CN116536663A - 一种阻垢、耐磨及耐腐蚀转炉风机涂层的制备工艺 - Google Patents
一种阻垢、耐磨及耐腐蚀转炉风机涂层的制备工艺 Download PDFInfo
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Abstract
本发明提供一种阻垢、耐磨及耐腐蚀转炉风机涂层的制备工艺,该工艺包括以下步骤。步骤1:通过激光熔覆工艺将Fe‑Ni合金熔覆在转炉风机表面,形成0.5‑1.5mm厚度的熔覆层;步骤2:对转炉风机表面的熔覆层进行磨削,控制熔覆层厚度在0.5‑1mm之间;步骤3:对熔覆层清洗去污,干燥后进行喷砂处理,表面清洁度达到Sa2.5等级以上,粗糙度控制在Ra8‑15μm;步骤4:采用热喷涂工艺将WC基材料喷涂在熔覆层上,形成0.1‑0.2mm厚度的喷涂层;步骤5:将封孔剂涂覆在喷涂层上,对喷涂层孔隙进行封填;步骤6:喷涂完成的转炉风机表面复合涂层通过研磨抛光,加工风机叶轮表面的尺寸精度和表面粗糙度。本发明的有益效果:激光熔覆涂层开裂敏感性较小且适合大范围推广使用。
Description
技术领域
发明属于涂层制备技术领域,具体涉及一种阻垢、耐磨及耐腐蚀转炉风机涂层的制备工艺。
背景技术
涂层,是涂料一次施涂所得到的固态连续膜,是为了防护,绝缘,装饰等目的,涂布于金属,织物,塑料等基体上的塑料薄层。涂料可以为气态、液态、固态,通常根据需要喷涂的基质决定涂料的种类和状态。涂层在生产的过程中会用到废料接收箱。
激光熔覆技术是激光表面改性技术中的重要组成部分,由于可以显著改善材料的耐磨性、耐蚀性、耐热性以及一些电气性能,在生产应用中得到快速发展。然而当前采用的激光熔覆粉末一方面是沿用热喷涂材料的镍基、铁基、钴基自熔性合金粉末;另一方面就是在合金粉末中添加WC、TiC、SiC等陶瓷材料来提高熔覆层的硬度和耐磨性,但其裂纹敏感性也会增加。因此,研究具有良好耐磨性、耐蚀性和抗热性等综合性能的激光熔覆粉末,用于机械零件易损部位的修复,获得耐磨、耐蚀层,可以大大延长机器设备的使用寿命,不仅可以提高生产效率,还能够克服在堆焊、热喷涂等传统表面处理技术中普遍存在的工件变形大和结合强度低的问题,具有巨大的发展潜力。然而当前采用的激光熔覆粉末一方面是沿用含有硼和硅的热喷涂用自熔合金粉末,其不足之处在于绝大多数自熔合金粉末中硼和硅的含量较高,由于激光熔覆过程中冷却速度快,使得一些夹杂如硼硅酸盐无法顺利从快速凝固的熔池内浮出,导致激光熔覆层开裂敏感性较大;另一方面就是采用含有三四种元素的专用粉末,不适合大范围推广使用。因此,研究不含硼和硅的全新合金体系的激光熔覆粉末显得十分必要。
发明内容
发明的目的在于提供一种磨料机用废料收集箱,旨在解决现有技术中磨料机用废料收集箱使用时候工人的劳动强度较大的问题。
为实现上述目的,发明提供如下技术方案:一种阻垢、耐磨及耐腐蚀转炉风机涂层的制备工艺,具体如下:
步骤1:通过激光熔覆工艺将Fe-Ni合金熔覆在转炉风机表面,形成0.5-1.5mm厚度的熔覆层;
步骤2:对转炉风机表面的熔覆层进行磨削,控制熔覆层厚度在0.5-1mm之间;
步骤3:对熔覆层清洗去污,干燥后进行喷砂处理,表面清洁度达到Sa2 .5等级以上,粗糙度控制在Ra8-15μm;
步骤4:使用激光熔覆工艺使得自洁涂层熔覆在转炉风机表面,所述自洁涂层具有孔洞之间相互贯通的多孔结构,且所述涂层所含孔洞的体积占所述涂层总体积的20%-98%,所述多孔结构中的孔洞的孔径为0.5nm-50nm,所述自洁涂层主要由主体材料制备而成,所述主体材料为氧化钛、氧化锆、氮化钛、氧化硅、氧化钨、g-C3N4半导体聚合物、钙钛矿半导体、银、铁、金、铝、铜、锌、锡和铂中的一种或多种。
