长江水/泥砂多相流动体系中金属的防护研究
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摘要
举世瞩目的三峡工程是关系到我国21世纪国计民生的重大工程。它所涉
及的许多建筑物及金属结构长期处于水／泥砂多相流动体系环境冲蚀磨损工况
之下，破坏非常严重。针对三峡工程某些金属设备和结构，开展磨蚀与防护
试验与研究是一项急需而又具有现实意义的工作。本工作进行了环氧耐磨涂
料的配方设计，通过采用自制的圆筒型冲蚀磨损仪，从磨粒、材料性质、介
质流速等多方面因素考虑，对国内外12种和自制6种环氧耐磨涂层进行了实
验室加速冲蚀磨损试验，对高、中流速含泥砂水条件下环氧耐磨涂层的冲蚀
磨损行为进行了研究。通过测定试样失重从而比较试样的抗冲蚀性及相对耐
冲蚀性，并采用电子扫描显微镜显微分析方法，对环氧耐磨涂层的冲蚀机理
进行了初步探讨，所得结论如下：
(1) 许多涂层在各流速下均表现出不同的抗冲蚀性。这表明采用合适的有机
耐磨涂层对钢材进行防护，可有效提高金属构件在水／泥砂多相流动体系中的
抗冲蚀性能，延长其使用寿命。
(2) 在不同磨料粒径冲蚀条件下，各种涂层的相对耐冲蚀性可能有一定差异；
在同一条件冲蚀下的各种涂层，测得其抗冲耐磨数据相对稳定。随着磨料粒
径的增加，涂层的相对耐冲蚀性下降。流速对冲蚀率的影响比磨料粒径的影
响更大。另外，随着浓度的增大，各涂层间的相对耐冲蚀性有逐渐缩小的趋
势，在低浓度下抗冲蚀较好的涂层有时在高浓度时不一定也同样抗冲蚀，表
明涂层的抗冲蚀性是有条件的。
(3) 随着时间的延长，涂层总的冲蚀磨损量逐渐增加，但单位时间内各涂层
的冲蚀磨损量逐渐减小，冲蚀率趋于稳定。涂料中树脂本身并不耐磨蚀，起
主要耐磨蚀作用的相成分是填料。另外，各种涂料添加剂的加入均对涂层的
抗冲蚀性均有一定影响。
(4) 环氧耐磨涂层的脆性冲蚀特征较为明显，冲蚀由显微切削机制和断裂机
制等机制决定。由于磨料粒径的不同，冲蚀机制可能有所改变。
The Three Gorge Project is a world-famous project. For many components,the erosion resistance of slurry water at medium or high speed is a dominant factor. To reduce the erosion rate of metals,organic protective coatings are widely used. In this work,Mass loss tests have been carried out on eighteen types of modified epoxy coating materials and six kinds of mild steels in slurry water. A modified rotating disk test rig was used to simulate silt abrasion and erosion with different quart sands at different velocities. The synthesis of six wear-resistant epoxy coatings was performed. The resistances of the various epoxy coatings to silt abrasion had been measured and compared under specified test conditions. On the one hand,the effects of curing agents,fillers,lubricant and coupling agents of the epoxy coatings had been discussed. On the other hand,the effects of quart sand contents,diameter of the quart sands and flow velocity on the erosion resistance of the epoxy coatings had been studied through mass loss t
est and SEM observation. Among the selected materials,the results are as follows:
1. Almost all of the modified epoxy coatings show good wear-resistance at different speeds,which illustrates that it is effective to use modified epoxy coatings to protect steel. Therefore,the lifetime of metal is prolonged.
2. Under the erosion conditions of different sand diameters,not all of the coatings have the same order;Under the same erosion conditions,the data of all the coatings are relatively stable. With the increase of erosion particle diameter,the relative wear-resistance of coatings decreases. Moreover,the effect of flow velocity is much greater than that of particle diameter. In addition,with the increase of concentration,the relative wear-resistance of coatings has a slow tendency of decrease.
3. With time going,the total erosion masses of coatings increase gradually,but the erosion masses of coatings in one unit of time decrease gradually,and the erosion rate tends to be stable. The erosion rate of epoxy coatings mainly comes
from resin matrix because the erosion-resistance of resin matrix is much lower than that of the fillers. Furthermore,all of the addictives added have some effects on erosion-resistance of the coatings.
4. Pure epoxy coating shows typical brittle erosion behavior,and the erosion is determined by both micro-cutting mechanism and fracture mechanism. Owning to the differences of particle diameters,the erosion mechanism may be different.
