CN108435525B - Method for separating bonding layer and ceramic layer powder from thermal barrier coating spraying waste powder - Google Patents
Method for separating bonding layer and ceramic layer powder from thermal barrier coating spraying waste powder Download PDFInfo
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- CN108435525B CN108435525B CN201810190688.2A CN201810190688A CN108435525B CN 108435525 B CN108435525 B CN 108435525B CN 201810190688 A CN201810190688 A CN 201810190688A CN 108435525 B CN108435525 B CN 108435525B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B07—SEPARATING SOLIDS FROM SOLIDS; SORTING
- B07B—SEPARATING SOLIDS FROM SOLIDS BY SIEVING, SCREENING, SIFTING OR BY USING GAS CURRENTS; SEPARATING BY OTHER DRY METHODS APPLICABLE TO BULK MATERIAL, e.g. LOOSE ARTICLES FIT TO BE HANDLED LIKE BULK MATERIAL
- B07B1/00—Sieving, screening, sifting, or sorting solid materials using networks, gratings, grids, or the like
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B03—SEPARATION OF SOLID MATERIALS USING LIQUIDS OR USING PNEUMATIC TABLES OR JIGS; MAGNETIC OR ELECTROSTATIC SEPARATION OF SOLID MATERIALS FROM SOLID MATERIALS OR FLUIDS; SEPARATION BY HIGH-VOLTAGE ELECTRIC FIELDS
- B03C—MAGNETIC OR ELECTROSTATIC SEPARATION OF SOLID MATERIALS FROM SOLID MATERIALS OR FLUIDS; SEPARATION BY HIGH-VOLTAGE ELECTRIC FIELDS
- B03C1/00—Magnetic separation
- B03C1/02—Magnetic separation acting directly on the substance being separated
Abstract
The invention discloses a method for separating bonding layer powder and ceramic layer powder from thermal barrier coating spraying waste powder. Firstly, screening powder particles in different particle size distribution ranges by using vibrating screens with different meshes on the collected waste powder, and removing large particles and fine particles according to the particle size ranges of the bonding layer powder and the ceramic layer powder; then, according to the fact that different powder particles have different magnetism, the remaining powder particles are separated through paramagnetic separation of a magnetic separator, and the separated powder particles are made of magnetic materials and non-magnetic materials; then, the nonmagnetic material is also separated into a diamagnetic material and a nonmagnetic material by the same diamagnetic separation method. Wherein the diamagnetic material is a high-purity bonding layer material, and the non-diamagnetic material is a ceramic layer material. The method separates the spraying waste powder generated in the preparation process of the thermal barrier coating, not only can reduce the preparation cost of the coating, but also is environment-friendly and has obvious economic value, can be applied to the separation of the thermal barrier coating powder and has important engineering application value.
Description
Technical Field
The invention belongs to the field of coating powder separation, and particularly relates to a method for separating bonding layer powder and ceramic layer powder from thermal barrier coating spraying waste powder.
Background
Thermal barrier coatings are high temperature protective coatings used on blades of advanced aircraft engines, gas turbines, and the like. For aeroengines, thermal barrier coatings have the characteristics of improving the working temperature and corrosion resistance, reducing the amount of cooling air, prolonging the working life, reducing the oil consumption rate, simplifying the structure and the like, so the thermal barrier coatings have long become important high-temperature protection technologies for hot end parts of aeroengines. Thermal barrier coatings are generally composed of a top ceramic layer and an intermediate bonding layer, and are prepared by using techniques such as Atmospheric Plasma Spraying (APS) or electron beam physical vapor deposition (EB-PVD).
According to measurement and calculation, the total market space of China civil aircraft engines, military aircraft engines, naval gas turbines, industrial gas turbines and aircraft engine package transferring services is about 2.7 trillion yuan, which corresponds to about 1350 trillion yuan of average annual market space, and the domestic market space of aircraft engines is huge. Market space for military aircraft engines is expected to add up to 5600 billion dollars in the future 20 years.
With the continuous development of the whole aviation market and the gas turbine market, the problem of waste of the spray powder in the preparation process of the thermal barrier coating also draws wide attention of people. In a common 8YSZ thermal barrier coating, the bonding layer material is MCrAlY (M is Fe, Co, Ni or Ni-Co), the ceramic layer is yttrium-stabilized zirconia ceramic, molten bonding layer powder and ceramic layer powder impact a high-temperature alloy substrate at a certain speed at a high temperature of plasma flame flow, impact and spread on the substrate, splash is generated at a small part, a layer sheet is formed by solidification, and the layer sheet is continuously accumulated to finally form the coating. During the deposition of the layer on the coating, part of the bonding layer material is oxidized to generate various bonding layer oxides, and part of the ceramic layer material and the bonding layer material are not deposited on the workpiece. Whether Atmospheric Plasma Spraying (APS) or electron beam physical vapor deposition (EB-PVD) is adopted, the deposition rate of the coating is between 40 and 70 percent, and powder which is not deposited on the blade is pumped by an exhaust fan and finally treated by waste powder. This treatment increases the production cost and also causes a great waste of raw materials. Therefore, the recovery and separation of the waste powder have great economic value.
