CN102909904B - Intelligent coating precise sensing damage and preparation method of intelligent coating - Google Patents
Intelligent coating precise sensing damage and preparation method of intelligent coating Download PDFInfo
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- CN102909904B CN102909904B CN201210364488.7A CN201210364488A CN102909904B CN 102909904 B CN102909904 B CN 102909904B CN 201210364488 A CN201210364488 A CN 201210364488A CN 102909904 B CN102909904 B CN 102909904B
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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 under arms time, if its dynamic damage cannot perception, then cannot control the state of wear of piece surface.
Current piece surface fatigue wear test mainly with the change of the factors such as vibrations, coefficient of friction, temperature as the basis for estimation assessing piece surface state of wear.When the actual value of selected factor of judgment has exceeded the threshold value preset, then illustrate that piece surface lost efficacy, then fracture analysis has been carried out to disabling elements, oppositely infer failure mechanism by experience or classical theory.But thisly can not judge the borderline failure state of piece surface based on the failure behaviour of " judge " and study mechanism afterwards, therefore dynamic cannot be set up monitor and to control the control of piece surface inefficacy machine-processed.
Because smart sensor can monitor the state of wear of piece surface in real time, therefore, piece surface arranges intelligent sensing unit and just become the first-selection of people.
Current conventional a kind of intelligent sensing unit is piezoelectric transducer, and described piezoelectric transducer utilizes the piezo-electric effect of piezoelectric to prepare.At piezoelectric transducer in the process being applied to plant equipment, need piezoelectric transducer to be pasted on equipment (or part).
But due to complex structure or the work under bad environment of some plant equipment, make the conjugation of described piezoelectric transducer and equipment room poor, the accuracy of detection causing piezoelectric transducer is poor, the problem even come 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 greatly can improve the bond strength between sensor and equipment base, and then avoids the accuracy of detection of piezoelectric transducer poor, the problem even come off.。
For achieving the above object, the invention provides following technical scheme:
A kind of smart coat, comprising:
Substrate, described substrate is the substrate of arbitrary shape;
Insulating barrier, described insulating barrier covers on described substrate surface;
Multiple first sensing unit and multiple second sensing unit, described first sensing unit and the second sensing unit are arranged on described surface of insulating layer, there is piezo-electric effect, and described first sensing unit extends along first direction, described second sensing unit extends along second direction, described multiple first sensing unit and multiple second sensing unit intersect, mutually in latticed;
Wearing layer, described wearing layer covers on described first sensing unit, the second sensing unit and surface of insulating layer.
Preferably, described first direction and second direction are mutually vertical.
Preferably, the width of described first sensing unit width and the second sensing unit is 1.5mm ~ 2.5mm.
Preferably, the distance between two the second sensing units that the Distance geometry between two adjacent the first sensing units is adjacent 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 first sensing unit and the second sensing unit is PbTiO3.
Preferably, described wearing layer is FeGrBSi layer.
Preferably, described smart coat also comprises:
First top electrode, described first top electrode is arranged on described first sensing unit on the surface;
First bottom electrode, described first bottom electrode is arranged on described first sensing unit lower surface edge;
Second top electrode, described second top electrode is arranged on described second sensing unit on the surface;
Second bottom electrode, described second bottom electrode is arranged on described second sensing unit lower surface edge.
A preparation method for smart coat, comprising:
A substrate surface forms insulating barrier;
Described surface of insulating layer is formed multiple first sensing unit and multiple second sensing unit, described first sensing unit extends along first direction, described second sensing unit extends along second direction, and described multiple first sensing unit and multiple second sensing unit intersect, mutually in latticed;
Described first sensing unit, the second sensing unit and surface of insulating layer form wearing layer;
Polarization process is carried out to described first sensing unit and the second sensing unit, makes described first sensing unit and the second sensing unit have piezo-electric effect.
Preferably, describedly on a substrate surface, form insulating barrier, comprising:
On described substrate surface, insulating barrier is formed by Supersonic Plasma Spraying technique.
Preferably, describedly on described surface of insulating layer, form multiple first sensing unit and multiple second sensing unit, comprising:
The mask with multiple first sensing unit and multiple second sensing unit shape is covered on described surface of insulating layer;
On described surface of insulating layer, multiple first sensing unit and multiple second sensing unit is formed by Supersonic Plasma Spraying technique.
Preferably, described first sensing unit, the second sensing unit and surface of insulating layer form wearing layer, comprising:
On described first sensing unit, the second sensing unit and surface of insulating layer, wearing layer is formed by Supersonic Plasma Spraying technique.
