CN113909016A - Multi-combustion-chamber high-power high-efficiency supersonic flame thermal spraying spray gun and thermal spraying device thereof - Google Patents
Multi-combustion-chamber high-power high-efficiency supersonic flame thermal spraying spray gun and thermal spraying device thereof Download PDFInfo
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- CN113909016A CN113909016A CN202111295844.XA CN202111295844A CN113909016A CN 113909016 A CN113909016 A CN 113909016A CN 202111295844 A CN202111295844 A CN 202111295844A CN 113909016 A CN113909016 A CN 113909016A
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- spray gun
- laval nozzle
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- thermal spraying
- combustion chamber
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
- B05B7/00—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas
- B05B7/16—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed
- B05B7/20—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed by flame or combustion
- B05B7/201—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed by flame or combustion downstream of the nozzle
- B05B7/205—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed by flame or combustion downstream of the nozzle the material to be sprayed being originally a particulate material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
- B05B7/00—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas
- B05B7/02—Spray pistols; Apparatus for discharge
- B05B7/12—Spray pistols; Apparatus for discharge designed to control volume of flow, e.g. with adjustable passages
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
- B05B7/00—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas
- B05B7/16—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed
Abstract
The invention discloses a multi-combustion-chamber high-power high-efficiency supersonic flame thermal spraying spray gun and a thermal spraying device thereof, wherein the spray gun comprises a spray gun shell, a core unit comprising a Laval nozzle, a plurality of independent combustion chambers and a gun barrel is arranged in the spray gun shell, and a water cooling sleeve is arranged outside the spray gun shell; the tail end of the expansion section of the laval nozzle is fixedly connected with the gun barrel, the independent combustion chamber is uniformly arranged in the circumferential direction of the middle section of the laval nozzle, high-pressure air and spraying powder enter the laval nozzle cavity from the tail part of the laval nozzle, the independent combustion chamber is used for spraying oil-gas mixture into the laval nozzle cavity and igniting the oil-gas mixture, and a multi-channel double-layer water cooling channel is formed among the water cooling sleeve, the spray gun shell and the core unit. The invention can solve the problems of insufficient combustion, uneven temperature distribution, overhigh temperature and pressure of a gun body and the like caused by singly increasing the size of the spray gun in order to improve the thermal spraying efficiency in the traditional scheme, and has the advantages of large flame flow size, high power, high powder deposition efficiency and high water cooling efficiency.
Description
Technical Field
The invention relates to the field of surface engineering and remanufactured coatings, in particular to a multi-combustion-chamber high-power high-efficiency supersonic flame thermal spraying spray gun and a thermal spraying device thereof
Background
The supersonic flame thermal spraying technology has the characteristics of ultrahigh flame flow speed, relatively low temperature, wide application range in the field of surface treatment, suitability for spraying materials, high coating bonding strength, high coating compactness and the like. But when spraying parts with ultra-large areas, the efficiency is lower and the construction time is long. Because the flame flow size of the advanced supersonic flame thermal spraying spray gun which is mainstream in the world at present is not large, the diameter is generally below 20 mm. The ultra-high flame flow velocity requires very high temperatures and pressures in the lance combustion system, so forcing an increase in the size of the supersonic flame flow places very high demands on the supply and combustion conditions of the lance fuel and oxygen, and the burden on the lance cooling system is greatly increased. Therefore, if the size of the gun body is simply increased, the problems of insufficient combustion in a combustion chamber, uniform temperature distribution, heavy burden of a water cooling system, high temperature of the gun body, nonuniform powder heating and the like can be caused, the technological requirements of supersonic flame thermal spraying are met, and great technical difficulty and potential safety hazards are caused. If a plurality of supersonic flame spray guns work simultaneously for spraying, the flames of the spray guns can generate the influence of mutual interference, mutual pollution and the like, thereby influencing the performance of the coating.
Disclosure of Invention
The invention aims to break through the bottleneck of the prior art and solve the problem of insufficient efficiency when supersonic thermal spraying is carried out on oversized parts. The supersonic flame hot spraying spray gun, the device and the coating preparation process have the advantages of multiple combustion chambers, large flame flow size, high power, high powder deposition efficiency and high water cooling efficiency.
The technical scheme adopted by the invention for solving the problems is as follows:
a multi-combustion chamber high-power high-efficiency supersonic flame thermal spraying spray gun comprises a spray gun shell, wherein a core unit comprising a Laval nozzle, a plurality of independent combustion chambers and a gun barrel is arranged in the spray gun shell, and a water cooling sleeve is arranged outside the spray gun shell; the tail end caliber of the expansion section of the laval nozzle is matched with the caliber of the gun barrel, the expansion section of the laval nozzle and the gun barrel are tightly connected, a plurality of through holes are uniformly formed in the middle section of the laval nozzle in the circumferential direction, an independent combustion chamber is installed at each through hole, high-pressure air and spraying powder enter the laval nozzle cavity from the tail portion of the laval nozzle, the independent combustion chamber is used for spraying oil-gas mixture into the laval nozzle cavity and igniting the oil-gas mixture, and a multi-path double-layer water cooling channel is formed among the water cooling sleeve, the spray gun shell and the core unit.
