CN117088686B - Modified zirconia coating and preparation method thereof - Google Patents
Modified zirconia coating and preparation method thereof Download PDFInfo
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- CN117088686B CN117088686B CN202311355328.0A CN202311355328A CN117088686B CN 117088686 B CN117088686 B CN 117088686B CN 202311355328 A CN202311355328 A CN 202311355328A CN 117088686 B CN117088686 B CN 117088686B
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- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical class O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 title claims abstract description 277
- 238000000576 coating method Methods 0.000 title claims abstract description 113
- 239000011248 coating agent Substances 0.000 title claims abstract description 112
- 238000002360 preparation method Methods 0.000 title claims abstract description 13
- 238000000034 method Methods 0.000 claims abstract description 21
- RVTZCBVAJQQJTK-UHFFFAOYSA-N oxygen(2-);zirconium(4+) Chemical compound [O-2].[O-2].[Zr+4] RVTZCBVAJQQJTK-UHFFFAOYSA-N 0.000 claims abstract description 17
- 229910001928 zirconium oxide Inorganic materials 0.000 claims abstract description 17
- 239000002994 raw material Substances 0.000 claims abstract description 16
- XLOMVQKBTHCTTD-UHFFFAOYSA-N Zinc monoxide Chemical compound [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 claims abstract description 14
- 239000000758 substrate Substances 0.000 claims abstract description 12
- FRWYFWZENXDZMU-UHFFFAOYSA-N 2-iodoquinoline Chemical compound C1=CC=CC2=NC(I)=CC=C21 FRWYFWZENXDZMU-UHFFFAOYSA-N 0.000 claims abstract description 8
- LTPBRCUWZOMYOC-UHFFFAOYSA-N beryllium oxide Inorganic materials O=[Be] LTPBRCUWZOMYOC-UHFFFAOYSA-N 0.000 claims abstract description 8
- 229910000416 bismuth oxide Inorganic materials 0.000 claims abstract description 8
- 229910000420 cerium oxide Inorganic materials 0.000 claims abstract description 8
- TYIXMATWDRGMPF-UHFFFAOYSA-N dibismuth;oxygen(2-) Chemical compound [O-2].[O-2].[O-2].[Bi+3].[Bi+3] TYIXMATWDRGMPF-UHFFFAOYSA-N 0.000 claims abstract description 8
- 229910003437 indium oxide Inorganic materials 0.000 claims abstract description 8
- PJXISJQVUVHSOJ-UHFFFAOYSA-N indium(iii) oxide Chemical compound [O-2].[O-2].[O-2].[In+3].[In+3] PJXISJQVUVHSOJ-UHFFFAOYSA-N 0.000 claims abstract description 8
- BMMGVYCKOGBVEV-UHFFFAOYSA-N oxo(oxoceriooxy)cerium Chemical compound [Ce]=O.O=[Ce]=O BMMGVYCKOGBVEV-UHFFFAOYSA-N 0.000 claims abstract description 8
- WGLPBDUCMAPZCE-UHFFFAOYSA-N Trioxochromium Chemical compound O=[Cr](=O)=O WGLPBDUCMAPZCE-UHFFFAOYSA-N 0.000 claims abstract description 7
- 229910052810 boron oxide Inorganic materials 0.000 claims abstract description 7
- 229910000423 chromium oxide Inorganic materials 0.000 claims abstract description 7
- JKWMSGQKBLHBQQ-UHFFFAOYSA-N diboron trioxide Chemical compound O=BOB=O JKWMSGQKBLHBQQ-UHFFFAOYSA-N 0.000 claims abstract description 7
- 229910000449 hafnium oxide Inorganic materials 0.000 claims abstract description 7
- WIHZLLGSGQNAGK-UHFFFAOYSA-N hafnium(4+);oxygen(2-) Chemical compound [O-2].[O-2].[Hf+4] WIHZLLGSGQNAGK-UHFFFAOYSA-N 0.000 claims abstract description 7
- 239000011787 zinc oxide Substances 0.000 claims abstract description 7
- 239000002245 particle Substances 0.000 claims description 70
- 239000000843 powder Substances 0.000 claims description 49
- 238000010438 heat treatment Methods 0.000 claims description 22
- 238000007750 plasma spraying Methods 0.000 claims description 14
- 239000011230 binding agent Substances 0.000 claims description 13
- 239000011159 matrix material Substances 0.000 claims description 13
- 239000011268 mixed slurry Substances 0.000 claims description 13
- 238000005507 spraying Methods 0.000 claims description 13
- 238000002156 mixing Methods 0.000 claims description 12
- 238000004321 preservation Methods 0.000 claims description 10
- 239000000919 ceramic Substances 0.000 claims description 9
- 239000011247 coating layer Substances 0.000 claims description 9
- 238000001694 spray drying Methods 0.000 claims description 9
- 238000000498 ball milling Methods 0.000 claims description 8
- 238000005245 sintering Methods 0.000 claims description 8
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 8
- 239000002904 solvent Substances 0.000 claims description 7
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 claims description 6
- LYCAIKOWRPUZTN-UHFFFAOYSA-N Ethylene glycol Chemical compound OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 claims description 6
- OKKJLVBELUTLKV-UHFFFAOYSA-N Methanol Chemical compound OC OKKJLVBELUTLKV-UHFFFAOYSA-N 0.000 claims description 6
- 239000004372 Polyvinyl alcohol Substances 0.000 claims description 6
- YXFVVABEGXRONW-UHFFFAOYSA-N Toluene Chemical compound CC1=CC=CC=C1 YXFVVABEGXRONW-UHFFFAOYSA-N 0.000 claims description 6
- 239000007788 liquid Substances 0.000 claims description 6
- 229920002401 polyacrylamide Polymers 0.000 claims description 6
- 229920002451 polyvinyl alcohol Polymers 0.000 claims description 6
- 239000002344 surface layer Substances 0.000 claims description 6
- 229920000609 methyl cellulose Polymers 0.000 claims description 5
- 239000001923 methylcellulose Substances 0.000 claims description 5
- 235000010981 methylcellulose Nutrition 0.000 claims description 5
- 239000000126 substance Substances 0.000 claims description 5
- KFZMGEQAYNKOFK-UHFFFAOYSA-N Isopropanol Chemical compound CC(C)O KFZMGEQAYNKOFK-UHFFFAOYSA-N 0.000 claims description 4
- 239000000155 melt Substances 0.000 claims description 4
- 239000007769 metal material Substances 0.000 claims description 4
