CN112430097A - Modified silicon carbide powder for thermal spraying and preparation method thereof - Google Patents
Modified silicon carbide powder for thermal spraying and preparation method thereof Download PDFInfo
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- CN112430097A CN112430097A CN202011347071.0A CN202011347071A CN112430097A CN 112430097 A CN112430097 A CN 112430097A CN 202011347071 A CN202011347071 A CN 202011347071A CN 112430097 A CN112430097 A CN 112430097A
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/515—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
- C04B35/56—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides
- C04B35/565—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides based on silicon carbide
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/62222—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products obtaining ceramic coatings
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/327—Iron group oxides, their mixed metal oxides, or oxide-forming salts thereof
- C04B2235/3279—Nickel oxides, nickalates, or oxide-forming salts thereof
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- C—CHEMISTRY; METALLURGY
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/40—Metallic constituents or additives not added as binding phase
- C04B2235/402—Aluminium
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/48—Organic compounds becoming part of a ceramic after heat treatment, e.g. carbonising phenol resins
- C04B2235/483—Si-containing organic compounds, e.g. silicone resins, (poly)silanes, (poly)siloxanes or (poly)silazanes
Abstract
The invention discloses modified silicon carbide powder for thermal spraying, which is in a core-shell shape, and comprises the following components in percentage by mass: raw materials, 10.0 to 20.0 percent of carbonyl nickel powder, 2.5 to 5.0 percent of superfine aluminum powder and 75.0 to 87.5 percent of silicon carbide powder; the adhesive accounts for 1.5-4.0% of the total mass of the raw materials. The invention prepares a layer of carbonyl nickel powder and aluminum powder composite coating layer on the surface of the silicon carbide by a physical bonding method, realizes the surface coating modification of the silicon carbide powder, the nickel-aluminum coating layer firstly generates exothermic reaction in plasma flame flow to generate a nickel-aluminum intermetallic compound and form a liquefied protective film, effectively avoids the decomposition of the silicon carbide, and simultaneously, the nickel-aluminum intermetallic compound acts as a high-temperature binding phase to be beneficial to the deposition of the silicon carbide coating.
Description
Technical Field
The invention belongs to the technical field of thermal spraying and material processing, and particularly relates to modified silicon carbide powder for thermal spraying; in particular to a preparation method of the modified silicon carbide powder for thermal spraying.
Background
The silicon carbide has stable chemical performance, high heat conductivity coefficient, small thermal expansion coefficient and good wear resistance, and has other purposes besides being used as an abrasive, for example, the silicon carbide powder is coated on the inner wall of a water turbine impeller or a cylinder body by a special process, so that the wear resistance of the silicon carbide powder can be improved, and the service life of the silicon carbide powder is prolonged by 1-2 times; the high-grade refractory material has the advantages of thermal shock resistance, small volume, light weight, high strength and good energy-saving effect. The low-grade silicon carbide (containing SiC about 85%) is an excellent deoxidizer, and can be used for speeding up steel-making, easily controlling chemical composition and raising steel quality. In addition, silicon carbide is also used in great quantity to make silicon carbide rod for electric heating element.
Because of stable chemical properties, the silicon carbide does not react with chlorine, oxygen, sulfur and strong acid at high temperature, has high heat conductivity coefficient, small thermal expansion coefficient and good wear resistance, and the price is only 1/10-1/30 of hard alloys such as tungsten carbide, chromium carbide and the like, thereby being an ideal hard-surface coating material. However, when the plasma spraying process is adopted to prepare the silicon carbide coating, the temperature of plasma flame flow is up to 15000 ℃, silicon carbide is sublimated at the temperature of more than 1800 ℃, and the powder is partially decomposed into vapor containing carbon and silicon at high temperature, so that the coating is difficult to form. At present, no silicon carbide powder suitable for plasma spraying exists in the market, and how to fully utilize the physical and chemical properties of silicon carbide to prepare a hard surface coating is one of the research hotspots in the field of thermal spraying materials at present.
