等离子喷涂铝灰渣终料涂层工艺参数的优化
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摘要
为了有效处理铝灰渣终料工业固废,通过初筛-水解-过滤烘干-球磨过筛等工艺制备喷涂粉末,并对喷涂粉末的微观组织和流动性进行分析;通过正交试验法考察了等离子喷涂工艺的4个主要参数电压、电流、送粉电压和主气流量对铝灰渣终料涂层显微硬度、磨损率和结合强度的影响,并对优化工艺进行了验证试验。结果表明,优化喷涂工艺后的铝灰渣终料涂层的平均显微硬度达到601.32 HV,磨损率为9.68×10~(-3)g/min,结合强度为14.24 MPa。与45钢基体材料相比,显微硬度提高了约100%。通过对铝灰渣终料造粒后,粉末的流动性可以满足等离子喷涂设备的要求。喷涂工艺优化后能显著提高铝灰渣终料涂层的性能。
In order to treat effectively ultimate aluminum ash,a kind of industrial solid waste,a spray powder is prepared by the comprehensive process including primary screening-hydrolysis-filtration drying-ball milling and so on.The microstructure and fluidity of the spray powder samples are analyzed.The effects of voltage,current,powder feeding voltage and main gas flow rate on the microhardness,wear rate and bonding strength of ultimate aluminum ash coatings are investigated by orthogonal test,and the optimized process is verified via tests.It is shown that the average microhardness,wear rate and bonding strength of the coating samples are 601.32 HV,9.68×10~(-3)g·min~(-1)and 14.24MPa respectively.Compared to 45~#steel matrix,the microhardness of samples increases by about 100%.After granulating ultimate aluminum ash,the fluidity of powder can meet the requirements of plasma spraying equipment.After optimization of spraying process,the performance of coating can be significantly improved.
In order to treat effectively ultimate aluminum ash,a kind of industrial solid waste,a spray powder is prepared by the comprehensive process including primary screening-hydrolysis-filtration drying-ball milling and so on.The microstructure and fluidity of the spray powder samples are analyzed.The effects of voltage,current,powder feeding voltage and main gas flow rate on the microhardness,wear rate and bonding strength of ultimate aluminum ash coatings are investigated by orthogonal test,and the optimized process is verified via tests.It is shown that the average microhardness,wear rate and bonding strength of the coating samples are 601.32 HV,9.68×10~(-3)g·min~(-1)and 14.24MPa respectively.Compared to 45~#steel matrix,the microhardness of samples increases by about 100%.After granulating ultimate aluminum ash,the fluidity of powder can meet the requirements of plasma spraying equipment.After optimization of spraying process,the performance of coating can be significantly improved.
引文
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[16]周京,李文卓,牟玲龙,等.7075铝合金微弧氧化膜层致密性的电参数优化研究[J].热加工工艺,2018,(6):165-168,172.
[2]倪红军,陈祥,吕帅帅,等.铝渣合成无机材料的研究现状及进展[J].现代化工,2015,35(11):19-22.
[3]郭冉,刘雄章,李青达,等.铝灰高值化回收利用技术现状[J].无机盐工业,2017,49(11):12-15,25.
[4]张宁燕,宁平,谢天鉴,等.铝灰有价组分回收及综合利用研究进展[J].硅酸盐通报,2017,36(6):1951-1956.
[5]孟月,李志扬,陈雨飞,等.铝灰综合回收利用的技术现状(英文)[J].南通大学学报(自然科学版),2017,16(4):64-69.
[6]Li J J,Wang J,Chen H,et al.Microstructure observation ofβ-sialon-15R ceramics synthesized from aluminum dross[J].Ceramics International,2012,38(4):3075-3080.
[7]Murayama N,Maekawa I,Ushiro H,et al. Synthesis of various layered double hydroxides using aluminum dross generated in aluminum recycling process[J]. International Journal of Mineral Processing,2012,s 110-111:46-52.
[8]David E,Kopac J.Hydrolysis of aluminum dross material to achieve zero hazardous waste[J]. Journal of Hazardous Materials,2012,209-210(4):501-509.
[9]Ewais E M M,Khalil N M,Amin M S,et al.Utilization of aluminum sludge and aluminum slag(dross)for the manufacture of calcium aluminate cement[J].Ceramics International,2009,35(8):3381-3388.
[10]Sahu S P,Satapathy A,Patnaik A,et al.Development,characterization and erosion wear response of plasma sprayed fly ash-aluminum coatings[J].Materials&Design,2010,31(3):1165-1173.
[11]Mishra S C,Rout K C,Padmanabhan P V A,et al. Plasma spray coating of fly ash pre-mixed with aluminium powder deposited on metal substrates[J]. Journal of Materials Processing Tech,2000,102(1):9-13.
[12]Satapathy A. Tribo-performance analysis of fly ash-aluminum coatings using experimental design and ANN[J]. Tribology Transactions,2010,53(4):533-542.
[13]刘亮,张宁,姚俊,等.制粒工艺对安全气囊气体发生剂颗粒性能的影响[J].中国粉体技术,2016,22(1):67-70.
[14]郝光照,王超会,刘剑虹,等.改性玄武岩火焰喷涂粉末的制备及其性能[J].材料热处理学报,2014,35(1):192-196.
[15]张爽.等离子弧制备金属粉末装置研制及粉末性能研究[D].长春:长春工业大学,2017.
[16]周京,李文卓,牟玲龙,等.7075铝合金微弧氧化膜层致密性的电参数优化研究[J].热加工工艺,2018,(6):165-168,172.