A composite rust conversion solution and repair process suitable for special equipment parts

Abstract

The application discloses a composite rust conversion film forming liquid, which is configured from a certain amount of ethanol, tannic acid, concentrated H3PO4, HEDP, manganese iron phosphate, fluorosilicate, a composite film forming accelerator, a surfactant and an antifreezing agent. The application discloses a quick repair process of the composite rust conversion film forming liquid for the rusted parts of special equipment, which comprises the following steps: configuration of the conversion liquid, pretreatment of the rusted parts, alcohol cleaning, application of the conversion liquid, drying and repair painting. The application solves the problem that the rust of the steel and aluminum alloy parts of the weapon equipment in the production and service period affects the battle index and service life, and ensures the tactical index and application performance of the weapon equipment in the whole life cycle, so as to meet the national security and defense requirements.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of metal material corrosion protection technology and applied chemistry, in particular to a composite rust conversion film forming liquid and a preparation method thereof, and further relates to a process for rapidly repairing rusted parts of special equipment by using the composite rust conversion film forming liquid. BACKGROUND

[0002] Material corrosion causes huge losses to the national economy, even catastrophic accidents, not only wasting valuable resources and energy, but also polluting the environment. According to statistics, 2 tons of steel are corroded into rust every 1.5 minutes in the world, and 10% of the steel produced in the world is corroded every year. The "China Corrosion Survey Report" in 2013 states that a car spends an average of 1260 yuan on corrosion prevention every year. The results of "China Corrosion Status and Control Strategy Research" in 2014 show that the corrosion cost is 21278.2 billion yuan, accounting for about 3.34% of the GDP of that year, and each citizen bears 1555 yuan on average. It can be seen from this that the loss caused by corrosion is so huge.

[0003] Explosion accidents and more than 90% of underground pipeline ruptures are caused by corrosion.

[0004] For weapons and equipment, due to the vast territory of China, spanning multiple climate zones, the environmental conditions differ greatly, and the weapons and equipment in different regions work or store in harsh climate environments such as wind and sand, rain and snow, heat and humidity, and salt spray for a long time, which will be affected by environmental conditions to different degrees, causing corrosion damage to equipment parts, and having an important influence on the performance, safety and reliability of weapons and equipment. Due to salt spray corrosion in marine environment, the service life of a certain ship-borne helicopter of our army is less than 20% of that on land; most of the engine blades begin to corrode after 20h of work, causing the aircraft to be grounded, which is related to improper selection of materials and corrosion control. The copper alloy propeller of a certain type of high-speed torpedo boat is severely cavitation corroded, and some propellers are scrapped after 8h of navigation; a certain type of aluminum-hulled torpedo boat developed by China has been corroded by half of the 7mm thick boat plate in less than half a year due to improper selection of corrosion prevention measures, which seriously affects the design and standardization of the type of boat and the army's equipment.

[0005] The corrosion of the weapon equipment has long-term and hidden characteristics, and will cause great influence in military and economic aspects. The loss is amazing. The inspection results of the stock weapon equipment show that the failure rate of the weapon equipment caused by corrosion is 17.3%; the corrosion control and maintenance of the weapon equipment has large workload, long time consumption and large manpower input. According to the statistics, more than 80% of the total manpower is involved in the corrosion prevention and maintenance of the equipment, and the manpower consumption for corrosion prevention accounts for more than 90% of the total maintenance manpower; the corrosion prevention cost accounts for more than 70% of the total maintenance cost of the weapon equipment. Therefore, the corrosion phenomenon seriously affects the safety, reliability, service life and combat capability of the equipment, and leads to high equipment maintenance and repair cost to a great extent. Especially in today's rapid development of military science and technology, the development and deployment of a large number of high, fine and sharp weapon equipment will cause greater loss caused by corrosion.

