Wear-resistant flux-cored wire for electric arc spraying and coating preparation method

Abstract

The invention relates to the field of thermal spraying in material processing engineering, in particular to a wear-resistant flux-cored wire for electric arc spraying and a coating preparation method, and aims to solve the problems of poor wear resistance, corrosion resistance and bonding strength of a coating for existing electric arc spraying. According to the preparation method, the iron powder, the nickel powder, the boron powder and the silicon powder are reasonably matched to effectively improve the mechanical property of the coating, the chromium powder can improve the wear resistance of the coating, the coating synergistically strengthened by tungsten carbide and chromium carbide dual-element ceramic particles has excellent wear resistance, the light rare earth can improve the wear resistance of the coating and improve the plasticity and hardness of the coating, and the service life of the coating is prolonged. The composite ceramic is prepared by compounding titanium diboride, boron carbide and carbon and has excellent corrosion resistance and wear resistance, the friction coefficient of the coating can be reduced by adding the composite coating, corrosion medium permeation is blocked, and the bonding strength is improved.

Description

Technical Field

[0001] This invention relates to the field of thermal spraying in materials processing engineering, specifically to a wear-resistant arc spraying core wire and a coating preparation method. Background Technology

[0002] Early failure and scrapping of materials and components due to wear and corrosion result in staggering energy and material consumption. Failures caused by various types of wear, corrosion, and oxidation often occur on the surface of materials and components. To prevent parts operating under conditions such as high speed, high temperature, high pressure, heavy load, and corrosive media from being scrapped due to localized surface damage, and to improve the reliability and extend the service life of parts, it is particularly important to research and apply new technologies and processes that can improve the surface performance of parts. Arc spraying has received widespread attention both domestically and internationally due to its advantages such as high efficiency, low cost, safe and simple operation, and suitability for large-area in-situ construction.

[0003] However, the arc-sprayed wear-resistant coatings currently available on the market mainly use carbon-reinforced alloy wires, which do not have high wear resistance and bonding strength.

[0004] Therefore, developing a wear-resistant arc spraying core wire and coating preparation method is of great significance for the surface strengthening and protection of materials and their components. Summary of the Invention

[0005] To overcome the aforementioned technical problems, the present invention aims to provide a wear-resistant arc spraying core wire and a coating preparation method. The method involves rolling 310S stainless steel strip into a U-shaped cross-section steel strip groove; mixing iron powder, nickel powder, boron powder, chromium powder, silicon powder, light rare earth elements, multiphase ceramics, chromium carbide, tungsten carbide, and a composite coating, and feeding the mixture into the U-shaped cross-section steel strip groove; closing the U-shaped cross-section steel strip groove using rollers; and then obtaining the wear-resistant arc spraying core wire by wire drawing and diameter reduction. The coating is then prepared using an arc spraying process. This method solves the problem that existing arc spraying coatings lack high wear resistance and bonding strength.

[0006] The objective of this invention can be achieved through the following technical solutions: In a first aspect, the present invention provides a wear-resistant arc spraying cored wire, comprising the following components in parts by weight: 40-60 parts iron powder, 10-20 parts nickel powder, 3-8 parts boron powder, 8-15 parts chromium powder, 1-3 parts silicon powder, 0.5-2 parts light rare earth, 15-30 parts multiphase ceramics, 10-18 parts chromium carbide, 5-12 parts tungsten carbide, 8-15 parts composite coating, and 100 parts 310S stainless steel strip; The main components of the light rare earth elements are cerium 48.76%, lanthanum 26.54%, neodymium 16.17%, praseodymium 5.41%, samarium 1.86%, and europium 1.26%.

[0007] As a further aspect of the present invention: the multiphase ceramic is prepared by the following steps: Step a1: Add titanium diboride powder and anhydrous ethanol to a stainless steel ball mill jar lined with polytetrafluoroethylene, and add silicon carbide as grinding balls. The ball-to-powder ratio is 5:1, the rotation speed is 300 r / min, and the mixture is ball-milled for 6-12 hours. After ball milling, filter and separate the slurry and grinding balls through a funnel. The grinding balls are separated in the funnel, and the slurry is collected in a beaker. Dry the slurry collected in the beaker using a rotary evaporator. The water bath temperature during the evaporation process is 60℃, the rotation speed is 65 r / min, and the rotary evaporation is carried out for 1-2 hours. Transfer the powder dried by rotary evaporation to a vacuum drying oven at 60℃ and continue drying for 24 hours. The dried powder is then passed through a 100-mesh sieve to obtain the intermediate product. Step a2: Add the intermediate product, boron carbide powder, and anhydrous ethanol to a mixing bottle and mix. Add silicon carbide grinding balls to the mixing bottle at a ball-to-powder ratio of 5:1. Place the mixing bottle in a drum mixer at a speed of 30 r / min and mix and ball mill for 12 h. Then filter and separate the slurry and grinding balls through a funnel. Dry the slurry using a rotary evaporator. During the evaporation process, the water bath temperature is 60℃, the rotation speed is 65 r / min, and the rotary evaporation is carried out for 1-2 h. Transfer the powder dried by rotary evaporation to a vacuum drying oven at 60℃ and continue drying for 24 h to obtain multiphase powder. Step a3: After passing the multiphase powder through a 200-mesh sieve, place it in a graphite mold for hot pressing and sintering. Argon gas is introduced for protection, and the sintering pressure is set to 10 MPa. During the hot pressing and sintering process, the heating rate is 20℃ / min from 25℃ to 1500℃ and 10℃ / min from 1500℃ to 1950℃. Then, it is held at 1950℃ for 30 minutes. After sintering, the heating element of the hot press furnace is turned off, and the temperature is allowed to drop naturally to 25℃ to obtain the multiphase ceramic.

