CN112080745B - 一种包含非晶态合金识别层的复合涂层及其制备方法和应用 - Google Patents
一种包含非晶态合金识别层的复合涂层及其制备方法和应用 Download PDFInfo
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- 229910000808 amorphous metal alloy Inorganic materials 0.000 title claims abstract description 92
- 238000000576 coating method Methods 0.000 title claims abstract description 57
- 239000011248 coating agent Substances 0.000 title claims abstract description 55
- 239000002131 composite material Substances 0.000 title claims abstract description 52
- 238000002360 preparation method Methods 0.000 title abstract description 8
- 239000010410 layer Substances 0.000 claims abstract description 115
- 239000002344 surface layer Substances 0.000 claims abstract description 61
- 239000002245 particle Substances 0.000 claims abstract description 56
- 238000005507 spraying Methods 0.000 claims abstract description 54
- 239000000919 ceramic Substances 0.000 claims abstract description 53
- 229910017053 inorganic salt Inorganic materials 0.000 claims abstract description 53
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims abstract description 29
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 claims abstract description 26
- 238000000034 method Methods 0.000 claims abstract description 26
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 26
- 229910001868 water Inorganic materials 0.000 claims abstract description 26
- 238000004939 coking Methods 0.000 claims abstract description 17
- WGLPBDUCMAPZCE-UHFFFAOYSA-N Trioxochromium Chemical compound O=[Cr](=O)=O WGLPBDUCMAPZCE-UHFFFAOYSA-N 0.000 claims abstract description 15
- 238000005488 sandblasting Methods 0.000 claims abstract description 15
- 229910000423 chromium oxide Inorganic materials 0.000 claims abstract description 14
- 239000000377 silicon dioxide Substances 0.000 claims abstract description 14
- 239000004111 Potassium silicate Substances 0.000 claims abstract description 13
