A wear-resistant composition and preparation method thereof

Abstract

This application discloses a wear-resistant composition comprising the following raw materials in parts by weight: 60-80 parts by weight of alloy powder, 10-20 parts by weight of a reinforcing phase, and 10-20 parts by weight of a curing agent; the alloy powder comprises Mo, Cr, Si, and Co; the reinforcing phase comprises modified ceramic powder, tungsten carbide, vanadium carbide, and aluminum oxide; and the curing agent comprises an epoxy resin, a silicone resin, and a polyurethane-modified vinyl resin. This application also provides a method for preparing the aforementioned wear-resistant composition. The wear-resistant composition and preparation method provided herein have excellent hardness, wear resistance, and high strength, and can meet the more stringent high-temperature friction and wear requirements of components such as the pipe and tongue of a cigarette making machine.

Description

Technical Field

[0001] The present application relates to the technical field of wear-resistant materials, and in particular to a wear-resistant composition and a preparation method thereof. Background Art

[0002] Cigarette factories commonly use cigarette-rolling machines to produce cigarettes. During the production process, cigarette paper and tobacco are rolled into shape using the cigarette-rolling machine's pipe. Cigarettes travel through the pipe at speeds of up to 600 m / min. This high speed causes friction between the cigarettes and the pipe, rapidly wearing the pipe's inner wall and shortening the pipe's lifespan. This worn pipe's inner wall then affects the passage of cigarettes, severely impacting the uniformity of produced cigarettes.

[0003] Spraying or coating the inner wall of the smoke gun with a wear-resistant coating material is an effective solution. A number of metal spraying materials are disclosed in the prior art, but there are still problems with high-temperature hardness, self-lubrication and anti-sticking properties, which still need further improvement. Summary of the Invention

[0004] In order to solve the above technical problems, the first object of the present invention is to provide a wear-resistant composition; the second object of the present invention is to provide a method for preparing the above wear-resistant composition;

[0005] The technical solutions provided by the present invention are as follows:

[0006] A wear-resistant composition comprises the following raw materials in parts by weight: 60-80 parts by weight of alloy powder, 10-20 parts by weight of a reinforcing phase, and 10-20 parts by weight of a curing agent;

[0007] The alloy powder includes Mo, Cr, Si and Co;

[0008] The reinforcing phase includes modified ceramic powder, tungsten carbide, vanadium carbide and aluminum oxide;

[0009] The curing agent includes epoxy resin, silicone resin and polyurethane modified vinyl resin.

[0010] Preferably, the raw materials include the following parts by weight: 65-75 parts by weight of alloy powder, 15-18 parts by weight of reinforcing phase, and 15-18 parts by weight of curing agent.

[0011] Preferably, the alloy powder comprises 28-32 wt% Mo, 8-10 wt% Cr, 2.5-3.5 wt% Si, and the balance is Co;

[0012] The reinforcing phase comprises 30-40 wt% modified ceramic powder, 25-33 wt% tungsten carbide, 10-15 wt% vanadium carbide, and the balance is alumina;

[0013] The curing agent comprises 35-40 wt% of epoxy resin, 25-35% of silicone resin, and the balance is polyurethane modified vinyl resin.

[0014] Preferably, the alloy powder comprises 28-30 wt% Mo, 8-9 wt% Cr, 2.5-3 wt% Si, and the balance is Co;

[0015] The reinforcing phase comprises 30-35wt% modified ceramic powder, 30-33wt% tungsten carbide, 14-15wt% vanadium carbide, and the balance is aluminum oxide;

[0016] The curing agent comprises 38-40 wt% of epoxy resin, 30-33% of silicone resin, and the balance is polyurethane modified vinyl resin.

[0017] Preferably, the modified ceramic powder is prepared by the following method:

[0018] 1) Ultrasonic dispersion of nano-ceramic powder and metaaluminate in water to obtain an aqueous dispersion;

[0019] 2) ultrasonically dispersing the nano-silica and the alkylphenol polyoxyethylene ether in ethanol to obtain an alcohol dispersion;

[0020] 3) Mixing the aqueous dispersion and the alcohol dispersion to obtain a mixed dispersion; then heating the mixture in a water bath to 50-60° C., adding a titanate coupling agent, stirring and keeping the mixture warm for 2-3 hours, filtering, and drying the filtrate to obtain the mixed dispersion.

