CN111020453A - 一种获得独立的大气等离子喷涂涂层的方法 - Google Patents
一种获得独立的大气等离子喷涂涂层的方法 Download PDFInfo
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Abstract
本发明属于喷涂应用领域，具体涉及一种获得独立的大气等离子喷涂涂层的方法。本发明所需原料经济，易得。本发明采用不锈钢基底，通过在目标涂层与不锈钢基底之间加入在去离子水中的溶解度很高的NaCl作为溶解层，使得目标涂层置于去离子水中会短时间内脱离不锈钢基底，且保持形貌完整，在去除涂层基底的过程中不会对涂层的形貌、性能及内部结构产生影响。本发明所用不锈钢基底由于NaCl在去离子水中溶解后形貌不会受其影响，所以涂层基底可以重复利用，减少资源浪费。
Description
技术领域
本发明属于喷涂应用领域，具体涉及一种获得独立的大气等离子喷涂涂层的方法。
背景技术
随着无线电技术和雷达探测技术的快速发展，军事领域的雷达隐身技术也得到了迅猛的发展。目前国内外主要以两种手段实现雷达隐身：(1)通过添加雷达吸波材料对电磁波进行损耗吸收；(2)通过武器外形的隐身设计来降低其雷达散射截面RCS(Radar cross-section)。飞行器隐身涂层的设计除一般部件外，对于发动机尾喷管内的高温雷达涂层的设计是目前的一个研究难点。在正常工作条件下，其尾喷管内的局部温度可达500℃，甚至1000℃。由于受到高温气流冲刷的影响，使用结构材料进行雷达吸波的研究存在力学性能和稳定性的严苛的双重要求，短期内难以投入使用。使用添加了磁性吸波剂的涂层可以有效降低涂层厚度。
应用热喷涂陶瓷吸波涂层是一种被广泛研究并使用的降低雷达信号的方法。使用这种方法研究涂层介电性能时，必须将涂层与基底分离，由此出现了分离喷涂涂层的方法。传统的剥离喷涂涂层的方法是将目标涂层喷涂在石墨基底上，再通过机械剥离的方法使其分离。这种方法要求目标涂层较厚，对于飞行器隐身涂层而言，其厚度直接影响到实用性。目前设计的飞行器吸波涂层厚度在500μm左右，且涂层面积较大。受涂层力学性能影响，使用传统方法剥离涂层容易造成破损，且无法保证石墨被彻底去除，不可避免地对后续性能测试的准确性造成影响。
发明内容
针对上述存在问题或不足，为实现剥离低厚度目标涂层的形状完整，且不破坏表面形貌与内部结构的需求。本发明提供了一种获得独立的大气等离子喷涂涂层的方法，该方法是基于NaCl涂层在去离子水中的高溶解度的剥离涂层的方法。
本发明为实现发明目的，采用如下技术方案：
步骤1、备料：
将分析纯NaCl粉末加工处理，获得粒径小于63μm适用于热喷涂技术的粉末；以及制备适用于热喷涂技术的目标涂层粉末。
步骤2、涂层制备：
将不锈钢基底打砂之后，首先利用大气等离子喷涂集成系统使用步骤1制备的NaCl粉末在粘结层上进行喷涂，制备溶解层。
最后喷涂需要分离的目标涂层在溶解层上。
步骤3、分离目标涂层：
将步骤2制备完成的整体涂层结构完全放入去离子水中，待目标涂层自动脱离不锈钢基底后，再使用去离子水清洗脱离基底的目标涂层，以去除目标涂层上的残留NaCl，即可得到完整的目标涂层。
进一步的，所述步骤2涂层制备时，溶解层与不锈钢基底之间还制备了一层粘结层，粘结层用以增加溶解层与不锈钢基底之间的结合强度。
进一步的，所述粘结层为NiCrAlY层，利用大气等离子喷涂集成系统喷涂于不锈钢基底打砂侧。
与现有技术相比，本发明的优点体现在
1、本发明所需原料经济，易得。本发明使用粉体为商用45μmNiCrAlY粉末与分析纯NaCl粉末。其中NiCrAlY粘结层的作用是增强NaCl溶解层与不锈钢基底之间的结合，防止NaCl溶解层在喷涂目标涂层的过程中脱落。所以NiCrAlY涂层并不完全需要且可替换成其他过渡层材料。