[0008] As a further aspect of the present invention: the ratio of titanium diboride powder to anhydrous ethanol in step a1 is 40g:400mL.

[0009] As a further aspect of the present invention: the ratio of the intermediate product, boron carbide powder and anhydrous ethanol in step a2 is 4g:16g:250mL.

[0010] As a further aspect of the present invention: the composite coating is prepared by the following steps: Step b1: Add aluminum nitrate nonhydrate, ferric nitrate nonhydrate, and deionized water to a three-necked flask equipped with a stirrer, thermometer, and gas delivery tube. Stir magnetically for 20-30 minutes at 25°C and 200-300 r / min. Add 3 mol / L ammonia to adjust the pH to 7. Filter the precipitate in the solution and wash it 2-3 times each with deionized water and anhydrous ethanol. Dry it in an oven at 60°C for 1-2 hours to obtain the precursor. Calcine the precursor at 770°C for 2 hours. Then, wash it 2-3 times with hydrochloric acid and anhydrous ethanol at 100°C by centrifugation. Dry it at 50-55°C for 2-3 hours to obtain the intermediate. Step b2: The intermediate was ultrasonically cleaned in acetone and alcohol for 15-30 min and centrifuged. The centrifuged particles were dried in an oven at 50°C. An ionic liquid at 25°C was added, and the mixture was magnetically stirred in a glove box for 15-30 min. The glove box was then removed and ultrasonically cleaned for 30 min to obtain a suspension. The suspension was placed in a glove box, with ferritic stainless steel 1Cr17 as the positive electrode and an aluminum plate as the negative electrode. The positive electrode was polished to 800# with water-polished sandpaper, and then ultrasonically cleaned in acetone for 15 min and dried. The aluminum plate was ultrasonically cleaned in 50% (v / v) nitric acid solution, deionized water, methanol, and acetone for 15 min each. The current density was set to 2 A / dm, and the coating was applied for 45 min to obtain a composite coating.

[0011] As a further aspect of the present invention: the ratio of aluminum nitrate nonahydrate, ferric nitrate nonahydrate, and deionized water in step b1 is 0.004 mol: 0.02 mol: 200 mL; the molar concentration of hydrochloric acid is 4 mol / L.

[0012] As a further aspect of the present invention: the ratio of the intermediate to the ionic liquid in step b2 is 0.5g:50mL; the ionic liquid is composed of aluminum chloride and 1-methyl-3-ethylimidazole chloride in a molar ratio of 2:1.

[0013] Secondly, the present invention provides a method for preparing a coating of a wear-resistant arc spraying cored wire, comprising the following steps: Step 1: Weigh out the following components by weight: 40-60 parts iron powder, 10-20 parts nickel powder, 3-8 parts boron powder, 8-15 parts chromium powder, 1-3 parts silicon powder, 0.5-2 parts light rare earth, 15-30 parts multiphase ceramic, 10-18 parts chromium carbide, 5-12 parts tungsten carbide, 8-15 parts composite coating, and 100 parts 310S stainless steel strip. Step 2: Roll the 310S stainless steel strip through a roller press to form a U-shaped cross-section steel strip groove; Step 3: Iron powder, nickel powder, boron powder, chromium powder, silicon powder, light rare earth, multiphase ceramics, chromium carbide, tungsten carbide, and composite coating are mixed and fed into a U-shaped cross-section steel strip groove by a belt-type powder feeding machine. The U-shaped cross-section steel strip groove is closed by the rollers of the roller press, forming a completely closed O-shaped cross-section flux core. Then, the diameter is reduced to 1.5-2.0mm by wire drawing to obtain wear-resistant arc spraying flux core wire. Step 4: Prepare the coating using an electric arc spraying process. The spraying process parameters are: voltage 25-35V, current 180-220A, spraying distance 190-210mm, and compressed air pressure 0.5-0.6MPa.

[0014] The beneficial effects of this invention are: This invention involves rolling 310S stainless steel strip using a roller press to form a "U"-shaped cross-section steel strip groove. Iron powder, nickel powder, boron powder, chromium powder, silicon powder, light rare earth elements, multiphase ceramics, chromium carbide, tungsten carbide, and a composite coating are mixed and fed into the "U"-shaped cross-section steel strip groove via a belt-driven powder feeder. The roller press rolls close the "U"-shaped cross-section steel strip groove, forming a completely closed "O"-shaped cross-section flux core. The core wire for wear-resistant arc spraying is then obtained through wire drawing and diameter reduction. The coating is then prepared using an arc spraying process. The rational combination of iron powder, nickel powder, boron powder, and silicon powder in this preparation method effectively improves the mechanical properties and high-temperature resistance of the coating. It possesses oxidation resistance, good plasticity and toughness. Chromium powder can reduce the formation of the γ phase in the alloy and stabilize the α phase, thereby improving the wear resistance of the coating. High-hardness tungsten carbide can significantly enhance the microhardness of the composite coating. Chromium carbide can promote the formation of a protective oxide film. The coating synergistically reinforced by tungsten carbide and chromium carbide binary ceramic particles has excellent wear resistance. Light rare earth elements can improve the coating's resistance to abrasive wear, and improve the coating's plasticity and hardness. Multiphase ceramics prepared by combining titanium diboride, boron carbide and carbon have excellent corrosion resistance and wear resistance. Adding composite coatings can reduce the coating's friction coefficient, block the penetration of corrosive media, and improve the bonding strength.

