Spraying area: Grinding tool to strengthen protection
Work status: strengthening regional: engineering model cavity working status: fatigue wear
Solution: the supersonic flame spraying/plasma surface strengthening
Coating material: high wear-resisting corrosion resistant metal composite materials
Use effect: technical performance, improve the service life is 5 to 10 times, using plasma spraying technique, spraying ceramic coating, improve the mould surface hardness, wear resistance, corrosion resistance, heat resistance and lubricity; And can be convenient to take off the film.
The company has domestic leading supersonic HVOF flame, plasma, arc, three kinds of spray coating technology.
1, plasma spraying processing: high-performance ceramic coating, spray coating materials including aluminum oxide powder, chrome oxide, titanium oxide, zirconium oxide, molybdenum carbide, etc.
2, the supersonic fuel (HVOF) spray processing, spraying hard alloy, metal ceramic coating, coating materials including tungsten carbide powder, nickel chromium carbide, chromium, nickel, chrome, etc.
3, speeding the arc spraying processing: spraying line wire stainless steel, zinc, aluminum, copper, lead, molybdenum, babbitt and so on all sorts of function coating.
The thermal spraying material and coating function and application
A the thermal spraying material
Has been realized in the practical application in industrial production of coating materials such as metals, alloys and ceramics, mainly used in powder, wire and bar state, including spraying powder for spraying materials more than 70% of the total amount. Used as a coating material are:
1, thermal spraying powder
Pure metal powder: W, Mo, Al, Cu, Ni, Ti, Ta, Nb, etc
Alloy powder: Al - Ni, Ni - Cr, Ti, Ni, Co - Cr - Ni - Cr - Al, W, MCrAlY (M = Co, Ni, Fe), Co, Ni, Fe base metal, etc
Oxide ceramic powder: Al2O3, ZrO2, Cr2O3, TiO2, etc
Carbide powder: WC, TiC, Cr3C2, etc
Metal ceramic powder: WC - Co, Cr3C2, NiCr, etc
Plastic powder: nylon, polyethylene, PPS etc
2, thermal spray wires
Al, Cu and zinc, Sn, Al - zinc alloy, babbitt alloy, stainless steel,
Ni - Al wire, etc.
3, thermal spray bar
Al2O3, ZrO2, Cr2O3, etc
B coating function and application
1, antiwear coating
Wear industry equipment damage is one of the main reasons that may lead to abrasion working conditions including micro vibration, sliding, shock, abrasion, erosion, etc. Wear resistance coating should be hard, but also the performance of the heat resistance and resistance to chemical corrosion. Fe, Ni, Co in the metal and WC - Co and Cr3C2 - NiCr metal ceramic, Al2O3 and Cr2O3 ceramic material has these properties. The coating technology improve the surface wear resistance has a very wide range of applications, such as piston ring, the gear synchronous ring spraying Mo coating, textile machinery parts and components such as roller, spinning hook on the spraying and fiber resistance of Al2O3, Al2O3 and TiO2 ceramic coating, pump and valve sealing surface coating Cr2O3, WC - Co wear-resistant coating, high power and large truck crankshaft mill, exhaust fan shaft using Fe base alloy material repair wear and abrasion resistant reinforcement, etc.
2, anticorrosion coating
Long exposure to outdoor atmosphere (Marine, industrial and urban and rural atmosphere) and different medium (water, river water solvent and oil, etc.) in the environment of large steel structures, such as power transmission tower, steel structure bridge, offshore drilling platform, derrick in coal mine, and all kinds of chemical containers such as storage tanks, etc., by different degree of oxidation and erosion environment. With Al, zinc, and Al - zinc alloy and stainless steel protective coating, can obtain long-term protective effect for 20 years. Some components by gas corrosion and chemical corrosion, can according to the specific conditions (such as the medium, concentration, temperature, pressure, etc.) select the appropriate coating materials such as metals, alloys, ceramics and plastic for protection.
3, high temperature oxidation and hot corrosion resistance coating
For some exposure to high temperature corrosion in the gas components, by high temperature, gas corrosion, and the function of air flow scouring, seriously affected the life and safe operation of the equipment. In addition to high temperature oxidation and hot corrosion resistance of materials must be resistant to high temperature oxidation and corrosion, must also have similar to the substrate material coefficient of thermal expansion, the party won't be caused by local overheat temperature cycle and the coating thermal fatigue performance degradation. Used as high temperature oxidation and hot corrosion resistance of coating material has: NiCr, leicester, MCrAl, MCrAlY (M = Co, Ni, Fe) and Hastiloy and Stellite alloy, etc. This kind of coating of four typical applications such as power plant boiler tubes (water wall tube, reheater and economizer, superheater tube) and water wall of high temperature oxidation corrosion has been electric power, papermaking, chemical industry and other industrial boiler users need to solve the problem, after years of research and practice has proved that the electric arc spraying Ni - Cr, Fe - Cr - Al and Ni - Cr - Al, 45 ct coating can achieve a good protective effect, the service life of up to nine years. MCrAlY coating used in aviation turbine engine blade coating as well as turbine engine combustion chamber, such as flame tube with a thermal barrier coating bonding layer.
