阅读说明：本技术 一种高能量辅助喷涂方法及喷涂系统 (High-energy auxiliary spraying method and spraying system ) 是由 卢静 孙澄川 吴应东 解路 但幸东 汤烈明 李挺 于 2020-12-11 设计创作，主要内容包括：本发明提供的高能量辅助喷涂方法及喷涂系统,对基体进行预处理,采用喷涂的方式在所述基体表面制备涂层,并对所述涂层进行重熔处理；或采用喷涂的方式在所述基体表面制备涂层,并在所述喷涂过程中对所述涂层进行实时的重熔处理,本发明提供的高能量辅助喷涂方法及喷涂系统,通过高能热源产生的能量,对已沉积涂层进行重熔处理,或者在喷涂过程中能够对基体或者已沉积涂层进行实时重熔处理,使得涂层或者沉积体的孔隙率降低(<0.1％),并且结合强度有明显提升(>70MPa)；可以根据喷涂材料的种类的不同而更换热源,且拆卸简单。(The high-energy auxiliary spraying method and the high-energy auxiliary spraying system provided by the invention have the advantages that a matrix is pretreated, a coating is prepared on the surface of the matrix in a spraying mode, and the coating is subjected to remelting treatment; or preparing a coating on the surface of the substrate by adopting a spraying mode, and carrying out real-time remelting treatment on the coating in the spraying process, wherein the high-energy auxiliary spraying method and the spraying system provided by the invention carry out remelting treatment on the deposited coating by using energy generated by a high-energy heat source, or can carry out real-time remelting treatment on the substrate or the deposited coating in the spraying process, so that the porosity of the coating or the deposited body is reduced (less than 0.1%), and the bonding strength is obviously improved (more than 70 MPa); the heat source can be replaced according to different types of spraying materials, and the disassembly is simple.)

1. A high-energy auxiliary spraying method is characterized by comprising the following steps:

pretreating a substrate; and

preparing a coating on the surface of the substrate in a spraying mode, and remelting the coating; or

Preparing a coating on the surface of the substrate in a spraying mode, and carrying out real-time remelting treatment on the coating in the spraying process.

2. The high energy assisted spray coating process of claim 1 wherein the substrate is at least one of carbon steel or stainless steel or a superalloy or an aluminum alloy or copper or a copper alloy or a titanium alloy or ceramic.

3. The high energy assisted spray coating method of claim 1, wherein the spray coating means includes thermal spray coating and cold spray coating.

4. The high energy assisted spray coating process of claim 1, wherein the coating includes metal and alloy coatings, ceramic-alloy coatings and ceramic coatings.

5. The high-energy auxiliary spraying method as claimed in claim 4, wherein the step of preparing the coating on the surface of the substrate by spraying and remelting the coating comprises the following steps:

spraying the surface of the substrate by adopting a thermal spraying or cold spraying mode, and depositing to form a coating or a deposition body with a certain size and shape;

and carrying out remelting treatment on the coating or the sediment by using a high-energy heat source.

6. The high-energy auxiliary spraying method as claimed in claim 5, wherein the step of preparing the coating on the surface of the substrate by spraying and remelting the coating in real time during the spraying process comprises the following steps:

fixing a high-energy heat source and a spray gun and enabling the high-energy heat source to be consistent with the moving track of the spray gun;

the high-energy heat source is used for carrying out preheating treatment on the matrix;

the spray gun is used for spraying the preheated substrate to form a coating on the surface of the substrate;

and changing the relative position of the high-energy heat source or the spray gun and the substrate, and repeating the steps to perform real-time remelting treatment on the coating.

7. The high energy assisted spray method of claim 6, wherein the high energy heat source includes, but is not limited to, a laser or a plasma or electric arc and the spray gun is a thermal spray gun or a cold spray gun.

8. The high-energy auxiliary spraying method as claimed in claim 7, wherein the high-energy heat source and the spray gun are moved by a robot arm or the high-energy heat source and the spray gun are stationary, and the substrate moves along with the movement of the work platform.