[0015] In the preparation of the wear-resistant arc spraying core wire and coating, a multiphase ceramic was first prepared. Titanium diboride powder and anhydrous ethanol were added to a ball mill jar, milled, filtered, rotary evaporated, and vacuum dried to obtain an intermediate product. The intermediate product, boron carbide powder, and anhydrous ethanol were added to a mixing bottle and mixed. Silicon carbide milling balls were added to the mixing bottle, and the mixture was ball-milled, filtered, rotary evaporated, and vacuum dried to obtain a multiphase powder. The multiphase powder was then rotary evaporated and sintered, followed by natural cooling to obtain the multiphase ceramic. The ball milling process refined and modified the raw material powder, improving its sintering activity. The composite ceramic material prepared by the hot-pressing sintering process exhibited high density and excellent performance. The boron oxide-titanium oxide film formed by the oxidation of titanium diboride surface reduced the friction coefficient, boron atoms strengthened the iron matrix through solid solution, graphite improved the friction compatibility of the coating, and boron carbide exhibited low... Titanium diboride possesses numerous excellent properties, including high density, high hardness, high elastic modulus, high melting point, good corrosion resistance and wear resistance, high neutron absorption performance, and semiconductivity. It exhibits high hardness and low density. Adding titanium diboride as a second phase to prepare multiphase ceramics increases fracture toughness, resulting in a toughening effect. Silicon carbide has high hardness and wear resistance. Using silicon carbide as a grinding ball to refine titanium diboride powder, the silicon carbide mixed in during the ball milling process enhances the material's oxidation resistance. By using titanium diboride and graphite to co-toughen boron carbide, the prepared multiphase ceramic material exhibits high fracture toughness. The crack deflection, bridging, and branching induced by graphite further improve the fracture toughness of the multiphase ceramic material. Through multiphase synergy and interface optimization, this multiphase ceramic enables the arc-sprayed coating to simultaneously achieve ultra-high wear resistance, excellent toughness, and high-temperature stability.

[0016] In the preparation of the wear-resistant arc spraying core wire and coating, a composite coating was first prepared. Aluminum nitrate nonahydrate, ferric nitrate nonahydrate, and deionized water were added to a three-necked flask, magnetically stirred, and adjusted to pH 7. The mixture was then filtered, washed, and dried to obtain a precursor. The precursor was calcined, centrifuged, washed, and dried to obtain an intermediate. The intermediate was ultrasonically cleaned and centrifuged, then dried again. An ionic liquid was added, and the mixture was magnetically stirred and ultrasonically injected to obtain a suspension. The suspension was placed in a glove box, and a composite coating was deposited using ferritic stainless steel 1Cr17 as the positive electrode and an aluminum plate as the negative electrode. The nano-alumina particles were uniformly embedded... Integrating into the iron matrix, a micro-bearing effect is formed. The amorphous carbon film formed by ionic liquid electrodeposition provides solid lubrication, reducing the coating friction coefficient and minimizing wear loss of the arc-sprayed coating. Nano-alumina fills the micropores of the coating, and the decomposition products of the ionic liquid form a chloride passivation film, synergistically blocking the penetration of corrosive media. The electrodeposited layer and the ferritic stainless steel 1Cr17 cathode form a metallurgical transition layer. The pinning effect of nano-alumina inhibits the propagation of cracks within the coating and improves the bonding strength of the coating. At high temperatures, alumina is transformed into a dense alumina film, increasing hardness. The composite oxide layer of alumina and iron oxide blocks oxygen diffusion and optimizes high-temperature wear resistance. Detailed Implementation

