CN115926499B - Wear-resistant ceramic coating and lining protection structure - Google Patents
Wear-resistant ceramic coating and lining protection structure Download PDFInfo
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- CN115926499B CN115926499B CN202211646302.7A CN202211646302A CN115926499B CN 115926499 B CN115926499 B CN 115926499B CN 202211646302 A CN202211646302 A CN 202211646302A CN 115926499 B CN115926499 B CN 115926499B
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Abstract
The invention provides a wear-resistant ceramic coating, which 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 substrate material at least comprises a component A, the filling material comprises a carrier filling material formed by water glass gel and a component B which can react with the compound A at high temperature to form an inorganic metal compound, and the component B is dispersed in the carrier filling material. 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 solidified to form the ceramic coating, the microsphere composite material can form a structure with stronger integrity with the ceramic substrate, 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 based on the wear-resistant ceramic coating.
Background
High-temperature equipment such as high-temperature boilers, gas burners, flues and the like in industries such as petroleum, chemical industry, metallurgy, coal and the like commonly have serious corrosion and abrasion problems, for example, the flues of garbage incinerators can be subjected to inner wall scour abrasion and corrosion abrasion caused by carrying solid particles in flue gas and frequent soot blowing, so that the equipment maintenance workload is large, and the maintenance cost is high. The ceramic coating is a gel material, and is mainly composed of a matrix material capable of forming a ceramic structure and a bonding agent for providing a bonding effect, and a coating formed after the ceramic coating is solidified 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 structure on the surface of equipment so as to protect parts, such as a flue, which are easy to wear. For example, patent application number 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 can reduce the shutdown maintenance frequency of equipment, reduce maintenance costs, save resources and ensure working efficiency after forming a coating on the surface of the equipment.
Ceramic coatings are often used in the flue and other situations where it is desirable to deliver a flow of hot gases, and it is desirable to provide a thermal insulating coating to reduce heat loss. The patent document with the patent application number of CN202011418871.7 discloses a light high-silicon ceramic 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 ceramic. The addition of the hollow microspheres can reduce the heat conductivity of the coating on one hand, reduce the heat exchange at two sides of the coating, play a role in protection or heat preservation, and reduce the density of the coating on the other hand, so that the coating is lighter. However, the addition of the hollow microspheres can lead to the reduction of the structural strength of the ceramic coating, 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 surfaces of high-temperature equipment such as a high-temperature boiler, a gas burner, a flue and the like, and has the advantages of 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 substrate material at least comprises a component A, the filling material comprises a carrier filling material formed by water glass gel and a component B which can react with the compound A at high temperature to form an inorganic metal compound, and the component B is dispersed in the carrier filling material.
The invention is different from the scheme adopted by the existing ceramic coating, the existing ceramic coating generally adopts closed-pore hollow microspheres with smaller size as modified filler, so that the density of the ceramic coating is reduced, the heat insulation performance is improved, the microsphere composite material is prepared by taking open-pore hollow microspheres with larger size as raw materials, and then the microsphere composite material is used as modified filler to be mixed with other ceramic coating components. Specifically, in the invention, the hollow microsphere is internally filled with water glass gel, and when ceramic paint is coated on the surface of equipment and is heated and solidified, the water glass gel is dehydrated and decomposed to form silicon dioxide and other substances, and volume shrinkage occurs, so that the cavity originally filled with the microsphere composite material regenerates a hollow structure. The product formed by decomposing the hydrogel has good compatibility with the binding agent, the hydrogel decomposition process can lead the component B loaded in the product to be in contact with the component A dispersed in the binding agent, and inorganic metal compounds are generated under the high-temperature condition when the equipment is in operation, the inorganic metal compounds generated under the high temperature lead the inside of the microsphere to be in communication with the outside 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 largest contact probability between the component A and the component B is the hole of the hollow microsphere, so the generated inorganic metal compounds can seal the holes, and the regenerated hollow structure inside the microsphere is kept intact. Specifically, the combination of the component A and the component B can be alumina and yttrium oxide, alumina and magnesium oxide, silica and zirconium oxide, and the like, and the combination can respectively generate yttrium aluminum garnet, magnesia aluminum spinel, forsterite and zirconite at high temperature.
Further, the microsphere composite material is prepared by 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 a filling material precursor, stirring under reduced pressure, then adjusting the pH of the solution to 4-6 to enable water glass to form gel, and continuously stirring to obtain hollow microspheres with the inside being filled; d. and c, drying the hollow microspheres obtained in the step c to obtain the microsphere composite material. In the invention, the water glass gel is used as a carrier, so that 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, and the water glass in the microsphere composite material is in an incompletely dehydrated state, so that the water glass can be further decomposed at a high temperature state 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 substrate 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-based filler to the inorganic component A in the substrate material is 9:1-12:1; the mass ratio of the substrate material to the microsphere composite material is 7:1-9:1.