2、本发明由于采用了NaCl作为溶解层，在去离子水中的溶解度很高，因此目标涂层置于去离子水中会短时间内脱离不锈钢基底，且保持形貌完整，在去除涂层基底的过程中不会对涂层的形貌、性能及内部结构产生影响。
3、本发明所用涂层基底可以重复利用。由于NaCl在去离子水中溶解后，基底形貌不会受其影响，所以涂层基底可以重复利用，减少资源浪费。
综上所述，本发明采用不锈钢基底，通过在目标涂层与不锈钢基底之间加入在去离子水中的溶解度很高的NaCl作为溶解层，使得目标涂层置于去离子水中会短时间内脱离不锈钢基底，且保持形貌完整，在去除涂层基底的过程中不会对涂层的形貌、性能及内部结构产生影响。本发明所用不锈钢基底由于NaCl在去离子水中溶解后形貌不会受其影响，所以涂层基底可以重复利用，减少资源浪费。
附图说明
图1为本发明实事例1所得CaO-B2O3-SiO2(CBS)微晶玻璃喷涂粉末的SEM形貌图；
图2为本发明实事例1所得CaO-B2O3-SiO2(CBS)微晶玻璃涂层的SEM形貌图；
图3为本发明实事例1中剥离的CaO-B2O3-SiO2(CBS)微晶玻璃涂层的相机照片；
图4为本发明实事例1中剥离的CaO-B2O3-SiO2(CBS)微晶玻璃涂层与未进行剥离的CaO-B2O3-SiO2(CBS)微晶玻璃涂层的XRD的对比图；
图5为本发明实事例2中剥离的Fe/Al2O3涂层与剥离后316不锈钢基底的相机照片。
具体实施方式
实事例1
步骤1、备料：
将分析纯NaCl粉末在120℃烘箱中烘1小时，随后与其4倍质量的氧化锆球混合，使用行星式球磨机球磨30分钟。所得粉末使用63μm筛网过筛。将最终获得的NaCl原始粉末放入干燥箱中保存。
NiCrAlY粉末选用商用45μmNiCrAlY粉末。
取1500gCaO-B2O3-SiO2(CBS)微晶玻璃原始粉末，加入30g的粘结剂PEI，12g的消泡剂柠檬酸铵以及7500g的氧化锆球(5mm和10mm的氧化锆球按质量比1：1混合)，最后加入1875g的去离子水。混合球磨24小时，使浆料混合均匀后通过喷雾造粒获得直径约30到80μm间的目标涂层喷涂粉末。
步骤2、涂层制备：
将不锈钢基底打砂之后，首先利用大气等离子喷涂集成系统使用步骤1制备的NiCrAlY粉末对不锈钢基底打砂侧进行喷涂，制备粘结层。
然后利用大气等离子喷涂集成系统使用步骤1制备的NaCl粉末在粘结层上进行喷涂，制备溶解层。
喷涂具体工艺参数见表1。
| 功率 | 喷涂距离 | 涂层厚度 | 氩气流速 | 氮气流速 | 氢气流速 | |
| NiCrAlY层 | 65kW | 120mm | 50μm | 200SCFH | 80SCFH | 60SCFH |
| NaCl层 | 65kW | 100mm | 6μm | 160SCFH | 80SCFH | 60SCFH |
表1
最后喷涂需要分离的目标涂层在溶解层上，CBS涂层进行大气等离子喷涂，具体参数如表2，涂层的尺寸为50mm×50mm。
| 功率 | 喷涂距离 | 涂层厚度 | 氩气流速 | 氮气流速 | 氢气流速 | |
| CBS涂层 | 55kW | 100mm | 400μm | 200SCFH | 80SCFH | 60SCFH |
表2
步骤3、分离目标涂层：
将步骤2制备完成的整体涂层结构完全放入去离子水中，待目标涂层自动脱离基底后，再使用去离子水清洗脱离基底的目标涂层，以去除目标涂层上的残留NaCl，即可得到完整的目标涂层。
本实施例所用CaO-B2O3-SiO2(CBS)微晶玻璃喷涂粉末的SEM形貌如图1所示。