- 239000004115 Sodium Silicate Substances 0.000 claims abstract description 13
- OKIWLDVQGKRUNR-UHFFFAOYSA-L magnesium;hydrogen phosphate;trihydrate Chemical compound O.O.O.[Mg+2].OP([O-])([O-])=O OKIWLDVQGKRUNR-UHFFFAOYSA-L 0.000 claims abstract description 13
- NNHHDJVEYQHLHG-UHFFFAOYSA-N potassium silicate Chemical compound [K+].[K+].[O-][Si]([O-])=O NNHHDJVEYQHLHG-UHFFFAOYSA-N 0.000 claims abstract description 13
- 229910052913 potassium silicate Inorganic materials 0.000 claims abstract description 13
- 235000019353 potassium silicate Nutrition 0.000 claims abstract description 13
- 235000012239 silicon dioxide Nutrition 0.000 claims abstract description 13
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 claims abstract description 13
- 229910052911 sodium silicate Inorganic materials 0.000 claims abstract description 13
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims abstract description 12
- 239000004927 clay Substances 0.000 claims abstract description 12
- 239000011651 chromium Substances 0.000 claims abstract description 10
- 239000007921 spray Substances 0.000 claims description 17
- 238000003466 welding Methods 0.000 claims description 16
- 238000010891 electric arc Methods 0.000 claims description 13
- 239000011259 mixed solution Substances 0.000 claims description 9
- 239000002002 slurry Substances 0.000 claims description 9
- 238000002156 mixing Methods 0.000 claims description 7
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 claims description 4
- 238000005536 corrosion prevention Methods 0.000 claims description 3
- RVTZCBVAJQQJTK-UHFFFAOYSA-N oxygen(2-);zirconium(4+) Chemical compound [O-2].[O-2].[Zr+4] RVTZCBVAJQQJTK-UHFFFAOYSA-N 0.000 claims description 3
- 230000002265 prevention Effects 0.000 claims description 3
- 229910001928 zirconium oxide Inorganic materials 0.000 claims description 3