[0021] Preferably, the mass ratio of nano-ceramic powder to metaaluminate is 20-30:1;

[0022] The mass ratio of nano-silicon dioxide to alkylphenol polyoxyethylene ether is 20-30:1;

[0023] The mass ratio of nano-ceramic powder to nano-silicon dioxide is 5-10:1;

[0024] The mass ratio of nano-silica to titanate coupling agent is 5-8:1.

[0025] Preferably, the titanate coupling agent is any one of isopropyl trioleyl titanate and isopropyl triisostearate titanate;

[0026] The metaaluminate is either sodium metaaluminate or potassium metaaluminate.

[0027] Preferably, in the alloy powder, the average particle size of Mo, Cr, Si, and Co is less than 100 μm;

[0028] In the reinforcement phase, the average particle size of the modified ceramic powder, vanadium carbide, and aluminum oxide is less than 10 μm;

[0029] In the reinforcement phase, the tungsten carbide includes 75-85wt% of tungsten carbide with a particle size of 0.1-1 mm, and the remainder is tungsten carbide with a particle size of less than 0.1 mm.

[0030] Preferably, in the curing agent, the epoxy resin is epoxy resin E44, the silicone resin is methyl silicone resin, and the polyurethane-modified vinyl resin is commercially available DSM 6325 reagent from the Netherlands.

[0031] The preparation method of the above-mentioned wear-resistant composition comprises the following steps:

[0032] Premixing the various components of the alloy powder and the various components of the reinforcement phase;

[0033] The alloy powder and the reinforcing phase are placed in a container, a curing agent is added, and the mixture is mixed. Then, the mixture is vacuumed and further mixed for 8-15 minutes to obtain a finished product.

[0034] The present application improves the cobalt-based high-temperature wear-resistant material. Compared with the simple cobalt alloy wear-resistant material disclosed in the prior art, the present application adds a reinforcing phase on the basis of the cobalt alloy through formula process design to further improve the high-temperature strength, high-temperature hardness and thermal stability of the coating, so that the coating has high thermal strength, thermal fatigue, toughness and wear resistance; at the same time, a compound curing agent is added to improve the self-lubricating and anti-steel sticking properties of the coating, which not only has good bonding ability with the metal matrix, but also has excellent high-temperature oxidation resistance.

[0035] Modified ceramic powder, tungsten carbide, vanadium carbide, and aluminum oxide are added to the reinforcing phase used in the present application. The addition of ceramic powder greatly enhances the wear resistance of the cobalt-based coating. The present application also uses modified ceramic powder. The nano-ceramic powder is surface-treated with a salt of metabisulphite, and the nano-silica is surface-treated with an alkylphenol polyoxyethylene ether. Finally, the treated nano-ceramic powder and nano-silica are coupled with a titanate coupling agent to solve the inherent morphological defects of the particle surface present in the coupling agent or surfactant, and the problem of poor binding performance with the resin curing agent. This avoids the situation where the ceramic powder floats to the surface of the coating or decomposes in the cladding layer, causing the coating to crack, when the wear-resistant composition provided by the present application is sprayed or coated to form a coating, and fails to play a reinforcing role. The modified ceramic powder is thus used to significantly improve the wear resistance of the coating.

[0036] In addition, tungsten carbide is another effective reinforcement phase. During the coating forming process, WC decomposes and re-reacts to form new reinforcement phases, including W2C and SiC. At the same time, the addition of vanadium carbide changes the phase structure of the cobalt-based cladding layer, and through the supplement of fine-grained alumina, the coating becomes denser and more uniform, more closely bonded to the substrate, and has a low porosity, which greatly improves the hardness of the coating.

[0037] This application uses epoxy resin, silicone resin, and polyurethane-modified vinyl resin as coating film-forming materials. Epoxy resin has excellent corrosion resistance and high adhesion to the substrate, but is relatively brittle; silicone resin has excellent high-temperature resistance, flexibility, electrical properties, and waterproof properties, and is resistant to high temperatures, but has poor adhesion to metal substrates; this application adds polyurethane-modified vinyl resin as an enhanced adhesive. Through the compounding of the three, it combines the high adhesion of epoxy resin coatings, the high flexibility and excellent corrosion resistance of silicone resins, and the high adhesion of polyurethane-modified vinyl resins. After being added to metal wear-resistant coatings, it can significantly improve the adhesion of the wear-resistant coating to the substrate and greatly enhance the friction resistance of the coating.