The gun barrel, its aperture ratio is bigger than traditional hot spraying spray gun barrel, matches with multi-functional Laval nozzle expansion section end port footpath, the bottom closely cooperates with the Laval nozzle mouth, fastens through fastening screw, high temperature resistant sealing washer is sealed. The caliber size range of the gun barrel is 19mm-33mm, and the larger the caliber is, the longer the gun barrel is, the length is preferably 170 mm-450 mm; the gun tube can raise flame speed and make the powder heated for proper time to reach optimal smelting state.
The gun shell, the gun body shell and the gun body rear cover form a spray gun shell; the gun shell and the gun shell are in threaded sealing connection, and the contact port is sealed by a rubber sealing ring, so that cooling water is prevented from leaking. The barrel shell mouth has the stable support ring with the barrel mouth, improves the stability and the axiality of barrel, avoids the barrel to warp, promotes the life-span of barrel, seals with high temperature resistant sealing washer simultaneously.
The water cooling sleeve is connected to the gun body shell through threads and sealed through a sealing ring, and smooth and sealed water outlet backflow is guaranteed.
The gun body shell is of a hollow special-shaped structure, a main body frame of the spray gun is ensured to be in threaded connection with the gun shell and the water cooling jacket, the sealing ring is sealed, and a threaded opening of the water inlet is reserved at the tail of the gun body shell.
The periphery of the multifunctional Laval nozzle is provided with a plurality of axisymmetric through holes which are uniformly distributed and can be tightly and hermetically connected with a plurality of independent combustion chambers to form a communicating space. Furthermore, a plurality of small bosses are uniformly distributed on the side surface of the multifunctional laval nozzle, the boss surface is in clearance fit with the inner wall of the gun shell, a certain supporting effect is achieved, grooves are formed between the small bosses and the small bosses, cooling water can smoothly pass through the small bosses, the cooling area of the multifunctional laval nozzle and the cooling area of the independent combustion chamber are increased through the small bosses, and the cooling efficiency is greatly improved. Furthermore, the inner wall of the tail part of the multifunctional Laval nozzle is provided with a circle of limiting bulges which are contacted with the high-temperature resistant ceramic chip, so that the functions of limiting the position and moving of the high-temperature resistant ceramic chip are achieved.
One side of each independent combustion chamber is hermetically connected with a through hole on the side surface of the multifunctional Laval nozzle, and the other side of each independent combustion chamber is hermetically connected with the oil-gas coaxial injector; the number of the independent combustion chambers is preferably controlled to be 3-9, and the main function is to fully combust the energy required by the working of the spray gun through multipoint dispersed combustion of a large amount of fuel, so that higher heat efficiency is obtained.
The high-temperature-resistant porous ceramic plate is provided with two through holes, wherein the through holes are used for allowing powder feeding needles to pass through, the through holes are multiple and are axially and symmetrically and uniformly distributed on the ceramic plate, and the through holes are used for allowing high-pressure air to pass through, are more, denser and smaller and are axially and symmetrically and uniformly distributed on the ceramic plate.
Furthermore, the powder feeding needles and the powder feeding needle through holes are used for feeding powder more efficiently and more uniformly under the condition of large powder feeding amount, so that the powder is heated more uniformly.
Further, the high pressure air through holes serve to accelerate the powder and to distribute the powder more evenly in the flame stream.
Furthermore, one side of the ceramic plate is in contact with a circle of limiting bulges on the inner wall of the Laval nozzle, and the other side of the ceramic plate is in contact with an air separator and is sealed by a sealing ring of the air separator.
Further, when the spray gun works, the high-temperature-resistant ceramic plate is heated to be above the ignition point of fuel, so that the continuous ignition function is realized, and the combustion state in the multifunctional Laval nozzle can be greatly improved.
The inside a lot of through-holes that have of air separator, make high-pressure air transmit multi-functional porous potsherd uniformly, both ends face edge all is equipped with the arch, protruding and the potsherd sealing contact of one end, lid sealing contact behind the other end arch and the rifle body to still open a plurality of screw holes, this screw hole with send the external screw thread fit on the powder needle, be used for the fixed powder needle that sends.
The powder feeding needle penetrates through the gun body rear cover, the air separator and the powder feeding needle hole of the high-temperature resistant ceramic chip in sequence and is matched and fastened with a threaded hole in the air separator, and the gun body rear cover and the air separator section can be sealed by rubber sealing rings. The quantity of the powder feeding needle is determined according to the quantity and the powder feeding quantity of the independent combustion chambers, the quantity of the powder feeding needle is generally equal to that of the independent combustion chambers, the aperture of the powder feeding needle is determined according to the type and the particle size of the sprayed powder, and the positions of the powder feeding needles are arranged according to the size of flame flow.
The gun body rear cover is in threaded connection with the gun body shell and is provided with a plurality of air inlets, water inlets and powder feeding needle holes.
