CN117004951A - Composite phosphating method for new energy reducer product - Google Patents
Composite phosphating method for new energy reducer product Download PDFInfo
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- CN117004951A CN117004951A CN202311130892.2A CN202311130892A CN117004951A CN 117004951 A CN117004951 A CN 117004951A CN 202311130892 A CN202311130892 A CN 202311130892A CN 117004951 A CN117004951 A CN 117004951A
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- 238000000034 method Methods 0.000 title claims abstract description 55
- 239000002131 composite material Substances 0.000 title claims abstract description 31
- 239000003638 chemical reducing agent Substances 0.000 title claims abstract description 26
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 32
- 239000002253 acid Substances 0.000 claims abstract description 24
- 238000011282 treatment Methods 0.000 claims abstract description 17
- 230000000694 effects Effects 0.000 claims abstract description 14
- 238000005406 washing Methods 0.000 claims abstract description 12
- 238000005461 lubrication Methods 0.000 claims abstract description 11
- 229910019142 PO4 Inorganic materials 0.000 claims abstract description 10
- NBIIXXVUZAFLBC-UHFFFAOYSA-K phosphate Chemical compound [O-]P([O-])([O-])=O NBIIXXVUZAFLBC-UHFFFAOYSA-K 0.000 claims abstract description 10
- 239000010452 phosphate Substances 0.000 claims abstract description 10
- 230000005540 biological transmission Effects 0.000 claims abstract description 8
- 150000002500 ions Chemical class 0.000 claims abstract description 8
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 claims abstract description 8
- 238000001179 sorption measurement Methods 0.000 claims abstract description 7
- 230000002265 prevention Effects 0.000 claims abstract description 6
- XEEYBQQBJWHFJM-UHFFFAOYSA-N iron Substances [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 38
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 claims description 15
- 238000004140 cleaning Methods 0.000 claims description 14
- 239000000243 solution Substances 0.000 claims description 13
- VEXZGXHMUGYJMC-UHFFFAOYSA-N Hydrochloric acid Chemical compound Cl VEXZGXHMUGYJMC-UHFFFAOYSA-N 0.000 claims description 10
- 150000002696 manganese Chemical class 0.000 claims description 10
- 239000011572 manganese Substances 0.000 claims description 10
- LPXPTNMVRIOKMN-UHFFFAOYSA-M sodium nitrite Chemical compound [Na+].[O-]N=O LPXPTNMVRIOKMN-UHFFFAOYSA-M 0.000 claims description 10
- 238000005238 degreasing Methods 0.000 claims description 9
- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 claims description 8
- CDBYLPFSWZWCQE-UHFFFAOYSA-L Sodium Carbonate Chemical compound [Na+].[Na+].[O-]C([O-])=O CDBYLPFSWZWCQE-UHFFFAOYSA-L 0.000 claims description 8
- 239000013527 degreasing agent Substances 0.000 claims description 8
- 238000005237 degreasing agent Methods 0.000 claims description 8
- 229910052748 manganese Inorganic materials 0.000 claims description 8
- 150000001875 compounds Chemical class 0.000 claims description 7
- 229910052742 iron Inorganic materials 0.000 claims description 7
- 238000002791 soaking Methods 0.000 claims description 7
- NBIIXXVUZAFLBC-UHFFFAOYSA-N Phosphoric acid Chemical compound OP(O)(O)=O NBIIXXVUZAFLBC-UHFFFAOYSA-N 0.000 claims description 6
- 239000012535 impurity Substances 0.000 claims description 5
- 238000004519 manufacturing process Methods 0.000 claims description 5
- 235000010288 sodium nitrite Nutrition 0.000 claims description 5
- 239000003795 chemical substances by application Substances 0.000 claims description 4
- CPSYWNLKRDURMG-UHFFFAOYSA-L hydron;manganese(2+);phosphate Chemical compound [Mn+2].OP([O-])([O-])=O CPSYWNLKRDURMG-UHFFFAOYSA-L 0.000 claims description 4
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N iron oxide Inorganic materials [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 claims description 4
- 239000007788 liquid Substances 0.000 claims description 4
- 229910000029 sodium carbonate Inorganic materials 0.000 claims description 4
- 239000011550 stock solution Substances 0.000 claims description 4
- 229910000147 aluminium phosphate Inorganic materials 0.000 claims description 3
- 238000002156 mixing Methods 0.000 claims description 3
- 239000002245 particle Substances 0.000 claims description 3
- 238000003756 stirring Methods 0.000 claims description 3
- GRYLNZFGIOXLOG-UHFFFAOYSA-N Nitric acid Chemical compound O[N+]([O-])=O GRYLNZFGIOXLOG-UHFFFAOYSA-N 0.000 claims description 2
- 239000004115 Sodium Silicate Substances 0.000 claims description 2
- KBJMLQFLOWQJNF-UHFFFAOYSA-N nickel(ii) nitrate Chemical compound [Ni+2].[O-][N+]([O-])=O.[O-][N+]([O-])=O KBJMLQFLOWQJNF-UHFFFAOYSA-N 0.000 claims description 2
