steel structure are 170mm and 340mm respectively, the spraying angles of the spraying guns are 50 degrees, the arc voltages are 30V and 35V respectively, the arc currents are 150A and 220A, the conveying speeds of the spraying materials are 1.25m/min and 0.67m/min respectively, and the pressure of compressed air is 0.7MPa, so that a ZnNiAl surface layer is obtained.
Through detection, the thickness of the ZnNiAl wear-resistant and corrosion-resistant coating prepared by the embodiment is 115 mu m, and the microhardness is 172HV 0.5 The interface bonding strength of the ZnNiAl coating and the steel structure is 33MPa, and therefore the ZnNiAl coating prepared by the embodiment is high in hardness and is tightly bonded with the steel structure.
The ZnNiAl coating prepared in the embodiment is detected according to ASTM G133-05 Standard Test Method for Linear conditioning Ball-on-Flat Sliding Wear, and the result shows that the ZnNiAl coating prepared in the embodiment has the Wear resistance time of 3840s under the normal load of 1.96N (0.2 kilogram force), which indicates that the ZnNiAl coating prepared in the embodiment has better Wear resistance.
The ZnNiAl coating prepared in the embodiment is detected according to GB/T10125-1997 salt spray test for artificial atmosphere corrosion test, and the result shows that the salt spray resistance time of the ZnNiAl coating prepared in the embodiment is 1420h, which indicates that the ZnNiAl coating prepared in the embodiment has better corrosion resistance.
Example 3
The corrosion-resistant and wear-resistant ZnNiAl coating in the embodiment 3 comprises the following components in percentage by mass: zn 79.5wt.%, ni 12.3wt.%, al 10.2wt.%.
The spraying method comprises the following steps:
s1: pretreating the surface of the steel structure to Sa2.5 grade by adopting a sand blasting method;
s2: heating the spraying material to a molten state by adopting an electric arc spraying method, spraying the spraying material to the surface of the steel structure pretreated in the step S1 through a multi-wire inclined electric arc under the action of compressed air, and firstly forming a bottom layer: the Ni-Al base coat is obtained by adopting Ni-10wt.% Al wire material, wherein the distance between the Ni-10wt.% Al wire material and the surface of a steel structure is 300mm, the spraying angle of a spray gun is 80 degrees, the arc voltage is 38V, the arc current is 150A, the conveying speed of the spraying material is 0.6 m/min, and the pressure of compressed air is 0.8 MPa. And then forming a surface layer: the distances between a spray gun of Zn-11wt.% Al wire and a spray gun of Ni-9wt.% Al wire and the surface of a steel structure are respectively 160 mm and 480mm, the spraying angles of the spray guns are both 60 degrees, the arc voltages are respectively 25V and 38V, the arc currents are 180A and 250A, the conveying speeds of the spraying materials are respectively 1.22m/min and 0.53 m/min, and the pressure of compressed air is 0.8MPa, so that a ZnNiAl surface layer is obtained.
Through detection, the thickness of the ZnNiAl wear-resistant and corrosion-resistant coating prepared by the embodiment is 98 mu m, and the microhardness is 162HV 0.5 The interface bonding strength of the ZnNiAl coating and the steel structure is 31MPa, which shows that the ZnNiAl coating prepared by the embodiment has higher hardness and is tightly bonded with the steel structure.
The ZnNiAl coating prepared in the embodiment is detected according to ASTM G133-05 Standard Test Method for Linear conditioning Ball-on-Flat Sliding Wear, and the result shows that the ZnNiAl coating prepared in the embodiment has the Wear resistance time of 3630s under the normal load of 1.96N (0.2 kilogram force), which indicates that the ZnNiAl coating prepared in the embodiment has better Wear resistance.
The ZnNiAl coating prepared in the embodiment is detected according to GB/T10125-1997 salt spray test for artificial atmosphere corrosion test, and the result shows that the salt spray resistance time of the ZnNiAl coating prepared in the embodiment is 1280h, which indicates that the ZnNiAl coating prepared in the embodiment has better corrosion resistance.