[0006] The weapon equipment uses a large amount of special alloy materials, and the corrosion of the weapon equipment is rust. Since the loose and porous structure of the rust layer does not protect the base material, and the rust layer easily absorbs the moisture and other corrosive media in the air, which in turn accelerates the corrosion of the base material. Therefore, before repair and coating, the metal surface must be strictly degreased, derusted and roughened and converted, so as to achieve good corrosion prevention effect.

[0007] The commonly used derusting and roughening process is polishing and sand blasting. The polishing efficiency is low and the derusting is not thorough. The sand blasting is commonly used but has large process labor intensity, serious dust pollution, complex equipment, large energy consumption and residual stress of the base after sand blasting. At the same time, due to the particularity of the weapon equipment, the application of sand blasting is greatly limited. For example, the corrosion prevention of the warehouse equipment has great difficulty in sand blasting, and the sparks generated by the impact are easy to cause explosion danger; during the repair and construction of various ships and vehicles, especially during the repair of the cabin, although the recyclable equipment is used for sand blasting, a large amount of dust and sand particles still leak out, which easily causes pollution and damage to the instrument equipment. In addition, the corrosion prevention of the components with complex structure is also greatly restricted. Therefore, it is of great significance to invent a process technology for converting rust into a corrosion prevention layer, which can prolong the service life of the product and conveniently, quickly and safely repair the rust of the weapon equipment.

[0008] At present, the commonly used rust conversion agent can react with the rust products to generate inert substances, which have certain corrosion prevention effect on the material surface, but there are still many problems:

[0009] (1) Since the metal material used in the weapon equipment is a special alloy material, the composition of the rust layer is complex, the effect of the commonly used rust conversion agent is poor, it is not suitable for aluminum alloy material, and it will cause secondary rust of the parts;

[0010] (2) Traditional rust conversion agent generally has the defects of insufficient adhesion and hardness, under external force and other adverse environmental factors, the coating effect time will be greatly affected, leading to the need to use rust conversion agent for regular coating of metal, increasing the workload, and the short-term rust removal and rust prevention treatment has great limitations on the actual engineering operation;

[0011] (3) The main components of the commonly used rust conversion agent are tannic acid or phosphoric acid. When phosphoric acid is used, the rust conversion layer has poor water resistance and is easy to cause blistering and peeling of the subsequent coating; when tannic acid is used, the rusted metal surface is relatively smooth.

[0012] (4) Chromium, lead and other rust-proof pigments are often used in rust conversion agents to achieve the purpose of rust prevention. However, they all have certain toxicity and can easily pollute the environment and harm human health.

[0013] Therefore, it is of great significance to develop a composite rust conversion agent suitable for steel, aluminum and other materials, which does not contain environmentally limited elements, and the conversion film layer has excellent rust prevention, hardness, adhesion and durability, etc., to improve the performance and prolong the service life of weapons and equipment. SUMMARY

[0014] In view of the rust problem of different weapon equipment parts during assembly, use and storage, the technical problem to be solved by the present application is to provide a composite rust conversion film forming liquid and its preparation method, and a process for quickly repairing rusted parts of special equipment using the composite rust conversion film forming liquid. The repair process can quickly and conveniently convert the rust layer into an anti-corrosion layer, and the anti-corrosion layer after conversion has excellent hardness, adhesion, durability and other properties, laying a good foundation for subsequent brushing of different coatings.

[0015] To solve the above technical problems, the technical solution adopted by the present application is:

[0016] A composite rust conversion film forming liquid, the content of each component per liter is: ethanol 90-120 ml / L, tannic acid 5-8 g / L, concentrated H3PO4 25-35 ml / L, HEDP 20-30 ml / L, manganese iron phosphate 20-25 g / L, fluorosilicate 3-6 g / L, composite film forming accelerator 4-6 g / L, surfactant 2-4 g / L, antifreeze 4-6 g / L.

[0017] The composite film forming accelerator is a mixture of inositol derivative and cobalt salt with a mass ratio of 2:1; the surfactant is a combination of two of AES, AEO and BS-12 with a mass ratio of 1:1; the antifreeze is a mixture of ethylene glycol and diethylene glycol with a mass ratio of 1:1.