Further, the binding agent is selected from phosphates and/or silicates.
Further, the particle size of the hollow microspheres is 0.5-1 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.
Another object of the present invention is to provide a liner protection structure, which includes a substrate and a ceramic protection layer covering the surface of the substrate, wherein the ceramic protection layer is formed by heat treatment of at least the above wear-resistant ceramic coating.
Furthermore, a tortoise shell net framework is also arranged in the ceramic protective layer.
In summary, the following beneficial effects can be obtained by applying the technical scheme of the invention:
1. according to the invention, the hollow microspheres with open pore structures and the filling materials filled in the hollow microspheres are added into the ceramic coating to form the microsphere composite material, after the ceramic coating forms a coating, the filling materials in the microsphere composite material are heated and decomposed to generate volume shrinkage, so that the microspheres regenerate the hollow structures, and the inner structures of the microspheres can be connected with the ceramic matrix by utilizing the holes of the hollow microspheres, so that the hollow microspheres and the ceramic matrix are more integrated, and the overall structural strength of the coating is improved.
2. The base material and the filling material respectively comprise the component A and the component B, the component A and the component B can react at high temperature to form inorganic metal compounds, namely mineral materials, the formation of the mineral materials can further improve the integration of the hollow microspheres and the ceramic matrix, and the mineral materials are mainly formed at the holes of the hollow microspheres, so that the holes can be closed, and the hollow structure inside the microspheres can be kept intact.
3. The invention can select hollow microsphere with larger size, and compared with the hollow microsphere with small size in the prior art, the invention can lead the coating to have lower density and better heat insulation performance, and can maintain the structural strength of the coating.
Detailed Description
The invention will be further described with reference to specific examples for a better understanding of the invention by those skilled in the relevant art. It should be understood that the specific examples described herein are for purposes of illustration only and are not intended to limit the scope of 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 water glass solution with the concentration of 25%;
b. adding 4 parts of aluminum oxide powder into the water glass solution, and uniformly stirring;
c. adding 10 parts of open-pore alumina microsphere material into the water glass solution, stirring and dispersing, wherein the size of the alumina microsphere material is 0.5-1 mm; then adding acid to adjust the pH value of the water glass solution to 4-6 to form water glass gel, and continuously stirring in a reduced pressure environment to enable the water glass gel and alumina powder dispersed in the water glass gel to be filled into the alumina microspheres;
d. and c, drying the alumina microspheres obtained in the step c and drying at 100-120 ℃ 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 a ceramic protection layer formed on the inner surface and the outer surface of the substrate and formed by the wear-resistant ceramic coating, 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 waiting for drying, and then performing heat treatment at about 200 ℃ for 1-2 hours 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 water glass solution with the concentration of 25%;
b. adding 3 parts of zirconia powder into the water glass solution, and uniformly stirring;
c. adding 10 parts of open-pore alumina microsphere material into the water glass solution, stirring and dispersing, wherein the size of the alumina microsphere material is 0.5-1 mm; then adding acid to adjust the pH value of the water glass solution to 4-6 to form water glass gel, and continuously stirring in a reduced pressure environment to enable the water glass gel and zirconia powder dispersed in the water glass gel to be filled into the alumina microspheres;
d. and c, drying the alumina microspheres obtained in the step c and drying at 130-140 ℃ for 30min to obtain the microsphere composite material.
The embodiment also provides a lining protection structure, which comprises a substrate formed by a burner of a converter gas burner and a 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 waiting for drying, and then performing heat treatment at about 250 ℃ for 1-2 hours 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 water glass solution with the concentration of 25%;
b. adding 4 parts of aluminum oxide powder into the water glass solution, and uniformly stirring;
c. adding 10 parts of open-pore alumina microsphere material into the water glass solution, stirring and dispersing, wherein the size of the alumina microsphere material is 0.5-1 mm; then adding acid to adjust the pH value of the water glass solution to 4-6 to form water glass gel, and continuously stirring in a reduced pressure environment to enable the water glass gel and alumina powder dispersed in the water glass gel to be filled into the alumina microspheres;
d. and c, drying the alumina microspheres obtained in the step c and drying at 100-120 ℃ for 30min to obtain the microsphere composite material.
