Composite ceramic particle reinforced aluminum alloy anti-icing coating and preparation method thereof

Abstract

The invention relates to the technical field of aluminum alloy anti-icing coatings, and discloses a composite ceramic particle reinforced aluminum alloy anti-icing coating and a preparation method thereof.The preparation method comprises the steps that ceramic particles and aluminum alloy powder are mixed based on a preset proportion; preparing the mixed powder into a uniformly dispersed mixture through a ball mill; spraying the mixture on the surface of a base material by adopting a thermal spraying technology to form a coating; and the coating is subjected to heat treatment based on preset parameters so as to enhance the anti-icing performance of the coating, and by executing the steps, it is ensured that the prepared ceramic particle reinforced aluminum coating has excellent anti-icing performance; and the unexpected problem caused by inappropriate gas injection rate and the problem of poor microstructure uniformity caused by difficult avoidance of gas holes and defects when the composite layer on the aluminum alloy matrix is formed through the spraying process can be avoided.

Description

Technical Field

[0001] The invention relates to the technical field of aluminum alloy anti-icing coatings, and specifically to a composite ceramic particle reinforced aluminum alloy anti-icing coating and a preparation method thereof. Background Art

[0002] An anti-icing coating for aluminum alloy adopts a composite ceramic particle reinforcement method. This technology uses high-speed spraying to combine ceramic particles with the aluminum alloy matrix to form a protective layer with anti-icing function.

[0003] However, there are many challenges in this process: first, when the particles are sprayed onto the aluminum alloy surface at high speed, the poor wettability between the two can easily lead to insufficient interface bonding; second, the thermal expansion characteristics of the coating are significantly different from those of the aluminum alloy substrate, which may cause cracks or complete peeling during the cooling and solidification stage; third, in extremely low temperature environments, stress concentration often occurs in the ceramic particle area, causing fine cracks to begin to spread and eventually expand into larger cracks; over time and under repeated environmental influences, the surface ceramic particles will gradually lose their effectiveness, compromising the long-term effectiveness of the anti-icing coating;

[0004] In addition, during the preparation of this composite coating using spraying technology, pores and other structural defects are often unavoidable. These factors further reduce the consistency and integrity of the coating microstructure and have a negative impact on the effective performance of the final material. Summary of the invention

[0005] The purpose of the present invention is to provide a composite ceramic particle reinforced aluminum alloy anti-icing coating and a preparation method thereof, which solves the problem of poor microstructural uniformity caused by unavoidable gas holes and defects when a composite layer is formed on an aluminum alloy substrate by a spraying process in the background technology.

[0006] In order to solve the above technical problems, the present invention provides the following technical solutions:

[0007] A composite ceramic particle reinforced aluminum alloy anti-icing coating and a preparation method thereof, comprising the following steps:

[0008] S1: mixing ceramic particles and aluminum alloy powder based on a preset ratio;

[0009] S2: The mixed powders are subjected to a ball mill to form a uniformly dispersed mixture;

[0010] S3: spraying the mixture onto the surface of the substrate to form a coating using a thermal spraying technique;

[0011] S4: heat-treating the coating based on preset parameters to enhance its anti-icing performance.

[0012] Preferably, the step of mixing ceramic particles and aluminum alloy powder based on a preset ratio specifically includes:

[0013] S101: Select the ratio P1 of the diameter D of the ceramic particles to the diameter d of the aluminum alloy powder;

[0014] S102: Set the mixing ratio M according to the desired strengthening effect, that is, the ratio of the weight of the ceramic particles to the weight of the aluminum alloy powder;

[0015] S103: Ensure that the ball milling time T1 for ensuring mixing uniformity exceeds the threshold value Tmin, where Tmin is calculated based on the volume V of the mixture and the mass Q of the grinding balls, and the calculation method is: Tmin = (V / Q)^5, where V represents the total volume parameter and Q represents the total mass parameter;

[0016] S104: Further increase the active components in the aluminum alloy powder to promote the wetting and bonding of the ceramic particles in the aluminum alloy.

[0017] Preferably, the process of enhancing the coating performance based on heat treatment includes the steps:

[0018] S401: Set the annealing temperature Tanneal for stress concentration phenomenon not lower than the critical value Tcrit to ensure the elimination of most internal stresses; Tcrit > Tanneal, where Tcrit represents the critical annealing temperature parameter and Tanneal represents the actual annealing temperature used;

[0019] S402: Conduct heat preservation treatment on the coating to ensure the minimum degree of mutual dissolution between the ceramic and the metal to improve the coating bonding strength and reduce the cracking tendency;

[0020] S403: Use a rapid cooling method to reduce the difference in thermal expansion coefficients between the ceramic and the aluminum alloy, and reduce the risk of coating cracking and peeling caused thereby;

[0021] S404: Ensure that the final treatment temperature after annealing meets the requirements of the best performance of the material without causing grain coarsening or other harmful changes.

[0022] Preferably, the heat treatment based on preset parameters during the spraying process is further specified as follows:

[0023] S405: Set the oxygen content A in the spraying chamber not exceeding the maximum safety limit Amx to ensure no coating oxidation problem caused by oxygen introduction: A < Amx, A is the real-time oxygen content parameter in the spraying booth, and Amx is the maximum safe oxygen content parameter;

[0024] S406: Use an inert gas purge to prevent oxidation during the spraying process and remove the residual gas to improve the spraying quality;

[0025] S407: Maintain the spraying equipment to ensure the working accuracy and spraying efficiency of the spray gun;

[0026] S408: Multiple overlapping spraying is used to ensure that the microstructure of the coating is uniform and free of voids.

[0027] Preferably, the control conditions to prevent the problem of poor microstructure uniformity are as follows:

[0028] A1: Control the spraying thickness S each time not to exceed the recommended maximum single thickness Smax, and meet the thickness condition S≤Smax, S is the spraying thickness parameter, Smax is the recommended maximum spraying thickness parameter, which helps to prevent the gas discharge channel in the coating from being blocked;

[0029] A2: Add surfactant or adjust the proportion of spray material components to improve liquid fluidity and reduce voids;

[0030] A3: Implement auxiliary heating or cooling measures before the coating is fully cured to help eliminate internal bubbles;

[0031] A4: Use online detection equipment to monitor the coating deposition rate and spray parameter consistency to avoid micro defects caused by the spraying process.

[0032] Preferably, measures are taken to ensure long-term performance in response to the problem of long-term protection performance degradation:

[0033] Establish a rule that the density distribution C of ceramic particles must exceed a certain limit Cb to ensure the stable attachment of particles: C>Cb, C represents the average concentration level of ceramic particles in the coating, and Cb represents the minimum concentration limit to ensure the integrity of the coating;

[0034] Adopt regular re-spraying or local reinforcement maintenance strategies to prevent the overall protection capability from deteriorating due to long-term use;

[0035] Improve the wear resistance, toughness and chemical stability of the coating to adapt to more severe working environments and longer time periods;

[0036] By selecting a composite coating material with appropriate hardness level and impact resistance to resist external physical damage.