Disclosure of Invention
The invention aims to provide a preparation method of modified silicon carbide powder for thermal spraying, which aims to solve the problem that the powder proposed in the background technology is partially decomposed into steam containing carbon and silicon, so that a coating is difficult to form.
In order to achieve the purpose, the invention adopts the following technical scheme:
the modified silicon carbide powder for thermal spraying is in a core-shell shape, and comprises the following components in percentage by mass:
raw materials, 10.0 to 20.0 percent of carbonyl nickel powder, 2.5 to 5.0 percent of superfine aluminum powder and 75.0 to 87.5 percent of silicon carbide powder;
the adhesive accounts for 1.5-4.0% of the total mass of the raw materials.
Preferably, the formula of the modified silicon carbide powder for thermal spraying comprises the following components in percentage by mass: 100 g of carbonyl nickel powder, 25 g of superfine aluminum powder, 875 g of silicon carbide and 20 g of adhesive.
Preferably, the formula of the modified silicon carbide powder for thermal spraying comprises the following components in percentage by mass: 200 g of carbonyl nickel powder, 50 g of superfine aluminum powder, 750 g of silicon carbide and 35 g of adhesive.
Preferably, the formula of the modified silicon carbide powder for thermal spraying comprises the following components in percentage by mass: 150 g of carbonyl nickel powder, 37.5 g of superfine aluminum powder, 812.5 g of silicon carbide and 30 g of adhesive.
Preferably, the binder comprises a mixture of one or more of PVA, PVP, PA, PE, epoxy, alkyd or polysiloxane.
A preparation method of modified silicon carbide powder for thermal spraying comprises the following steps:
s1, preparing materials, namely weighing the materials according to the formula of the modified silicon carbide powder for thermal spraying by mass percentage for later use;
s2, ball-milling raw materials, sequentially putting carbonyl nickel powder, superfine aluminum powder and silicon carbide into a ball mill, performing mechanical ball-milling mixing for 20-40 minutes, and then separating the ball material by using a screen;
s3, mixing, namely putting the ball-milled raw materials into a stirring kettle, simultaneously adding an adhesive accounting for 1.5-4.0% of the weight of the raw materials, and continuously stirring for 10-20 minutes;
s4, drying, namely transferring the mixed materials into a drying oven, and keeping the temperature at 40-70 ℃ for 1-5 hours for drying;
s5, screening the finished product, and screening the dried material according to the required granularity to obtain the product.
Preferably, in the ball milling of the raw material described in step S2, the particle size of the nickel carbonyl powder is 1 to 5 microns, the particle size of the ultrafine aluminum powder is 0.5 to 3 microns, and the particle size of the silicon carbide is 38 to 100 microns.
Preferably, the ball mill is a wind power material discharging ball mill, materials enter the ball mill from a feeding port, after impact and grinding are carried out on the materials by a grinding medium, the materials move from an inlet to an outlet of the ball mill gradually, an outlet end of the ball mill is connected with a wind pipe, a separator, a powder concentrator, a dust remover and an inlet of a fan are connected in series in the system, when wind power material discharging starts to operate, the inside of the ball mill body is relatively at low negative pressure, the crushed and ground materials enter a pipeline system from a discharging port along with wind power, the powder concentrator separates coarse particles and then feeds the coarse particles into the inlet of the ball mill again, and the ground materials are separated and recovered by the separator.
Preferably, in the step S3, a stainless steel stirring kettle is adopted for stirring and mixing, and the stirring speed of the stainless steel stirring kettle is 40r/min to 120 r/min.
