CN102909904A - Intelligent coating and preparation method of intelligent coating - Google Patents
Intelligent coating and preparation method of intelligent coating Download PDFInfo
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- CN102909904A CN102909904A CN2012103644887A CN201210364488A CN102909904A CN 102909904 A CN102909904 A CN 102909904A CN 2012103644887 A CN2012103644887 A CN 2012103644887A CN 201210364488 A CN201210364488 A CN 201210364488A CN 102909904 A CN102909904 A CN 102909904A
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Abstract
The embodiment of the invention discloses an intelligent coating which comprises a base, an insulating layer covered on the surface of the base, a plurality of first sensing units, a plurality of second sensing units and a wear layer, wherein the plurality of first sensing units and the plurality of second sensing units are arranged on the surface of the insulating layer, have piezoelectric effects, are mutually intersected and form a lattice, and the intelligent coating can monitor and feed back a wear state of a part surface (namely the wear layer) in real time, therefore, a sensor does not need to be pasted again. Compared with the existing sensor and base combined in a sticking manner, the intelligent coating can avoid the problem of poor adhesion degree between the sensor and the base; the position of an injury can be precisely located; more and more accurate information can be provided for the wear state of the part surface, and monitoring and later analysis of the wear state of the part surface are more facilitated.
Description
Technical field
The present invention relates to technical field of surface coating, more particularly, relate to a kind of smart coat and preparation method thereof.
Background technology
Existing piece surface is under arms the time, if its dynamic damage can't perception, then can't control the state of wear of piece surface.
The test of current piece surface fatigue wear is mainly with the variation of the factors such as vibrations, coefficient of friction, the temperature basis for estimation as assessment piece surface state of wear.When the actual value of selecting factor of judgment has surpassed default threshold value, illustrate that then piece surface lost efficacy, then the inefficacy part is carried out fracture analysis, oppositely infer failure mechanism by experience or classical theory.But this take " judge " afterwards as main failure behaviour and mechanism research, can not judge the borderline failure state of piece surface, so it is machine-processed to set up the control of capable of dynamic monitoring and the inefficacy of control piece surface.
Since smart sensor can the Real Time Monitoring piece surface state of wear, therefore, at piece surface the first-selection that the intelligent sensing unit has just become people is set.
Current a kind of intelligent sensing unit commonly used is piezoelectric transducer, and described piezoelectric transducer is to utilize the piezo-electric effect of piezoelectric to prepare.Be applied at piezoelectric transducer in the process of plant equipment, piezoelectric transducer need to be being pasted on the equipment (or part).
But, because complex structure or the work under bad environment of some plant equipment so that the conjugation of described piezoelectric transducer and equipment room is poor, have caused the accuracy of detection of piezoelectric transducer poor, even the problem that comes off.
Summary of the invention
In view of this, the invention provides a kind of smart coat and preparation method thereof, the method for this smart coat can greatly improve the bond strength between sensor and equipment base, and then avoids the accuracy of detection of piezoelectric transducer poor, even the problem that comes off.。
For achieving the above object, the invention provides following technical scheme:
A kind of smart coat comprises:
Substrate, described substrate are the substrate of arbitrary shape;
Insulating barrier, described insulating barrier cover on the described substrate surface;
A plurality of the first sensing units and a plurality of the second sensing unit, described the first sensing unit and the second sensing unit are arranged on the described surface of insulating layer, has piezo-electric effect, and described the first sensing unit extends along first direction, described the second sensing unit extends along second direction, described a plurality of the first sensing unit and a plurality of the second sensing unit intersect mutually, are latticed;
Wearing layer, described wearing layer cover on described the first sensing unit, the second sensing unit and the surface of insulating layer.
Preferably, described first direction is mutually vertical with second direction.
Preferably, the width of described the first sensing unit width and the second sensing unit is 1.5mm～2.5mm.
Preferably, the distance between the distance between two adjacent the first sensing units and adjacent two the second sensing units is 3mm～4mm.
Preferably, described insulating barrier is the alloy-layer of alumina layer or titanium oxide layer or aluminium oxide and titanium oxide.
Preferably, the making material of described the first sensing unit and the second sensing unit is PbTiO3.
Preferably, described wearing layer is the FeGrBSi layer.
Preferably, described smart coat also comprises:
The first top electrode, described the first top electrode are arranged on described the first sensing unit surface;
The first bottom electrode, described the first bottom electrode are arranged on described the first sensing unit lower surface edge;
The second top electrode, described the second top electrode are arranged on described the second sensing unit surface;
The second bottom electrode, described the second bottom electrode are arranged on described the second sensing unit lower surface edge.
A kind of preparation method of smart coat comprises:
Form insulating barrier at a substrate surface;
Form a plurality of the first sensing units and a plurality of the second sensing unit at described surface of insulating layer, described the first sensing unit extends along first direction, described the second sensing unit extends along second direction, and described a plurality of the first sensing units and a plurality of the second sensing unit intersect mutually, are latticed;
Form wearing layer at described the first sensing unit, the second sensing unit and surface of insulating layer;
To the processing that polarizes of described the first sensing unit and the second sensing unit, make described the first sensing unit and the second sensing unit have piezo-electric effect.