Example 4
The components of the corrosion-resistant wear-resistant ZnNiAl coating in the embodiment 4 in percentage by mass are as follows: zn 65.2wt.%, ni 20.7wt.%, al 14.1wt.%.
The spraying method comprises the following steps:
s1: pretreating the surface of the steel structure to Sa2.5 grade by adopting a sand blasting method;
s2: heating the spraying material to a molten state by adopting an electric arc spraying method, spraying the spraying material to the surface of the steel structure pretreated in the step S1 through a multi-wire inclined electric arc under the action of compressed air, and firstly forming a bottom layer: the Ni-Al base coat is obtained by adopting Ni-5wt.% Al wire material with the distance of 300mm from the surface of a steel structure, the spraying angle of a spray gun is 80 degrees, the arc voltage is 40V, the arc current is 150A, the conveying speed of the spraying material is 0.6 m/min, and the pressure of compressed air is 0.9 MPa. And then forming a surface layer: distances between a spray gun of Zn-15wt.% Al wire and Ni-5wt.% Al wire and the surface of the steel structure are 400mm and 200mm respectively, spraying angles of the spray guns are 30 degrees, arc voltages are 25V and 38V respectively, arc currents are 100A and 250A, conveying speeds of the spraying materials are 0.92m/min and 0.63 m/min respectively, and the pressure of compressed air is 0.9MPa, so that the ZnNiAl surface layer is obtained.
The ZnNiAl coating prepared by the embodiment is detected to have the thickness of 106 mu m and the microhardness of 205 HV 0.5 The interface bonding strength of the ZnNiA coating and the steel structure is 43MPa, which shows that the ZnNiAl coating prepared by the embodiment has higher hardness and is more tightly bonded with the steel structure.
The ZnNiAl coating prepared in the embodiment is detected according to ASTM G133-05 Standard Test Method for Linear repairing Ball-on-Flat Sliding Wear, and the result shows that the Wear resistance time of the ZnNiAl coating prepared in the embodiment under a normal load of 1.96N (0.2 kilogram force) is 4530s, which shows that the ZnNiAl coating prepared in the embodiment has better Wear resistance.
The ZnNiAl coating prepared in the embodiment is detected according to GB/T10125-1997 salt spray test for artificial atmosphere corrosion test, and the result shows that the salt spray resistance time of the ZnNiAl coating prepared in the embodiment is 1320h, which indicates that the ZnNiAl coating prepared in the embodiment has better corrosion resistance.
Example 5
The corrosion-resistant wear-resistant ZnNiAl coating of the embodiment 5 comprises the following components in percentage by mass: zn 64.9wt.%, ni 25.3wt.%, al 9.8wt.%.
The spraying method comprises the following steps:
s1: pretreating the surface of the steel structure to Sa2.5 grade by adopting a sand blasting method;
s2: and (3) heating the spraying material to a molten state by adopting an electric arc spraying method, and spraying the spraying material to the surface of the steel structure pretreated in the step (S1) through a multi-wire inclined electric arc under the action of compressed air. Firstly, forming a bottom layer: adopting Ni-10wt.% Al wire, wherein the distance between a spray gun and the surface of a steel structure is 150mm, the spraying angle of the spray gun is 90 degrees, the arc voltage is 30V, the arc current is 100A, the conveying speed of a spraying material is 0.3m/min, and the pressure of compressed air is 0.5MPa, so as to obtain a Ni-Al base coat;
and then forming a surface layer: pure Zn wire and Ni-10wt.% Al wire are adopted, the distances between a double-spraying gun and the surface of a steel structure are respectively 150mm and 400mm, the spraying angles of the spraying guns are both 45 degrees, the arc voltages are respectively 20V and 40V, the arc currents are 120A and 240A, the conveying speeds of the spraying materials are respectively 1.50m/min and 0.59m/min, and the pressure of compressed air is 0.5MPa, so that the ZnNiAl surface layer is obtained.