[0037] Preferably, mixing ceramic particles and aluminum alloy powder based on a preset ratio specifically includes:

[0038] Based on the optimal wetting ratio a:b of the ceramic particles A and the aluminum alloy powder B, the ratio x:y=a:b of the ceramic particles A and the aluminum alloy powder B is preset to ensure the optimal physical compatibility between the two to enhance the interface bonding strength;

[0039] Add in proportion under an inert atmosphere and stir thoroughly to form a stable suspension state to avoid sedimentation and separation of ceramic particles A;

[0040] Preheating the aluminum alloy powder B to temperature T1 before powder mixing to reduce the stress and crack risk caused by mismatch of thermal expansion coefficient during coating solidification;

[0041] During the stirring process, the relative humidity is controlled below H3% to inhibit the generation of gas holes and microscopic defects caused by moisture.

[0042] Preferably, before the mixed powder is passed through a ball mill to form a uniformly dispersed mixture, a first size medium ball of diameter d1 is filled in the ball mill at a ratio of p, and then a second size medium ball of diameter d2 is filled at a ratio of q (satisfying the formula q>p), wherein the first size d1 is larger than the second size d2, to ensure effective contact of the medium balls and slow down the breakage caused by collision between the medium balls;

[0043] d1, d2 represent the size of dielectric balls, d1>d2, p, q are the filling volume ratios of two different sized balls respectively;

[0044] Where: If the ratio of the dielectric ball sizes d1 and d2 is not appropriate, the efficiency will be reduced and the energy consumption will increase. Therefore, the relationship d1 / d2≥5 needs to be satisfied to ensure dispersion and prevent excessive wear.

[0045] Preferably, before spraying, the heating rate v1 (cm / min) before coating formation is dynamically adjusted by measuring the initial temperature T1 of the substrate and the preheating temperature T3 of the aluminum alloy powder B based on a temperature sensor to reduce the internal stress concentration of the ceramic particles C caused by the temperature difference;

[0046] Set the heating rate v1 so that the difference between T1 and the ambient reference temperature ΔT = T3Tenvironment ≤ 5°C, reducing the probability of coating cracking caused by thermal shock to the substrate;

[0047] ΔT represents the change in substrate temperature relative to the ambient temperature, and Tambient is the base temperature of the environment during the spraying process;

[0048] If the relationship ΔT=T3T environment <5℃ is not satisfied, then adjust the v1 value appropriately to ensure the coating quality.

[0049] Preferably, the formed coating J is heat treated according to preset parameters, and the heat treatment temperature T4 should be determined based on the coating thickness H and the cooling rate dHdT (μm / s) of the spraying temperature to maintain a uniform temperature distribution throughout the treatment process, improve the interface bonding strength between the ceramic particles and the aluminum alloy, and promote the uniformity of the microstructure;

[0050] Establish the relationship of T4 = H*dHdT + correction coefficient (Tcorr = 60), so that the ceramic material can be well crystallized and the residual internal pressure can be minimized without reducing the wettability of the interface;

[0051] The correction factor is used to compensate for theoretical deviations under the influence of other variables;

[0052] When it is not equal to T4≥1 / 2*H 25, it is necessary to increase the heating time t1 or increase the heat treatment furnace temperature setting to compensate for the insufficient heat treatment amount in order to optimize the comprehensive performance of the coating.

[0053] Compared with the prior art, the beneficial effects achieved by the present invention are:

[0054] 1. The surface integrity and anti-icing effect are ensured by using the same formula of mixed powder for point spraying supplement or local repair; at the same time, in order to improve the micro-uniformity of the coating and reduce the performance degradation caused by porosity, the spraying process is finely controlled, and the spray deposition method under an inert atmosphere is used to exclude the pores formed by air intervention as much as possible, ensuring the good density of the generated coating structure. This comprehensive solution effectively overcomes the above-mentioned common but critical preparation obstacles.

[0055] 2. Through the determined conditions, the formed coating is subjected to a specially designed multi-stage heating and slow cooling procedure to release the residual internal stress and reduce the risk of cracking caused by the difference in thermal expansion coefficients between different materials. For the microstructural problems of the material that may be caused by the change in the use temperature, this heat treatment step also includes adjusting the phase change temperature range of the coating to the operating temperature range, which can effectively prevent the occurrence and expansion of microcracks and ensure that a large amount of stress will not accumulate around the ceramic particles, thereby improving the overall crack resistance of the coating and its ability to resist environmental changes.

[0056] 3. Based on a pre-set ratio, ceramic particles with high strength, high hardness and high temperature resistance are accurately mixed with aluminum alloy powder with good formability and high toughness; the resulting mixture is then placed in a ball mill for long-term and sufficient grinding to achieve a uniform dispersion state at the nanometer or micrometer level. This refinement treatment helps to improve the contact area and wettability between the particles and the metal phase, thereby solving the problem of unstable interface bonding caused by the poor initial wettability between the particles and the aluminum alloy. BRIEF DESCRIPTION OF THE DRAWINGS

[0057] Figure 1 It is a flow chart of steps of a method for preparing a composite ceramic particle reinforced aluminum alloy anti-icing coating;

[0058] Figure 2 It is a specific flow chart of the steps of mixing ceramic particles and aluminum alloy powder based on a preset ratio;

[0059] Figure 3 It is a flow chart of the process steps for enhancing coating properties based on heat treatment;

[0060] Figure 4 It is a flow chart of heat treatment based on preset parameters during spraying process;

[0061] Figure 5 It is a flow chart of the conditions to be controlled when the problem of poor microstructural uniformity occurs;

[0062] Figure 6 It is a flowchart of measures to ensure long-term performance in response to the problem of long-term protection performance degradation;

[0063] Figure 7 It is a specific flow chart based on mixing ceramic particles and aluminum alloy powder in a preset ratio;

[0064] Figure 8 It is a flow chart before the mixed powder is passed through a ball mill to form a uniformly dispersed mixture;

[0065] Fig. 9 It is a flow chart measured by a temperature sensor before spraying;

[0066] Fig.10 It is a flow chart of heat treating the formed coating J according to preset parameters. DETAILED DESCRIPTION

[0067] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0068] The present invention discloses a method for preparing a composite ceramic particle reinforced aluminum alloy anti-icing coating, which comprises the steps of mixing, ball milling, thermal spraying and heat treatment, and aims to overcome various technical challenges. First, a specific type of ceramic particles such as alumina (Al2O3) particles and an aluminum alloy with good mechanical properties such as AA2024 series powder are mixed according to a certain mass ratio. This step aims to utilize the heat resistance and corrosion resistance of the ceramic to improve the performance of the overall coating.

