CN116899846A - 一种工件表面涂层及涂装工艺 - Google Patents
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Abstract
本发明公开了一种工件表面涂层及涂装工艺,包括以下步骤:S1,表面处理:工件表面处理必须彻底,涂装之前要进行除油、除锈、喷砂等处理工作;S2,预处理防腐:通过磷化、电泳等方式对工件的表面进行预处理防腐;S3,底漆涂装:对预处理防腐后的工件,进行表面喷涂底漆;S4,中漆涂装:然后在底漆上喷涂中漆;S5,面漆涂装:对工件中漆上再次喷涂面漆;S6,后处理;S7检验:最后对经过喷涂的工件进行检测以确保表面质量符合涂装技术标准。本发明可以有效提高金属工件本体表面的硬度;通过设置防腐涂层,可以在金属工件本体表面生成一层致密的薄膜,能够有效提高金属工件本体表面的耐腐蚀性,进一步延长金属工件本体的使用寿命。
Description
技术领域
本发明涉及涂装工艺领域,特别涉及一种工件表面涂层及涂装工艺。
背景技术
金属工件腐蚀是人们面临的一个十分严重而又最为普遍的问题,全世界每年因腐蚀造成的经济损失约占各国GDP的2%~4%,因腐蚀而报废的金属工件达亿吨以上。在金属工件表面设置防腐层是有效解决金属腐蚀的方法,然而,目前的防腐涂层的寿命较短,难以达到较好的防腐效果。
发明内容
本发明的目的在于提供一种工件表面涂层及涂装工艺,以解决上述背景技术中提出的问题。
为实现上述目的,本发明提供如下技术方案:一种工件表面涂层,包括防腐涂层、底漆层、中漆层和面漆层,所述防腐涂层喷涂于工件的表面,所述底漆层喷涂于防腐涂层上,所述中漆层喷涂于底漆层上,所述面漆层喷涂于中漆层上。
优选的,所述底漆层的厚度为200-300nm。
优选的,所述中漆层的厚度为150-250nm。
优选的,所述面漆层的厚度为300-450nm。
一种工件表面涂装工艺,涂层工艺流程包括以下步骤:
S1,表面处理:工件表面处理必须彻底,涂装之前要进行除油、除锈、喷砂等处理工作,以保证表面光洁、无油、无锈、均匀粗糙度;
S2,预处理防腐:就是在表面处理之后塑料喷涂,是实现表面防腐的关键。常见的预处理方式有磷化、电泳等方式;
S3,底漆涂装:涂装过程中,选用底漆是为工件做好一次性塑料涂层。底漆的涂装要求厚度匀称、无气泡、无断垂等缺陷,同时也应符合相应国家标准或行业标准要求。底漆的涂装方式有手动、自动喷涂等方法;
S4,中涂涂装:中涂是为了增加涂装层与底漆的附着力,增大涂料层厚度、均匀度和光泽度,中涂的涂装要求坑和气泡缺陷较少,干燥速度适中,从而保证工件质量,中涂的涂装方式有手动、自动喷涂等方法;
S5,面漆涂装:面漆涂装是强化工件表面的一层保护膜,让表面更加光滑、坚硬、防水、防腐、抗紫外线辐射、抗应力等,有着很高的要求。面漆的涂装要求涂层均匀、光滑,无起泡、流挂、跑色、剌缀等缺陷。面漆的涂装方式有手动、自动喷涂等方法;
S6,后处理:涂装完成后,要配合适当的后处理工序。通常是烘干及高温煅烧等处理程序;
S7检验:最后对经过喷涂的工件进行检测以确保表面质量符合涂装技术标准,包括外观检测、膜厚度测量、粘着力检测等。
优选的,S21,磷化:磷化是指在工件表面形成具有化学反应性和缓蚀性的磷化层,从而提高工件抗腐蚀能力和涂层附着力。磷化一般采用浸泡或者喷淋的方式,可以选用无铬磷化和含铬磷化两种方式;
S22,电泳涂装:电泳涂装是利用介电介质形成电场的方法,在金属工件表面形成一层带电涂层,并在工件上制造均匀电场,然后将涂料颗粒带入电场,并静电吸附在工件表面进行喷涂。该方法的优点是涂层均匀,质量稳定;
S22,烘干:对于磷化和电泳涂装工艺,需要对工件进行烘干,以去除表面水份,使得涂料固定在工件表面。
优选的,所述步骤S21中,工件表面磷化处理包括以下步骤:
S211,浸泡磷化:将准备好的磷酸和其他所需物料混合,按照一定比例加入工件处理槽中,然后放入待处理的工件进行浸泡磷化。通过调节磷酸浓度、浸泡时间、温度等参数,使工件表面形成磷化层,提高表面耐腐蚀能力和增强涂层附着力;
S212,清洗:将磷化后的工件从处理槽中取出,进行冲洗即去除表面多余物质和杂质,这是表面的磷酸盐等残留物,确保工件无运行到其他生产线后产生的污染;
S213,中和处理:将清洗干净的工件再次浸入到中和液中,弥补磷酸溶液可能造成的损伤和腐蚀;