- 229910004298 SiO 2 Inorganic materials 0.000 claims description 3
- 229910010413 TiO 2 Inorganic materials 0.000 claims description 3
- 238000005488 sandblasting Methods 0.000 claims description 3
- 238000003801 milling Methods 0.000 claims description 2
- 229910052782 aluminium Inorganic materials 0.000 abstract description 21
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 abstract description 20
- 239000000203 mixture Substances 0.000 description 26
- 239000000463 material Substances 0.000 description 19
- 238000003723 Smelting Methods 0.000 description 7
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 description 6
- 239000011819 refractory material Substances 0.000 description 6
- 229910001257 Nb alloy Inorganic materials 0.000 description 5
- 238000005299 abrasion Methods 0.000 description 5
- 229910052751 metal Inorganic materials 0.000 description 5
- 239000002184 metal Substances 0.000 description 5
- 230000035939 shock Effects 0.000 description 5
- 230000035882 stress Effects 0.000 description 5
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 4
- 238000001816 cooling Methods 0.000 description 4
- 230000007797 corrosion Effects 0.000 description 4
- 238000005260 corrosion Methods 0.000 description 4
- 229910045601 alloy Inorganic materials 0.000 description 3
- 239000000956 alloy Substances 0.000 description 3
- 239000011449 brick Substances 0.000 description 3
- RKTYLMNFRDHKIL-UHFFFAOYSA-N copper;5,10,15,20-tetraphenylporphyrin-22,24-diide Chemical compound [Cu+2].C1=CC(C(=C2C=CC([N-]2)=C(C=2C=CC=CC=2)C=2C=CC(N=2)=C(C=2C=CC=CC=2)C2=CC=C3[N-]2)C=2C=CC=CC=2)=NC1=C3C1=CC=CC=C1 RKTYLMNFRDHKIL-UHFFFAOYSA-N 0.000 description 3
- 239000013078 crystal Substances 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 238000009413 insulation Methods 0.000 description 3
- 229910052697 platinum Inorganic materials 0.000 description 3
- 238000012360 testing method Methods 0.000 description 3
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- KDLHZDBZIXYQEI-UHFFFAOYSA-N Palladium Chemical compound [Pd] KDLHZDBZIXYQEI-UHFFFAOYSA-N 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 2
- 238000006243 chemical reaction Methods 0.000 description 2
- 238000005336 cracking Methods 0.000 description 2
- 238000000151 deposition Methods 0.000 description 2
- 238000002844 melting Methods 0.000 description 2
- 230000008018 melting Effects 0.000 description 2
- 229910044991 metal oxide Inorganic materials 0.000 description 2
- 150000004706 metal oxides Chemical class 0.000 description 2
- 150000002739 metals Chemical class 0.000 description 2
- 239000011259 mixed solution Substances 0.000 description 2
- 239000000243 solution Substances 0.000 description 2
- 239000003381 stabilizer Substances 0.000 description 2
- 230000000087 stabilizing effect Effects 0.000 description 2
- 229910018072 Al 2 O 3 Inorganic materials 0.000 description 1
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 1
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 description 1
- ZLMJMSJWJFRBEC-UHFFFAOYSA-N Potassium Chemical compound [K] ZLMJMSJWJFRBEC-UHFFFAOYSA-N 0.000 description 1
- KJTLSVCANCCWHF-UHFFFAOYSA-N Ruthenium Chemical compound [Ru] KJTLSVCANCCWHF-UHFFFAOYSA-N 0.000 description 1
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 1
- 241001062472 Stokellia anisodon Species 0.000 description 1
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 description 1
- 239000002253 acid Substances 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 239000012298 atmosphere Substances 0.000 description 1
- 229910052792 caesium Inorganic materials 0.000 description 1
- TVFDJXOCXUVLDH-UHFFFAOYSA-N caesium atom Chemical compound [Cs] TVFDJXOCXUVLDH-UHFFFAOYSA-N 0.000 description 1
- 238000005266 casting Methods 0.000 description 1
- 238000005524 ceramic coating Methods 0.000 description 1
- 229910010293 ceramic material Inorganic materials 0.000 description 1
- 238000010924 continuous production Methods 0.000 description 1
- 238000000354 decomposition reaction Methods 0.000 description 1
- 230000008021 deposition Effects 0.000 description 1
- 238000001514 detection method Methods 0.000 description 1
- 239000003344 environmental pollutant Substances 0.000 description 1
- 230000003628 erosive effect Effects 0.000 description 1
- 238000009851 ferrous metallurgy Methods 0.000 description 1
- 239000008187 granular material Substances 0.000 description 1
- 238000000227 grinding Methods 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 238000000462 isostatic pressing Methods 0.000 description 1
- 239000010410 layer Substances 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 238000010309 melting process Methods 0.000 description 1
- 238000005058 metal casting Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 229910000510 noble metal Inorganic materials 0.000 description 1
- 230000001590 oxidative effect Effects 0.000 description 1
- 239000011224 oxide ceramic Substances 0.000 description 1
- 239000003973 paint Substances 0.000 description 1
- 229910052763 palladium Inorganic materials 0.000 description 1
- 238000011056 performance test Methods 0.000 description 1
- 238000013001 point bending Methods 0.000 description 1
- 231100000719 pollutant Toxicity 0.000 description 1
- 229910052700 potassium Inorganic materials 0.000 description 1
- 239000011591 potassium Substances 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 230000002035 prolonged effect Effects 0.000 description 1
- 238000010791 quenching Methods 0.000 description 1
- 230000000171 quenching effect Effects 0.000 description 1
- 229910052707 ruthenium Inorganic materials 0.000 description 1
