CN116083836A - Novel wire for electric arc spraying and preparation method thereof - Google Patents
Novel wire for electric arc spraying and preparation method thereof Download PDFInfo
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- 238000005507 spraying Methods 0.000 title claims abstract description 65
- 238000010891 electric arc Methods 0.000 title claims abstract description 31
- 238000002360 preparation method Methods 0.000 title claims abstract description 29
- 229910052751 metal Inorganic materials 0.000 claims abstract description 270
- 239000002184 metal Substances 0.000 claims abstract description 270
- 239000000843 powder Substances 0.000 claims abstract description 147
- 239000011858 nanopowder Substances 0.000 claims abstract description 122
- 239000000463 material Substances 0.000 claims abstract description 40
- 238000000034 method Methods 0.000 claims abstract description 40
- 239000002245 particle Substances 0.000 claims abstract description 25
- 239000007787 solid Substances 0.000 claims abstract description 10
- 230000008569 process Effects 0.000 claims description 29
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 claims description 28
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Chemical compound O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 21
- 238000005096 rolling process Methods 0.000 claims description 19
- 230000001154 acute effect Effects 0.000 claims description 12
- 239000002985 plastic film Substances 0.000 claims description 10
- 239000004033 plastic Substances 0.000 claims description 9
- 229910001369 Brass Inorganic materials 0.000 claims description 7
- 238000004519 manufacturing process Methods 0.000 claims description 6
- 229910018072 Al 2 O 3 Inorganic materials 0.000 claims description 5
- 229910006404 SnO 2 Inorganic materials 0.000 claims description 4
- 239000010951 brass Substances 0.000 claims description 4
- 238000003892 spreading Methods 0.000 claims description 4
- 230000007480 spreading Effects 0.000 claims description 4
- 238000003825 pressing Methods 0.000 claims description 3
- 238000004804 winding Methods 0.000 claims description 3
- 239000012153 distilled water Substances 0.000 claims description 2
- 238000003756 stirring Methods 0.000 claims 1
- 239000011248 coating agent Substances 0.000 abstract description 19
- 238000000576 coating method Methods 0.000 abstract description 19
- 150000002739 metals Chemical class 0.000 abstract description 4
- 230000003647 oxidation Effects 0.000 abstract description 4
- 238000007254 oxidation reaction Methods 0.000 abstract description 4
- 238000005299 abrasion Methods 0.000 abstract description 2
- 239000000203 mixture Substances 0.000 description 11
- 238000010586 diagram Methods 0.000 description 10
- 229910016006 MoSi Inorganic materials 0.000 description 7
- 229910007570 Zn-Al Inorganic materials 0.000 description 6
- VNNRSPGTAMTISX-UHFFFAOYSA-N chromium nickel Chemical compound [Cr].[Ni] VNNRSPGTAMTISX-UHFFFAOYSA-N 0.000 description 5
- 239000012792 core layer Substances 0.000 description 5
- 239000010410 layer Substances 0.000 description 5
- 229910001120 nichrome Inorganic materials 0.000 description 5
- 239000003086 colorant Substances 0.000 description 4
- 239000011159 matrix material Substances 0.000 description 4
- 229910052725 zinc Inorganic materials 0.000 description 4
- 229910017944 Ag—Cu Inorganic materials 0.000 description 3
- 229910018182 Al—Cu Inorganic materials 0.000 description 3
- 229910010413 TiO 2 Inorganic materials 0.000 description 3
- 229910007565 Zn—Cu Inorganic materials 0.000 description 3
- 239000011247 coating layer Substances 0.000 description 3
- 239000000470 constituent Substances 0.000 description 3
- TVZPLCNGKSPOJA-UHFFFAOYSA-N copper zinc Chemical compound [Cu].[Zn] TVZPLCNGKSPOJA-UHFFFAOYSA-N 0.000 description 3
- 238000009826 distribution Methods 0.000 description 3
- 239000011253 protective coating Substances 0.000 description 3
- 239000000126 substance Substances 0.000 description 3
- OMOVVBIIQSXZSZ-UHFFFAOYSA-N [6-(4-acetyloxy-5,9a-dimethyl-2,7-dioxo-4,5a,6,9-tetrahydro-3h-pyrano[3,4-b]oxepin-5-yl)-5-formyloxy-3-(furan-3-yl)-3a-methyl-7-methylidene-1a,2,3,4,5,6-hexahydroindeno[1,7a-b]oxiren-4-yl] 2-hydroxy-3-methylpentanoate Chemical compound CC12C(OC(=O)C(O)C(C)CC)C(OC=O)C(C3(C)C(CC(=O)OC4(C)COC(=O)CC43)OC(C)=O)C(=C)C32OC3CC1C=1C=COC=1 OMOVVBIIQSXZSZ-UHFFFAOYSA-N 0.000 description 2
- 229910052804 chromium Inorganic materials 0.000 description 2
- 229910052802 copper Inorganic materials 0.000 description 2
- 238000005260 corrosion Methods 0.000 description 2
- 230000007797 corrosion Effects 0.000 description 2
- 229910052742 iron Inorganic materials 0.000 description 2
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- 230000001737 promoting effect Effects 0.000 description 2
- YLZOPXRUQYQQID-UHFFFAOYSA-N 3-(2,4,6,7-tetrahydrotriazolo[4,5-c]pyridin-5-yl)-1-[4-[2-[[3-(trifluoromethoxy)phenyl]methylamino]pyrimidin-5-yl]piperazin-1-yl]propan-1-one Chemical compound N1N=NC=2CN(CCC=21)CCC(=O)N1CCN(CC1)C=1C=NC(=NC=1)NCC1=CC(=CC=C1)OC(F)(F)F YLZOPXRUQYQQID-UHFFFAOYSA-N 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
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- 229910002065 alloy metal Inorganic materials 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 230000007123 defense Effects 0.000 description 1
- 230000008021 deposition Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 229910052737 gold Inorganic materials 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 230000001681 protective effect Effects 0.000 description 1
- 238000005488 sandblasting Methods 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
- 239000000725 suspension Substances 0.000 description 1
- 238000007751 thermal spraying Methods 0.000 description 1
- 229910052718 tin Inorganic materials 0.000 description 1
- 238000005491 wire drawing Methods 0.000 description 1
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Classifications
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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
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