[0017] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0018] Example 1: This embodiment describes a method for preparing a wear-resistant arc spraying core wire and coating, including the following steps: Step S1: Add 40g of titanium diboride powder and 400mL of anhydrous ethanol to a stainless steel ball mill jar lined with polytetrafluoroethylene. Add silicon carbide as grinding balls. The ball-to-powder ratio is 5:1. The rotation speed is 300r / min. Mix and ball mill for 6h. After ball milling, filter and separate the slurry and grinding balls through a funnel. The grinding balls are separated in the funnel, and the slurry is collected in a beaker. Dry the slurry collected in the beaker using a rotary evaporator. The water bath temperature during the evaporation process is 60℃, the rotation speed is 65r / min, and the rotary evaporation is carried out for 1h. Transfer the powder dried by rotary evaporation to a vacuum drying oven at 60℃ and continue drying for 24h. The dried powder is then passed through a 100-mesh sieve to obtain the intermediate product. Step S2: Add 4g of intermediate product, 16g of boron carbide powder and 250mL of anhydrous ethanol to a mixing bottle and mix. Add silicon carbide grinding balls to the mixing bottle, with a ball-to-powder ratio of 5:1. Place the mixing bottle in a drum mixer at a speed of 30r / min and mix and ball mill for 12h. Then filter and separate the slurry and grinding balls through a funnel. Dry the slurry using a rotary evaporator. During the evaporation process, the water bath temperature is 60℃, the rotation speed is 65r / min, and the rotary evaporation is carried out for 1h. Transfer the powder dried by rotary evaporation to a vacuum drying oven at 60℃ and continue drying for 24h to obtain multiphase powder. Step S3: After passing the multiphase powder through a 200-mesh sieve, place it in a graphite mold for hot pressing and sintering. Argon gas is introduced for protection, and the sintering pressure is set to 10 MPa. During the hot pressing and sintering process, the heating rate is 20℃ / min from 25℃ to 1500℃ and 10℃ / min from 1500℃ to 1950℃. Then, it is held at 1950℃ for 30 minutes. After sintering, the heating element of the hot press furnace is turned off, and the temperature is allowed to drop naturally to 25℃ to obtain multiphase ceramic. Step S4: Add 0.004 mol aluminum nitrate nonhydrate, 0.02 mol ferric nitrate nonhydrate, and 200 mL deionized water to a three-necked flask equipped with a stirrer, thermometer, and gas delivery tube. Stir magnetically for 20 min at 25 °C and 200 r / min. Add 3 mol / L ammonia to adjust the pH to 7. Filter the precipitate in the solution, wash twice with deionized water and anhydrous ethanol, and dry in an oven at 60 °C for 1 h to obtain the precursor. Calcine the precursor at 770 °C for 2 h, and then wash twice by centrifugation with 4 mol / L hydrochloric acid and anhydrous ethanol at 100 °C. Dry at 50 °C for 2 h to obtain the intermediate. Step S5: 0.5g of the intermediate was ultrasonically cleaned in acetone and alcohol for 15min and centrifuged. The centrifuged particles were dried in an oven at 50℃. 50mL of an ionic liquid mixed with aluminum chloride and 1-methyl-3-ethylimidazole chloride at a molar ratio of 2:1 was added at 25℃. The mixture was magnetically stirred in a glove box for 15min. The glove box was removed and ultrasonically cleaned for 30min to obtain a suspension. The suspension was placed in a glove box with ferritic stainless steel 1Cr17 as the positive electrode and an aluminum plate as the negative electrode. The positive electrode was polished to 800# with water-polished sandpaper. Then, it was ultrasonically cleaned in acetone for 15min and dried. The aluminum plate was ultrasonically cleaned in 50% nitric acid solution, deionized water, methanol and acetone for 15min respectively. The current density was set to 2A / dm, and the coating was applied for 45min to obtain a composite coating. Step S6: Weigh out the following components by weight: 40 parts iron powder, 10 parts nickel powder, 3 parts boron powder, 8 parts chromium powder, 1 part silicon powder, 0.5 parts light rare earth, 15 parts multiphase ceramic, 10 parts chromium carbide, 5 parts tungsten carbide, 8 parts composite coating, and 100 parts 310S stainless steel strip. Step S7: Roll the 310S stainless steel strip through a roller press to form a U-shaped cross-section steel strip groove; Step S8: Iron powder, nickel powder, boron powder, chromium powder, silicon powder, light rare earth, multiphase ceramics, chromium carbide, tungsten carbide and composite coating are mixed and fed into a U-shaped cross-section steel strip groove by a belt-type powder feeding machine. The U-shaped cross-section steel strip groove is closed by the rollers of the roller press, and a completely closed O-shaped cross-section flux core is formed. Then, the diameter is reduced to 1.5mm by wire drawing to obtain wear-resistant arc spraying flux core wire. Step S9: Prepare a coating using an electric arc spraying process. The spraying process parameters are: voltage 25V, current 180A, spraying distance 190mm, and compressed air pressure 0.5MPa.

