A method of processing for thermal spraying of flat workpieces

Abstract

This invention discloses a processing method for thermal spraying of flat workpieces. The processing method includes: taking a flat workpiece to be processed and constraining it using a processing fixture, the processing fixture including a support platform and a constraint component; placing the flat workpiece on the support platform and pressing the flat workpiece onto the support platform using the constraint component; operating a sandblasting device and a spraying device to sequentially perform sandblasting and spraying treatments on a first working surface of the flat workpiece; removing the flat workpiece, flipping it over, and pressing the flat workpiece onto the support platform again using the constraint component; operating the sandblasting device and the spraying device again to sequentially perform sandblasting and spraying treatments on a second working surface of the flat workpiece; removing the flat workpiece after sandblasting and spraying treatments and placing it in a heat treatment furnace for heat treatment to obtain the finished flat workpiece, maintaining the stability of the workpiece in the secondary processing, and improving the reliability and efficiency of the thermal spraying operation.

Description

Technical Field

[0001] This application relates to the field of thermal spraying processing technology, and in particular to a processing method for thermal spraying of flat workpieces. Background Technology

[0002] In the application of thermal barrier coatings for hot-end components of gas turbines, the thermal spraying process for flat workpieces (such as stainless steel partition plates) faces core challenges: the impact of high-temperature, high-speed jets can easily cause workpiece deformation and warping, leading to process interruptions and equipment damage due to impacts with the spray gun. Furthermore, deformed workpieces hinder sandblasting and spraying operations, severely restricting production efficiency. Existing processing techniques often result in uneven surface roughness and discontinuous coating coverage; simultaneously, they cannot effectively eliminate internal stress during spraying, leading to high fluctuations in workpiece flatness and low yield. More critically, existing processes cannot completely eliminate deformation problems. Thin plates are prone to severe deformation or even detachment under the impact of supersonic spray guns (high particle beam velocity and high temperature), further exacerbating production failure rates. These combined problems make it difficult for existing technologies to meet the high-quality, high-efficiency requirements of customized thermal barrier coatings in high-temperature industrial applications. Summary of the Invention

[0003] In view of the deficiencies in the prior art, this application provides a processing method for thermal spraying of flat workpieces to solve the problem that the deformation amount is impossible in the thermal spraying process of flat workpieces in the prior art.

[0004] The above-mentioned objectives of this application are mainly achieved through the following technical solutions: A processing method for thermal spraying of flat workpieces, the processing method comprising: The flat workpiece to be processed is constrained and limited using a processing fixture, which includes a support platform and a constraint component. The flat workpiece is placed on the support platform, and the constraint component is operated to press the flat workpiece onto the support platform. The sandblasting equipment and the spraying equipment are used to sequentially perform sandblasting and spraying treatments on the first working surface of the flat workpiece. Remove the flat workpiece, flip it over, and then operate the constraint assembly again to press the flat workpiece onto the support platform; The sandblasting and spraying equipment are operated again to sequentially perform sandblasting and spraying treatments on the second working surface of the flat workpiece. After sandblasting and coating, the flat workpiece is removed and placed in a heat treatment furnace for heat treatment to obtain the finished flat workpiece.

[0005] In an optional embodiment, the thickness of the flat workpiece is no greater than 5 mm.

[0006] In an optional embodiment, the sandblasting pressure is 0.2MPa-0.5MPa, the distance between the spray gun and the workpiece surface is 200mm-600mm, and the spray gun moving speed is 400mm / s-900mm / s.

[0007] In an optional implementation, the step distance during sandblasting is 5mm-20mm, and the step speed is 10mm / s-35mm / s.

[0008] In an optional embodiment, the power of the base coat spraying process is 18kW-25kW, and the distance between the spray gun and the workpiece surface is 80mm-200mm.

[0009] In an optional embodiment, the surface coating power of the spraying treatment is 25kW-35kW.

[0010] In an optional embodiment, the heat treatment temperature is not lower than 800°C, the holding time is 1 hour, and the flatness of the flat workpiece after heat treatment is controlled within ±5mm.

[0011] In an optional embodiment, when the flat workpiece is flipped, it is rotated 180 degrees and then repressed.

[0012] In an optional implementation, when performing sandblasting and spraying, the sandblasting and spraying equipment are operated along a preset path, which is arc-shaped and extends from one side of the flat workpiece to the other.

[0013] In an optional implementation, the thickness of the flat workpiece is monitored using a thickness measuring tool during sandblasting and coating processes.