- 229910017604 nitric acid Inorganic materials 0.000 claims description 2
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 claims description 2
- 229910052911 sodium silicate Inorganic materials 0.000 claims description 2
- 235000019832 sodium triphosphate Nutrition 0.000 claims description 2
- 238000005242 forging Methods 0.000 abstract description 10
- 239000010410 layer Substances 0.000 description 10
- 238000006243 chemical reaction Methods 0.000 description 8
- 239000000126 substance Substances 0.000 description 7
- 229910000831 Steel Inorganic materials 0.000 description 6
- 239000000306 component Substances 0.000 description 6
- 239000010959 steel Substances 0.000 description 6
- 230000007797 corrosion Effects 0.000 description 5
- 238000005260 corrosion Methods 0.000 description 5
- 239000000853 adhesive Substances 0.000 description 3
- 230000001070 adhesive effect Effects 0.000 description 3
- 229910052751 metal Inorganic materials 0.000 description 3
- 239000002184 metal Substances 0.000 description 3
- 238000002360 preparation method Methods 0.000 description 3
- 230000003746 surface roughness Effects 0.000 description 3
- 238000004381 surface treatment Methods 0.000 description 3
- CWYNVVGOOAEACU-UHFFFAOYSA-N Fe2+ Chemical compound [Fe+2] CWYNVVGOOAEACU-UHFFFAOYSA-N 0.000 description 2
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 2
- 239000010953 base metal Substances 0.000 description 2
- 239000011248 coating agent Substances 0.000 description 2
- 238000000576 coating method Methods 0.000 description 2
- 230000003750 conditioning effect Effects 0.000 description 2
- 239000008367 deionised water Substances 0.000 description 2
- 229910021641 deionized water Inorganic materials 0.000 description 2
- 238000003487 electrochemical reaction Methods 0.000 description 2
- 229910001448 ferrous ion Inorganic materials 0.000 description 2
- 238000000227 grinding Methods 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- 239000003921 oil Substances 0.000 description 2
- 229910052760 oxygen Inorganic materials 0.000 description 2
- 239000001301 oxygen Substances 0.000 description 2
- 239000003973 paint Substances 0.000 description 2
- 230000000737 periodic effect Effects 0.000 description 2
- 150000003839 salts Chemical class 0.000 description 2
- 229910000859 α-Fe Inorganic materials 0.000 description 2
- 230000002378 acidificating effect Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000003749 cleanliness Effects 0.000 description 1
- 230000000052 comparative effect Effects 0.000 description 1
- 238000012790 confirmation Methods 0.000 description 1
- 238000007739 conversion coating Methods 0.000 description 1
- 239000008358 core component Substances 0.000 description 1
- 238000002425 crystallisation Methods 0.000 description 1
- 230000008025 crystallization Effects 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 239000000295 fuel oil Substances 0.000 description 1
- -1 iron ions Chemical class 0.000 description 1
- 238000011068 loading method Methods 0.000 description 1
- 239000000314 lubricant Substances 0.000 description 1
- WPBNNNQJVZRUHP-UHFFFAOYSA-L manganese(2+);methyl n-[[2-(methoxycarbonylcarbamothioylamino)phenyl]carbamothioyl]carbamate;n-[2-(sulfidocarbothioylamino)ethyl]carbamodithioate Chemical compound [Mn+2].[S-]C(=S)NCCNC([S-])=S.COC(=O)NC(=S)NC1=CC=CC=C1NC(=S)NC(=O)OC WPBNNNQJVZRUHP-UHFFFAOYSA-L 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 229910021645 metal ion Inorganic materials 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000007800 oxidant agent Substances 0.000 description 1
- 238000010422 painting Methods 0.000 description 1
- 238000007746 phosphate conversion coating Methods 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 230000037452 priming Effects 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 238000005482 strain hardening Methods 0.000 description 1
- 239000002344 surface layer Substances 0.000 description 1
- 239000004094 surface-active agent Substances 0.000 description 1
- 230000000007 visual effect Effects 0.000 description 1
Classifications
-
- 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
- C23G—CLEANING OR DE-GREASING OF METALLIC MATERIAL BY CHEMICAL METHODS OTHER THAN ELECTROLYSIS
- C23G1/00—Cleaning or pickling metallic material with solutions or molten salts
- C23G1/02—Cleaning or pickling metallic material with solutions or molten salts with acid solutions
- C23G1/08—Iron or steel
-
- 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
- C23C22/00—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
- C23C22/05—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions
-
- 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
- C23C22/00—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
- C23C22/05—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions
- C23C22/06—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions using aqueous acidic solutions with pH less than 6
- C23C22/07—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions using aqueous acidic solutions with pH less than 6 containing phosphates
- C23C22/08—Orthophosphates
- C23C22/18—Orthophosphates containing manganese cations
Abstract
The application discloses a composite phosphating method for new energy reducer products, which comprises the steps of firstly blackening the products to form a layer of oxide film on the meshed or matched surfaces of the products; then combining with an acid washing procedure, reacting the compact oxide film with acid, partially converting into ions and dissolving in water, forming very fine and uniformly distributed micro-convex-concave morphology on the original relatively flat surface, and increasing the surface adsorption capacity; finally, phosphate film is formed on the surface of the product by using phosphating treatment, so that the wear-resistant lubrication and rust prevention effects are enhanced when the product is used, and the transmission stability is improved. In order to solve the problem of poor NVH effect in the high-speed running process of the new energy speed reducer, a layer of compact phosphating film with a complete blackening-phosphating double-layer structure is added on a meshed pinion gear pair (or a spherical gasket matched with a spherical surface) at the finish forging side, so that the effects of wear resistance, lubrication, rust prevention and the like are achieved, and the transmission is more stable. The friction-reducing lubrication function is achieved in the running process (or spherical matching) of the gear pair.
Description
Technical Field
The application relates to a compound phosphating method for a new energy reducer product, and belongs to the technical field of surface processing.
Background
The speed reducer is a single-stage transmission. The speed changer is one of core components of the traditional fuel oil vehicle, is mainly used for matching with a clutch, ensures the normal starting of the vehicle, and ensures that the engine is stably at the working rotation speed through gear shifting (speed change ratio) in the change of the vehicle speed. A single-stage transmission is commonly referred to as a retarder.
For dynamic and economical reasons, the new energy automobile needs to use a speed reducer. The speed reducer is mainly used for reducing the rotating speed and improving the torque.
In general, a series of surface treatments are needed to control the roughness of the surface of a product for a finish forging gear or a spherical gasket for a speed reducer, and the blackening of the gear is a common means for chemical surface treatment, and the principle is that a layer of oxide film is generated on the surface of metal so as to isolate air and achieve the aim of rust prevention.
Phosphating is a process of forming a phosphate chemical conversion coating by chemical and electrochemical reactions, and the phosphate conversion coating formed is called a phosphate coating.
The purpose of phosphating is mainly to provide protection for the base metal and prevent the metal from being corroded to a certain extent; the paint is used for priming before painting, and improves the adhesive force and the corrosion resistance of a paint film layer; the friction-reducing lubricating agent is used in the metal cold working process.
Phosphating of automobile gears is a very common treatment. Gao Wenmeng the phosphating film can improve the friction and wear performance and corrosion resistance of the steel surface and prolong the service life of the steel surface. Under the existing conditions, phosphating the surface of the product is finished through degreasing, cleaning, surface conditioning, phosphating and post-cleaning. In the whole process, the phosphating reaction process has direct influence on the quality of products such as gears to be phosphated, wherein the thickness and the quality of the phosphating film after phosphating on different roughness and processing surfaces have obvious difference and are not easy to control. Resulting in insufficient lubrication during operation of the gear pair (or spherical fit). Particularly, in the early stage of high-speed engagement, the occurrence frequency of the squeaking phenomenon is difficult to obviously reduce the engagement noise of the gear pair.