- 238000004519 manufacturing process Methods 0.000 claims description 2
- 230000006835 compression Effects 0.000 claims 1
- 238000007906 compression Methods 0.000 claims 1
- 239000002994 raw material Substances 0.000 claims 1
- 230000007797 corrosion Effects 0.000 abstract description 18
- 238000005260 corrosion Methods 0.000 abstract description 18
- 238000001035 drying Methods 0.000 description 9
- 150000003377 silicon compounds Chemical class 0.000 description 8
- RYZCLUQMCYZBJQ-UHFFFAOYSA-H lead(2+);dicarbonate;dihydroxide Chemical compound [OH-].[OH-].[Pb+2].[Pb+2].[Pb+2].[O-]C([O-])=O.[O-]C([O-])=O RYZCLUQMCYZBJQ-UHFFFAOYSA-H 0.000 description 7
- 229910052751 metal Inorganic materials 0.000 description 6
- 239000002184 metal Substances 0.000 description 6
- 238000003756 stirring Methods 0.000 description 5
- 229910000831 Steel Inorganic materials 0.000 description 4
- 238000001816 cooling Methods 0.000 description 4
- 238000012423 maintenance Methods 0.000 description 4
- 239000010959 steel Substances 0.000 description 4
- 230000000052 comparative effect Effects 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 239000000571 coke Substances 0.000 description 2
- 238000005034 decoration Methods 0.000 description 2
- 238000003912 environmental pollution Methods 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 150000001768 cations Chemical class 0.000 description 1
- 239000003518 caustics Substances 0.000 description 1
- 239000011247 coating layer Substances 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- QDOXWKRWXJOMAK-UHFFFAOYSA-N dichromium trioxide Chemical compound O=[Cr]O[Cr]=O QDOXWKRWXJOMAK-UHFFFAOYSA-N 0.000 description 1
- XPPKVPWEQAFLFU-UHFFFAOYSA-J diphosphate(4-) Chemical compound [O-]P([O-])(=O)OP([O-])([O-])=O XPPKVPWEQAFLFU-UHFFFAOYSA-J 0.000 description 1
- 235000011180 diphosphates Nutrition 0.000 description 1