[0014] Compared with the prior art, the advantages of this application are: The processing method in this application is used for thermal spraying of flat workpieces. The processing method includes: taking the flat workpiece to be processed and constraining it using a processing fixture, the processing fixture including a support platform and a constraint component; placing the flat workpiece on the support platform and pressing the flat workpiece onto the support platform using the constraint component; operating a sandblasting device and a spraying device to sequentially perform sandblasting and spraying treatments on the first working surface of the flat workpiece; removing the flat workpiece, flipping it over, and pressing the flat workpiece onto the support platform again using the constraint component; operating the sandblasting device and the spraying device again to sequentially perform sandblasting and spraying treatments on the second working surface of the flat workpiece; removing the flat workpiece after sandblasting and spraying treatments and placing it in a heat treatment furnace for heat treatment to obtain the finished flat workpiece.

[0015] In this processing method, the pressure exerted by the constraint components on the flat workpiece creates a rigid fixation, offsetting the impact force of the high-temperature, high-speed flame on the thin plate and avoiding workpiece warping and spray gun impact caused by excessive pressure in traditional processes. During the sandblasting stage, the double-sided processing maintains the stability of the workpiece during the secondary processing through the secondary pressure of the constraint components, solving the problem of cumulative workpiece deformation caused by single-sided processing in existing technologies.

[0016] Significant benefits have been achieved in production practice, with improved yield rates and a substantial reduction in rework and equipment damage; enhanced process continuity and shorter single-batch processing time; and through precise parameter control, the feasibility and reliability of customized thermal barrier coating production are fundamentally guaranteed, providing a replicable technical paradigm for thin-plate thermal spraying processes in high-temperature industrial fields. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 A schematic flowchart illustrating the processing method provided in an embodiment of this application; Figure 2 A top view schematic diagram of thermal spraying of a flat workpiece provided in an embodiment of this application; Figure 3 Appendix provided for the embodiments of this application Figure 1 Cross-sectional view at point M-M'; In the diagram: 1. Supporting platform; 2. Constraint components; 3. Flat workpiece. Detailed Implementation

[0019] The present invention will be further described below with reference to the accompanying drawings and specific embodiments. It should be noted that the description of these embodiments is intended to aid in understanding the invention, but does not constitute a limitation thereof. The specific structural and functional details disclosed herein are merely for describing exemplary embodiments of the invention. However, the invention can be embodied in many alternative forms and should not be construed as being limited to the embodiments described herein.

[0020] like Figure 2 , Figure 3 As shown, Figure 2 This is a top view of the flat workpiece 3 during thermal spraying, as provided in an embodiment of this application. Figure 3 Appendix provided for the embodiments of this application Figure 1 Schematic diagram of the cross section at point M-M'; attached Figure 1O-O' in the text refers to the preset operating path for thermal spraying in sandblasting and spraying equipment.

[0021] like Figure 1 As shown, Figure 1 This is a schematic flowchart of the processing method provided in the embodiments of this application; a processing method for thermal spraying of a flat workpiece 3, the processing method comprising: The flat workpiece to be processed is constrained and limited by a processing fixture. The processing fixture includes a support platform 1 and a constraint component 2. The flat workpiece 3 is placed on the support platform 1, and the constraint component 2 is operated to press the flat workpiece 3 onto the support platform 1. The sandblasting and spraying equipment are used to sequentially perform sandblasting and spraying treatments on the first working surface of the flat workpiece 3. Remove the flat workpiece 3, flip it over, and then operate the constraint component 2 again to press the flat workpiece 3 onto the support platform 1; The sandblasting and spraying equipment are operated again to sequentially perform sandblasting and spraying treatments on the second working surface of the flat workpiece 3. After sandblasting and coating, the flat workpiece 3 is removed and placed in a heat treatment furnace for heat treatment to obtain the finished flat workpiece 3.

[0022] During this processing method, corresponding processing fixtures are configured. The constraint component 2 can be a pressure bar or a locking element, which constrains the deformation of the flat workpiece 3 on the bearing platform 1. Sandblasting increases surface roughness, making it easier for thermal barrier coatings to adhere to the workpiece surface and increasing the bonding strength between the coating and the substrate. In actual operation, a turntable can be used in conjunction with a six-axis robot to complete the sandblasting of the flat workpiece 3. The six-axis robot is connected to the spray gun via a flange on the sixth axis to control the sandblasting gun; the machining fixture is placed on the turntable, with the center of the flat workpiece 3 coinciding with the center of the turntable.