Through retrieval, CN102978599A discloses a normal-temperature phosphating process, which adopts special phosphating solution and adjusts the proportion of free acidity and total acidity to be 1: (20-30), adopting a normal-temperature phosphating process without heating to achieve the surface treatment effect of high-temperature phosphating. Under the conditions of no need of heating, simple solution components and convenient operation, the film is rapidly formed, and the corrosion resistance and the wear resistance are greatly improved, and the gray black or dark gray black phosphating film which is uniform in crystallization, compact, firm and complete is obtained. The normal temperature phosphating process can reach the high and medium temperature phosphating effect and surface quality requirement, and has the features of short treatment time and high production efficiency. However, the method focuses on the compactness and firmness of the phosphating film, and cannot solve the difference of the thickness and quality of the phosphating film caused by different roughness of the gear surface.
Disclosure of Invention
Aiming at the defects of the prior art, the application provides a compound phosphating method for new energy reducer products, which aims to solve the problem of poor NVH effect in the high-rotating-speed running process of the new energy reducer, and a layer of complete blackening-phosphating double-layer structured compact phosphating film is added on the new energy reducer products, such as meshed finish forging side pinion gear pairs (or spherical gaskets matched with spherical surfaces), so that the effects of wear resistance, lubrication, rust resistance and the like are achieved, and the transmission is more stable.
The surface of the running gear pair (or the matched spherical surface) can be subjected to chemical and electrochemical reactions to form a layer of specific phosphate chemical conversion film, so that the corrosion of the base metal is prevented to a certain extent; the friction-reducing lubrication function is achieved in the running process (or spherical matching) of the gear pair.
The application relates to a compound phosphating method for new energy reducer products, which can be used in blackening-phosphating processing processes of products such as finish forging gears, spherical gaskets and the like; the process method is convenient to use, smooth to operate, high in consistency and good in safety.
The application adopts the technical means for solving the problems that:
the composite phosphating method for new energy reducer product includes blackening the product to form one oxide film on the meshed or matched surface of the product; then combining with an acid washing procedure, reacting the compact oxide film with acid, partially converting into ions and dissolving in water, forming micro convex-concave morphology which is very fine and uniformly distributed on the original surface, and increasing the surface adsorption capacity; finally, phosphate film is formed on the surface of the product by using phosphating treatment, so that the wear-resistant lubrication and rust prevention effects are enhanced when the product is used, and the transmission stability is improved.
Further, the method comprises the following steps:
s1, hanging: placing the product to be treated in a water-permeable tray, and calculating the addition of each tank liquor stock solution according to the surface area of the actually loaded product;
s2, degreasing: mixing and adding degreasing agent and clear water according to the weight ratio of 1:15-25, setting the temperature to 65-75 ℃ and the total alkalinity to 10Pt-30Pt; degreasing a product to be treated for 8-15 min;
s3, cleaning for the first time: the pH is 6.0-7.2, the water is replaced periodically, overflowed and updated, and impurities on the surface of the product are removed at 15-45 ℃;
s4, blackening treatment: soaking the cleaned product in blackening liquid at 120-140 ℃ for 10-15 min; blackening treatment to form Fe 3 O 4 Or Fe (Fe) 2 O 3 FeO composite oxide, which prepares second order iron atoms for subsequent phosphating, has a composite oxide film thickness of 0.5 μm to 1.5 μm;
s5, cleaning for the second time: periodically replacing and overflowing at pH of 6.0-7.2, and removing black liquor on the surface of the product at 15-45 ℃;
s6, acid washing: the volume concentration of the hydrochloric acid is 5-7%, and the hydrochloric acid acts for 5-10 s at the temperature of 15-45 ℃ to increase the surface adsorption capacity;
s7, cleaning for the third time: the pH is 6.0-7.2, the acid liquor and the ion residues adhered to the surface of the product are removed completely at 15-45 ℃ after regular replacement and overflow update;
s8, table adjustment: the manganese series surface regulator is weighed according to the proportion with water, the mass percentage is 7% -10%, the temperature is set to 55-65 ℃, the time is 30-60s, and the pH is 8-9. Air stirring is adopted; active particles of the manganese series surface regulator are uniformly adsorbed on the surface of a product to form active points;
s9, phosphating: adding manganese phosphating solution, adding a proper amount of iron powder for curing, setting the temperature to be 85-95 ℃ for 8-15min, and setting the total acidity to be 40-60 Pt, the free acidity to be 4-10 Pt and the acid ratio to be 6-10; and forming a manganese and iron composite phosphating film on the surface of the product.