The invention has the technical effects and advantages that: compared with the prior art, the modified silicon carbide powder for thermal spraying provided by the invention has the following advantages:
the coating is uniform in coating and high in deposition efficiency, and the coating formed by spraying the modified silicon carbide powder prepared by the method is compact, high in hardness and good in corrosion resistance; meanwhile, the preparation method has the advantages of simple process, easy operation, low production cost, good product quality, large production capacity, economy, reliability, industrial popularization and the like.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all embodiments. The specific embodiments described herein are merely illustrative of the invention and do not delimit the invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Example 1
A modified silicon carbide powder for thermal spraying, the formulation of which comprises, by mass: 100 g of carbonyl nickel powder, 25 g of superfine aluminum powder, 875 g of silicon carbide and 20 g of adhesive.
Wherein the adhesive comprises one or more of PVA, PVP, PA, PE, epoxy resin, alkyd resin or polysiloxane.
The invention relates to a modified silicon carbide powder for thermal spraying, which comprises the following steps:
s1, preparing materials, namely weighing the materials according to the formula of the modified silicon carbide powder for thermal spraying by mass percentage for later use;
s2, ball-milling raw materials, sequentially putting carbonyl nickel powder, superfine aluminum powder and silicon carbide into a ball mill, mechanically ball-milling and mixing for 20 minutes, and then separating the ball material by using a screen;
s3, mixing, namely putting the ball-milled raw materials into a stirring kettle, adding an adhesive, and continuously stirring for 10 minutes;
s4, drying, namely transferring the mixed materials into a drying oven, and keeping the temperature at 50 ℃ for 3 hours for drying;
s5, screening the finished product, and screening the dried material according to the required granularity to obtain the product.
Wherein, in the raw material ball milling in the step S2, the granularity of the carbonyl nickel powder is 1-5 microns, the granularity of the superfine aluminum powder is 0.5-3 microns, and the granularity of the silicon carbide is 38-100 microns.
The preparation method of the modified silicon carbide powder for thermal spraying can also be used for modifying other powder such as tungsten carbide, chromium boride, titanium diboride, boron carbide, titanium carbide, silicon nitride and the like.
The ball mill is a wind power discharging ball mill, materials enter the ball mill from a feeding port, after impact and grinding are carried out on the materials by a grinding medium, the materials move from an inlet to an outlet of the ball mill gradually, an outlet end of the ball mill is connected with a wind pipe, a separator, a powder concentrator, a dust remover and an inlet of a fan are connected in series in the system, when wind power discharging starts to operate, the inside of the ball mill body is relatively at low negative pressure, the ground materials enter a pipeline system from a discharging port along with wind power, the powder concentrator separates coarse particles and then feeds the coarse particles into the inlet of the ball mill again, and the ground materials are separated and recovered by the separator;
the main bearing of the wind power discharging ball mill adopts a large-diameter double-row self-aligning roller bearing to replace the original sliding bearing, so that the friction is reduced, the energy consumption is reduced, the mill is easy to start, and the feeder of the wind power discharging ball mill is divided into a combined feeder and a drum-shaped feeder, so that the structure is simple and the split installation is realized.
In the step S3, a stainless steel stirring kettle is adopted for stirring and mixing, and the stirring speed of the stainless steel stirring kettle is 40r/min-120 r/min;
the stainless steel stirring kettle is set to be a temperature-controllable stainless steel stirring kettle, and when the temperature-controllable stainless steel stirring kettle is used, temperature control can be carried out according to actual preparation requirements, so that modified silicon carbide powder for hot spraying can be prepared better.
The modified silicon carbide powder for thermal spraying prepared by the method is sprayed on carbon steel by adopting a certain current, voltage, main gas flow, auxiliary gas flow, feeding speed and spraying distance, the surface of the prepared coating has no cracks, and performance tests show that the microhardness of the coating is in the range of 1200 plus 1350, the coating has good bonding strength with a matrix and corrosion resistance, and the hardness of the coating has no obvious change after 700 ℃ heat treatment, which indicates that the high-temperature hardness of the coating is good.
