CN114959543A - Thermal spraying strengthening repair method for superficial defects of metal casting part - Google Patents
Thermal spraying strengthening repair method for superficial defects of metal casting part Download PDFInfo
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Images
Classifications
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
- C23C4/129—Flame spraying
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/02—Pretreatment of the material to be coated, e.g. for coating on selected surface areas
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
- C23C4/06—Metallic material
- C23C4/073—Metallic material containing MCrAl or MCrAlY alloys, where M is nickel, cobalt or iron, with or without non-metal elements
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
- C23C4/10—Oxides, borides, carbides, nitrides or silicides; Mixtures thereof
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
- C23C4/131—Wire arc spraying
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
- C23C4/134—Plasma spraying
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/18—After-treatment
- C23C4/185—Separation of the coating from the substrate
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Physics & Mathematics (AREA)
- Plasma & Fusion (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Coating By Spraying Or Casting (AREA)
Abstract
The invention discloses a thermal spraying strengthening repair method for superficial defects of a metal casting part, which comprises the following steps: and (2) pretreating the surface of the metal casting, putting the pretreated metal casting into a closed container for vacuum hole sealing, curing and drying, and preparing a thermal spraying coating on the surface of the dried metal casting by adopting a thermal spraying process. The thermal spraying strengthening repair method for the superficial defects of the metal casting can effectively repair tiny holes and possibly existing slender gaps in the superficial surface layer of the metal casting.
Description
Technical Field
The invention relates to the technical field of metal strengthening repair, in particular to a thermal spraying strengthening repair method for superficial defects of a metal casting part.
Background
The casting part is easy to generate defects such as holes, cracks, inclusions, segregation and the like on a shallow surface due to the limitation of the manufacturing process, and the defects influence the working durability of the part under different conditions, such as corrosion resistance, shock resistance, fatigue, shock absorption and the like, and machinability, weldability and other process properties.
The quality of the casting has great influence on the service performance of mechanical products. For example, the wear resistance and dimensional stability of machine tool castings directly affect the precision retention life of the machine tool; the sizes of the impellers and the inner cavities of the shells of various pumps, the accuracy of molded lines and the surface roughness directly influence the working efficiency, the energy consumption, the development of cavitation erosion and the like of the pumps and the hydraulic systems; the defects of holes, cracks and slag inclusion on the surfaces of the inner cavities of various pump bodies directly influence the complete enveloping performance of the pump shell on the medium, and leakage occurs in severe cases; the strength and chilling and heating resistance of castings such as a cylinder body, a cylinder cover, a cylinder sleeve, a piston ring, an exhaust pipe and the like of the internal combustion engine directly influence the service life of the engine.
The defects of the shallow surface of the casting are generally as follows: air holes, bonded sand, sand inclusion, sand holes, expanded sand and the like. Some defects are located on the inner side of the shallow surface layer, and the appearance inspection method cannot detect the defects. During the service period of the casting part, the superficial defects are exposed one by one along with the corrosion and the penetration of the surface material by the medium, and the defects become more serious along with the increase of the service time, and finally develop into cracks, cracks or perforations.
Once the defects of the shallow surface layer of the metal casting in service are found, the repair is required, and the current industry generally adopts methods such as welding, cold welding, metal repairing agent smearing and the like. However, the welding repair method has the disadvantages that the input heat of the cast part is too large, hot cracks and thermal stress are easily generated, the toughness and the plasticity of the cast part are reduced, and the large-area repair is not suitable; although the heat input amount of the cold welding repair method is not large, the cold welding repair method is only suitable for repairing local small-area areas and is not suitable for repairing large areas; the metal healant and metal are physically combined, the bonding force is general, the metal healant is easy to fall off, and the metal healant is only suitable for temporary repair and is not suitable for long-term use.
