CN115011908A

CN115011908A - Rare earth aluminum alloy anticorrosion thermal spraying construction method suitable for seawater environment

Info

Publication number: CN115011908A
Application number: CN202210668849.0A
Authority: CN
Inventors: 陈光达; 魏帅; 黄允波; 廖信勇; 钟振宏; 郑桂燃; 梁升广; 谢泽宇; 陈晓娜; 傅荣誉
Original assignee: Guangdong Yuantian Engineering Co Ltd
Current assignee: Guangdong Yuantian Engineering Co Ltd
Priority date: 2022-06-14
Filing date: 2022-06-14
Publication date: 2022-09-06

Abstract

The invention relates to the technical field of thermal spraying construction, in particular to a rare earth aluminum alloy anticorrosion thermal spraying construction method suitable for a seawater environment.

Description

Rare earth aluminum alloy anticorrosion thermal spraying construction method suitable for seawater environment

Technical Field

Background

The hydraulic metal structure is an important component of hydraulic and hydroelectric engineering, the corrosion resistance quality of the hydraulic metal structure has great influence on the service life of the hydraulic metal structure and the safe operation of the hydraulic and hydroelectric engineering, and at the present stage, a method for thermally spraying a metal coating can have a good corrosion resistance effect in a seawater environment, but no metal material capable of achieving a good corrosion resistance effect and a good service life cycle exists in the existing sprayed metal material.

In the process of hydraulic and hydroelectric engineering construction, the quality of the corrosion-resistant construction quality of the hydraulic metal structure is extremely important, because the corrosion-resistant construction quality of the hydraulic metal structure has great beneficial effects on the service life of the hydraulic metal structure and the safe operation of the hydraulic and hydroelectric engineering, especially in a seawater operation environment.

Chinese patent publication No.: CN112789257A discloses a dry thermal spray material for heat and a dry thermal spray method, in which a mixture containing a refractory and a binder is pressure-fed through a pipe toward a spray nozzle, water is added to the tip of the spray nozzle, and spraying is performed in an environment of 600 ℃ or higher;

therefore, the dry thermal spraying construction method is not suitable for the corrosion prevention construction process of the hydraulic metal structure due to different applicable environments and applicable materials.

Disclosure of Invention

Therefore, the invention provides the rare earth aluminum alloy anticorrosion thermal spraying construction method suitable for the seawater environment, and aims to solve the problems that the anticorrosion coating cannot thoroughly exert the performance and the service life of the anticorrosion coating due to certain errors in manual operation in the anticorrosion spraying construction method of the hydraulic metal structure in the prior art.

In order to achieve the purpose, the invention provides a rare earth aluminum alloy anticorrosion thermal spraying construction method suitable for a seawater environment, which comprises the following steps:

step S1, performing rust removal treatment on the hydraulic metal structure base layer to a preset standard before anticorrosive spraying;

step S2, performing thermal spraying on the rare earth aluminum alloy as a substrate coating to a preset thickness;

step S3, spraying epoxy zinc phosphate paint serving as sealing paint to a preset thickness;

step S4, spraying epoxy resin paint serving as intermediate paint to a preset thickness;

and step S5, spraying epoxy resin paint as finish paint to a preset thickness.

Presetting the thickness of a dry film of a rare earth aluminum alloy coating thermally sprayed on the effective surface of a metal matrix to be 160-200 microns;

presetting the dry film thickness of the epoxy zinc phosphate coating of the sealing paint to be 30-50 microns;

presetting the intermediate paint as an epoxy resin coating, wherein the dry film thickness of the epoxy resin coating is 80-100 micrometers;

the thickness of the dry film of the epoxy resin coating is 100-120 microns.

In step S1, a blasting rust removal method is used to remove rust from the hydraulic metal structural base layer, wherein,

and step S11, when the sand blasting and rust removing treatment is carried out, the compressed air is preset to be dry and clean air, so that the surface of the hydraulic metal component is not polluted by oil stains and water in the sand blasting process.

Step S12, when the sand blasting rust removal treatment is carried out, the relative humidity of the air in the preset construction environment is 50% to 85%, and the relation between the surface temperature x of the preset base layer and the dew point temperature k is that k +3 ℃ is more than x and less than k +12 ℃;

step S13, when the sand blasting and rust removing treatment work is carried out, the working pressure of compressed air of a compressor in the sand blasting work is preset to be 6 kilograms per square centimeter to 8 kilograms per square centimeter, the included angle between the spraying direction of the abrasive material and the normal line of the working surface is preset to be 15 degrees to 30 degrees, and the distance between a preset nozzle and a workpiece is 100 millimeters to 300 millimeters;

step S14, after the sand blasting and rust removing treatment is finished, the surface floating dust and debris are swept by dry and oilless compressed air;

step S15, after the sand blasting and rust removing treatment, the preset standard of the surface of the hydraulic metal structure after the treatment is the rust removing grade Sa2.5 specified in GB8923, and the preset standard of the surface roughness of the hydraulic metal structure is Ry60 microns to 80 microns;

and step S16, finishing quality inspection and the first rare earth aluminum spraying process within eight hours after the sand blasting rust removal work is finished and the inspection is qualified.

In step S2, performing arc thermal spraying rare earth aluminum alloy operation on the hydraulic metal structure qualified for sand blasting and rust removal by the rare earth aluminum alloy coating by using an arc spraying method and an arc spraying device, adjusting the current equipment component in real time according to the judgment result of a central control module arranged in the arc spraying device, performing field measurement by using a detection sensor arranged in the arc spraying device, performing real-time adjustment according to the comparison result of the measurement result and a preset value, and then spraying to ensure that each item of data of the thermal spraying rare earth aluminum alloy coating reaches a preset standard, and the coating has uniform and compact appearance, no unmelted large particles exceeding the preset value, and no spray leakage phenomenon;

step S21, in the operation of thermal spraying of the rare earth aluminum alloy, adjusting the pressure value of compressed air in the electric arc spraying equipment to be a preset process parameter value, and opening an oil-water separator blow-down valve at intervals of preset time for blow-down in the operation of thermal spraying of the rare earth aluminum alloy so as to avoid influencing the quality of a coating;