步骤5:采用热喷涂工艺将WC基材料喷涂在熔覆层上,形成0.1-0.2mm厚度的喷涂层;
步骤6:将封孔剂涂覆在喷涂层上,对喷涂层孔隙进行封填;
步骤7:喷涂完成的转炉风机表面复合涂层通过研磨抛光,加工风机叶轮表面的尺寸精度和表面粗糙度。
激光熔覆技术是指以不同的填料方式在被涂覆基体表面上放置选择的涂层材料,经激光辐照使之和基体表面一薄层同时熔化,并快速凝固后形成稀释度极低并与基体材料成冶金结合的表面涂层,从而显著改善基体材料表面的耐磨、耐蚀、耐热、 抗氧化及电器特性等的工艺方法。
喷砂工艺:利用高速砂流的冲击作用清理和粗化基体表面的过程。采用压缩空气为动力,以形成高速喷射束将喷料(铜矿砂、石英砂、金刚砂、铁砂、海南砂)高速喷射到需要处理的工件表面,使工件表面的外表面的外表或形状发生变化,由于磨料对工件表面的冲击和切削作用,使工件的表面获得一定的清洁度和不同的粗糙度,使工件表面的机械性能得到改善,因此提高了工件的抗疲劳性,增加了它和涂层之间的附着力,延长了涂膜的耐久性,也有利于涂料的流平和装饰。
一种磨料机用废料收集箱,包括底座,所述底座上铰接设置有箱体,所述箱体上设置有出料门,所述底座上设置有用以撞击箱体底部使得箱体做往复摆动的撞击装置。
具体的,所述撞击装置包括设置在底座上的驱动装置,所述驱动装置的驱动端设置有和底座转动安装的用以撞击底座下部的凸轮。
具体的,所述驱动装置为电机。
为了使得该一种磨料机用废料收集箱具有给电机散热的作用,作为发明一种优选的,所述箱体的底部设置有气囊,所述气囊的下部开设有朝向电机的小孔,所述小孔处设置有滤网。
为了使得该一种磨料机用废料收集箱具有方便移动收集箱的作用,作为发明一种优选的,所述底座的下部设置有移动装置。
具体的,所述移动装置为万向轮。
为了使得该一种磨料机用废料收集箱具有方便打开出料门的作用,作为发明一种优选的,所述箱体上铰接设置有出料门,所述出料门的边缘处设置有橡胶条。
与现有技术相比,发明的有益效果是:
1.该一种磨料机用废料收集箱,启动电机,电机带动凸轮转动,凸轮的转动使得箱体的底部间歇性的被顶起,由于箱体和底座铰接,使得箱体出现往复摆动,残留在箱体上的磨料在箱体的抖动下就可以使得箱体内的磨料可以下的更快,提高了磨料废料的下料效率。
2.箱体的底部设置有气囊,气囊的下部开设有朝向电机的小孔,小孔处设置有滤网,由于箱体的底部设置有气囊,使得气囊被凸轮间歇性的顶起,气囊被压缩时候就会把气体挤压出来,正好把气体吹在电机上,实现对电机的散热,节约了散热电机需要的资源,还能兼顾散热效率。
3.箱体上铰接设置有出料门,出料门的边缘处设置有橡胶条,橡胶条使得出料门和箱体的密封性更好,铰接设置的出料门在箱体摆动的时候,受重力作用依然竖直向下,此时和箱体之间产生夹角,废料得以流出来。
附图说明
附图用来提供对发明的进一步理解,并且构成说明书的一部分,与发明的实施例一起用于解释发明,并不构成对发明的限制。在附图中:
图1为发明中的具体实施例的对比文献的示意图;
图2为发明中的具体实施例的结构示意图;
图3为发明中的具体实施例的仰视图;
图4为发明中的具体实施例的仰视图的A处的放大图。
图中:1.底座;2.万向轮;3.气囊;4.箱体;5.出料门;6.凸轮;7.电机;8.出气孔。
具体实施方式
下面将结合发明实施例中的附图,对发明实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例仅仅是发明一部分实施例,而不是全部的实施例。基于发明中的实施例,本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例,都属于发明保护的范围。