9. The high-energy auxiliary spraying method as claimed in claim 8, wherein the moving track of the high-energy heat source and the spray gun is S-shaped or other shapes.

10. A coating system for a high-energy auxiliary coating method according to any one of claims 1 to 9, wherein said coating system is a coating system for a high-energy auxiliary coating method

The remelting treatment device is used for preparing a coating on the surface of the substrate in a spraying mode and remelting the coating; or preparing a coating on the surface of the substrate by adopting a spraying mode, and carrying out real-time remelting treatment on the coating in the spraying process.

11. The spray system of claim 10, wherein the remelting treatment device comprises a spray gun, a high-energy heat source, and a robot arm, wherein the robot arm fixes the high-energy heat source and the spray gun and enables the high-energy heat source and the spray gun to be consistent in moving track;

the high-energy heat source carries out preheating treatment on the substrate, the spray gun carries out spraying on the substrate after the preheating treatment, so that a coating is formed on the surface of the substrate, the relative position of the high-energy heat source or the spray gun and the substrate is changed, the steps are repeated, and the coating is subjected to real-time remelting treatment.

Technical Field

The invention relates to the technical field of surface engineering, in particular to a high-energy auxiliary spraying method and a related spraying operation system.

Background

The surface of the substrate can be protected by preparing a functional coating (such as corrosion resistance, wear resistance, heat insulation and the like) with certain shape and size on the surface of the substrate. The current techniques for preparing coatings mainly include thermal spraying, cold spraying, vapor deposition and the like. Although the vapor deposition technology has less material consumption and compact and uniform film formation, the film formation speed is slow and the thickness is very limited, and generally the thickness does not exceed 100 mu m. Thermal spraying techniques include plasma spraying, supersonic flame spraying, electric arc spraying, explosive spraying, etc., wherein powders or wires are heated to a molten or semi-molten state during the spraying process and then deposited to form a coating, which can generally prepare coatings of hundreds of micrometers to several millimeters, but the porosity inside the coating is high, thus having adverse effects on other properties of the coating, such as corrosion resistance, etc. The cold spraying technology utilizes mechanical combination generated by collision of high-speed deformation of particles and a matrix to deposit and form a coating, but the cold spraying technology is generally used for depositing materials with certain plastic deformation, and a compact coating is difficult to form for materials with poor plasticity or high hardness, such as TC4, Ni-based high-temperature alloy, WC-Co and the like; in addition, the cold spraying technology can be used for depositing bulk materials with larger size, but the mechanical property of the cold spraying deposition body is far lower than that of a common cast material due to the layered structure of multiple interfaces in the coating.

In order to improve the density of the coating, researchers adopt a laser remelting mode to process the deposited TC4 coating, and research results show that the pores in the coating can be obviously reduced after the laser remelting treatment; the ceramic-metal composite coating is prepared by micro-plasma arc auxiliary thermal spraying technology (electric arc spraying and plasma spraying), and the coating presents a compact tissue structure after being solidified and has no cracks on the surface.

Although the existing thermal spraying technology can be used for preparing various metal and alloy coatings, ceramic coatings and the like, the coating has obvious pores inside, so that the performance of the coating is adversely affected, and the cold spraying technology can be used for preparing a denser coating, but the coating is deposited by plastic deformation, so that the coating also has obvious pores inside when powder with poor plastic deformation capability is sprayed. This limits the further widespread application of coating technology, and there is a strong need for a method for increasing the density of the coating.

At present, aiming at the current situation that the porosity of a coating is high, a laser remelting technology can be adopted to carry out remelting treatment on the coating, but a laser is expensive, related peripheral equipment needs to be configured, and in the long-time use process, the optical fiber is possibly burnt due to insufficient cooling speed, so that expensive maintenance cost is brought; the plasma arc has relatively low cost, can assist the hot spraying technology to prepare the ceramic-metal base coating, but has narrow application range at present, and the plasma arc carries out remelting treatment on the sprayed coating, does not provide a scheme of real-time treatment, reduces the production efficiency and improves the time cost.

