CN115926499A - Wear-resistant ceramic coating and lining body protection structure - Google Patents
Wear-resistant ceramic coating and lining body protection structure Download PDFInfo
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- CN115926499A CN115926499A CN202211646302.7A CN202211646302A CN115926499A CN 115926499 A CN115926499 A CN 115926499A CN 202211646302 A CN202211646302 A CN 202211646302A CN 115926499 A CN115926499 A CN 115926499A
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Abstract
The invention provides a wear-resistant ceramic coating, which comprises a substrate material, a binding agent, a solvent and a microsphere composite material; the microsphere composite material comprises hollow microspheres with open pore structures and a filling material filled in the hollow microspheres; the base material contains at least one component A, the filling material contains a carrier filling composed of water glass gel and a component B capable of reacting with the compound A at high temperature to form an inorganic metal compound, and the component B is dispersed in the carrier filling. According to the invention, the hollow microspheres and the filling material are added into the ceramic coating to form the microsphere composite material, and when the ceramic coating is cured to form the ceramic coating, the microsphere composite material and the ceramic substrate can form a structure with stronger integrity, so that the overall structural strength of the coating is improved.
Description
Technical Field
The invention relates to the technical field of coatings, in particular to a wear-resistant ceramic coating and a lining protection structure formed on the basis of the wear-resistant ceramic coating.
Background
High-temperature equipment such as high-temperature boilers, gas burners, flues and the like in the industries of petroleum, chemical engineering, metallurgy, coal and the like generally has serious corrosion and abrasion problems, for example, the flues of garbage incinerators can be subjected to inner wall scouring abrasion and corrosive abrasion caused by carrying solid particles in flue gas and frequently blowing soot, so that the equipment maintenance workload is large, and the maintenance cost is high. The ceramic coating is a gel material, mainly comprises a substrate material capable of forming a ceramic structure and a bonding agent for providing a bonding effect, and a coating formed after curing has the advantages of non-adhesion, high temperature resistance, high hardness, high weather resistance, corrosion resistance and the like, and is often used for forming a lining body structure on the surface of equipment and protecting parts, such as a flue and the like, which are easily abraded. For example, patent document CN202210494288.7 discloses a wear-resistant ceramic coating, which is composed of a main material for forming a ceramic structure and an additive including a binder, a reinforcing agent, a stabilizer, a water reducing agent and a fluidity additive, and the ceramic coating can reduce the frequency of equipment shutdown and maintenance, reduce maintenance cost, save resources and ensure working efficiency after forming a coating on the surface of equipment.
Ceramic coatings are often used in the scenes such as flues where hot air flow needs to be conveyed, and in order to reduce heat loss, the coating formed by the ceramic coatings is expected to have the effects of heat preservation and heat insulation. Patent document CN202011418871.7 discloses a light high-silicon ceramizable resin coating, wherein 5% -7% of hollow microspheres are added into the coating, and the hollow microspheres are made of one or more of glass, silicon dioxide, floating beads, aluminum oxide, zirconium oxide, titanium dioxide and ceramics. The addition of the hollow microspheres can reduce the thermal conductivity of the coating, reduce the heat exchange on two sides of the coating, play a role in protection or heat preservation, and reduce the density of the coating to lighten the coating. However, the addition of the hollow microspheres can cause the structural strength of the ceramic coating to be reduced, and the problem of poor integrity of the hollow microspheres and the matrix can also occur.
Disclosure of Invention
The invention provides a wear-resistant ceramic coating which can be used for forming a wear-resistant coating on the surface of high-temperature equipment such as a high-temperature boiler, a gas burner, a flue and the like, and the formed wear-resistant coating has low density, good heat insulation effect and high overall structural strength.
A wear-resistant ceramic coating comprises a substrate material, a bonding agent, a solvent and a microsphere composite material; the microsphere composite material comprises hollow microspheres with open pore structures and filling materials filled in the hollow microspheres; the base material contains at least one component A, the filling material contains a carrier filling composed of water glass gel and a component B capable of reacting with the compound A at high temperature to form an inorganic metal compound, and the component B is dispersed in the carrier filling.