[0019] Example 2: This embodiment describes a method for preparing a wear-resistant arc spraying core wire and coating, including the following steps: Step S1: Add 40g of titanium diboride powder and 400mL of anhydrous ethanol to a stainless steel ball mill jar lined with polytetrafluoroethylene. Add silicon carbide as grinding balls. The ball-to-powder ratio is 5:1. The rotation speed is 300r / min. Mix and ball mill for 9h. After ball milling, filter and separate the slurry and grinding balls through a funnel. The grinding balls are separated in the funnel, and the slurry is collected in a beaker. Dry the slurry collected in the beaker using a rotary evaporator. The water bath temperature during the evaporation process is 60℃, the rotation speed is 65r / min, and the rotary evaporation is carried out for 1.5h. Transfer the powder dried by rotary evaporation to a vacuum drying oven at 60℃ and continue drying for 24h. The dried powder is then passed through a 100-mesh sieve to obtain the intermediate product. Step S2: Add 4g of intermediate product, 16g of boron carbide powder and 250mL of anhydrous ethanol to a mixing bottle and mix. Add silicon carbide grinding balls to the mixing bottle, with a ball-to-powder ratio of 5:1. Place the mixing bottle in a drum mixer at a speed of 30r / min and mix and ball mill for 12h. Then filter and separate the slurry and grinding balls through a funnel. Dry the slurry using a rotary evaporator. During the evaporation process, the water bath temperature is 60℃, the rotation speed is 65r / min, and the rotary evaporation is carried out for 1.5h. Transfer the powder dried by rotary evaporation to a vacuum drying oven at 60℃ and continue drying for 24h to obtain multiphase powder. Step S3: After passing the multiphase powder through a 200-mesh sieve, place it in a graphite mold for hot pressing and sintering. Argon gas is introduced for protection, and the sintering pressure is set to 10 MPa. During the hot pressing and sintering process, the heating rate is 20℃ / min from 25℃ to 1500℃ and 10℃ / min from 1500℃ to 1950℃. Then, it is held at 1950℃ for 30 minutes. After sintering, the heating element of the hot press furnace is turned off, and the temperature is allowed to drop naturally to 25℃ to obtain multiphase ceramic. Step S4: Add 0.004 mol aluminum nitrate nonhydrate, 0.02 mol ferric nitrate nonhydrate, and 200 mL deionized water to a three-necked flask equipped with a stirrer, thermometer, and gas delivery tube. Stir magnetically for 25 min at 25℃ and 250 r / min. Add 3 mol / L ammonia to adjust the pH to 7. Filter the precipitate in the solution, wash three times each with deionized water and anhydrous ethanol, and dry in an oven at 60℃ for 1.5 h to obtain the precursor. Calcine the precursor at 770℃ for 2 h, and then wash three times at 100℃ with 4 mol / L hydrochloric acid and anhydrous ethanol by centrifugation. Dry at 53℃ for 2.5 h to obtain the intermediate. Step S5: 0.5g of the intermediate was ultrasonically cleaned in acetone and alcohol for 25min and centrifuged. The centrifuged particles were dried in an oven at 50℃. 50mL of an ionic liquid composed of aluminum chloride and 1-methyl-3-ethylimidazole chloride in a molar ratio of 2:1 was added at 25℃. The mixture was magnetically stirred in a glove box for 15-30min. The glove box was removed and ultrasonically cleaned for 30min to obtain a suspension. The suspension was placed in a glove box with ferritic stainless steel 1Cr17 as the positive electrode and an aluminum plate as the negative electrode. The positive electrode was polished to 800# with water-polished sandpaper. Then, it was ultrasonically cleaned in acetone for 15min and dried. The aluminum plate was ultrasonically cleaned in 50% nitric acid solution, deionized water, methanol and acetone for 15min each. The current density was set to 2A / dm, and the coating was applied for 45min to obtain a composite coating. Step S6: Weigh out 50 parts of iron powder, 15 parts of nickel powder, 5 parts of boron powder, 12 parts of chromium powder, 2 parts of silicon powder, 1 part of light rare earth, 18 parts of multiphase ceramic, 14 parts of chromium carbide, 8 parts of tungsten carbide, 12 parts of composite coating, and 100 parts of 310S stainless steel strip according to the weight composition. Step S7: Roll the 310S stainless steel strip through a roller press to form a U-shaped cross-section steel strip groove; Step S8: Iron powder, nickel powder, boron powder, chromium powder, silicon powder, light rare earth, multiphase ceramics, chromium carbide, tungsten carbide and composite coating are mixed and fed into a U-shaped cross-section steel strip groove by a belt-type powder feeding machine. The U-shaped cross-section steel strip groove is closed by the rollers of the roller press, and a completely closed O-shaped cross-section flux core is formed. Then, the diameter is reduced to 1.8mm by wire drawing to obtain wear-resistant arc spraying flux core wire. Step S9: Prepare a coating using an electric arc spraying process. The spraying process parameters are: voltage 30V, current 200A, spraying distance 200mm, and compressed air pressure 0.6MPa.

[0020] Example 3: This embodiment describes a method for preparing a wear-resistant arc spraying core wire and coating, including the following steps: Step S1: Add 40g of titanium diboride powder and 400mL of anhydrous ethanol to a stainless steel ball mill jar lined with polytetrafluoroethylene. Add silicon carbide as grinding balls. The ball-to-powder ratio is 5:1. The rotation speed is 300r / min. Mix and ball mill for 12h. After ball milling, filter and separate the slurry and grinding balls through a funnel. The grinding balls are separated in the funnel, and the slurry is collected in a beaker. Dry the slurry collected in the beaker using a rotary evaporator. The water bath temperature during the evaporation process is 60℃, the rotation speed is 65r / min, and the rotary evaporation is carried out for 2h. Transfer the powder dried by rotary evaporation to a vacuum drying oven at 60℃ and continue drying for 24h. The dried powder is then passed through a 100-mesh sieve to obtain the intermediate product. Step S2: Add 4g of intermediate product, 16g of boron carbide powder and 250mL of anhydrous ethanol to a mixing bottle and mix. Add silicon carbide grinding balls to the mixing bottle, with a ball-to-powder ratio of 5:1. Place the mixing bottle in a drum mixer with a speed of 30r / min and mix and ball mill for 12h. Then filter and separate the slurry and grinding balls through a funnel. Dry the slurry using a rotary evaporator. During the evaporation process, the water bath temperature is 60℃, the rotation speed is 65r / min, and the rotary evaporation is carried out for 2h. Transfer the powder dried by rotary evaporation to a vacuum drying oven at 60℃ and continue drying for 24h to obtain multiphase powder. Step S3: After passing the multiphase powder through a 200-mesh sieve, place it in a graphite mold for hot pressing and sintering. Argon gas is introduced for protection, and the sintering pressure is set to 10 MPa. During the hot pressing and sintering process, the heating rate is 20℃ / min from 25℃ to 1500℃ and 10℃ / min from 1500℃ to 1950℃. Then, it is held at 1950℃ for 30 minutes. After sintering, the heating element of the hot press furnace is turned off, and the temperature is allowed to drop naturally to 25℃ to obtain multiphase ceramic. Step S4: Add 0.004 mol aluminum nitrate nonhydrate, 0.02 mol ferric nitrate nonhydrate, and 200 mL deionized water to a three-necked flask equipped with a stirrer, thermometer, and gas delivery tube. Stir magnetically for 30 min at 25 °C and 300 r / min. Add 3 mol / L ammonia to adjust the pH to 7. Filter the precipitate in the solution and wash it three times each with deionized water and anhydrous ethanol. Dry it in an oven at 60 °C for 2 h to obtain the precursor. Calcine the precursor at 770 °C for 2 h. Then, wash it three times by centrifugation with 4 mol / L hydrochloric acid and anhydrous ethanol at 100 °C. Dry it at 55 °C for 3 h to obtain the intermediate. Step S5: 0.5g of the intermediate was ultrasonically cleaned in acetone and alcohol for 30min and centrifuged. The centrifuged particles were dried in an oven at 50℃. 50mL of an ionic liquid mixed with aluminum chloride and 1-methyl-3-ethylimidazole chloride at a molar ratio of 2:1 was added at 25℃. The mixture was magnetically stirred in a glove box for 30min. The glove box was removed and ultrasonically cleaned for 30min to obtain a suspension. The suspension was placed in a glove box with ferritic stainless steel 1Cr17 as the positive electrode and an aluminum plate as the negative electrode. The positive electrode was polished to 800# with water-polished sandpaper. Then, it was ultrasonically cleaned in acetone for 15min and dried. The aluminum plate was ultrasonically cleaned in 50% nitric acid solution, deionized water, methanol and acetone for 15min each. The current density was set to 2A / dm, and the coating was applied for 45min to obtain a composite coating. Step S6: Weigh out the following components by weight: 60 parts iron powder, 20 parts nickel powder, 8 parts boron powder, 15 parts chromium powder, 3 parts silicon powder, 2 parts light rare earth, 30 parts multiphase ceramic, 18 parts chromium carbide, 12 parts tungsten carbide, 8-15 parts composite coating, and 100 parts 310S stainless steel strip. Step S7: Roll the 310S stainless steel strip through a roller press to form a U-shaped cross-section steel strip groove; Step S8: Iron powder, nickel powder, boron powder, chromium powder, silicon powder, light rare earth, multiphase ceramics, chromium carbide, tungsten carbide and composite coating are mixed and fed into a U-shaped cross-section steel strip groove by a belt-type powder feeding machine. The U-shaped cross-section steel strip groove is closed by the rollers of the roller press, and a completely closed O-shaped cross-section flux core is formed. Then, the diameter is reduced to 2.0mm by wire drawing to obtain wear-resistant arc spraying flux core wire. Step S9: Prepare a coating using an electric arc spraying process. The spraying process parameters are: voltage 35V, current 220A, spraying distance 210mm, and compressed air pressure 0.6MPa.