4, thermal barrier coatings
ZrO2, Al2O3 ceramic coating, high melting point, low thermal conductivity, under the condition of high temperature of substrate metal has good heat insulation protection is referred to as thermal barrier coating. The coating generally consists of two systems, one is make by metal bottom, another is make by ceramic surface. Sometimes in order to reduce the difference in thermal expansion between the metal and ceramic and improve the stress distribution in the coating, usually between the bonding layer and ceramic layer increase a transition layer, the transition layer or on the bottom metal with different mixing ratio of ceramic materials and the surface layers of coatings or coating of metallic and ceramic material continuous variation on grounds to form the so-called composition gradient coating (or function). Metal bond for bottom Co or Ni, Cr, Al, Y alloy materials, ceramic materials, had better use by Y2O3 and stable ZrO2, thermal barrier coatings (TBCS) are used for diesel engine, turbine engine combustion chamber, piston valve, flame stabilizer and so on.
5, insulation coating
Ceramic material has high hardness and good wear resistance, but also has very good insulation performance, with high energy plasma spraying the Al2O3 coating of dense, high dielectric strength, is the ideal insulation coating. If the organic or inorganic epicuticular spray hole sealing layer again, and will get more good insulating effect. The current height of the insulation coating has been used in polymer thin films for corona discharge roller surface activation treatment, effect is good.
6, the control of the gaps between the coating
With composite powder, spraying on the matrix can wear soft sealing coating is in the aviation and aerospace industry rapidly developed high temperature sealing, accused of gap technology, is one of the important application of modern thermal spray coating. Mating parts in contact sports can wear at the coating is made of two kinds of powder mixed powder or reunion, prepared by flame or plasma spraying. In general, can wear coating is composed of ontology metal and non-metallic filler, filler is typically graphite, polyester, boron nitride etc. Weakened the function of packing is the integrity of the coating itself and thus enhance coating can wear. Has developed a series of spraying can wear coating material, the coating to the surface of the sealing parts, air compressor or turbine blade and metal surface structure or machine brake, good sealing effect can be obtained. Can wear also can be used in the labyrinth seal coating, the coating used for cooling air channel, reduce the loss of compressed air engine, and maintain pressure balance of rotor shaft.
7, Size restore coating
Thermal spraying is to restore parts size of the economy of a kind of effective method. Whether it is because of work wear and tear or caused by processing of the workpiece size don't meet requirement, all can be reinstated using thermal spraying technique. When neither the welding deformation of the problems with this approach, also not as expensive as special plating process. At the same time, the new surface can be made of wear resistant and corrosion resistant material, can also be the same as the composition of workpiece materials. Repair all kinds of axle and the plunger is a typical application, including his shaft, motor shaft, reciprocating plunger and shaft neck, roll, paper dryer and pump impeller blade and the shell of petroleum and chemical industry, etc. Generator in the cylinder faceted field thermal spray repair is thermal spraying recovery of plane workpiece size a successful application cases. Generator cylinders in the long-term use of faceted due to micro vibration, corrosion and erosion of hot gas flow function and produce several different shapes, area and depth of damage, leakage and affect the efficiency of generator. Thermal spraying methods, respectively to spraying to fill the damage, and then through grinding cylinder surface healing and achieve the required dimensional accuracy. Thermal spraying technology is a big weight, complex and expensive cylinder structure of the split the security at the site (not happen deformation), simple and efficient method.
8, biological function coating
In spraying biological functional ceramic coatings on stainless steel or titanium substrates, such as hydroxyapatite, can effectively overcome the metal type artificial bone with biological tissue fluid corrosion problems and incompatibility, and can improve the body's tissues and the combination of artificial implants.
9, far red radiation coating
Some oxides with high rate of thermal radiation, in the heat waves can radiate far red, when the wave energy to be macromolecule organic matter (such as paint), water, air and other substances molecules absorb resonate and internal heat generation, so as to accelerate the process. Spraying the coating on the heating element, and its energy-saving efficiency of the general average about 25 to 40%.