The invention is different from the scheme adopted by the existing ceramic coating, the existing ceramic coating usually adopts closed-pore hollow microspheres with smaller size as modified fillers, so that the density of the ceramic coating is reduced, and the heat insulation performance is improved. Specifically, in the invention, the hollow microspheres are filled with water glass gel, when the ceramic coating is coated on the surface of equipment and heated and cured, the water glass gel can be dehydrated and decomposed to form silicon dioxide and other substances, and volume shrinkage is generated, so that the originally filled inner cavity of the microsphere composite material generates a hollow structure again. The product formed by the decomposition of the hydrogel has good compatibility with the binding agent, the loaded component B in the hydrogel is contacted with the component A dispersed in the binding agent in the decomposition process of the hydrogel, and an inorganic metal compound is generated under the high-temperature condition when the equipment operates, the interior of the microsphere is communicated with the exterior of the microsphere through the holes of the hollow microsphere, the integrity between the microsphere and the ceramic matrix is improved, and the part with the highest contact probability of the component A and the component B is the hole of the hollow microsphere, so the generated inorganic metal compound can seal the holes, and the hollow structure regenerated in the microsphere is kept intact. Specifically, the combination of the component a and the component B may be alumina and yttria, alumina and magnesia, silica and zirconia, etc., which may produce yttrium aluminum garnet, magnesium aluminum spinel, forsterite, zircon, respectively, at high temperatures.
Further, the preparation method of the microsphere composite material comprises the following steps: a. preparing a water glass solution; b. dispersing the component A in a water glass solution to obtain a filling material precursor; c. adding hollow microspheres into the filling material precursor, stirring under reduced pressure, then adjusting the pH of the solution to 4~6 to enable the water glass to form gel, and continuously stirring to obtain hollow microspheres with the filling formed inside; d. and c, drying the hollow microspheres obtained in the step c to obtain the microsphere composite material. According to the invention, the water glass gel is used as a carrier, the component A is dispersed in the water glass gel and filled in the hollow microspheres, and then the hollow microspheres are dried to obtain the microsphere composite material, wherein the water glass in the microsphere composite material is in an incomplete dehydration state, so that the water glass can be further decomposed at a high temperature to regenerate a hollow structure in the microsphere composite material.
Further, the mass concentration of the water glass solution in the step a is 20-30%, and the drying temperature in the step d is 100-150 ℃.
Further, the base material at least comprises a ceramic-based filler and the component A, wherein the ceramic-based filler is selected from one or more of corundum, silicon carbide, flint clay and mullite.
Further, the mass ratio of the ceramic matrix filler to the inorganic component A in the base material is 9 to 12; the mass ratio of the substrate material to the microsphere composite material is 7 to 1.
Further, the binder is selected from phosphates and/or silicates.
Further, the particle size of the hollow microsphere is 0.5 to 1 mm.
Further, the phosphate is selected from one or more of aluminum dihydrogen phosphate, magnesium phosphate, sodium phosphate, calcium phosphate, zinc phosphate or iron phosphate; the silicate is selected from one or more of sodium silicate, potassium silicate or lithium silicate.
The invention also aims to provide a liner protection structure, which comprises a substrate and a ceramic protection layer covering the surface of the substrate, wherein the ceramic protection layer is formed by performing heat treatment on at least the wear-resistant ceramic coating.
Furthermore, a tortoise-shell net framework is further arranged in the ceramic protective layer.
In summary, the following beneficial effects can be achieved by applying the technical scheme of the invention:
1. the invention adds the hollow microspheres with the open pore structure and the filling material filled in the hollow microspheres into the ceramic coating to form the microsphere composite material, after the ceramic coating forms a coating, the filling material in the microsphere composite material is heated and decomposed to generate volume shrinkage, so that the microspheres regenerate the hollow structure, and the inner structure of the microspheres can be connected with the ceramic matrix by utilizing the holes of the hollow microspheres, thereby the integration of the hollow microspheres and the ceramic matrix is stronger, and the integral structural strength of the coating is improved.
2. The base material and the filling material respectively contain a component A and a component B, the component A and the component B can react at high temperature to form an inorganic metal compound, namely a mineral material, the formation of the mineral material can further improve the integrity of the hollow microspheres and the ceramic matrix, and the mineral material is mainly formed at the holes of the hollow microspheres and can seal the holes, so that the hollow structure in the microspheres is kept intact.
3. The invention can select larger-size hollow microspheres, and compared with the small-size hollow microspheres in the prior art, the invention can ensure that the coating has lower density and better heat insulation performance, and can keep the structural strength of the coating.
Detailed Description
The present invention will be further described with reference to specific examples in order to provide those skilled in the art with a better understanding of the present invention. It should be understood that the specific examples described herein are for purposes of illustration only and are not intended to limit the invention.
Example 1
The embodiment provides a wear-resistant ceramic coating which is formed by mixing the following components in parts by weight: 45 parts of flint clay, 15 parts of silicon carbide, 5 parts of magnesium oxide, 8 parts of microsphere composite material, 10 parts of aluminum dihydrogen phosphate and 60 parts of water.