[0038] The wear-resistant composition provided in the present application has good hardness, wear resistance and high strength, and can meet the more stringent use requirements of high-temperature friction and wear of components such as the cigarette gun and cigarette tongue of a cigarette making machine.

[0039] The nano ceramic powder used in this application is a conventional commercial nano ceramic powder. When the nano ceramic powder and metaaluminate are ultrasonically dispersed in water, there is no particular limitation on the power and time of the ultrasound, as long as the materials can be dispersed. DETAILED DESCRIPTION

[0040] In order to help those skilled in the art better understand the technical solutions in this application, the technical solutions in the embodiments of this application will be clearly and completely described below. Obviously, the embodiments described are only part of the embodiments of this application, not all of the embodiments. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without making any creative efforts shall fall within the scope of protection of this application.

[0041] Unless otherwise specified, the raw materials used in the examples are common commercially available products.

[0042] 1. The alloy powder used is as follows:

[0043] Alloy powder 1: 30wt% Mo, 9wt% Cr, 3wt% Si, and the rest is Co;

[0044] Alloy powder 2: 28wt% Mo, 8wt% Cr, 2.5wt% Si, and the remainder Co;

[0045] Alloy powder 3: 32wt% Mo, 10wt% Cr, 3.5wt% Si, and the remainder Co;

[0046] The average particle sizes of Mo, Cr, Si and Co are all below 100 μm.

[0047] 2. The reinforcement phase components used are as follows:

[0048] Reinforcement phase 1: 35wt% modified ceramic powder, 33wt% tungsten carbide, 14wt% vanadium carbide, and the rest is alumina;

[0049] Reinforcement phase 2: 30wt% modified ceramic powder, 30wt% tungsten carbide, 15wt% vanadium carbide, and the rest is alumina;

[0050] Reinforcement phase 3: 40wt% modified ceramic powder, 25wt% tungsten carbide, 10wt% vanadium carbide, and the rest is alumina;

[0051] Reinforcement phase 1': 35wt% ceramic powder (unmodified), 33wt% tungsten carbide, 14wt% vanadium carbide, and the rest is alumina;

[0052] Reinforcement phase 2': 35wt% modified ceramic powder, 14wt% vanadium carbide, and the rest is alumina;

[0053] Reinforcement phase 3': 35wt% modified ceramic powder, 33wt% tungsten carbide, and the rest is alumina;

[0054] The average particle sizes of the modified ceramic powder, vanadium carbide and aluminum oxide are all below 10 μm; 80 wt% of the tungsten carbide has a particle size of 0.1-1 mm, and the rest is tungsten carbide with a particle size below 0.1 mm.

[0055] The modified ceramic powder is prepared by the following method:

[0056] 1) adding nano-ceramic powder and potassium metaaluminate in a mass ratio of about 25:1 to water and ultrasonically dispersing them to obtain a dispersion;

[0057] 2) adding nano-silica and alkylphenol polyoxyethylene ether in a mass ratio of about 25:1 into ethanol and performing ultrasonic dispersion to obtain an alcohol dispersion;

[0058] 3) The dispersion from step 1) is mixed with the alcohol dispersion from step 2) to obtain a mixed dispersion, which is then heated in a water bath to approximately 55° C., and isopropyl trioleyl titanate is added while stirring. The mixture is kept warm for 2-3 hours, filtered, and the filtrate is dried. The mass ratio of the nano-ceramic powder to the nano-silicon dioxide is 8:1, and the mass ratio of the nano-silicon dioxide to the isopropyl trioleyl titanate is 6:1.