Example 2
Unlike example 1, the formulation of the modified silicon carbide powder for thermal spraying includes, by mass: 200 g of carbonyl nickel powder, 50 g of superfine aluminum powder, 750 g of silicon carbide and 35 g of adhesive;
during preparation, 200 g of carbonyl nickel powder, 50 g of superfine aluminum powder and 750 g of silicon carbide are weighed, put into a ball mill, mechanically ball-milled and mixed for 30 minutes, then separated by a screen, put into a stirrer, added with epoxy resin accounting for 3.5 percent of the weight of the raw materials and continuously stirred for 20 minutes; and then transferring the materials into an oven, keeping the temperature at 70 ℃ for 5 hours, drying, and finally sieving the dried powder to obtain a finished product.
The modified silicon carbide powder for thermal spraying prepared by the method is sprayed on carbon steel by adopting a certain current, voltage, main gas flow, auxiliary gas flow, feeding speed and spraying distance, the surface of the prepared coating has no cracks, and performance tests show that the microhardness of the coating is within the range of 1000 plus materials 1150, the coating has good bonding strength with a matrix and corrosion resistance, and the hardness of the coating has no obvious change after 700 ℃ heat treatment, which indicates that the high-temperature hardness of the coating is good.
Example 3
Unlike example 1, the formulation of the modified silicon carbide powder for thermal spraying includes, by mass: 150 g of carbonyl nickel powder, 37.5 g of superfine aluminum powder, 812.5 g of silicon carbide and 30 g of adhesive;
during preparation, firstly weighing 150 g of carbonyl nickel powder, 37.5 g of superfine aluminum powder and 812.5 g of silicon carbide, putting into a ball mill, carrying out mechanical ball milling and mixing for 25 minutes, and then separating the ball material by using a screen mesh; then putting the ball-milled raw materials into a stirrer, simultaneously adding alkyd resin accounting for 3.0 percent of the weight of the raw materials, and continuously stirring for 15 minutes; then transferring the materials into an oven, and keeping the temperature at 60 ℃ for 4 hours for drying; and finally, sieving the dried powder to obtain a finished product.
The modified silicon carbide powder for thermal spraying prepared by the method is sprayed on carbon steel by adopting a certain current, voltage, main gas flow, auxiliary gas flow, feeding speed and spraying distance, the surface of the prepared coating has no cracks, and performance tests show that the microhardness of the coating is in the range of 1100-1250, and the coating has good bonding strength with a matrix and corrosion resistance. The hardness of the coating after heat treatment at 700 ℃ has no obvious change, which shows that the coating has good high-temperature hardness.
The specific formulation data for three sets of examples of the invention are given in the following table:
example 1 | Example 2 | Example 3 | |
Nickel carbonyl powder | 100 g | 200 g | 150 g |
Superfine aluminium powder | 25 g | 50 g | 37.5 g |
Silicon carbide | 875 g | 750 g | 812.5 g |
Adhesive agent | 20 g | 35 g | 30 g |
According to the invention, a layer of carbonyl nickel powder and aluminum powder composite coating layer is prepared on the surface of silicon carbide by a physical bonding method, so that the surface coating modification of silicon carbide powder is realized, the nickel-aluminum coating layer firstly generates an exothermic reaction in a plasma flame flow to generate a nickel-aluminum intermetallic compound and form a liquefied protective film, the decomposition of silicon carbide is effectively avoided, and meanwhile, the nickel-aluminum intermetallic compound serves as a high-temperature binder phase, so that the deposition of the silicon carbide coating layer is facilitated;
the coating is uniform, the deposition efficiency is high, and the coating formed by spraying the modified silicon carbide powder prepared by the method is compact, high in hardness and good in corrosion resistance; meanwhile, the preparation method has the advantages of simple process, easy operation, low production cost, good product quality, large production capacity, economy, reliability, industrial popularization and the like.
Finally, it should be noted that: although the present invention has been described in detail with reference to the foregoing embodiments, it will be apparent to those skilled in the art that modifications may be made to the embodiments or portions thereof without departing from the spirit and scope of the invention.
