CN115354263A - 一种防爆叉车货叉用耐磨涂层组合物及涂层的制备方法 - Google Patents
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Abstract
本发明公开一种防爆叉车货叉用耐磨涂层组合物及涂层的制备方法，耐磨涂层组合物包含以下粉末状成分：Al2O3：40%‑60%；TiO2：20%‑40%；CeO2：10%‑20%；涂层的制备方法包括以下步骤：对防爆叉车货叉外表面进行喷砂粗化处理；准备具有等离子喷涂装置和感应加热重熔装置的高频感应加热重熔线；把防爆叉车货叉装夹在输送网带上输送；将预先混合均匀的耐磨涂层组合物由等离子喷涂装置对防爆叉车货叉表面进行喷涂；输送网带将防爆叉车货叉输送至感应加热重熔装置进行感应加热熔融，冷却后即得耐磨涂层；该涂层可以多道重熔工艺提升涂层厚度增加耐磨性能。由本发明耐磨涂层组合物制备的耐磨涂层与铁接触不会起火、耐磨、耐腐蚀、可快速修复。
Description
技术领域
本发明涉及一种防爆叉车货叉用耐磨涂层组合物及涂层的制备方法。
背景技术
在正常的运行条件下，防爆型工业车辆上可能同外部发生摩擦和碰撞的部分为无火花材质，正常使用在摩擦和碰撞时不产生机械火花的材料包覆起来。例如，铜、铜锌合金、铜铍合金、不锈钢等材料都可以用来防止产生机械火花，因而常规的方法是在叉车上使用黄铜或不锈钢将货叉包覆起来。
防爆叉车的前置货叉等活动部件都采用铜板或者不锈钢材料包裹的工艺，是采用铜板或者不锈钢板做成一个铜套或者不锈钢套包裹住货叉，但存在如下问题：铜板或者不锈钢板套耐磨性能较差；防爆叉车一般在有***性环境使用，该环境中普遍存在硫离子、氯离子等离子的化合物容易造成铜板或者不锈钢板套的腐蚀。目前也有采用等离子喷涂方法和感应加热重熔方法制备防爆涂层的技术，但喷涂后的涂层为金属涂层，仍然存在耐磨性能差、容易受到腐蚀的问题。
发明内容
为了解决现有防爆叉车的前置货叉因采用包裹套或采用金属涂层而产生的耐磨性能差、容易受到腐蚀的问题，本发明提供一种防爆叉车货叉用耐磨涂层组合物及涂层的制备方法。
本发明所述防爆叉车货叉用耐磨涂层组合物，包含以下粉末状成分：
Al2O3：40%-60%；TiO2：20%-40%；CeO2：10%-20%。
上述各成分的粒径均为50-100nm。
本发明还提供一种防爆叉车货叉用耐磨涂层的制备方法，包括以下步骤：
1）对防爆叉车货叉外表面进行喷砂粗化处理；
2）准备高频感应加热重熔线，高频感应加热重熔线包括输送网带和沿输送网带依次分布的等离子喷涂装置和感应加热重熔装置；
3）把防爆叉车货叉装夹在输送网带上，启动输送网带输送防爆叉车货叉；
4）使用等离子喷涂装置将预先混合均匀的上述的防爆叉车货叉用耐磨涂层组合物等离子喷涂到由输送网带送过来的防爆叉车货叉表面；
5）输送网带将涂布了耐磨涂层组合物的防爆叉车货叉输送至感应加热重熔装置，感应加热重熔装置对耐磨涂层组合物进行感应加热熔融，冷却后即得。
在步骤1）中，喷砂粗化处理采用自动喷砂机进行。
在步骤4）中，等离子喷涂时，等离子气体采用氩气作为主气和氢气作为辅气，氩气流量与氢气流量之比为2:1，喷涂电流为550-600A，喷涂电压为50-70V，喷涂距离为80-150mm，送粉量为30-60 min-1，喷涂角度为90°，喷涂一层的厚度为3mm以上。
本发明还提供一种防爆叉车货叉用耐磨涂层，其使用上述的防爆叉车货叉用耐磨涂层的制备方法而得。
有益效果：采用本发明耐磨涂层组合物并使用等离子喷涂技术及感应加热重熔方法能够在货叉表面形成一层厚度为3cm以上的防爆涂层，防爆涂层为陶瓷合成材料，具有高的结合强度、断裂韧性及防腐性能，即具有高的耐磨性及耐腐蚀性，与铁接触不会起火，熔点相对较低，同时存在易修复的特点，可以对磨损部分进行再重熔修复。
附图说明
图1为现有的高频感应加热重熔线的立体结构示意图；
图2为现有的高频感应加热重熔线的平面结构示意图；
图中，1、输送网带；2、等离子喷涂装置；3、感应加热重熔装置。
具体实施方式
下面通过实施例对本发明技术方案进行详细说明，但是本发明的保护范围不局限于所述实施例。
实施例1
一种防爆叉车货叉用耐磨涂层组合物，包含以下粉末状成分：Al2O3：50%；TiO2：30%；CeO2：20%。各成分的粒径均为50-100nm。