step S22, in the operation of thermal spraying rare earth aluminum alloy, the central control module controls the spraying distance according to the spraying distance parameter from a preset nozzle to a working surface, when the spraying distance is too small, the temperature difference of a coating is too large, so that the coating shrinks to generate the phenomenon of warping and separation, and the tempering phenomenon possibly occurs, namely the burning speed of gas mixed by gas and air (the speed of flame propagation) is greater than the speed of the mixed gas sprayed out of a fire hole, so that the flame can retract into the fire hole, and the tempering phenomenon occurs; when the spraying distance is too large, the spraying distance of the metal particles is increased, so that the spraying kinetic energy of the metal particles is reduced, the density of the metal particles in the coating is reduced, and the anti-permeability of the coating is further reduced;

step S23, in the operation of thermal spraying the rare earth aluminum alloy, adjusting the spraying angle to be vertical to the hydraulic metal component so as to obtain the optimal coating adhesion, compactness and utilization rate of the rare earth aluminum wire;

step S24, in the operation of thermal spraying rare earth aluminum alloy, the preset spraying speed is 25 to 80 microns per second;

step S25, in the operation of thermal spraying rare earth aluminum alloy, the optimal spraying overlap is one third of the overlap of the new spraying area and the old spraying area, so as to ensure that the metal coatings are mutually vertical, cross-covered and uniform in thickness, if the spray gun moves and shakes to enable the metal coatings to be smaller than the minimum requirement of the preset thickness, re-spraying is carried out according to the difference value between the current metal coating thickness and the preset thickness judged by the central control module until the metal coatings are mutually vertical, cross-covered and uniform in thickness;

step S26, in the operation of thermal spraying rare earth aluminum alloy, when the coarse particles in the sprayed area are larger than the preset standard, the central control module judges that the operation needs to be stopped at the moment, and sends out prompt tone to remind that the sprayed area of the coarse particle area larger than the preset standard needs to be scraped for re-spraying, and the input current of the electric arc spraying equipment is adjusted before re-spraying, the wire feeding speed is reduced to A1, the air pressure is improved, the fact that the coarse particles do not appear in the re-spraying area is ensured, if the coarse particles still appear in the re-spraying area, the sprayed area with the coarse particles is scraped for re-spraying, and the wire feeding speed is reduced to A2, wherein A1 is more than A2, and the air pressure is improved until the sprayed particles in the re-spraying area meet the preset standard;

and step S27, after the operation of thermal spraying the rare earth aluminum alloy is completed, blowing the surface of the rare earth aluminum layer by using compressed air to remove surface dust, ensuring that the thickness of the surface dust is less than or equal to the preset thickness requirement of the surface dust in the spraying work of the epoxy zinc phosphate paint, and scraping the heavy spraying if the thickness of the surface dust is greater than the preset thickness requirement of the surface dust.

In step S3, in the spray coating operation using zinc phosphate epoxy paint as the sealer, a compressed air spray coating method and an arc thermal spraying apparatus are used to perform paint seal spray coating on the surface of the qualified arc sprayed rare earth aluminum alloy that has been air-dried, and the main detection index of the seal coating is whether the thickness meets the preset requirement, and if the thickness is smaller than the preset requirement, the surface of the qualified arc sprayed rare earth aluminum alloy that has been air-dried needs to be sprayed again according to the difference until the thickness of the intermediate coating meets or exceeds the preset requirement.

In step S4, in the spraying operation using the epoxy resin paint as the intermediate paint, when the dried surface of the zinc epoxy phosphate paint is sprayed, the main detection index is whether the thickness meets the preset requirement, and if the thickness is smaller than the preset requirement, the dried surface of the zinc epoxy phosphate paint needs to be sprayed again according to the difference until the thickness of the intermediate paint meets or is greater than the preset requirement.

In step S5, in the spraying operation using the epoxy resin paint as the finish paint, when the surface of the dried epoxy resin paint is sprayed, it is mainly detected whether the thickness meets the preset requirement, and if the thickness is smaller than the preset requirement, the surface of the dried epoxy resin paint needs to be sprayed again according to the difference until the thickness of the finish paint meets or is larger than the preset requirement.

The sand for sand blasting and rust removing adopts hard quartz sand with edges and corners, dryness (water content is less than 3 percent), no soil and impurities, and medium-coarse sand with preset grain size of 0.5 mm to 2.0 mm. The preset diameter of the rare earth aluminum wire is 3 mm. The sealing paint primer is epoxy zinc phosphate paint, and the intermediate paint and the finish paint are epoxy resin paint.

The spraying mode with the preset times of N1-N2 is adopted in the spraying work, N1 is less than N2, N1 and N2 are positive integers, so that the phenomenon that paint is sagging due to the fact that the coating sprayed at a certain time is too thick is avoided, and the surface flatness of the coating does not meet the preset requirement.

In step S2, the arc spraying apparatus of the rare earth aluminum alloy anticorrosive thermal spraying construction method suitable for the seawater environment includes a movable base, a control box, a multi-axis manipulator, and an arc spray gun, wherein,

the bottom of the movable base is provided with a moving unit which is used for moving the movable base, and the movable base is provided with an armrest which is used for pushing the movable base to move;

the control box is arranged on the movable base and used for providing power supply service, wire feeding service, compressed air supply service and control service for the electric arc spraying equipment;

the multi-shaft mechanical arm is arranged on the control box and used for carrying the electric arc spray gun to perform spraying work according to preset actions, and the multi-shaft mechanical arm is internally provided with a central control module used for controlling the actions of the multi-shaft mechanical arm, the temperature of the electric arc spray gun and the wire feeding speed;

the electric arc spray gun is arranged at the tail end of the multi-shaft mechanical arm and used for spraying, a connecting device is arranged outside the electric arc spray gun and used for being connected with the tail end of the multi-shaft mechanical arm, a thickness detection sensor, a horizontal detection sensor and a distance detection sensor are arranged inside the electric arc spray gun, wherein,

the thickness detection sensor is used for detecting the thickness of the coating in real time during spraying, sending the measured data to the central control module, and carrying out corresponding control adjustment on the multi-axis mechanical arm and the electric arc spray gun by the central control module according to the contrast value of the detected thickness data and preset thickness data;

setting the data of the current coating thickness as THK1, and setting the data of the preset thickness as THK0, wherein THK0 represents an interval (THK01, THK02), THK01 is less than THK 02;