Claims (9)
1. A modified silicon carbide powder for thermal spraying, characterized in that: the silicon carbide powder is in a core-shell shape, and the formula of the modified silicon carbide powder for thermal spraying comprises the following components in percentage by mass:
raw materials, 10.0 to 20.0 percent of carbonyl nickel powder, 2.5 to 5.0 percent of superfine aluminum powder and 75.0 to 87.5 percent of silicon carbide powder;
the adhesive accounts for 1.5-4.0% of the total mass of the raw materials.
2. The modified silicon carbide powder for thermal spraying according to claim 1, wherein: the formula of the modified silicon carbide powder for thermal spraying comprises the following components in mass percent: 100 g of carbonyl nickel powder, 25 g of superfine aluminum powder, 875 g of silicon carbide and 20 g of adhesive.
3. The modified silicon carbide powder for thermal spraying according to claim 1, wherein: the formula of the modified silicon carbide powder for thermal spraying comprises the following components in mass percent: 200 g of carbonyl nickel powder, 50 g of superfine aluminum powder, 750 g of silicon carbide and 35 g of adhesive.
4. The modified silicon carbide powder for thermal spraying according to claim 1, wherein: the formula of the modified silicon carbide powder for thermal spraying comprises the following components in mass percent: 150 g of carbonyl nickel powder, 37.5 g of superfine aluminum powder, 812.5 g of silicon carbide and 30 g of adhesive.
5. The modified silicon carbide powder for thermal spraying according to claim 1, wherein: the adhesive comprises one or more of PVA, PVP, PA, PE, epoxy resin, alkyd resin or polysiloxane.
6. The method of preparing a modified silicon carbide powder for thermal spraying according to claim 1, comprising the steps of:
s1, preparing materials, namely weighing the materials according to the formula of the modified silicon carbide powder for thermal spraying by mass percentage for later use;
s2, ball-milling raw materials, sequentially putting carbonyl nickel powder, superfine aluminum powder and silicon carbide into a ball mill, performing mechanical ball-milling mixing for 20-40 minutes, and then separating the ball material by using a screen;
s3, mixing, namely putting the ball-milled raw materials into a stirring kettle, simultaneously adding an adhesive accounting for 1.5-4.0% of the weight of the raw materials, and continuously stirring for 10-20 minutes;
s4, drying, namely transferring the mixed materials into a drying oven, and keeping the temperature at 40-70 ℃ for 1-5 hours for drying;
s5, screening the finished product, and screening the dried material according to the required granularity to obtain the product.
7. The method of claim 6, wherein the modified silicon carbide powder for thermal spraying comprises: in the raw material ball milling of step S2, the particle size of the carbonyl nickel powder is 1-5 microns, the particle size of the superfine aluminum powder is 0.5-3 microns, and the particle size of the silicon carbide is 38-100 microns.
8. The method of claim 6, wherein the modified silicon carbide powder for thermal spraying comprises: the ball mill is a wind power material discharging ball mill, materials enter the ball mill from a feeding port, after impact and grinding are carried out on the materials by a grinding medium, the materials move from an inlet to an outlet of the ball mill gradually, an outlet end is connected with a wind pipe, a separator, a powder concentrator, a dust remover and a fan are connected in series in the system, when wind power material discharging starts to operate, the interior of the ball mill body is relatively at low negative pressure, the crushed and levigated materials enter a pipeline system from a discharging port along with wind power, the powder concentrator separates coarse particles and then feeds the coarse particles into the inlet of the ball mill again, and the ground materials are separated and recovered by the separator.
9. The method of claim 6, wherein the modified silicon carbide powder for thermal spraying comprises: and step S3, stirring and mixing by adopting a stainless steel stirring kettle, wherein the stirring speed of the stainless steel stirring kettle is 40-120 r/min.
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