Author:Zhou Jianlong (Material Science) Directed by:Prof. Xiao Yide
及的许多建筑物及金属结构长期处于水／泥砂多相流动体系环境冲蚀磨损工况
之下，破坏非常严重。针对三峡工程某些金属设备和结构，开展磨蚀与防护
试验与研究是一项急需而又具有现实意义的工作。本工作进行了环氧耐磨涂
料的配方设计，通过采用自制的圆筒型冲蚀磨损仪，从磨粒、材料性质、介
质流速等多方面因素考虑，对国内外12种和自制6种环氧耐磨涂层进行了实
验室加速冲蚀磨损试验，对高、中流速含泥砂水条件下环氧耐磨涂层的冲蚀
磨损行为进行了研究。通过测定试样失重从而比较试样的抗冲蚀性及相对耐
冲蚀性，并采用电子扫描显微镜显微分析方法，对环氧耐磨涂层的冲蚀机理
进行了初步探讨，所得结论如下：
(1) 许多涂层在各流速下均表现出不同的抗冲蚀性。这表明采用合适的有机
耐磨涂层对钢材进行防护，可有效提高金属构件在水／泥砂多相流动体系中的
抗冲蚀性能，延长其使用寿命。
(2) 在不同磨料粒径冲蚀条件下，各种涂层的相对耐冲蚀性可能有一定差异；
在同一条件冲蚀下的各种涂层，测得其抗冲耐磨数据相对稳定。随着磨料粒
径的增加，涂层的相对耐冲蚀性下降。流速对冲蚀率的影响比磨料粒径的影
响更大。另外，随着浓度的增大，各涂层间的相对耐冲蚀性有逐渐缩小的趋
势，在低浓度下抗冲蚀较好的涂层有时在高浓度时不一定也同样抗冲蚀，表
明涂层的抗冲蚀性是有条件的。
(3) 随着时间的延长，涂层总的冲蚀磨损量逐渐增加，但单位时间内各涂层
的冲蚀磨损量逐渐减小，冲蚀率趋于稳定。涂料中树脂本身并不耐磨蚀，起
主要耐磨蚀作用的相成分是填料。另外，各种涂料添加剂的加入均对涂层的
抗冲蚀性均有一定影响。
(4) 环氧耐磨涂层的脆性冲蚀特征较为明显，冲蚀由显微切削机制和断裂机
制等机制决定。由于磨料粒径的不同，冲蚀机制可能有所改变。
The Three Gorge Project is a world-famous project. For many components,the erosion resistance of slurry water at medium or high speed is a dominant factor. To reduce the erosion rate of metals,organic protective coatings are widely used. In this work,Mass loss tests have been carried out on eighteen types of modified epoxy coating materials and six kinds of mild steels in slurry water. A modified rotating disk test rig was used to simulate silt abrasion and erosion with different quart sands at different velocities. The synthesis of six wear-resistant epoxy coatings was performed. The resistances of the various epoxy coatings to silt abrasion had been measured and compared under specified test conditions. On the one hand,the effects of curing agents,fillers,lubricant and coupling agents of the epoxy coatings had been discussed. On the other hand,the effects of quart sand contents,diameter of the quart sands and flow velocity on the erosion resistance of the epoxy coatings had been studied through mass loss t
est and SEM observation. Among the selected materials,the results are as follows:
1. Almost all of the modified epoxy coatings show good wear-resistance at different speeds,which illustrates that it is effective to use modified epoxy coatings to protect steel. Therefore,the lifetime of metal is prolonged.
2. Under the erosion conditions of different sand diameters,not all of the coatings have the same order;Under the same erosion conditions,the data of all the coatings are relatively stable. With the increase of erosion particle diameter,the relative wear-resistance of coatings decreases. Moreover,the effect of flow velocity is much greater than that of particle diameter. In addition,with the increase of concentration,the relative wear-resistance of coatings has a slow tendency of decrease.
3. With time going,the total erosion masses of coatings increase gradually,but the erosion masses of coatings in one unit of time decrease gradually,and the erosion rate tends to be stable. The erosion rate of epoxy coatings mainly comes
from resin matrix because the erosion-resistance of resin matrix is much lower than that of the fillers. Furthermore,all of the addictives added have some effects on erosion-resistance of the coatings.
4. Pure epoxy coating shows typical brittle erosion behavior,and the erosion is determined by both micro-cutting mechanism and fracture mechanism. Owning to the differences of particle diameters,the erosion mechanism may be different.
Author:Zhou Jianlong (Material Science) Directed by:Prof. Xiao Yide
引文
1． I.Finnie, Erosion of surface by solid particles, Wear, 1960, 3:87
2． H.hojo, K. tsuda and T.Yabu, Erosion damage of polymeric material by slurry, Wear, 1986, 112:17
3． H.Grein and W.Meier, Damage to hydraulic machinery caused dy cavitation, abrasion wear and corrosion, Translation from Report No. 100, 1988, by the Laboratory of Hydraulics, Hydrology and Glaciology of the ETH, Zurich.