[0069] Suppose we want to prepare an anti-icing coating sample for high-speed train components. According to the optimal ratio determined by the experimental design (for example, the mass ratio of ceramic to metal is 20%:80%), we weigh 100 grams of AA2024 aluminum alloy powder and 25 grams of Al2O3 particles as the base material. After mixing these powders together, they are placed in a ball mill for dry grinding to ensure that the ceramic particles can be evenly surrounded by the metal particles and the direct physical contact between the two is minimized, effectively improving the wettability problem between the two. The ball milling process usually lasts for several hours (such as 12 to 72 hours) to achieve a closer mixing between the materials.

[0070] Specifically, in this example, we can pour the mixed powder into a rotating mold with steel balls, set the corresponding rotation speed and duration, and through this process, the two materials can be combined at a very fine level. The composite powder obtained after such treatment can form a more stable coating structure during the subsequent thermal spraying, and effectively reduce the problem of insufficient coating interface bonding strength caused by poor wettability.

[0071] After a sufficiently uniformly distributed powder is prepared, the thermal spraying step is entered. Here, high-pressure air or oxygen or other carrier gases can be used to blow the preset composite powder into a plasma jet or flame at a temperature of more than a thousand degrees, causing it to instantly heat up and melt into molten droplets and quickly spray onto the cleaned aluminum alloy substrate surface. In order to reduce the risk of cracking and peeling caused by internal stress caused by the difference in thermal expansion coefficients between the two materials, it is necessary to accurately control the heating of the substrate to a temperature slightly lower than the melting point of the spray, and ensure that the entire substrate is heated evenly and the thickness of the thermal spray is consistent, so that the two phases can shrink synchronously during the solidification process.

[0072] Taking the example of the present invention as an example to illustrate this operation, we preheat the substrate of the sample to about 500°C before spraying, while ensuring that factors such as the pressure of the carrier gas (e.g., 3 to 4 bars), the nozzle distance (usually 50 to 200 mm) and the scanning rate are maintained at optimal values, so as to obtain a smooth surface coating with good density without generating large internal tension.

[0073] The next problem to be solved is the stress problem that is easy to be generated in the coating under extremely low temperature working environment. This can be solved by selecting ceramic particles with appropriate morphology or chemical properties to reduce the elastic modulus ratio between them and the aluminum alloy substrate. In addition, the influence of particle size effect should also be considered; for example, the use of fine particles of smaller size (such as less than about 20μm) can increase the interfacial area per unit area, make the microstructure more solid, help inhibit the development of microcracks, and reduce the surface roughness to prevent the subsequent use of wear and damage.

[0074] To ensure the actual effect is significant, we can try to prepare a batch of samples with particle sizes concentrated in a certain range. Assuming that the size of our microsphere Al2O3 particles does not exceed about 10 microns, in the subsequent testing phase, it can be found that the anti-icing coating under this specification can not only effectively resist small damage caused by cold temperature, but also maintain a high-quality appearance and internal characteristics under long-term service conditions.

[0075] The final heat treatment process is mainly to further stabilize the phase change of the coating, improve the anti-ice adhesion ability and life span. It can be optimized by adjusting the temperature gradient or aging time. The goal is to enhance the durability without damaging the original mechanical properties. For example, the product obtained after spraying is gradually heated to 200 to 350°C under protective atmosphere conditions, and the temperature is maintained for a period of time sufficient to allow the grains to recrystallize and fully precipitate hard particles, and finally slowly cooled to room temperature and taken out to complete the strengthening process. After this, an advanced aluminum alloy protection system with excellent comprehensive performance is obtained, which is suitable for a variety of harsh outdoor environment conditions.

[0076] Next, the steps of mixing ceramic particles and aluminum alloy powder based on a preset ratio of the present invention are described in detail. First, the ratio P1 between the ceramic particle diameter D and the aluminum alloy powder diameter d is selected. This selection directly affects the mechanical properties of the final coating. For example, for anti-ice coating applications, if larger ceramic particles are used to improve the hardness and toughness of the coating, then P1 should be set to a higher value to ensure that the ceramic particles are not too fine to affect their mechanical performance; if weight reduction is important, a smaller particle size ratio P1 should be considered to optimize the overall material performance and coating adhesion.

[0077] Then, the mixing ratio M, i.e. the ratio between the weight of ceramic particles and the weight of aluminum alloy powder, is determined according to the desired reinforcement effect. When designing an anti-icing coating, it is necessary to consider the erosion, wear and other challenges faced by the coating under actual environmental conditions. If the reinforcement effect is to enhance the surface strength of the coating and reduce the adhesion of ice, a high ratio such as M = 0.3-0.7 can be selected to increase the hardness while maintaining enough aluminum alloy to ensure that the coating has strong adhesion and is not brittle.

[0078] Then, in order to ensure that the mixing operation can make the two different materials thoroughly evenly dispersed and tightly combined, a minimum ball milling time T1 needs to be set. The minimum required time is obtained by the formula **Tmin=(V / Q)^5**, where V refers to the total volume of the mixture and Q represents the total weight of the grinding balls involved in the mixing. For example, assuming that an appropriate volume of material and enough grinding balls are to be mixed to cover all internal surface areas and prevent dead corners, the calculated Tmin can help avoid insufficient or excessive mixing. This step is critical to the performance of the final product. If Tmin is set too short, it may cause uneven distribution of materials and affect the consistency of the coating. If it is too long, it may introduce unnecessary energy, causing unnecessary damage or even chemical changes. The optimal time is to allow the two materials to be completely mixed without wasting resources.

[0079] After ensuring the previous preparations, it is necessary to further add appropriate activators to improve the contact and wettability of aluminum alloy to ceramic particles, so that the two can more easily form a new alloy composite layer with a tight three-dimensional structure during the heat treatment stage. In a specific embodiment, additives with high aluminum activity, such as rare earth metals or other components that can form a favorable intermediate phase with Al, are appropriately added to enhance the mutual solubility of the coating at the microscopic level. In this way, the working efficiency and service stability of the final anti-icing coating can be improved in this way.