The oil-gas mixing atomizer is in threaded connection with the oil-gas coaxial injector, and the sealing ring is sealed; the oil-gas mixing atomizer is a sealed hollow structure, the inside of the oil-gas mixing atomizer is provided with a separator with multiple pores, the outside of the oil-gas mixing atomizer is provided with an oil inlet, an oxygen inlet and an ignition needle port, the oil-gas mixing atomizer mainly has the functions of fully and uniformly mixing kerosene and oxygen, atomizing the mixture through the separator, sending the oil-oxygen mixture into an oil-gas coaxial injector, injecting the oil-oxygen mixture into each independent combustion chamber,
the oil-gas coaxial injector is in sealing contact with the independent combustion chamber, is in threaded connection with the gun shell, is sealed by the sealing ring, and is internally provided with a coaxial oil-gas outlet and an ignition needle hole.
The spray gun can also be provided with sensing detection elements such as a pressure sensor and the like, and the spray gun can also be provided with matched equipment comprising: the hot spraying device comprises a central control cabinet, a water cooling machine with a plurality of circulating water pumps, a kerosene control box with a plurality of oil pumps, a plurality of powder feeders, an air compressor and a cold dryer which can provide clean and dry high-pressure air, a high-pressure oxygen supply system and an ignition device, thereby forming a complete set of hot spraying device.
The water cooling machine with the multiple circulating water pumps is characterized in that a water cooling loop driven by each circulating water pump is matched with each water inlet and each water outlet, performance parameters and the quantity of the circulating water pumps and the water cooling loops are based on the generated heat of the whole system, and the temperature of the spray gun during continuous working is required to be kept within a reasonable temperature range.
Take the kerosene control box of a plurality of oil pumps, every oil pump corresponds every independent combustion chamber, constitutes a spray gun combustion system, kerosene supplies can external kerosene pipeline or external kerosene bin.
The powder feeders are provided with a plurality of powder feeding tanks and powder feeding pipelines, but a microcomputer control system is integrated on a central control box, the quantity of the powder feeding tanks and the powder feeding pipelines is the same as that of the powder feeding needles, the powder feeder can fully undertake and decompose the task of large powder feeding amount, and the powder feeding state is more uniform in the multifunctional Laval nozzle.
The pressure and flow of the air compressor and the cold dryer for providing clean and dry air need to meet the requirement of the spray gun for compressed air.
The high-pressure oxygen supply is realized by a plurality of liquid oxygen tanks with high pressure, after the liquid oxygen is gasified by a gasification tower, a plurality of pipelines connect the oxygen to the oxygen inlet of the oil-gas mixing atomizer on each independent combustion chamber, and each branch pipeline is provided with a pressure reducing valve to regulate and control the oxygen supply of each branch pipeline.
The ignition device adopts a multi-line high-voltage spark plug to perform the ignition function of the independent combustion chamber, and each line is matched with one spark plug and the independent combustion chamber to form a plurality of independent ignition systems.
The central control cabinet integrally controls the on-off and adjustment of the water cooling systems, the high-pressure air system, the powder feeding system, the oil supply system, the oxygen supply system and the ignition system, monitors the state of each system, and can feed back and alarm in time if problems occur.
The specific working process of the device is as follows:
(1) checking whether the power supply system, the gas supply system, the oil supply system, the powder feeding system and the ignition system are in normal states or not, and determining whether problems exist or not;
(2) opening the water-cooling machine to enable the spray gun to be in a water-cooling state, enabling multi-path cooling water to enter from a water inlet at the tail end of the spray gun, firstly flowing through the independent combustion chamber, then flowing through the converging section, the throat section and the expanding section of the multifunctional Laval nozzle, then flowing through the gun barrel, flowing out from an opening at the front part of the gun barrel shell, entering a space between the water-cooling jacket and the gun barrel shell, then entering a space between the water-cooling jacket and the gun barrel shell, finally being discharged from a water outlet of the water-cooling jacket, and returning to the water-cooling machine; the multi-channel double-layer water-cooling channel spray gun structure greatly improves the water-cooling area and obviously improves the water-cooling efficiency.
(3) Opening high-pressure air and powder feeding carrier gas, wherein the powder feeding carrier gas can be argon, nitrogen or other inert gases, so that an independent combustion chamber, a multifunctional Laval nozzle and a gun barrel in the spray gun are in certain pressure and flow rate states;
(4) synchronously turning on a kerosene pump and an oxygen supply switch, adjusting the flow range required by reasonable ignition, fully mixing kerosene and oxygen through an oil gas atomizer to form oil gas mist flow, discharging the oil gas mist flow into each independent combustion chamber from an outlet, converging the oil gas mist flow into a multifunctional Laval nozzle, and discharging the oil gas mist flow from a gun barrel;
(5) synchronously turning on a switch of an ignition system, simultaneously igniting a plurality of independent combustion chambers, sharply boosting the internal space of the spray gun at the moment, enabling the flame to pass through a converging section of a laval nozzle, increasing the speed, enabling the flame to pass through a throat part of the multifunctional laval nozzle, passing through an expanding section, forming supersonic speed flame, and further accelerating the speed through a gun pipe section;
(6) after the ignition procedure is finished, the flow of air, kerosene and oxygen is automatically adjusted to set parameters required by spray gun spraying, the flame speed is further increased, and meanwhile, the temperature of the high-temperature resistant ceramic chip is increased to be higher than the melting point of the fuel, so that the continuous ignition and heating effects are achieved, the combustion state in the multifunctional Laval nozzle is further enhanced, and finally supersonic flame of Mach 5-9 is formed;
(7) synchronously turning on a switch of the powder feeder, feeding powder by a plurality of powder feeding needles, fully heating and accelerating the powder at the central position of flame, converting the state into uniform and stable flame flow in a supersonic melting state, and ejecting the flame flow out through a gun barrel;
(8) the powder is sprayed to the surface of a workpiece at the central position of the flame flow, so that the escape of the powder is greatly reduced, the deposition rate is greatly improved, and meanwhile, the problems of uneven distribution of light spot powder and excessive accumulation of axial powder in single axial powder feeding are solved by mixing a plurality of powder flows which are distributed centrosymmetrically.