- 150000003839 salts Chemical class 0.000 description 1
- 239000002893 slag Substances 0.000 description 1
- 229910052708 sodium Inorganic materials 0.000 description 1
- 239000011734 sodium Substances 0.000 description 1
- 239000007921 spray Substances 0.000 description 1
- 238000010998 test method Methods 0.000 description 1
- 230000008646 thermal stress Effects 0.000 description 1
- 229910052726 zirconium Inorganic materials 0.000 description 1
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/48—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on zirconium or hafnium oxides, zirconates, zircon or hafnates
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/62222—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products obtaining ceramic coatings
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- C04B35/66—Monolithic refractories or refractory mortars, including those whether or not containing clay
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- 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
- C23C4/10—Oxides, borides, carbides, nitrides or silicides; Mixtures thereof
- C23C4/11—Oxides
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- 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
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- C23C4/134—Plasma spraying
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- C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/3205—Alkaline earth oxides or oxide forming salts thereof, e.g. beryllium oxide
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- C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/3286—Gallium oxides, gallates, indium oxides, indates, thallium oxides, thallates or oxide forming salts thereof, e.g. zinc gallate
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- C04B2235/34—Non-metal oxides, non-metal mixed oxides, or salts thereof that form the non-metal oxides upon heating, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/3409—Boron oxide, borates, boric acids, or oxide forming salts thereof, e.g. borax
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- C04B2235/74—Physical characteristics
- C04B2235/77—Density
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
- C04B2235/96—Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
Abstract
The invention discloses a modified zirconia coating and a preparation method thereof, wherein the modified zirconia coating comprises a first coating arranged on the surface of a substrate and a second coating attached to the surface of the first coating; the first coating comprises the following raw materials in parts by weight: 80-95 parts of zirconia, 0.1-0.5 part of bismuth oxide, 2-5 parts of cerium oxide, 0.1-2.5 parts of chromium oxide and 0.5-3 parts of boron oxide; the second coating comprises the following raw materials in parts by weight: 65-90 parts of zirconium oxide, 3-8 parts of zinc oxide, 1-5 parts of hafnium oxide, 0.5-3.5 parts of indium oxide and 0.1-1 part of beryllium oxide. The first coating prepared by the specific proportion and the second coating prepared by the specific proportion are matched and act together, so that the method is suitable for preparing the aluminum-based refractory product used in the field of ultrahigh temperature (above 2500 ℃), and the aluminum-based refractory product prepared by the zirconia coating has the advantages of high service temperature, long service life and the like.
Description
Technical Field
The invention belongs to the field of refractory materials, and particularly relates to a modified zirconia coating and a preparation method thereof, wherein the modified zirconia coating has ultrahigh temperature stability and enough strength; in particular, the aluminum-based adhesive is attached to the surface of an aluminum-based product, so that the high temperature resistance and the cracking resistance of the aluminum-based product under the condition of cold and hot circulation can be greatly improved.
Background
Zirconia belongs to novel ceramics, or is called a special refractory raw material, has a melting point as high as 2715 ℃, has excellent physical and chemical properties, and can not react with molten metals such as aluminum, iron, nickel, platinum and the like, silicate, acid slag and the like even if heated to 1900 ℃ or more. The zirconia refractory prepared by using the zirconia refractory as a main raw material has the advantages of stable chemical property at high temperature, high use temperature (up to 2400 ℃), difficult decomposition at high temperature, suitability for use in oxidizing or reducing atmosphere and the like, can successfully smelt platinum noble metals such as platinum, palladium, ruthenium, cesium and the like and alloys thereof, and can also be used for smelting potassium, sodium, quartz glass, oxides, salts and the like. In addition, there are also many refractory materials on the market, in order to improve the service performance, a certain amount of zirconia such as fused AZS bricks and Al is added 2 O 3 -ZrO 2 C brick, cr 2 O 3 -Al 2 O 3 -ZrO 2 Bricks, and the like. Compared with other metal oxide ceramic materials, the zirconia has good high-temperature heat stability and excellent heat insulation performance,is widely used as ceramic coating and high-temperature refractory products in the field of refractory materials, can not be replaced by other metal oxide materials when being used at the high temperature of more than 2000 ℃, and is the most mature refractory material for the ultra-high temperature field which can be industrially produced and applied at present.