when the THK01 is more than the THK1 and more than the THK02, the central control module judges that the current coating thickness meets preset data, and the multi-axis mechanical arm and the electric arc spray gun do not need to be adjusted;

when the THK1 is greater than the THK01, the central control module judges that the current coating thickness is lower than preset data, the multi-axis mechanical arm does not adjust, and the electric arc spray gun is controlled to gradually increase the spraying density until the THK01 is greater than the THK1 and greater than the THK 02;

when the THK1 is larger than the THK02, the central control module judges that the current coating thickness is higher than preset data, the multi-axis mechanical arm does not adjust, and the electric arc spray gun is controlled to gradually reduce the spraying density until the THK01 is larger than the THK1 and the THK02 are larger than the preset data;

setting the current temperature of the electric arc spray gun to be TEMP2, setting the maximum temperature of the electric arc spray gun to be TEMP3 and setting the minimum temperature of the electric arc spray gun to be TEMP1, wherein TEMP3 is more than TEMP2 is more than TEMP 1;

setting the wire feeding speed of the electric arc spray gun to be PO3 when the temperature of the electric arc spray gun is TEMP3, setting the wire feeding speed of the electric arc spray gun to be PO1 when the temperature of the electric arc spray gun is TEMP1, and setting the wire feeding speed of the electric arc spray gun to be PO2 when the temperature of the electric arc spray gun is TEMP2, wherein PO3 is greater than PO2 is greater than PO 1;

setting the wire feeding speed of the arc spray gun at PO3, the spraying density of the arc spray gun at FPP3, setting the wire feeding speed of the arc spray gun at PO1, the spraying density of the arc spray gun at FPP1, and setting the wire feeding speed of the arc spray gun at PO2, the spraying density of the arc spray gun at FPP2, wherein FPP3 > FPP2 > FPP 1;

when THK1 is less than THK01, the central control module controls the electric arc spray gun to gradually increase the current spraying density FPP2 to THK01, THK1 and THK02, and then the current spraying density FPP 2' is obtained,

when THK1 is greater than THK02, the central control moduleControlling the electric arc spray gun to gradually reduce the current spraying density FPP2 to THK01 < THK1 < THK02, obtaining the current spraying density FPP 2',

the horizontal detection sensor is used for detecting the levelness of the electric arc spray gun in real time during spraying, sending the detected data to the central control module, and carrying out corresponding control adjustment on the multi-axis mechanical arm and the electric arc spray gun by the central control module according to the contrast value of the detected levelness data and preset levelness data;

setting the current levelness data as LN1 and the preset levelness data as LN0, wherein LN0 represents a section (LN01, LN02), and LN01 is less than LN 02;

when LN01 is larger than LN1 and smaller than LN02, the central control module judges that the current levelness of the electric arc spray gun meets preset data, and the multi-axis mechanical arm and the electric arc spray gun do not need to be adjusted;

when LN1 is smaller than LN01, the central control module judges that the current levelness of the arc spraying gun is lower than preset data, the multi-shaft mechanical arm is adjusted to gradually increase the tail end angle of the mechanical arm, the arc spraying gun is not adjusted until LN01 is smaller than LN1 and smaller than LN02, and at the moment, the current tail end angle LN1 ', LN 1' ═ LN1+ (LN01-LN1) of the mechanical arm is obtained;

when LN1 is larger than LN02, the central control module judges that the current arc spray gun levelness is higher than preset data, the multi-axis mechanical arm is adjusted to gradually reduce the tail end angle of the mechanical arm, the arc spray gun is not adjusted until LN01 is larger than LN1 and smaller than LN02, and then the current tail end angle LN1 ', LN 1' -LN 1+ (LN1-LN02) of the mechanical arm is obtained.

The distance detection sensor is used for detecting the distance between the arc spray gun and the working face in real time during spraying, sending the detected data to the central control module, and carrying out corresponding control adjustment on the multi-axis mechanical arm and the arc spray gun by the central control module according to the comparison value between the detected distance data and preset distance data;

setting the current distance data as D1 and setting the preset distance data as D0, wherein LN0 represents a section (D01, D02), and D01 < D02;

when D01 is larger than D1 and is larger than D02, the central control module judges that the current distance data accord with preset distance data, and the multi-axis mechanical arm and the electric arc spray gun do not need to be adjusted;

when D1 is less than D01, the central control module judges that the current distance data is less than preset data, the multi-axis mechanical arm is adjusted to gradually increase the distance from the tail end of the mechanical arm to the working surface, the electric arc spray gun is not adjusted until D01 is less than D1 and less than D02, and at the moment, the current distance D1' from the tail end of the mechanical arm to the working surface is obtained, and D1 ═ D1+ (D01-D1);

when D1 is larger than D02, the central control module judges that the current distance data are higher than preset data, the multi-axis manipulator is adjusted to gradually reduce the distance from the tail end of the manipulator to the working surface, the electric arc spray gun is not adjusted until D01 is larger than D1 and D02 is smaller, and then the current distance D1' from the tail end of the manipulator to the working surface is obtained, and D1 ═ D1+ (D1-D02).

The central control module carries out corresponding comprehensive adjustment on the multi-axis mechanical arm and the electric arc spray gun according to the comparison value of the data detected by the thickness detection sensor, the horizontal detection sensor and the distance detection sensor in real time and preset data;

when the THK1 is THK0, the LN1 is LN0, and the D1 is D0, the central control module judges that the current measurement data accord with preset distance data, and the multi-axis mechanical arm and the arc spray gun do not need to be adjusted;

when THK1 is not equal to THK0, and/or LN1 is not equal to LN0, and/or D1 is not equal to D0, the central control module judges that the current measurement data is not equal to the preset data, and corresponding adjustment is required to be carried out on the spraying density of the arc spray gun, the tail end angle of the multi-axis mechanical arm and the distance from the tail end of the multi-axis mechanical arm to the working surface according to the corresponding adjustment method and numerical value in sequence until THK01 is greater than THK1 and less than THK02, LN01 is greater than LN1 and less than LN02, and D01 is greater than D1 and less than D02.

Compared with the prior art, the invention has the beneficial effects that compared with the surface of a zinc spraying coating, the surface of the thermal spraying rare earth aluminum alloy coating has higher surface hardness, better wear resistance and stronger damage resistance, and compared with the surface of a stainless steel spraying coating, the surface of the thermal spraying rare earth aluminum alloy coating has better corrosion resistance, is not easy to corrode, has flat surface, weak water permeability, strong covering compactness and is not easy to peel off.