When the device is used for preparing the coating, the preferred technological parameters are as follows:
the kerosene flow of a single independent combustion chamber is 10-30L/h, and the kerosene pressure is 1.5-1.8 MPa; the oxygen flow is 700-1000L/min, and the pressure is 1.8-3 MPa; the high-pressure air flow is 10-90m3Min, pressure is 0.8-1 MPa; only needs to provide 3000-; the powder feeding nitrogen flow rate corresponding to a single powder feeding is 5-15L/min, and the nitrogen pressure is 0.8-1.2 MPa. If the independent combustion chamber quantity is n (the recommended value is 3-9), the total kerosene flow is n (10-30L/h), the oxygen flow is n (700-1000L/min) and the cooling water flow is n (3000-5000L/h). If the quantity of powder injection is m (the recommended value is 3-9), the total nitrogen flow rate of powder injection is m (5-30L/min). In addition, the diameter range of the flame flow is recommended to be 34.5 mm-60 mm, the performance of the prepared coating is not lower than the current mainstream level, and the production efficiency is greatly improved.
The invention adopts a plurality of unique independent combustion chambers, a multifunctional Laval nozzle and a gun barrel (19-33 mm) with an ultra-large caliber to form a super supersonic flame spray gun structure. The problem of in order to improve hot spraying efficiency among the traditional scheme, the burning that single increase spray gun size brought is insufficient, temperature distribution is inhomogeneous and the rifle body temperature and the too high great potential safety hazard of pressure is solved. The powder feeding device adopts an innovative multi-path symmetrical and uniform distribution mode to synthesize a bundle of powder flow with large diameter, large powder feeding amount and uniform powder distribution, and a plurality of independent combustion chambers are arranged to be subjected to multipoint dispersed and sufficient combustion so as to obtain higher heat efficiency, so that the powder flow with large diameter is positioned at the central position of flame, the deposition rate and the powder feeding uniformity of powder on the surface of a part are greatly improved, and the spraying time is reduced by times due to the powder flow with large diameter; in addition, an innovative multi-path double-layer water cooling system structure is adopted in the scheme of the invention, so that the water cooling efficiency of the spray gun is greatly improved; the novel supersonic flame thermal spraying spray gun has large flame flow size, high power, high powder deposition efficiency and high water cooling efficiency, and can be effectively applied to coating spraying of oversized parts.
Drawings
FIG. 1 is a schematic structural view of a multi-combustion chamber high-power high-efficiency supersonic flame thermal spraying spray gun;
FIG. 2 is a schematic view of a multi-combustion chamber high power high efficiency supersonic flame thermal spray apparatus;
FIG. 3 is a schematic view of a multi-functional Laval nozzle;
fig. 4 is a schematic structural diagram of a high-temperature resistant ceramic wafer.
In the figure: 1-water cooling jacket, 2-first cooling water channel, 3-gun barrel shell, 4-second cooling water channel, 5-gun barrel, 6-stable support ring, 7-gun body shell, 8-multifunctional Laval nozzle, 9-water outlet, 10-independent combustion chamber, 11-oil-gas coaxial injector, 12-oil-gas mixing atomizer, 13-oxygen inlet, 14-kerosene inlet, 15-separator, 16-water inlet, 17-high pressure air inlet, 18-powder injection, 19-air distributor, 20-high temperature resistant ceramic chip, 21-gun body rear cover and 22-ignition needle port.
Detailed Description
The invention will be further explained with reference to the accompanying drawings
Referring to fig. 1, a structural schematic diagram of a 4-combustion-chamber high-power high-efficiency supersonic flame thermal spraying spray gun is shown, wherein a gun tube 5 is larger in diameter than a traditional thermal spraying spray gun barrel, the bottom of the gun tube is tightly matched with a Laval nozzle opening, fastening is carried out through a fastening screw, and a high-temperature-resistant sealing ring is sealed. The barrel 5 may first increase the flame speed and second allow the powder to be heated for a suitable time to achieve an optimum melt state. Gun shell 3 and gun shell 7 thread sealing connection to the contact port uses rubber seal to seal, guarantees that the cooling water does not reveal. Barrel shell mouth and barrel mouth have stable support ring 6, improve the stability and the axiality of barrel, avoid the barrel to warp, promote the life-span of barrel, are sealed with high temperature resistant sealing washer simultaneously. The water cooling jacket 1 is connected to the gun body shell 3 through threads and sealed through a sealing ring, and the smoothness of backflow of cooling water in the first cooling water channel 2 is guaranteed. The gun body shell 3 is a hollow special-shaped structure, a main body frame of the spray gun is ensured, the gun body shell 3 is in threaded connection with the water cooling jacket 1, a sealing ring is sealed, and a threaded opening of a water inlet is reserved at the tail part of the gun body shell 3. The side surface of the multifunctional Laval nozzle 8 is provided with 4 axisymmetric through holes which are uniformly distributed and can be tightly and hermetically connected with a plurality of independent combustion chambers 10 to form a communicating space. In order to make the flame flow pass smoothly, the included angle between the axis of the independent combustion chamber and the axis of the Laval nozzle is not too large or too small, and the included angle between the axis of the independent combustion chamber and the axis of the Laval nozzle is preferably 30-45 degrees.