The embodiment also provides a lining protection structure, which comprises a substrate formed by the flue equipment body and a ceramic protection layer formed on the inner surface of the substrate and formed by the wear-resistant ceramic coating and the tortoise shell net framework, wherein the ceramic protection layer is formed by the following steps: firstly, paving a tortoise shell net framework on the inner surface of flue equipment, welding the tortoise shell net framework with the flue equipment, then paving a wear-resistant ceramic coating on the inner surface of the flue equipment on the basis of the tortoise shell net framework, filling grids of the tortoise shell net framework with the wear-resistant ceramic coating, covering the tortoise shell net framework, then spraying the wear-resistant ceramic coating on the surface of a flue equipment body, standing at room temperature for waiting for drying, and then performing heat treatment at about 200 ℃ for 1-2 hours to form the ceramic protection 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 water glass solution with the concentration of 25%;
b. adding 4 parts of aluminum oxide powder into the water glass solution, and uniformly stirring;
c. adding 10 parts of open-pore alumina microsphere material into the water glass solution, stirring and dispersing, wherein the size of the alumina microsphere material is 0.5-1 mm; then adding acid to adjust the pH value of the water glass solution to 4-6 to form water glass gel, and continuously stirring in a reduced pressure environment to enable the water glass gel and alumina powder dispersed in the water glass gel to be filled into the alumina microspheres;
d. and c, drying the alumina microspheres obtained in the step c and drying at 100-120 ℃ 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 a ceramic protection layer formed on the inner surface and the outer surface of the substrate and formed by the wear-resistant ceramic coating, 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 onto the surface of a flue equipment body, standing at room temperature for waiting for drying, then performing heat treatment at about 200 ℃ for 1-2 hours to form an intermediate coating, and finally adopting laser cladding equipment to treat the surface of the intermediate coating to form a surface coating on the surface of the intermediate coating to form 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 water glass solution with the concentration of 25%;
b. adding 4 parts of aluminum oxide powder into the water glass solution, and uniformly stirring;
c. adding 10 parts of open-pore alumina microsphere material into the water glass solution, stirring and dispersing, wherein the size of the alumina microsphere material is 0.5-1 mm; then adding acid to adjust the pH value of the water glass solution to 4-6 to form water glass gel, and continuously stirring in a reduced pressure environment to enable the water glass gel and alumina powder dispersed in the water glass gel to be filled into the alumina microspheres;
d. and c, drying the alumina microspheres obtained in the step c and drying at 100-120 ℃ 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 a ceramic protection layer formed on the inner surface and the outer surface of the substrate and formed by the wear-resistant ceramic coating, wherein the ceramic protection layer is formed by the following method: polishing the surface of a substrate to form a rough surface structure, preparing the wear-resistant ceramic coating, spraying the wear-resistant ceramic coating onto the surface of a flue equipment body, standing at room temperature for drying, performing heat treatment at about 200 ℃ for 1-2 hours, and then treating the wear-resistant ceramic coating by using laser cladding equipment to form an undercoat; continuously spraying wear-resistant ceramic paint on the bottom coating, standing at room temperature for drying, and performing heat treatment at about 200 ℃ for 1-2 hours to form an intermediate coating; then, the surface of the intermediate coating is treated by using laser cladding equipment to form a surface coating on the surface of the intermediate coating, namely, the ceramic protective layer is formed; 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 (9)
1. The wear-resistant ceramic coating is characterized in that: 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 filling materials filled in the hollow microspheres; the substrate material at least comprises a component A, the filling material comprises a carrier filling material formed by water glass gel and a component B which can react with the component A at high temperature to form an inorganic metal compound, and the component B is dispersed in the carrier filling material; the particle size of the hollow microspheres is 0.5-1 mm; the combination of the component A and the component B is selected from one of aluminum oxide and yttrium oxide, aluminum oxide and magnesium oxide, silicon oxide and zirconium oxide, and yttrium aluminum garnet, magnesia-alumina spinel, forsterite and zircon are respectively generated at high temperature.
2. A wear resistant ceramic coating according to 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 a filling material precursor, stirring under reduced pressure, then adjusting the pH of the solution to 4-6 to enable water glass to form gel, and continuously stirring to obtain hollow microspheres with the inside being filled; d. and c, drying the hollow microspheres obtained in the step c to obtain the microsphere composite material.
3. A wear resistant ceramic coating according to 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 according to claim 1, wherein: the substrate material at least comprises a ceramic-based filler and the component A, wherein the ceramic-based filler is one or more selected from corundum, silicon carbide, flint clay and mullite.
5. A wear resistant ceramic coating according to claim 1, wherein: the mass ratio of the ceramic-based filler to the inorganic component A in the substrate material is 9:1-12:1; the mass ratio of the substrate material to the microsphere composite material is 7:1-9:1.
6. A wear resistant ceramic coating according to claim 1, wherein: the binding agent is selected from phosphates and/or silicates.
7. A wear resistant ceramic coating according to 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. The utility model provides a lining protection architecture, includes the basement and covers the ceramic protection layer on the basement surface, its characterized in that: the ceramic protective layer is formed by heat treatment of the wear-resistant ceramic paint according to any one of claims 1 to 7.
9. A liner protection structure according to claim 8, 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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| CN115926499B true 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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