- 239000000428 dust Substances 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 238000011056 performance test Methods 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 230000002035 prolonged effect Effects 0.000 description 1
- 230000001681 protective effect Effects 0.000 description 1
- 230000035939 shock Effects 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
- 238000005728 strengthening Methods 0.000 description 1
- 238000010998 test method Methods 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
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Abstract
本发明公开了一种包含非晶态合金识别层的复合涂层及其制备方法和应用,属于复合材料喷涂技术领域。所述包含非晶态合金识别层的复合涂层,包括非晶合金底层和无机盐陶瓷颗粒面层,所述非晶合金底层包括如下重量份的组分:Fe:50~55份、Cr:24~28份、Mo:15~19份、B:2~2.5份和C:1.5~2.5份;所述无机盐陶瓷颗粒面层包括如下重量份的组分:水38~60份,氧化锆11~14份,硅酸钾11~13份,氧化铬4~7份,氧化铝11~18份,硅酸钠4~6份,三水磷酸氢镁3~5份,二氧化硅0.2~1份和耐火黏土8~12份。本发明提供的复合涂层既能有效解决水冷壁腐蚀结焦的问题,又能减少喷砂工艺频率。
Description
技术领域
本发明属于复合材料喷涂技术领域,具体涉及一种包含非晶态合金识别层的复合涂层及其制备方法和应用。
背景技术
电厂锅炉运行过程中,常会发生水冷壁遭到腐蚀结焦的问题,在出现类似问题的情况下,如果没有及时采取应对措施或采用了不当的措施,都会对锅炉运行造成不良影响。目前普遍采用电弧喷涂一层耐腐蚀金属抵抗腐蚀,但该方法存在的问题是耐腐蚀金属仅能保证自身短时间内不受腐蚀影响,但电弧喷涂时会留有一定的缝隙,腐蚀物质会通过缝隙进入水冷壁,同时耐腐蚀金属表面仍然会黏着大量结焦及污垢粉尘,严重影响锅炉水冷壁热交换。而且一旦耐腐蚀金属被腐蚀消耗完毕,再次喷涂时必须对水冷壁进行喷砂处理才可以二次喷涂,而喷砂工艺对环境污染极大,且无法与其他维修工种同时作业,极大的破坏环境,且延长电厂锅炉维修工期。
发明内容
本发明的目的在于提供一种包含非晶态合金识别层的复合涂层及其制备方法和应用,既能有效解决水冷壁腐蚀结焦的问题,又能减少喷砂工艺频率。
为实现上述目的,本发明提供如下技术方案:
本发明提供了一种包含非晶态合金识别层的复合涂层,包括非晶合金底层和无机盐陶瓷颗粒面层,所述非晶合金底层包括如下重量份的组分:Fe:50~55份、Cr:24~28份、Mo:15~19份、B:2~2.5份和C:1.5~2.5份;所述无机盐陶瓷颗粒面层包括如下重量份的组分:水38~60份,氧化锆11~14份,硅酸钾11~13份,氧化铬4~7份,氧化铝11~18份,硅酸钠4~6份,三水磷酸氢镁3~5份,二氧化硅0.2~1份和耐火黏土8~12份。
优选的,所述非晶合金底层包括如下重量份的组分:Fe:52份、Cr:26份、Mo:16份、B:2.1份和C:2份。
优选的,所述无机盐陶瓷颗粒面层包括如下重量份的组分:水50份,氧化锆12份,硅酸钾12份,氧化铬6份,氧化铝15份,硅酸钠5份,三水磷酸氢镁4份,二氧化硅0.6份和耐火黏土10份。
优选的,所述无机盐陶瓷颗粒面层中氧化锆、氧化铬、氧化铝和二氧化硅颗粒的粒度分别独立为0.2~0.5μm。
本发明提供了上述方案所述的包含非晶态合金识别层的复合涂层的制备方法,包括如下步骤:
1)将锅炉水冷壁进行预处理,得到预处理后的锅炉水冷壁;
2)将非晶态合金底层的各组分混合制备成非晶焊丝,将非晶焊丝喷涂到所述步骤1)的预处理后的锅炉水冷壁上,得到非晶态合金底层;
3)将无机盐陶瓷颗粒的各组分混合,将得到的混合液喷涂到所述步骤2)的非晶态合金底层上,得到复合涂层。