- C23C4/131—Wire arc spraying
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B82—NANOTECHNOLOGY
- B82Y—SPECIFIC USES OR APPLICATIONS OF NANOSTRUCTURES; MEASUREMENT OR ANALYSIS OF NANOSTRUCTURES; MANUFACTURE OR TREATMENT OF NANOSTRUCTURES
- B82Y40/00—Manufacture or treatment of nanostructures
-
- 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
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
- C23C4/06—Metallic material
-
- 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
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
- C23C4/06—Metallic material
- C23C4/08—Metallic material containing only metal elements
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Physics & Mathematics (AREA)
- Plasma & Fusion (AREA)
- Mechanical Engineering (AREA)
- Materials Engineering (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Nanotechnology (AREA)
- Condensed Matter Physics & Semiconductors (AREA)
- General Physics & Mathematics (AREA)
- Manufacturing & Machinery (AREA)
- Crystallography & Structural Chemistry (AREA)
- Coating By Spraying Or Casting (AREA)
Abstract
The invention discloses a novel wire for electric arc spraying and a preparation method thereof, belonging to the technical field of surface protection of metals. The wire material mainly comprises a conductive metal sheath or a conductive metal sheath and an internal nano powder core, wherein the thickness of the conductive metal sheath is 5-50 mu m, and the particle size of the powder is 1-100 nm. The length of the prepared wire is between 12cm and 220cm, and the diameter of the wire is between 1mm and 3mm. The method can realize the preparation of solid metal wires and nano powder core wires with high efficiency and low cost, and can realize the preparation of the coating with high efficiency and low cost when being applied to electric arc spraying, and the prepared coating can be used for preventing the high-temperature oxidation, room-temperature oxidation, abrasion and the like of metals.
Description
Technical Field
The invention belongs to the technical field of metal surface protection, and particularly relates to a novel wire for electric arc spraying and a preparation method thereof.
Background
Arc spraying is one of all thermal spraying techniques that has the highest spraying efficiency and highest energy utilization. The method is widely applied to the field of materials and can prevent high-temperature oxidation corrosion, room-temperature oxidation corrosion and friction and abrasion of the materials. With the continuous development of the economic society in China, the fields of petrochemical industry, machinery, national defense and the like have higher and higher performance requirements on protective materials, and the functional requirements are more and more, and the requirements are difficult to be met by singly improving the performance of electric arc spraying equipment to prepare the protective coating on the surface of the material. At the moment, the novel wire material with a novel structure and a plurality of better performances is obtained by innovating the preparation process of the wire material used for electric arc spraying, and the improvement of the performances of the electric arc spraying protective coating is of great significance.
At present, wires used for arc spraying are two main types, namely solid metal wires, and powder core wires consisting of external metal sheaths and internal powder, wherein the powder core wires can be used for modifying an arc spraying coating by adjusting the composition of the internal powder. The general preparation process is that the thicker metal skin is rolled by a plurality of shaft rollers to form a round groove shape, then powder is filled into the round groove-shaped metal belt, the round groove-shaped metal belt is rolled by one shaft roller, is sealed and takes a cylindrical shape, and then the powder core wire with the required diameter is obtained through wire drawing. The powder core wire prepared by the process has the advantages that the powder cores are distributed inside, the metal outer skin is outside, the powder cores are easy to be unevenly and insufficiently melted during spraying, and the powder is unevenly distributed when deposited on a substrate to form a coating after being melted; and the process is difficult to realize small-batch customized production, which limits the application range of the prepared nano powder core wire.
Disclosure of Invention
Aiming at the trend of the future materials towards the directions of complexity, multifunction, low cost and high performance, the invention aims to provide two novel wires for electric arc spraying, wherein one novel wire for electric arc spraying consists of a metal sheath, the wire is mainly prepared from a conductive metal sheath, the thickness of the conductive metal sheath is 5-50 mu m, and the width of the conductive metal sheath is 4-60 cm; the length of the prepared wire is between 12cm and 220cm, and the diameter of the wire is between 1mm and 3mm.
The metal sheath is preferably one or more of Al, fe, sn, cu, ag, au, zn, mg and brass, the thickness of the metal sheath is 5-50 μm, and the width of the metal sheath is 4-60 cm.
The novel wire material for electric arc spraying consists of a metal sheath and an internal nano powder core, wherein the wire material is mainly prepared from the conductive metal sheath and the internal nano powder core, the thickness of the metal sheath is 5-50 mu m, the width is 4-60 cm, and the particle size of the nano powder core is 1-100 nm.
Preferably, the metal sheath is one or more of Al, fe, sn, cu, ag, au, zn, mg and brass, the thickness of the metal sheath is 5-50 μm, and the width is 4-60 cm; the powder core is Al 2 O 3 Powder, tiO 2 Powder, zrO 2 Powder, Y 2 O 3 Powder, cr 3 C 2 Powder, WC powder, cr powder, niCr powder, moSi 2 Powder, siC powder, cu powder, fe powder and SnO 2 Powder, mgO powder, cuO powder, znO powder and Cr 2 O 3 One or more of the powders are arbitrarily combined, and the particle size of the powder is 1nm-100nm; the mass ratio of the nano powder core to the metal sheath is (5-1) (1-5).