Refer to fig. 2 and show a multi-functional laval nozzle structure detail sketch map, multi-functional laval nozzle 8 side evenly distributed a lot of little bosss, boss surface and 3 inner wall clearance fit of rifle body shell, play the effect of certain support, have certain distance between little boss and the little boss simultaneously, make smooth the passing through of cooling water in second cooling water passageway 4 smoothly, little boss has increased the area of contact of multi-functional laval nozzle 8 with the cooling water simultaneously, make cooling efficiency improve greatly. Furthermore, the inner wall of the tail part of the multifunctional Laval nozzle 8 is provided with a circle of bulges which are contacted with the high-temperature resistant ceramic chip 20, thereby playing the role of limiting the position and moving of the high-temperature resistant ceramic chip 20.
Referring to fig. 3, a schematic structural diagram of a high temperature resistant ceramic chip suitable for 4 powder feeding needles is shown, the high temperature resistant ceramic chip 20 is provided with two through holes, one through hole is used for the powder feeding needles to pass through, the 4 through holes are axisymmetrically and uniformly distributed on the ceramic chip, and the reasonable distance between the through holes ensures that the powder flow cross section has equal powder quantity; the other through holes are communicated with high-pressure air, are more, denser and smaller, are axially and uniformly distributed on the high-temperature-resistant ceramic plate 20, and have the functions of accelerating powder and enabling the powder to be distributed more uniformly in flame flow. 4 powder feeding needles ensure the large powder feeding amount required by spraying, so that the powder feeding is more efficient and uniform, and the powder is heated more uniformly.
One side of the high-temperature resistant ceramic chip 20 is contacted with a circle of limiting bulges on the inner wall of the multifunctional Laval nozzle 8, and the other side is contacted with the air separator 19 and sealed by a sealing ring of the air separator 19. When the spray gun works, the high-temperature resistant ceramic plate 20 is heated to be above the melting point of fuel, has a continuous ignition function, and can greatly improve the combustion state inside the multifunctional Laval nozzle 8. The air separator 19 is provided with a plurality of through holes inside, so that high-pressure air is uniformly transmitted to the multifunctional porous ceramic plate 20, the edges of two end faces of the air separator are respectively provided with a circle of bulges, one end of each bulge is in sealing contact with the ceramic plate 20, the other end of each bulge is in sealing contact with the gun body rear cover 21, and the air separator is also provided with 4 threaded holes, and the threaded holes are matched with external threads on the powder feeding needle 18 and used for fixing the powder feeding needle. The gun body rear cover 21 is in threaded connection with the gun body shell 3 and is provided with 4 air inlets, a water inlet and a powder feeding needle hole. The oil-gas mixing atomizer 12 is of a hollow structure, a separator 15 with multiple pores is arranged in the oil-gas mixing atomizer, an oil inlet 14, an oxygen inlet 13 and an ignition needle port 22 are arranged outside the oil-gas mixing atomizer, the main function is to fully and uniformly mix and atomize kerosene and oxygen, send oil-oxygen mixed gas into the oil-gas coaxial injectors 11, inject the oil-oxygen mixed gas into each independent combustion chamber 10, and are in threaded connection with the oil-gas coaxial injectors 11, and sealing rings are sealed. The oil-gas coaxial injector 11 is in sealing contact with a high-temperature sealing ring of the independent combustion chamber 8, is in threaded connection with the gun shell 7, is sealed by the sealing ring, and is internally provided with a coaxial oil-gas outlet and an ignition needle hole.