Further, hot spraying metal ladder coating can't satisfy the anticorrosive needs under water of hydraulic structure, and hot spraying tombarthite aluminum alloy coating can adapt to the anticorrosive needs under water of most hydraulic metal structures, zinc-sprayed coating or spraying stainless steel coating are used alone, can't obtain good anticorrosive effect, and the engineering life is shorter, and use hot spraying tombarthite aluminum alloy coating not only can adapt to more hydraulic metal material, and can reach better anticorrosive effect, and the engineering life is longer, do not need to organize the secondary construction, the engineering life cycle cost has been showing and has been reduced.

Furthermore, the thermal spraying rare earth aluminum alloy is adopted as a substrate coating, the epoxy zinc phosphate is used as a sealing layer, the epoxy resin coating is used as a middle layer, and a surface layer material has a good anti-corrosion effect in a seawater environment, so that the coating can be widely applied to the anti-corrosion construction of metal components such as sluice gates, embedded parts, trash racks and the like in a seawater operation environment.

Furthermore, the rare earth aluminum alloy is thermally sprayed by adopting the electric arc spraying equipment, the current equipment component can be adjusted in real time according to the judgment result of a central control module arranged on the electric arc spraying equipment, the detection sensor arranged on the electric arc spraying equipment is used for carrying out on-site measurement, and the rare earth aluminum alloy is sprayed after being adjusted in real time according to the comparison result of the measurement result and a preset numerical value, so that each item of data of the thermal spraying rare earth aluminum alloy coating reaches a preset standard, the coating is uniform and compact in appearance, large unmelted particles exceeding the preset value are avoided, and the phenomenon of spraying leakage is avoided.

Drawings

FIG. 1 is a schematic structural diagram of a rare earth aluminum alloy anticorrosion thermal spraying construction method suitable for a seawater environment according to an embodiment of the invention;

FIG. 2 is a schematic structural diagram of an electric arc spraying device of the rare earth aluminum alloy anticorrosion thermal spraying construction method applicable to a seawater environment in the embodiment of the invention;

in the figure: the device comprises a movable base 1, a moving unit 2, an armrest 3, a control box 4, a multi-axis mechanical arm 5, a mechanical arm longitudinal shaft 51, a mechanical arm transverse shaft 52, an electric arc spray gun 6 and a connecting device 7.

Detailed Description

In order that the objects and advantages of the invention will be more clearly understood, the invention is further described below with reference to examples; it should be understood that the specific embodiments described herein are merely illustrative of the invention and do not delimit the invention.

Preferred embodiments of the present invention are described below with reference to the accompanying drawings. It should be understood by those skilled in the art that these embodiments are only for explaining the technical principle of the present invention, and do not limit the scope of the present invention.

It should be noted that in the description of the present invention, the terms of direction or positional relationship indicated by the terms "upper", "lower", "left", "right", "inner", "outer", etc. are based on the directions or positional relationships shown in the drawings, which are only for convenience of description, and do not indicate or imply that the device or element must have a specific orientation, be constructed in a specific orientation, and be operated, and thus, should not be construed as limiting the present invention.

Furthermore, it should be noted that, in the description of the present invention, unless otherwise explicitly specified or limited, the terms "mounted," "connected," and "connected" are to be construed broadly, and may be, for example, fixedly connected, detachably connected, or integrally connected; can be mechanically or electrically connected; they may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meanings of the above terms in the present invention can be understood by those skilled in the art according to specific situations.

Fig. 1 is a schematic structural diagram of a rare earth aluminum alloy thermal spray coating method for corrosion prevention in a seawater environment according to an embodiment of the present invention, where the embodiment includes:

step S1, derusting the hydraulic metal structure base layer to a preset standard before anticorrosive spraying;

step S5, spraying epoxy resin paint as finish paint to a preset thickness;

in the present embodiment, it is preferred that,

setting the thickness of a dry film of the rare earth aluminum alloy coating thermally sprayed on the effective surface of the metal matrix to be 160-200 microns;

setting the dry film thickness of the epoxy zinc phosphate coating of the sealing paint to be 30-50 micrometers;

setting the dry film thickness of the epoxy resin coating as the intermediate paint to be 80-100 micrometers;

the topcoat is set to a dry film thickness of 100 to 120 microns for the epoxy coating.

step S14, after the sand blasting and rust removing treatment is finished, blowing floating dust and debris on the surface by using dry and oilless compressed air;

in the embodiment, the preset time interval between the opening of the oil-water separator blowdown valve and the blowdown is 1 to 20 minutes, wherein the time interval is 8 minutes is optimal.

in this embodiment, the spraying distance interval is 50 mm to 500 mm, the preset spraying distance is optimally 150 mm, the spraying distance after adjustment is the spraying distance before adjustment plus the spraying distance parameter, and the spraying distance parameter from the preset nozzle to the working surface is set to be

In step S3, in the spraying operation using the zinc epoxy phosphate paint as the seal coat, the seal coat is sprayed on the surface of the qualified arc sprayed rare earth aluminum alloy by using a compressed air spraying method and an arc thermal spraying apparatus, wherein the main detection index of the seal coat is whether the thickness meets the preset requirement, and if the thickness is smaller than the preset requirement, the surface of the qualified arc sprayed rare earth aluminum alloy which is dried needs to be sprayed again according to the difference until the thickness of the intermediate coat meets or is larger than the preset requirement.

In this embodiment, the operator must wear a helmet visor, protective clothing, gloves, and earplugs with an air distributor to ensure the operator's physical health.

In this embodiment, the sand for blasting rust removal is made of hard and angular quartz sand (water content less than 3%), which is free of clay and impurities, and medium-coarse sand with a particle size of 0.5 mm to 2.0 mm is used. The rare earth aluminum wire is selected to have a diameter of 3 mm. The sealing paint primer is epoxy zinc phosphate paint, and the intermediate paint and the finish paint are epoxy resin paint.

In the embodiment, a small number of spraying modes are adopted in the spraying work, so that the phenomenon that paint is sagging due to the fact that a coating sprayed at a certain time is too thick is avoided, and the surface flatness of the coating does not meet the preset requirement.