Through detection, the thickness of the ZnNiAl wear-resistant and corrosion-resistant coating prepared by the embodiment is 109 micrometers, the microhardness is 156HV0.5, and the interface bonding strength of the ZnNiAl coating and a steel structure is 27MPa, so that the ZnNiAl coating prepared by the embodiment has higher hardness and is more tightly bonded with the steel structure.
The ZnNiAl coating prepared in the embodiment is detected according to ASTM G133-05 Standard Test Method for Linear conditioning Ball-on-Flat Sliding Wear, and the result shows that the Wear resistance time of the ZnNiAl coating prepared in the embodiment under a normal load of 1.96N (0.2 kilogram force) is 3110s, which indicates that the ZnNiAl coating prepared in the embodiment has better Wear resistance.
The ZnNiAl coating prepared in the embodiment is detected according to GB/T10125-1997 salt spray test for artificial atmosphere corrosion test, and the result shows that the salt spray resistance time of the ZnNiAl coating prepared in the embodiment is 1260h, which indicates that the ZnNiAl coating prepared in the embodiment has better corrosion resistance.
Example 6
The corrosion-resistant wear-resistant ZnNiAl coating of the embodiment 6 comprises the following components in percentage by mass: zn 65.6wt.%, ni 29.3wt.%, al 5.1wt.%.
The spraying method comprises the following steps:
s1: pretreating the surface of the steel structure to Sa2.5 grade by adopting a sand blasting method;
s2: and (3) heating the spraying material to a molten state by adopting an electric arc spraying method, and spraying the spraying material to the surface of the steel structure pretreated in the step (S1) through a multi-wire inclined electric arc under the action of compressed air. Firstly, forming a bottom layer: adopting Ni-8wt.% Al wire, wherein the distance between a spray gun and the surface of a steel structure is 250mm, the spraying angle of the spray gun is 85 degrees, the arc voltage is 35V, the arc current is 140A, the conveying speed of a spraying material is 1.0m/min, and the pressure of compressed air is 0.9MPa, so as to obtain a Ni-Al priming coat;
and then forming a surface layer: the ZnNiAl surface layer is obtained by adopting Zn-10wt.% Al wire and Ni-10wt.% Al wire, the distance between a double-spraying gun and the surface of a steel structure is 200mm and 300mm, the spraying angles of the spraying guns are both 55 degrees, the arc voltages are respectively 30V and 39V, the arc currents are 160A and 210A, the conveying speeds of the spraying materials are respectively 1.05m/min and 0.79m/min, and the pressure of compressed air is 0.7 MPa.
Through detection, the thickness of the ZnNiAl wear-resistant and corrosion-resistant coating prepared by the embodiment is 117 microns, the microhardness is 188HV0.5, and the interface bonding strength between the ZnNiAl coating and a steel structure is 36MPa, so that the ZnNiAl coating prepared by the embodiment has higher hardness and is tightly bonded with the steel structure.
The ZnNiAl coating prepared in the embodiment is detected according to ASTM G133-05 Standard Test Method for Linear repairing Ball-on-Flat Sliding Wear, and the result shows that the Wear resistance time of the ZnNiAl coating prepared in the embodiment under the normal load of 1.96N (0.2 kilogram force) is 3960s, which indicates that the ZnNiAl coating prepared in the embodiment has better Wear resistance.
The ZnNiAl coating prepared in the embodiment is detected according to GB/T10125-1997 salt spray test for artificial atmosphere corrosion test, and the result shows that the salt spray resistance time of the ZnNiAl coating prepared in the embodiment is 1390h, which indicates that the ZnNiAl coating prepared in the embodiment has better corrosion resistance.
Comparative example 1
The corrosion-resistant wear-resistant ZnNiAl coating of the comparative example 1 comprises the following components in percentage by mass: zn 83.1wt.%, ni 9.1wt.%, al 7.8wt.%.