Preferably, described method also comprises:
The first top electrode is formed on the surface at described first sensing unit;
The first bottom electrode is formed at described first sensing unit lower surface edge;
The second top electrode is formed on the surface at described second sensing unit;
The second bottom electrode is formed at described second sensing unit lower surface edge;
Dry.
Preferably, before a substrate surface forms insulating barrier, also comprise:
Pretreatment is carried out to described substrate surface, obtains coarse substrate surface.
Based on a localization method for above-mentioned smart coat, comprising:
When described wearing layer is worn damage, described multiple first sensing unit produces multiple first detection signal, and described multiple second sensing unit produces multiple second detection signal;
Described multiple first detection signal and multiple second detection signal are screened, chooses the first maximum detection signal and the second maximum detection signal;
Described wearing layer damage position is in a second direction located by the first sensing unit producing maximum first detection signal;
Described wearing layer damage position is in a first direction located by the second sensing unit producing maximum second detection signal;
The damage position of described wearing layer is determined with the damage position in second direction in a first direction by described wearing layer.Multiple first sensing unit and multiple second sensing unit of the smart coat provided due to the application have piezo-electric effect, wear-resisting layer covering on described first sensing unit, the second sensing unit and surface of insulating layer, then can the state of wear of piece surface (i.e. wearing layer) be monitored in real time, be fed back, therefore without the need to pasting sensor again, compare with substrate by pasting the sensor combined with existing, the smart coat that the application provides can avoid the problem of degree of adhesion difference between sensor and substrate.
And described first sensing unit extends along first direction, described second sensing unit extends along second direction, described multiple first sensing unit and multiple second sensing unit intersect mutually, in latticed, then when described wearing layer sustains damage, described multiple first sensing unit and multiple 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 most forceful electric power signal, can accurate orientated damage position, state of wear for piece surface provides more, information more accurately, be more conducive to the monitoring to the state of wear of piece surface and post analysis.
Accompanying drawing explanation
In order to be illustrated more clearly in the embodiment of the present invention or technical scheme of the prior art, be briefly described to the accompanying drawing used required in embodiment or description of the prior art below, apparently, accompanying drawing in the following describes is only some embodiments of the present invention, for those of ordinary skill in the art, under the prerequisite not paying creative work, other accompanying drawing can also be obtained according to these accompanying drawings.
The top view of a kind of smart coat that Fig. 1 provides for the embodiment of the present invention;
A kind of smart coat that Fig. 2 provides for the embodiment of the present invention is along the profile of B-B ' line;
The schematic flow sheet of a kind of smart coat preparation method that Fig. 3 provides for the embodiment of the present invention.
Detailed description of the invention
For enabling above-mentioned purpose of the present invention, feature and advantage become apparent more, are described in detail the specific embodiment of the present invention below in conjunction with accompanying drawing.
Set forth a lot of detail 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 to implement, those skilled in the art can when without prejudice to doing similar popularization when intension of the present invention, therefore the present invention is by the restriction of following public specific embodiment.
The embodiment of the invention discloses a kind of smart coat, as shown in Fig. 1 (conveniently check in Fig. 1, represented by dashed line go out the extension line of the first sensing unit and the second sensing unit) and Fig. 2, comprising:
Substrate 1, described substrate 1 is the substrate of arbitrary shape, the i.e. part that can have any shape of described substrate 1, being preferably described substrate is metallic substrates, be more preferably 45# steel, namely described substrate can be the moving parts of steam turbines, compressor, pump, also can be the parts such as gear, axle, piston pin (part need through high frequency or flame surface quenching), and can be foundry goods; Or described substrate is copper substrate or aluminium substrate, to adapt to the parts of other applications.
Insulating barrier 2, described insulating barrier 2 covers described substrate 1 on the surface, and described insulating barrier 2 is preferably the alloy-layer of alumina layer or titanium oxide layer or aluminium oxide and titanium oxide.