S214,清洗:在中和处理后的工件进行二次清洗,从而去除表面多余物质和杂质,以确保表面清洁,在接下来的泼涂很重要;
S215,干燥:将清洗后的工件放入烘箱中进行干燥。经过干燥后的工件就可以进行下一步的涂装或其它处理过程。
优选的,所述步骤S22中,工件电泳涂装包括以下步骤:
S221,电泳预处理:将工件悬挂在电泳槽中,进行电泳预处理。预处理通常包括电解反应、阳极氧化、光催化氧化等步骤,以使涂料更好地附着在工件表面;
S222,炉前处理:经过电泳预处理后,将工件送入炉前,进行烘烤、前处理、涂装等步骤,以保证涂料的耐久性和表面效果;
S223,电泳涂装:将经过炉前处理的工件悬挂在电泳槽中,通过直流电流使涂料离子在液中运动并沉积在工件表面上形成涂膜;
S224,固化和烘烤:涂装完毕的工件送入固化炉中,经过一定的时间和温度,使涂层固化、烘干,成为一个坚固、平整、光滑的涂层。
本发明的技术效果和优点:
本发明利用防腐涂层和底漆层相配合的设置方式,可以有效提高金属工件本体表面的硬度;通过设置防腐涂层,可以在金属工件本体表面生成一层致密的薄膜,能够有效提高金属工件本体表面的耐腐蚀性,进一步延长金属工件本体的使用寿命。
附图说明
图1为本发明涂层结构示意图。
图中:1、防腐涂层;2、底漆层;3、中漆层;4、面漆层。
具体实施方式
下面将结合本发明实施例中的附图,对本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本发明一部分实施例,而不是全部的实施例。基于本发明中的实施例,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,都属于本发明保护的范围。
本发明提供了如图1所示的一种工件表面涂层及涂装工艺一种工件表面涂层,包括防腐涂层1、底漆层2、中漆层3和面漆层4,防腐涂层1喷涂于工件的表面,底漆层2喷涂于防腐涂层1上,中漆层3喷涂于底漆层2上,面漆层4喷涂于中漆层3上。
优选的,底漆层2的厚度为200-300nm。
优选的,中漆层3的厚度为150-250nm。
优选的,面漆层4的厚度为300-450nm。
一种工件表面涂装工艺,涂层工艺流程包括以下步骤:
S1,表面处理:工件表面处理必须彻底,涂装之前要进行除油、除锈、喷砂等处理工作,以保证表面光洁、无油、无锈、均匀粗糙度;
S2,预处理防腐:就是在表面处理之后塑料喷涂,是实现表面防腐的关键。常见的预处理方式有磷化、电泳等方式;
S3,底漆涂装:涂装过程中,选用底漆是为工件做好一次性塑料涂层。底漆的涂装要求厚度匀称、无气泡、无断垂等缺陷,同时也应符合相应国家标准或行业标准要求。底漆的涂装方式有手动、自动喷涂等方法;
S4,中涂涂装:中涂是为了增加涂装层与底漆的附着力,增大涂料层厚度、均匀度和光泽度,中涂的涂装要求坑和气泡缺陷较少,干燥速度适中,从而保证工件质量,中涂的涂装方式有手动、自动喷涂等方法;
S5,面漆涂装:面漆涂装是强化工件表面的一层保护膜,让表面更加光滑、坚硬、防水、防腐、抗紫外线辐射、抗应力等,有着很高的要求。面漆的涂装要求涂层均匀、光滑,无起泡、流挂、跑色、剌缀等缺陷。面漆的涂装方式有手动、自动喷涂等方法;
S6,后处理:涂装完成后,要配合适当的后处理工序。通常是烘干及高温煅烧等处理程序;
S7检验:最后对经过喷涂的工件进行检测以确保表面质量符合涂装技术标准,包括外观检测、膜厚度测量、粘着力检测等。
优选的,S21,磷化:磷化是指在工件表面形成具有化学反应性和缓蚀性的磷化层,从而提高工件抗腐蚀能力和涂层附着力。磷化一般采用浸泡或者喷淋的方式,可以选用无铬磷化和含铬磷化两种方式;
S22,电泳涂装:电泳涂装是利用介电介质形成电场的方法,在金属工件表面形成一层带电涂层,并在工件上制造均匀电场,然后将涂料颗粒带入电场,并静电吸附在工件表面进行喷涂。该方法的优点是涂层均匀,质量稳定;
S22,烘干:对于磷化和电泳涂装工艺,需要对工件进行烘干,以去除表面水份,使得涂料固定在工件表面。
优选的,步骤S21中,工件表面磷化处理包括以下步骤:
S211,浸泡磷化:将准备好的磷酸和其他所需物料混合,按照一定比例加入工件处理槽中,然后放入待处理的工件进行浸泡磷化。通过调节磷酸浓度、浸泡时间、温度等参数,使工件表面形成磷化层,提高表面耐腐蚀能力和增强涂层附着力;