Further, the degreasing agent comprises the main components of 4-10g/L sodium tripolyphosphate, 0-10g/L sodium silicate and 4-10g/L sodium carbonate, and the total adding amount is 40Kg/m 3 -60Kg/m 3 。
Further, the blackening agent is flaky sodium hydroxide and sodium nitrite, and the proportion of the flaky sodium hydroxide to the sodium nitrite is 2:1.
further, the content of the phosphating agent is as follows: 10% -30% of phosphoric acid, 20% -30% of manganese phosphate, 1% -5% of nitric acid, 0.1% -1% of nickel nitrate and the balance of water.
Further, the adding amount of the iron powder is 40g-120g of newly-prepared phosphating bath solution per m.
Further, the component of the phosphating film is mainly MnFe (HPO) 4 ) 2 With Mn 3 (HPO 4 ) 2 。
Further, the thickness of the phosphating film prepared by the steps S1-S7 is multiplied with the repetition times.
Further, under the automatic control of a PLC program, the temperature, the current, the pH value and the process time parameters in the production process of the product in each step are monitored in real time.
Further, in step S8, a manganese series surface conditioner or sodium carbonate is added for adjustment when the pH value is lower than the required value.
Compared with the prior art, the application has the beneficial effects that:
the new energy decelerator product combines blackening and phosphating by the compound phosphating method, and the surface roughness of the product reaches the optimal value by optimizing the surface morphology of the specific product and acid washing and water washing, so that the whole phosphating film thickness is more stable and uniform.
The compound phosphating method for the new energy reducer product is particularly suitable for products such as finish forging gears, spherical gaskets and the like, and the formed phosphating film of the gear pair (or the matching surface) is more durable and has better lubrication and wear resistance.
Drawings
FIG. 1 is a metallographic structure picture of a 100x composite phosphating film on the surface of a finish forging gear prepared by a composite phosphating method for a new energy reducer product of the application.
Fig. 2 is a metallographic structure picture of a 400x composite phosphate coating on the surface of a finish forging gear prepared by the composite phosphate method for the new energy reducer product of the application.
Detailed Description
The application is further described below with reference to the accompanying drawings. Wherein the drawings are for illustrative purposes only and are shown in schematic, non-physical, and not intended to be limiting of the present patent; for the purpose of better illustrating embodiments of the application, certain elements of the drawings may be omitted, enlarged or reduced and do not represent the size of the actual product; it will be appreciated by those skilled in the art that certain well-known structures in the drawings and descriptions thereof may be omitted.
The application relates to a composite phosphating method for new energy reducer products, which comprises the steps of firstly blackening the products to form a layer of oxide film on the meshed or matched surfaces of the products; then combining with an acid washing procedure, reacting the compact oxide film with acid, partially converting into ions and dissolving in water, forming very fine and uniformly distributed micro-convex-concave morphology on the original relatively flat surface, and increasing the surface adsorption capacity; finally, phosphate film is formed on the surface of the product by using phosphating treatment, so that the wear-resistant lubrication and rust prevention effects are enhanced when the product is used, and the transmission stability is improved. The method is particularly suitable for surface processing of products such as finish forging gears, spherical gaskets and the like in the new energy decelerator. The precision forging gear will now be described in detail as an example.
Example 1
The compound phosphating method for the new energy reducer product comprises the following steps:
s1, hanging: placing the product to be treated in a water-permeable tray, and calculating the addition of each tank liquor stock solution according to the surface area of the actually loaded product; specifically, the material preparation is carried out on the products to be phosphated at the loading and hanging time, and the products are uniformly distributed in a material tray with a water leakage basket structure in a lattice mode; automatically scanning and calculating the surface area of the required phosphorization through a visual scanning system; after confirmation, calculating the addition amount of each tank liquor stock solution according to the surface area of the actually loaded product; then the production line is programmed, and each process stage is automatically operated and monitored.