Multiple first sensing unit 31 and multiple second sensing unit 32, described first sensing unit 31 and the second sensing unit 32 are positioned at same layer, are arranged on described insulating barrier 2 on the surface.And described first sensing unit 31 extends along first direction, in 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, the width of the white space namely between described two adjacent the first sensing units 31 is about 3mm.Described second sensing unit 32 extends along second direction, in strip, width is 1.5mm ~ 2.5mm, be preferably 2mm, distance between two second adjacent sense unit 32 is 3mm ~ 4mm, be preferably 3.5mm, the width of the white space namely between described two adjacent the second sensing units 32 is about 3mm.Described first direction and second direction are mutually vertical, or are bordering on vertical, namely mutually intersect, in latticed between described first sensing unit 31 and the second sensing unit 32.Wherein, the part exposing described insulating barrier 2 is rectangular, and the four limit length of sides of described rectangle are any number between 3mm or 2.5mm ~ 3.5mm.Described first sensing unit 31 and the second sensing unit 32 are for having the unit of piezo-electric effect, and it makes material and is preferably piezoelectric ceramics, is more preferably PbTiO3 or BaTiO3 or PZT.
Wearing layer 4, described wearing layer 4 covers described first sensing unit 31, second sensing unit 32 and insulating barrier 2 on the surface, and described wearing layer is 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 using described FeCrBSi alloy as the making material of wearing layer 4, further can increase the wearability of piece surface, and difficult drop-off.
Multiple first sensing unit 31 and multiple second sensing unit 32 of the smart coat provided due to the embodiment of the present application have piezo-electric effect, in described first sensing unit 31, second sensing unit 32 and insulation 2 layers wear-resisting layer covering 4 on the surface, then can the state of wear of piece surface (i.e. wearing layer 4) be monitored in real time, be fed back, therefore without the need to pasting sensor again, compare with substrate by pasting the sensor combined with existing, the smart coat that the application provides can avoid the problem of degree of adhesion difference between sensor and part.
And, described first sensing unit 31 extends along first direction, described second sensing unit 32 extends along second direction, described multiple first sensing unit 31 and multiple second sensing unit 32 intersect mutually, in latticed, then when described wearing layer 4 sustains damage, described multiple first sensing unit 31 and multiple 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 most forceful electric power signal, can accurate orientated damage position, state of wear for piece surface provides more, information more accurately, be more conducive to the monitoring to the state of wear of piece surface and post analysis.
And, described multiple first sensing unit 31 and be provided with insulating barrier 2 between multiple second sensing unit 32 and substrate 1, the signal of telecommunication that described multiple first sensing unit 31 and multiple second sensing unit 32 then can be avoided to produce flows into substrate 1, namely avoid the loss of the signal of telecommunication, increase the detection sensitivity to damage.
Visible, when collecting abrasive damage or the micro-fracture of Parts Surface Coating (wearing layer 4), the judgement that the electric current that described smart coat sends can come coating borderline failure state as characteristic signal, namely be the continuous judgment model of the multiselect formula of " complete ... more complete ... not lose efficacy ... borderline failure ... to lose efficacy " to the judgment model of Parts Surface Coating state, what can complete the inefficacy evolution process of Parts Surface Coating is real-time, online and dynamic grasp, and accurately can locate abration position, state of wear for piece surface provides more, information more accurately, be more conducive to the monitoring to the state of wear of piece surface and post analysis.
In addition, described smart coat also comprises:
First top electrode 51, described first top electrode 51 is arranged on described first sensing unit 31 on the surface, first bottom electrode 52, described first bottom electrode 52 is arranged on described first sensing unit 31 lower surface edge, and described first top electrode 51 and the first bottom electrode 52 are the leadout electrode of the electric current that described first sensing unit 31 pairs of coating damages produce.
Second top electrode 53, described second top electrode 53 is arranged on described second sensing unit 32 on the surface, second bottom electrode 54, described second bottom electrode 54 is arranged on described second sensing unit 32 lower surface edge, and described second top electrode 53 and the second bottom electrode 54 are the leadout electrode of the electric current that described second sensing unit 32 pairs of coating damages produce.
In addition, described first top electrode 51, first bottom electrode 52, second top electrode 53 and the second bottom electrode 54 also need connecting lead wire, to be derived by described electric current.
Preferably, described first top electrode 51, first bottom electrode 52, second top electrode 53 and the second bottom electrode 54 are gold electrode, to improve electric conductivity, reduce the loss of electric current.Further, described first top electrode 51, first bottom electrode 52, second top electrode 53 and the second bottom electrode 54 are all arranged on the non-abrading section of described coating, to avoid due 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:
A substrate surface forms insulating barrier.
Described substrate is the substrate of arbitrary shape, the i.e. part that can have any shape of described substrate, being preferably described substrate is metallic substrates, be more preferably 45# steel, namely described substrate can be the moving parts of steam turbines, compressor, pump, also can be the parts such as gear, axle, piston pin (part need through high frequency or flame surface quenching), and can be foundry goods; Or described substrate is copper substrate or aluminium substrate, to adapt to the parts of other applications.