The preparation method of the microsphere composite material comprises the following steps:
a. preparing a 25% water glass solution;
b. adding 4 parts of alumina powder into the water glass solution, and uniformly stirring;
c. adding 10 parts of an open-pore alumina microsphere material into the water glass solution, and stirring and dispersing, wherein the diameter of the alumina microsphere material is 0.5 to 1mm; then adding acid to adjust the pH of the water glass solution to 4~6 to form water glass gel, and continuously stirring the water glass gel and the alumina powder dispersed in the water glass gel under a reduced pressure environment to fill the water glass gel and the alumina powder into the alumina microspheres;
d. and d, drying the alumina microspheres obtained in the step c and drying at the temperature of 100 to 120 ℃ for 30min to obtain the microsphere composite material.
The embodiment also provides a lining protection structure, which comprises a substrate formed by flue equipment and ceramic protection layers formed on the inner surface and the outer surface of the substrate and formed by the wear-resistant ceramic paint, wherein the ceramic protection layer is formed by the following method: firstly, preparing the wear-resistant ceramic paint, then spraying the wear-resistant ceramic paint on the surface of a flue equipment body, standing at room temperature for drying, and then carrying out heat treatment at about 200 ℃ for 1-2h to form the ceramic protective layer.
Example 2
The embodiment provides a wear-resistant ceramic coating which is formed by mixing the following components in parts by weight: 40 parts of flint clay, 10 parts of corundum, 10 parts of mullite, 5 parts of silicon oxide, 8 parts of microsphere composite material, 10 parts of aluminum dihydrogen phosphate and 60 parts of water.
The preparation method of the microsphere composite material comprises the following steps:
a. preparing a 25% water glass solution;
b. adding 3 parts of zirconia powder into the water glass solution, and uniformly stirring;
c. adding 10 parts of an open-pore alumina microsphere material into the water glass solution, and stirring and dispersing, wherein the diameter of the alumina microsphere material is 0.5-1mm; then adding acid to adjust the pH of the water glass solution to 4~6 to form water glass gel, and continuously stirring the water glass gel and the zirconium oxide powder dispersed in the water glass gel under a reduced pressure environment to fill the water glass gel and the zirconium oxide powder into the aluminum oxide microspheres;
d. and c, drying the alumina microspheres obtained in the step c and drying at the temperature of 130-140 ℃ for 30min to obtain the microsphere composite material.
The embodiment also provides a lining body protection structure, which comprises a substrate formed by the burner of the converter gas burner and the swirl plate thereof and a ceramic protection layer formed on the surface of the substrate and formed by the wear-resistant ceramic coating, wherein the ceramic protection layer is formed by the following steps: firstly, preparing the wear-resistant ceramic paint, then spraying the wear-resistant ceramic paint on the surface of a flue equipment body, standing at room temperature for drying, and then carrying out heat treatment at about 250 ℃ for 1 to 2h to form the ceramic protective layer.
Example 3
The embodiment provides a wear-resistant ceramic coating which is formed by mixing the following components in parts by weight: 45 parts of flint clay, 15 parts of silicon carbide, 5 parts of magnesium oxide, 8 parts of microsphere composite material, 10 parts of aluminum dihydrogen phosphate and 60 parts of water.
The preparation method of the microsphere composite material comprises the following steps:
a. preparing a 25% water glass solution;
b. adding 4 parts of alumina powder into the water glass solution, and uniformly stirring;
c. adding 10 parts of an open-pore alumina microsphere material into the water glass solution, and stirring and dispersing, wherein the diameter of the alumina microsphere material is 0.5-1mm; then adding acid to adjust the pH of the water glass solution to 4~6 to form water glass gel, and continuously stirring the water glass gel and the alumina powder dispersed in the water glass gel under a reduced pressure environment to fill the water glass gel and the alumina powder into the alumina microspheres;
d. and c, drying the alumina microspheres obtained in the step c and drying for 30min at the temperature of 100 to 120 ℃ to obtain the microsphere composite material.
The embodiment also provides a lining protection structure, which comprises a substrate formed by a flue equipment body and a ceramic protection layer formed on the inner surface of the substrate and formed by the wear-resistant ceramic paint and a tortoise-shell net framework, wherein the ceramic protection layer is formed by the following method: firstly, laying a tortoise shell net framework on the inner surface of flue equipment, welding the tortoise shell net framework and the flue equipment, then laying wear-resistant ceramic paint on the inner surface of the flue equipment on the basis of the tortoise shell net framework, filling the wear-resistant ceramic paint into meshes of the tortoise shell net framework, covering the tortoise shell net framework, then spraying the wear-resistant ceramic paint on the surface of a flue equipment body, standing at room temperature for drying, and then carrying out heat treatment at about 200 ℃ for 1 to 2h to form the ceramic protective layer.