S212,清洗:将磷化后的工件从处理槽中取出,进行冲洗即去除表面多余物质和杂质,这是表面的磷酸盐等残留物,确保工件无运行到其他生产线后产生的污染;
S213,中和处理:将清洗干净的工件再次浸入到中和液中,弥补磷酸溶液可能造成的损伤和腐蚀;
S214,清洗:在中和处理后的工件进行二次清洗,从而去除表面多余物质和杂质,以确保表面清洁,在接下来的泼涂很重要;
S215,干燥:将清洗后的工件放入烘箱中进行干燥。经过干燥后的工件就可以进行下一步的涂装或其它处理过程。
优选的,步骤S22中,工件电泳涂装包括以下步骤:
S221,电泳预处理:将工件悬挂在电泳槽中,进行电泳预处理。预处理通常包括电解反应、阳极氧化、光催化氧化等步骤,以使涂料更好地附着在工件表面;
S222,炉前处理:经过电泳预处理后,将工件送入炉前,进行烘烤、前处理、涂装等步骤,以保证涂料的耐久性和表面效果;
S223,电泳涂装:将经过炉前处理的工件悬挂在电泳槽中,通过直流电流使涂料离子在液中运动并沉积在工件表面上形成涂膜;
S224,固化和烘烤:涂装完毕的工件送入固化炉中,经过一定的时间和温度,使涂层固化、烘干,成为一个坚固、平整、光滑的涂层。
最后应说明的是:以上仅为本发明的优选实施例而已,并不用于限制本发明,尽管参照前述实施例对本发明进行了详细的说明,对于本领域的技术人员来说,其依然可以对前述各实施例所记载的技术方案进行修改,或者对其中部分技术特征进行等同替换,凡在本发明的精神和原则之内,所作的任何修改、等同替换、改进等,均应包含在本发明的保护范围之内。
Claims (8)
1.一种工件表面涂层,包括防腐涂层(1)、底漆层(2)、中漆层(3)和面漆层(4),其特征在于,所述防腐涂层(1)喷涂于工件的表面,所述底漆层(2)喷涂于防腐涂层(1)上,所述中漆层(3)喷涂于底漆层(2)上,所述面漆层(4)喷涂于中漆层(3)上。
2.根据权利要求1所述的一种工件表面涂层,其特征在于,所述底漆层(2)的厚度为200-300nm。
3.根据权利要求1所述的一种工件表面涂层,其特征在于,所述中漆层(3)的厚度为150-250nm。
4.根据权利要求1所述的一种工件表面涂层,其特征在于,所述面漆层(4)的厚度为300-450nm。
5.根据权利要求1-4任意一项的一种工件表面涂装工艺,其特征在于,涂层工艺流程包括以下步骤:
S1,表面处理:工件表面处理必须彻底,涂装之前要进行除油、除锈、喷砂等处理工作;
S2,预处理防腐:通过磷化、电泳等方式对工件的表面进行预处理防腐;
S3,底漆涂装:对预处理防腐后的工件,进行表面喷涂底漆;
S4,中漆涂装:然后在底漆上喷涂中漆;
S5,面漆涂装:对工件中漆上再次喷涂面漆;
S6,后处理:涂装完成后,对喷涂完成后的工件进行烘干及高温煅烧等处理程序;
S7检验:最后对经过喷涂的工件进行检测。
6.根据权利要求5所述的一种工件表面涂装工艺,其特征在于,所述工件预处理防腐工艺流程主要包括以下几个步骤:
S21,磷化处理,采用浸泡或者喷淋的方式对表面处理后的工件进行磷化处理;
S22,电泳涂装:利用介电介质形成电场的方法,对工件表面进行喷涂;
S22,烘干:对已经磷化和电泳涂装后的工件,进行烘干。
7.根据权利要求6所述的一种工件表面涂装工艺,其特征在于,所述步骤S21中,工件表面磷化处理包括以下步骤:
S211,浸泡磷化:将准备好的磷酸和其他所需物料混合,放入待处理的工件进行浸泡磷化;
S212,清洗:将磷化后的工件从处理槽中取出,进行冲洗即去除表面多余物质和杂质;
S213,中和处理:将清洗干净的工件再次浸入到中和液中;
S214,清洗:在中和处理后的工件进行二次清洗;
S215,干燥:将清洗后的工件放入烘箱中进行干燥。
8.根据权利要求6所述的一种工件表面涂装工艺,其特征在于,所述步骤S22中,工件电泳涂装包括以下步骤:
S221,电泳预处理:将工件悬挂在电泳槽中,进行电泳预处理;
S222,炉前处理:经过电泳预处理后,将工件送入炉前,进行烘烤;
S223,电泳涂装:在工件表面上形成涂膜;
S224,固化和烘烤:涂装完毕的工件送入固化炉中,经过一定的时间和温度,使涂层固化、烘干。
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