Described surface of insulating layer is formed multiple first sensing unit and multiple second sensing unit, described first sensing unit extends along first direction, described second sensing unit extends along second direction, and described multiple first sensing unit and multiple second sensing unit intersect, mutually in latticed.
Described first sensing unit, the second sensing unit and surface of insulating layer form wearing layer.
Polarization process is carried out to described first sensing unit and the second sensing unit, makes described first sensing unit and the second sensing unit have piezo-electric effect, complete the making of described smart coat.
Because described 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, namely the smart coat obtained has the function of piezoelectric transducer, can the state of wear of piece surface (i.e. wearing layer) be monitored in real time, be fed back, therefore without the need to pasting sensor again.Compare with substrate by pasting the sensor combined with existing, the preparation method of the PbTiO3 smart coat that the application provides can avoid the problem of degree of adhesion difference between sensor and substrate.
And, described first sensing unit extends along first direction, described second sensing unit extends along second direction, described multiple first sensing unit and multiple second sensing unit intersect mutually, in latticed, then when described wearing layer sustains damage, described multiple first sensing unit and multiple 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 most forceful electric power signal, can accurate orientated damage position, state of wear for piece surface provides more, information more accurately, be more conducive to the monitoring to the state of wear of piece surface and post analysis.
And, described multiple first sensing unit and be provided with insulating barrier between multiple second sensing unit and substrate, the signal of telecommunication that described multiple first sensing unit and multiple second sensing unit then can be avoided to produce flows into substrate, namely avoids the loss of the signal of telecommunication, increases the detection sensitivity to damage.
Visible, when collecting abrasive damage or the micro-fracture of Parts Surface Coating (wearing layer), the judgement that the electric current that described smart coat sends can come coating borderline failure state as characteristic signal, namely be the continuous judgment model of the multiselect formula of " complete ... more complete ... not lose efficacy ... borderline failure ... to lose efficacy " to the judgment model of Parts Surface Coating state, what can complete the inefficacy evolution process of Parts Surface Coating is real-time, online and dynamic grasp, and accurately can locate abration position, state of wear for piece surface provides more, information more accurately, be more conducive to the monitoring to the state of wear of piece surface and post analysis.
Another embodiment of the present invention discloses the preparation method of another kind of smart coat, comprising:
A 45# steel substrate surface forms insulating barrier, described surface of insulating layer is formed the first sensing unit and the second sensing unit, the thickness of described first sensing unit and the second sensing unit is below 150 μm, preferably, the thickness of described first sensing unit and the second sensing unit is 100 μm or less, at described first sensing unit, second sensing unit and surface of insulating layer form wearing layer, the thickness of described wearing layer is also 100 μm or less, then can in occasion part thickness being had to particular/special requirement, the part of described smart coat is applied and becomes possibility.
Polarization process is carried out to described first sensing unit and the second sensing unit, makes described 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:
In a metal substrate surface, form insulating barrier by Supersonic Plasma Spraying technique, 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, comprising:
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 with multiple first sensing unit and multiple second sensing unit shape is covered on described surface of insulating layer, on described surface of insulating layer, forms multiple first sensing unit and multiple second sensing unit by Supersonic Plasma Spraying technique.
In the present embodiment, the making material of described first sensing unit and the second sensing unit is piezoelectric ceramics, is preferably PbTiO3.By Supersonic Plasma Spraying technique, PbTiO3 being sprayed to surface of insulating layer, finally not formed the first sensing unit and the second sensing unit by the position that mask blocks, can expose insulating barrier in the position of being blocked by mask.
Form the Supersonic Plasma Spraying technique of described multiple first sensing unit and multiple second sensing unit, 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 insulating barrier, then have very strong conjugation between described PbTiO3 sensing layer and insulating barrier.And also have very strong conjugation between described insulating barrier and substrate.Accordingly, the combination between described PbTiO3 sensing layer and substrate can be more firm.
In addition, the first sensing unit and the second sensing unit can also be formed by chemical vapor deposition method on described surface of insulating layer.
Wherein, depositing temperature is 900 DEG C ~ 1150 DEG C, and be preferably 100 DEG C, sedimentation time is 4h ~ 8h, and be preferably 6h, depositional environment pressure is 6KPa ~ 15KPa, is preferably 10KPa.