Referring to fig. 4, a schematic diagram of a 4-combustion-chamber high-power high-efficiency supersonic flame thermal spraying device is shown. The water cooling machine with 4 circulating water pumps is provided, a water cooling loop driven by each circulating water pump is matched with each water inlet and each water outlet, and the temperature of the spray gun in continuous operation is required to be kept within a reasonable temperature range. Kerosene control box with 4 oil pumpsEach oil pump corresponds each independent combustion chamber, constitutes a spray gun combustion system, and kerosene supplies can external connection kerosene pipeline or kerosene storage tank. The powder feeder is provided with 4 powder feeding tanks and powder feeding pipelines, so that the task of large powder feeding amount is fully shared, and the powder feeding state is more uniform in the multifunctional Laval nozzle. The pressure and flow rate of the air compressor and the cold dryer for providing clean and dry air need to meet the requirements of the spray gun for compressed air, the pressure requirement is 0.8-1MP, and the flow rate is 10-90m3And/min. The high-pressure oxygen supply can adopt 8 high-pressure liquid oxygen tanks, after liquid oxygen is gasified by a gasification tower, 4 pipelines connect the oxygen to the oxygen inlet of the oil-gas mixing atomizer on each independent combustion chamber 10, and each branch pipeline regulates the oxygen supply of each branch pipeline by an oxygen pressure reducing valve. The ignition device adopts 4 lines of high-voltage spark plugs to perform the ignition function of the independent combustion chamber 10, and 4 independent ignition systems are formed. The central control cabinet is used for integrally controlling the on-off and adjustment of the water cooling system, the high-pressure air system, the powder feeding system, the oil supply system, the oxygen supply system and the ignition system, and monitoring the state of each system, and if a problem occurs, the central control cabinet can timely feed back an alarm.
The device and the method of the invention have the specific working process that:
(1) checking whether the power supply system, the gas supply system, the oil supply system, the powder feeding system and the ignition system are in normal states or not, and determining whether problems exist or not;
(2) the water cooling machine is opened, the spray gun is in a water cooling state, 4 paths of cooling water enter from a water inlet 16 at the tail end of the spray gun and flow through the second cooling water channel 4 successively, the first cooling water channel 2 flows back to the water cooling machine, the multi-path double-layer water cooling channel spray gun structure enables the water cooling area to be greatly improved, and the water cooling efficiency is obviously improved.
(3) Opening high-pressure air and powder feeding carrier gas, wherein the powder feeding carrier gas can be argon, nitrogen or other inert gases, so that the spaces of the independent combustion chamber 10 of the spray gun, the multifunctional Laval nozzle 8 and the gun barrel 5 are in certain pressure and flow rate states;
(4) synchronously turning on 4 kerosene pumps and oxygen supply switches, adjusting the flow range required by reasonable ignition, fully mixing kerosene and oxygen through an oil gas atomizer 12 to form oil gas mist flow, spraying the oil gas mist flow into each independent combustion chamber 10 from a coaxial outlet, then converging the oil gas mist flow into a multifunctional Laval nozzle 8, and spraying the oil gas mist flow from an outlet of a gun barrel 5;
(5) synchronously turning on a switch of an ignition system, simultaneously igniting the 4 independent combustion chambers, rapidly boosting the internal space of the spray gun at the moment, enabling the flame to pass through a converging section of the Laval nozzle 8, increasing the speed, enabling the flame to pass through a throat part of the multifunctional Laval nozzle 8, passing through an expanding section, forming supersonic speed flame, and further accelerating the speed through a barrel 5 section;
(6) after the ignition program is finished, the flow of air, kerosene and oxygen is automatically adjusted to the set parameters required by the spray gun spraying, the flame speed is further increased, and meanwhile, the temperature of the high-temperature resistant ceramic chip 20 is increased to be higher than the melting point of the fuel, so that the continuous ignition and heating effects are achieved, the combustion state in the multifunctional Laval nozzle 8 is further enhanced, and finally the supersonic flame with the speed of 5-9 Mach is formed;
(7) synchronously opening 4 powder feeder switches, feeding powder simultaneously by 4 paths of powder feeding needles, fully heating and accelerating the powder at the central position of flame, changing the state into uniform and stable flame flow in a supersonic melting state, and spraying the flame flow out through a gun barrel;
(8) the powder is sprayed to the surface of a workpiece at the central position of the flame flow, so that the escape of the powder is greatly reduced, the deposition rate is greatly improved, and meanwhile, the problems of uneven distribution of light spot powder and excessive accumulation of axial powder in single axial powder feeding are solved by mixing a plurality of powder flows which are distributed centrosymmetrically.
Detailed embodiment of the Process parameters for preparing coatings 1
The technological parameters of the four-combustion chamber type high-power high-efficiency supersonic flame hot spraying WC-10Co-4Cr powder to prepare the coating are as follows: the kerosene flow of a single independent combustion chamber is 24L/h, and the kerosene pressure is 1.7 MPa; the oxygen flow is 850L/min, and the pressure is 2.0 MPa; the flow rate of nitrogen for single powder feeding is 10L/min, and the pressure is 1 MPa; high pressure air flow rate is 20m3Min, pressure is 1.0 MPa; a single water pump is required to provide 4000L/h of cooling water flow. The total kerosene flow was 96L/h, the oxygen flow was 3400L/min and the cooling water flow was 16000L/h). The total powder feeding nitrogen flow rate was 40L/min. The distance between the spray gun and the workpiece is 690mm,under the combined action of the 4-combustion-chamber supersonic flame thermal spraying spray gun and the 4-path symmetrical and uniform distribution powder flow, the area of effective powder flow in flame is greatly increased, the deposition rate is increased to about 67 percent, the deposition rate is increased by about 23 percent compared with about 42 percent of the current advanced oxygen kerosene supersonic flame thermal spraying gun, and meanwhile, the diameter of the flame flow is about 40mm, so that the spraying time of the coating with the same thickness and area is reduced by about 84 percent, and the production efficiency of the coating is remarkably improved. And the performance indexes of the prepared coating are as follows: the bonding strength of the coating and the matrix is more than or equal to 82MPa, the porosity of the coating is less than or equal to 0.6 percent, and the average microhardness is 1270HV0.2The abrasion resistance is about 11.5 times that of 0Cr13Ni5Mo stainless steel.