Referring to fig. 2, it is shown that the arc spraying apparatus of the rare earth aluminum alloy corrosion prevention thermal spraying construction method applied to the seawater environment in the embodiment of the present invention includes a movable base 1, a control box 4, a multi-axis robot 5, an arc spray gun 6, and a central control module, wherein,

the bottom of the movable base 1 is provided with a moving unit 2, the moving unit 2 is used for moving the movable base 1, and the movable base is provided with an armrest 3 for pushing the movable base 1 to displace;

the control box 4 is arranged on the movable base 1 and used for providing power supply service, wire feeding service, compressed air supply service and control service for the electric arc spraying equipment;

in this embodiment, the moving unit 2 disposed at the bottom of the movable base 1 may be an electric fixed wheel or a universal locking wheel, and only needs to satisfy the moving requirement of the movable base 1 in this embodiment, which is not described herein again.

The multi-shaft mechanical arm 5 is arranged on the control box 4, the multi-shaft mechanical arm 5 is used for carrying the electric arc spray gun 6 to perform spraying work according to preset actions, and a central control module is arranged in the multi-shaft mechanical arm 5 and used for controlling the actions of the multi-shaft mechanical arm 5, the temperature of the electric arc spray gun 6 and the wire feeding speed;

the central control module is arranged in the control box 4, is electrically connected with the multi-axis manipulator 5 and the arc spray gun 6 respectively, and is used for controlling the action of the multi-axis manipulator 5, the temperature of the arc spray gun 6 and the wire feeding speed;

the electric arc spray gun 6 is arranged at the tail end of the multi-shaft mechanical arm 5 and is used for spraying, the connecting device 7 is arranged outside the electric arc spray gun 6 and is used for being connected with the tail end of the multi-shaft mechanical arm 5, the thickness detection sensor, the horizontal detection sensor and the distance detection sensor are arranged inside the electric arc spray gun 6, wherein,

the thickness detection sensor is used for detecting the thickness of the coating in real time during spraying, sending the measured data to the central control module, and carrying out corresponding control adjustment on the multi-axis mechanical arm 5 and the electric arc spray gun 6 by the central control module according to the contrast value of the detected thickness data and preset thickness data;

when the THK01 is greater than the THK1 and less than the THK02, the central control module judges that the current coating thickness accords with preset data, and the multi-axis mechanical arm 5 and the electric arc spray gun 6 do not need to be adjusted;

when the THK1 is greater than the THK01, the central control module judges that the current coating thickness is lower than preset data, the multi-axis mechanical arm 5 does not adjust, and the electric arc spray gun 6 is controlled to gradually increase the spraying density until the THK01 is greater than the THK1 and the THK02 are greater;

when the THK1 is larger than the THK02, the central control module judges that the thickness of the current coating is higher than preset data, the multi-axis mechanical arm 5 does not adjust, and the electric arc spray gun 6 is controlled to gradually reduce the spraying density until the THK01 is larger than the THK1 and the THK02 are larger than the preset data;

setting the current temperature of the electric arc spray gun 6 as TEMP2, setting the maximum temperature of the electric arc spray gun 6 as TEMP3 and setting the minimum temperature of the electric arc spray gun 6 as TEMP1, wherein TEMP3 is more than TEMP2 is more than TEMP 1;

setting the wire feeding speed of the electric arc spray gun 6 to be PO3 when the temperature of the electric arc spray gun 6 is TEMP3, setting the wire feeding speed of the electric arc spray gun 6 to be PO1 when the temperature of the electric arc spray gun 6 is TEMP1, and setting the wire feeding speed of the electric arc spray gun 6 to be PO2 when the temperature of the electric arc spray gun 6 is TEMP2, wherein PO3 is more than PO2 is more than PO 1;

setting the wire feeding speed of the electric arc spray gun 6 at PO3, the spraying density of the electric arc spray gun 6 at FPP3, the wire feeding speed of the electric arc spray gun 6 at PO1, the spraying density of the electric arc spray gun 6 at FPP1, and the wire feeding speed of the electric arc spray gun 6 at PO2, the spraying density of the electric arc spray gun 6 at FPP2, wherein FPP3 > FPP2 > FPP 1;

when THK1 is less than THK01, the central control module controls the electric arc spray gun 6 to gradually increase the current spraying density FPP2 to THK01, THK1 and THK02, and then the current spraying density FPP 2' is obtained,

when THK1 is greater than THK02, the central control module controls the electric arc spray gun 6 to gradually reduce the current spraying density FPP2 to THK01 which is greater than THK1 which is greater than THK02, and the current spraying density FPP2 ″' is obtained at the moment，

The horizontal detection sensor is used for detecting the levelness of the electric arc spray gun 6 in real time during spraying, sending the detected data to the central control module, and carrying out corresponding control adjustment on the multi-axis mechanical arm 5 and the electric arc spray gun 6 by the central control module according to the contrast value of the detected levelness data and the preset levelness data;

setting the current levelness data as LN1, and setting the preset levelness data as LN0, wherein LN0 represents an interval (LN01, LN02), and LN01 is less than LN 02;

when LN01 is larger than LN1 and smaller than LN02, the central control module judges that the current levelness of the arc spray gun 6 meets preset data, and the multi-axis mechanical arm 5 and the arc spray gun 6 do not need to be adjusted;

when LN1 is smaller than LN01, the central control module judges that the current levelness of the electric arc spray gun 6 is lower than preset data, the multi-axis mechanical arm 5 is adjusted to gradually increase the angle of the tail end of the mechanical arm, the electric arc spray gun 6 is not adjusted until LN01 is smaller than LN1 and smaller than LN02, and at this time, the current angle LN 1' of the tail end of the multi-axis mechanical arm 5, LN1 ═ LN1+ (LN01-LN1) is obtained;

when LN1 is larger than LN02, the central control module judges that the current levelness of the electric arc spray gun 6 is higher than preset data, the multi-axis manipulator 5 is adjusted to gradually reduce the angle of the tail end of the multi-axis manipulator 5, the electric arc spray gun 6 is not adjusted until LN01 is smaller than LN1 and smaller than LN02, and then the current angle LN1 ', LN 1' -LN 1+ (LN1-LN02) of the tail end of the multi-axis manipulator 5 is obtained.