Preferably, describedly form insulating barrier at a substrate surface, comprising:
Form insulating barrier by Supersonic Plasma Spraying technique at described substrate surface.
Preferably, described at described surface of insulating layer a plurality of the first sensing units of formation and a plurality of the second sensing unit, comprising:
The mask that will have a plurality of the first sensing units and a plurality of the second sensing unit shapes covers on the described surface of insulating layer;
Form a plurality of the first sensing units and a plurality of the second sensing unit by Supersonic Plasma Spraying technique at described surface of insulating layer.
Preferably, form wearing layer at described the first sensing unit, the second sensing unit and surface of insulating layer, comprising:
Form wearing layer by Supersonic Plasma Spraying technique at described the first sensing unit, the second sensing unit and surface of insulating layer.
Preferably, described method also comprises:
Form the first top electrode on described the first sensing unit surface;
Form the first bottom electrode at described the first sensing unit lower surface edge;
Form the second top electrode on described the second sensing unit surface;
Form the second bottom electrode at described the second sensing unit lower surface edge;
Oven dry.
Preferably, before a substrate surface forms insulating barrier, also comprise:
Described substrate surface is carried out preliminary treatment, obtain coarse substrate surface.
A kind of localization method based on above-mentioned smart coat comprises:
When described wearing layer was worn damage, described a plurality of the first sensing units produced a plurality of the first detection signals, and described a plurality of the second sensing units produce a plurality of the second detection signals;
Described a plurality of the first detection signals and a plurality of the second detection signal are screened, choose the first maximum detection signal and the second maximum detection signal;
Locate the damage position of described wearing layer on second direction by the first sensing unit that produces maximum the first detection signal;
Locate the damage position of described wearing layer on first direction by the second sensing unit that produces maximum the second detection signal;
By described wearing layer on the first direction and the damage position on the second direction determine the damage position of described wearing layer.Because a plurality of the first sensing units and a plurality of second sensing unit of the smart coat that the application provides have piezo-electric effect, wear-resisting layer covering on described the first sensing unit, the second sensing unit and surface of insulating layer, then can be to state of wear Real Time Monitoring, the feedback of piece surface (being wearing layer), therefore need not to paste again sensor, compare with substrate by the sensor of pasting combination with existing, the smart coat that the application provides can be avoided the poor problem of degree of adhesion between sensor and the substrate.
And described the first sensing unit extends along first direction, described the second sensing unit extends along second direction, described a plurality of the first sensing unit and a plurality of the second sensing unit intersect mutually, be latticed, then when described wearing layer sustains damage, described a plurality of the first sensing unit and a plurality of the second sensing unit all can produce the signal of telecommunication, and the signal of telecommunication that first sensing unit nearest apart from damage position produces is the strongest, equally, the signal of telecommunication that second sensing unit nearest apart from damage position produces also is the strongest, by the detection to forceful electric power signal, can accurately locate damage position, for the state of wear of piece surface provides more, information is more conducive to monitoring and post analysis to the state of wear of piece surface more accurately.
Description of drawings
In order to be illustrated more clearly in the embodiment of the invention or technical scheme of the prior art, the below will do to introduce simply to the accompanying drawing of required use in embodiment or the description of the Prior Art, apparently, accompanying drawing in the following describes only is some embodiments of the present invention, for those of ordinary skills, under the prerequisite of not paying creative work, can also obtain according to these accompanying drawings other accompanying drawing.
The top view of a kind of smart coat system that Fig. 1 provides for the embodiment of the invention;
A kind of smart coat that Fig. 2 provides for the embodiment of the invention is along the profile of B-B ' line;
A kind of smart coat preparation method's that Fig. 3 provides for the embodiment of the invention schematic flow sheet.
The specific embodiment
For above-mentioned purpose of the present invention, feature and advantage can be become apparent more, below in conjunction with accompanying drawing the specific embodiment of the present invention is described in detail.
A lot of details have been set forth in the following description so that fully understand the present invention, but the present invention can also adopt other to be different from alternate manner described here and implement, those skilled in the art can do similar popularization in the situation of intension of the present invention, so the present invention is not subjected to the restriction of following public specific embodiment.
To the embodiment of the invention discloses a kind of smart coat, such as Fig. 1 (in order conveniently checking, having dotted out the extension line of the first sensing unit and the second sensing unit among Fig. 1) and shown in Figure 2, to comprise:
Substrate 1, described substrate 1 is the substrate of arbitrary shape, it is the part that described substrate 1 can have any shape, being preferably described substrate is metallic substrates, be more preferably the 45# steel, be that described substrate can be the moving parts of steam turbines, compressor, pump, also can be the parts such as gear, axle, piston pin (part needs through high frequency or flame surface quenching), and can be foundry goods; Perhaps, described substrate is copper substrate or aluminium substrate, to adapt to the parts of other applications.
Insulating barrier 2, described insulating barrier 2 cover on described substrate 1 surface, and described insulating barrier 2 is preferably the alloy-layer of alumina layer or titanium oxide layer or aluminium oxide and titanium oxide.