S2, degreasing: mixing and adding degreasing agent and clear water according to the weight ratio of 1:15, setting the temperature to 65 ℃ and the total alkalinity to 10Pt-15Pt; degreasing a product to be treated for 12-15 min; the degreasing in this example uses an alkaline degreasing agent consisting of two components: A. and B, wherein A generally consists of alkaline substances, B consists of various surfactants, and the ratio and the dosage are as follows: a:2% -4%, B: when in use, 1% -2% of the working fluid is directly prepared into a tank for use.
S3, cleaning for the first time: the pH is 6.0-7.2, the water is replaced periodically, overflowed and updated, and impurities on the surface of the product are removed at 15-25 ℃; the present cleaning can be divided into two stages. The first section: the pH is 6.0-7.2, the water is replaced periodically, overflowed and updated, and the temperature is 15-30 ℃ for 30-60s; removing impurities such as degreasing agent, greasy dirt, salt and the like on the surface of the workpiece; and a second stage: the pH is 6.5-7.2, the water is replaced periodically, overflowed and updated, the temperature is 15-45 ℃ and the time is 30-60s; ensuring the surface cleanliness and a layer of active water film; the first stage and the second stage are separately provided with water in two areas, so that impurities such as oil stains and salt on the surface layer can be further removed.
S4, blackening treatment: soaking the cleaned product in blackening liquid, and setting the temperature to 120-130 ℃ for 15min; blackening treatment to form Fe 3 O 4 Or Fe (Fe) 2 O 3 FeO composite oxide powder, second-order iron atoms are prepared for subsequent phosphating, and the components of the phosphating film mainly consist of MnFe (HPO) 4 ) 2 With Mn 3 (HPO 4 ) 2 A second-order iron atom; the influence of ferrous ions on the film weight of the phosphating film is the greatest, and the higher the content of the ferrous ions in the phosphating solution is, the MnFe (HPO) 4 ) 2 The content is increased. The thickness of the composite oxide film is 0.5-1.5 mu m; the blackening oxide film has good contact with the surface of the steel matrix, good adhesive force, uniform and compact tissue and thickness of 05-1.5 μm. The grains of the phosphating film are respectively uniform and fine, and the larger the film weight is, the wear resistance is enhanced. Mainly depending on the concentration of oxygen in the solution. High oxygen concentration generates Fe 2 O 3 Causing the surface to reddish. Therefore, the content of the oxidizing agent should be properly controlled to obtain black crystalline Fe 3 O 4 And (3) a film.
S5, cleaning for the second time: periodically replacing and overflowing at pH of 6.0-7.2, and removing black liquor on the surface of the product at 15-45 ℃; the present cleaning can be divided into two stages. The first section: the pH is 6.0-7.2, the overflow is updated at a temperature of 15-45 ℃ for 30-60s; and washing to remove sodium hydroxide and sodium nitrite. The pH value in the second stage is 6.5-7.2, the overflow is updated at 15-45 ℃ for 30-60s; and the other water tank is used for further reducing residues.
S6, acid washing: the volume concentration of the hydrochloric acid is 5-7%, the reaction is carried out for 5-10 s at the temperature of 15-45 ℃, the compact ferrite reacts with the acid, part of the ferrite is converted into iron ions and is dissolved in water, the micro convex-concave morphology which is very fine and uniformly distributed is formed on the original relatively flat surface, and the surface adsorption capacity is improved.
S7, cleaning for the third time: the pH is 6.0-7.2, the acid liquor and the ion residues adhered to the surface of the product are removed completely by periodic replacement and overflow update at the pH of 6.0-7.2, the pH of the first section is 6.0-7.2, the periodic replacement and overflow update are carried out for 30s-60s at the temperature of 15-45 ℃; soaking and rinsing, so as to reduce acid liquor and other residues and protect the remained oxide film layer; the second section is another water tank, and fresh deionized water is used for soaking, spraying and cleaning, so that residues such as acid liquor, ions and the like adhered on the surface of the workpiece are completely removed.
S8, table adjustment: the manganese series surface regulator is weighed according to the proportion with water, the mass percentage is 7% -10%, the temperature is set to 55-65 ℃, the time is 30s-60s, and the pH is 8-9. Air stirring is adopted; active particles of the manganese series surface regulator are uniformly adsorbed on the surface of a product to form active points; the manganese-based surface conditioner is a surface conditioner used before the surface of steel is treated with a manganese phosphate film. After the surface of the steel is subjected to alkaline or acidic rust removal, for example, manganese series surface conditioning treatment is carried out, so that a compact and fine-crystallized manganese phosphate film can be obtained.