[0080] Next, the process of enhancing coating performance based on heat treatment of the present invention is described, which includes the steps of: setting the annealing temperature T anneal not lower than the critical value Tcrit for the stress concentration phenomenon to ensure that most of the internal stress is eliminated; Tcrit> T anneal, where Tcrit represents the critical annealing temperature parameter, and T anneal represents the annealing temperature actually used. The purpose of this step is to remove or reduce the internal residual stress generated during the processing. The set T anneal needs to be higher than Tcrit to effectively eliminate these stresses and avoid failure of the material due to internal pressure during subsequent use. For example, when manufacturing an anti-icing coating, if there is residual tensile stress on the surface of the aluminum alloy substrate, appropriate annealing can release the stress in this area and improve the stability of the coating.

[0081] The coating is held at a temperature to ensure that the ceramic and metal dissolve to a minimum to improve the coating bonding strength and reduce the tendency to crack. This measure is intended to optimize the interfacial bonding state between the coating and the substrate. The appropriate holding time allows the coating and the substrate to achieve good bonding without causing excessive dissolution between them. In one embodiment, for a composite material of aluminum oxide (Al2O3) particles deposited on 6061 aluminum alloy, precise control of temperature and holding time helps to achieve good adhesion while suppressing any over-alloying that may cause interfacial cracks.

[0082] Use a rapid cooling method to reduce the difference in thermal expansion coefficients between ceramics and aluminum alloys, and reduce the risk of resulting coating cracking and peeling. Different materials have different thermal expansion characteristics, and this difference can cause tensile stress during the condensation process, leading to structural integrity problems. By adopting a rapid cooling strategy, the impact of this difference can be reduced, minimizing the pressure at the interface. For example, applying a rapid cooling treatment with liquid nitrogen on the anti-icing coating can effectively limit the relative movement between the coating and aluminum and the possible delamination phenomenon.

[0083] Ensure that the final treatment temperature after annealing meets the requirements for the best performance of the material without causing grain coarsening or other harmful changes. After annealing, the cooling process and the final temperature must be controlled to prevent grain growth or deterioration of the material properties. At this specific step, it is crucial to adjust the temperature to a suitable range that does not damage the microstructure but still retains the improved performance. In practice, maintain a moderate cooling rate after annealing, such as several degrees to dozens of degrees per hour, to avoid abnormal grain growth and maintain the best wear and corrosion resistance of the anti-icing coating.

[0084] Next, the heat treatment based on preset parameters during the spraying process of the present invention is further specified as follows:

[0085] Set the oxygen content A in the spraying chamber not to exceed the maximum safety limit Amx to ensure no coating oxidation problem caused by oxygen introduction: A < Amx. This condition indicates that the actual oxygen content A in the spraying chamber at any time should be lower than the set maximum oxygen content Amx. The oxygen content parameter A represents the oxygen concentration level in the spraying environment during actual operation, and Amx is the safety value predetermined to prevent adverse reactions of the coating due to the presence of excessive oxygen. For example, when preparing an anti-icing coating for aluminum alloy, Amx may be set at a certain percentage to ensure that the entire process will not cause coating oxidation and deterioration due to excessive oxygen.

[0086] Use an inert gas purge to prevent oxidation during the spraying process and remove residual gases to improve the spraying quality; use inert gases (such as argon, nitrogen, etc.) during the coating process. These gases have stable chemical properties and are not easily involved in redox reactions, and can effectively isolate reactive gases such as oxygen in the coating environment. In one embodiment, continuously purge the spraying area with an inert gas to form a protective barrier and displace the oxygen originally remaining inside the working space.

[0087] Maintain the spraying equipment to ensure the working accuracy and spraying efficiency of the spray gun; this means performing regular maintenance to ensure that the spray gun and its supporting equipment are in the best working condition, including cleaning, checking whether the parts are damaged, etc. Specifically, to avoid problems of uneven spraying affecting the product quality, the nozzle needs to be unblocked, and the spray head should maintain an accurate angle to achieve an ideal atomization effect.

[0088] The use of multiple overlapping spraying methods ensures that the microstructure of the coating is uniform and free of holes; multiple overlapping means that the coating operation is performed multiple times in the same area instead of forming it in one go. The purpose of this technology is to avoid the situation where a single spraying causes local over-thickness and defects. For example, in the production of anti-icing ceramic aluminum alloy coatings, in order to achieve good bonding strength and density, multiple process routes are precisely controlled to ensure that no air or other impurities are trapped between the coating layers. This ensures that the final coating is both strong and defect-free.

[0089] Next, the conditions for controlling in order to prevent the problem of poor microstructure uniformity from occurring in the present invention are described as follows:

[0090] Control the thickness S of each spraying not to exceed the recommended maximum single thickness Smax, and meet the thickness condition S≤Smax, where S is the spraying thickness parameter and Smax is the recommended maximum spraying thickness parameter. This helps prevent the gas exhaust channel in the coating from being blocked; the key to this step is to limit the spraying amount of each layer within a reasonable range to avoid the gas inside the coating being unable to escape due to spraying too thick. Specifically, S should usually range from a few microns to tens of microns, depending on the specific spraying conditions and the type of coating. For example, when preparing a layer of composite ceramic particle reinforced aluminum alloy anti-icing coating with a thickness not exceeding 30 microns, if the material manual recommends Smax of 30 microns, the spraying should be strictly monitored to ensure that the sprayed layer does not exceed this limit.

[0091] Add surfactants or adjust the proportion of spray material components to improve liquid fluidity and reduce voids; this step is intended to improve the leveling effect of the liquid coating during application and minimize the situation where the coating leaves too many pores after drying. For example, in one embodiment, when preparing the spray solution, the ratio of ceramic particles to aluminum metal matrix can be appropriately increased to obtain a more fluid and dense result.

[0092] Before the coating is completely cured, auxiliary heating or cooling measures are implemented to help remove internal bubbles; this step is to adjust external conditions such as temperature after spraying and before the coating is completely solidified, so as to promote the floating of bubbles and reduce the number and volume of voids or gaps in the coating. Specifically, a specific temperature range can be set in advance, and hot air can be applied to the part that has just been sprayed within this range or it can be placed in a temperature-controlled environment and wait for a period of time, so that the bubbles can be better released without leaving hidden dangers.

[0093] Use online detection devices to monitor the coating deposition rate and spray parameter consistency to avoid micro defects caused by the spraying process. This last point is to ensure that there is an effective monitoring mechanism to capture and promptly correct any subtle changes in the spraying process. For example, install sensors to monitor the actual thickness of the coating and compare it with the preset target thickness. If the deviation is too large, it can be compensated by adjusting the speed or other parameters of the machine operation, thereby ensuring the excellent quality of the final product.

[0094] The determination of each parameter needs to be combined with various test data and experience in actual production, and the existence of the formula S≤Smax provides a clear guideline: always maintain the consistency of spraying and the single thickness cannot exceed the maximum limit. This regulation can not only effectively manage the quality of the coating, but also help control the variation factors in the production process, making the entire preparation method more optimized and reliable.