[0018] The preparation method of the composite rust conversion film forming solution is as follows:

[0019] (1) The calculated tannic acid and composite film forming accelerator are added into the calculated amount of 95% ethanol and stirred until completely dissolved;

[0020] (2) The calculated concentrated H3PO4, HEDP and manganese iron phosphate are sequentially added into one-third of the preparation amount of tap water, stirred, dissolved and impurities such as precipitates are removed;

[0021] (3) The calculated fluorosilicate, surfactant and antifreeze are sequentially added into one-fourth of the preparation amount of tap water, stirred, dissolved and impurities such as precipitates are removed;

[0022] (4) The mixed solution of (1), (2) and (3) is sequentially added into a container containing tap water, stirred until the solution is translucent, then water is added to the required volume, heated to about 50°C, kept for about 1 hour, naturally cooled to room temperature, and then kept still for 24 hours, the precipitate at the bottom of the tank is removed, and then poured into a special glass bottle for use.

[0023] A rapid repair process suitable for rusted parts of special equipment, comprising the following steps:

[0024] Step 1: surface finishing, using a spatula or industrial scouring pad to polish the rusted parts of the components to remove protruding rust and coating;

[0025] Step 2: cleaning, using 75% alcohol to wipe the parts treated in step 1 to remove surface grease and other contaminants;

[0026] Step 3: rust conversion, using a brush to dip the composite rust conversion film forming solution on the surface cleaned in step 2 and apply 3-4 times, using a cotton cloth or toilet paper to wipe off the composite rust conversion film forming solution flowing to other parts, and after 6-8 minutes of reaction, using a hand-held air blower to dry;

[0027] Step 4: if painting is required, painting is performed within 12-24 hours.

[0028] In step 3, the operation is performed at an ambient temperature of 25°C or above.

[0029] The composite rust conversion film forming solution, preparation method and rapid repair process for rusted parts of special equipment designed by the above technical solution have the following beneficial effects through a large number of orthogonal tests and optimization adjustment of each component of the conversion solution:

[0030] (1) The conversion temperature can be applied at room temperature, saving a large amount of energy;

[0031] (2) The conversion solution does not contain Cr 6+ , Ni2+ Pb 2+ The harmful elements which cause serious pollution to human body and environment are eliminated, and clean production and safety hidden trouble are eliminated.

[0032] (3) The synchronous film forming of different performance and material parts is realized, and the application range is expanded.

[0033] (4) The corrosion resistance of the conversion layer and the matching with paint are greatly improved.

[0034] (5) The operation is simple, the production efficiency is high, and the rework quality is consistent with the original treatment. BRIEF DESCRIPTION OF DRAWINGS

[0035] Figure 1 The process flow chart of the quick repair process for the rusted parts of special equipment is shown. DETAILED DESCRIPTION

[0036] The compound rust conversion film forming liquid, the preparation method and the quick repair process for the rusted parts of special equipment will be described in detail below in combination with the drawings and examples. Example 1

[0037] The compound rust conversion film forming liquid of the present application contains the following components per liter: ethanol 90ml / L, tannic acid 5g / L, concentrated H3PO4 25ml / L, HEDP 20ml / L, manganese iron phosphate salt 20g / L, fluorosilicate 3g / L, compound film forming accelerator 4g / L, surfactant 2g / L, and antifreeze 4g / L.

[0038] The compound film forming accelerator is a mixture of inositol derivative and cobalt salt with a mass ratio of 2:1; the surfactant is a combination of two of AES, AEO and BS-12 with a mass ratio of 1:1; and the antifreeze is a mixture of ethylene glycol and diethylene glycol with a mass ratio of 1:1.