The general spraying waste powder comprises the following components: bonding layer powder, ceramic layer powder, bonding layer and ceramic layer powder large-size remelted particles, oxidized bonding layer powder, small particles formed by splashing of molten particles, other small debris particles, and the like (mixed in a channel of an exhaust fan). The powder particles with different sizes are randomly and disorderly stacked to finally form a large amount of spraying waste powder.
The powder recovery device mentioned in patent CN204891517U is only a simple recovery of powder, but does not separate it. The CN206122033U patent only recycles the surplus powder after spraying, but does not dispose of a large amount of waste powder.
Therefore, the method for separating the bonding layer powder and the ceramic layer powder from the thermal barrier coating spraying waste powder is researched, the coating preparation cost can be reduced, and the method is environment-friendly and has obvious economic value.
All substances have magnetism, and a magnetic field exists in any space, and the difference is that the strength of the magnetic field is different. Each powder material has different magnetism, the difficulty of different materials magnetization is represented by magnetic susceptibility, and magnetic substances are classified according to the difference of the magnetic susceptibility of the substances, and the method comprises the following steps: diamagnetic materials, paramagnetic materials, ferromagnetic materials, antiferromagnetic materials, ferrimagnetic materials. Under the action of the magnetic field, the conduction electrons of the positive spin and the negative spin have different energies, which results in a small amount of conduction electron spin inversion near the fermi surface, thereby generating a weak paramagnetic effect. The magnetic field is perpendicular to the magnetic field direction, so that the magnetic sensitive particles are deviated from the path under the action of gravity. The magnetically sensitive particles are deflected along the magnetic barrier and the magnetically insensitive particles pass through the chute into the separator. Such as magnetic separators, high gradient magnetic separators, and the like. The invention uses the magnetic difference of different materials to separate the powder materials.
Disclosure of Invention
The invention provides a method for separating bonding layer powder and ceramic layer powder from thermal barrier coating spraying waste powder aiming at the problems in the prior art. Firstly, screening powder particles in different particle size distribution ranges by using collected waste powder through vibrating screens with different meshes, and removing large particles and fine particles; then, according to the fact that different powder particles have different magnetism, the remaining powder particles are separated through paramagnetic separation of a magnetic separator, and the separated powder particles are strong paramagnetic materials and weak paramagnetic materials; then, a diamagnetic separation method is used for the weak paramagnetic materials, and the materials are divided into diamagnetic materials and non-diamagnetic materials. Wherein the diamagnetic material is a high-purity bonding layer material, and the non-diamagnetic material is a ceramic layer material.
In order to achieve the purpose, the invention adopts the following technical scheme:
a method for separating bonding layer powder and ceramic layer powder from 8YSZ thermal barrier coating spraying waste powder comprises the following steps:
(1) collecting 8YSZ thermal barrier coating spraying waste powder, wherein the grain sizes of a bonding layer and a ceramic layer powder in the 8YSZ thermal barrier coating are 35-75 mu m, the grain size of the bonding layer powder is 35-60 mu m, and the grain size of the ceramic layer powder is 50-75 mu m;
(2) screening the sprayed waste powder for 1-3 times according to different particle sizes, firstly screening out waste powder particles with the particle size of more than 100 microns through a 140-mesh sieve, and secondly screening out waste powder particles with the particle size of less than 30 microns through a 400-mesh sieve, wherein the sum of the two accounts for 1% of the mass of the 8YSZ thermal barrier coating sprayed waste powder;
(3) the screened powder particles are separated by a paramagnetic method, and the specific operation comprises the following steps: adjusting the magnetic field intensity of the magnetic separator to 16500 to 19000 gauss, and separating the screened powder particles by the magnetic separator for 3-5 times;
(4) the non-magnetic material separated by the paramagnetic method is further separated by a diamagnetic separation method, and the specific operations comprise: adjusting the magnetic field intensity of the magnetic separator to 15500-16000 gauss, and separating the nonmagnetic material by the magnetic separator for 3-5 times.