请参阅图2-4,发明提供以下技术方案:一种阻垢、耐磨及耐腐蚀转炉风机涂层的制备工艺,具体如下:
步骤1:通过激光熔覆工艺将Fe-Ni合金熔覆在转炉风机表面,形成0.5-1.5mm厚度的熔覆层;
步骤2:对转炉风机表面的熔覆层进行磨削,控制熔覆层厚度在0.5-1mm之间;
步骤3:对熔覆层清洗去污,干燥后进行喷砂处理,表面清洁度达到Sa2 .5等级以上,粗糙度控制在Ra8-15μm;
步骤4:使用激光熔覆工艺使得自洁涂层熔覆在转炉风机表面,所述自洁涂层具有孔洞之间相互贯通的多孔结构,且所述涂层所含孔洞的体积占所述涂层总体积的20%-98%,所述多孔结构中的孔洞的孔径为0.5nm-50nm,所述自洁涂层主要由主体材料制备而成,所述主体材料为氧化钛、氧化锆、氮化钛、氧化硅、氧化钨、g-C3N4半导体聚合物、钙钛矿半导体、银、铁、金、铝、铜、锌、锡和铂中的一种或多种。
步骤5:采用热喷涂工艺将WC基材料喷涂在熔覆层上,形成0.1-0.2mm厚度的喷涂层;
步骤6:将封孔剂涂覆在喷涂层上,对喷涂层孔隙进行封填;
步骤7:喷涂完成的转炉风机表面复合涂层通过研磨抛光,加工风机叶轮表面的尺寸精度和表面粗糙度。
激光熔覆技术是指以不同的填料方式在被涂覆基体表面上放置选择的涂层材料,经激光辐照使之和基体表面一薄层同时熔化,并快速凝固后形成稀释度极低并与基体材料成冶金结合的表面涂层,从而显著改善基体材料表面的耐磨、耐蚀、耐热、 抗氧化及电器特性等的工艺方法。
喷砂工艺:利用高速砂流的冲击作用清理和粗化基体表面的过程。采用压缩空气为动力,以形成高速喷射束将喷料(铜矿砂、石英砂、金刚砂、铁砂、海南砂)高速喷射到需要处理的工件表面,使工件表面的外表面的外表或形状发生变化,由于磨料对工件表面的冲击和切削作用,使工件的表面获得一定的清洁度和不同的粗糙度,使工件表面的机械性能得到改善,因此提高了工件的抗疲劳性,增加了它和涂层之间的附着力,延长了涂膜的耐久性,也有利于涂料的流平和装饰。
现有的废料收集箱在收集废料的时候,需要靠人力把收集箱里面的废物拿出来或者倾斜一定角度倒出来,废物重量较大,使得工人的劳动强度较大。
为了解决上述问题,产生了一下实施例:
一种磨料机用废料收集箱,包括底座1,底座1上铰接设置有箱体4,箱体4上设置有出料门5,底座1上设置有用以撞击箱体4底部使得箱体4做往复摆动的撞击装置。
具体的,撞击装置包括设置在底座1上的驱动装置,驱动装置的驱动端设置有和底座1转动安装的用以撞击底座1下部的凸轮6;具体的,驱动装置为电机7。
在发明的具体实施例中,启动电机7,电机7带动凸轮6转动,凸轮6的转动使得箱体4的底部间歇性的被顶起,由于箱体4和底座1铰接,使得箱体4出现往复摆动,残留在箱体4上的磨料在箱体4的抖动下就可以使得箱体4内的磨料可以下的更快,提高了磨料废料的下料效率。
在发明的另一具体实施例中,箱体4的底部设置有气囊3,气囊3的下部开设有朝向电机7的小孔8,小孔8处设置有滤网;由于箱体4的底部设置有气囊3,使得气囊3被凸轮6间歇性的顶起,气囊3被压缩时候就会把气体挤压出来,正好把气体吹在电机7上,实现对电机7的散热,节约了散热电机7需要的资源,还能兼顾散热效率。
进一步的,底座1的下部设置有移动装置,使得移动磨料接收箱便捷。
具体的,移动装置为万向轮2。
优选的,箱体4上铰接设置有出料门5,出料门5的边缘处设置有橡胶条,橡胶条使得出料门5和箱体4的密封性更好,铰接设置的出料门5在箱体4摆动的时候,受重力作用依然竖直向下,此时和箱体4之间产生夹角,废料得以流出来。