Disclosure of Invention

In view of the above, it is necessary to provide a high-energy auxiliary spraying method which can improve the bonding strength of the coating and improve the wear resistance, corrosion resistance, etc. of the coating.

In order to solve the problems, the invention adopts the following technical scheme:

a high energy assisted spray coating process comprising the steps of:

pretreating a substrate; and

preparing a coating on the surface of the substrate in a spraying mode, and remelting the coating; or

Preparing a coating on the surface of the substrate in a spraying mode, and carrying out real-time remelting treatment on the coating in the spraying process.

In some of these embodiments, the substrate is at least one of carbon steel or stainless steel or a superalloy or an aluminum alloy or copper or a copper alloy or a titanium alloy or ceramic.

In some embodiments, the step of pretreating the substrate specifically includes:

machining the substrate into a certain shape and size by adopting a mechanical machining method;

and cleaning the surface of the machined substrate or performing sand blasting treatment on the surface of the machined substrate.

In some of these embodiments, the spray pattern includes thermal spray and cold spray.

In some of these embodiments, the coatings include metal and alloy coatings, ceramic-alloy coatings, and ceramic coatings.

In some of these embodiments, the metal and alloy coatings include Cu and Cu alloys, Al and Al alloys, Ti and Ti alloys, superalloys, stainless steel and carbon steels, amorphous alloys; the ceramic-alloy coating comprises WC-Co, NiCr-Cr₃C₂、TiB₂-Al₂O₃(ii) a The ceramic coating includes an alumina-based, a chromia-based, and a zirconia-based.

In some of these embodiments, the coating is a wear resistant and corrosion resistant coating having a thickness of 100 μm to 2mm or a deposit having a thickness of greater than 2 mm.

In some embodiments, the step of preparing the coating on the surface of the substrate by spraying and remelting the coating specifically comprises the following steps:

spraying the surface of the substrate by adopting a thermal spraying or cold spraying mode, and depositing to form a coating with a certain size and shape;

and carrying out remelting treatment on the coating by using a high-energy heat source.

In some embodiments, the step of preparing the coating on the surface of the substrate by spraying and performing real-time remelting treatment on the coating in the spraying process specifically includes the following steps:

fixing a high-energy heat source and a spray gun and enabling the high-energy heat source to be consistent with the moving track of the spray gun;

the high-energy heat source is used for carrying out preheating treatment on the matrix;

the spray gun is used for spraying the preheated substrate to form a coating on the surface of the substrate;

and changing the relative position of the high-energy heat source or the spray gun and the substrate, and repeating the steps to perform real-time remelting treatment on the coating.

In some embodiments, the high energy heat source is secured to the lance by a robotic arm.

In some of these embodiments, the high energy heat source includes, but is not limited to, a laser or a plasma or electric arc, and the torch is a thermal spray torch or a cold spray torch.

In some embodiments, the high-energy heat source and the spray gun may be moved by the robot arm or the high-energy heat source and the spray gun may be stationary, and the substrate moves along with the movement of the work platform.

In some embodiments, the high-energy heat source and the spray gun move in an S shape or other shapes.

In addition, the invention also provides a spraying system of the high-energy auxiliary spraying method, which comprises the following steps:

the pretreatment device is used for pretreating the substrate; and

the remelting treatment device is used for preparing a coating on the surface of the substrate in a spraying mode and remelting the coating; or preparing a coating on the surface of the substrate by adopting a spraying mode, and carrying out real-time remelting treatment on the coating in the spraying process.

In some embodiments, the remelting treatment device comprises a spray gun and a high-energy heat source, wherein the spray gun is used for spraying on the surface of the substrate in a thermal spraying or cold spraying mode and depositing to form a coating or a deposition body with a certain size and shape; and the high-energy heat source carries out remelting treatment on the coating or the deposition body.