优选的,所述步骤1)中预处理的方式为喷砂处理。
优选的,所述步骤2)中采用电弧喷涂的方法进行喷涂,喷涂的厚度为0.1~0.2mm;所述采用电弧喷涂时的工艺条件为:电压:33~35V,电流:235~245A,喷嘴距水冷壁表面距离:200mm,压缩空气压力:0.5MPa,压缩空气流量:5.5m3/min~6.5m3/min。
优选的,所述步骤3)中采用带浆液罐的压缩空气喷枪将得到的混合液喷涂到非晶态合金底层上;采用带浆液罐的压缩空气喷枪进行喷涂时的工艺条件为:压缩空气压力0.5MPa,压缩空气流量:5.5m3/min~6.5m3/min,喷枪到喷涂表面的距离为25~35cm。
优选的,无机盐陶瓷颗粒面层的总厚度为0.2~0.3mm,分多次喷涂,每次喷涂的厚度为0.005~0.075mm。
本发明还提供了一种上述方案所述的包含非晶态合金识别层的复合涂层在锅炉水冷壁防腐、防结焦中的应用。
与现有技术相比,本发明的有益效果是:
本发明提供了一种包含非晶态合金识别层的复合涂层,包括非晶合金底层和无机盐陶瓷颗粒面层。在本发明中,通过将水、氧化锆、硅酸钾、氧化铬、氧化铝、硅酸钠、三水磷酸氢镁、二氧化硅和耐火黏土按特定比例制备成面层,使锅炉中的结焦物难以与面层紧密结合,从而减轻锅炉水冷壁的结焦现象。而且,面层可以覆盖住采用电弧喷涂方式制备的非晶态合金底层留有的孔隙,进一步提高防腐性能。同时,采用非晶合金作为底层,底层具有优异的耐腐蚀性和耐磨性,在面层被消耗掉后不会继续消耗底层,这样底层的表面状态会持续保留。本发明将无机盐陶瓷颗粒面层和非晶态合金底层相互配合,当面层被破坏后,只需采用高压蒸汽将残余面层及其他附着物清洗干净,直接在下面的非晶态合金底层上喷涂面层即可重新恢复涂层的保护效果,无需再次喷砂,大幅度降低喷砂次数,减轻环境污染并提高工作效率。
同时,本发明提供的复合涂层,非晶合金底层为银白色,无机盐陶瓷颗粒面层为绿色,底层和面层在色泽上有明显差异,底层还可发挥识别的作用,当面层被破坏时,容易发觉,从而可以及时进行喷涂。
具体实施方式
本发明提供了一种包含非晶态合金识别层的复合涂层,包括非晶合金底层和无机盐陶瓷颗粒面层,所述非晶合金底层包括如下重量份的组分:Fe:50~55份、Cr:24~28份、Mo:15~19份、B:2~2.5份和C:1.5~2.5份;所述无机盐陶瓷颗粒面层包括如下重量份的组分:水38~60份,氧化锆11~14份,硅酸钾11~13份,氧化铬4~7份,氧化铝11~18份,硅酸钠4~6份,三水磷酸氢镁3~5份,二氧化硅0.2~1份和耐火黏土8~12份。
本发明提供的包含非晶态合金识别层的复合涂层中包括非晶态合金识别层底层,所述非晶态合金底层中包括Fe。按重量份计,包括50~55份,优选为52份。
本发明提供的包含非晶态合金识别层的复合涂层中包括非晶态合金识别层底层,所述非晶态合金底层中包括Cr。按重量份计,包括24~28份,优选为26份。
本发明提供的包含非晶态合金识别层的复合涂层中包括非晶态合金识别层底层,所述非晶态合金底层中包括Mo。按重量份计,包括15~19份,优选为16份。
本发明提供的包含非晶态合金识别层的复合涂层中包括非晶态合金识别层底层,所述非晶态合金底层中包括B。按重量份计,包括2~2.5份,优选为2.1份。
本发明提供的包含非晶态合金识别层的复合涂层中包括非晶态合金识别层底层,所述非晶态合金底层中包括C。按重量份计,包括1.5~2.5份,优选为2份。
在本发明中,所述非晶态合金具有极强的耐腐蚀和耐磨损性能,能够持续保持稳定的表面状态。
本发明对所述Fe、Cr、Mo、B和C的来源没有特殊限定,采用本领域常规市售产品即可。
本发明提供的包含非晶态合金识别层的复合涂层中包括无机盐陶瓷颗粒面层,所述无机盐陶瓷颗粒面层中包括水。按重量份计,包括38~60份,优选为50份。
本发明提供的包含非晶态合金识别层的复合涂层中包括无机盐陶瓷颗粒面层,所述无机盐陶瓷颗粒面层中包括氧化锆。按重量份计,包括11~14份,优选为12份。在本发明中,所述氧化锆的粒度优选为0.2~0.5μm。
本发明提供的包含非晶态合金识别层的复合涂层中包括无机盐陶瓷颗粒面层,所述无机盐陶瓷颗粒面层中包括硅酸钾。按重量份计,包括4~7份,优选为6份。
本发明提供的包含非晶态合金识别层的复合涂层中包括无机盐陶瓷颗粒面层,所述无机盐陶瓷颗粒面层中包括氧化铝。按重量份计,包括11~18份,优选为15份。在本发明中,所述氧化铝的粒度优选为0.2~0.5μm。