When the nano-powder core wire is applied to electric arc spraying, the powder can be fully and uniformly melted, and the nano-powder core wire can be uniformly distributed in the coating when the coating is formed by deposition; the gradient coating can be prepared by electric arc spraying; can realize small-batch customized production of nano-powder core wires, and has wider application range and excellent application prospect.
Preferably, the length of the wire is 12cm-220cm, and the diameter of the wire is 1mm-3mm.
Another object of the present invention is to provide a method for preparing a novel wire for arc spraying without adding a nano powder core, wherein the process flow is shown in fig. 1, and specifically comprises the following steps:
(1) A metal skin having a thickness of 5 μm to 50 μm, a width of 4cm to 60cm and a length of 4cm to 220cm was prepared and laid flat on a clean and flat platform as shown in FIG. 1.1.
(2) A piece of rubber sheet, plastic sheet or metal sheet is placed above the middle position of the metal sheath and pressed to be tightly attached to the surface of the metal sheath, as shown in fig. 1.2.
(3) The metal skins on two sides of the rubber sheet, the plastic sheet or the metal sheet are respectively folded towards the middle to form an acute angle with the plane, as shown in figure 1.3.
(4) The rubber sheet, plastic sheet or metal sheet is removed as shown in fig. 1.4.
(5) The metal skin at this time was preliminarily compacted by a flat plate as shown in fig. 1.5 and 1.6.
(6) And then a round bar rolls along the length direction of the metal skins, and a force vertical to the metal skins is applied during the rolling process of the round bar so as to tightly contact the metal skins, and the metal skins are further compacted, as shown in figures 1.7 and 1.8.
(7) Folding the metal skin along the middle to form an acute angle between the metal skin on one side and the metal skin on the other side, preliminarily compacting the metal skin at the moment by using a flat plate, rolling the metal skin on the flat plate by using a round bar, and further compacting the metal skin, wherein the metal skin is shown in figures 1.9-1.13; this process is repeated until the desired width and thickness of the metal skin is obtained, as shown in fig. 1.14.
(8) Winding the obtained metal skin on a metal round bar: the metal sheath may be wound symmetrically over the metal round bar or in a spiral fashion over the metal round bar, forming the metal sheath into a wire-like round bar shape, as shown in fig. 1.15.
(9) The round bar-shaped metal skin is pressed by a rectangular flat plate, the flat plate is horizontally slid to roll, and the wire material similar to the round bar is changed into the wire material of the round bar in the rolling process, so that the preparation of the solid metal wire material for arc spraying is completed, and the solid metal wire material is shown in figures 1.16-1.18.
The invention also aims to provide a preparation method of the wire for electric arc spraying with the nano powder core, which specifically comprises the following steps:
(1) Preparing a metal skin with the thickness of 5-50 mu m, the width of 4-60 cm and the length of 4-220 cm, and spreading the metal skin on a clean and flat platform; the nano powder is respectively placed in distilled water or alcohol, and then is mechanically stirred to ensure that the nano powder is uniformly distributed in the water or the alcohol.
(2) Placing a rubber frame, a plastic frame or a metal frame above the middle position of the metal sheath, and pressing to tightly adhere the rubber frame, the plastic frame or the metal frame to the surface of the metal sheath; slowly pouring the water or alcohol with the nano powder cores into the 3 boxes with a certain depth in sequence, enabling the water or alcohol with the powder cores to be in full contact with the surface of the metal skin and uniformly distributed, and standing for a period of time until the water or alcohol volatilizes completely.
(3) The metal skins on two sides of the rubber frame, the plastic frame or the metal frame are respectively folded towards the middle to form an acute angle with the plane.
(4) And taking out the rubber frame, the plastic frame or the metal frame.
(5) The metal skin at this time was preliminarily compacted by a flat plate.
(6) And then a round bar rolls along the length direction of the metal skin, and a force perpendicular to the metal skin is applied in the rolling process of the round bar so as to tightly contact the metal skin and the nano powder core, and further compact the metal skin and the nano powder core.
(7) Folding the metal skin along the middle to enable the metal skin on one side and the metal skin on the other side to form an acute angle, preliminarily compacting the metal skin at the moment by using a flat plate, rolling the metal skin on the flat plate by using a round rod, and further compacting the metal skin and the nano powder core; this process is repeated until the desired width and thickness of the metal skin is obtained.
(8) The metal skin is wound on a metal round bar, so that the metal skin forms a shape similar to a round bar.
(9) The round bar-shaped metal skin is pressed by a rectangular flat plate, the flat plate is horizontally slid to roll, and the wire material similar to the round bar is changed into the wire material of the round bar in the rolling process, so that the preparation of the nano powder core wire material for electric arc spraying is completed.
Compared with the prior art for producing the wire for electric arc spraying, the invention has the following beneficial effects:
the coating components sprayed by the nano powder core wire prepared by the method are more uniformly distributed, and the gradient coating can be prepared; the process is simple, and can realize the low-cost preparation of the high-performance nano-powder core wire; the process can realize small-batch customized production of metal wires and nano powder core wires; the process can combine a plurality of different metal skins to prepare a solid metal wire, and further continuously prepare a coating consisting of a plurality of metals through electric arc spraying; meanwhile, various metal skins and various nano powders can be combined to prepare nano core wires, and then a coating consisting of various metals and various nano powders is continuously prepared by electric arc spraying. The multi-metal or multi-metal ceramic composite coating prepared by the process and then by electric arc spraying is expected to be applied to environments with special performance requirements or extremely severe environments; the method has positive significance for further promoting the application of electric arc spraying, improving the performance of electric arc spraying coating and promoting the high quality and innovative development of the electric arc spraying industry in China.