On described first sensing unit, the second sensing unit and surface of insulating layer, wearing layer is formed by Supersonic Plasma Spraying technique.
Concrete, in the present embodiment, on described first sensing unit, the second sensing unit and surface of insulating layer, form wearing layer by Supersonic Plasma Spraying technique, comprising:
Spray voltage is 110V ~ 130V, and be preferably 120V, spraying current is 410A ~ 430A, and be preferably 420A, spray power is 40kW ~ 55kW, and be preferably 48kW, spray distance is 90mm ~ 100mm, is preferably 95mm.
Due to FeCrBSi alloy low price, and wearability is good, so using described FeCrBSi alloy as the making material of wearing layer, further can increase the wearability of piece surface, and difficult drop-off.
Polarization process is carried out to described first sensing unit and the second sensing unit, makes described first sensing unit and the second sensing unit have piezo-electric effect, comprising:
Described first sensing unit and the second sensing unit are put into polarized electric field, poling temperature is 180 DEG C ~ 200 DEG C, be preferably 190 DEG C, polarized electric field intensity is 2.4KV/mm ~ 2.6KV/mm, is preferably 2.5KV/mm, to described first sensing unit and the second sensing unit polarization process, duration is not less than 15min, preferably, the duration is 15min ~ 20min, is more preferably 18min.
It should be noted that, Supersonic Plasma Spraying technique belongs to the one in hot-spraying technique, is the important process of preparation table finishing coat.By in Supersonic Plasma Spraying technical process, the plasma torch stream of higher temperature can be produced, various sprayed on material can be heated to molten condition.Not only can prepare high-quality metal and alloy coat, dystectic pottery and metal-cermic coating can also be prepared, thus greatly improve the wearability of coating.
Because described 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, namely the smart coat obtained has the function of piezoelectric transducer, can the state of wear of piece surface (i.e. wearing layer) be monitored in real time, be fed back, therefore without the need to pasting sensor again.Compare with substrate by pasting the sensor combined with existing, the preparation method of the PbTiO3 smart coat that the application provides can avoid the problem of degree of adhesion difference between sensor and substrate.
And, described first sensing unit extends along first direction, described second sensing unit extends along second direction, described multiple first sensing unit and multiple second sensing unit intersect mutually, in latticed, then when described wearing layer sustains damage, described multiple first sensing unit and multiple 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 most forceful electric power signal, can accurate orientated damage position, state of wear for piece surface provides more, information more accurately, be more conducive to the monitoring to the state of wear of piece surface and post analysis.
And, described multiple first sensing unit and be provided with insulating barrier between multiple second sensing unit and substrate, the signal of telecommunication that described multiple first sensing unit and multiple second sensing unit then can be avoided to produce flows into substrate, namely avoids the loss of the signal of telecommunication, increases the detection sensitivity to damage.
Visible, when collecting abrasive damage or the micro-fracture of Parts Surface Coating (wearing layer), the judgement that the electric current that described smart coat sends can come coating borderline failure state as characteristic signal, namely be the continuous judgment model of the multiselect formula of " complete ... more complete ... not lose efficacy ... borderline failure ... to lose efficacy " to the judgment model of Parts Surface Coating state, what can complete the inefficacy evolution process of Parts Surface Coating is real-time, online and dynamic grasp, and accurately can locate abration position, state of wear for piece surface provides more, information more accurately, be more conducive to the monitoring to the state of wear of piece surface and post analysis.
Further embodiment of this invention discloses the preparation method of another smart coat, comprising:
A substrate surface forms insulating barrier;
Described surface of insulating layer is formed the first sensing unit and the second sensing unit, described first sensing unit extends along first direction, described second sensing unit extends along second direction, and described multiple first sensing unit and multiple second sensing unit intersect, mutually in latticed;
Described first sensing unit, the second sensing unit and surface of insulating layer form wearing layer;
Form the first top electrode on the surface at described first sensing unit, form the first bottom electrode at described first sensing unit lower surface edge, described first top electrode and the first bottom electrode are that described first sensing unit is to the leadout electrode of the electric current that coating damage produces;
Form the second top electrode on the surface at described second sensing unit, form the second bottom electrode at described second sensing unit lower surface edge, described second top electrode and the second bottom electrode are that described second sensing unit is to the leadout electrode of the electric current that coating damage produces;
Dry, in drying course, bake out temperature is more than 120 DEG C, and preferably, described bake out temperature is 120 DEG C ~ 150 DEG C, is more preferably 130 DEG C, and drying time, at more than 15min, is preferably 20min;
Polarization process is carried out to described first sensing unit and the second sensing unit, makes described first sensing unit and the second sensing unit have piezo-electric effect.