[0095] Next, the present invention describes the problem of long-term protection performance decline and takes measures to ensure long-term performance:

[0096] Establish a rule that the density distribution of ceramic particles C must exceed a certain limit Cb to ensure that the particles are firmly attached: C>Cb, where C refers to the average concentration of ceramic particles in the coating, which can be expressed in the number of particles per cubic centimeter, and Cb is the minimum concentration of ceramic particles required for the coating to maintain good structural integrity. For example, if C is set to 5000 particles per cubic centimeter and Cb is 3000, it means that in order to ensure effective bonding of particles and overall structural strength, the particle concentration in the coating should be greater than or equal to 3000 particles per cubic centimeter to ensure that poor performance is not caused by excessive spacing between particles;

[0097] A maintenance strategy of regular re-spraying or local reinforcement is adopted to prevent the overall protection capability from being degraded due to long-term use. For example, in one embodiment, if it is found that the coating of an aluminum alloy part is partially worn or thinned due to long-term exposure to a low-temperature environment, it can be inspected every six months and repair measures can be performed on the damaged area or the coating thickness can be fully updated to restore the protection function if necessary;

[0098] Improve the wear resistance, toughness and chemical stability of the coating to adapt to more severe working environments and longer time periods. Specifically, the coating can be designed by controlling the element combination and particle morphology in the alloy, so that the coating is not easily damaged even under extreme temperature conditions;

[0099] By selecting a composite coating material with the right hardness level and impact resistance to resist external physical damage, this step can ensure that the aluminum alloy surface can still be effectively protected against ice even when facing continuous external forces caused by hail impact or ice and snow accumulation.

[0100] The above strategies and requirements form part of the foundation of coating preparation technology, and provide detailed guidance for each key node in the coating development process. It should be noted that, for example, the determination of the C value should be carried out through a large number of actual measurements under specific conditions to obtain accurate data, and the Cb value should be adjusted according to the specific working conditions (such as temperature changes, mechanical loads, humidity) to match the optimal performance requirements, and ultimately achieve excellent anti-icing and damage protection for aluminum alloy parts in long-term service. All the above-mentioned conditional judgment parameters should be carefully calibrated according to the specific actual use environment, and the optimal configuration should be found through continuous test iterations to ensure long-term stable and reliable performance output.

[0101] Next, the present invention is described as mixing ceramic particles and aluminum alloy powder based on a preset ratio, which specifically includes the following steps. First, determine the optimal wetting ratio a:b between ceramic particles A and aluminum alloy powder B, which means that according to the material properties, select the ratio x:y that can maximize the interface bonding strength so that this ratio meets the optimal physical compatibility requirements. This setting can reduce the loss of mechanical properties due to interface defects. For example, if the optimal weight ratio of ceramic particles obtained by experiment is 1:4, it means that 4 parts by mass of aluminum alloy powder are required for every 1 part by mass of ceramic particles to achieve the best dispersion effect.

[0102] Next, the two are mixed in a protective or inert atmosphere according to the above preset ratio, and are continuously stirred to keep the mixture stable and uniform, prevent the ceramic particles from settling, and ensure that the coating has consistent properties. In one embodiment, argon can be used as an inert gas because this gas can effectively remove oxygen and moisture, reduce the risk of oxidation, and maintain the suspension of particles and alloys. The key point of this operation is to stir in an inert atmosphere rather than in air to ensure that there is no contamination.

[0103] Subsequently, the aluminum alloy powder is preheated to a specific temperature T1 before adding it to the mixing container. The purpose of this step is to reduce the thermal stress caused by the different thermal expansion coefficients between the aluminum alloy powder and the ceramic particles during the curing stage of the coating. Specifically, it is assumed that the required T1 is an optimized setting value in the range of about 150°C to 250°C, in order to improve the comprehensive performance of the coating while ensuring the plasticity of the aluminum alloy without overheating and deformation. The selection of the temperature range depends on the characteristics of the aluminum alloy powder and its thermodynamic compatibility with the ceramic particles.

[0104] Finally, during the entire powder handling and mixing process, the environmental conditions must be controlled so that the relative humidity is always kept at a strictly controlled level of H3%. If H3 is defined as 5%, it can effectively prevent water vapor from condensing in the alloy or ceramic to form pores, thereby affecting the overall quality and functional performance of the coating. This restriction is based on the fact that aluminum alloy powder is very sensitive to water and is prone to chemical reactions to form hydrogen bubbles in a high humidity environment, so as to avoid microscopic defects caused by these bubbles.

[0105] Next, the present invention is described in which, before the mixed powder is passed through a ball mill to form a uniformly dispersed mixture, first-size medium balls of diameter d1 are filled in a proportion of p inside the ball mill, and then second-size medium balls of d2 are filled in a proportion of q (satisfying the formula q>; p), wherein the first size d1 is larger than the second size d2, to ensure effective contact of the medium balls and to slow down the breakage caused by collision of the medium balls; d1, d2 represent the sizes of the medium balls, d1>; d2, p, q are the filling volume ratios of the two different sizes of balls, respectively; wherein: if the ratio of the sizes of the medium balls d1 and d2 is not appropriate, the efficiency will be reduced and the energy consumption will be increased, and the relationship d1 / ; d2≥5 needs to be satisfied to ensure dispersion and prevent excessive wear.

[0106] The mixed composite ceramic particles and aluminum alloy powder need to be loaded with media balls before undergoing a specific ball milling process. In this process, a batch of larger diameter media balls d1 are first loaded according to the ratio p, which is a value of the space occupied relative to the total volume of the ball mill. After this operation, the smaller second-size media balls d2 are then filled at a higher ratio q. Here, q should be strictly greater than p to ensure the effective distribution of large and small-sized media balls. This mixed filling design can increase the contact opportunities and friction frequency of the materials, making the powder more evenly mixed. At the same time, it can also reduce the direct head-on collisions between media balls of the same diameter, thereby reducing the destructive force caused by severe friction, and helping to extend the life of the mechanical balls and their ancillary systems.

[0107] In practical applications, such as the preparation of composite ceramic particle reinforced aluminum alloy anti-icing coating, a certain proportion p of relatively large steel balls or porcelain beads (d1 = 5mm, assuming p is 30% volume) is pre-filled inside a ball mill. Then, while ensuring that the filled large steel balls or porcelain beads are fully dispersed, a larger number of small diameter beads (d2 = 1mm) are filled at a higher proportion q (q>30%). This ensures that the mixing process will not form a situation where the mixing of other materials is mainly driven by a large ball, but a state that is conducive to both shearing and grinding is formed. This method effectively avoids excessive wear of materials caused by single-size steel balls and improves the processing quality and energy efficiency of the process.