4． 陈冠国，楮秀萍等．关于冲蚀磨损问题，河北理工学院学报，1 997，19(4) ：27
5． Eyre T.S. Treatise on Materials Science and Technology, Wear, 1968, 13:363
6． 何奖爱，王玉玮编著．材料磨损与耐磨材料，东北大学出版社，2001
7． 庞佑霞，郭源君等．水轮机过流部件磨蚀机理的研究，润滑与密封，2001，4：29
8． 黄河水利委员会水利科学研究所机械抗磨研究室编．环氧沙浆涂料在水力 机械上的应用，水利电力出版社，1978
9． 卢进玉，符建平．水轮机过流部件表面的磨蚀与防护，第二届表面工程国际会 议论文集：278
10． Yoshiro Iwai, Kazuyuki Nambu, Slurry wear properties of pump lining materials, Wear, 1997, 210:211
11． Levy A.V, The solid particle erosion behavior of steel as a function of microstructure, Wear, 1981, 68:269
12． 孙家枢．金属的磨损，第一版，冶金工业出版社，1992，p510
13． 段昌国．水轮机沙粒磨损，第一版，清华大学出版社，1981，p5
14． R.J.K.Wood. The sand erosion performance of coatings, Material and Design, 1999,20:179
15． H.Uuemois, I.Kleis. A critical analysis of erosion problems which have been little studied, Wear, 1975, 31:359
16． Iain Finnie. Some reflection on the past and future of erosion, Wear, 1995, 186-187:1
17． E.Heitz. Chemo-Mechanical Effects of Flow on Corrosion, Corrosion, 1991, 47(2) : 135
18． 温诗铸．世纪回顾与展望--摩擦学研究的发展趋势，中国机械工程学会 会讯，2001，1：9
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20． Heinrich Reshetnyak, Jakob Kuybarsepp. Mechanical properties of hard metals and their erosive wear resistance, Wear, 1994, 177:185
21． Alan V.Levy, Buqian Wang. Erosion of hard material coating systems, Wear, 1988,121:325
22． 柳伟，郑玉贵等．激光熔敷钴合金涂层的抗空蚀和冲刷磨损性能，材料保护， 2002，35(3) ：18
23． 潘牧，罗志平．材料的冲蚀问题，材料科学与工程，1999，17(3) ：92
24． 宋君亮，陆大钧编．环氧涂层及其在水利工程中的应用，水利出版社，1981， p98
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2． H.hojo, K. tsuda and T.Yabu, Erosion damage of polymeric material by slurry, Wear, 1986, 112:17
3． H.Grein and W.Meier, Damage to hydraulic machinery caused dy cavitation, abrasion wear and corrosion, Translation from Report No. 100, 1988, by the Laboratory of Hydraulics, Hydrology and Glaciology of the ETH, Zurich.
4． 陈冠国，楮秀萍等．关于冲蚀磨损问题，河北理工学院学报，1 997，19(4) ：27
5． Eyre T.S. Treatise on Materials Science and Technology, Wear, 1968, 13:363
6． 何奖爱，王玉玮编著．材料磨损与耐磨材料，东北大学出版社，2001
7． 庞佑霞，郭源君等．水轮机过流部件磨蚀机理的研究，润滑与密封，2001，4：29
8． 黄河水利委员会水利科学研究所机械抗磨研究室编．环氧沙浆涂料在水力 机械上的应用，水利电力出版社，1978
9． 卢进玉，符建平．水轮机过流部件表面的磨蚀与防护，第二届表面工程国际会 议论文集：278
10． Yoshiro Iwai, Kazuyuki Nambu, Slurry wear properties of pump lining materials, Wear, 1997, 210:211
11． Levy A.V, The solid particle erosion behavior of steel as a function of microstructure, Wear, 1981, 68:269
12． 孙家枢．金属的磨损，第一版，冶金工业出版社，1992，p510
13． 段昌国．水轮机沙粒磨损，第一版，清华大学出版社，1981，p5
14． R.J.K.Wood. The sand erosion performance of coatings, Material and Design, 1999,20:179
15． H.Uuemois, I.Kleis. A critical analysis of erosion problems which have been little studied, Wear, 1975, 31:359
16． Iain Finnie. Some reflection on the past and future of erosion, Wear, 1995, 186-187:1
17． E.Heitz. Chemo-Mechanical Effects of Flow on Corrosion, Corrosion, 1991, 47(2) : 135
18． 温诗铸．世纪回顾与展望--摩擦学研究的发展趋势，中国机械工程学会 会讯，2001，1：9
19． M.C.Wang, S.Z.Ren, X.B.Wang, S.Z.Li. A study of sand slurry erosion of W-alloy white cast irons, Wear, 1993, 160:259
20． Heinrich Reshetnyak, Jakob Kuybarsepp. Mechanical properties of hard metals and their erosive wear resistance, Wear, 1994, 177:185
21． Alan V.Levy, Buqian Wang. Erosion of hard material coating systems, Wear, 1988,121:325
22． 柳伟，郑玉贵等．激光熔敷钴合金涂层的抗空蚀和冲刷磨损性能，材料保护， 2002，35(3) ：18
23． 潘牧，罗志平．材料的冲蚀问题，材料科学与工程，1999，17(3) ：92
24． 宋君亮，陆大钧编．环氧涂层及其在水利工程中的应用，水利出版社，1981， p98
25． 刘家浚．材料磨损原理及其耐磨性，清华大学出版社，1993，11：180
26． G.L.Sheldon and I.Finnie. On the ductile behavior of nominally brittle materials during erosion cutting, Trans ASME, 1966, 88B:387
27． Z.Rymuza. The tribology of anti-friction polymer, Wydawnictwa Naukowo Technizne, Warszawa, 1986
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