In some embodiments, the remelting treatment device comprises a spray gun, a high-energy heat source and a mechanical arm, wherein the mechanical arm fixes the high-energy heat source and the spray gun and enables the high-energy heat source and the spray gun to move in a track;

the high-energy heat source carries out preheating treatment on the substrate, the spray gun carries out spraying on the substrate after the preheating treatment, so that a coating is formed on the surface of the substrate, the relative position of the high-energy heat source or the spray gun and the substrate is changed, the steps are repeated, and the coating is subjected to real-time remelting treatment.

By adopting the technical scheme, the invention has the following technical effects:

the high-energy auxiliary spraying method and the high-energy auxiliary spraying system provided by the invention have the advantages that a matrix is pretreated, a coating is prepared on the surface of the matrix in a spraying mode, and the coating is subjected to remelting treatment; or preparing a coating on the surface of the substrate by adopting a spraying mode, and carrying out real-time remelting treatment on the coating in the spraying process, wherein the high-energy auxiliary spraying method and the spraying system provided by the invention carry out remelting treatment on the deposited coating by using energy generated by a high-energy heat source, or can carry out real-time remelting treatment on the substrate or the deposited coating in the spraying process, so that the porosity of the coating or the deposited body is reduced (less than 0.1%), and the bonding strength is obviously improved (more than 70 MPa); and the heat source can be replaced according to different types of spraying materials, and the disassembly is simple.

Drawings

In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings needed to be used in the embodiments of the present invention or in the description of the prior art will be briefly described below, and it is obvious that the drawings described below are only some embodiments of the present invention, and it is obvious for those skilled in the art that other drawings can be obtained according to the drawings without creative efforts.

FIG. 1 is a flow chart of the steps of a high energy assisted spray coating process provided in example 1 of the present invention;

FIG. 2 is a schematic diagram of a high energy assisted spray method provided in example 1 of the present invention;

fig. 3 is a schematic diagram of a moving track of a high-energy heat source and a spray gun of the high-energy auxiliary spraying method provided in embodiment 1 of the present invention.

Detailed Description

Reference will now be made in detail to embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like or similar reference numerals refer to the same or similar elements or elements having the same or similar function throughout. The embodiments described below with reference to the drawings are illustrative and intended to be illustrative of the invention and are not to be construed as limiting the invention.

In the description of the present invention, it is to be understood that the terms "upper", "lower", "horizontal", "inside", "outside", and the like, indicate orientations or positional relationships based on the orientations or positional relationships shown in the drawings, are only for convenience in describing the present invention and simplifying the description, and do not indicate or imply that the referred device or element must have a specific orientation, be constructed in a specific orientation, and be operated, and thus, should not be construed as limiting the present invention.

Furthermore, the terms "first", "second" and "first" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of the present invention, "a plurality" means two or more unless specifically defined otherwise.

In the embodiment of the invention, the coating is prepared on the surface of the substrate by adopting a thermal spraying technology (plasma spraying, supersonic flame, electric arc spraying, explosion spraying and the like) or a cold spraying technology; the sedimentary body is a large-size block material prepared by adopting a thermal spraying technology or a cold spraying technology; the remelted layer refers to a coating or a deposition body treated by a high-energy heat source.

In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is described in further detail below with reference to the accompanying drawings and embodiments.

Referring to fig. 1, a flow chart of steps of a high-energy auxiliary spraying method according to an embodiment of the present invention includes the following steps:

step S110: and (4) pretreating the substrate.

Further, in the step of pretreating the substrate, the method specifically comprises the following steps:

machining the substrate into a certain shape and size by adopting a mechanical machining method; and cleaning the surface of the machined matrix or performing sand blasting treatment on the surface of the machined matrix to remove oil stains and oxide impurities on the surface.

In some embodiments, the substrate is at least one of carbon steel or stainless steel or a superalloy or an aluminum alloy or copper or a copper alloy or a titanium alloy or ceramic.