Drawings
Fig. 1 is a schematic diagram of a flow chart and a longitudinal section structure of a wire for arc spraying according to the present invention.
Fig. 2 is a schematic diagram of a flow chart and a longitudinal section structure of a wire for arc spraying according to embodiment 1 of the present invention.
Fig. 3 is a schematic diagram of a flow chart and a longitudinal section structure of a wire for arc spraying according to embodiment 2 of the present invention.
Fig. 4 is a schematic diagram of a flow chart and a longitudinal section structure of a wire for arc spraying according to embodiment 3 of the present invention.
Fig. 5 is a schematic view of a flow chart and a longitudinal section structure of a wire for arc spraying according to embodiment 4 of the present invention.
Fig. 6 is a schematic diagram of a flow chart and a longitudinal section structure of a wire for arc spraying according to embodiment 5 of the present invention.
Fig. 7 is a schematic view of a flow chart and a longitudinal section structure of a wire for arc spraying according to example 6 of the present invention.
Fig. 8 is a schematic diagram of a flow chart and a longitudinal section structure of a wire for arc spraying according to embodiment 7 of the present invention.
FIG. 9 is a schematic view of a longitudinal section of a metal wire for arc spraying according to example 8 of the present invention;
fig. 10 is a schematic view of a flow chart and a longitudinal section structure of a wire for arc spraying according to embodiment 9 of the present invention.
Fig. 11 is a schematic diagram showing a flow chart and a longitudinal section structure of a wire for arc spraying according to embodiment 10 of the present invention.
FIGS. 12.1 and 12.2 are 5 times of metallographic morphology of the cross section of the sample; FIGS. 12.3 and 12.4 are the metallographic shapes of 10 times of the cross section of the sample; FIGS. 12.5 and 12.6 show the metallographic morphology of the sample with 20 times of the cross section.
Detailed Description
The present invention will be described in further detail with reference to specific examples, but the scope of the present invention is not limited to the above.
Example 1
The novel wire for electric arc spraying and the preparation method thereof can prepare a solid brass metal wire, the process flow of which is shown in figure 2, and the black rectangle shown in figure 2.1 represents a brass metal skin; the method specifically comprises the following steps:
(1) A brass metal skin 5 μm thick, 4cm wide and 30cm long was prepared and laid flat on a clean and flat platform as shown in fig. 2.1.
(2) A piece of rubber sheet, plastic sheet or metal sheet is placed above the middle position of the metal sheath and pressed to be tightly attached to the surface of the metal sheath, as shown in fig. 2.2.
(3) The metal skins on two sides of the rubber sheet, the plastic sheet or the metal sheet are respectively folded towards the middle to form an acute angle with the plane, as shown in figure 2.3.
(4) The rubber sheet, plastic sheet or metal sheet is removed as shown in fig. 2.4.
(5) Preliminary compacting the metal skin at this time with a flat plate as shown in fig. 2.5 and 2.6; and then a round bar rolls along the length direction of the metal skins, and a force vertical to the metal skins is applied during the rolling process of the round bar so as to tightly contact the metal skins, and the metal skins are further compacted, as shown in figures 2.7 and 2.8.
(6) Folding the metal skin along the middle to form an acute angle between the metal skin on one side and the metal skin on the other side, preliminarily compacting the metal skin at the moment by using a flat plate, rolling the metal skin on the flat plate by using a round bar, and further compacting the metal skin, wherein the metal skin is shown in figures 2.9-2.13. This process is repeated until the desired width and thickness of the skin is obtained, as shown in fig. 2.14. The metal skin is wound on a metal round bar, and the metal skin can be symmetrically wound on the metal round bar or wound on the metal round bar in a spiral manner, so that the metal skin forms a shape similar to a round bar, as shown in fig. 2.15.
(7) The round bar-shaped metal skin is pressed by a rectangular flat plate, the flat plate is horizontally slid to roll, and the metal skin similar to a round bar is changed into a wire material in a round bar shape in the rolling process, so that the preparation of the solid metal wire material for arc spraying is completed, and the solid metal wire material is shown in figures 2.16-2.18.
Example 2
Novel wire for electric arc spraying and preparation method thereof can prepare Al-coated nano Al 2 O 3 The powder core wire of the powder has the process flow shown in fig. 3, wherein the black rectangle in fig. 3.1 represents the metal sheath, and the black circle in fig. 3.3 represents the nano powder core.
(1) Firstly, nanometer Al 2 O 3 Placing the powder in a beaker filled with alcohol, and then uniformly distributing the nano powder in water or alcohol by mechanical stirring; through experiments, the nano powder can be suspended in water or alcohol under the action of mechanical stirring, and the smaller the particle size of the powder is, the better the suspension effect is, and the more uniform the distribution in the water or alcohol is.
(2) An Al metal skin 15 μm thick, 5cm wide and 30cm long was prepared and laid flat on a clean and flat platform as shown in fig. 3.1.
(3) A rubber square frame (plastic or metal material can be selected randomly according to the requirement) with a certain depth is placed in the middle of the metal sheath and pressed to be tightly attached to the surface of the metal sheath, as shown in fig. 3.2.
(4) Then slowly pouring the water or alcohol with the nano powder core into the square frame with a certain depth, so that the water or alcohol with the powder core is fully contacted with the surface of the metal skin and uniformly distributed, as shown in fig. 3.3. Standing for a period of time, and after water or alcohol volatilizes, folding the metal skins at two sides of the square frame respectively to the middle so that the metal skins form an acute angle with the plane, as shown in fig. 3.4.
(5) The rubber block was removed as shown in fig. 3.5.
(6) The metal skin at this time was preliminarily compacted by a flat plate as shown in fig. 3.6 and 3.7.