[0108] There is a clear mathematical expression for the requirement d1 / d2 ≥ 5 between the parameters d1 and d2. This relationship is proposed mainly based on experience and research, and is intended to maintain a significant size difference between the two. This design allows large medium balls to provide the required cutting ability and stirring effect, while using smaller balls to make up for the mixing in the fine gaps that the large balls cannot reach, thereby achieving efficient mixing and reducing physical damage to the material itself. The value of a ratio greater than or equal to 5 is the optimal threshold setting obtained from the accumulation of experimental data. It ensures that there is sufficient difference between different particle size ranges for effective mixing while taking into account the durability of the material itself and the effective operation of the mechanical device, preventing unnecessary increase in energy consumption and accumulation of mechanical damage risks.

[0109] Next, the present invention is described in which, before spraying, the initial temperature T1 of the substrate and the preheating temperature T3 of the aluminum alloy powder B are measured based on a temperature sensor to dynamically adjust the heating rate v1 (cm / min) before coating formation to reduce the internal stress concentration of the ceramic particles C caused by the temperature difference; the heating rate v1 is set so that the difference between T1 and the ambient reference temperature ΔT=|T3-Tenvironment|≤5°C, thereby reducing the probability of coating cracking caused by thermal shock to the substrate; ΔT represents the change in substrate temperature relative to the ambient temperature, and Tenvironment is the basic temperature of the environment in which the spraying process is located; if the relationship ΔT=|T3-Tenvironment|<5°C is not satisfied, the v1 value is appropriately adjusted to ensure the coating quality.

[0110] The initial temperature of the substrate T1 refers to the actual temperature of the substrate surface before spraying begins. The preheating temperature T3 of the aluminum alloy powder B refers to the temperature when it is heated to a suitable working state for the spraying process. During the dynamic adjustment process, the heating speed v1 will be dynamically adjusted according to these two temperatures and the ambient temperature to reduce the thermal stress and deformation caused by the temperature difference. The goal of controlling this difference so that the temperature difference is no more than 5 degrees Celsius (that is, ΔT = |T3-Tenvironment|≤5℃) is to minimize the risk of micro-cracks inside the material caused by sudden temperature changes. If the substrate temperature exceeds this limit relative to the ambient temperature, the speed of v1 must be reduced until the required temperature consistency is achieved.

[0111] In a specific example, suppose a manufacturer is using the above method to produce composite coating materials, the base temperature of the environment is 25°C, and according to experiments, the optimal operating temperature of aluminum alloy powder for optimal spraying should be set at around 275°C. Then, before starting spraying, the T1 of the substrate surface at this time should be measured, for example, T1 is detected to be 30°C. In this case, to ensure the success of the spraying process, the heating rate needs to be set to an appropriate value to ensure that the ΔT between the substrate and the surrounding environment does not exceed ±5°C (meaning that the target substrate temperature should be between 20-30°C), so T3 needs to be adjusted accordingly based on this limit.

[0112] If the calculated difference between T1 = 30°C and the ambient temperature (25°C) exceeds the 5°C standard, the heating rate v1 needs to be reduced to ensure that the final temperature difference is controlled within 5°C. For example, the originally calculated initial heating rate may be 2cm / min, and in order to meet the temperature difference control standard, it may need to be reduced to 1.5cm / min or lower until the optimal spraying conditions are achieved.

[0113] Such a design allows for more precise control of the interface characteristics between the material surface and the coating material, reducing the thermal stress caused by improper temperature differences, thus greatly improving the strength and service life of the final product. The selection of parameter T3 is generally based on laboratory optimization tests and is adjusted according to actual conditions; the most ideal v1 is determined by multiple factors such as material properties and substrate characteristics. Through precise monitoring, the temperature difference does not exceed 5°C, which ensures that the thermal shock to the substrate is minimized, further improving the quality and reliability of the coating.

[0114] Next, the present invention is described in which the formed coating J is heat treated according to preset parameters. The heat treatment temperature T4 should be determined based on the coating thickness H and the cooling rate dHdT (μm / s) of the spraying temperature to maintain a uniform temperature distribution throughout the entire treatment process, improve the interface bonding force between the ceramic particles and the aluminum alloy, and promote the uniformity of the microstructure; establish the relationship of T4=H*dHdT+correction coefficient (Tcorr=60), so that the ceramic material can be well crystallized and the residual internal pressure can be minimized without reducing the wettability of the interface; the correction coefficient is used to compensate for theoretical deviations under the influence of other variables; when it is not equal to T4≥1 / 2*H 25, it is necessary to increase the heating time t1 or increase the heat treatment furnace temperature setting to compensate for the insufficient heat treatment amount, so as to optimize the comprehensive performance of the coating.

[0115] First, determine the conditions required for the heat treatment. To achieve this, the actual thickness of the coating, H, must first be taken into account. This thickness parameter is crucial to understanding the required heat input. The cooling rate dHdT refers to the speed at which the coating is cooled from the high temperature at the time of spraying to a specified low temperature; it directly affects how the coating material forms on the aluminum alloy substrate, ensures uniform heat distribution throughout the layer, and improves the quality of the interfacial bond.

[0116] For example, in one embodiment, if the coating design thickness H is set to 500 microns, the cooling rate dHdT after the spraying process is 5 microns per second. This means that it takes a certain amount of time for heat to be transferred from the coating surface to the substrate, and proper control of this cooling rate helps control the development of the material microstructure and the accumulation of stress.

[0117] Specifically, the initial calculation of the heat treatment can be obtained by multiplying the actual cooling thickness H (in micrometers, such as 500 micrometers in the above embodiment) of the coating after spraying by its corresponding cooling rate dHdT (here 5 micrometers per second), and adding a pre-set correction coefficient Tcorr to obtain the optimal heat treatment temperature T4. This correction constant is used to compensate for the deviation of the model in real conditions. Assuming that the correction coefficient is a constant value Tcorr = 60°C, it can be obtained that T4 = H*dHdT + Tcorr, then the optimal temperature of the heat treatment is: T4 = 500μm*5um / s + 60°C = 2560 + 60°C = 2620°C. Please note that in practice this value will be further adjusted according to the actual application.

[0118] However, if the heat treatment temperature does not meet the requirement of at least half the temperature of half the thickness of the coating plus a constant (for example, in this embodiment, T4≠1 / 2×H×25=6250℃+60℃), it means that the existing thermal energy setting is not enough to ensure that the coating is fully sintered or forms sufficient crystallinity; it may be improved by extending the heating time or increasing the overall temperature of the heat treatment process. This step is to ensure that the coating obtains the desired quality characteristics and performance level while preventing overheating from damaging the coating. This optimization of the heat treatment parameters is very important to achieve the expected interface wettability and minimized residual stress.