The zirconium-containing products which can be used in the ultra-high temperature environment are mainly full-zirconia refractory products, generally refer to refractory products with the zirconia (including stabilizing agents) content of more than 98%, zirconium oxide particles or zirconia hollow spheres, zirconia fine powder, stabilizing agents, binding agents and the like are used as raw materials, and the refractory materials with the required shapes are prepared by forming means such as casting, pouring, machine pressing, isostatic pressing, ramming and the like, and can be roughly divided into zirconia hollow sphere products and zirconia heavy products. The main material of the granular material used by the zirconia hollow ball product is zirconia hollow balls, the zirconia hollow balls are prepared by spraying zirconia solution through high-pressure air, and the zirconia hollow balls have lower heat conductivity due to higher porosity, and are mainly used for heat preservation and heat insulation at the temperature of more than 1800 ℃. Zirconia heavy articles are generally referred to as having a bulk density greater than 3.8g/cm 3 The zirconia fused grain is prepared by cooling and crushing fused zirconia solution, and the zirconia heavy product has high structural strength, corrosion resistance, erosion resistance and higher use temperature, and is mainly used for high-temperature reaction lining above 1800 ℃ and heat preservation and heat insulation above 2000 ℃.
However, the full zirconia refractory also suffers from the following disadvantages: 1. the zirconia market is in tension, and metal aluminum has more substitutes, so the production cost of the full zirconia refractory product is far higher than that of the high alumina refractory product; 2. the existing zirconia products are relatively brittle, and the main reasons are as follows: zirconia belongs to a polycrystalline converter, has three different crystal forms of monoclinic, tetragonal and cubic, and can be mutually converted along with the change of temperature. The stable low temperature phase is monoclinic phase, when the temperature is raised to about 1170 ℃, zirconium oxide crystals with the particle size of micron or larger can be transformed from monoclinic phase to tetragonal phase, and cubic phase is gradually formed above 2370 ℃. Because larger volume change is generated when monoclinic phase changes to tetragonal phase, larger volume change is generated in the opposite direction when cooling is performed, phase change stress is generated in the material, and 7-9% of volume expansion and shrinkage can possibly occur, particularly for large-size refractory materials in actual use, the volume change easily causes cracking of zirconia materials, and the materials are unstable. In the later use process, the material is easy to crack due to temperature change, and the heat resistance and the electrical property of the material are further drastically reduced.
Disclosure of Invention
Based on the above problems, the invention provides a modified zirconia coating and a preparation method thereof.
Specifically, the method comprises the following technical scheme:
a modified zirconia coating, characterized in that it comprises a first coating layer arranged on the surface of a substrate, and a second coating layer attached to the surface of the first coating layer;
the first coating comprises the following raw materials in parts by weight: 80-95 parts of zirconia, 0.1-0.5 part of bismuth oxide, 2-5 parts of cerium oxide, 0.1-2.5 parts of chromium oxide and 0.5-3 parts of boron oxide;
the second coating comprises the following raw materials in parts by weight: 65-90 parts of zirconium oxide, 3-8 parts of zinc oxide, 1-5 parts of hafnium oxide, 0.5-3.5 parts of indium oxide and 0.1-1 part of beryllium oxide.
The modified zirconia coating prepared according to the formula has better comprehensive performance: low thermal conductivity, thermal expansion coefficient matched with the matrix, low sintering activity, high thermal stability and good thermal shock resistance and corrosion resistance. Meanwhile, the first coating and the second coating provided by the invention have excellent impact resistance and breaking strength, can reduce the internal stress of the coating, prevent crack growth and reduce tipping in a rapid cooling and rapid heating thermal cycle environment. In particular, the first coating prepared by adopting the technical scheme is more firmly combined with the substrate, so that the second coating can be firmly fixedly connected with the substrate.
In some possible implementations, in the first coating, the zirconia includes a mass ratio of (2-5): 1 and zirconia particles and zirconia fines; in the second coating layer, the zirconia comprises the following components in mass ratio (3-8): 1 and zirconia fine powder.
In some possible embodiments, the zirconia particles have a particle size of 0.15-3mm; the granularity of the zirconia fine powder is 30-150 mu m; the granularity of the zirconia micropowder is 0.1-30 mu m.
In some possible implementations, the zirconia particles include a mass ratio of 1: (0.5-2): (3-5) zirconia particles having a particle size of 0.5-1mm, a particle size of 0.35-0.5mm and a particle size of 0.15-0.35 mm.
In some possible implementations, the zirconia fine powder includes a mass ratio of (5-8): (1-3): (0.5-1) zirconia fine powder having a particle size of 90-135 μm, a particle size of 65-90 μm and a particle size of 30-65 μm.
By adopting the technical scheme, in the preparation of the first coating, the raw materials such as zirconia and the like with the proportion are prepared into molten liquid at a higher temperature, various oxides are fully fused to generate substances with complex composition and very uniform structure, so that the stability of the finally prepared material is greatly improved, and the material structure is not easy to be influenced by external force in the use process to cause damage. Cerium oxide and bismuth oxide are also added into the preparation raw materials, the cerium oxide has very high stabilizing effect on cubic phase zirconium oxide, and the addition of the bismuth oxide can reduce stress concentration in the material and reduce the probability of cracks on the surface of a coating. In addition, the addition of the boron oxide and the chromium oxide improves the phase change stability of the zirconium oxide and the bonding strength of the zirconium oxide and a matrix, so that the prepared material has better comprehensive mechanical properties.