[0021] Comparative Example 1: This comparative example describes a wear-resistant arc spraying core wire and a coating preparation method, including the following steps: Step S1: Weigh out 50 parts of iron powder, 15 parts of nickel powder, 5 parts of boron powder, 12 parts of chromium powder, 2 parts of silicon powder, 1 part of light rare earth, 14 parts of chromium carbide, 8 parts of tungsten carbide, and 100 parts of 310S stainless steel strip according to the weight composition. Step S2: Roll the 310S stainless steel strip through a roller press to form a U-shaped cross-section steel strip groove; Step S3: Iron powder, nickel powder, boron powder, chromium powder, silicon powder, light rare earth, chromium carbide and tungsten carbide are mixed and fed into a U-shaped cross-section steel strip groove by a belt-type powder feeding machine. The U-shaped cross-section steel strip groove is closed by the rollers of the roller press, and a completely closed O-shaped cross-section flux core is formed. Then, the diameter is reduced to 1.8mm by wire drawing to obtain wear-resistant arc spraying flux core wire. Step S4: Prepare a coating using an electric arc spraying process. The spraying process parameters are: voltage 30V, current 200A, spraying distance 200mm, and compressed air pressure 0.6MPa.

[0022] Comparative Example 2: This comparative example describes a wear-resistant arc spraying core wire and a coating preparation method, including the following steps: Step S1: Add 40g of titanium diboride powder and 400mL of anhydrous ethanol to a stainless steel ball mill jar lined with polytetrafluoroethylene. Add silicon carbide as grinding balls. The ball-to-powder ratio is 5:1. The rotation speed is 300r / min. Mix and ball mill for 9h. After ball milling, filter and separate the slurry and grinding balls through a funnel. The grinding balls are separated in the funnel, and the slurry is collected in a beaker. Dry the slurry collected in the beaker using a rotary evaporator. The water bath temperature during the evaporation process is 60℃, the rotation speed is 65r / min, and the rotary evaporation is carried out for 1.5h. Transfer the powder dried by rotary evaporation to a vacuum drying oven at 60℃ and continue drying for 24h. The dried powder is then passed through a 100-mesh sieve to obtain the intermediate product. Step S2: Add 4g of intermediate product, 16g of boron carbide powder and 250mL of anhydrous ethanol to a mixing bottle and mix. Add silicon carbide grinding balls to the mixing bottle, with a ball-to-powder ratio of 5:1. Place the mixing bottle in a drum mixer at a speed of 30r / min and mix and ball mill for 12h. Then filter and separate the slurry and grinding balls through a funnel. Dry the slurry using a rotary evaporator. During the evaporation process, the water bath temperature is 60℃, the rotation speed is 65r / min, and the rotary evaporation is carried out for 1.5h. Transfer the powder dried by rotary evaporation to a vacuum drying oven at 60℃ and continue drying for 24h to obtain multiphase powder. Step S3: After passing the multiphase powder through a 200-mesh sieve, place it in a graphite mold for hot pressing and sintering. Argon gas is introduced for protection, and the sintering pressure is set to 10 MPa. During the hot pressing and sintering process, the heating rate is 20℃ / min from 25℃ to 1500℃ and 10℃ / min from 1500℃ to 1950℃. Then, it is held at 1950℃ for 30 minutes. After sintering, the heating element of the hot press furnace is turned off, and the temperature is allowed to drop naturally to 25℃ to obtain multiphase ceramic. Step S4: Weigh out 50 parts of iron powder, 15 parts of nickel powder, 5 parts of boron powder, 12 parts of chromium powder, 2 parts of silicon powder, 1 part of light rare earth, 18 parts of multiphase ceramic, 14 parts of chromium carbide, 8 parts of tungsten carbide, and 100 parts of 310S stainless steel strip according to the weight composition. Step S5: Roll the 310S stainless steel strip through a roller press to form a U-shaped cross-section steel strip groove; Step S6: Iron powder, nickel powder, boron powder, chromium powder, silicon powder, light rare earth, multiphase ceramics, chromium carbide and tungsten carbide are mixed and fed into a U-shaped cross-section steel strip groove by a belt-type powder feeding machine. The U-shaped cross-section steel strip groove is closed by the roller press, and a completely closed O-shaped cross-section flux core is formed. Then, the diameter is reduced to 1.8mm by wire drawing to obtain wear-resistant arc spraying flux core wire. Step S7: Prepare a coating using an electric arc spraying process. The spraying process parameters are: voltage 30V, current 200A, spraying distance 200mm, and compressed air pressure 0.6MPa.