The 8YSZ thermal barrier coating spraying waste powder comprises: the powder of the bonding layer, the powder of the ceramic layer, the bonding layer and the large-size re-melting particles of the powder of the ceramic layer, the powder of the oxidized bonding layer, the particles of the oxidized bonding layer coating the ceramic layer, small particles formed by splashing of the melting particles, and other small debris particles mixed in the channel of the exhaust fan. The powder particles with different sizes are randomly and disorderly stacked to finally form a large amount of spraying waste powder.
Wherein, the bonding layer powder is diamagnetic material, the ceramic layer powder is non-diamagnetic material, and the oxidized bonding layer powder and the particles of the oxidized bonding layer coating ceramic layer are strongly paramagnetic material.
The main component of the bonding layer powder is MCrAlY, wherein M is Fe and Co, and the ceramic layer powder is zirconia powder.
The paramagnetic material separated in the step (3) accounts for 11% of the mass of the 8YSZ thermal barrier coating spraying waste powder, is oxidized bonding layer powder and particles of an oxidized bonding layer coating ceramic layer generated in various spraying processes, and the nonmagnetic material accounts for 88% of the mass of the 8YSZ thermal barrier coating spraying waste powder.
The diamagnetic material separated by the diamagnetic separation method in the step (4) accounts for 21% of the mass of the nonmagnetic material, and the nonmagnetic material accounts for 79% of the mass of the nonmagnetic material.
The invention has the following remarkable advantages:
the invention provides a method for separating bonding layer powder and ceramic layer powder from 8YSZ thermal barrier coating spraying waste powder, which separates the spraying waste powder generated in the preparation process of the 8YSZ thermal barrier coating, not only can reduce the preparation cost of the coating, but also is environment-friendly and has obvious economic value, can be applied to the separation of the 8YSZ thermal barrier coating powder, and has very important engineering application value.
Drawings
FIG. 1 is a schematic diagram showing the separation of 8YSZ thermal barrier coating spraying waste powder according to an embodiment of the present invention; in the figure: a-bonding layer powder, B-ceramic layer powder, C-oxidized bonding layer powder, particles of a D-oxidized bonding layer coating ceramic layer, small particles formed by splashing E-molten particles, F-other small debris particles (mixed in a channel of an exhaust fan), G-bonding layer and large-size re-melted particles of the ceramic layer powder;
FIG. 2 is an electron microscope image of particles of a bonding layer powder of an 8YSZ thermal barrier coating according to an embodiment of the invention;
FIG. 3 is an electron microscope image of a single powder particle of an 8YSZ thermal barrier coating bonding layer according to an embodiment of the invention;
FIG. 4 is an electron microscope image of a ceramic layer powder particle of an 8YSZ thermal barrier coating according to an embodiment of the invention;
FIG. 5 is an electron microscope image of the splattering of small particles of molten droplets impinging on the substrate during spraying.
Detailed Description
For further disclosure, but not limitation, the present invention is described in further detail below with reference to examples.
Example 1
A method for separating bonding layer powder and ceramic layer powder from 8YSZ thermal barrier coating spraying waste powder comprises the following steps:
(1) collecting 8YSZ thermal barrier coating spraying waste powder, wherein the grain sizes of a bonding layer and a ceramic layer powder in the 8YSZ thermal barrier coating are 35-75 mu m, the grain size of the bonding layer powder is 35-60 mu m, and the grain size of the ceramic layer powder is 50-75 mu m;
(2) screening the sprayed waste powder for 1-3 times according to different particle sizes, firstly screening out waste powder particles with the particle size of more than 100 microns through a 140-mesh sieve, and secondly screening out waste powder particles with the particle size of less than 30 microns through a 400-mesh sieve, wherein the sum of the two accounts for 1% of the mass of the 8YSZ thermal barrier coating sprayed waste powder;
(3) the screened powder particles are separated by a paramagnetic method, and the specific operation comprises the following steps: adjusting the magnetic field intensity of a magnetic separator to 16500 to 19000 gauss, separating the powder particles after sieving by the magnetic separator for 3-5 times, wherein the total obtained strong paramagnetic material accounts for 11 percent of the mass of the 8YSZ thermal barrier coating spraying waste powder, the strong paramagnetic material is the oxidized bonding layer powder generated in various spraying processes and the particles of the oxidized bonding layer coating ceramic layer, and the non-magnetic material accounts for 88 percent of the mass of the 8YSZ thermal barrier coating spraying waste powder;
(4) the non-magnetic material separated by the paramagnetic method is further separated by a diamagnetic separation method, and the specific operations comprise: adjusting the magnetic field intensity of the magnetic separator to 15500-16000 gauss, separating the nonmagnetic material by the magnetic separator for 3-5 times, wherein the diamagnetic material obtained by separation accounts for 21% of the mass of the nonmagnetic material, and the nonmagnetic material accounts for 79% of the mass of the nonmagnetic material; the diamagnetic material is a high-purity bonding layer material, the non-diamagnetic material is a ceramic layer material, the lowest purity of the two materials is 3N9, the bonding layer material obtained after separation accounts for 18.48% of the total ratio, and the ceramic layer material obtained after separation accounts for 69.52% of the total ratio.