(7) And then a round bar rolls along the length direction of the metal skin, and a force vertical to the metal skin is applied in the rolling process of the round bar so as to tightly contact the metal skin and the nano powder core, and the metal skin and the nano powder core are further compacted, as shown in figures 3.8 and 3.9.
(8) Folding the metal skin along the middle to form an acute angle between the metal skin on one side and the metal skin on the other side, preliminarily compacting the metal skin at the moment by using a flat plate, rolling the metal skin on the flat plate by using a round bar, and further compacting the metal skin and the nano powder core, wherein the metal skin and the nano powder core are shown in figures 3.10-3.14.
(9) This process is repeated until the desired width and thickness of the skin is obtained, as shown in fig. 3.15; the resulting skin is wrapped around a round metal rod and the skin may be wrapped around the round metal rod symmetrically or in a spiral fashion to form the skin into a round rod-like shape as shown in fig. 3.16.
(10) The round bar-shaped nano powder core wire is pressed by a rectangular flat plate, the flat plate is horizontally slid to roll, the wire similar to a round bar is changed into a wire with a round bar in the rolling process, and thus the preparation of the wire with a single nano powder core for electric arc spraying is completed, as shown in figures 3.17 and 3.18.
FIG. 12 shows Al with a grain size of 100nm for a 15 μm thick Al metal sheath prepared according to the specification described in example 2 2 O 3 The powder core wire corresponding to the powder is subjected to the metallurgical morphology of a coating sample prepared by electric arc spraying, the upper part is a coating, the matrix is Q195 steel, the surface of the matrix is subjected to sand blasting treatment before spraying, and the average thickness of the coating after electric arc spraying is 190 mu m; FIGS. 12.1 and 12.2 are 5 times of metallographic morphology of the cross section of the sample; FIG. 12.3, 12.4 shows a sample10 times of metallographic morphology of the cross section; FIGS. 12.5 and 12.6 are the metallographic shapes of the cross sections of the samples, which are 20 times; the figure shows that the coating is tightly combined with the interface of the matrix, the thickness of the coating is uniformly distributed, and the coating has higher density, which shows that the nano-powder core wire prepared by the process can be successfully applied to preparing the protective coating on the surface of the material by electric arc spraying.
Example 3
The novel wire for arc spraying and the preparation method thereof can prepare wires with nano-powder cores with different components or nano-powder core structures with gradient components, the process flow is shown in fig. 4, black rectangles in fig. 4.1 represent Fe metal skins, and rectangles in fig. 4.3 formed by horizontal, inclined and vertical line segments respectively represent nano-powder cores (nano ZrO 2 、Y 2 O 3 And Al 2 O 3 Powder) or nano powder core (nano 30wt% ZrO) with gradient component structure 2 -Y 2 O 3 、60wt％ZrO 2 -Y 2 O 3 、90wt％ZrO 2 -Y 2 O 3 Powder), the specific preparation process was the same as in example 2, except that:
preparing an Fe metal skin with the thickness of 20 mu m, the width of 10cm and the length of 40cm, and spreading the Fe metal skin on a clean and flat platform, as shown in fig. 4.1; a rubber block with 3 blocks was placed in the middle of the metal skin and pressed against the surface of the metal skin as shown in fig. 4.2. Then, the alcohol solutions distributed with different nano powder cores are slowly poured into the 3 boxes with a certain depth in sequence, so that the water or alcohol with the powder cores is fully contacted with the surface of the metal skin and uniformly distributed, and as shown in fig. 4.3, the alcohol solutions with different nano powder cores are specifically distributed with the following two schemes:
scheme one: the rectangle formed by the horizontal line segments represents the powder of the A component (ZrO 2 Powder), the rectangle formed by the inclined line segments represents the powder (Y) of the B component 2 O 3 Powder), and the rectangle formed by the horizontal line segments represents the powder (Al) of the C component 2 O 3 Powder) so as to sequentially comprise powder of A, B and C three different components along the length direction of the wire, and the wireA nano-powder core structure with different components.
Scheme II: the rectangle formed by the horizontal line segments represents 30% of powder a (ZrO 2 Powder) and 70% of B powder (Y 2 O 3 Powder), the rectangle formed by the inclined line segments represents 60% of powder A (ZrO 2) 2 Powder) and 40% of B powder (Y 2 O 3 Powder), the rectangle formed by the vertical line segments represents 90% of powder a (ZrO 2 Powder) and 10% of B powder (Y 2 O 3 Powder), wherein the contents of the substance A and the substance B are distributed in a gradient manner along the length direction of the wire, the gradient variation of the powder component is 30%, and the wire has a gradient component nano-powder core structure.
Example 4
The process flow of the novel wire for arc spraying and the preparation method thereof are shown in fig. 5, wherein black rectangles in fig. 5.1 represent Sn metal skins, and black circles in fig. 5.3 represent nano powder cores with different structures or gradient structures (powder particle sizes or crystalline states, etc.), such as nano powder cores with different crystalline states (crystalline nano Cr powder, quasi-crystalline nano Cr powder and amorphous nano Cr powder), and nano powder cores with different particle sizes (Cr powder with particle sizes of 30nm, 60nm and 90 nm); the specific preparation process is the same as in example 3, except that:
a sheet of Sn metal skin 25 μm thick, 15cm wide and 70cm long was prepared and laid flat on a clean and flat platform as shown in fig. 5.1. Then, the alcohol solutions distributed with different nano powder cores are slowly poured into the 3 boxes with a certain depth in sequence, so that the water or alcohol with the powder cores is fully contacted with the surface of the metal skin and uniformly distributed, and as shown in fig. 4.3, the alcohol solutions with different nano powder cores are specifically distributed with the following two schemes:
scheme one: the black circles with smaller diameters represent powder with a structure A (crystalline nano Cr powder), the black circles with larger diameters represent powder with a structure B (quasi-crystalline nano Cr powder), and the black circles with the largest diameters represent powder with a structure C (amorphous nano Cr powder), so that the powder with a A, B structure and powder with a three different structures C are sequentially arranged along the length direction of the wire, and the wire has nano powder core structures with different structures.