By adopting the technical scheme, in the preparation of the second coating, the addition of beryllium oxide can improve the compactness of the coating, and meanwhile, indium oxide is beneficial to exerting the surface effect, so that grains are refined, the generated crystal image is promoted to be more uniform, the conductivity of the zirconia material can be optimized, and the electrical property of the zirconia material is improved. The indium oxide, the zinc oxide, the beryllium oxide and the hafnium oxide which are designed in the proportion are added into the raw materials for preparation, so that the stabilizing effect on the zirconium oxide is achieved, and the surface of the zirconium oxide material prepared by the raw materials in the proportion is not easy to crack when the zirconium oxide material is subjected to external force or extreme environment.
In some possible implementations, the first coating further includes 0.1-1 parts binder and 30-65 parts solvent; the second coating layer further comprises 25-40 parts of water and 5-15 parts of methyl cellulose.
In some possible implementations, the binder includes a mass ratio of 1: polyvinyl alcohol and polyacrylamide of (1-8); the solvent is at least one of water, methanol, ethanol, toluene, isopropanol and ethylene glycol.
In some possible implementations, the first coating thickness is 50-90 μm; the thickness of the second coating is 100-150 mu m.
In some possible implementations, the zirconia is fused zirconia in which ZrO 2 Not less than 99.5% by mass, fe 2 O 3 Not more than 0.01% by mass of TiO 2 Not more than 0.005% by mass of SiO 2 Not more than 0.01% by mass.
On the other hand, a preparation method of the modified zirconia coating is also provided, and the preparation method of the modified zirconia coating comprises the following steps: a) Fully mixing zirconium oxide, bismuth oxide, cerium oxide, chromium oxide and boron oxide according to a proportion, then adding a binder and a solvent with preset proportions, ball-milling for 3-10 hours at the rotating speed of 300-1800rpm/min, and uniformly mixing to obtain first mixed slurry; then adding the first mixed slurry into an electric furnace, heating to 1600-1700 ℃ for heat preservation for 20-30min, heating to 2050-2500 ℃ for heat preservation for 30-50min, heating to 2600-2800 ℃ for heat preservation for 1-3h, and carrying out heat preservation at 2600-2800 ℃ for 1-3h to obtain molten liquid;
b) Preparing a first coating on the surface of the substrate by adopting a plasma spraying method from the melt obtained in the step a);
c) Fully mixing zirconium oxide, indium oxide, zinc oxide, beryllium oxide and hafnium oxide according to a proportion to obtain a premix; then adding water and methyl cellulose in a preset proportion, ball milling for 3-10 hours at the rotating speed of 300-1800rpm/min, and uniformly mixing to prepare second mixed slurry; preparing the second mixed slurry into spherical powder with the particle size of 10-70 mu m by adopting a spray drying method; adopting an electric furnace to carry out high-temperature sintering treatment on the spherical powder to obtain spherical powder with a ceramic surface layer;
d) And preparing a second coating on the first coating by adopting a plasma spraying method to prepare the spherical powder of the ceramic surface layer.
In some possible implementations, the plasma spraying described in step b) and step d) is low pressure plasma spraying or atmospheric plasma spraying.
The invention adopts a plasma spraying method to prepare the first coating and the second coating, and the method has good stability, can accelerate the material to be sprayed at a high speed, so as to spread and solidify on the surface of a base material rapidly, and is a high-quality coating which is formed into a sheet-shaped stacking structure and covers one by one. Moreover, when the plasma arc is adopted for spraying, the high-temperature plasma arc jet flow has little influence on the surface of the matrix, and the matrix structure cannot be changed due to heating. Meanwhile, the plasma spraying equipment is light and flexible, is easy to produce and operate, and has high deposition efficiency for preparing the coating during mass continuous production.
In the process of completing the invention, it is found that when the first coating is prepared, the first mixed solution is directly placed into a spray gun for heating and spraying, and the raw materials are not completely melted due to the shorter heating process, so that the first mixed solution is sprayed on the substrate and cannot meet the requirements of sufficient strength and adhesion. The invention can greatly improve the flexural strength and the impact resistance of the first coating and the bonding strength of the first coating and the surface of the matrix by putting the first mixed slurry into the spraying equipment after being melted at high temperature.
In some possible implementations, the ball milling in step a) and step c) employs chemical zirconia ceramic balls as milling balls.
In some possible implementations, the substrate is sandblasted or frosted prior to step b). Before spraying, the matrix is subjected to sand blasting or frosting treatment to remove surface pollutants and roughen the surface so as to facilitate the adhesion of the zirconia coating. In addition, the sand blasting or sanding treatment can activate the surface of the matrix and improve the residual stress of the surface of the matrix.
In some possible implementations, the spray drying conditions described in step c) are: the spray drying temperature is 160-280 ℃, the air quantity is 5-50L/min, and the rotating speed of an atomizing disk is 1500-3000rpm/min;
the conditions of the sintering process described in step c) are: heating to 800-1500 ℃, preserving heat for 1-10 h, and heating at a rate of 10-60 ℃/min;
the spraying parameters are as follows: n (N) 2 Pressure of 3-5MPa, H 2 Pressure of 5-7MPa, flow rate of N2 of 30-45L/min and H 2 The flow is 10-25L/min, the voltage is 60-90V, and the current is 450-700A;
the matrix is a metal material.
By adopting the technical parameters, a great amount of polycrystalline structure can be obtained in the coating in the process of spraying and depositing the zirconia raw material liquid into the coating, so that the impact resistance and the flexural strength of the prepared coating are improved.
In some possible implementations, the substrate is a metallic material. Further, the matrix is an aluminum-based material. The technical scheme provided by the embodiment of the invention has the beneficial effects that at least:
1. the invention provides a modified zirconia coating with high comprehensive performance, which has low heat conductivity coefficient, thermal expansion coefficient matched with a matrix, low sintering activity, high thermal stability, good thermal shock resistance and corrosion resistance, and can be directly sprayed on a high-aluminum matrix material to prepare a high-performance aluminum-based refractory product.