The current value produced due to described first sensing unit and the second sensing unit is less, then described 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, reduces the loss of electric current.Described first top electrode, the first bottom electrode, the second top electrode and the second bottom electrode are formed by coating processes, in order to make described gold electrode thickness evenly, then preferably divide three times apply formed described gold electrodes.
It should be noted that, described first top electrode, the first bottom electrode, the second top electrode and the second bottom electrode can also select silver electrode or aluminium electrode according to the actual requirements, concrete material does not do any restriction, in order to obtain more excellent conductive capability in the present embodiment, therefore selects gold electrode.Further, described first top electrode, the first bottom electrode, the second top electrode and the second bottom electrode are all arranged on the non-abrading section of described coating, to avoid due 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 pretreatment is carried out to described substrate surface, obtain coarse substrate surface;
Described substrate surface forms insulating barrier;
Described surface of insulating layer is formed multiple first sensing unit and multiple second sensing unit, described first sensing unit extends along first direction, described second sensing unit extends along second direction, and described multiple first sensing unit and multiple second sensing unit intersect, mutually in latticed;
Described first sensing unit, the second sensing unit and surface of insulating layer form wearing layer;
The first top electrode is formed on the surface at described first sensing unit;
The first bottom electrode is formed at described first sensing unit lower surface edge;
The second top electrode is formed on the surface at described second sensing unit;
The second bottom electrode is formed at described second sensing unit lower surface edge;
Dry, in described drying course, bake out temperature is 120 DEG C, and drying time is 20min;
Polarization process is carried out to described first sensing unit and the second sensing unit, makes described first sensing unit and the second sensing unit have piezo-electric effect.
Concrete, pretreated process is carried out to described substrate surface, comprising:
Adopt substrate surface described in blasting craft process, in described blasting craft, take Brown Alundum as sand material, the granularity of described Brown Alundum is 15 order ~ 30 orders, is preferably 16 orders, sandblasting air pressure is 0.5MPa ~ 1MPa, be preferably 0.7MPa, sandblasting angle is 30 ° ~ 60 °, is preferably 45 °, sandblasting distance is 130mm ~ 160mm, is preferably 145mm.
Described preprocessing process can increase the roughness of substrate, makes the conjugation between described insulating barrier and substrate higher.
Further embodiment of this invention discloses the preparation method of another smart coat, as shown in the figure, comprising:
Substrate is provided, and Quenching Treatment is carried out to described substrate, to improve the hardness of described substrate, and make the hardness of described substrate reach about HRC55.
With Brown Alundum, blasting treatment is carried out to described substrate surface, make described substrate surface have certain roughness.
To alumina powder, titanium oxide powder, PbTiO3 powder and the autonomous granulation of FeCrBSi powder, make the uniform particle sizes of described alumina powder, titanium oxide powder, PbTiO3 powder and FeCrBSi powder, and the particle diameter of institute's alumina powder, titanium oxide powder, PbTiO3 powder and FeCrBSi powder all reaches 40 μm ~ 70 μm.
Put into powder feeder by through the alumina powder of autonomous granulation and titanium oxide powder, adjustment powder sending quantity, makes powder sending quantity be 30g/min, sprays the above-mentioned substrate surface through blasting treatment.
Concrete, first at described substrate surface spray aluminum oxide and titanium oxide, form insulating barrier.In 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 using hydrogen as assist gas, and the flow velocity of described assist gas is 0.25m
3/ h, spray distance is 110mm, and thickness of insulating layer is controlled at 60 μm.
The mask with the first sensing unit and the second sensing unit figure is covered at described surface of insulating layer, PbTiO3 powder through autonomous granulation is put into powder feeder, adjustment powder sending quantity, makes powder sending quantity be 30g/min, sprays the above-mentioned substrate surface being formed with insulating barrier.In 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 using hydrogen as assist gas, and the flow velocity of described assist gas is 0.3m
3/ h, spray distance is 100mm, makes the first sensing unit and the second sensing unit THICKNESS CONTROL at 100 μm.