A plurality of the first sensing units 31 and a plurality of the second sensing unit 32, described the first sensing unit 31 and the second sensing unit 32 are positioned at same layer, are arranged on described insulating barrier 2 surfaces.And described the first sensing unit 31 extends along first direction, be strip, width is 1.5mm～2.5mm, be preferably 2mm, distance between two adjacent the first sensing units 31 is 3mm～4mm, be preferably 3.5mm, namely the width of the white space between described adjacent two the first sensing units 31 is about 3mm.Described the second sensing unit 32 extends along second direction, be strip, width is 1.5mm～2.5mm, be preferably 2mm, distance between two the second adjacent sense unit 32 is 3mm～4mm, be preferably 3.5mm, namely the width of the white space between described adjacent two the second sensing units 32 is about 3mm.Described first direction is mutually vertical with second direction, or is bordering on vertically, namely mutually intersects between described the first sensing unit 31 and the second sensing unit 32, is latticed.Wherein, the part of exposing described insulating barrier 2 is rectangular, and the four limit length of sides of described rectangle are any number between 3mm or the 2.5mm～3.5mm.Described the first sensing unit 31 and the second unit of sensing unit 32 for having piezo-electric effect, it is made material and is preferably piezoelectric ceramics, more preferably PbTiO3 or BaTiO3 or PZT.
Wearing layer 4, described wearing layer 4 cover on described the first sensing unit 31, the second sensing unit 32 and insulating barrier 2 surfaces, and described wearing layer is the FeGrBSi layer.Described FeCrBSi alloy low price, good with the conjugation of the first sensing unit 31 and the second sensing unit 32, and wearability is good, then with the making material of described FeCrBSi alloy as wearing layer 4, can further increase the wearability of piece surface, and difficult drop-off.
Because a plurality of the first sensing units 31 and a plurality of second sensing unit 32 of the smart coat that the embodiment of the present application provides have piezo-electric effect, wear-resisting layer covering 4 on described the first sensing unit 31, the second sensing unit 32 and the 2 layers of surface of insulating, then can be to state of wear Real Time Monitoring, the feedback of piece surface (being wearing layer 4), therefore need not to paste again sensor, compare with substrate by the sensor of pasting combination with existing, the smart coat that the application provides can be avoided the poor problem of degree of adhesion between sensor and the part.
And, described the first sensing unit 31 extends along first direction, described the second sensing unit 32 extends along second direction, described a plurality of the first sensing unit 31 and a plurality of the second sensing unit 32 intersect mutually, be latticed, then when described wearing layer 4 sustains damage, described a plurality of the first sensing unit 31 and a plurality of the second sensing unit 32 all can produce the signal of telecommunication, and the signal of telecommunication that first sensing unit 31 nearest apart from damage position produces is the strongest, equally, the signal of telecommunication that second sensing unit 32 nearest apart from damage position produces also is the strongest, by the detection to forceful electric power signal, can accurately locate damage position, for the state of wear of piece surface provides more, information is more conducive to monitoring and post analysis to the state of wear of piece surface more accurately.
And, be provided with insulating barrier 2 between described a plurality of the first sensing unit 31 and a plurality of the second sensing unit 32 and the substrate 1, the signal of telecommunication that then can avoid described a plurality of the first sensing unit 31 and a plurality of the second sensing unit 32 to produce flows into substrate 1, namely avoid the loss of the signal of telecommunication, increase the detection sensitivity to damage.
As seen, when the abrasive damage of collecting Parts Surface Coating (wearing layer 4) or micro-fracture, the electric current that described smart coat sends can be used as characteristic signal and finishes judgement to coating borderline failure state, it namely is the continuous judgment model of the multiselect formula of " complete ... more complete ... as not lose efficacy ... borderline failure ... as to lose efficacy " to the judgment model of Parts Surface Coating state, can finish to the inefficacy evolution process of Parts Surface Coating in real time, online and dynamic the grasp, and can accurately locate abration position, for the state of wear of piece surface provides more, information is more conducive to monitoring and post analysis to the state of wear of piece surface more accurately.
In addition, described smart coat also comprises:
The first top electrode 51, described the first top electrode 51 is arranged on described the first sensing unit 31 surfaces, the first bottom electrode 52, described the first bottom electrode 52 is arranged on described the first sensing unit 31 lower surface edges, and described the first top electrode 51 and the first bottom electrode 52 are the leadout electrode of the electric current of 31 pairs of coating damages generations of described the first sensing unit.
The second top electrode 53, described the second top electrode 53 is arranged on described the second sensing unit 32 surfaces, the second bottom electrode 54, described the second bottom electrode 54 is arranged on described the second sensing unit 32 lower surface edges, and described the second top electrode 53 and the second bottom electrode 54 are the leadout electrode of the electric current of 32 pairs of coating damages generations of described the second sensing unit.
In addition, described the first top electrode 51, the first bottom electrode 52, the second top electrode 53 and the second bottom electrode 54 also need connecting lead wire, so that described electric current is derived.
Preferably, described the first top electrode 51, the first bottom electrode 52, the second top electrode 53 and the second bottom electrode 54 are gold electrode, to improve electric conductivity, reduce the loss of electric current.And described the first top electrode 51, the first bottom electrode 52, the second top electrode 53 and the second bottom electrode 54 all are arranged on the non-abrading section of described coating, to avoid owing to the impact of Parts Surface Coating wearing and tearing on electrode.