Example 4
The embodiment provides a wear-resistant ceramic coating which is formed by mixing the following components in parts by weight: 45 parts of flint clay, 15 parts of silicon carbide, 5 parts of magnesium oxide, 8 parts of microsphere composite material, 10 parts of aluminum dihydrogen phosphate and 60 parts of water.
The preparation method of the microsphere composite material comprises the following steps:
a. preparing a 25% water glass solution;
b. adding 4 parts of alumina powder into the water glass solution, and uniformly stirring;
c. adding 10 parts of an open-pore alumina microsphere material into the water glass solution, and stirring and dispersing, wherein the diameter of the alumina microsphere material is 0.5-1mm; then adding acid to adjust the pH of the water glass solution to 4~6 to form water glass gel, and continuously stirring the water glass gel and the alumina powder dispersed in the water glass gel under a reduced pressure environment to fill the water glass gel and the alumina powder into the alumina microspheres;
d. and c, drying the alumina microspheres obtained in the step c and drying for 30min at the temperature of 100 to 120 ℃ to obtain the microsphere composite material.
The embodiment also provides a lining protection structure, which comprises a substrate formed by flue equipment and ceramic protection layers formed on the inner surface and the outer surface of the substrate and formed by the wear-resistant ceramic paint, wherein the ceramic protection layer is formed by the following method: firstly, preparing the wear-resistant ceramic paint, then spraying the wear-resistant ceramic paint on the surface of a flue equipment body, standing at room temperature for drying, then carrying out heat treatment at about 200 ℃ for 1-2h to form an intermediate coating, and finally adopting laser cladding equipment to treat the surface of the intermediate coating to form a top coating on the surface of the intermediate coating, namely forming the ceramic protective layer; the laser cladding power is 1.8kw, the rectangular light spot is 1.5mm multiplied by 14mm, the lap joint rate is 25%, and the scanning speed is 520mm/min.
Example 5
The embodiment provides a wear-resistant ceramic coating which is formed by mixing the following components in parts by weight: 45 parts of flint clay, 15 parts of silicon carbide, 5 parts of magnesium oxide, 8 parts of microsphere composite material, 10 parts of aluminum dihydrogen phosphate and 60 parts of water.
The preparation method of the microsphere composite material comprises the following steps:
a. preparing a 25% water glass solution;
b. adding 4 parts of alumina powder into the water glass solution, and uniformly stirring;
c. adding 10 parts of an open-pore alumina microsphere material into the water glass solution, and stirring and dispersing, wherein the diameter of the alumina microsphere material is 0.5-1mm; then adding acid to adjust the pH of the water glass solution to 4~6 to form water glass gel, and continuously stirring the water glass gel and the alumina powder dispersed in the water glass gel under a reduced pressure environment to fill the water glass gel and the alumina powder into the alumina microspheres;
d. and c, drying the alumina microspheres obtained in the step c and drying for 30min at the temperature of 100 to 120 ℃ to obtain the microsphere composite material.
The embodiment also provides a lining protection structure, which comprises a substrate formed by flue equipment and ceramic protection layers formed on the inner surface and the outer surface of the substrate and formed by the wear-resistant ceramic paint, wherein the ceramic protection layer is formed by the following method: polishing the surface of a substrate to form a rough surface structure, then preparing the wear-resistant ceramic paint, spraying the wear-resistant ceramic paint on the surface of a flue equipment body, standing at room temperature for drying, carrying out heat treatment at about 200 ℃ for 1-2h, and then treating the wear-resistant ceramic paint by using laser cladding equipment to form a bottom coating; continuously spraying the wear-resistant ceramic paint on the bottom coating, standing at room temperature for drying, and performing heat treatment at about 200 ℃ for 1-2h to form an intermediate coating; then, processing the surface of the intermediate coating by using laser cladding equipment to form a surface coating on the surface of the intermediate coating, namely forming the ceramic protective layer; the laser cladding power is 1.8kw, the rectangular light spot is 1.5mm multiplied by 14mm, the lap joint rate is 25%, and the scanning speed is 520mm/min.