FeCrBSi powder through autonomous granulation is put into powder feeder, and adjustment powder sending quantity, makes powder sending quantity be 30g/min, described first sensing unit, the second sensing unit and surface of insulating layer sprays FeCrBSi alloy wear-resisting layer.In 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 using hydrogen as assist gas, and the flow velocity of described assist gas is 0.4m
3/ h, spray distance is 100mm, makes wearing layer THICKNESS CONTROL at 300 μm.
After spraying terminates, check, remove the burr at edge, the defect such as cleaning dirty.Then check one by one with high resistant megger, by too little the picking out of resistance, to ensure that PbTiO3 sensing layer can reach the polarizability of standard.
Filter or change insulating oil, clean with ensure to polarize groove and polarization oil and polarising sheet.The charge pin of moving coil temperature adjusting apparatus being adjusted to poling temperature point, by adding thermal poling groove, making oil temperature rise to required poling temperature.The time relay is adjusted to the time (15min ~ 30min) needing polarization.The substrate that be formed with first sensing unit and second sensing unit preheated by poling temperature is placed on polarization groove positive and negative electrode between, shut polarization room door.By logical rectifier part low-voltage power switch, preheating opens high-voltage switch gear after a few minutes, and now, the time relay starts timing.Raise the magnitude of voltage between positive and negative electrode slowly, from 2500V, every 100V or 200V is one grade, until default value (5000V), polarization time one arrives, and high-voltage switch gear disconnects automatically, then after polarization terminates, described first sensing unit and the second sensing unit possess piezo-electric effect, complete the making of smart coat.
The another embodiment of the application discloses a kind of localization method based on smart coat described in above-mentioned any embodiment, comprising:
When described wearing layer is worn damage, described multiple first sensing unit produces multiple first detection signal, and described multiple second sensing unit produces multiple second detection signal.
As seen from Figure 1, when there is the abrasive damage centered by A point, near A point the first sensing unit 31 and coating (wearing layer 4) suffered by the second sensing unit 32 tear or pull produced stress, and from A point more close to the stress that is subject to of sensing unit larger.Based on characteristic of piezoelectric ceramics itself, the first sensing unit 31 and the second sensing unit 32 all can produce piezoelectric current, and are more that the piezoelectric current that produces near the sensing unit of A point is larger.Piezoelectric current all can be produced as detection signal using described first sensing unit 31 and the second sensing unit 32, accordingly, described multiple first sensing unit 31 produces multiple piezoelectric current as multiple first detection signal, and multiple piezoelectric currents that described multiple second sensing unit 32 produces are as multiple second detection signal.
Described multiple first detection signal and multiple second detection signal are screened, chooses the first maximum detection signal and the second maximum detection signal.
The piezoelectric current produced due to the sensing unit that distance A point is nearer is larger, namely the first sensing unit 31 that distance A point is nearest can produce maximum first detection signal, second sensing unit 32 can produce the second maximum detection signal, therefore, conversely just by first sensing unit 31 that can produce maximum first detection signal and produce the second maximum detection signal the second sensing unit 32 to determine the particular location of A point.
First direction and second direction are put into direct coordinate system, with described first direction for the X-direction in coordinate system, second direction is the Y direction in coordinate system, the first sensing unit 31 then by producing maximum first detection signal can locate described wearing layer damage position in a second direction, the i.e. Y-coordinate of A point, described wearing layer damage position is in a first direction located by the second sensing unit 32 producing maximum second detection signal, the i.e. X-coordinate of A point, the damage position of described wearing layer is determined with the damage position (the X-Y coordinate of A point) in second direction in a first direction by described wearing layer.State of wear for substrate surface provides more, information more accurately, is more conducive to the monitoring to the state of wear of substrate surface and post analysis.
To the above-mentioned explanation of the disclosed embodiments, professional and technical personnel in the field are realized or uses the present invention.To be apparent for those skilled in the art to the multiple amendment of these embodiments, General Principle as defined herein can without departing from the spirit or scope of the present invention, realize in other embodiments.Therefore, the present invention can not be restricted to these embodiments 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 is the substrate of arbitrary shape;
Insulating barrier, described insulating barrier covers on described substrate surface;
Multiple first sensing unit made by piezoceramic material and multiple second sensing unit, described first sensing unit and the second sensing unit are arranged on described surface of insulating layer, there is piezo-electric effect, and described first sensing unit extends along first direction, described second sensing unit extends along second direction, described multiple first sensing unit and multiple second sensing unit intersect, mutually in latticed;
Wearing layer, described wearing layer covers on described first sensing unit, the second sensing unit and surface of insulating layer.
2. smart coat according to claim 1, it is characterized in that, described first direction and second direction are mutually vertical.