2. According to the zirconia coating provided by the embodiment of the invention, by adopting the technical scheme, the first coating prepared in the specific proportion and the second coating prepared in the specific proportion are mutually matched and jointly acted, so that further crack expansion can be effectively prevented, the thermal stress of the coating is reduced, the bonding strength of the coating is improved, and the high-alumina refractory product prepared by adopting the zirconia coating has high heat-resistant temperature, high compactness, high strength and toughness, higher wear resistance and corrosion resistance and greatly prolonged service life.
3. The aluminum-based refractory product prepared by the zirconia coating can be used at a temperature of more than 2500 ℃, is particularly suitable for smelting equipment for preparing active metal or alloy by vacuum smelting, and under the temperature use condition, the components of the refractory product do not react with melt, so that the purity of the melt under the ultra-high temperature condition can be improved.
Detailed Description
In order to make the technical scheme and advantages of the present invention more apparent, the following detailed description of the embodiments of the present invention will be provided.
As an example, the modified zirconia coating of the present invention is prepared as follows:
a) Fully mixing zirconium oxide, bismuth oxide, cerium oxide, chromium oxide and boron oxide according to a proportion, then adding a binder and a solvent with preset proportions, ball-milling for 8 hours at a rotating speed of 1000rpm/min, and uniformly mixing to obtain first mixed slurry; then adding the first mixed slurry into an electric furnace, heating to 1650 ℃ for 25min, heating to 2300 ℃ for 40min, and heating to 2700 ℃ for 2h to obtain molten liquid;
b) Spraying the molten liquid obtained in the step a) by adopting a plasma spraying method to prepare a first coating with the thickness of 80 mu m; spraying parameters: n (N) 2 Pressure 3.5MPa, H 2 Pressure 6MPa, N2 flow 35L/min and H 2 15L/min of flow, 70V of voltage and 600A of current;
c) Fully mixing zirconium oxide, zinc oxide, hafnium oxide, indium oxide and beryllium oxide in proportion to obtain premix; then adding water and methyl cellulose in a preset proportion, ball milling for 5 hours at a rotating speed of 1500rpm/min, and uniformly mixing to obtain second mixed slurry; preparing the second mixed slurry into spherical powder with the particle size of 20-30 mu m by adopting a spray drying method; adopting an electric furnace to carry out high-temperature sintering treatment on the spherical powder to obtain spherical powder with a ceramic surface layer; the spray drying conditions are as follows: spray drying temperature is 230 ℃, air quantity is 20L/min, and rotating speed of an atomizing disk is 2000rpm/min; the sintering treatment conditions are as follows: heating to 1000 ℃, preserving heat for 5 hours, and heating at a speed of 30 ℃/min;
d) Spraying the spherical powder of the ceramic surface layer on the first coating by adopting a plasma spraying method to prepare a second coating with the thickness of 120 mu m; spraying parameters: n (N) 2 Pressure 4MPa, H 2 Pressure 6.5MPa, N2 flow 40L/min and H 2 Flow 20L/min, voltage 80V, current 650A.
Wherein the zirconia is fused zirconia, and ZrO in the fused zirconia 2 Not less than 99.5% by mass, fe 2 O 3 Not more than 0.01% by mass of TiO 2 Not more than 0.005% by mass of SiO 2 Not more than 0.01% by mass.
The raw materials and proportions of the first coating and the second coating in the modified zirconia coating in examples 1 to 4 are as follows:
the compositions of the zirconia and the binder in each example are as follows:
example 1: in the first coating, zirconia is a mixture of zirconia particles and zirconia fine powder in a mass ratio of 2:1, wherein the zirconia particles are a mixture of zirconia particles with a particle size of 0.5-1mm, a particle size of 0.35-0.5mm and a particle size of 0.15-0.35mm in a mass ratio of 1:0.5:3, the zirconia fine powder is a mixture of zirconia fine powder with a particle size of 90-135 mu m, a particle size of 65-90 mu m and a particle size of 30-65 mu m in a mass ratio of 5:3:0.5, and the binder is a mixture of polyvinyl alcohol and polyacrylamide in a mass ratio of 1:1; in the second coating, the zirconia is a mixture of zirconia fine powder and zirconia micro powder in a mass ratio of 3:1, and the zirconia fine powder is a mixture of zirconia fine powder with a granularity of 90-135 mu m, a granularity of 65-90 mu m and a granularity of 30-65 mu m in a mass ratio of 5:1:1.
Example 2: in the first coating, zirconia is a mixture of zirconia particles and zirconia fine powder in a mass ratio of 5:1, wherein the zirconia particles are a mixture of zirconia particles with a particle size of 0.5-1mm, a particle size of 0.35-0.5mm and a particle size of 0.15-0.35mm in a mass ratio of 1:0.5:5, the zirconia fine powder is a mixture of zirconia fine powder with a particle size of 90-135 mu m, a particle size of 65-90 mu m and a particle size of 30-65 mu m in a mass ratio of 5:3:1, and the binder is a mixture of polyvinyl alcohol and polyacrylamide in a mass ratio of 1:3; in the second coating, the zirconia is a mixture of zirconia fine powder and zirconia micro powder in a mass ratio of 8:1, and the zirconia fine powder is a mixture of zirconia fine powder with a particle size of 90-135 mu m, a particle size of 65-90 mu m and a particle size of 30-65 mu m in a mass ratio of 8:1:0.5.