Step S120: preparing a coating on the surface of the substrate in a spraying mode, and remelting the coating; or preparing a coating on the surface of the substrate by adopting a spraying mode, and carrying out real-time remelting treatment on the coating in the spraying process.

In some of these embodiments, the spray pattern includes thermal spray and cold spray.

In some of these embodiments, the coatings include metal and alloy coatings, ceramic-alloy coatings, and ceramic coatings.

In some of these embodiments, the metal and alloy coatings include Cu and Cu alloys, Al and Al alloys, Ti and Ti alloys, superalloys, stainless steel and carbon steels, amorphous alloys; the ceramic-alloy coating comprises WC-Co, NiCr-Cr₃C₂、TiB₂-Al₂O₃(ii) a The ceramic coating includes an alumina-based, a chromia-based, and a zirconia-based.

Further, the coating is a wear-resistant and corrosion-resistant coating with the thickness of 100 mu m-2mm or a deposition body with the thickness of more than 2 mm.

In some embodiments, the step of preparing the coating on the surface of the substrate by spraying and remelting the coating specifically comprises the following steps:

spraying the surface of the substrate by adopting a thermal spraying or cold spraying mode, and depositing to form a coating with a certain size and shape; and carrying out remelting treatment on the coating by using a high-energy heat source.

Referring to fig. 2, a schematic diagram of a principle of preparing a coating on the surface of the substrate by spraying and performing real-time remelting treatment on the coating in the spraying process according to this embodiment is provided.

Specifically, the step of preparing the coating on the surface of the substrate by adopting a spraying mode and carrying out real-time remelting treatment on the coating in the spraying process specifically comprises the following steps:

step S121: the high-energy heat source 2 is fixed with the spray gun 1 and is made to coincide with the moving track of the spray gun.

Wherein: the high-energy heat source 2 and the spray gun 1 are fixed through the mechanical arm 3, the high-energy heat source 2 comprises laser or plasma arc or electric arc, and the spray gun 1 is a thermal spraying spray gun or a cold spraying spray gun.

In some embodiments, the high-energy heat source 2 and the spray gun 1 may be moved by the robot 3 to move the high-energy heat source 2 and the spray gun 1 or the high-energy heat source 2 and the spray gun 1 are fixed, and the substrate 4 moves along with the movement of the work platform.

In some embodiments, the trajectory of the high-energy heat source 2 and the spray gun 1 is S-shaped or other shapes, please refer to fig. 3.

Step S122: the high-energy heat source 2 performs a preheating treatment on the substrate 4.

Step S123: the spray gun 1 sprays the preheated substrate 4, so that a coating is formed on the surface of the substrate 4.

Further, the coating is a wear-resistant and corrosion-resistant coating with the thickness of 100 mu m-2mm or a deposition body with the thickness of more than 2 mm.

Step S124: and changing the relative position of the high-energy heat source 2 or the spray gun 1 and the substrate 4, and repeating the steps to perform real-time remelting treatment on the coating.

It can be understood that the moving point of the high-energy heat source 2 is slightly earlier than that of other spray guns, so that the high-energy heat source can preheat a matrix or remelting a deposited coating, and subsequently deposited particles can be metallurgically bonded with the preheated matrix or the remelted coating, so that the compactness and the bonding strength are improved.

The high-energy auxiliary spraying method provided by the invention comprises the steps of pretreating a substrate, preparing a coating on the surface of the substrate in a spraying mode, and remelting the coating; the high-energy auxiliary spraying method and the spraying system provided by the invention can carry out remelting treatment on the deposited coating through the energy generated by a high-energy heat source, or can carry out remelting treatment on the substrate or the deposited coating in real time in the spraying process, so that the porosity of the coating or the deposited body is reduced (< 0.1%) and the bonding strength is obviously improved (>70 MPa).