Specific embodiment of the Process parameters for preparing the coating 2
The technological parameters of the four-combustion-chamber type high-power high-efficiency supersonic flame thermal spraying Co-Cr-Ni-Al-Y powder for preparing the coating are as follows: the kerosene flow of a single independent combustion chamber is 22L/h, and the kerosene pressure is 1.7 MPa; the oxygen flow is 830L/min, and the pressure is 1.9 MPa; the flow rate of nitrogen for single powder feeding is 10L/min, and the pressure is 1 MPa; high pressure air flow rate is 16m3Min, pressure is 1 MPa; a single water pump is required to provide 4000L/h of cooling water flow. The total kerosene flow was 88L/h, the oxygen flow was 3320L/min and the cooling water flow was 16000L/h. The total powder feeding nitrogen flow rate was 40L/min. The distance between the spray gun and the workpiece is 600 mm. The deposition rate is improved to about 69.5 percent, and is improved by about 24.5 percent compared with the deposition rate of about 45 percent of the current advanced oxy-kerosene supersonic flame thermal spraying gun. Meanwhile, the diameter of the flame flow is about 40mm, so that the spraying time of the coating with the same thickness and area is reduced by about 84%, and the production efficiency of the coating is obviously improved. The performance parameters of the Co-Cr-Ni-Al-Y alloy coating prepared at the same time are as follows: the average porosity is less than or equal to 0.5 percent, the bonding strength of the coating is more than or equal to 67MPa, the thermal shock resistance frequency at 700 ℃ is more than or equal to 40 times, and the surface roughness Ra is about 6.1um, thereby being beneficial to the bonding of the working layer and the transition layer.
Detailed embodiment of the Process parameters for preparing coatings 3
The technological parameters of the coating prepared by the four-combustion-chamber type high-power high-efficiency supersonic flame thermal spraying of WC-12Co powder are as follows: the kerosene flow of a single independent combustion chamber is 23L/h, and the kerosene pressure is 1.7 MPa; oxygen flow rate is 840L/min, pressure is 1.9MPa; the flow rate of nitrogen for single powder feeding is 10L/min, and the pressure is 1 MPa; high pressure air flow rate is 18m3Min, pressure is 1.0 MPa; a single water pump is required to provide 4000L/h of cooling water flow. The total kerosene flow was 92L/h, the oxygen flow was 3360L/min and the cooling water flow was 16000L/h). The total output powder nitrogen flow was 40L/min. The distance between the spray gun and the workpiece is 650mm, the area of effective powder flow in the flame is greatly increased under the combined action of the 4-combustion-chamber supersonic flame thermal spraying spray gun and the 4-path symmetrical and uniform powder flow distribution mode, the deposition rate is increased to about 66 percent, the deposition rate is increased by about 26 percent compared with about 40 percent of the current advanced oxygen kerosene supersonic flame thermal spraying gun, and meanwhile, the diameter of the flame flow is about 40mm, so that the coating spraying time of the coating with the same thickness and area is reduced by about 85 percent, and the coating production efficiency is remarkably improved. And the performance indexes of the prepared coating are as follows: the bonding strength of the coating and the matrix is more than or equal to 76MPa, the porosity of the coating is less than or equal to 0.9 percent, and the average microhardness is 1150HV0.2。
The above description is only a preferred embodiment of the present invention, and several modifications may be made without departing from the technical spirit of the present invention, and it should be construed as being within the scope of the present invention.
Claims (10)
1. A multi-combustion chamber high-power high-efficiency supersonic flame thermal spraying spray gun is characterized by comprising a spray gun shell, wherein a core unit comprising a Laval nozzle, a plurality of independent combustion chambers and a gun barrel is arranged in the spray gun shell; the tail end caliber of the expansion section of the laval nozzle is matched with the caliber of the gun barrel, the expansion section of the laval nozzle and the gun barrel are tightly connected, a plurality of through holes are uniformly formed in the middle section of the laval nozzle in the circumferential direction, an independent combustion chamber is installed at each through hole, high-pressure air and spraying powder enter the laval nozzle cavity from the tail portion of the laval nozzle, the independent combustion chamber is used for spraying oil-gas mixture into the laval nozzle cavity and igniting the oil-gas mixture, and a multi-path double-layer water cooling channel is formed among the water cooling sleeve, the spray gun shell and the core unit.
2. The multi-combustion chamber high power high efficiency supersonic flame thermal spray gun of claim 1, wherein the barrel bore is 19mm to 33 mm.