Claims (10)
1. The wear-resistant ceramic coating is characterized in that: comprises a substrate material, a bonding agent, a solvent and a microsphere composite material; the microsphere composite material comprises hollow microspheres with open pore structures and filling materials filled in the hollow microspheres; the base material contains at least one component A, the filling material contains a carrier filling composed of water glass gel and a component B capable of reacting with the compound A at high temperature to form an inorganic metal compound, and the component B is dispersed in the carrier filling.
2. A wear-resistant ceramic coating as claimed in claim 1, wherein: the preparation method of the microsphere composite material comprises the following steps: a. preparing a water glass solution; b. dispersing the component A in a water glass solution to obtain a filling material precursor; c. adding hollow microspheres into the filling material precursor, stirring under reduced pressure, then adjusting the pH of the solution to 4~6 to enable the water glass to form gel, and continuously stirring to obtain hollow microspheres with the filling formed inside; d. and d, drying the hollow microspheres obtained in the step c to obtain the microsphere composite material.
3. A wear-resistant ceramic coating as claimed in claim 2, wherein: the mass concentration of the water glass solution in the step a is 20-30%, and the drying temperature in the step d is 100-150 ℃.
4. A wear-resistant ceramic coating as claimed in claim 1, wherein: the base material at least comprises a ceramic-based filler and the component A, wherein the ceramic-based filler is selected from one or more of corundum, silicon carbide, flint clay and mullite.
5. A wear-resistant ceramic coating as claimed in claim 1, wherein: the mass ratio of the ceramic matrix filler to the inorganic component A in the substrate material is 9 to 1; the mass ratio of the substrate material to the microsphere composite material is 7 to 1.
6. A wear-resistant ceramic coating as claimed in claim 1, wherein: the binder is selected from phosphates and/or silicates.
7. The wear-resistant ceramic coating of claim 6, wherein: the phosphate is selected from one or more of aluminum dihydrogen phosphate, magnesium phosphate, sodium phosphate, calcium phosphate, zinc phosphate or iron phosphate; the silicate is selected from one or more of sodium silicate, potassium silicate or lithium silicate.
8. A wear-resistant ceramic coating as claimed in claim 1, wherein: the particle size of the hollow microsphere is 0.5 to 1 mm.
9. A lining body protection structure comprises a substrate and a ceramic protection layer covering the surface of the substrate, and is characterized in that: the ceramic protective layer is formed from at least the abrasion resistant ceramic coating of any of claims 1~8 by heat treatment.
10. A lining protection structure according to claim 9, wherein: and a tortoise shell net framework is also arranged in the ceramic protective layer.
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| CN202211646302.7A CN115926499B (en) | 2022-12-21 | 2022-12-21 | Wear-resistant ceramic coating and lining protection structure |
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| Application Number | Priority Date | Filing Date | Title |
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| CN202211646302.7A CN115926499B (en) | 2022-12-21 | 2022-12-21 | Wear-resistant ceramic coating and lining protection structure |
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| CN115926499B CN115926499B (en) | 2023-08-29 |
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Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4793980A (en) * | 1978-09-21 | 1988-12-27 | Torobin Leonard B | Hollow porous microspheres as substrates and containers for catalyst |
| CN1990799A (en) * | 2005-12-27 | 2007-07-04 | 财团法人工业技术研究院 | High temperature insulating mould coating |
| RU2012129324A (en) * | 2012-07-12 | 2014-01-20 | Виталий Степанович Беляев | THERMAL INSULATION, ANTI-CORROSION AND SOUND-ABSORBING COATING AND METHOD OF ITS PRODUCTION |
| CN113968751A (en) * | 2020-10-23 | 2022-01-25 | 深圳优易材料科技有限公司 | Wear-resistant coating for flue of garbage incinerator |
-
2022
- 2022-12-21 CN CN202211646302.7A patent/CN115926499B/en active Active
Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4793980A (en) * | 1978-09-21 | 1988-12-27 | Torobin Leonard B | Hollow porous microspheres as substrates and containers for catalyst |
| CN1990799A (en) * | 2005-12-27 | 2007-07-04 | 财团法人工业技术研究院 | High temperature insulating mould coating |
| RU2012129324A (en) * | 2012-07-12 | 2014-01-20 | Виталий Степанович Беляев | THERMAL INSULATION, ANTI-CORROSION AND SOUND-ABSORBING COATING AND METHOD OF ITS PRODUCTION |
| CN113968751A (en) * | 2020-10-23 | 2022-01-25 | 深圳优易材料科技有限公司 | Wear-resistant coating for flue of garbage incinerator |
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| CN115926499B (en) | 2023-08-29 |
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