Another embodiment of the present invention discloses a kind of preparation method of smart coat, as shown in Figure 3, comprising:
Form insulating barrier at a substrate surface.
Described substrate is the substrate of arbitrary shape, it is the part that described substrate can have any shape, being preferably described substrate is metallic substrates, be more preferably the 45# steel, be that described substrate can be the moving parts of steam turbines, compressor, pump, also can be the parts such as gear, axle, piston pin (part needs through high frequency or flame surface quenching), and can be foundry goods; Perhaps, described substrate is copper substrate or aluminium substrate, to adapt to the parts of other applications.
Form a plurality of the first sensing units and a plurality of the second sensing unit at described surface of insulating layer, described the first sensing unit extends along first direction, described the second sensing unit extends along second direction, and described a plurality of the first sensing units and a plurality of the second sensing unit intersect mutually, are latticed.
Form wearing layer at described the first sensing unit, the second sensing unit and surface of insulating layer.
To the processing that polarizes of described the first sensing unit and the second sensing unit, make described the first sensing unit and the second sensing unit have piezo-electric effect, finish the making of described smart coat.
Because described the first sensing unit and the second sensing unit have piezo-electric effect, then described sensing layer can produce the signal of telecommunication to the damage of piece surface, the smart coat that namely obtains has the function of piezoelectric transducer, can to state of wear Real Time Monitoring, the feedback of piece surface (being wearing layer), therefore need not to paste again sensor.Compare with substrate by the sensor of pasting combination with existing, the preparation method of the PbTiO3 smart coat that the application provides can avoid the poor problem of degree of adhesion between sensor and the substrate.
And, described the first sensing unit extends along first direction, described the second sensing unit extends along second direction, described a plurality of the first sensing unit and a plurality of the second sensing unit intersect mutually, be latticed, then when described wearing layer sustains damage, described a plurality of the first sensing unit and a plurality of the second sensing unit all can produce the signal of telecommunication, and the signal of telecommunication that first sensing unit nearest apart from damage position produces is the strongest, equally, the signal of telecommunication that second sensing unit nearest apart from damage position produces also is the strongest, by the detection to forceful electric power signal, can accurately locate damage position, for the state of wear of piece surface provides more, information is more conducive to monitoring and post analysis to the state of wear of piece surface more accurately.
And, be provided with insulating barrier between described a plurality of the first sensing unit and a plurality of the second sensing unit and the substrate, the signal of telecommunication that then can avoid described a plurality of the first sensing unit and a plurality of the second sensing unit to produce flows into substrate, namely avoids the loss of the signal of telecommunication, increases the detection sensitivity to damage.
As seen, when the abrasive damage of collecting Parts Surface Coating (wearing layer) or micro-fracture, the electric current that described smart coat sends can be used as characteristic signal and finishes judgement to coating borderline failure state, it namely is the continuous judgment model of the multiselect formula of " complete ... more complete ... as not lose efficacy ... borderline failure ... as to lose efficacy " to the judgment model of Parts Surface Coating state, can finish to the inefficacy evolution process of Parts Surface Coating in real time, online and dynamic the grasp, and can accurately locate abration position, for the state of wear of piece surface provides more, information is more conducive to monitoring and post analysis to the state of wear of piece surface more accurately.
Another embodiment of the present invention discloses the preparation method of another kind of smart coat, comprising:
Form insulating barrier on a 45# steel base surface, form the first sensing unit and the second sensing unit at described surface of insulating layer, the thickness of described the first sensing unit and the second sensing unit is below 150 μ m, preferably, the thickness of described the first sensing unit and the second sensing unit is 100 μ m or less, at described the first sensing unit, form wearing layer on the second sensing unit and the surface of insulating layer, the thickness of described wearing layer also is 100 μ m or less, then can in the occasion that part thickness is had specific (special) requirements, make the part application of described smart coat become possibility.
To the processing that polarizes of described the first sensing unit and the second sensing unit, make described the first sensing unit and the second sensing unit have piezo-electric effect.
Further embodiment of this invention discloses the preparation method of another smart coat, comprising:
Form insulating barrier by Supersonic Plasma Spraying technique in a metal substrate surface, the making material of described insulating barrier is the alloy of aluminium oxide or titanium oxide or aluminium oxide and titanium oxide.
Concrete, in the present embodiment, the Supersonic Plasma Spraying technique of described formation insulating barrier comprises:
Spray voltage is 110V～130V, is preferably 120V; Spraying current is 370A～400A, is preferably 385A; Spray power is 30kW～50kW, is preferably 40kW; Spray distance is 100mm～120mm, is preferably 110mm.
The mask that will have a plurality of the first sensing units and a plurality of the second sensing unit shapes covers on the described surface of insulating layer, forms a plurality of the first sensing units and a plurality of the second sensing unit by Supersonic Plasma Spraying technique at described surface of insulating layer.
In the present embodiment, the making material of described the first sensing unit and the second sensing unit is piezoelectric ceramics, is preferably PbTiO3.By Supersonic Plasma Spraying technique PbTiO3 is sprayed to surface of insulating layer, finally can form the first sensing unit and the second sensing unit in the position of not blocked by mask, can expose insulating barrier in the position of being blocked by mask.