The 8YSZ thermal barrier coating spraying waste powder comprises: the powder of the bonding layer, the powder of the ceramic layer, the bonding layer and the large-size re-melting particles of the powder of the ceramic layer, the powder of the oxidized bonding layer, the particles of the oxidized bonding layer coating the ceramic layer, small particles formed by splashing of the melting particles, and other small debris particles mixed in the channel of the exhaust fan.
Wherein, the bonding layer powder is diamagnetic material, the ceramic layer powder is non-diamagnetic material, and the oxidized bonding layer powder and the particles of the oxidized bonding layer coating ceramic layer are strongly paramagnetic material.
The main component of the bonding layer powder is MCrAlY, wherein M is Fe and Co, and the ceramic layer powder is zirconia powder.
The above description is only a preferred embodiment of the present invention, and all equivalent changes and modifications made in accordance with the claims of the present invention should be covered by the present invention.
Claims (6)
1. A method for separating bonding layer powder and ceramic layer powder from 8YSZ thermal barrier coating spraying waste powder is characterized by comprising the following steps:
(1) collecting 8YSZ thermal barrier coating spraying waste powder, wherein the grain sizes of a bonding layer and a ceramic layer powder in the 8YSZ thermal barrier coating are 35-75 mu m, the grain size of the bonding layer powder is 35-60 mu m, and the grain size of the ceramic layer powder is 50-75 mu m;
(2) screening the sprayed waste powder for 1-3 times according to different particle sizes, firstly screening out waste powder particles with the particle size of more than 100 microns through a 140-mesh sieve, and secondly screening out waste powder particles with the particle size of less than 30 microns through a 400-mesh sieve, wherein the sum of the two accounts for 1% of the mass of the 8YSZ thermal barrier coating sprayed waste powder;
(3) the screened powder particles are separated by a paramagnetic method, and the specific operation comprises the following steps: adjusting the magnetic field intensity of the magnetic separator to 16500 to 19000 gauss, and separating the screened powder particles by the magnetic separator for 3-5 times;
(4) the non-magnetic material separated by the paramagnetic method is further separated by a diamagnetic separation method, and the specific operations comprise: adjusting the magnetic field intensity of the magnetic separator to 15500-16000 gauss, and separating the nonmagnetic material by the magnetic separator for 3-5 times.
2. The method of separating a bond coat powder and a ceramic layer powder from an 8YSZ thermal barrier coating spray paint waste of claim 1, wherein the 8YSZ thermal barrier coating spray paint waste comprises: the powder of the bonding layer, the powder of the ceramic layer, the bonding layer and the large-size re-melting particles of the powder of the ceramic layer, the powder of the oxidized bonding layer, the particles of the oxidized bonding layer coating the ceramic layer, small particles formed by splashing of the melting particles, and other small debris particles mixed in the channel of the exhaust fan.
3. The method of claim 2, wherein the bonding layer powder is a diamagnetic material, the ceramic layer powder is a non-diamagnetic material, and the oxidized bonding layer powder and the particles of the oxidized bonding layer coating the ceramic layer are strongly paramagnetic materials.
4. The method for separating the bond coat powder and the ceramic layer powder from 8YSZ thermal barrier coating spraying waste powder as claimed in claim 1 or 2, wherein the bond coat powder mainly comprises MCrAlY, wherein M is Fe and Co, and the ceramic layer powder is zirconia powder.
5. The method for separating the bonding layer powder and the ceramic layer powder from the 8YSZ thermal barrier coating spraying waste powder as claimed in claim 1, wherein the paramagnetic material separated in step (3) accounts for 11% of the mass of the 8YSZ thermal barrier coating spraying waste powder, the paramagnetic material is the oxidized bonding layer powder and the oxidized bonding layer coated ceramic layer particles generated in various spraying processes, and the non-magnetic material accounts for 88% of the mass of the 8YSZ thermal barrier coating spraying waste powder.
6. The method for separating the bonding layer powder and the ceramic layer powder from 8YSZ thermal barrier coating spraying waste powder according to claim 1, wherein the diamagnetic material separated by the diamagnetic separation method in the step (4) accounts for 21% of the mass of the nonmagnetic material, and the nonmagnetic material accounts for 79% of the mass of the nonmagnetic material.
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