The thermal spray coating repair technique is a commonly used surface repair and strengthening technique. The thermal spraying technology is a method of heating a spraying material to a molten or semi-molten state by using a heat source, spraying and depositing the spraying material on the surface of a pretreated substrate at a certain speed to form a coating, and endowing the surface of the substrate with special properties. The thermal spraying repair process is a process in which particles in a molten or semi-molten state interact with the surface of a workpiece and the particles, and the basic physical process is described as follows: the molten or semi-molten particles impact/stack on the workpiece surface; the particles are cooled/solidified on the surface of the workpiece and are bonded with the surface of the workpiece; the subsequent particles continue to impact the deposited particles to form a coating; all particles are gradually cooled. But the existing thermal spraying application has the defects of casting surface repair:
1) partial defect can not be filled
The surface and the inner part of the shallow surface of the metal casting have the defects of micropores, air holes, slag inclusion and the like. If the thermal spraying coating technology is adopted for repairing, roughening pretreatment is needed, more micro holes in the shallow surface layer and possibly existing slender gaps can be exposed on the roughened surface of the metal casting, and the size is 0.1mm to millimeter level.
During the construction of the thermal spraying spray gun, the caliber of the spray gun is generally 5-10mm, the caliber is far larger than the size of a tiny defect, and molten or semi-molten particles are sprayed out from a gun mouth and generally travel at a constant speed to sequentially spray and cover the surface of the whole workpiece. Therefore, the thermal spraying technology is suitable for large-area and flat workpieces without local defects. For local micropores, air holes and slag inclusion, the spray gun can not spray and fill at fixed points, so that the condition that local defects can not be filled is inevitably existed when the surface of a casting is repaired.
2) Unfilled defects become performance weaknesses
Hot spraying unfilled micro defects (micropores, pores, slag inclusion pores) which are microscopically a depressed area. Taking a workpiece used in a corrosive environment as an example, during the service period of the workpiece, the depressed area is easy to gather media and generate a local high-concentration corrosive area, which has adverse effects on a coating material, the long-term service may cause the damage of the depressed area of the coating, once the depressed area is cracked or peeled off, the media enters the bonding surface of the coating and a workpiece substrate through the damaged part, the bonding of the coating and the substrate is gradually damaged, and finally the coating is peeled off and failed wholly.
Therefore, the existing technology for the tiny holes inside the shallow surface layer and the possible slender gaps can not be effectively repaired by the thermal spraying technology.
Disclosure of Invention
In view of the above, in order to overcome the defects of the prior art, the present invention aims to provide a thermal spray strengthening repair method for shallow defects of metal castings.
In order to achieve the purpose, the invention adopts the following technical scheme:
a thermal spraying strengthening repair method for superficial defects of a metal casting part comprises the following steps: and (2) pretreating the surface of the metal casting, putting the pretreated metal casting into a closed container for vacuum hole sealing, curing and drying, and preparing a thermal spraying coating on the surface of the dried metal casting by adopting a thermal spraying process.
According to some preferred embodiments of the invention, the sealing agent used in sealing is a synthetic resin-based organic sealing agent such as a methacrylate sealing agent having a viscosity of 0.05 to 0.0.09 Pa.S at 25 ℃.
According to some preferred embodiments of the present invention, the parameters for sealing the pores are: vacuum degree is less than or equal to 100Pa (abs); the hole sealing time is more than or equal to 2 hours; temperature at the time of curing: 85-90 ℃; the curing time is more than or equal to 1 hour; the drying is natural drying for more than or equal to 8 hours or hot air drying for more than or equal to 1 hour.
According to some preferred embodiments of the invention, the thermal spray process is a supersonic flame spray with the parameters: the flame temperature is 2500-3500 ℃ and the temperature is preferably 3000 ℃, and the impact velocity of the molten particles is 650-700 m/s.
According to some preferred embodiments of the invention, the thermal spray process is arc spraying, and the parameters are: the flame temperature is 4000-.
According to some preferred embodiments of the invention, the thermal spray process is plasma spray with parameters of: the flame temperature is 9000-11000 ℃ and preferably 10000 ℃, and the impact velocity of the molten particles is 300-350 m/s.