Scheme II: the black circles with smaller diameters represent powder with a particle size of 0.3a (Cr powder with a particle size of 30 nm), the black circles with larger diameters represent powder with a particle size of 0.6a (Cr powder with a particle size of 60 nm), and the black circles with the largest diameters represent powder with a particle size of 0.9a (Cr powder with a particle size of 90 nm), so that the powder diameters are distributed in a gradient manner along the length direction of the wire, the gradient variation amount of the powder particle size is 0.3a (30 nm), and the wire has a gradient structure nano-powder core structure.
The schematic longitudinal section structure of the nano powder core wire prepared in this embodiment is shown in fig. 5.19, and the metal layers and the nano powder core layers are alternately distributed.
Example 5
The novel wire for arc spraying and the preparation method thereof can prepare nano powder cores with different components and different structures, nano powder cores with different components and gradient structures, nano powder cores with gradient components and nano powder cores with different structures, nano powder cores with gradient components and nano powder core structures with gradient structures, and the wire with the nano powder cores with gradient structures, wherein the technological process is shown in the figure 6, the black rectangle in the figure 6.1 represents Zn metal sheath, the black circle with different sizes in the figure 6.3 represents nano powder cores with different structures or in gradient structures (powder particle size or crystalline state and the like), such as nano powder cores with different particle sizes (TiO with particle sizes of 30nm, 60nm and 90 nm) 2 Powder), and nano-powder cores of different crystalline states (crystalline nano-TiO 2 Powder, quasi-crystalline nano TiO 2 Powder and amorphous nano TiO 2 Powder). The rectangles consisting of horizontal, inclined and vertical segments in FIG. 6.3 represent the nano powder cores (nano MgO powder, cr) of different compositions, respectively 2 O 3 Powder and SiC powder) or nano powder core with gradient component structure (nano 30wt% cr) 2 O 3 -SiC、60wt％Cr 2 O 3 -SiC、90wt％Cr 2 O 3 -SiC powder).
The specific preparation process is the same as in example 4, except that: the prepared wire material also has nano powder cores with different structures or nano powder core structures with gradient structures; the schematic diagram of the longitudinal section structure of the nano powder core wire prepared by the process is shown in fig. 6.19, and the metal layers and the nano powder core layers are alternately distributed.
Example 6
The process flow of the novel wire for arc spraying and the preparation method thereof are shown in fig. 7, and the light black, dark black and rectangles with colors between the light black, the dark black and the dark black in fig. 7.1 respectively represent metal skins with different components (Zn, al and Mg metal skins) or metal skins with gradient components (30 wt% Zn-Al, 60wt% Zn-Al and 90wt% Zn-Al metal skins) are shown in fig. 7. The specific preparation method is the same as in example 1, except that:
3 Zn, al and Mg metal skins with the thickness of 35 mu m, the width of 12cm and the length of 30cm are respectively prepared, pressed on a part of the Zn, al and Mg metal skins from front to back and are spread on a clean and flat platform, and as shown in fig. 7.1, the metal skins with different components are selected as follows:
the rectangular distribution of the first scheme, light black, dark black and color between the two represents alloy metal skins with the components of 30% of A (Zn) -70% of B (Al), 60% of A (Zn) -40% of B (Al) and 90% of A (Zn) -10% of B (Al), the contents of substances A and B are distributed in a gradient manner in the length direction of the wire, the gradient variation of the metal wire component is 30%, and the obtained wire has a gradient component structure.
Scheme II: the rectangular distribution of light black, dark black and colors between them represents A, B and C three kinds of constituent metal skins (Zn, al and Mg metal skins), and in the length direction, the wire has A, B and C three kinds of different constituents, and the wire has a structure of different constituents. The schematic longitudinal section structure of the solid wire prepared by the process is shown in fig. 7.19.
Example 7
The process flow of the novel wire for arc spraying and the preparation method thereof are shown in fig. 8, wherein the light black, the dark black and the rectangles with colors between the light black and the dark black in fig. 8.1 respectively represent different components (Au, ag and Cu metal skins) or metal skins with a gradient component structure (30 wt% of Ag-Cu, 60wt% of Ag-Cu and 90wt% of Ag-Cu metal skins), and the black circles in fig. 8.3 represent nano cores (nano Cu powder).
The specific method of this example is the same as that of example 6, except that: the nano powder core is added, and the specific process is as follows: a rubber block with 1 block was placed over the middle of the metal skin and pressed against the metal skin surface as shown in fig. 8.2. Then slowly pouring the water or alcohol with the nano powder core into the square frame with a certain depth, so that the water or alcohol with the powder core is fully contacted with the surface of the metal skin and uniformly distributed, as shown in fig. 8.3.
The embodiment obtains the nano powder core wire with the gradient component metal sheath structure or the nano powder core wire with the different component metal sheath structure for electric arc spraying, and the metal layers and the nano powder core layers are alternately distributed.
Example 8
The novel wire for arc spraying and the preparation method thereof can prepare wires with gradient component metal skins and gradient component nano powder core structures, wires with different component metal skins and gradient component nano powder core structures, wires with gradient component metal skins and different component nano powder core structures, and nano powder core wires with different component metal skins and different component nano powder core structures, and the technological process is shown in figure 9. The rectangles in fig. 9.1, light black, dark black and between them, represent the different components (Fe, cu and Al metal skins) or metal skins having a gradient composition (30 wt% Al-Cu, 60wt% Al-Cu, 90wt% Al-Cu metal skin) structure, respectively, and the rectangles in fig. 9.3, which are composed of horizontal, oblique and vertical line segments, represent the different components (nano NiCr, moSi, respectively 2 SiC powder) or gradient composition (30 wt% NiCr-MoSi nanometer) 2 、60wt％NiCr-MoSi 2 、90wt％NiCr-MoSi 2 Powder) structured nano-powder cores.