The spraying method comprises the following steps:
s1, pretreating the surface of a steel structure to Sa2.5 level by adopting a sand blasting method;
s2, heating the spraying material to a molten state by adopting an electric arc spraying method, spraying the spraying material to the surface of the steel structure pretreated in the step S1 through a multi-wire inclined electric arc under the action of compressed air, and firstly forming a priming coat, wherein the priming coat forming process comprises the following steps: adopting Ni-5wt.% Al wire, wherein the distance between a spray gun and the surface of a steel structure is 300mm, the spraying angle of the spray gun is 70 degrees, the arc voltage is 20V, the arc current is 90A, the conveying speed of the spraying material is 0.5m/min, and the pressure of compressed air is 0.5MPa, so as to obtain a Ni-Al base coat;
the ZnNiAl surface layer spraying process comprises the following steps: zn-15wt.% Al wire and Ni-5wt.% Al are adopted, the distances between a double-spraying gun and the surface of a steel structure are respectively 150mm and 600mm, the spraying angles of the spraying guns are both 45 degrees, the arc voltages are respectively 20V and 45V, the arc currents are respectively 90A and 260A, the conveying speeds of the spraying materials are respectively 1.2m/min and 0.97m/min, and the pressure of compressed air is 0.7MPa, so that a ZnNiAl surface layer is obtained.
Through detection, the thickness of the ZnNiAl wear-resistant and corrosion-resistant coating prepared by the comparative example is 150 μm, and the microhardness is 137HV 0.5 And the interface bonding strength of the ZnNiAl coating and the steel structure is 39MPa.
The ZnNiAl coatings prepared in this comparative example were tested according to ASTM G133-05 Standard Test Method for Linear conditioning Ball-on-Flat Sliding Wear, and showed a Wear time of 2070s under a normal load of 1.96N (0.2 kilogram force).
The ZnNiAl coating prepared in the comparative example is detected according to GB/T10125-1997 salt spray test for artificial atmosphere corrosion test, and the result shows that the salt spray resistant time of the ZnNiAl coating prepared in the comparative example is 1120h.
Comparative example 2
A multi-wire inclined electric arc spraying ZnNiAl coating without a Ni-Al bottoming layer comprises the following components in percentage by mass: zn 73.2wt.%, ni 16.1wt.%, al 10.7wt.%.
The spraying method comprises the following steps:
s1, pretreating the surface of a steel structure to Sa2.5 level by adopting a sand blasting method;
s2, adopting Zn-15wt.% Al wire and Ni-5wt.% Al wire, enabling the distances between double spray guns and the surface of the steel structure to be 200mm, enabling the spraying angles of the spray guns to be 45 degrees, enabling the arc voltage to be 25V and 38V respectively, enabling the arc current to be 120A and 200A, enabling the conveying speeds of the spraying materials to be 1.19m/min and 0.91 m/min respectively, and enabling the pressure of compressed air to be 0.6MPa, so as to obtain the ZnNiAl spraying coating.
Through detection, the thickness of the ZnNiAl wear-resistant and corrosion-resistant coating prepared by the comparative example is 120 mu m, and the microhardness is 156HV 0.5 And the interface bonding strength of the ZnNiAl coating and the steel structure is 13MPa.
The ZnNiAl coating prepared in the comparative example was examined according to ASTM G133-05 Standard Test Method for Linear repairing Ball-on-Flat Sliding Wear, and showed a Wear resistance time of 2980s under a normal load of 1.96N (0.2 kilogram force).
The ZnNiAl coating prepared in the comparative example is detected according to GB/T10125-1997 salt spray test for artificial atmosphere corrosion test, and the result shows that the salt spray resistant time of the ZnNiAl coating prepared in the comparative example is 930h.
TABLE 1 Performance data for examples 1-6 and comparative examples 1-2
Comparing the performance data of the examples 1-6 and the comparative examples 1-2, it can be seen that the hardness of the ZnNiAl coating prepared in the examples 1-6 is obviously higher than that of the comparative examples 1-2, and the bonding force with the steel structure is obviously higher than that of the ZnNiAl coating prepared in the comparative example 2.