本发明提供的包含非晶态合金识别层的复合涂层中包括无机盐陶瓷颗粒面层,所述无机盐陶瓷颗粒面层中包括氧化铬。按重量份计,包括4~7份,优选为6份。在本发明中,所述氧化铬的粒度优选为0.2~0.5μm。
本发明提供的包含非晶态合金识别层的复合涂层中包括无机盐陶瓷颗粒面层,所述无机盐陶瓷颗粒面层中包括硅酸钠。按重量份计,包括4~6份,优选为5份。
本发明提供的包含非晶态合金识别层的复合涂层中包括无机盐陶瓷颗粒面层,所述无机盐陶瓷颗粒面层中包括三水磷酸氢镁。按重量份计,包括3~5份,优选为4份。
本发明提供的包含非晶态合金识别层的复合涂层中包括无机盐陶瓷颗粒面层,所述无机盐陶瓷颗粒面层中包括二氧化硅。按重量份计,包括0.2~1份,优选为0.6份。在本发明中,所述二氧化硅的粒度优选为0.2~0.5μm。
本发明提供的包含非晶态合金识别层的复合涂层中包括无机盐陶瓷颗粒面层,所述无机盐陶瓷颗粒面层中包括耐火粘土。按重量份计,包括8~12份,优选为10份。
在本发明中,所述硅酸钾和硅酸钠作为无机粘接剂在高温下固化后具有粘接力强,能耐1000℃高温的特性,可将面层添加的其余组分与基体牢固结合并在高温下保持良好的物理性能,提高涂层的稳定性。所述氧化锆,氧化铬和氧化铝作为耐高温骨料起到提高涂层整体强度和硬度的作用,三种成分复合添加能够减少由于成分单一造成的内部结构简单,易于开裂的问题,可显著提高面层的抗热震性能。面层成分中的三水磷酸氢镁在高温下脱水并与熔融的结焦物中的金属阳离子结合,生成耐温超过1000℃的焦磷酸盐粉末,使结焦物难以与面层紧密结合,明显减轻锅炉水冷壁的结焦现象。
本发明先以非晶合金作为底层,提高水冷壁的耐腐蚀性和耐磨性,进一步再将无机盐陶瓷颗粒面层包覆在底层上,不仅可以覆盖住底层非晶态合金识别层留有的缝隙,避免耐腐成分通过缝隙进入水冷壁。同时,可以减轻锅炉水冷壁的结焦现象。将底层和面层两者结合,共同提高水冷壁的防腐、防结焦性。
本发明对所述氧化锆、硅酸钾、氧化铬、氧化铝、硅酸钠、三水磷酸氢镁、二氧化硅和耐火黏土的来源没有特殊限定,采用本领域常规市售产品即可。
本发明提供了上述方案所述的包含非晶态合金识别层的复合涂层的制备方法,包括如下步骤:
1)将锅炉水冷壁进行预处理,得到预处理后的锅炉水冷壁;
2)将非晶态合金底层的各组分混合制备成非晶焊丝,将非晶焊丝喷涂到所述步骤1)的预处理后的锅炉水冷壁上,得到非晶态合金底层;
3)将无机盐陶瓷颗粒的各组分混合,将得到的混合液喷涂到所述步骤2)的非晶态合金底层上,得到复合涂层。
本发明将锅炉水冷壁进行预处理,得到预处理后的锅炉水冷壁。在本发明中,所述预处理的方式优选为喷砂处理。在本发明中,对锅炉水冷壁喷砂处理要求优选达到Sa2.5级别。
得到预处理后的锅炉水冷壁后,本发明将非晶态合金底层的各组分混合制备成非晶焊丝,将非晶焊丝喷涂到所述步骤1)的预处理后的锅炉水冷壁上,得到非晶态合金底层。本发明对所述制备非晶焊丝的方法没有特殊限定,采用本领域常规制造方法即可。本发明实施例中采用本领域的常用方法-钢带法制备非晶焊丝。在本发明中,所述非晶焊丝的直径优选为1.6mm。在本发明中,优选采用电弧喷涂的方法进行喷涂。所述喷涂的厚度优选为0.1~0.2mm。在本发明中,所述电弧喷涂时的工艺条件优选为:电压:33~35V,电流:235~245A,喷嘴距水冷壁表面距离:200mm,压缩空气压力:0.5MPa,压缩空气流量:5.5m3/min~6.5m3/min。
得到非晶态合金底层后,本发明将无机盐陶瓷颗粒的各组分混合,将得到的混合液喷涂到所述非晶态合金底层上,得到复合涂层。在本发明中,所述混合的方式优选为搅拌;所述搅拌的转速优选为1500rpm;搅拌的时间优选为30~60min。
在本发明中,优选采用带浆液罐的压缩空气喷枪将得到的混合液喷涂到非晶态合金底层上。在本发明中,无机盐陶瓷颗粒面层的总厚度优选为0.2~0.3mm,在本发明中,所述无机盐陶瓷颗粒面层优选分多次喷涂,每次喷涂的厚度优选为0.005~0.075mm。在本发明中,每一次喷涂完毕后优选进行干燥。每次干燥的时间不超过1h。在本发明中,采用带浆液罐的压缩空气喷枪进行喷涂时的工艺条件优选为:压缩空气压力0.5MPa,压缩空气流量:5.5m3/min~6.5m3/min,喷枪到喷涂表面的距离为25~35cm。
得到复合涂层后,本发明优选进行干燥后再使用锅炉。在本发明中,所述干燥时的时间优选在10h以上,所述干燥时的环境温度优选大于10℃。