[0119] Next, the present invention is described in which the surface treatment parameter S is adjusted based on the ratio of the average roughness Ra and the maximum roughness Rz of the coating surface during the above-mentioned heat treatment process, and whether the surface roughness is sufficient to prevent the occurrence of icing during long-term operation is determined by the formula Ra / Rz<7; when the above-mentioned relationship is not achieved, additional treatment is added to reduce Ra or increase Rz to increase friction; wherein Ra represents the arithmetic mean roughness; Rz represents the maximum pit depth of the surface; if the standard is not met, polishing and other means are required until the standard of Ra / Rz≤0.7 is achieved.

[0120] Step 1 involves adjusting the treatment parameters S during the heat treatment process. The heat treatment process is to optimize the performance of the composite ceramic particle reinforced anti-icing coating on the aluminum alloy surface, including the problem of ice accumulation under long-term working conditions by controlling the roughness. In order to achieve the goal, the temperature and time of the treatment and other related factors need to be precisely adjusted.

[0121] As mentioned in the second step, Ra and Rz are the surface arithmetic mean roughness and the vertical distance (Rz) between the maximum profile peak and valley, i.e., the maximum unevenness depth on the surface. If the ratio of these two parameters is less than 7, the surface roughness is considered to meet the standard. This is because a low ratio indicates relatively more uniform surface characteristics, which can reduce the accumulation of ice and snow on the metal. The main purpose of choosing Ra / Rz < 7 is to avoid ice accumulation while ensuring the necessary friction to prevent sliding damage to the coating caused by wind and snow.

[0122] If the Ra / Rz ratio exceeds the predetermined 7, some remedial measures need to be taken, such as mechanical polishing or chemical treatment techniques to reduce Ra, or physical deposition or other methods to increase Rz to enhance the surface friction.

[0123] Specifically, if the Ra / Rz ratio exceeds the threshold after the coating is tested, further operations are required to reduce this ratio to 0.7 or lower to achieve optimal surface characteristics.

[0124] Suppose in an embodiment a company is testing a batch of new aluminum alloy anti-icing coatings. After heat treatment, the roughness index of the coating surface is measured, and Ra = 3μm and Rz = 15μm are obtained. Since the calculated Ra / Rz ratio is 0.2, it clearly meets the anti-icing standard (below 7) and is even more ideal because it further drops into the more recommended range of ≤ 0.7. In this case, no more treatment is needed, and the anti-icing effect of this surface is considered to be the most ideal. However, if the initial ratio is 15 and it is not improved through direct processing techniques, additional operations will be carried out to bring the ratio into the ideal range.

[0125] Next, based on the surface microstructure inspection of the present invention, if it is found that the pore density D (mm-2) and the number of defects F exceed the preset tolerance limit T, measures should be immediately taken to reduce the gas injection rate V (mL / min) until the relationship D*V + F / T < T*50% is satisfied, so as to avoid the problem of poor microstructure uniformity; here D represents the number of pores per unit area, and F refers to the total number of defects.

[0126] The present invention provides a method for preparing a composite ceramic particle reinforced aluminum alloy anti-icing coating, comprising: accurately mixing ceramic particles (such as alumina or zirconium dioxide, etc.) with high strength, high hardness and high temperature resistance and aluminum alloy powder with good formability and high toughness based on a preset ratio; then placing the obtained mixture in a ball mill for long-term and sufficient grinding to achieve a uniform dispersion state at the nanometer or micrometer level, and this refinement treatment helps to improve the contact area and wettability between the particles and the metal phase, thereby solving the problem of unstable interface bonding caused by the initial poor wettability between the particles and the aluminum alloy; then using an efficient and mature thermal spraying process such as high-speed flame spraying, plasma spraying, etc. to form a coating with uniform thickness and good density on the preheated substrate, which can further ensure the formation of an effective metallurgical bond between the ceramic particles and the aluminum alloy during the thermal spraying process; then subjecting the formed coating to a specially designed multi-stage heating and The slow cooling procedure is used to release the residual internal stress and reduce the risk of cracking caused by the difference in thermal expansion coefficients between different materials. For the microstructure problems of the material that may be caused by the change in the use temperature, this heat treatment step also includes adjusting the phase change temperature range of the coating to the operating temperature range, which can effectively prevent the occurrence and expansion of microcracks and ensure that a large amount of stress will not accumulate around the ceramic particles, thereby improving the overall crack resistance and environmental resistance of the coating. Finally, in order to address the problem of the decline in the protective function of the coating, we continuously monitor the use status and respond to the characterization results. If repair is required, the same formula of mixed powder is used for point spraying or local repair to ensure the surface integrity and anti-icing effect. At the same time, in order to improve the micro-uniformity of the coating and reduce the performance degradation caused by the porosity, the spraying process is finely controlled, and the spray deposition method under an inert atmosphere is used to exclude the pores formed by air intervention as much as possible, ensuring the good density of the generated coating structure. Through such a comprehensive solution, the above-mentioned common but critical preparation obstacles are effectively overcome.

[0127] Although the embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and alterations may be made to the embodiments without departing from the principles and spirit thereof, and the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A composite ceramic particle reinforced aluminum alloy anti-icing coating and a preparation method thereof, characterized in that: It includes the following steps: S1: Mix ceramic particles and aluminum alloy powder based on a preset ratio; S2: Make the mixed powder into a uniformly dispersed mixture through a ball mill; S3: Use thermal spraying technology to spray the mixture onto the surface of a substrate to form a coating; S4: Perform heat treatment on the coating based on preset parameters to enhance its anti-icing performance.

2. The method for preparing a composite ceramic particle reinforced aluminum alloy anti-icing coating according to claim 1, characterized in that: The step of mixing ceramic particles and aluminum alloy powder based on a preset ratio specifically includes: S101: Select the ratio P1 of the diameter D of ceramic particles to the diameter d of aluminum alloy powder; S102: Set the mixing ratio M according to the required enhancement effect, that is, the ratio of the weight of ceramic particles to the weight of aluminum alloy powder; S103: Ensure that the ball milling time T1 for ensuring mixing uniformity exceeds the threshold Tmin, where Tmin is calculated based on the volume V of the mixture and the mass Q of the grinding balls, and the calculation method is: Tmin=(V / Q)^5, where V represents the total volume parameter and Q represents the total mass parameter; S104: Further increase the active components in the aluminum alloy powder to promote the wetting and bonding of ceramic particles in the aluminum alloy.