Example 3: in the first coating, zirconia is a mixture of zirconia particles and zirconia fine powder in a mass ratio of 3:1, the zirconia particles are a mixture of zirconia particles with a particle size of 0.5-1mm, a particle size of 0.35-0.5mm and a particle size of 0.15-0.35mm in a mass ratio of 1:2:3, the zirconia fine powder is a mixture of zirconia fine powder with a particle size of 90-135 mu m, a particle size of 65-90 mu m and a particle size of 30-65 mu m in a mass ratio of 6:1:1, and the binder is a mixture of polyvinyl alcohol and polyacrylamide in a mass ratio of 1:5; in the second coating, the zirconia is a mixture of zirconia fine powder and zirconia micro powder in a mass ratio of 5:1, and the zirconia fine powder is a mixture of zirconia fine powder with a particle size of 90-135 mu m, a particle size of 65-90 mu m and a particle size of 30-65 mu m in a mass ratio of 5:3:1.
Example 4: in the first coating, zirconia is a mixture of zirconia particles and zirconia fine powder in a mass ratio of 4:1, wherein the zirconia particles are a mixture of zirconia particles with a particle size of 0.5-1mm, a particle size of 0.35-0.5mm and a particle size of 0.15-0.35mm in a mass ratio of 1:1:4, the zirconia fine powder is a mixture of zirconia fine powder with a particle size of 90-135 mu m, a particle size of 65-90 mu m and a particle size of 30-65 mu m in a mass ratio of 8:1:0.5, and the binder is a mixture of polyvinyl alcohol and polyacrylamide in a mass ratio of 1:8; in the second coating, the zirconia is a mixture of zirconia fine powder and zirconia micro powder in a mass ratio of 6:1, and the zirconia fine powder is a mixture of zirconia fine powder with a particle size of 90-135 mu m, a particle size of 65-90 mu m and a particle size of 30-65 mu m in a mass ratio of 8:2:1.
The paint provided in the proportion of examples 1-4 is sprayed on the surface of the metal aluminum material layer according to the process to form a zirconia coating. Vacuum melting Nb alloy (placing 0.5kg of Nb alloy block into the alumina-coated aluminum-based refractory product, and then installing the Nb alloy block in a vacuum heat treatment furnace (261W vacuum heat treatment furnace, germany, prime Co.) by adopting the alumina-coated aluminum-based refractory products prepared by the coatings according to examples 1-4), adjusting the melting process parameters, vacuumizing to 1X 10 -3 Pa, smelting at 2600 ℃, preserving heat at 2600 ℃ for 30min, cooling to room temperature (25 ℃) along with a furnace, and taking out; the detection of the aluminum-based refractory product containing the zirconia coating shows that the surface of the aluminum-based refractory product does not participate in the reaction of Nb alloy, and the Nb alloy does not contain the components of the aluminum-based product containing the zirconia coating, which shows that the aluminum-based refractory product containing the zirconia coating has ultrahigh temperature heat stability, and does not react with melt when the use temperature is more than 2500 ℃, thereby ensuring the purity of the melt during ultrahigh temperature smelting, and being particularly suitable for smelting equipment for preparing active metals or alloys by ultrahigh temperature vacuum smelting.
Other performance tests: the abrasion resistance of the coating was determined by the rotating rubber grinding wheel test (calculation of mass loss after 15 hours abrasion, i.e. mass loss = lost mass/original mass x 100%; the smaller the mass loss at the same revolution, the better the abrasion resistance of the coating);
the impact resistance of the coating was measured with an impact tester (see how much joule (J) energy the coating is damaged, the greater the impact energy it can resist, the better the impact resistance) with reference to GBT 20624;
the bulk density of the coating was determined with reference to GB/T2997-2015 standard;
the normal temperature flexural strength is measured by referring to GB/T6569-2006 standard (the equipment used is a digital display electric flexural strength tester, and the ultimate stress which can be born when a coating is pressurized on a three-point bending device without breaking at room temperature is measured);
reference to ferrous metallurgy standard YB/T376.3-2004 section 3 of refractory products Heat shock resistance test method: the water quenching-crack judging method measures the thermal shock resistance of the coating (the temperature change times of quenching and heating is 2000 times, and whether cracks appear on the surface of the coating is observed);
the bond strength of the coating to the aluminum-based substrate is determined with reference to the measurement according to ASTM C-633-79. The test data are shown in Table 1.
Table 1: test data sheet
The embodiment of the invention specifically provides a zirconia coating based on a metal material, and as can be seen from table 1, the coating has better comprehensive properties, and specifically comprises the following steps: the coating has a bulk density of 7.5 g/cm 3 After 15 hours of abrasion, the mass loss is lower than 0.015 percent, which indicates that the coating has high density and excellent abrasion resistance; furthermore, under the condition of spraying the thinner coating, the aluminum-based refractory product can resist 165J impact energy, the pressure bearable at room temperature is more than 250MPa, and when the cold and hot cycle is 2000 times, no visible crack exists on the surface of the coating, which indicates that the coating has better impact resistance, breaking strength and thermal shock resistance. In particular, the aluminum-based refractory product prepared by the zirconia coating is suitable for continuous metal casting equipment in the ultra-high temperature field.
The above examples illustrate only a few embodiments of the invention, which are described in detail and are not to be construed as limiting the scope of the invention. It should be noted that it will be apparent to those skilled in the art that several variations and modifications can be made without departing from the spirit of the invention, which are all within the scope of the invention. Accordingly, the scope of protection of the present invention is to be determined by the appended claims.