[0023] Comparative Example 3: This comparative example describes a wear-resistant arc spraying core wire and a coating preparation method, including the following steps: Step S1: Add 0.004 mol aluminum nitrate nonhydrate, 0.02 mol ferric nitrate nonhydrate, and 200 mL deionized water to a three-necked flask equipped with a stirrer, thermometer, and gas delivery tube. Stir magnetically for 25 min at 25℃ and 250 r / min. Add 3 mol / L ammonia to adjust the pH to 7. Filter the precipitate in the solution, wash it three times each with deionized water and anhydrous ethanol, and dry it in an oven at 60℃ for 1.5 h to obtain the precursor. Calcine the precursor at 770℃ for 2 h, and then wash it three times by centrifugation with 4 mol / L hydrochloric acid and anhydrous ethanol at 100℃. Dry it at 53℃ for 2.5 h to obtain the intermediate. Step S2: 0.5g of the intermediate was ultrasonically cleaned in acetone and alcohol for 25min and centrifuged. The centrifuged particles were dried in an oven at 50℃. 50mL of an ionic liquid composed of aluminum chloride and 1-methyl-3-ethylimidazole chloride in a molar ratio of 2:1 was added at 25℃. The mixture was magnetically stirred in a glove box for 15-30min. The glove box was removed and ultrasonically cleaned for 30min to obtain a suspension. The suspension was placed in a glove box with ferritic stainless steel 1Cr17 as the positive electrode and an aluminum plate as the negative electrode. The positive electrode was polished to 800# with water-polished sandpaper. Then, it was ultrasonically cleaned in acetone for 15min and dried. The aluminum plate was ultrasonically cleaned in 50% nitric acid solution, deionized water, methanol and acetone for 15min each. The current density was set to 2A / dm, and the coating was applied for 45min to obtain a composite coating. Step S3: Weigh out 50 parts of iron powder, 15 parts of nickel powder, 5 parts of boron powder, 12 parts of chromium powder, 2 parts of silicon powder, 1 part of light rare earth, 14 parts of chromium carbide, 8 parts of tungsten carbide, 12 parts of composite coating, and 100 parts of 310S stainless steel strip according to the weight composition. Step S4: Roll the 310S stainless steel strip through a roller press to form a U-shaped cross-section steel strip groove; Step S5: Iron powder, nickel powder, boron powder, chromium powder, silicon powder, light rare earth, chromium carbide, tungsten carbide and composite coating are mixed and fed into the "U" section steel strip groove by a belt-type powder feeding machine. The "U" section steel strip groove is closed by the roller press, and a completely closed "O" section core is formed. Then, the core wire for wear-resistant arc spraying is obtained by wire drawing and diameter reduction to 1.8mm. Step S6: Prepare a coating using an electric arc spraying process. The spraying process parameters are: voltage 30V, current 200A, spraying distance 200mm, and compressed air pressure 0.6MPa.

[0024] The wear-resistant arc spraying core wires and coatings of Examples 1-3 and Comparative Examples 1-3 were tested for abrasive wear (50N load, 80-mesh silicon carbide sand, 0.5m / s) according to ASTM G65 standard, bond strength according to ASTM C633 standard, and salt spray test (5% NaCl, 35℃) according to ISO 9227 standard. The test results are shown in the table below:

[0025] Referring to the table above, based on the comparison between Examples 1-3 and Comparative Examples 1-3, it can be seen that adding multiphase ceramics and composite coatings can significantly improve the wear resistance and bonding strength of the coating, and the prepared coating has good corrosion resistance.

[0026] In the description of this specification, references to terms such as "an embodiment," "example," "specific example," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the invention. In this specification, illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0027] The above description is merely an example and illustration of the present invention. Those skilled in the art can make various modifications or additions to the specific embodiments described or use similar methods to replace them, as long as they do not deviate from the invention or exceed the scope defined in this application, they should all fall within the protection scope of the present invention.

Claims

1. A wear-resistant flux-cored wire for arc spraying, characterized in that, Includes the following components by weight: 40-60 parts iron powder, 10-20 parts nickel powder, 3-8 parts boron powder, 8-15 parts chromium powder, 1-3 parts silicon powder, 0.5-2 parts light rare earth, 15-30 parts multiphase ceramics, 10-18 parts chromium carbide, 5-12 parts tungsten carbide, 8-15 parts composite coating, and 100 parts 310S stainless steel strip; The main components of the light rare earth elements are 48.76% cerium, 24.54% lanthanum, 16.17% neodymium, and 5.41% praseodymium.