Form the Supersonic Plasma Spraying technique of described a plurality of the first sensing unit and a plurality of the second sensing units, comprising:
Spray voltage is 110V～130V, is preferably 120V; Spraying current is 350A～380A, is preferably 365A; Spray power is 35kW～55kW, is preferably 45kW; Spray distance is 90mm～110mm, is preferably 100mm.
There is micro metallurgic bonding between described PbTiO3 sensing layer and the insulating barrier, then between described PbTiO3 sensing layer and the insulating barrier very strong conjugation arranged.And very strong conjugation arranged also between described insulating barrier and the substrate.Accordingly, the combination between described PbTiO3 sensing layer and the substrate can be more firm.
In addition, can also form the first sensing unit and the second sensing unit at described surface of insulating layer by chemical vapor deposition method.
Wherein, depositing temperature is 900 ℃～1150 ℃, is preferably 100 ℃, and sedimentation time is 4h～8h, is preferably 6h, and depositional environment pressure is 6KPa～15KPa, is preferably 10KPa.
Form wearing layer by Supersonic Plasma Spraying technique at described the first sensing unit, the second sensing unit and surface of insulating layer.
Concrete, in the present embodiment, form wearing layer by Supersonic Plasma Spraying technique at described the first sensing unit, the second sensing unit and surface of insulating layer, comprising:
Spray voltage is 110V～130V, is preferably 120V, and spraying current is 410A～430A, is preferably 420A, and spray power is 40kW～55kW, is preferably 48kW, and spray distance is 90mm～100mm, is preferably 95mm.
Because FeCrBSi alloy low price, and wearability is good, thus with the making material of described FeCrBSi alloy as wearing layer, can further increase the wearability of piece surface, and difficult drop-off.
To the processing that polarizes of described the first sensing unit and the second sensing unit, make described the first sensing unit and the second sensing unit have piezo-electric effect, comprising:
Described the first sensing unit and the second sensing unit are put into polarized electric field, the polarization temperature is 180 ℃～200 ℃, be preferably 190 ℃, polarized electric field intensity is 2.4KV/mm～2.6KV/mm, is preferably 2.5KV/mm, and described the first sensing unit and the polarization of the second sensing unit are processed, duration is not less than 15min, preferably, the duration is 15min～20min, more preferably 18min.
Need to prove that Supersonic Plasma Spraying technique belongs to a kind of in the hot-spraying technique, is the important process of preparation table finishing coat.In the Supersonic Plasma Spraying technical process, can produce the plasma torch stream of higher temperature, various sprayed on material can be heated to molten condition.Not only can prepare high-quality metal and alloy coat, can also prepare dystectic pottery and metal-cermic coating, thereby greatly improve the wearability of coating.
Because described the first sensing unit and the second sensing unit have piezo-electric effect, then described sensing layer can produce the signal of telecommunication to the damage of piece surface, the smart coat that namely obtains has the function of piezoelectric transducer, can to state of wear Real Time Monitoring, the feedback of piece surface (being wearing layer), therefore need not to paste again sensor.Compare with substrate by the sensor of pasting combination with existing, the preparation method of the PbTiO3 smart coat that the application provides can avoid the poor problem of degree of adhesion between sensor and the substrate.
And, described the first sensing unit extends along first direction, described the second sensing unit extends along second direction, described a plurality of the first sensing unit and a plurality of the second sensing unit intersect mutually, be latticed, then when described wearing layer sustains damage, described a plurality of the first sensing unit and a plurality of the second sensing unit all can produce the signal of telecommunication, and the signal of telecommunication that first sensing unit nearest apart from damage position produces is the strongest, equally, the signal of telecommunication that second sensing unit nearest apart from damage position produces also is the strongest, by the detection to forceful electric power signal, can accurately locate damage position, for the state of wear of piece surface provides more, information is more conducive to monitoring and post analysis to the state of wear of piece surface more accurately.
And, be provided with insulating barrier between described a plurality of the first sensing unit and a plurality of the second sensing unit and the substrate, the signal of telecommunication that then can avoid described a plurality of the first sensing unit and a plurality of the second sensing unit to produce flows into substrate, namely avoids the loss of the signal of telecommunication, increases the detection sensitivity to damage.
As seen, when the abrasive damage of collecting Parts Surface Coating (wearing layer) or micro-fracture, the electric current that described smart coat sends can be used as characteristic signal and finishes judgement to coating borderline failure state, it namely is the continuous judgment model of the multiselect formula of " complete ... more complete ... as not lose efficacy ... borderline failure ... as to lose efficacy " to the judgment model of Parts Surface Coating state, can finish to the inefficacy evolution process of Parts Surface Coating in real time, online and dynamic the grasp, and can accurately locate abration position, for the state of wear of piece surface provides more, information is more conducive to monitoring and post analysis to the state of wear of piece surface more accurately.