The distance detection sensor is used for detecting the distance between the arc spray gun 6 and the working surface in real time during spraying, sending the detected data to the central control module, and performing corresponding control adjustment on the multi-axis mechanical arm 5 and the arc spray gun 6 by the central control module according to the contrast value of the detected distance data and preset distance data;

setting the current distance data as D1 and the preset distance data as D0, wherein LN0 represents a section (D01, D02), and D01 < D02;

when D01 is larger than D1 and is larger than D02, the central control module judges that the current distance data accord with preset distance data, and the multi-axis mechanical arm 5 and the electric arc spray gun 6 do not need to be adjusted;

when D1 is less than D01, the central control module judges that the current distance data is less than preset data, adjusts the multi-axis manipulator 5 to gradually increase the distance from the tail end of the multi-axis manipulator 5 to the working surface, the electric arc spray gun 6 is not adjusted until D01 is less than D1 and less than D02, and at the moment, the current distance D1' from the tail end of the multi-axis manipulator 5 to the working surface, and D1 ═ D1+ (D01-D1) are obtained;

when D1 is larger than D02, the central control module judges that the current distance data is higher than the preset data, adjusts the multi-axis manipulator 5 to gradually reduce the distance from the tail end of the multi-axis manipulator 5 to the working surface, and the electric arc spray gun 6 is not adjusted until D01 is smaller than D1 and D02 is smaller than D1+, and then the current distance D1 'from the tail end of the multi-axis manipulator 5 to the working surface and D1' ═ D1+ (D1-D02) are obtained.

The central control module correspondingly and comprehensively adjusts the multi-shaft mechanical arm 5 and the arc spray gun 6 according to the comparison value of the data detected by the thickness detection sensor, the horizontal detection sensor and the distance detection sensor in real time and preset data;

when the THK1 is THK0, the LN1 is LN0, and the D1 is D0, the central control module determines that the current measurement data meet preset distance data, and the multi-axis manipulator 5 and the arc spray gun 6 do not need to be adjusted;

when THK1 is not equal to THK0, and/or LN1 is not equal to LN0, and/or D1 is not equal to D0, the central control module judges that the current measurement data is not equal to the preset data, and corresponding adjustment is required to be carried out in sequence according to the corresponding adjustment method and numerical value to the spraying density of the arc spray gun 6, the tail end angle of the multi-axis mechanical arm 5 and the distance from the tail end of the multi-axis mechanical arm 5 to the working surface until THK01 is greater than THK1 and less than THK02, LN01 is greater than LN1 and less than LN02, and D01 is greater than D1 and less than D02.

In this embodiment, the connecting device provided outside the arc spraying gun 6 and the end of the multi-axis mechanical arm 5 may be a buckle device or an electric self-locking device, and only the connection requirement of the connecting device in this embodiment needs to be satisfied, which is not described herein again.

In this embodiment, the multi-axis robot 5 may be a six-axis robot or a five-axis robot, and only the motion requirement of the multi-axis robot 5 in this embodiment needs to be met, which is not described herein again.

So far, the technical solutions of the present invention have been described in connection with the preferred embodiments shown in the drawings, but it is apparent to those skilled in the art that the scope of the present invention is not limited to these specific embodiments. Equivalent changes or substitutions of related technical features can be made by those skilled in the art without departing from the principle of the invention, and the technical scheme after the changes or substitutions can fall into the protection scope of the invention.

The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention; various modifications and alterations to this invention will become apparent to those skilled in the art. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.

Claims

1. A rare earth aluminum alloy anticorrosion thermal spraying construction method suitable for a seawater environment is characterized by comprising the following steps of,

step S1, performing rust removal treatment on the hydraulic metal structure base layer by adopting sand blasting rust removal before anticorrosive spraying;

step S2, performing thermal spraying on the rare earth aluminum alloy serving as a substrate coating to a preset thickness, performing electric arc thermal spraying on the hydraulic metal structure subjected to sand blasting and rust removal qualified by the rare earth aluminum alloy coating by adopting an electric arc spraying method and an electric arc spraying device, adjusting the current equipment component in real time according to the judgment result of a central control module arranged in the electric arc spraying device, measuring through a sensor for detecting levelness, distance and angle arranged in the electric arc spraying device, adjusting in real time according to the comparison result of the measurement result and a preset value, and spraying until the thickness of the thermal spraying rare earth aluminum alloy coating reaches a preset standard;

wherein, in the step S2,

in the spraying operation of using epoxy zinc phosphate paint as sealing paint, carrying out paint sealing spraying on the dried qualified electric arc spraying rare earth aluminum surface by adopting a compressed air spraying method, detecting whether the thickness of a sealing coating layer meets a preset requirement, and if the thickness of the sealing coating layer is smaller than the preset requirement, spraying the dried qualified electric arc spraying rare earth aluminum surface again according to the difference until the thickness of the middle coating layer meets or is larger than the preset requirement;

in the spraying operation using the epoxy resin coating as the intermediate coating, when the surface of the dried epoxy zinc phosphate paint coating is sprayed, the detection index of the intermediate coating is whether the thickness meets the preset requirement, if the thickness is smaller than the preset requirement, the surface of the dried epoxy zinc phosphate paint coating needs to be sprayed again according to the difference value until the thickness of the intermediate coating meets or is larger than the preset requirement;

in the spraying operation using the epoxy resin coating as the finish paint, when the surface of the dried epoxy resin coating is sprayed, the detection index of the surface coating is whether the thickness meets the preset requirement, if the thickness is smaller than the preset requirement, the surface of the dried epoxy resin coating needs to be sprayed again according to the difference value until the thickness of the finish paint coating meets or is larger than the preset requirement, and the spraying is finished.