实施例2
一种防爆叉车货叉用耐磨涂层组合物，包含以下粉末状成分：Al2O3：40%；TiO2：40%；CeO2：20%。各成分的粒径均为50-100nm。
实施例3
一种防爆叉车货叉用耐磨涂层组合物，包含以下粉末状成分：Al2O3：60%；TiO2：30%；CeO2：10%。各成分的粒径均为50-100nm。
一种防爆叉车货叉用耐磨涂层的制备方法，包括以下步骤。
预先使用混粉机将实施例1的防爆叉车货叉用耐磨涂层组合物混合3h，混合均匀后待用。
1）采用自动辊道式喷砂机（常州苏聚机械设备有限公司）对防爆叉车货叉外表面进行喷砂粗化处理。
2）准备高频感应加热重熔线，高频感应加热重熔线如图1所示，包括输送网带1（SUS314材质，耐1200度以上的高温）和沿输送网带1依次分布的等离子喷涂装置2和感应加热重熔装置3。上述等离子喷涂装置2和感应加热重熔装置3均可参照使用现有技术。
3）把防爆叉车货叉装夹在输送网带1上，启动输送网带1输送防爆叉车货叉。
4）使用等离子喷涂装置2将混合均匀待用的实施例1的防爆叉车货叉用耐磨涂层组合物等离子喷涂到由输送网带1送过来的防爆叉车货叉表面。
在等离子喷涂时，等离子气体采用氩气作为主气和氢气作为辅气，氩气流量与氢气流量之比为2:1，喷涂电流为600A，喷涂电压为70V，喷涂距离为100mm，送粉量为50 min-1，喷涂角度为90°，喷涂一层的厚度为3mm。
5）输送网带1将涂布了耐磨涂层组合物的防爆叉车货叉输送至感应加热重熔装置3，感应加热重熔装置3对耐磨涂层组合物进行感应加热熔融，加热温度为1000℃，消除气孔等缺陷，改善组织不均匀性。冷却后即得防爆叉车货叉用耐磨涂层。
上述制得的防爆叉车货叉用耐磨涂层为陶瓷合成材料，使用陶瓷孔隙率测试仪（DA-600PC）测定的孔隙率为0，使用数显显微硬度计（HVS-1000，载荷为200gf，加载时间为15s）测定的平均显微硬度为HV 900。可见耐磨涂层具有高的结合强度和断裂韧性，耐磨涂层的组成和显微结构能长期保持稳定，耐磨性能可达到货叉基体材质的5-10倍。上述耐磨涂层与铁接触不会起火，熔点相对较低，与基体铁能通过融熔技术高强度结合，且耐磨。
上述未特别提及的技术均参照现有技术。
如上所述，尽管参照特定的优选实施例已经表示和表述了本发明，但其不得解释为对本发明自身的限制。在不脱离所附权利要求定义的本发明的精神和范围前提下，可对其在形式上和细节上作出各种变化。
Claims (6)
1.一种防爆叉车货叉用耐磨涂层组合物，其特征在于，包含以下粉末状成分：
Al2O3：40%-60%；TiO2：20%-40%；CeO2：10%-20%。
2.根据权利要求1所述的防爆叉车货叉用耐磨涂层组合物，其特征在于，各成分的粒径均为50-100nm。
3.一种防爆叉车货叉用耐磨涂层的制备方法，其特征在于，包括以下步骤：
1）对防爆叉车货叉外表面进行喷砂粗化处理；
2）准备高频感应加热重熔线，高频感应加热重熔线包括输送网带和沿输送网带依次分布的等离子喷涂装置和感应加热重熔装置；
3）把防爆叉车货叉装夹在输送网带上，启动输送网带输送防爆叉车货叉；
4）使用等离子喷涂装置将预先混合均匀的权利要求1或2所述的防爆叉车货叉用耐磨涂层组合物等离子喷涂到由输送网带送过来的防爆叉车货叉表面；
5）输送网带将涂布了耐磨涂层组合物的防爆叉车货叉输送至感应加热重熔装置，感应加热重熔装置对耐磨涂层组合物进行感应加热熔融，冷却后即得。
4.根据权利要求3所述的防爆叉车货叉用耐磨涂层的制备方法，其特征在于，在步骤1）中，喷砂粗化处理采用自动喷砂机进行。
5. 根据权利要求3所述的防爆叉车货叉用耐磨涂层的制备方法，其特征在于，在步骤4）中，等离子喷涂时，等离子气体采用氩气作为主气和氢气作为辅气，氩气流量与氢气流量之比为2:1，喷涂电流为550-600A，喷涂电压为50-70V，喷涂距离为80-150mm，送粉量为30-60 min-1，喷涂角度为90°，喷涂一层的厚度为3mm以上。
6.一种防爆叉车货叉用耐磨涂层，其特征在于，使用权利要求3-5中任一项所述的防爆叉车货叉用耐磨涂层的制备方法而得。
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