The high-energy auxiliary spraying method provided by the invention is a device and a method for reducing the internal porosity of the coating or the sedimentary body and improving the bonding strength of the coating, is particularly suitable for refractory materials or materials which are not easy to deform, and has a promoting effect on the wear resistance, corrosion resistance and other properties of the coating.

In addition, the invention also provides a spraying system of the high-energy auxiliary spraying method, which comprises the following steps: the pretreatment device is used for pretreating the substrate; the remelting treatment device is used for preparing a coating on the surface of the substrate in a spraying mode and remelting the coating; or preparing a coating on the surface of the substrate by adopting a spraying mode, and carrying out real-time remelting treatment on the coating in the spraying process.

Referring to fig. 2 again, the remelting treatment device comprises a spray gun and a high-energy heat source, wherein the spray gun is used for spraying on the surface of the substrate in a thermal spraying or cold spraying mode and depositing to form a coating with a certain size and shape; and the high-energy heat source carries out remelting treatment on the coating.

In some embodiments, the remelting treatment device comprises a spray gun, a high-energy heat source and a mechanical arm, wherein the mechanical arm fixes the high-energy heat source and the spray gun and enables the high-energy heat source and the spray gun to move in a track;

the high-energy heat source carries out preheating treatment on the substrate, the spray gun carries out spraying on the substrate after the preheating treatment, so that a coating is formed on the surface of the substrate, the relative position of the high-energy heat source or the spray gun and the substrate is changed, the steps are repeated, and the coating is subjected to real-time remelting treatment.

The detailed working scheme is described in the foregoing, and is not described in detail here.

The high-energy auxiliary spraying system provided by the invention is used for pretreating a substrate, preparing a coating on the surface of the substrate in a spraying mode and remelting the coating; the high-energy auxiliary spraying method and the spraying system provided by the invention can carry out remelting treatment on the deposited coating through the energy generated by a high-energy heat source, or can carry out remelting treatment on the substrate or the deposited coating in real time in the spraying process, so that the porosity of the coating or the deposited body is reduced (< 0.1%) and the bonding strength is obviously improved (>70 MPa).

The following detailed description is given with reference to specific examples.

Embodiment 1:

firstly, SS316L powder with the particle size range of 10-50 mu m is prepared, the spraying substrate is SS316L, firstly, a coating with the thickness of about 600 mu m is prepared on the substrate by adopting a cold spraying technology, and the spraying process parameters are as follows: the pressure is 4MPa, the temperature is 650 ℃, the spraying distance is 20mm, and the moving speed of the spray gun is 1000 mm/min. After the coating is prepared, remelting the coating by adopting a fiber laser with the power of 5KW to obtain a compact coating.

Embodiment 2:

first, In625 powder having a particle size of-300 mesh was prepared, In718 was sprayed as a base, and the plasma arc spray gun and the cold spray gun were fixed to a robot arm together. Firstly, adjusting parameters of a plasma arc spray gun to preheat a substrate, and then spraying to deposit particles on the preheated substrate, wherein the cold spraying process parameters are as follows: the pressure is 4.5MPa, the temperature is 750 ℃, the spraying distance is 20mm, and the moving speed of a spray gun is 1000 mm/min; after the coating is deposited on the substrate, the spraying is continued to grow into a block material gradually.

The high-energy heat source auxiliary spraying device and the method provided by the embodiment can reduce the pores in the coating in a remelting mode, improve the bonding strength of the coating, enable the bonding strength to reach the metallurgical bonding level, improve the wear resistance, corrosion resistance and other properties of the coating, are particularly suitable for refractory materials or non-deformable materials, and promote the wear resistance, corrosion resistance and other properties of the coating.

The foregoing is considered as illustrative only of the preferred embodiments of the invention, and is presented merely for purposes of illustration and description of the principles of the invention and is not intended to limit the scope of the invention in any way. Any modifications, equivalents and improvements made within the spirit and principles of the invention and other embodiments of the invention without the creative effort of those skilled in the art are included in the protection scope of the invention based on the explanation here.