S9, phosphating: adding manganese phosphating solution, adding a proper amount of iron powder for curing, and adding 40-80g of iron powder into each m new phosphating bath solution in the embodiment; setting the temperature to be 85-90 ℃ for 10-15 min, wherein the total acidity is 40-60 Pt, the free acidity is 4-10 Pt, and the acid ratio is 6-10; and forming a manganese and iron composite phosphating film on the surface of the product. The manganese phosphating solution reacts with pure iron, the adding amount of the pure iron powder is gradually added, and the mixture is uniformly stirred and fully dissolved, and the acid value reaches the specified range. Chemical reaction and blackening to form a layer of Fe on the surface of the product 3 O 4 The oxide film mainly reacts with chemical substances such as phosphoric acid to form a composite phosphate film of manganese, iron and the like.
S10, hot water washing: setting the temperature of the clear water at 60-80 ℃ for 30-60s; and updating periodically. The fresh pure water is sprayed directly through normal-temperature fresh pure water (deionized water) so as to achieve the effect of completely removing phosphating solution adhered to the surface of a workpiece, and simultaneously achieve the effect of completely replacing ionized water on the surface of the workpiece, thereby reducing the residual of metal ions.
S11, soaking the gear rust-proof oil, and putting the gear into a rack. The metallographic structure pictures of the composite phosphating film on the surface of the finish forging gear prepared by the composite phosphating method of the new energy reducer product of the embodiment are shown in fig. 1 and 2.
The whole process is repeatedly operated, such as circulation for several times, and the thickness of the phosphating film layer is multiplied, such as 3-5 μm at one time and 6-10 μm at the other time.
In this embodiment, before phosphating, blackening treatment may be performed first, and parameters such as blackening time, concentration, etc. are controlled; the surface roughness of the surface of the fine grinding surface and the like can be properly changed, so that the subsequent uniform production and coverage of the phosphating film are facilitated. As the oxide film is added, the roughness of the finish grinding surface is properly increased, and the reaction area and the adhesive force in the phosphating process are improved. Before phosphating, after blackening, parameters such as acid washing time, concentration and the like can be adjusted according to the change condition of the surface characteristics, and the surface roughness and component composition parameters can be changed by controlling the chemical reaction of acid and an oxide film, so that the optimal surface morphology can be obtained. The process for forming the complete compact phosphating film on the normal-temperature blackening film of the steel has higher corrosion resistance and lubrication effect.
Example 2
The composite phosphating method for new energy reducer products of the implementation is approximately the same as the method of the embodiment 1, and is different in that the method comprises the following steps:
s2, degreasing: FC-4360C degreasing agent is mixed with clear water according to the ratio of 1:20, the temperature is set to 65-75 ℃, the time is 8-15min, and the total alkalinity is 10-30Pt.
S4, blackening treatment: soaking the cleaned product in blackening liquid, and setting the temperature to 130-140 ℃ for 10min; blackening treatment to form Fe 3 O 4 Or Fe (Fe) 2 O 3 FeO complex oxide.
S9, adding 100-120g of iron powder into each m newly prepared phosphating bath solution; the temperature is set to be 90-95 ℃ and the time is 8-12 min.
Comparative example 1
The preparation method adopts the existing gear phosphating process, and the process flow is as follows: the preparation process parameters of the gear are approximately the same as those of the embodiment, and the prepared gear has different roughness, obvious difference of the thickness and quality of the phosphating film after phosphating the processed surface, and is not easy to control.
The above is merely an embodiment of the present application, and the present application is not limited to the field of the present embodiment, but the specific structure and characteristics of the present application are not described in detail. It should be noted that modifications and improvements can be made by those skilled in the art without departing from the present application, which should also be considered as the scope of the present application, and which does not affect the effect of the present application and the utility of the patent. The protection scope of the present application is subject to the content of the claims, and the description of the specific embodiments and the like in the specification can be used for explaining the content of the claims.