2. The wear-resistant arc spraying core wire according to claim 1, characterized in that, The multiphase ceramic is prepared by the following steps: Step a1: Add titanium diboride powder and anhydrous ethanol to a ball mill jar, add silicon carbide as grinding balls, mix and ball mill. After ball milling, filter and separate the slurry and grinding balls through a funnel. Collect the slurry in a beaker. Dry the slurry in the beaker using a rotary evaporator. Transfer the powder dried by rotary evaporation to a vacuum drying oven for further drying. The dried powder is then passed through a 100-mesh sieve to obtain the intermediate product. Step a2: Add the intermediate product, boron carbide powder and anhydrous ethanol to a mixing bottle and mix. Add silicon carbide grinding balls to the mixing bottle and place the mixing bottle in a drum mixer for ball milling. Then filter and separate the slurry and grinding balls through a funnel. Dry the slurry using a rotary evaporator. Transfer the powder dried by rotary evaporation to a vacuum drying oven for further drying to obtain multiphase powder. Step a3: After passing the multiphase powder through a 200-mesh sieve, place it in a graphite mold for hot pressing and sintering. Argon gas is introduced for protection, and the sintering pressure is set to 10 MPa. During the hot pressing and sintering process, the heating rate is 20℃ / min from 25℃ to 1500℃ and 10℃ / min from 1500℃ to 1950℃. Then, it is held at 1950℃ for 30 minutes. After sintering, the heating element of the hot press furnace is turned off, and the temperature is allowed to drop naturally to 25℃ to obtain the multiphase ceramic.

3. The wear-resistant arc spraying core wire according to claim 2, characterized in that, The ratio of titanium diboride powder to anhydrous ethanol in step a1 is 40g:400mL.

4. The wear-resistant arc spraying core wire according to claim 2, characterized in that, The ratio of the intermediate product, boron carbide powder, and anhydrous ethanol used in step a2 is 4g:16g:250mL.

5. The wear-resistant arc spraying core wire according to claim 1, characterized in that, The composite coating is prepared by the following steps: Step b1: Add aluminum nitrate nonhydrate, ferric nitrate nonhydrate, and deionized water to a three-necked flask equipped with a stirrer, thermometer, and gas delivery tube. Stir magnetically for 20-30 minutes at 25°C and 200-300 r / min. Add 3 mol / L ammonia to adjust the pH to 7. Filter the precipitate in the solution and wash it 2-3 times each with deionized water and anhydrous ethanol. Dry it in an oven at 60°C for 1-2 hours to obtain the precursor. Calcine the precursor at 770°C for 2 hours. Then, wash it 2-3 times with hydrochloric acid and anhydrous ethanol at 100°C by centrifugation. Dry it at 50-55°C for 2-3 hours to obtain the intermediate. Step b2: The intermediate was ultrasonically cleaned in acetone and alcohol for 15-30 min and centrifuged. The centrifuged particles were dried in an oven at 50°C. An ionic liquid at 25°C was added, and the mixture was magnetically stirred in a glove box for 15-30 min. The glove box was then removed and ultrasonically cleaned for 30 min to obtain a suspension. The suspension was placed in a glove box, with ferritic stainless steel 1Cr17 as the positive electrode and an aluminum plate as the negative electrode. The positive electrode was polished to 800# with water-polished sandpaper, and then ultrasonically cleaned in acetone for 15 min and dried. The aluminum plate was ultrasonically cleaned in 50% nitric acid solution, deionized water, methanol, and acetone for 15 min each. The current density was set to 2 A / dm, and the coating was applied for 45 min to obtain a composite coating.

6. The wear-resistant arc spraying core wire according to claim 5, characterized in that, In step b1, the ratio of aluminum nitrate nonhydrate, ferric nitrate nonhydrate, and deionized water is 0.004 mol: 0.02 mol: 200 mL; the molar concentration of hydrochloric acid is 4 mol / L.

7. The wear-resistant arc spraying core wire according to claim 5, characterized in that, The ratio of the intermediate to the ionic liquid in step b2 is 0.5 g: 50 mL; the ionic liquid is a mixture of aluminum chloride and 1-methyl-3-ethylimidazole chloride in a molar ratio of 2:

1.

8. A method for preparing a wear-resistant arc spray coating for flux-cored wire as described in any one of claims 1-7, characterized in that, Includes the following steps: Step 1: Weigh out the following components by weight: 40-60 parts iron powder, 10-20 parts nickel powder, 3-8 parts boron powder, 8-15 parts chromium powder, 1-3 parts silicon powder, 0.5-2 parts light rare earth, 15-30 parts multiphase ceramic, 10-18 parts chromium carbide, 5-12 parts tungsten carbide, 8-15 parts composite coating, and 100 parts 310S stainless steel strip. Step 2: Roll the 310S stainless steel strip through a roller press to form a "U" shaped cross-section steel strip groove; Step 3: Iron powder, nickel powder, boron powder, chromium powder, silicon powder, light rare earth, multiphase ceramics, chromium carbide, tungsten carbide, and composite coating are mixed and fed into a U-shaped cross-section steel strip groove by a belt-type powder feeding machine. The U-shaped cross-section steel strip groove is closed by the rollers of the roller press, forming a completely closed O-shaped cross-section flux core. Then, the diameter is reduced to 1.5-2.0mm by wire drawing to obtain wear-resistant arc spraying flux core wire. Step 4: Prepare the coating using an electric arc spraying process. The spraying process parameters are: voltage 25-35V, current 180-220A, spraying distance 190-210mm, and compressed air pressure 0.5-0.6MPa.

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