The method of this example is the same as that of example 7, except that:
a rubber block with 3 blocks was placed in the middle of the metal skin and pressed against the surface of the metal skin as shown in fig. 4.2. Then, the alcohol solutions distributed with different nano powder cores are slowly poured into the 3 boxes with a certain depth in sequence, so that the water or alcohol with the powder cores is fully contacted with the surface of the metal skin and uniformly distributed, and as shown in fig. 4.3, the alcohol solutions with different nano powder cores are specifically distributed with the following two schemes:
scheme one: the rectangle formed by the horizontal line segment represents the powder of the component A (NiCr powder), and the rectangle formed by the inclined line segment represents the powder of the component B (MoSi 2 Powder), the rectangle formed by the horizontal line segments represents the powder of component C (SiC powder), thus the powder of three different components A, B and C are sequentially arranged along the length direction of the wire, and the wire has a nano-powder core structure of different components.
Scheme II: the rectangle formed by the horizontal line segments represents a powder consisting of 30% of powder A (NiCr powder) and 70% of powder B (MoSi 2 Powder) and the rectangle formed by the inclined line segments represents a mixture of 60% of powder a (NiCr powder) and 40% of powder B (MoSi) 2 Powder), the rectangle formed by the horizontal line segments represents a mixture of 90% of powder a (NiCr powder) and 10% of powder B (MoSi) 2 Powder), wherein the contents of the substance A and the substance B are distributed in a gradient manner along the length direction of the wire, the gradient variation of the powder component is 30%, and the wire has a gradient component nano-powder core structure.
In this example, 4 kinds of wires for arc spraying can be prepared: the wire material with the gradient component metal sheath and the gradient component nano powder core structure, the wire material with the different component metal sheath and the gradient component nano powder core structure, the wire material with the gradient component metal sheath and the different component nano powder core structure, and the nano powder core wire material with the different component metal sheath and the different component nano powder core structure are shown in fig. 9.17 and 9.18.
The schematic diagram of the longitudinal section structure of the nano powder core wire prepared by the process is shown in fig. 9.19, and the metal layers and the nano powder core layers are alternately distributed.
Example 9
The method of this example is the same as that of example 8, except that: the specific process of the nano-core powder is shown in figure 10, wherein nano-powder cores with different particle sizes, different grain sizes and different structures are selected.
The rectangles in fig. 10.3, light black, dark black and between the two, represent different compositions (Fe, zn and Al metal skins) or metal skins having a gradient composition (30 wt% Zn-Al, 60wt% Zn-Al, 90wt% Zn-Al metal skin) structure, respectively. Black circles with different sizes in fig. 10.3 represent nano powder cores with different structures or in gradient structures (powder particle size or crystalline state, etc.), such as nano powder cores with different grain sizes (Cu powder with particle sizes of 30nm, 60nm and 90 nm), and different crystalline nano powder cores (crystalline nano Cu powder, quasi-crystalline nano Cu powder and amorphous nano Cu powder).
The wire material with the gradient component metal sheath and the gradient structure nano-powder core structure, the wire material with the different component metal sheath and the gradient structure nano-powder core structure, the wire material with the gradient component metal sheath and the different structure nano-powder core structure and the wire material with the different component metal sheath and the different structure nano-powder core structure are prepared in the embodiment, and are shown in fig. 10.17 and 10.18.
The schematic diagram of the longitudinal section structure of the nano powder core wire prepared by the process is shown in fig. 10.19, and the metal layers and the nano powder core layers are alternately distributed.
Example 10
The method of this example is the same as that of example 9, except that: the specific process is shown in fig. 11, and the light black, dark black and rectangles with colors between the light black and dark black in fig. 11.1 respectively represent metal skins (Sn, zn and Cu metal skins) with different components or metal skins with gradient component structures (30 wt% Zn-Cu, 60wt% Zn-Cu and 90wt% Zn-Cu metal skin). The rectangles in FIG. 11.3, which are composed of horizontal, inclined and vertical segments, represent nano-powder cores (nano SnO) of different compositions, respectively 2 ZnO and CuO powder) or nano powder core (nano 30wt% SnO) with gradient component structure 2 -CuO、60wt％SnO 2 -CuO、90wt％SnO 2 -CuO powder). FIG. 11.3 hasBlack circles of different sizes represent nano-powder cores having different structures or in a gradient structure (particle size or crystalline state, etc.), such as nano-powder cores of different particle sizes (nano-Fe powder of particle sizes 30nm, 60nm and 90 nm), and nano-powder cores of different crystalline states (crystalline nano-Fe powder, quasi-crystalline nano-Fe powder and amorphous nano-Fe powder).
The wire material with the gradient component metal sheath, the gradient structure and the gradient component nano powder core structure is prepared in the embodiment; a wire material with a gradient component metal sheath, a gradient structure and a nano powder core structure with different components; a wire material with a gradient component metal sheath, a different structure and a gradient component nano-powder core structure; a wire material with a gradient component metal sheath, a different structure and a different component nano powder core structure; wires with different components of metal skins, different structures and different components of nano powder core structures; wires with different components of metal skins, different structures and gradient components of nano-powder core structures; wires with metal sheaths of different components, gradient structures and nano powder core structures of different components; preparation of different composition metal skins, gradient structures and gradient composition nano-core structure wires as shown in fig. 11.17 and 11.18.