Claims (10)
1. A compound phosphating method for new energy decelerator products is characterized in that blackening treatment is firstly adopted for the products, and a layer of oxide film is formed on the meshed or matched surfaces of the products; then combining with an acid washing procedure, reacting the compact oxide film with acid, partially converting into ions and dissolving in water, forming micro convex-concave morphology which is very fine and uniformly distributed on the original surface, and increasing the surface adsorption capacity; finally, phosphate film is formed on the surface of the product by using phosphating treatment, so that the wear-resistant lubrication and rust prevention effects are enhanced when the product is used, and the transmission stability is improved.
2. The composite phosphating method for new energy reducer products according to claim 1, comprising the following steps:
s1, hanging: placing the product to be treated in a water-permeable tray, and calculating the addition of each tank liquor stock solution according to the surface area of the actually loaded product;
s2, degreasing: mixing and adding degreasing agent and clear water according to the weight ratio of 1:15-25, setting the temperature to 65-75 ℃ and the total alkalinity to 10Pt-30Pt; degreasing a product to be treated for 8-15 min;
s3, cleaning for the first time: the pH is 6.0-7.2, the water is replaced periodically, overflowed and updated, and impurities on the surface of the product are removed at 15-45 ℃;
s4, blackening treatment: soaking the cleaned product in blackening liquid at 120-140 ℃ for 10-15 min; blackening treatment to form Fe 3 O 4 Or Fe (Fe) 2 O 3 FeO composite oxide, which prepares second order iron atoms for subsequent phosphating, has a composite oxide film thickness of 0.5 μm to 1.5 μm;
s5, cleaning for the second time: periodically replacing and overflowing at pH of 6.0-7.2, and removing black liquor on the surface of the product at 15-45 ℃;
s6, acid washing: the volume concentration of the hydrochloric acid is 5-7%, and the hydrochloric acid acts for 5-10 s at the temperature of 15-45 ℃ to increase the surface adsorption capacity;
s7, cleaning for the third time: the pH is 6.0-7.2, the acid liquor and the ion residues adhered to the surface of the product are removed completely at 15-45 ℃ after regular replacement and overflow update;
s8, table adjustment: the manganese series surface regulator is weighed according to the proportion with water, the mass percentage is 7% -10%, the temperature is set to 55-65 ℃, the time is 30s-60s, and the pH is 8-9. Air stirring is adopted; active particles of the manganese series surface regulator are uniformly adsorbed on the surface of a product to form active points;
s9, phosphating: adding manganese phosphating solution, curing with iron powder, setting the temperature at 85-95 ℃ for 8-15min, total acidity of 40-60 Pt, free acidity of 4-10 Pt and acid ratio of 6-10; and forming a manganese and iron composite phosphating film on the surface of the product.
3. The composite phosphating method for new energy decelerator products according to claim 2, wherein the degreasing agent comprises the main components of sodium tripolyphosphate 4-10g/L, sodium silicate 0-10g/L, sodium carbonate 4-10g/L, and the total addition amount is 40Kg/m 3 -60Kg/m 3 。
4. The composite phosphating method for new energy reducer products according to claim 2, wherein the blackening agent is flaky sodium hydroxide and sodium nitrite, and the proportion of the flaky sodium hydroxide to the sodium nitrite is 2:1.
5. the composite phosphating method for new energy reducer products according to claim 2, wherein the content of phosphating agent of the manganese series phosphating solution is: 10% -30% of phosphoric acid, 20% -30% of manganese phosphate, 1% -5% of nitric acid, 0.1% -1% of nickel nitrate and the balance of water.
6. The composite phosphating method for new energy reducer products according to claim 2, wherein in step S9, the iron powder is added in an amount of 40g-120g per m new phosphating baths.
7. The method for composite phosphating of new energy decelerator products according to claim 2, wherein the phosphating film mainly contains MnFe (HPO) 4 ) 2 With Mn3 (HPO) 4 ) 2 。
8. The composite phosphating method for new energy reducer products according to claim 2, wherein the thickness of the phosphating film prepared by the steps S1-S7 is multiplied with the repetition number.
9. The composite phosphating method for new energy decelerator products according to any one of claims 1 to 8, wherein temperature, current, ph and process time parameters in the production process of each step product are monitored in real time under the automatic control of a PLC program.
10. The method of composite phosphating for new energy decelerator products according to claim 9, wherein in step S8, manganese series surface regulator or sodium carbonate is added for adjustment when pH is lower than a desired value.
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