在发明的描述中,除非另有明确的规定和限定,术语“安装”、“相连”、“连接”应做广义理解,例如,可以是固定连接,也可以是可拆卸连接,或一体地连接;可以是机械连接,也可以是电连接;可以是直接相连,也可以通过中间媒介间接相连,可以是两个元件内部的连通。对于本领域的普通技术人员而言,可以具体情况理解上述术语在发明中的具体含义。
对于本领域技术人员而言,显然发明不限于上述示范性实施例的细节,而且在不背离发明的精神或基本特征的情况下,能够以其他的具体形式实现发明。因此,无论从哪一点来看,均应将实施例看作是示范性的,而且是非限制性的,发明的范围由所附权利要求而不是上述说明限定,因此旨在将落在权利要求的等同要件的含义和范围内的所有变化囊括在发明内。不应将权利要求中的任何附图标记视为限制所涉及的权利要求。
此外,应当理解,虽然本说明书按照实施方式加以描述,但并非每个实施方式仅包含一个独立的技术方案,说明书的这种叙述方式仅仅是为清楚起见,本领域技术人员应当将说明书作为一个整体,各实施例中的技术方案也可以经适当组合,形成本领域技术人员可以理解的其他实施方式。
Claims (9)
1.一种阻垢、耐磨及耐腐蚀转炉风机涂层的制备工艺,其特征在于:
步骤1:通过激光熔覆工艺将Fe-Ni合金熔覆在转炉风机表面,形成0.5-1.5mm厚度的熔覆层;
步骤2:对转炉风机表面的熔覆层进行磨削,控制熔覆层厚度在0.5-1mm之间;
步骤3:对熔覆层清洗去污,干燥后进行喷砂处理,表面清洁度达到Sa2 .5等级以上,粗糙度控制在Ra8-15μm;
步骤4:使用激光熔覆工艺使得自洁涂层熔覆在转炉风机表面,所述自洁涂层具有孔洞之间相互贯通的多孔结构,且所述涂层所含孔洞的体积占所述涂层总体积的20%-98%,所述多孔结构中的孔洞的孔径为0.5nm-50nm,所述自洁涂层主要由主体材料制备而成,所述主体材料为氧化钛、氧化锆、氮化钛、氧化硅、氧化钨、g-C3N4半导体聚合物、钙钛矿半导体、银、铁、金、铝、铜、锌、锡和铂中的一种或多种。
步骤5:采用热喷涂工艺将WC基材料喷涂在熔覆层上,形成0.1-0.2mm厚度的喷涂层;
步骤6:将封孔剂涂覆在喷涂层上,对喷涂层孔隙进行封填;
步骤7:喷涂完成的转炉风机表面复合涂层通过研磨抛光,加工风机叶轮表面的尺寸精度和表面粗糙度。
2.根据权利要求1所述的一种阻垢、耐磨及耐腐蚀转炉风机涂层的制备工艺用废料收集箱,包括底座(1),其特征在于,所述底座(1)上铰接设置有箱体(4),所述箱体(4)上设置有出料门(5),所述底座(1)上设置有用以撞击箱体(4)底部使得箱体(4)做往复摆动的撞击装置。
3.根据权利要求2所述的一种磨料机用废料收集箱,其特征在于:所述撞击装置包括设置在底座(1)上的驱动装置,所述驱动装置的驱动端设置有和底座(1)转动安装的用以撞击底座(1)下部的凸轮(6)。
4.根据权利要求3所述的一种磨料机用废料收集箱,其特征在于:所述驱动装置为电机(7)。
5.根据权利要求2所述的一种磨料机用废料收集箱,其特征在于:所述箱体(4)的底部设置有气囊(3),所述气囊(3)的下部开设有朝向电机(7)的小孔(8)。
6.根据权利要求5所述的一种磨料机用废料收集箱,其特征在于:所述小孔(8)处设置有滤网。
7.根据权利要求1所述的一种磨料机用废料收集箱,其特征在于:所述底座(1)的下部设置有移动装置。
8.根据权利要求7所述的一种磨料机用废料收集箱,其特征在于:所述移动装置为万向轮(2)。
9.根据权利要求1-6任一项所述的一种磨料机用废料收集箱,其特征在于:所述箱体(4)上铰接设置有出料门(5),所述出料门(5)的边缘处设置有橡胶条。
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