[0039] The preparation method of the compound rust conversion film forming liquid is as follows:

[0040] (1) The calculated tannic acid and compound film forming accelerator are added to the calculated amount of 95% ethanol and stirred until completely dissolved;

[0041] (2) The calculated concentrated H3PO4, HEDP and manganese iron phosphate salt are sequentially added to one-third of tap water, stirred, dissolved and impurities such as precipitates are removed;

[0042] (3) The calculated fluorosilicate, surfactant and antifreeze are sequentially added to one-fourth of tap water, stirred, dissolved and impurities such as precipitates are removed;

[0043] (4). The mixed solution of (1), (2) and (3) is sequentially added into a container containing tap water, stirred until the solution is translucent, then water is added to the scale, heated to about 50°C, kept for about 1h, naturally cooled to room temperature, kept still for 24h, the sediment at the bottom of the tank is removed, and then poured into a special glass bottle for use.

[0044] The rapid repair process of the special equipment rusty parts by using the composite rust conversion film forming liquid includes the following steps:

[0045] Step 1: surface finishing, using a spatula or industrial scouring pad to polish the rusty parts of the components to remove the protruding rust and coating;

[0046] Step 2: cleaning, using 75% alcohol to wipe the parts treated in step 1 to remove surface grease and other dirt;

[0047] Step 3: rust conversion, using a brush to dip the composite rust conversion film forming liquid on the surface cleaned in step 2, and then applying 3-4 times, using cotton or toilet paper to wipe the composite rust conversion film forming liquid flowing to other parts, and then drying after 6-8 minutes of reaction, the operation in this step is best in the environment above 25°C;

[0048] Step 4: if painting is needed, then painting is performed within 12h-24h. Example 2

[0049] The composite rust conversion film forming liquid of the present application contains the following components per liter: ethanol 100ml / L, tannic acid 6.5g / L, concentrated H3PO430ml / L, HEDP 25ml / L, manganese iron phosphate salt 23g / L, fluorosilicate 4.5g / L, composite film forming accelerator 5g / L, surfactant 3g / L, and antifreeze 5g / L.

[0050] The preparation method of the composite rust conversion film forming liquid and the rapid repair process of the special equipment rusty parts by using the composite rust conversion film forming liquid are the same as those in Example 1. Example 3

[0051] The composite rust conversion film forming liquid of the present application contains the following components per liter: ethanol 120ml / L, tannic acid 8g / L, concentrated H3PO435ml / L, HEDP 30ml / L, manganese iron phosphate salt 25g / L, fluorosilicate 6g / L, composite film forming accelerator 6g / L, surfactant 4g / L, and antifreeze 6g / L.

[0052] The preparation method of the composite rust conversion film forming liquid and the rapid repair process of the special equipment rusty parts by using the composite rust conversion film forming liquid are the same as those in Example 1.

[0053] Effect of the present application

[0054] 1. The 35CrMnSi and 2A12 material samples are placed in a high humidity environment until rust appears on the surface, and then treated with the composite rust conversion film forming liquid of the application. The film layer is subjected to corrosion resistance detection according to WJ536-2007, and the rust conversion is subjected to salt spray test according to GB1771 after being coated with a military special paint. The test results meet the product corrosion index requirements.

[0055] 2. The rusted parts of the company's stored equipment are treated with the composite rust conversion film forming liquid of the application. The conversion film on the steel material is dark gray, and the film layer on the aluminum alloy is light gray. No rust is observed after one month of storage in a summer warehouse.

[0056] The process of the application solves the following problems: (1) solves the problem of rust affecting the use of weapon equipment parts during circulation, use and storage; (2) due to the special use and storage environment of weapon equipment, mostly in remote mountainous areas with inconvenient transportation, the application can conveniently and quickly solve the rust repair problem of stored equipment, and ensure the use performance of weapon equipment; (3) due to the special material of weapon equipment, the rust conversion effect of commonly used rust conversion liquid is poor, and the application solves this problem; (4) the application solves the limitations of commonly used conversion liquid, so that one rust conversion liquid can treat two kinds of metal materials, which is convenient to use and saves cost; (5) solves the problem of environmental pollution caused by the presence of heavy metals in commonly used rust conversion liquid; (6) solves the difficult problem of returned repair of stored products due to rust for many years, ensures the quality of weapon equipment, and meets the national defense needs.