Further embodiment of this invention discloses the preparation method of another smart coat, comprising:
Form insulating barrier at a substrate surface;
Form the first sensing unit and the second sensing unit at described surface of insulating layer, described the first sensing unit extends along first direction, described the second sensing unit extends along second direction, and described a plurality of the first sensing units and a plurality of the second sensing unit intersect mutually, are latticed;
Form wearing layer at described the first sensing unit, the second sensing unit and surface of insulating layer;
Form the first top electrode on described the first sensing unit surface, form the first bottom electrode at described the first sensing unit lower surface edge, described the first top electrode and the first bottom electrode are that described the first sensing unit is to the leadout electrode of the electric current of coating damage generation;
Form the second top electrode on described the second sensing unit surface, form the second bottom electrode at described the second sensing unit lower surface edge, described the second top electrode and the second bottom electrode are that described the second sensing unit is to the leadout electrode of the electric current of coating damage generation;
Oven dry, in drying course, bake out temperature is more than 120 ℃, and preferred, described bake out temperature is 120 ℃～150 ℃, and more preferably 130 ℃, drying time is preferably 20min more than 15min;
To the processing that polarizes of described the first sensing unit and the second sensing unit, make described the first sensing unit and the second sensing unit have piezo-electric effect.
Because the current value that described the first sensing unit and the second sensing unit produce is less, then described the first top electrode, the first bottom electrode, the second top electrode and the second bottom electrode are gold electrode and are preferably gold electrode, to improve electric conductivity, reduce the loss of electric current.Described the first top electrode, the first bottom electrode, the second top electrode and the second bottom electrode form by coating processes, and be more even for the thickness that makes described gold electrode, then preferably divides to apply for three times to form described gold electrode.
Need to prove, described the first top electrode, the first bottom electrode, the second top electrode and the second bottom electrode can also be selected silver electrode or aluminium electrode according to the actual requirements, concrete material is not done any restriction, in the present embodiment in order to obtain more excellent conductive capability, so select gold electrode.And described the first top electrode, the first bottom electrode, the second top electrode and the second bottom electrode all are arranged on the non-abrading section of described coating, to avoid owing to the impact of Parts Surface Coating wearing and tearing on electrode.
Further embodiment of this invention discloses the preparation method of another smart coat, comprising:
One substrate is provided, and described substrate surface is carried out preliminary treatment, obtain coarse substrate surface;
Form insulating barrier at described substrate surface;
Form a plurality of the first sensing units and a plurality of the second sensing unit at described surface of insulating layer, described the first sensing unit extends along first direction, described the second sensing unit extends along second direction, and described a plurality of the first sensing units and a plurality of the second sensing unit intersect mutually, are latticed;
Form wearing layer at described the first sensing unit, the second sensing unit and surface of insulating layer;
Form the first top electrode on described the first sensing unit surface;
Form the first bottom electrode at described the first sensing unit lower surface edge;
Form the second top electrode on described the second sensing unit surface;
Form the second bottom electrode at described the second sensing unit lower surface edge;
Oven dry, in the described drying course, bake out temperature is 120 ℃, drying time is 20min;
To the processing that polarizes of described the first sensing unit and the second sensing unit, make described the first sensing unit and the second sensing unit have piezo-electric effect.
Concrete, described substrate surface is carried out pretreated process, comprising:
Adopt blasting craft to process described substrate surface, in described blasting craft, take brown corundum as the sand material, the granularity of described brown corundum is 15 orders～30 orders, is preferably 16 orders, sandblast air pressure is 0.5MPa～1MPa, be preferably 0.7MPa, the sandblast angle is 30 °～60 °, is preferably 45 °, the sandblast distance is 130mm～160mm, is preferably 145mm.
Described preprocessing process can increase the roughness of substrate, makes the conjugation between described insulating barrier and the substrate higher.
Further embodiment of this invention discloses the preparation method of another smart coat, as shown in Figure 8, comprising:
Substrate is provided, and Quenching Treatment is carried out in described substrate, improving the hardness of described substrate, and the hardness of described substrate is reached about HRC55.
With brown corundum described substrate surface is carried out blasting treatment, make described substrate surface have certain roughness.
To alumina powder, titanium oxide powder, PbTiO3 powder and the autonomous granulation of FeCrBSi powder, make the particle diameter of described alumina powder, titanium oxide powder, PbTiO3 powder and FeCrBSi powder even, and the particle diameter of institute's alumina powder, titanium oxide powder, PbTiO3 powder and FeCrBSi powder all reach 40 μ m～70 μ m.
To put into powder feeder through alumina powder and the titanium oxide powder of autonomous granulation, and adjust powder sending quantity, making powder sending quantity is 30g/min, and above-mentioned substrate surface through blasting treatment is sprayed.
Concrete, at first at described substrate surface spray aluminum oxide and titanium oxide, form insulating barrier.In the described spraying process, spraying current is 378A, and spray voltage is 105V, and spray power is 42.6kW, and spraying main gas is argon gas, and the flow velocity of the main gas of described spraying is 3.0m
3/ h, and auxiliary with hydrogen as assist gas, and the flow velocity of described assist gas is 0.25m
3/ h, spray distance are 110mm, so that thickness of insulating layer is controlled at 60 μ m.