According to some preferred embodiments of the invention, when the thermal spray coating,
when chemical corrosion resistance is required, the thermal spraying coating material is Ni, NiCr, NiAl and Al 2 O 3 、TiO 2 、Y 2 O 3 One or more of Tai and Mo;
when the atmosphere/electrochemical corrosion resistance is required, the thermal spraying coating material is one or more of Al, Zn, AlZn, bronze, stainless steel, Monel alloy and nickel-based alloy;
when oxidation resistance is needed, the thermal spraying coating material is one or more of NiCr, MCrAlY (M is Ni, Co or Fe), Mo, nickel-based alloy and aluminide;
when the wear resistance is required, the thermal spraying coating material is Al 2 O 3 /TiO 2 、Cr 2 O 3 WC/Co, TiC/NiCr, high carbon steel, stainless steel, NiCrBSi, CoCrW, Cr 3 C 2 One or more of/NiCr and Mo;
when the thermal spray coating is a thermal barrier coating, the thermal spray coating material is ZrO 2 /Y 2 O 3 、ZrO 2 /MgO、ZrO 2 /CeO 2 One or more of MCrAlY and NiAl.
According to some preferred aspects of the invention, a post-coating treatment step is included: the method comprises the steps of coating an organic hole sealing agent on the surface of a coating, standing, and solidifying the hole sealing agent in the pores of the coating to fill the pores of the coating; and/or, remelting the coating; and/or machining the workpiece. Specifically, the anticorrosion coating is coated and sealed, an organic sealing agent is coated on the surface of the coating, and when the organic sealing agent slowly permeates into tiny pores of the coating, the coating is kept stand for a certain period of time, the sealing agent is solidified and solidified in the pores of the coating, and the pores of the coating are filled; remelting the coating on the workpiece bearing high stress load or impact abrasion; the workpiece with the requirement of dimensional accuracy is subjected to mechanical processing.
According to some preferred embodiments of the invention, the pre-treatment comprises cleaning the surface of the metal casting by one or more of laser cleaning, solvent cleaning, steam cleaning, alkaline cleaning, and thermal degreasing.
According to some preferred aspects of the invention, the pre-treatment comprises roughening the surface of the metal casting by one or more of sand blasting, machining, electro-galling roughening.
Due to the adoption of the technical scheme, compared with the prior art, the invention has the beneficial effects that: the thermal spraying strengthening repair method for the superficial defects of the metal casting can effectively repair tiny holes and possibly existing slender gaps in the superficial surface layer of the metal casting.
Drawings
In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings required to be used in the description of the embodiments are briefly introduced below, and it is obvious that the drawings in the description below are only some embodiments of the present invention, and it is obvious for those skilled in the art that other drawings can be obtained according to the drawings without creative efforts.
FIG. 1 is a schematic cross-sectional view of a metal casting in a preferred embodiment of the invention in its as-received condition without any treatment;
FIG. 2 is a schematic cross-sectional view of a metal casting after purging in a preferred embodiment of the invention;
FIG. 3 is a schematic cross-sectional view of a metal casting after roughening in accordance with a preferred embodiment of the present invention;
FIG. 4 is a schematic cross-sectional view of a metal casting after being sealed in accordance with a preferred embodiment of the present invention;
FIG. 5 is a schematic cross-sectional view of a metal casting after thermal spraying in a preferred embodiment of the invention;
in the attached drawing, a part-1 to be repaired, oil stains or impurities-2, holes-3, gaps-4, a hole sealing agent-5 and a coating-6.
Detailed Description
In order to make those skilled in the art better understand the technical solution of the present invention, the technical solution in the embodiment of the present invention will be clearly and completely described below with reference to the drawings in the embodiment of the present invention, and it is obvious that the described embodiment is only a part of the embodiment of the present invention, and not a whole embodiment. 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.
As shown in fig. 1, oil stains and impurities exist on the surface of the metal casting, and micropores and gaps exist on the shallow surface. In the prior art, effective repair cannot be realized for tiny holes in a shallow surface layer and possibly existing slender gaps.