[0059] 3. The specific components of the curing agent used are as follows:

[0060] Curing agent 1: 38wt% epoxy resin, 33% silicone resin, and the rest is polyurethane modified vinyl resin

[0061] Curing agent 2: 35wt% epoxy resin, 35% silicone resin, and the rest is polyurethane modified vinyl resin

[0062] Curing agent 3: 40wt% epoxy resin, 25% silicone resin, and the rest is polyurethane modified vinyl resin

[0063] Curing agent 1': 45wt% epoxy resin, 55% silicone resin;

[0064] Curing agent 2': 55wt% epoxy resin, 45% polyurethane modified vinyl resin.

[0065] Curing agent 3': 55wt% silicone resin, 45% polyurethane modified vinyl resin.

[0066] The epoxy resin is epoxy resin E44, the silicone resin is methyl silicone resin, and the polyurethane-modified vinyl resin uses the commercially available DSM 6325 reagent from the Netherlands.

[0067] Specific implementation cases

[0068] A method for preparing a wear-resistant material for a cigarette making machine comprises the following steps:

[0069] 1) Prepare the materials according to the recipe, see Table 1 for details;

[0070] 2) premixing the components in the alloy powder and premixing the components in the reinforcement phase;

[0071] 3) The alloy powder and the reinforcing phase are placed in a mixing and stirring container that can be vacuumed, and then the curing agent is added. All materials are fully mixed. Finally, the mixed materials are further fully mixed under vacuum for about 10 minutes to obtain the finished product.

[0072] Table 1 Composition of ingredients in Examples and Comparative Examples

[0073] alloy powder Enhanced Phase curing agent Example 1 70 parts alloy powder 1 16 parts of reinforcing phase 1 16 parts curing agent 1 Example 2 65 parts alloy powder 1 15 parts of reinforcing phase 2 15 parts of curing agent 3 Example 3 75 parts alloy powder 2 18 parts of reinforcing phase 1 18 parts of curing agent 3 Example 4 73 parts alloy powder 2 15 parts of reinforcing phase 2 16 parts curing agent 1 Example 5 68 parts alloy powder 3 17 parts of reinforcing phase 1 17 parts curing agent 1 Example 6 72 parts alloy powder 3 17 parts of reinforcing phase 2 17 parts curing agent 1 Example 7 66 parts alloy powder 3 16 parts of enhanced phase 3 17 parts curing agent 1 Example 8 60 parts alloy powder 2 10 parts reinforcement phase 2 10 parts curing agent 2 Example 9 80 parts alloy powder 3 20 parts of reinforcing phase 3 20 parts of curing agent 3 Example 10 68 parts alloy powder 1 19 parts of enhanced phase 3 18 parts of curing agent 2 Comparative Example 1 70 parts alloy powder 1 -- 16 parts curing agent 1 Comparative Example 2 70 parts alloy powder 1 16 parts of reinforcing phase 1 -- Comparative Example 3 70 parts alloy powder 1 16 parts of reinforcing phase 1' 16 parts curing agent 1 Comparative Example 4 70 parts alloy powder 1 16 parts of reinforcing phase 2' 16 parts curing agent 1 Comparative Example 5 70 parts alloy powder 1 16 parts of enhanced phase 3' 16 parts curing agent 1 Comparative Example 6 70 parts alloy powder 1 16 parts of reinforcing phase 1 16 parts of curing agent 1' Comparative Example 7 70 parts alloy powder 1 16 parts of reinforcing phase 1 16 parts of curing agent 2' Comparative Example 8 70 parts alloy powder 1 16 parts of reinforcing phase 1 16 parts of curing agent 3'

[0074] Experimental results test

[0075] The products prepared in Examples 1-10 and Comparative Examples 1-8 were applied to metal surfaces and tested according to industry standards. Wear resistance was tested using a Taber abrader on a rigid, flat surface. Tensile shear strength was measured using the GB / T7124-2008 adhesive tensile shear strength method, and flexural strength was tested using the GB / T9341-2008 method. The test results are shown in Table 2.

[0076] Table 2 Performance test results

[0077]

[0078]

[0079] In the data in Table 2, the higher the hardness, tensile shear strength, and bending strength, the better the performance, while the lower the wear resistance, the better the performance.

[0080] As can be seen from Table 2, the coatings prepared in Examples 1 to 10 are superior to those in Comparative Examples 1 to 8 in terms of hardness, wear resistance, tensile shear strength, and flexural strength. Among them, the coating prepared in Example 1 is the best in terms of hardness, tensile shear strength, and flexural strength.