Cover the mask with the first sensing unit and second sensing unit figure at described surface of insulating layer, to put into powder feeder through the PbTiO3 powder of autonomous granulation, adjust powder sending quantity, making powder sending quantity is 30g/min, and the above-mentioned substrate surface that is formed with insulating barrier is sprayed.In the described spraying process, spraying current is 360A, and spray voltage is 120V, and spray power is 43.2kW, and spraying main gas is argon gas, and the flow velocity of the main gas of described spraying is 3.2m
3/ h, and auxiliary with hydrogen as assist gas, and the flow velocity of described assist gas is 0.3m
3/ h, spray distance are 100mm, so that the first sensing unit and the second sensing unit THICKNESS CONTROL are at 100 μ m.
To put into powder feeder through the FeCrBSi powder of autonomous granulation, and adjust powder sending quantity, making powder sending quantity is 30g/min, at described the first sensing unit, the second sensing unit and surface of insulating layer spraying FeCrBSi alloy wear-resisting layer.In the described spraying process, spraying current is 420A, and spray voltage is 120V, and spray power is 50.9kW, and spraying main gas is argon gas, and the flow velocity of the main gas of described spraying is 2.8m
3/ h, and auxiliary with hydrogen as assist gas, and the flow velocity of described assist gas is 0.4m
3/ h, spray distance are 100mm, so that the wearing layer THICKNESS CONTROL is at 300 μ m.
After spraying finishes, check, remove the burr at edge, the defective such as cleaning dirty.Then check one by one with the high resistant megger, with too little the picking out of resistance, can reach the polarizability of standard to guarantee the PbTiO3 sensing layer.
Filter or change insulating oil, to guarantee the cleaning of polarization groove and polarization oil and polarising sheet.The charge pin of moving coil temperature adjusting apparatus is transferred to the polarization temperature spot, by adding the thermal poling groove, make oil temperature rise to needed polarization temperature.The time relay transfers to time of needing polarization (15min～30min).To be placed between the positive and negative electrode of polarization groove by the substrate that is formed with the first sensing unit and the second sensing unit that the polarization preheating temperature is crossed, shut the door of polarization chamber.By logical rectifier part low-voltage power switch, opening high pressure switch after preheating a few minutes, at this moment, the time relay begins timing.Magnitude of voltage between the positive and negative electrode slowly raises, from 2500V, every 100V or 200V are one grade, until default value (5000V), polarization time one arrives, and the high-voltage switch gear automatic disconnection is after then polarization finishes, described the first sensing unit and the second sensing unit possess piezo-electric effect, finish the making of smart coat.
The another embodiment of the application discloses a kind of localization method based on the described smart coat of above-mentioned arbitrary embodiment, comprising:
When described wearing layer was worn damage, described a plurality of the first sensing units produced a plurality of the first detection signals, and described a plurality of the second sensing units produce a plurality of the second detection signals.
As seen from Figure 1, when the abrasive damage that occurs centered by the A point, near the A point the first sensing unit 31 and the second sensing unit 32 suffered coatings (wearing layer 4) tear or pull the stress that produces, and the stress that is subject to from the sensing unit of A point close to more is larger.Based on the characteristic of piezoelectric ceramics own, the first sensing unit 31 and the second sensing unit 32 all can produce piezoelectric current, and more are to heal large near the piezoelectric current that the sensing unit that A is ordered produces.All can produce piezoelectric current as detection signal with described the first sensing unit 31 and the second sensing unit 32, accordingly, described a plurality of the first sensing unit 31 produces a plurality of piezoelectric currents as a plurality of the first detection signals, and a plurality of piezoelectric currents that described a plurality of the second sensing units 32 produce are as a plurality of the second detection signals.
Described a plurality of the first detection signals and a plurality of the second detection signal are screened, choose the first maximum detection signal and the second maximum detection signal.
Because the piezoelectric current that the nearer sensing unit of distance A point produces is larger, be that the first nearest sensing unit 31 of distance A point can produce maximum the first detection signal, the second sensing unit 32 can produce the second maximum detection signal, therefore, just can determine the particular location that A is ordered by the second sensing unit 32 that meeting produces the first sensing unit 31 of maximum the first detection signal and produces the second maximum detection signal conversely.
First direction and second direction are put into direct coordinate system, X-direction in take described first direction as coordinate system, second direction is the Y direction in the coordinate system, then can locate the damage position of described wearing layer on second direction by the first sensing unit 31 that produces maximum the first detection signal, it is the Y coordinate that A is ordered, by producing the damage position of the second sensing unit 32 described wearing layers in location on first direction of maximum the second detection signal, be the X coordinate that A is ordered, by described wearing layer on the first direction and the damage position (the X-Y coordinate that A is ordered) on the second direction determine the damage position of described wearing layer.For the state of wear of substrate surface provides more, information more accurately, be more conducive to monitoring and post analysis to the state of wear of substrate surface.
To the above-mentioned explanation of the disclosed embodiments, make this area professional and technical personnel can realize or use the present invention.Multiple modification to these embodiment will be apparent concerning those skilled in the art, and General Principle as defined herein can in the situation that does not break away from the spirit or scope of the present invention, realize in other embodiments.Therefore, the present invention will can not be restricted to these embodiment shown in this article, but will meet the widest scope consistent with principle disclosed herein and features of novelty.