The thermal spraying strengthening repair method in the embodiment specifically comprises the following steps:
1. pretreatment of
1) Purification
The surface of the metal casting is purified by one or more methods of laser cleaning, solvent cleaning, steam cleaning, alkali cleaning and heating degreasing, and is used for removing grease and tiny impurities on the surface of the workpiece, as shown in figure 2.
2) Coarsening
Roughening the surface of the purified metal casting by adopting one of sand blasting, machining (shafts) and electric roughening (used in the occasions where the former two methods cannot be used) for increasing the contact area between a subsequent coating and a base material; the surface roughness of the base material is increased (Ra is required to be 2-10 um), and the bonding strength of the thermal spraying coating and the workpiece matrix is increased; and the defects such as micropores, pores, slag inclusion holes, gaps and the like of the shallow surface layer (within 0.1 mm) are exposed, as shown in fig. 3.
In this embodiment, a sand blasting and roughening method is adopted, and the specific parameters are as follows: quartz sand or white corundum with the particle size of 8-12 meshes is used, and the sand blasting technological parameters are that the air pressure is 0.6-0.8 MPa, the sand blasting distance is 120-200 mm, and the sand blasting angle is 65-85 degrees.
2. Vacuum sealing
The vacuum hole sealing is to infiltrate a sealing medium (low viscosity liquid) into micropores (or fine seams) by a vacuumizing method, fill the gaps with the sealing medium, and then solidify the sealing medium in the gaps by natural (room temperature), cooling or heating methods and the like to achieve the effect of sealing the micropores and the gaps.
In this embodiment, the roughened workpiece is placed in a closed container, the container is evacuated, and then the sealant is poured to submerge the workpiece, and the sealant naturally flows into micropores and gaps on the surface layer of the workpiece. Due to the action of vacuumizing, air hardly exists in micropores and gaps, so that the micropores can be filled with the sealant, as shown in fig. 4, the integrity of the surface and the near-surface structure of the workpiece is ensured, the flatness of the surface of the workpiece is ensured, and the surface of the workpiece is favorable for preparing a thermal spraying coating on the surface of the workpiece in the next step.
The methacrylate organic hole sealing agent used in the embodiment has the advantages of small viscosity (the viscosity at 25 ℃ is 0.05-0.0.09 Pa & S), strong wetting property, high efficiency and good treatment effect.
The parameters of the vacuum sealing in the embodiment are as follows: vacuum degree: 100Pa (abs) or less; the hole sealing is long: not less than 2 hours; and (3) curing: use hot water solidification (hot water submergence part, hydrothermal conductivity is strong, and the part is whole to be heated up, and solidification effect is good), curing temperature: 85-90 ℃; curing time length: not less than 1 hour; and (3) drying: natural drying for more than or equal to 8 hours or hot air drying (the temperature is 65 ℃) for more than or equal to 1 hour.
3. Thermal spraying
According to different work piece operation requirements, coatings of different materials are prepared on the surface of the casting, as shown in fig. 5.
1) And selecting a proper coating material according to the requirements of the service environment of the metal casting and the casting material. The method is specifically shown in the following table 1:
TABLE 1 coating Material Properties Table
2) Thermal spraying processes include supersonic flame spraying, electric arc spraying, plasma spraying, and the like. Selecting a proper spraying process and corresponding spraying process parameters according to the thermal spraying material, and specifically referring to the following table 2:
TABLE 2 thermal spraying process parameter Table
| Spraying method | Temperature of | Impact velocity m/s of molten particles |
| Supersonic flame spraying | 2500-3500 | 650-700 |
| Electric arc spraying | 4000-5000 | 220-250 |
| Plasma spraying | 9000-11000 | 300-350 |
In the thermal spraying of the embodiment, firstly, the prepared workpiece surface is sprayed in as short a time (within 4 h) as possible; secondly, the aim of controlling the spraying parameters is to improve the spraying speed, increase the density of the coating, improve the bonding strength of the coating and obtain a high-quality coating. Meanwhile, the coating material is sprayed on the surface of the cast after hole sealing, the local part of the cast can be directly bonded with the hole sealing agent, the coating material and the thermal spraying parameters are the optimal results, the coating is processed according to the materials and the corresponding parameters, the coating can generate better bonding force with the hole sealing agent, and the bonding force reaches 40 MPa.