3. The method for preparing a composite ceramic particle reinforced aluminum alloy anti-icing coating according to claim 2, characterized in that: The process of enhancing the coating performance based on heat treatment includes the steps: S401: Set the annealing temperature T annealing not lower than the critical value Tcrit for stress concentration phenomenon to ensure that most of the internal stresses are eliminated; Tcrit>T annealing, where Tcrit represents the critical annealing temperature parameter and T annealing represents the actually used annealing temperature; S402: Perform heat preservation treatment on the coating to ensure the minimum degree of mutual dissolution between ceramics and metals to improve the coating bonding strength and reduce the cracking tendency; S403: Use a rapid cooling method to reduce the difference in thermal expansion coefficients between ceramics and aluminum alloys and reduce the risk of coating cracking and peeling caused thereby; S404: Ensure that the final treatment temperature after annealing meets the requirements for the best performance of the material without causing grain coarsening or other harmful changes.

4. The method for preparing a composite ceramic particle reinforced aluminum alloy anti-icing coating according to claim 3, characterized in that: The heat treatment based on preset parameters during the spraying process is further specified as follows: S405: Set the oxygen content A in the atmosphere in the spraying chamber not exceeding the maximum safety limit Amx to ensure no coating oxidation problem caused by oxygen introduction: A<Amx, A is the real-time oxygen content parameter in the spray booth, and Amx is the maximum safe oxygen content parameter; S406: Use an inert gas purge to prevent oxidation during the spraying process and remove residual gases to improve the spraying quality; S407: Maintain the spraying equipment to ensure the working accuracy and spraying efficiency of the spray gun; S408: Adopt a multi-pass overlapping spraying method to ensure that the microstructure of the coating is uniform and free of cavities.

5. The method for preparing a composite ceramic particle reinforced aluminum alloy anti-icing coating according to claim 4, characterized in that: The conditions for control when preventing the problem of poor microstructure uniformity are as described below: A1: Control the thickness S of each spraying not exceeding the recommended maximum single spraying thickness Smax and satisfy the thickness condition S≤Smax, S is the spraying thickness parameter, and Smax is the recommended maximum spraying thickness parameter, which helps to prevent the blockage of the gas discharge channels in the coating; A2: Add a surfactant in a timely manner or adjust the composition ratio of the spraying material to improve the fluidity of the liquid and reduce voids; A3: Implement auxiliary heating or cooling measures before the coating is completely cured to help remove internal bubbles; A4: Use online detection equipment to monitor the coating deposition rate and spray parameter consistency to avoid micro defects caused by the spraying process.

6. The method for preparing a composite ceramic particle reinforced aluminum alloy anti-icing coating according to claim 5, characterized in that: Take steps to address the issue of long-term protection degradation to ensure long-term performance: Establish a rule that the density distribution C of ceramic particles must exceed a certain limit Cb to ensure the stable attachment of particles: C>Cb, C represents the average concentration level of ceramic particles in the coating, and Cb represents the minimum concentration limit to ensure the integrity of the coating; Adopt regular re-spraying or local reinforcement maintenance strategies to prevent the overall protection capability from deteriorating due to long-term use; Improve the wear resistance, toughness and chemical stability of the coating to adapt to more severe working environments and longer time periods; By selecting a composite coating material with appropriate hardness level and impact resistance to resist external physical damage.

7. The method for preparing a composite ceramic particle reinforced aluminum alloy anti-icing coating according to claim 1, characterized in that: The ceramic particles and aluminum alloy powder are mixed based on a preset ratio, specifically including: Based on the optimal wetting ratio a:b of the ceramic particles A and the aluminum alloy powder B, the ratio x:y=a:b of the ceramic particles A and the aluminum alloy powder B is preset to ensure the optimal physical compatibility between the two to enhance the interface bonding strength; Add in proportion under an inert atmosphere and stir thoroughly to form a stable suspension state to avoid sedimentation and separation of ceramic particles A; Preheating the aluminum alloy powder B to temperature T1 before powder mixing to reduce the stress and crack risk caused by mismatch of thermal expansion coefficient during coating solidification; During the stirring process, the relative humidity is controlled below H3%, thereby suppressing the generation of gas holes and microscopic defects caused by moisture.

8. The method for preparing a composite ceramic particle reinforced aluminum alloy anti-icing coating according to claim 2, characterized in that: Before the mixed powder is passed through a ball mill to form a uniformly dispersed mixture, a first size medium ball of diameter d1 is filled in the ball mill at a ratio of p, and then a second size medium ball of diameter d2 is filled at a ratio of q (satisfying the formula q>p), wherein the first size d1 is larger than the second size d2, to ensure effective contact of the medium balls and slow down the breakage caused by collision between the medium balls; d1, d2 represent the size of dielectric balls, d1>d2, p, q are the filling volume ratios of two different sized balls respectively; Where: If the ratio of the dielectric ball sizes d1 and d2 is not appropriate, the efficiency will be reduced and the energy consumption will increase. Therefore, the relationship d1 / d2≥5 needs to be satisfied to ensure dispersion and prevent excessive wear.

9. The method for preparing a composite ceramic particle reinforced aluminum alloy anti-icing coating according to claim 3, characterized in that: Before spraying, the initial temperature T1 of the substrate and the preheating temperature T3 of the aluminum alloy powder B are measured by a temperature sensor to dynamically adjust the heating rate v1 (cm / min) before coating formation to reduce the internal stress concentration of the ceramic particles C caused by the temperature difference; Set the heating rate v1 so that the difference between T1 and the ambient reference temperature ΔT = T3 T ambient ≤ 5°C, reducing the probability of coating cracking caused by thermal shock to the substrate; ΔT represents the change in substrate temperature relative to the ambient temperature, and Tambient is the base temperature of the environment during the spraying process; If the relationship ΔT=T3 Tenvironment<5℃ is not satisfied, then adjust the v1 value appropriately to ensure the coating quality.

10. The method for preparing a composite ceramic particle reinforced aluminum alloy anti-icing coating according to claim 4, characterized in that: The formed coating J is heat treated according to preset parameters, and the heat treatment temperature T4 should be determined based on the coating thickness H and the cooling rate dHdT (μm / s) of the spraying temperature to maintain a uniform temperature distribution throughout the treatment process, improve the interface bonding strength between the ceramic particles and the aluminum alloy, and promote the uniformity of the microstructure; Establish the relationship of T4 = H*dHdT + correction coefficient (Tcorr = 60), so that the ceramic material can be well crystallized and the residual internal pressure can be minimized without reducing the wettability of the interface; The correction factor is used to compensate for theoretical deviations under the influence of other variables; When it is not equal to T4≥1 / 2*H 25, it is necessary to increase the heating time t1 or increase the heat treatment furnace temperature setting to compensate for the insufficient heat treatment amount in order to optimize the comprehensive performance of the coating.

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