Claims (15)
1. a smart coat is characterized in that, comprising:
Substrate, described substrate are the substrate of arbitrary shape;
Insulating barrier, described insulating barrier cover on the described substrate surface;
A plurality of the first sensing units and a plurality of the second sensing unit, described the first sensing unit and the second sensing unit are arranged on the described surface of insulating layer, has piezo-electric effect, and described the first sensing unit extends along first direction, described the second sensing unit extends along second direction, described a plurality of the first sensing unit and a plurality of the second sensing unit intersect mutually, are latticed;
Wearing layer, described wearing layer cover on described the first sensing unit, the second sensing unit and the surface of insulating layer.
2. described smart coat according to claim 1 is characterized in that described first direction is mutually vertical with second direction.
3. described smart coat according to claim 1 is characterized in that the width of described the first sensing unit width and the second sensing unit is 1.5mm～2.5mm.
4. described smart coat according to claim 1 is characterized in that the distance between the distance between two adjacent the first sensing units and two adjacent the second sensing units is 3mm～4mm.
5. described smart coat according to claim 1 is characterized in that described insulating barrier is the alloy-layer of alumina layer or titanium oxide layer or aluminium oxide and titanium oxide.
6. described smart coat according to claim 1 is characterized in that the making material of described the first sensing unit and the second sensing unit is PbTiO3.
7. described smart coat according to claim 1 is characterized in that described wearing layer is the FeGrBSi layer.
8. described smart coat according to claim 1 is characterized in that, also comprises:
The first top electrode, described the first top electrode are arranged on described the first sensing unit surface;
The first bottom electrode, described the first bottom electrode are arranged on described the first sensing unit lower surface edge;
The second top electrode, described the second top electrode are arranged on described the second sensing unit surface;
The second bottom electrode, described the second bottom electrode are arranged on described the second sensing unit lower surface edge.
9. the preparation method of a smart coat is characterized in that, comprising:
Form insulating barrier at a substrate surface;
Form a plurality of the first sensing units and a plurality of the second sensing unit at described surface of insulating layer, described the first sensing unit extends along first direction, described the second sensing unit extends along second direction, and described a plurality of the first sensing units and a plurality of the second sensing unit intersect mutually, are latticed;
Form wearing layer at described the first sensing unit, the second sensing unit and surface of insulating layer;
To the processing that polarizes of described the first sensing unit and the second sensing unit, make described the first sensing unit and the second sensing unit have piezo-electric effect.
10. described method according to claim 9 is characterized in that, describedly forms insulating barrier at a substrate surface, comprising:
Form insulating barrier by Supersonic Plasma Spraying technique at described substrate surface.
11. described method is characterized in that according to claim 9, and is described at described surface of insulating layer a plurality of the first sensing units of formation and a plurality of the second sensing unit, comprising:
The mask that will have a plurality of the first sensing units and a plurality of the second sensing unit shapes covers on the described surface of insulating layer;
Form a plurality of the first sensing units and a plurality of the second sensing unit by Supersonic Plasma Spraying technique at described surface of insulating layer.
12. described method is characterized in that according to claim 9, forms wearing layer at described the first sensing unit, the second sensing unit and surface of insulating layer, comprising:
Form wearing layer by Supersonic Plasma Spraying technique at described the first sensing unit, the second sensing unit and surface of insulating layer.
13. described method is characterized in that according to claim 9, also comprises:
Form the first top electrode on described the first sensing unit surface;
Form the first bottom electrode at described the first sensing unit lower surface edge;
Form the second top electrode on described the second sensing unit surface;
Form the second bottom electrode at described the second sensing unit lower surface edge;
Oven dry.
14. described method is characterized in that according to claim 9, before a substrate surface forms insulating barrier, also comprises:
Described substrate surface is carried out preliminary treatment, obtain coarse substrate surface.
15. the localization method based on the described smart coat of claim 1～8 is characterized in that, comprising:
When described wearing layer was worn damage, described a plurality of the first sensing units produced a plurality of the first detection signals, and described a plurality of the second sensing units produce a plurality of the second detection signals;
Described a plurality of the first detection signals and a plurality of the second detection signal are screened, choose the first maximum detection signal and the second maximum detection signal;
Locate the damage position of described wearing layer on second direction by the first sensing unit that produces maximum the first detection signal;
Locate the damage position of described wearing layer on first direction by the second sensing unit that produces maximum the second detection signal;
By described wearing layer on the first direction and the damage position on the second direction determine the damage position of described wearing layer.
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| CN201210364488.7A CN102909904B (en) | 2012-09-26 | 2012-09-26 | Intelligent coating precise sensing damage and preparation method of intelligent coating |
| US14/036,794 US9046468B2 (en) | 2012-09-26 | 2013-09-25 | Smart coating and method for manufacturing the same |
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| CN201210364488.7A CN102909904B (en) | 2012-09-26 | 2012-09-26 | Intelligent coating precise sensing damage and preparation method of intelligent coating |
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| CN101561430A (en) * | 2009-05-25 | 2009-10-21 | 重庆交通大学 | System for monitoring crack of piezoelectric-array converged alertness network structure and monitoring and installing methods |
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