According to metallographic morphology analysis, the coating layer of the wire prepared by the embodiment of the invention is tightly combined with the interface of the matrix, the thickness of the coating layer is uniformly distributed, and the coating layer has higher density.
Claims (7)
1. A novel wire for arc spraying, characterized in that: the wire is prepared from a conductive metal sheath, wherein the thickness of the conductive metal sheath is 5-50 mu m, and the width of the conductive metal sheath is 4-60 cm; the length of the prepared wire is between 12cm and 220cm, and the diameter of the wire is between 1mm and 3mm.
2. The novel wire for arc spraying according to claim 1, wherein: the metal sheath is one or more of Al, fe, sn, cu, ag, au, zn, mg and brass.
3. A novel wire for arc spraying, characterized in that: the wire is mainly prepared from a conductive metal sheath and an internal nano powder core, wherein the thickness of the metal sheath is 5-50 mu m, the width of the metal sheath is 4-60 cm, the particle size of the nano powder core is 1-100 nm, the length of the wire is 12-220 cm, and the diameter of the wire is 1-3 mm.
4. The novel wire for arc spraying according to claim 3, wherein: the metal sheath is one or more of Al, fe, sn, cu, ag, au, zn, mg and brass, the thickness of the metal sheath is 5-50 mu m, and the width is 4-60 cm; the nanometer powder core is Al 2 O 3 Powder, tiO 2 Powder, zrO 2 Powder, Y 2 O 3 Powder, cr 3 C 2 Powder, WC powder, cr powder, niCr powder, moSi 2 Powder, siC powder, cu powder, fe powder and SnO 2 Powder, mgO powder, cuO powder, znO powder and Cr 2 O 3 One or more of the powders are arbitrarily combined, and the particle size of the powder is 1nm-100nm.
5. The novel wire for arc spraying according to claim 3 or 4, wherein: the mass ratio of the nano powder core to the metal sheath is (5-1) (1-5).
6. The method for producing a novel wire for arc spraying according to claim 1 or 2, characterized by comprising the following production steps:
(1) Preparing a metal skin with the thickness of 5-50 mu m, the width of 4-60 cm and the length of 4-200 cm, and spreading the metal skin on a clean and flat platform;
(2) Placing a rubber sheet, a plastic sheet or a metal sheet above the middle position of the metal sheath, and pressing to tightly adhere the rubber sheet, the plastic sheet or the metal sheet to the surface of the metal sheath;
(3) Folding the metal skins on two sides of the rubber sheet, the plastic sheet or the metal sheet respectively to the middle so that the metal skins form an acute angle with the plane;
(4) Taking out the rubber sheet, the plastic sheet or the metal sheet;
(5) Preliminarily compacting the metal skin at the moment by using a flat plate;
(6) Rolling along the length direction of the metal skin by using a round bar, and applying a force perpendicular to the metal skin in the rolling process of the round bar so as to tightly contact the metal skins and further compact the metal skins;
(7) Folding the metal skin along the middle to enable the metal skin on one side and the metal skin on the other side to form an acute angle, preliminarily compacting the metal skin at the moment by using a flat plate, and rolling the metal skin on the flat plate by using a round rod to further compact the metal skin; this process is repeated until the desired width and thickness of the metal skin is obtained;
(8) Winding the obtained metal skin on a metal round bar to enable the metal skin to form a shape similar to the round bar;
(9) The round bar-shaped metal skin is pressed by a rectangular flat plate, the flat plate is horizontally slid to roll, and the wire material similar to the round bar is changed into the wire material of the round bar in the rolling process, so that the preparation of the solid metal wire material for electric arc spraying is completed.
7. The method for producing a novel wire for arc spraying according to claim 3 or 4, comprising the steps of:
(1) Preparing a metal skin with the thickness of 5-50 mu m, the width of 4-60 cm and the length of 4-200 cm, and spreading the metal skin on a clean and flat platform; respectively placing the nano powder into distilled water or alcohol, and mechanically stirring to uniformly distribute the nano powder in the water or alcohol;
(2) Placing a rubber frame, a plastic frame or a metal frame above the middle position of the metal sheath, and pressing to tightly adhere the rubber frame, the plastic frame or the metal frame to the surface of the metal sheath; slowly pouring water or alcohol distributed with nano powder cores into the 3 square frames with a certain depth in sequence, enabling the water or alcohol with the powder cores to be in full contact with the surface of the metal skin and uniformly distributed, standing for a period of time, and after the water or alcohol volatilizes;
(3) Folding the metal skins on two sides of the rubber frame, the plastic frame or the metal frame respectively to the middle so that the metal skins form an acute angle with the plane;
(4) Taking out the rubber frame, the plastic frame or the metal frame;
(5) Preliminarily compacting the metal skin at the moment by using a flat plate;
(6) Then a round bar rolls along the length direction of the metal skin, and a force vertical to the metal skin is applied in the rolling process of the round bar so as to tightly contact the metal skin and the nano powder core, and further compacts the metal skin and the nano powder core;
(7) Folding the metal skin along the middle to enable the metal skin on one side and the metal skin on the other side to form an acute angle, preliminarily compacting the metal skin at the moment by using a flat plate, rolling the metal skin on the flat plate by using a round rod, and further compacting the metal skin and the nano powder core; this process is repeated until the desired width and thickness of the metal skin is obtained;
(8) Winding the obtained metal skin on a metal round bar to enable the metal skin to form a shape similar to the round bar;
(9) The round bar-shaped metal skin is pressed by a rectangular flat plate, the flat plate is horizontally slid to roll, and the wire material similar to the round bar is changed into the wire material of the round bar in the rolling process, so that the preparation of the nano powder core wire material for electric arc spraying is completed.
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