本发明还提供了一种上述方案所述的包含非晶态合金识别层的复合涂层在锅炉水冷壁防腐、防结焦中的应用。
本发明制备得到的复合涂层,非晶合金底层为银白色,无机盐陶瓷颗粒面层为绿色,底层和面层在色泽上有明显差异。待锅炉使用一段时间后,检查涂层表面情况,由于底层和面层的颜色差异较大,底层可发挥识别作用,若面层被破坏后,则能够轻易通过视觉发现非晶合金识别层的区域,该区域即为需再次喷涂施工的区域,只需通过高温蒸汽将该区域彻底清洗干净,将无机盐陶瓷颗粒强化层重新喷涂即可继续使用。
为了进一步说明本发明,下面结合实施例对本发明提供的技术方案进行详细地描述,但不能将它们理解为对本发明保护范围的限定。
实施例1
1)将锅炉水冷壁进行喷砂处理,达到Sa2.5级别,得到预处理后的锅炉水冷壁。
2)将非晶态合金底层的各组分(Fe:50份、Cr:28份、Mo:15份、B:2.5份和C:1.5份)混合采用钢带法制备成直径为1.6mm的非晶焊丝,将非晶焊丝采用电弧喷涂到预处理后的锅炉水冷壁上(电弧喷涂时的工艺条件优选为:电压:33V,电流:245A,喷嘴距水冷壁表面距离:200mm,压缩空气压力:0.5MPa,压缩空气流量:5.6m3/min),得到厚度为0.1mm,银白色的非晶态合金底层;
3)将无机盐陶瓷颗粒的各组分(水38份,氧化锆14份,硅酸钾11份,氧化铬7份,氧化铝11份,硅酸钠6份,三水磷酸氢镁3份,二氧化硅1份和耐火黏土8份)以1500rpm的转速搅拌60min,将得到的混合液采用带浆液罐的压缩空气喷枪喷涂(压缩空气压力0.5MPa,压缩空气流量6.0m3/min,喷枪到喷涂表面的距离为25cm)到非晶态合金底层上,共喷涂5次,5次喷涂的厚度依次为0.005mm、0.020mm、0.050mm、0.075mm和0.070mm,每次喷涂完毕后干燥40min,得到总厚度为0.22mm,颜色呈绿色的无机盐陶瓷颗粒面层。颜色呈绿色的无机盐陶瓷颗粒面层覆盖在银白色的非晶态合金底层上,得到复合涂层,再在20℃干燥15h后,再使用锅炉。
实施例2
1)将锅炉水冷壁进行喷砂处理,达到Sa2.5级别,得到预处理后的锅炉水冷壁。
2)将非晶态合金底层的各组分(Fe:55份、Cr:24份、Mo:19份、B:2份和C:2.5份)混合采用钢带法制备成直径为1.6mm的非晶焊丝,将非晶焊丝采用电弧喷涂到预处理后的锅炉水冷壁上(电弧喷涂时的工艺条件优选为:电压:35V,电流:235A,喷嘴距水冷壁表面距离:200mm,压缩空气压力:0.5MPa,压缩空气流量:6.5m3/min),得到厚度为0.2mm,银白色的非晶态合金底层;
3)将无机盐陶瓷颗粒的各组分(水60份,氧化锆11份,硅酸钾13份,氧化铬4份,氧化铝18份,硅酸钠4份,三水磷酸氢镁5份,二氧化硅0.2份和耐火黏土12份)以1500rpm的转速搅拌30min,将得到的混合液采用带浆液罐的压缩空气喷枪喷涂(压缩空气压力0.5MPa,压缩空气流量:6.0m3/min,喷枪到喷涂表面的距离为35cm)到非晶态合金底层上,共喷涂4次,4次喷涂的厚度依次为0.050mm、0.050mm、0.070mm和0.070mm,每次喷涂完毕后干燥50min,得到总厚度为0.24mm,颜色呈绿色的无机盐陶瓷颗粒面层。颜色呈绿色的无机盐陶瓷颗粒面层覆盖在银白色的非晶态合金底层上,得到复合涂层,再在20℃干燥15h后,再使用锅炉。
实施例3
1)将锅炉水冷壁进行喷砂处理,达到Sa2.5级别,得到预处理后的锅炉水冷壁。
2)将非晶态合金底层的各组分(Fe:52份、Cr:26份、Mo:16份、B:2.1份和C:2份)混合采用钢带法制备成直径为1.6mm的非晶焊丝,将非晶焊丝采用电弧喷涂到预处理后的锅炉水冷壁上(电弧喷涂时的工艺条件优选为:电压:34V,电流:235A,喷嘴距水冷壁表面距离:200mm,压缩空气压力:0.5MPa,压缩空气流量:6.0m3/min),得到厚度:0.2mm,银白色的非晶态合金底层;
3)将无机盐陶瓷颗粒的各组分(水50份,氧化锆12份,硅酸钾12份,氧化铬6份,氧化铝15份,硅酸钠5份,三水磷酸氢镁4份,二氧化硅0.6份和耐火黏土10份)以1500rpm的转速搅拌40min,将得到的混合液采用带浆液罐的压缩空气喷枪喷涂(压缩空气压力0.5MPa,压缩空气流量6.0m3/min,喷枪到喷涂表面的距离为30cm)到非晶态合金底层上,共喷涂5次,5次喷涂的厚度依次为0.050mm、0.070mm、0.050mm、0.070mm和0.060mm,每次喷涂完毕后干燥40min,得到总厚度为0.30mm,颜色呈绿色的无机盐陶瓷颗粒面层。颜色呈绿色的无机盐陶瓷颗粒面层覆盖在银白色的非晶态合金底层上,得到复合涂层,再在25℃干燥15h后,再使用锅炉。