3. The multi-combustion-chamber high-power high-efficiency supersonic flame thermal spraying spray gun according to claim 1, wherein the independent combustion chamber is of a cylindrical structure, one end of the independent combustion chamber is hermetically connected with the through hole on the laval nozzle, and the other end of the independent combustion chamber is sequentially provided with the oil-gas coaxial injector and the oil-gas mixing atomizer, the oil-gas mixing atomizer is used for uniformly mixing and atomizing fuel and oxygen and then sending the atomized fuel and oxygen into the oil-gas coaxial injector so as to be sprayed into the independent combustion chamber, and the oil-gas mixing atomizer and the oil-gas coaxial injector are correspondingly provided with through ignition needle holes for extending an ignition needle into the independent combustion chamber.
4. The multi-combustion-chamber high-power high-efficiency supersonic flame thermal spraying spray gun according to claim 1, wherein 3-9 independent combustion chambers are uniformly distributed in the circumferential direction of the laval nozzle.
5. The multi-combustion-chamber high-power high-efficiency supersonic flame thermal spraying spray gun according to claim 1, wherein the tail of the laval nozzle is sequentially provided with a high-temperature resistant porous ceramic plate and an air separator, the air separator and the high-temperature resistant ceramic plate are correspondingly provided with a plurality of axially-symmetric and uniformly-distributed powder feeding pinholes which are used for extending a powder feeding needle into the laval nozzle cavity, the air separator is uniformly provided with through holes for uniformly transmitting high-pressure air to the high-temperature resistant porous ceramic plate, and the high-temperature resistant porous ceramic plate is uniformly provided with pores for uniformly transmitting the high-pressure air to the laval nozzle cavity.
6. The multi-combustion-chamber high-power high-efficiency supersonic flame thermal spraying spray gun according to claim 5, wherein a circle of limiting bulges are arranged on the inner wall of the Laval nozzle, a circle of bulges are arranged on the edges of the two ends of the air separator, one surface of the high-temperature resistant porous ceramic plate is abutted against the limiting bulges, the other surface of the high-temperature resistant porous ceramic plate is in sealing contact with the bulges at one end of the air separator, and the bulges at the other end of the air separator are in sealing contact with the spray gun shell; the powder feeding needle hole on the air separator is provided with threads to be matched with the threads of the powder feeding needle.
7. The multi-combustion-chamber high-power high-efficiency supersonic flame thermal spraying spray gun as claimed in claim 1, wherein a first sealed space is formed between the spray gun shell and the core unit, a second sealed space is formed between the water cooling jacket and the spray gun shell, a plurality of water inlets are formed at the tail end of the spray gun shell, a plurality of openings are formed at the front end of the spray gun shell, the first sealed space and the second sealed space are communicated through the openings, and a plurality of water outlets equal to the water inlets are formed at the tail end of the water cooling jacket, so that a multi-path double-layer water cooling channel is formed.
8. The multi-combustion-chamber high-power high-efficiency supersonic flame thermal spraying gun as claimed in claim 1, wherein a plurality of bosses independent of each other are uniformly arranged on the outer side wall of the laval nozzle, the surfaces of the bosses are in clearance fit with the gun housing, and cooling water passes through the bosses.
9. The multi-combustion-chamber high-power high-efficiency supersonic flame thermal spraying gun as claimed in claim 1, wherein the gun housing comprises a shell outside the laval nozzle and the independent combustion chamber, a shell outside the barrel, and a rear cover outside the rear of the laval nozzle, a stable support ring is arranged between the head end of the shell and the barrel for sealing, the end of the shell is connected with the shell in a sealing manner, and the rear cover is connected with the shell in a sealing manner and the end of the laval nozzle.
10. The multi-combustion chamber high power high efficiency supersonic flame thermal spray gun of claim 1, wherein the spray gun is adapted to perform when spraying: for each independent combustion chamber, the fuel flow is 10-30L/h, and the kerosene pressure is 1.5-1.8 MPa; the oxygen flow is 700-1000L/min, and the pressure is 1.8-3 MPa; 3000-5000L/h cooling water flow is required to be provided correspondingly; the high-pressure air flow is 10-90m3Min, pressure is 0.8-1 MPa; powder feeding nitrogen flow corresponding to single powder feeding5 to 15L/min, and the nitrogen pressure is 0.8 to 1.2 MPa.
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| CN202111295844.XA CN113909016A (en) | 2021-11-03 | 2021-11-03 | Multi-combustion-chamber high-power high-efficiency supersonic flame thermal spraying spray gun and thermal spraying device thereof |
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| CN1038597A (en) * | 1988-05-11 | 1990-01-10 | 珀金·埃尔默公司 | High velocity powder thermal and method |
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| JP2020037720A (en) * | 2018-09-03 | 2020-03-12 | トーカロ株式会社 | Formation method of sprayed coating, high-speed flame spraying equipment and high-speed flame spraying nozzle |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN1038597A (en) * | 1988-05-11 | 1990-01-10 | 珀金·埃尔默公司 | High velocity powder thermal and method |
| CN201043190Y (en) * | 2007-06-14 | 2008-04-02 | 中国民航大学 | Mixed combustion-supporting superspeed flame spraying gun in liquid fuel-oxygen-air gun |
| CN106016258A (en) * | 2016-06-23 | 2016-10-12 | 水利部杭州机械设计研究所 | Novel hypersonic flame spraying gun |
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