[0023] The spraying process is completed using a two-axis turntable in conjunction with a six-axis robot. The six-axis robot is connected to the spray gun base via a flange on its sixth axis, clamps the spray gun, and controls its movement. The machining fixture is placed on the turntable, with the center of the flat workpiece 3 coinciding with the center of the turntable. After the workpiece is sandblasted, the machining fixture and flat workpiece 3 are transferred to the turntable in the spray booth for spraying.

[0024] Before spraying, connect the spray gun, load the prepared spray powder into the powder feeding tank, use a robotic handheld spray gun to spray the base layer with the supersonic spray gun, and perform the spraying operation according to the set path and parameters. After spraying, check until the requirements are met.

[0025] In an optional embodiment, the processing method of this application is used for thermal spraying of a flat workpiece 3. The processing method is applied to a processing fixture, which includes a support platform 1 and a constraint component 2. The processing method includes: taking the flat workpiece 3 to be processed, and operating the constraint component 2 to press the flat workpiece 3 onto the support platform 1; operating a sandblasting device and a spraying device to sequentially perform sandblasting and spraying treatment on the first working surface of the flat workpiece 3; removing the flat workpiece 3, flipping it over, and operating the constraint component 2 again to press the flat workpiece 3 onto the support platform 1; operating the sandblasting device and the spraying device again to sequentially perform sandblasting and spraying treatment on the second working surface of the flat workpiece 3; removing the flat workpiece 3 after sandblasting and spraying treatment, and placing it in a heat treatment furnace for heat treatment to obtain the finished flat workpiece 3.

[0026] In this processing method, the pressure exerted by the constraint component 2 on the flat workpiece 3 creates a rigid fixation, offsetting the impact force of the high-temperature, high-speed flame on the thin plate and avoiding workpiece warping and spray gun impact caused by excessive pressure in traditional processes. During the sandblasting stage, the double-sided processing maintains the stability of the workpiece during the secondary processing through the secondary pressure of the constraint component 2, solving the problem of workpiece deformation accumulation caused by single-sided processing in existing technologies.

[0027] Significant benefits have been achieved in production practice, with improved yield rates and a substantial reduction in rework and equipment damage; enhanced process continuity and shorter single-batch processing time; and through precise parameter control, the feasibility and reliability of customized thermal barrier coating production are fundamentally guaranteed, providing a replicable technical paradigm for thin-plate thermal spraying processes in high-temperature industrial fields.

[0028] In an optional embodiment, the thickness of the flat workpiece 3 is no greater than 5mm. Limiting the thickness of the flat workpiece 3 to less than 5mm is a precise optimization based on the mechanical properties of thin-plate materials. When the workpiece thickness exceeds 5mm, the impact of the high-temperature, high-speed flame can easily cause significant buckling deformation, leading to spray gun collisions or process interruptions. By controlling the thickness, the workpiece is rigidly fixed under the pressure of the constraint component 2, effectively offsetting the sandblasting impact load and providing a stable base for subsequent sandblasting and coating, thus avoiding production failures caused by thick plate deformation in traditional processes.

[0029] In an optional implementation, the sandblasting pressure is 0.2MPa-0.5MPa, the distance between the spray gun and the workpiece surface is 200mm-600mm, and the spray gun moving speed is 400mm / s-900mm / s. The sandblasting pressure setting is significantly lower than the industry standard of over 0.6MPa, reducing the impact energy of the sand beam and avoiding localized over-blasting or thermal damage. Simultaneously, the 200mm-600mm spray gun distance ensures uniform sand beam dispersion, and the 400mm / s-900mm / s moving speed matches the thermal response characteristics of thin plates. This parameter combination maintains a stable workpiece surface roughness above 4μm, laying the foundation for coating adhesion. Compared to the roughness fluctuations caused by traditional high-pressure sandblasting, uniformity is improved, solving the core defect of high coating peeling rate.

[0030] In an optional implementation, the stepping distance during sandblasting is 5mm-20mm, and the stepping speed is 10mm / s-35mm / s. The coordinated limitation of the stepping distance (5mm-20mm) and stepping speed (10mm / s-35mm / s) achieves full coverage of the sandblasting path. Excessive stepping distance leads to gaps in coverage, while excessively fast stepping speed causes uneven sandblasting. Dynamic matching ensures that the sand beams form a continuous and uniform coating on the workpiece surface. Based on fluid dynamics principles, controlling the sand beam deposition density through stepping parameters avoids sandblasting blind spots, significantly improving surface treatment consistency and outperforming the coating discontinuity problem caused by stepping mismatch in existing technologies.