Claims

1. A composite rust conversion film forming liquid, characterized by The content of each component is: ethanol 90-120 ml / L, tannic acid 5-8 g / L, concentrated H3PO4 25-35 ml / L, HEDP 20-30 ml / L, manganese iron phosphate 20-25 g / L, fluorosilicate 3-6 g / L, composite film forming accelerator 4-6 g / L, surfactant 2-4 g / L, antifreeze 4-6 g / L.

2. The rust conversion film forming liquid according to claim 1, characterized by The content of each component is: ethanol 90 ml / L, tannic acid 5 g / L, concentrated H3PO4 25 ml / L, HEDP 20 ml / L, manganese iron phosphate 20 g / L, fluorosilicate 3 g / L, composite film forming accelerator 4 g / L, surfactant 2 g / L, antifreeze 4 g / L.

3. The composite rust conversion film forming solution according to claim 1, characterized by The content of each component is: ethanol 100 ml / L, tannic acid 6.5 g / L, concentrated H3PO4 30 ml / L, HEDP 25 ml / L, manganese iron phosphate 23 g / L, fluorosilicate 4.5 g / L, composite film forming accelerator 5 g / L, surfactant 3 g / L, antifreeze 5 g / L.

4. The composite rust conversion film forming solution according to claim 1, characterized by The content of each component is: ethanol 120 ml / L, tannic acid 8 g / L, concentrated H3PO4 35 ml / L, HEDP 30 ml / L, manganese iron phosphate 25 g / L, fluorosilicate 6 g / L, composite film forming accelerator 6 g / L, surfactant 4 g / L, antifreeze 6 g / L.

5. The composite rust conversion film forming solution according to any one of claims 1 to 4, characterized by The composite film forming accelerator is a mixture of inositol derivative and cobalt salt with a mass ratio of 2:1; the surfactant is a combination of two of AES, AEO, and BS-12 with a mass ratio of 1:1; and the antifreeze is a mixture of ethylene glycol and diethylene glycol with a mass ratio of 1:

1.

6. A method for preparing the composite rust conversion film forming liquid according to any one of claims 1 to 4, characterized by The preparation method is as follows: (1) The calculated tannic acid and composite film forming accelerator are added to 95% ethanol and stirred until completely dissolved; (2) The calculated concentrated H3PO4, HEDP, and manganese iron phosphate are sequentially added to one-third of the preparation amount of tap water, stirred, dissolved, and the precipitate impurities are removed; (3) The calculated fluorosilicate, surfactant, and antifreeze are sequentially added to one-fourth of the preparation amount of tap water, stirred, dissolved, and the precipitate impurities are removed; (4) The mixtures of (1), (2), and (3) are sequentially added to a container containing tap water, stirred until the solution is translucent, then water is added to the required volume, heated to 50°C for 1 hour, naturally cooled to room temperature, and left to stand for 24 hours, then the bottom sediment is removed and poured into a glass bottle for use.

7. A process for the rapid repair of specially equipped rusted parts characterized in that The steps include: Step 1: surface finishing, using a spatula or industrial scouring pad to polish the rusted parts to remove protruding rust and coatings; Step 2: cleaning, using 75% alcohol to wipe the parts treated in step 1 to remove surface grease and other contaminants; Step 3: rust conversion, using a brush to apply the composite rust conversion film forming liquid of any one of claims 1-4 to the surface cleaned in step 2 for 3-4 times, using cotton or toilet paper to wipe off the composite rust conversion film forming liquid that flows to other parts, and after 6-8 minutes of reaction, using a handheld air blower to dry; Step 4: if painting is required, painting is performed within 12-24 hours.

8. The process for quick repair of specially equipped rusted parts as claimed in claim 7 wherein In step 3, the operation is performed at an ambient temperature above 25°C.

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