本实施例所用CaO-B2O3-SiO2(CBS)微晶玻璃涂层的SEM形貌如图2所示，可以看出本实施例所得目标涂层存在完全熔融区域和部分熔融区域，符合热喷涂制备涂层的基本特征。
本实施例所用CaO-B2O3-SiO2(CBS)微晶玻璃涂层的相机照片如图3所示，可以看出所得目标涂层完整且厚度满足飞行器涂层设计要求。
本实施例所用剥离的CaO-B2O3-SiO2(CBS)微晶玻璃涂层与未进行剥离的CaO-B2O3-SiO2(CBS)微晶玻璃涂层的XRD的对比如图4所示，可以看出两者没有区别，即表示其内部结构没有发生变化。
实事例2
步骤1、备料：
将分析纯NaCl粉末在120℃烘箱中烘1小时，随后与其4倍质量的氧化锆球混合，使用行星式球磨机球磨30分钟。所得粉末使用63μm筛网过筛。将最终获得的NaCl原始粉末放入干燥箱中保存。
取400g铁粉与600gAl2O3粉末机械混合，获得Fe/Al2O3混合粉末。
NiCrAlY粉末选用商用45μmNiCrAlY粉末。
步骤2、涂层制备：
将不锈钢基底打砂之后，首先利用大气等离子喷涂集成系统使用步骤1制备的NiCrAlY粉末对不锈钢基底打砂侧进行喷涂，制备粘结层。
然后利用大气等离子喷涂集成系统使用步骤1制备的NaCl粉末在粘结层上进行喷涂，制备溶解层。
具体工艺参数见表3：
| 功率 | 喷涂距离 | 涂层厚度 | 氩气流速 | 氮气流速 | 氢气流速 | |
| NiCrAlY层 | 65kW | 120mm | 50μm | 200SCFH | 80SCFH | 60SCFH |
| NaCl层 | 65kW | 100mm | 6μm | 160SCFH | 80SCFH | 60SCFH |
表3
使用步骤1制备的Fe/Al2O3混合粉末进行大气等离子喷涂，喷涂的具体参数如表4，涂层的形状为直径20mm的圆片状。
| 功率 | 喷涂距离 | 涂层厚度 | 氩气流速 | 氮气流速 | 氢气流速 | |
| 涂层 | 65kW | 100mm | 250μm | 160SCFH | 80SCFH | 60SCFH |
表4
步骤3、分离目标涂层：
将步骤2制备完成的整体涂层结构完全放入去离子水中，待目标涂层自动脱离基底后，再使用去离子水清洗脱离基底的目标涂层，以去除目标涂层上的残留NaCl，即可得到完整的目标涂层。
本实施例所用剥离的Fe/Al2O3涂层与316不锈钢基底的相机照片如图5所示，可以看出涂层从基底上完全脱落且涂层与基底均保持完整。
Claims (3)
1.一种获得独立的大气等离子喷涂涂层的方法，包括以下步骤：
步骤1、备料：
将分析纯NaCl粉末加工处理，获得粒径小于63μm适用于热喷涂技术的粉末；以及制备适用于热喷涂技术的目标涂层粉末；
步骤2、涂层制备：
将不锈钢基底打砂之后，利用大气等离子喷涂集成系统使用步骤1制备的NaCl粉末在粘结层上进行喷涂，制备溶解层；
最后喷涂需要分离的目标涂层在溶解层上。
步骤3、分离目标涂层：
将步骤2制备完成的整体涂层结构完全放入去离子水中，待目标涂层自动脱离基底后，再使用去离子水清洗脱离不锈钢基底的目标涂层，以去除目标涂层上的残留NaCl，即可得到完整的目标涂层。
2.如权利要求1所述获得独立的大气等离子喷涂涂层的方法，其特征在于：所述步骤2涂层制备时，溶解层与不锈钢基底之间还制备了一层粘结层，粘结层用以增加溶解层与不锈钢基底之间的结合强度。
3.如权利要求1所述获得独立的大气等离子喷涂涂层的方法，其特征在于：所述粘结层为NiCrAlY层，利用大气等离子喷涂集成系统喷涂于不锈钢基底打砂侧。
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