[0031] In an optional embodiment, the bottom layer spraying power of the spraying treatment is 18kW-25kW, and the distance between the spray gun and the workpiece surface is 80mm-200mm. This optimized combination of 18kW-25kW bottom layer spraying power and 80mm-200mm spray gun distance is precisely designed to meet the interfacial diffusion requirements of the adhesive layer. The lower power avoids thermal shock to the thin plate, while the appropriate distance ensures sufficient powder melting and penetration into the substrate. This parameter increases the thickness of the diffusion layer at the interface between the metal substrate and the adhesive layer, forming a dense transition zone and effectively preventing subsequent surface layer peeling. In contrast, excessively high bottom layer power in traditional processes often leads to concentration of thermal stress at the interface. This solution improves adhesion through a power gradient.

[0032] In an optional embodiment, the surface coating power of the spraying treatment is 25kW-35kW. Increasing the surface coating power to 25kW-35kW creates a power gradient with the underlying layer, specifically optimized for the high porosity requirements of the ceramic layer. The high power ensures the ceramic powder melts fully and deposits uniformly, forming a low thermal conductivity insulating structure; simultaneously, the upper power limit prevents coating cracking due to overheating. This parameter significantly improves the thermal barrier coating's insulation efficiency, far exceeding the coating porosity problems caused by traditional surface coating power, providing more reliable high-temperature protection for gas turbine components.

[0033] In an optional embodiment, the heat treatment temperature is not lower than 800℃, the holding time is 1 hour, and the flatness of the flat workpiece 3 after heat treatment is controlled within ±5mm. The internal stress of the coating is eliminated through a thermal stress homogenization mechanism. At high temperatures, atomic diffusion at the metal-coating interface accelerates, forming a uniform diffusion layer and suppressing the cooling shrinkage gradient; while the holding time ensures sufficient stress release. This allows for precise control of workpiece flatness, improves yield, solves the problem of deformation accumulation caused by traditional heat treatment, and avoids the risk of equipment collisions caused by flatness deviations.

[0034] In an optional embodiment, when the flat workpiece 3 is flipped, it is rotated 180 degrees and then repressed, based on the symmetrical deformation characteristics of thin plates. Single-sided processing easily leads to stress accumulation on one side of the workpiece, causing deflection; the 180-degree flip allows the workpiece to restore its symmetrical state in the secondary processing, and the repeated pressing of the constraint component 2 eliminates accumulated deformation. This operation reduces the thickness difference of the double-sided coating, avoids process failure caused by asymmetry, and is significantly better than the deformation accumulation problem of traditional single-sided processes.

[0035] like Figure 2 As shown, in an optional embodiment, when performing sandblasting and spraying, the sandblasting equipment and spraying equipment are operated along a preset path, which is arc-shaped and extends from one side of the flat workpiece 3 to the other side.

[0036] The sandblasting and spraying equipment moves along an arc-shaped path, optimizing coverage uniformity. This arc-shaped path avoids edge omissions caused by straight-line movement, creating a continuous, wave-like coverage of the sand jet and flame on the workpiece surface, reducing uneven deposition caused by sudden speed changes. This improved coverage uniformity solves the problem of missing coating at edges caused by traditional straight-line paths, ensuring process consistency across the entire workpiece surface.

[0037] In an optional implementation, the thickness of the flat workpiece 3 is monitored using a thickness measuring tool during sandblasting and coating processes.

[0038] Real-time monitoring by thickness measurement tools ensures the quality of process input. Precise measurement of the thickness of the flat workpiece 3 before sandblasting prevents workpieces exceeding thickness limits from entering the processing flow, avoiding potential deformation risks. This step, along with thickness limits, forms a closed-loop control, improving the process pass rate, whereas traditional processes suffer from high workpiece scrap rates due to the lack of thickness monitoring.

[0039] In actual measurement, a micrometer screw gauge can be used to measure the thickness.

[0040] It should be understood that the terms "first," "second," etc., are used only for distinguishing descriptions and should not be construed as indicating or implying relative importance. Although the terms "first," "second," etc., may be used herein to describe various units, these units should not be limited by these terms. These terms are only used to distinguish one unit from another. For example, a first unit may be referred to as a second unit, and similarly, a second unit may be referred to as a first unit, without departing from the scope of the exemplary embodiments of the invention.