The ZnNiAl coatings prepared in examples 1-6 were more wear resistant than the control examples 1-2 in terms of wear time under a normal load of 1.96N (0.2 kilogram force). The ZnNiAl coatings prepared in examples 1-6 were more corrosion resistant than the control examples 1-2 in terms of salt spray time.
Comparing examples 1-6 with comparative example 1, it can be seen that it is necessary to obtain the optimum component content range of the ZnNiAl coating based on multi-wire inclined electric arc spraying by reasonably regulating and controlling the preparation process parameters of the sprayed Ni-Al primer layer and the ZnNiAl surface layer, so that the coating has good wear resistance and corrosion resistance.
Comparing examples 1-6 with comparative example 2, it can be seen that it is necessary to improve the adhesion of the coating to the substrate by spraying a Ni-Al primer layer to help improve the wear and corrosion resistance of the ZnNiAl coating.
The above description is only an embodiment of the present invention, and is not intended to limit the scope of the present invention, and all equivalent structures or equivalent processes performed by the present invention or directly or indirectly applied to other related technical fields are also included in the scope of the present invention.
Claims (8)
1. The corrosion-resistant wear-resistant ZnNiAl coating is characterized by comprising the following components in percentage by mass: 60-80 wt% of Zn, 10-30 wt% of Ni and 5-15 wt% of Al; the microhardness of the coating is more than or equal to 150HV 0.5 。
2. The ZnNiAl coating with corrosion resistance and wear resistance of claim 1, which comprises the following components in percentage by mass: zn 65wt.% to 80wt.%, ni 10wt.% to 25wt.%, and Al 10wt.% to 15wt.%, wherein the microhardness of the coating is more than or equal to 160HV 0.5 。
3. A method for spraying a corrosion-resistant and wear-resistant ZnNiAl coating, which is used for preparing the corrosion-resistant and wear-resistant ZnNiAl coating of claim 1, comprises the following steps:
s1: pretreating the surface of the steel structure to be more than Sa2.5 grade by adopting a sand blasting method;
s2: and heating the spraying material to a molten state by adopting an electric arc spraying method, and spraying the spraying material to the surface of the steel structure pretreated in the step S1 through a multi-wire inclined electric arc under the action of compressed air to form the corrosion-resistant and wear-resistant ZnNiAl coating.
4. The ZnNiAl coating with corrosion and wear resistance of claim 3, wherein the blasting method in the step S1 is high pressure water blasting.
5. The method for spraying the ZnNiAl coating with the corrosion resistance and the wear resistance as recited in claim 3, wherein the multi-wire inclined arc spraying of the step S2 comprises:
s2.1, spraying a priming coat;
s2.2, spraying a surface layer.
6. The method for spraying the ZnNiAl coating with the corrosion resistance and the wear resistance as set forth in claim 5, wherein the step S2.1 is as follows: the wire material adopts Ni-5-10 wt.% Al, the distance between a spray gun and the surface of the steel structure is 150-300 mm, the spraying angle of the spray gun is 80-90 degrees, the arc voltage is 30-40V, the arc current is 100-150A, the conveying speed of the spraying material is 0.3-1 m/min, and the pressure of compressed air is 0.5-0.9 MPa, so that the Ni-Al base coat is obtained.
7. The method as claimed in claim 5, wherein the step S2.2 is as follows: pure Zn or Zn-10-15 wt.% Al wire and Ni-5-10 wt.% Al are adopted as the wire, pure Zn or Zn-10-15 wt.% Al wire and Ni-5-10 wt.% Al are respectively sprayed by adopting double spray guns, the distance between the double spray guns and the surface of the steel structure is 150-500 mm, the spraying angles of the double spray guns are 30-60 degrees, the arc voltage is 20-40V, the arc current is 100-250A, the conveying speed of the spraying material is 0.4-1.5 m/min, and the pressure of compressed air is 0.5-0.9 MPa, so that the ZnNiAl surface layer is obtained.
8. The ZnNiAl coating with corrosion resistance and wear resistance of claim 1, wherein the ZnNiAl coating with corrosion resistance and wear resistance consists of a bottom layer and a surface layer, and the total thickness is 90-140 μm.
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