[0081] The above description of the disclosed embodiments is intended to enable one skilled in the art to implement or use the present invention. Various modifications to these embodiments will be readily apparent to one skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention is not limited to the embodiments shown herein but is intended to conform to the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A wear-resistant composition, characterized in that The invention comprises the following raw materials in parts by weight: 60-80 parts by weight of alloy powder, 10-20 parts by weight of reinforcing phase, and 10-20 parts by weight of curing agent; The alloy powder includes Mo, Cr, Si and Co; The reinforcing phase includes modified ceramic powder, tungsten carbide, vanadium carbide and aluminum oxide; The curing agent includes epoxy resin, silicone resin and polyurethane modified vinyl resin; The alloy powder includes 28-32wt% Mo, 8-10wt% Cr, 2.5-3.5wt% Si, and the balance is Co; the reinforcing phase includes 30-40wt% modified ceramic powder, 25-33wt% tungsten carbide, 10-15wt% vanadium carbide, and the balance is alumina; the curing agent includes 35-40wt% epoxy resin, 25-35% silicone resin, and the balance is polyurethane modified vinyl resin; The preparation method comprises the following steps: pre-mixing the components of the alloy powder and the components of the reinforcing phase respectively; placing the alloy powder and the reinforcing phase in a container, adding a curing agent, mixing, and then vacuuming and further mixing for 8-15 minutes to obtain a finished product.

2. The wear-resistant composition according to claim 1, characterized in that The invention comprises the following raw materials in parts by weight: 65-75 parts by weight of alloy powder, 15-18 parts by weight of reinforcing phase, and 15-18 parts by weight of curing agent.

3. The wear-resistant composition according to claim 1, characterized in that The alloy powder comprises 28-30wt% Mo, 8-9wt% Cr, 2.5-3wt% Si, and the balance is Co; The reinforcing phase comprises 30-35wt% modified ceramic powder, 30-33wt% tungsten carbide, 14-15wt% vanadium carbide, and the balance is alumina; The curing agent comprises 38-40 wt % of epoxy resin, 30-33 wt % of silicone resin, and the balance is polyurethane modified vinyl resin.

4. The wear-resistant composition according to any one of claims 1 to 2, characterized in that The modified ceramic powder is prepared by the following method: 1) Ultrasonic dispersion of nano-ceramic powder and metaaluminate in water to obtain an aqueous dispersion; 2) Ultrasonic dispersion of nano-silica and alkylphenol polyoxyethylene ether in ethanol to obtain an alcohol dispersion; 3) Mix the aqueous dispersion and the alcohol dispersion to obtain a mixed dispersion; then heat the mixture in a water bath to 50-60°C, add a titanate coupling agent, stir and keep warm for 2-3 hours, filter, and dry the filtrate.

5. The wear-resistant composition according to claim 4, characterized in that The mass ratio of nano ceramic powder to metaaluminate is 20-30:1; The mass ratio of nano-silicon dioxide to alkylphenol polyoxyethylene ether is 20-30:1; The mass ratio of nano-ceramic powder to nano-silicon dioxide is 5-10:1; The mass ratio of nano-silica to titanate coupling agent is 5-8:

1.

6. The wear-resistant composition according to claim 4, characterized in that The titanate coupling agent is any one of isopropyl trioleyl titanate and isopropyl triisostearate titanate; The metaaluminate is either sodium metaaluminate or potassium metaaluminate.

7. The wear-resistant composition according to claim 1, characterized in that In the alloy powder, the average particle size of Mo, Cr, Si and Co is less than 100 μm; In the reinforcement phase, the average particle size of the modified ceramic powder, vanadium carbide, and aluminum oxide is less than 10 μm; In the reinforcement phase, the tungsten carbide includes 75-85wt% of tungsten carbide with a particle size of 0.1-1 mm, and the remainder is tungsten carbide with a particle size of less than 0.1 mm.

8. The wear-resistant composition according to claim 1, characterized in that In the curing agent, the epoxy resin is epoxy resin E44, the silicone resin is methyl silicone resin, and the polyurethane modified vinyl resin adopts the commercially available Dutch DSM 6325 reagent.

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