[0041] It should be understood that the term "and / or" in this article is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can mean: A exists alone, B exists alone, and A and B exist simultaneously. The term " / and" in this article describes another relationship between related objects, indicating that two relationships can exist. For example, A / and B can mean: A exists alone, and A and B exist alone. In addition, the character " / " in this article generally indicates that the related objects before and after it are in an "or" relationship.

[0042] It should be understood that in the description of this invention, the terms "upper," "vertical," "inner," "outer," etc., indicate the orientation or positional relationship as commonly placed when the disclosed product is used, or the orientation or positional relationship commonly understood by those skilled in the art. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0043] In the description of this invention, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," and "connect" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0044] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments of the invention. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms unless the context clearly indicates otherwise. It should also be understood that the terms “comprising,” “including,” “containing,” and / or “including” as used herein specify the presence of the stated features, integers, steps, operations, units, and / or components, and do not exclude the presence or addition of one or more other features, quantities, steps, operations, units, components, and / or combinations thereof.

[0045] Specific details are provided in the following description to provide a complete understanding of the exemplary embodiments. However, those skilled in the art will understand that the exemplary embodiments can be implemented without these specific details. In other embodiments, well-known processes, structures, and techniques may be omitted in the depiction of non-essential details to avoid obscuring the exemplary embodiments.

[0046] The above are merely specific embodiments of this application, enabling those skilled in the art to understand or implement this application. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of this application. Therefore, this application is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features claimed herein.

[0047] It should be noted that the information disclosed in the background section above is only used to enhance the understanding of the background of this disclosure, and therefore may include information that does not constitute prior art known to those skilled in the art.

Claims

1. A processing method for thermal spraying of flat workpieces, characterized in that, The processing method includes: The flat workpiece to be processed is constrained and limited using a processing fixture, which includes a support platform and a constraint component. The flat workpiece is placed on the support platform, and the constraint component is operated to press the flat workpiece onto the support platform. The sandblasting equipment and the spraying equipment are used to sequentially perform sandblasting and spraying treatments on the first working surface of the flat workpiece. Remove the flat workpiece, flip it over, and then operate the constraint assembly again to press the flat workpiece onto the support platform; The sandblasting and spraying equipment are operated again to sequentially perform sandblasting and spraying treatments on the second working surface of the flat workpiece. After sandblasting and coating, the flat workpiece is removed and placed in a heat treatment furnace for heat treatment to obtain the finished flat workpiece.

2. The processing method for thermal spraying of flat workpieces as described in claim 1, characterized in that: The thickness of the flat workpiece is no more than 5mm.

3. The processing method for thermal spraying of flat workpieces as described in claim 1, characterized in that: The sandblasting pressure during sandblasting is 0.2MPa-0.5MPa, the distance between the spray gun and the workpiece surface is 200mm-600mm, and the spray gun moving speed is 400mm / s-900mm / s.

4. The processing method for thermal spraying of flat workpieces as described in claim 3, characterized in that: The step distance for sandblasting is 5mm-20mm, and the step speed is 10mm / s-35mm / s.

5. The processing method for thermal spraying of flat workpieces as described in claim 1, characterized in that: The power of the base coat spraying in the spraying process is 18kW-25kW, and the distance between the spray gun and the workpiece surface is 80mm-200mm.

6. The processing method for thermal spraying of flat workpieces as described in claim 1, characterized in that: The surface coating power for the spraying treatment is 25kW-35kW.

7. The processing method for thermal spraying of flat workpieces as described in claim 1, characterized in that: The heat treatment temperature is not lower than 800℃, the holding time is 1 hour, and the flatness of the flat workpiece after heat treatment is controlled within ±5mm.

8. The processing method for thermal spraying of flat workpieces as described in claim 1, characterized in that: When the flat workpiece is flipped, it is rotated 180 degrees and then repressed.

9. The processing method for thermal spraying of flat workpieces as described in claim 1, characterized in that: When performing sandblasting and spraying, the sandblasting and spraying equipment are operated according to a preset path, which is arc-shaped and extends from one side of the flat workpiece to the other.

10. The processing method for thermal spraying of flat workpieces as described in claim 1, characterized in that: When performing sandblasting and spraying processes, thickness measuring tools are used to monitor the thickness of flat workpieces.

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