4. Post-treatment of coatings
According to the service requirements of different types of coatings or workpieces, the post-treatment method generally comprises three types:
(1) for the anticorrosive coating, in order to prevent a medium from entering the coating and reaching a base material, the coating and sealing treatment is carried out, namely, an organic sealing agent is coated on the surface of the coating, when the organic sealing agent slowly permeates into tiny pores of the coating, the coating is kept stand for a certain period of time, the sealing agent is solidified and solidified in the pores of the coating, and the pores of the coating are filled.
The sealing agent used here is a sealing agent for the thermal spray coating itself, and a sodium silicate solution containing CrO may be used. The sealant for sealing the holes before thermal spraying is a sealant for casting holes, and the application objects of the sealant and the casting holes are different.
(2) For workpieces which are subjected to high stress loads or impact wear, the sprayed layer is remelted so that the coating which is mainly mechanically bonded with the base material and is loose and porous is changed into a compact sprayed and melted layer which is metallurgically bonded with the base body.
(3) The workpiece with the requirement of dimensional accuracy is subjected to mechanical processing.
Example (b):
the surface of a pump shell of a seawater pump of a certain company has the defects of casting air holes, slag inclusion and the like, and the problem of leakage occurs after 1 year of use. The thermal spraying strengthening repair method adopted in the embodiment is as follows:
(1) casting surface cleaning
The pump housing surface was continuously flushed for more than 2 hours with water containing 15% neutral surfactant (detergent) to ensure that the casting surface was free of dirt and rust.
(2) Surface roughening of castings
And (3) blasting sand to coarsen the part to be repaired on the surface of the pump casing, wherein quartz sand with the particle size of 12 meshes is adopted, and the blasting process parameters comprise 0.75MPa of air pressure, 155mm of blasting distance and 80 degrees of blasting angle.
(3) Vacuum sealing of casting surface
Putting the whole pump shell into a vacuum hole sealing container, and starting a vacuum hole sealing process. The method comprises the following specific steps: sealing holes for 2 hours by adopting an organic sealing agent under the vacuum degree of 95Pa (abs); then, the mixture was cured with hot water at 88 ℃ for 1.5 hours, and then dried with hot air at 65 ℃ for 1 hour.
(4) Hot spray coating strengthening
And preparing a thermal spraying coating on the surface of the pump shell casting in a thermal spraying workshop. The method comprises the following specific steps: selecting NiCr as a coating material to enable the coating to resist seawater corrosion; the thickness of the coating is 0.5 mm; supersonic flame spraying is adopted: the spraying current is 260A, the air pressure is 0.75MPa, the spraying distance is 165mm, and the spraying angle is 90 degrees.
(5) Post-treatment of coatings
And (3) coating the sealant on the surface of the pump shell after thermal spraying, and curing in the air for 24 hours.
Comparative example
This comparative example is different from the above examples in that the vacuum sealing step of the above step (3) is absent.
In the parts treated by the method, the parts subjected to thermal spraying after hole sealing in the embodiment can continuously run in seawater for more than 5 years without leakage, cracks and other faults, and the service life of the parts is prolonged by more than 5 years. The service life of the part directly subjected to thermal spraying without sealing in the comparative example was about 1 year.
According to the thermal spraying composite strengthening repair method based on the vacuum hole sealing technology, the technical combination of cleaning, coarsening, vacuum hole sealing and thermal spraying is adopted, so that the gap of the superficial defect of the metal casting is filled, and the defect that the surface of the casting is not beneficial to preparing a thermal spraying coating is overcome.