2. The rare earth aluminum alloy anticorrosive thermal spray construction method suitable for seawater environment according to claim 1, wherein, in the step S1,

when the sand blasting and rust removing work is carried out, the compressed air is preset to be dry and clean air, wherein the relative humidity of the dry air is 5-30%, the air cleanliness of the clean air is ISOClass 3-ISOClass 5, the relative humidity of the air in the preset construction environment is 50-85%, the relation between the surface temperature x of a preset base layer and the dew point temperature k is that k +3 ℃ is more than x and less than k +12 ℃, the working pressure of the compressed air of a compressor in the preset sand blasting work is 6-8 kilograms per square centimeter, the included angle between the spraying direction of the preset abrasive and the normal line of the working surface is 15-30 degrees, and the distance between a preset nozzle and a workpiece is 100-300 millimeters;

the preset standard of the surface of the hydraulic metal structure after the sand blasting rust removal treatment is the rust removal grade Sa2.5 grade specified in GB8923, the preset standard of the surface roughness of the hydraulic metal structure is the range of Ry60 micrometers to 80 micrometers, and the surface floating dust and debris are preset to be swept by dry oil-free compressed air, wherein the relative humidity of the dry air is 5% to 30%, and the oil content of the oil-free air is less than 0.1 milligram per cubic meter;

after the sand blasting rust removal work is finished and the inspection is qualified, the quality inspection and the first rare earth aluminum spraying process are finished within eight hours.

3. The rare earth aluminum alloy corrosion prevention thermal spraying construction method applicable to seawater environment as claimed in claim 1, wherein in the step S2, comprising,

step S21, the pressure value of compressed air in the electric arc spraying equipment is a preset process parameter value, and when the thermal spraying rare earth aluminum alloy works, the oil-water separator blow-down valve is opened at intervals of preset time for blow-down;

step S22, the central control module controls the spraying distance according to the spraying distance parameter from the preset nozzle to the working surface;

step S23, the spraying angle needs to be vertical to the hydraulic metal component;

step S24, presetting the spraying speed to be 25-80 microns per second;

step S25, presetting one third of the overlapping area of the new spraying area and the old spraying area, if the electric arc spray gun moves and shakes to make the metal coating less than the minimum requirement of the preset thickness, re-spraying according to the difference value of the current metal coating thickness and the preset thickness judged by the central control module until the metal coatings are mutually vertical, cross-covered and uniform in thickness;

step S26, when the coarse particles in the sprayed area are larger than the preset standard, the central control module judges that the operation needs to be stopped at the moment, and sends out a prompt tone to remind that the sprayed area of the coarse particle area larger than the preset standard needs to be scraped for re-spraying, and the input current of the electric arc spraying equipment is adjusted before re-spraying, the wire feeding speed is reduced to A1, the air pressure is increased, if the coarse particles still appear in the re-spraying area, the sprayed area with the coarse particles appears is scraped for re-spraying, and the wire feeding speed is reduced to A2, wherein A1 is more than A2, and the air pressure is increased until the sprayed particles in the re-spraying area meet the preset standard;

and step S27, after the operation of thermal spraying the rare earth aluminum alloy is completed, blowing the surface of the rare earth aluminum layer by using preset compressed air to remove surface dust, ensuring that the thickness of the surface dust is less than or equal to the preset surface dust thickness requirement in the spraying work of the epoxy zinc phosphate paint, and scraping the heavy spraying if the thickness of the surface dust is greater than the preset surface dust thickness requirement.

4. The method as claimed in claim 3, wherein in the step S1, the sand for blasting rust is preset to be hard, angular, dry, and free of mud and impurities, and medium coarse sand with a particle size of 0.5 mm to 2.0 mm is used;

in the step S2, the diameter of the rare earth aluminum wire for thermal spraying is 3 mm.

5. The thermal spraying construction method for corrosion prevention of rare earth aluminum alloy suitable for seawater environment as claimed in claim 4, wherein the arc spraying equipment comprises a movable base 1, a control box 4, a multi-axis manipulator 5, an arc spray gun 6, and a central control module,

the bottom of the movable base 1 is provided with a moving unit 2, the moving unit 2 is used for moving the movable base 1, and the movable base 1 is provided with an armrest 3 for pushing and displacing the movable base 1;

the control box 4 is arranged on the movable base 1 and used for protecting the electric arc spraying equipment from power supply equipment, wire feeding equipment, compressed air supply equipment and control equipment;

the multi-axis mechanical arm 5 is arranged on the control box 4, and the multi-axis mechanical arm 5 is used for carrying the electric arc spray gun 6 to perform spraying work according to preset actions;

the electric arc spray gun 6 is arranged at the tail end of the multi-shaft mechanical arm 5 and used for spraying, and a connecting device 7 is arranged outside the electric arc spray gun 6 and used for fixing the electric arc spray gun 6 at the tail end of the multi-shaft mechanical arm 5;

the central control module is arranged in the control box 4, is respectively and electrically connected with the multi-shaft mechanical arm 5 and the electric arc spray gun 6, and is used for controlling the action of the multi-shaft mechanical arm 5, the temperature of the electric arc spray gun 6 and the wire feeding speed.

6. The method for constructing anticorrosive thermal spraying of rare earth aluminum alloy according to claim 5, wherein a thickness detecting sensor, a level detecting sensor and a distance detecting sensor are installed inside the arc spraying torch 6 of the arc spraying apparatus, wherein,

the thickness detection sensor is used for detecting the thickness of a coating in real time during spraying, sending the measured data to the central control module, and performing corresponding control adjustment on the multi-axis mechanical arm 5 and the electric arc spray gun 6 by the central control module according to the contrast value of the detected thickness data and preset thickness data;

the horizontal detection sensor is used for detecting the levelness of the electric arc spray gun 6 in real time during spraying, sending the measured data to the central control module, and performing corresponding control and adjustment on the multi-axis mechanical arm 5 and the electric arc spray gun 6 by the central control module according to the contrast value of the detected levelness data and preset levelness data;

the distance detection sensor is used for detecting the distance between the arc spray gun 6 and a working face in real time during spraying, sending measured data to the central control module, and performing corresponding control and adjustment on the multi-axis mechanical arm 5 and the arc spray gun 6 by the central control module according to the contrast value of the detected distance data and preset distance data.