对比例1
除不进行步骤3)外,其他步骤与实施例3完全相同,得到厚度:0.2mm,银白色的非晶态合金识别层作为锅炉水冷壁的涂层。
实施例4
对实施例1~3和对比例1制备得到的涂层的腐蚀结焦性能及喷砂次数进行测试。
测试方法:
锅炉检修时,分别采用实例1~3和对比例1在锅炉水冷壁上选取工况一样的四个位置进行涂层制备,待锅炉使用6个月后,锅炉进行例行停机维护时进入锅炉内部观察四个部位水冷壁管腐蚀和结焦情况,通过实际使用进行对比测试,能够更直接的反映涂层防护效果,具体结果如表1所示:
表1涂层的性能测试结果
由表1可以看出按照本发明所述的方法制备复合涂层用于保护锅炉水冷壁,可使水冷壁不被腐蚀,同时有效减少结焦层厚度,表面的结焦层也可以通过高温蒸汽轻松清理干净,而仅喷涂底层的方式无法彻底保护水冷壁免受腐蚀,且结焦层明显变厚,结焦层与腐蚀产物相结合,仅采用高温蒸汽无法彻底清理,必须再次进行喷砂,不节能环保且保护效果不佳。
以上所述仅是本发明的优选实施方式,应当指出,对于本技术领域的普通技术人员来说,在不脱离本发明原理的前提下,还可以做出若干改进和润饰,这些改进和润饰也应视为本发明的保护范围。
Claims (9)
1.一种包含非晶态合金识别层的复合涂层,其特征在于,包括非晶合金底层和无机盐陶瓷颗粒面层,所述非晶合金底层包括如下重量份的组分:Fe:50~55份、Cr:24~28份、Mo:15~19份、B:2~2.5份和C:1.5~2.5份;所述无机盐陶瓷颗粒面层包括如下重量份的组分:水38~60份,氧化锆11~14份,硅酸钾11~13份,氧化铬4~7份,氧化铝11~18份,硅酸钠4~6份,三水磷酸氢镁3~5份,二氧化硅0.2~1份和耐火黏土8~12份;所述无机盐陶瓷颗粒面层中氧化锆、氧化铬、氧化铝和二氧化硅颗粒的粒度分别独立为0.2~0.5μm。
2.根据权利要求1所述的包含非晶态合金识别层的复合涂层,其特征在于,所述非晶合金底层包括如下重量份的组分:Fe:52份、Cr:26份、Mo:16份、B:2.1份和C:2份。
3.根据权利要求1所述的包含非晶态合金识别层的复合涂层,其特征在于,所述无机盐陶瓷颗粒面层包括如下重量份的组分:水50份,氧化锆12份,硅酸钾12份,氧化铬6份,氧化铝15份,硅酸钠5份,三水磷酸氢镁4份,二氧化硅0.6份和耐火黏土10份。
4.权利要求1~3任意一项所述的包含非晶态合金识别层的复合涂层的制备方法,其特征在于,包括如下步骤:
1)将锅炉水冷壁进行预处理,得到预处理后的锅炉水冷壁;
2)将非晶态合金底层的各组分混合制备成非晶焊丝,将非晶焊丝喷涂到所述步骤1)的预处理后的锅炉水冷壁上,得到非晶态合金底层;
3)将无机盐陶瓷颗粒的各组分混合,将得到的混合液喷涂到所述步骤2)的非晶态合金底层上,得到复合涂层。
5.根据权利要求4所述的包含非晶态合金识别层的复合涂层的制备方法,其特征在于,所述步骤1)中预处理的方式为喷砂处理。
6.根据权利要求4所述的包含非晶态合金识别层的复合涂层的制备方法,其特征在于,所述步骤2)中采用电弧喷涂的方法进行喷涂,喷涂的厚度为0.1~0.2mm;所述采用电弧喷涂时的工艺条件为:电压:33~35V,电流:235~245A,喷嘴距水冷壁表面距离:200mm,压缩空气压力:0.5MPa,压缩空气流量:5.5m3/min~6.5m3/min。
7.根据权利要求4所述的包含非晶态合金识别层的复合涂层的制备方法,其特征在于,所述步骤3)中采用带浆液罐的压缩空气喷枪将得到的混合液喷涂到非晶态合金底层上;采用带浆液罐的压缩空气喷枪进行喷涂时的工艺条件为:压缩空气压力0.5MPa,压缩空气流量:5.5m3/min~6.5m3/min,喷枪到喷涂表面的距离为25~35cm。
8.根据权利要求7所述的包含非晶态合金识别层的复合涂层的制备方法,其特征在于,无机盐陶瓷颗粒面层的总厚度为0.2~0.3mm,分多次喷涂,每次喷涂的厚度为0.005~0.075mm。
9.权利要求1~3任意一项所述的包含非晶态合金识别层的复合涂层在锅炉水冷壁防腐、防结焦中的应用。
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