Claims (8)
1. A modified zirconia coating, characterized in that it comprises a first coating layer arranged on the surface of a substrate, and a second coating layer attached to the surface of the first coating layer;
the first coating comprises the following raw materials in parts by weight: 80-95 parts of zirconia, 0.1-0.5 part of bismuth oxide, 2-5 parts of cerium oxide, 0.1-2.5 parts of chromium oxide and 0.5-3 parts of boron oxide;
the second coating comprises the following raw materials in parts by weight: 65-90 parts of zirconium oxide, 3-8 parts of zinc oxide, 1-5 parts of hafnium oxide, 0.5-3.5 parts of indium oxide and 0.1-1 part of beryllium oxide;
the first coating further comprises 0.1-1 part of binder and 30-65 parts of solvent; the second coating further comprises 25-40 parts of water and 5-15 parts of methyl cellulose;
wherein, the preparation of the modified zirconia coating comprises the following steps:
a) Fully mixing zirconium oxide, bismuth oxide, cerium oxide, chromium oxide and boron oxide according to a proportion, then adding a binder and a solvent with preset proportions, ball-milling for 3-10 hours at the rotating speed of 300-1800rpm/min, and uniformly mixing to obtain first mixed slurry; then adding the first mixed slurry into an electric furnace, heating to 1600-1700 ℃ for heat preservation for 20-30min, heating to 2050-2500 ℃ for heat preservation for 30-50min, heating to 2600-2800 ℃ for heat preservation for 1-3h, and carrying out heat preservation at 2600-2800 ℃ for 1-3h to obtain molten liquid;
b) Preparing a first coating on the surface of the substrate by adopting a plasma spraying method from the melt obtained in the step a);
c) Fully mixing zirconium oxide, indium oxide, zinc oxide, beryllium oxide and hafnium oxide according to a proportion to obtain a premix; then adding water and methyl cellulose in a preset proportion, ball milling for 3-10 hours at the rotating speed of 300-1800rpm/min, and uniformly mixing to prepare second mixed slurry; preparing the second mixed slurry into spherical powder with the particle size of 10-70 mu m by adopting a spray drying method; adopting an electric furnace to carry out high-temperature sintering treatment on the spherical powder to obtain spherical powder with a ceramic surface layer;
d) And preparing a second coating on the first coating by adopting a plasma spraying method to prepare the spherical powder of the ceramic surface layer.
2. The modified zirconia coating of claim 1, wherein in the first coating, the zirconia comprises a mass ratio of (2-5): 1 and zirconia particles and zirconia fines; in the second coating layer, the zirconia comprises the following components in mass ratio (3-8): 1 and zirconia fine powder.
3. The modified zirconia coating of claim 2, wherein the zirconia particles have a particle size of greater than or equal to 0.15mm and less than 3mm; the granularity of the zirconia fine powder is more than or equal to 30 mu m and less than 150 mu m; the granularity of the zirconia micropowder is more than or equal to 0.1 mu m and less than 30 mu m.
4. The modified zirconia coating of claim 3 wherein the zirconia particles comprise a mass ratio of 1: (0.5-2): (3-5) zirconia particles having a particle size of 0.5mm or more, less than 1mm, 0.35mm or more, less than 0.5mm and 0.15mm or more, less than 0.35 mm.
5. The modified zirconia coating as claimed in claim 3, wherein the zirconia fine powder comprises (5 to 8) in mass ratio: (1-3): (0.5-1) zirconia fine powder having a particle size of 90 μm or more, less than 135 μm, a particle size of 65 μm or more, less than 90 μm and a particle size of 30 μm or more, less than 65 μm.
6. The modified zirconia coating of claim 1, wherein the binder comprises a mass ratio of 1: polyvinyl alcohol and polyacrylamide of (1-8); the solvent is at least one of water, methanol, ethanol, toluene, isopropanol and ethylene glycol.
7. The modified zirconia coating of claim 1, wherein the first coating thickness is 50-90 μm; the thickness of the second coating is 100-150 mu m; the zirconia is fused zirconia, and ZrO in the fused zirconia 2 Mass fraction of (2)Not less than 99.5%, fe 2 O 3 Not more than 0.01% by mass of TiO 2 Not more than 0.005% by mass of SiO 2 Not more than 0.01% by mass.
8. The modified zirconia coating of claim 1, wherein in the preparation of the modified zirconia coating, the plasma spraying in step b) and step d) is low pressure plasma spraying or atmospheric plasma spraying;
the ball milling in step a) and step c) uses chemical zirconia ceramic balls as milling balls;
before step b), carrying out sand blasting or sanding treatment on the surface of the substrate;
the spray drying conditions described in step c) are: the spray drying temperature is 160-280 ℃, the air quantity is 5-50L/min, and the rotating speed of an atomizing disk is 1500-3000rpm/min;
the conditions of the sintering process described in step c) are: heating to 800-1500 ℃, preserving heat for 1-10 h, and heating at a rate of 10-60 ℃/min;
the spraying parameters are as follows: n (N) 2 Pressure of 3-5MPa, H 2 Pressure of 5-7MPa, N 2 Flow rate is 30-45L/min, H 2 The flow is 10-25L/min, the voltage is 60-90V, and the current is 450-700A;
the matrix is a metal material.
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| US9531004B2 (en) * | 2013-12-23 | 2016-12-27 | GM Global Technology Operations LLC | Multifunctional hybrid coatings for electrodes made by atomic layer deposition techniques |
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