The above embodiments are only for illustrating the technical idea and features of the present invention, and the purpose of the present invention is to enable those skilled in the art to understand the content of the present invention and implement the present invention, and not to limit the protection scope of the present invention by this means. All equivalent changes and modifications made according to the spirit of the present invention should be covered within the protection scope of the present invention.
Claims (11)
1. A thermal spraying strengthening repair method for superficial defects of a metal casting part is characterized by comprising the following steps: and (2) pretreating the surface of the metal casting, putting the pretreated metal casting into a closed container for vacuum hole sealing, curing and drying, and preparing a thermal spraying coating on the surface of the dried metal casting by adopting a thermal spraying process.
2. The thermal spray enhanced repair method according to claim 1, wherein the sealing agent used in sealing is a synthetic resin organic sealing agent having a viscosity of 0.05 to 0.0.09Pa · S at 25 ℃.
3. The thermal spray enhanced repair method according to claim 1, wherein the parameters during hole sealing are as follows: the vacuum degree is less than or equal to 100 Pa; the hole sealing time is more than or equal to 2 hours; temperature at the time of curing: 85-90 ℃; the curing time is more than or equal to 1 hour; the drying is natural drying for more than or equal to 8 hours or hot air drying for more than or equal to 1 hour.
4. The thermal spray enhanced repair method as claimed in claim 2, wherein the thermal spray coating is bonded to the surface of the metal casting and directly bonded to the sealant, and the bonding force between the thermal spray coating and the sealant is greater than or equal to 40 MPa.
5. The thermal spray enhanced repair method according to claim 1, wherein the thermal spray process is supersonic flame spray with parameters of: the flame temperature is 2500-3500 ℃, and the impact velocity of the molten particles is 650-700 m/s.
6. The thermal spray enhanced repair method according to claim 1, wherein the thermal spray process is arc spray with parameters of: the arc temperature is 4000-.
7. The thermal spray enhanced repair method according to claim 1, wherein the thermal spray process is plasma spray with parameters of: the plasma flame temperature is 9000-11000 ℃, and the molten particle impact velocity is 300-350 m/s.
8. The thermal spray enhanced repair method of claim 4, wherein the thermal spray coating material is Ni, NiCr, NiAl, Al 2 O 3 、TiO 2 、Y 2 O 3 One or more of Tai and Mo, so that the prepared coating is resistant to chemical corrosion; and/or the presence of a gas in the gas,
the thermal spraying coating material is one or more of Al, Zn, AlZn, bronze, stainless steel, Monel alloy and nickel-based alloy, so that the prepared coating is resistant to atmospheric/electrochemical corrosion; and/or the presence of a gas in the gas,
the thermal spraying coating material is one or more of NiCr, MCrAlY, Mo, nickel-based alloy and aluminide, so that the prepared coating is oxidation resistant; and/or the presence of a gas in the gas,
the thermal spraying coating material is Al 2 O 3 /TiO 2 、Cr 2 O 3 WC/Co, TiC/NiCr, high carbon steel, stainless steel, NiCrBSi, CoCrW, Cr 3 C 2 One or more of/NiCr and Mo, so that the prepared coating is wear-resistant; and/or the presence of a gas in the gas,
the thermal spraying coating material is ZrO 2 /Y 2 O 3 、ZrO 2 /MgO、ZrO 2 /CeO 2 MCrAlY and NiAl, so that the prepared coating is a thermal barrier coating.
9. The thermal spray enhanced repair method according to claim 1, comprising a post-coating treatment step of: coating the organic hole sealing agent on the surface of the coating, standing, and solidifying the hole sealing agent in the pores of the coating to fill the pores of the coating; and/or, remelting the coating; and/or machining the workpiece.
10. The thermal spray enhanced repair method as claimed in any one of claims 1 to 9, wherein said pretreatment comprises cleaning the surface of said metal casting by one or more of laser cleaning, solvent cleaning, steam cleaning, alkali cleaning, and thermal degreasing.
11. The thermal spray enhanced repair method of any one of claims 1 to 9, wherein the pre-treatment comprises roughening the surface of the metal casting by one or more of sand blasting, machining, electro-galling roughening.
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