7. The rare earth aluminum alloy corrosion prevention thermal spraying construction method suitable for the seawater environment as claimed in claim 6, wherein the preset thickness data THK0 is set in the central control module, wherein THK0 comprises intervals (THK01, THK02), THK01 < THK 02; the thickness detection sensor detects the thickness of the sprayed coating and transmits the current coating thickness data THK1 to the central control module, the central control module judges the current coating thickness data THK1 according to preset thickness data THK0,

when THK01 is greater than THK1 is greater than THK02, the central control module judges that the current coating thickness meets preset data, and the multi-axis mechanical arm 5 and the electric arc spray gun 6 are not adjusted;

when the THK1 is less than the THK01, the central control module judges that the current coating thickness is lower than preset data, maintains the current state of the multi-axis mechanical arm 5, and controls the electric arc spray gun 6 to adjust the spraying density until the THK01 is less than the THK1 and less than the THK 02;

when THK1 is greater than THK02, the central control module judges that the current coating thickness is higher than preset data, maintains the current state of the multi-axis mechanical arm 5, and controls the electric arc spray gun 6 to adjust the spraying density until THK01 is greater than THK1 and greater than THK 02;

setting the current temperature of the electric arc spray gun 6 to be TEMP2, setting the maximum temperature of the electric arc spray gun 6 to be TEMP3, and setting the minimum temperature of the electric arc spray gun 6 to be TEMP1, wherein TEMP3 is greater than TEMP2 is greater than TEMP 1;

setting the wire feeding speed of the electric arc spray gun 6 to be PO3 when the temperature of the electric arc spray gun 6 is TEMP3, setting the wire feeding speed of the electric arc spray gun 6 to be PO1 when the temperature of the electric arc spray gun 6 is TEMP1, and setting the wire feeding speed of the electric arc spray gun 6 to be PO2 when the temperature of the electric arc spray gun 6 is TEMP2, wherein PO3 is greater than PO2 is greater than PO 1;

setting the wire feeding speed of the electric arc spray gun 6 at PO3, the spraying density of the electric arc spray gun 6 at FPP3, setting the wire feeding speed of the electric arc spray gun 6 at PO1, the spraying density of the electric arc spray gun 6 at FPP1, and setting the wire feeding speed of the electric arc spray gun 6 at PO2, the spraying density of the electric arc spray gun 6 at FPP2, wherein FPP3 > FPP2 > FPP 1;

when THK1 < THK01, the central control module controls the electric arc spray gun 6 to increase the current spraying density FPP2 to THK01 < THK1 < THK02, and then the current spraying density FPP 2' is obtained,

when THK1 is more than THK02, the central control module controls the electric arc spray gun 6 to reduce the current spraying density FPP2 to THK01, THK1 and THK02, and then the current spraying density FPP 2' is obtained,

8. the rare earth aluminum alloy corrosion prevention thermal spraying construction method applicable to the seawater environment as claimed in claim 7, wherein the preset levelness data is LN0, wherein LN0 comprises intervals (LN01, LN02), LN01 < LN 02; the levelness detection sensor detects the levelness of the electric arc spray gun 6 and transmits the current levelness data LN1 to the central control module, the central control module judges the current coating thickness data LN1 according to the preset levelness data LN0,

when LN01 < LN1 < LN02, the central control module judges that the current levelness of the electric arc spray gun 6 meets preset data, and maintains the current states of the multi-axis mechanical arm 5 and the electric arc spray gun 6;

when LN1 is less than LN01, the central control module determines that the current levelness of the electric arc torch 6 is lower than preset data, the central control module maintains the current state of the electric arc torch 6, and the central control module increases the angle of the tail end of the multi-axis manipulator 5 until LN01 is less than LN1 and less than LN02, and then the current angle LN1 ', LN 1' ═ LN1+ (LN01-LN1) of the tail end of the multi-axis manipulator 5 is obtained;

when LN1 is greater than LN02, the control module determines that the current levelness of the arc spraying torch 6 is higher than preset data, the central control module maintains the current state of the arc spraying torch 6, and the central control module reduces the end angle of the multi-axis manipulator 5 until LN01 is greater than LN1 and less than LN02, and then the current end angle LN1 ', LN 1' -LN 1+ (LN1-LN02) of the multi-axis manipulator 5 is obtained.

9. The thermal spraying construction method for corrosion prevention of rare earth aluminum alloy suitable for seawater environment as claimed in claim 8, wherein the preset distance data set in the central control module is D0, wherein LN0 comprises intervals (D01, D02), D01 < D02; the distance detection sensor detects the distance from the nozzle of the electric arc spray gun 6 to the working surface and transmits the current distance data D1 to the central control module, the central control module judges the current coating thickness data D1 according to the preset distance data D0,

when D01 is more than D1 is more than D02, the central control module judges that the current distance data accord with preset distance data, and maintains the current states of the multi-axis manipulator 5 and the electric arc spray gun 6;

when D1 is less than D01, the central control module judges that the current distance data are less than preset data, the current state of the electric arc spray gun 6 is maintained, the central control module increases the distance from the nozzle of the electric arc spray gun 6 to the working surface at the tail end of the multi-shaft mechanical arm 5 until D01 is less than D1 and less than D02, and then the current distance D1 'from the nozzle of the electric arc spray gun 6 to the working surface and D1' ═ D1+ (D01-D1) are obtained;

when D1 is larger than D02, the central control module judges that the current distance data is higher than preset data, the current state of the electric arc spray gun 6 is maintained, the central control module reduces the distance from the nozzle of the electric arc spray gun 6 to the working surface at the tail end of the multi-shaft mechanical arm 5 until D01 is smaller than D1 and smaller than D02, and then the current distance D1 'and D1' -D1 + (D1-D02) from the nozzle of the electric arc spray gun 6 to the working surface is obtained.

10. The rare earth aluminum alloy anticorrosion thermal spraying construction method applicable to the seawater environment as claimed in claim 9, wherein the process of the central control module performing corresponding comprehensive adjustment on the multi-axis manipulator 5 and the arc spray gun 6 according to the comparison value between the real-time detected data of the thickness detection sensor, the real-time detected data of the horizontal detection sensor and the real-time detected data of the distance detection sensor and the preset data is as follows:

when the THK1 is THK0, the LN1 is LN0, and the D1 is D0, the central control module determines that the current measurement data conforms to preset distance data, and maintains the current states of the multi-axis manipulator 5 and the arc spray gun 6;

and when any one or more groups of data are not equal to the corresponding preset data in the three groups of data including the current coating thickness data, the current levelness data and the current distance data, the central control module judges that corresponding state adjustment is required to be performed in sequence according to the corresponding adjustment method and numerical value on the spraying density of the arc spray gun 6, the angle of the tail end of the multi-axis manipulator 5 and the distance from the tail end of the multi-axis manipulator 5 to the working surface until THK01 is more than THK1 and less than THK02, LN01 is more than LN1 and less than LN02, and D01 is more than D1 and less than D02.