3. smart coat according to claim 1, it is characterized in that, the width of described first sensing unit width and the second sensing unit is 1.5mm ~ 2.5mm.
4. smart coat according to claim 1, it is characterized in that, the distance between two the second sensing units that the Distance geometry between two adjacent the first sensing units is adjacent is 3mm ~ 4mm.
5. smart coat according to claim 1, it 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. smart coat according to claim 1, it is characterized in that, the making material of described first sensing unit and the second sensing unit is PbTiO3.
7. smart coat according to claim 1, it is characterized in that, described wearing layer is FeGrBSi layer.
8. smart coat according to claim 1, is characterized in that, also comprise:
First top electrode, described first top electrode is arranged on described first sensing unit on the surface;
First bottom electrode, described first bottom electrode is arranged on described first sensing unit lower surface edge;
Second top electrode, described second top electrode is arranged on described second sensing unit on the surface;
Second bottom electrode, described second bottom electrode is arranged on described second sensing unit lower surface edge.
9. a preparation method for smart coat, is characterized in that, comprising:
A substrate surface forms insulating barrier;
Described surface of insulating layer is formed multiple first sensing unit and multiple second sensing unit that are made by piezoceramic material, described first sensing unit extends along first direction, described second sensing unit extends along second direction, described multiple first sensing unit and multiple second sensing unit intersect, mutually in latticed;
Described first sensing unit, the second sensing unit and surface of insulating layer form wearing layer;
Polarization process is carried out to described first sensing unit and the second sensing unit, makes described first sensing unit and the second sensing unit have piezo-electric effect.
10. method according to claim 9, is characterized in that, describedly on a substrate surface, forms insulating barrier, comprising:
On described substrate surface, insulating barrier is formed by Supersonic Plasma Spraying technique.
11. methods according to claim 9, is characterized in that, describedly on described surface of insulating layer, form multiple first sensing unit and multiple second sensing unit, comprising:
The mask with multiple first sensing unit and multiple second sensing unit shape is covered on described surface of insulating layer;
On described surface of insulating layer, multiple first sensing unit and multiple second sensing unit is formed by Supersonic Plasma Spraying technique.
12. methods according to claim 9, is characterized in that, described first sensing unit, the second sensing unit and surface of insulating layer form wearing layer, comprising:
On described first sensing unit, the second sensing unit and surface of insulating layer, wearing layer is formed by Supersonic Plasma Spraying technique.
13. methods according to claim 9, is characterized in that, also comprise:
The first top electrode is formed on the surface at described first sensing unit;
The first bottom electrode is formed at described first sensing unit lower surface edge;
The second top electrode is formed on the surface at described second sensing unit;
The second bottom electrode is formed at described second sensing unit lower surface edge;
Dry.
14. methods according to claim 9, is characterized in that, before a substrate surface forms insulating barrier, also comprise:
Pretreatment is carried out to described substrate surface, obtains coarse substrate surface.
15. 1 kinds, based on the localization method of smart coat described in any one of claim 1 ~ 8, is characterized in that, comprising:
When described wearing layer is worn damage, described multiple first sensing unit produces multiple first detection signal, and described multiple second sensing unit produces multiple second detection signal;
Described multiple first detection signal and multiple second detection signal are screened, chooses the first maximum detection signal and the second maximum detection signal;
Described wearing layer damage position is in a second direction located by the first sensing unit producing maximum first detection signal;
Described wearing layer damage position is in a first direction located by the second sensing unit producing maximum second detection signal;
The damage position of described wearing layer is determined with the damage position in second direction in a first direction by 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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| CN1928539A (en) * | 2006-09-12 | 2007-03-14 | 吕志刚 | Damage detection information smart coat with subsidiary damage feature |
| 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 |
| CN102179969A (en) * | 2010-12-21 | 2011-09-14 | 苏州雅典娜科技有限公司 | Structure and method for accurately measuring stress in thermal barrier coating |
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| DE10238938B4 (en) * | 2002-08-24 | 2004-07-29 | Robert Bosch Gmbh | Process for producing a layer system and use of the process |
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| CN1928539A (en) * | 2006-09-12 | 2007-03-14 | 吕志刚 | Damage detection information smart coat with subsidiary damage feature |
| 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 |
| CN102179969A (en) * | 2010-12-21 | 2011-09-14 | 苏州雅典娜科技有限公司 | Structure and method for accurately measuring stress in thermal barrier coating |
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