A carbon fiber material workpiece with a surface sprayed stainless steel coating and a method for manufacturing the same

Abstract

The present application relates to the technical field of material, in particular to a kind of carbon fiber material workpiece with surface spray stainless steel coating and preparation method thereof.The carbon fiber material workpiece includes carbon fiber matrix, resin layer arranged on the surface of carbon fiber matrix, transition layer formed on the surface of resin layer and stainless steel layer formed on the surface of transition layer.Compared with prior art, the present application increases transition layer, the arrangement of the transition layer can assist to improve the hardness of surface stainless steel layer on the one hand, and can improve the bonding strength between stainless steel layer and carbon fiber matrix on the other hand, which is beneficial to maintain the service life of carbon fiber material workpiece, especially in the case of higher temperature in use environment, it can ensure that the coating has excellent stability and is not easy to fall off.

Description

Technical Field

[0001] The present invention relates to the field of material technology, and in particular to a carbon fiber material workpiece with a stainless steel coating sprayed on its surface and a preparation method thereof. Background Art

[0002] The main body of the rollers commonly used in current production lines is generally made of metal, which has a good static conductivity effect, but the cost is high, the roller mass is large, and the rotational energy required for operation is also large, which is not conducive to sudden turns and stops. It is easy to corrode after long-term use, and long-term horizontal placement can easily cause the roller body to bend and deform, affecting the accuracy of the roller body.

[0003] Carbon fiber boasts numerous excellent properties, including high strength, high modulus, high-temperature resistance, wear resistance, corrosion resistance, fatigue resistance, creep resistance, electrical and thermal conductivity, and far-infrared radiation. Carbon fiber tubing can be used in textile machinery, aluminum foil machinery, plastic film machinery, papermaking machinery, and printing / dying machinery, addressing the high cost of metal rollers, their susceptibility to corrosion over time, and the tendency for the roller body to bend and deform, affecting roller accuracy.

[0004] In order to give full play to the advantages of metal and carbon fiber materials and avoid their disadvantages, it is considered to spray a metal layer on the surface of the carbon fiber roller. This not only takes advantage of the lightweight and high-strength characteristics of the carbon fiber material itself, but also gives the workpiece surface good impact resistance and wear resistance.

[0005] For example, CN118063986A discloses a method for spraying tungsten carbide onto the surface of a carbon fiber composite material. This method involves spraying a layer of epoxy resin onto the surface of the carbon fiber composite material, then cold-spraying and curing a layer of alloy powder, and finally spraying tungsten carbide powder onto the surface to produce a carbon fiber roller containing a tungsten carbide layer. This method addresses the issue of fragile carbon fiber roller surfaces by forming an adhesive buffer layer with epoxy resin and alloy powder, stably attaching the functional coating to the carbon fiber composite surface. This method reduces process complexity while effectively controlling the probability of roller surface failure and scrapping.

[0006] The carbon fiber roller is expensive and cannot reflect the value of wear-resistant carbon rollers used for general purposes. Summary of the Invention

[0007] The purpose of the present invention is to solve the above-mentioned defects existing in the use of carbon fiber rollers and to provide a carbon fiber material workpiece with a stainless steel coating sprayed on the surface and a preparation method thereof.

[0008] In a first aspect of the present invention, there is provided a carbon fiber workpiece with a stainless steel coating sprayed on its surface, which adopts the following technical solution:

[0009] A carbon fiber material workpiece with a stainless steel coating sprayed on its surface comprises a carbon fiber matrix, a resin layer arranged on the surface of the carbon fiber matrix, a transition layer formed on the surface of the resin layer, and a stainless steel layer formed on the surface of the transition layer.

[0010] Compared with the existing technology mentioned in the background technology, a transition layer is added in this solution. The setting of this transition layer can, on the one hand, help improve the hardness of the surface stainless steel layer, and on the other hand, improve the bonding strength between the stainless steel layer and the carbon fiber matrix, which is beneficial to maintain the service life of the carbon fiber material workpiece, especially when the operating environment temperature is high, it can ensure that the coating has excellent stability and is not easy to fall off.

[0011] Preferably, the transition layer is a transition layer formed by alloy powder.

[0012] Preferably, the alloy powder is doped with magnetic material powder.

[0013] Preferably, the raw material of the stainless steel layer is any one of 304 stainless steel powder, 304L stainless steel powder, 316 stainless steel powder, and 316L stainless steel powder, or a mixture of several of them.

[0014] Preferably, the thickness of the transition layer is greater than the thickness of the resin layer.

[0015] Preferably, a sand layer is formed between the carbon fiber matrix and the resin layer. The sand layer increases the specific surface area of ​​the carbon fiber matrix, which is beneficial to the stable formation of the subsequent coating.

[0016] Preferably, the sand layer is formed by spraying white corundum with a mesh size of 30 to 50.

[0017] A second aspect of the present invention provides a method for preparing the above-mentioned carbon fiber material workpiece with a stainless steel coating sprayed on its surface, comprising the following steps:

[0018] (1) Providing a carbon fiber matrix;

[0019] (2) Clean the substrate surface and sandblast to form a sand layer;

[0020] (3) Spraying hot melt resin on the surface of the substrate with the sand layer formed thereon to form a resin layer;

[0021] (4) Spraying alloy powder on the surface of the resin layer to form a transition layer;

[0022] (5) Spray stainless steel powder on the surface of the transition layer to form a stainless steel layer.

[0023] Preferably, after step (4) and before forming the stainless steel layer, the workpiece is placed under high temperature and high pressure conditions for 20 to 40 minutes.

[0024] Preferably, the high temperature and high pressure conditions are a temperature 10 to 35 degrees Celsius lower than the melting point of the resin and a pressure of 2 to 5 atmospheres.

[0025] Preferably, in step (5), the spraying conditions of the stainless steel layer are: spraying current 400-500A, spraying voltage 30-40V, powder feeding speed 50-100g / min, and coating spraying thickness 250-300 microns.

[0026] By implementing the above technical solution, the present invention has the following advantages compared to the prior art:

[0027] 1. The present invention forms a stainless steel layer on the surface of the carbon fiber matrix, giving the workpiece surface good impact resistance and wear resistance.

[0028] 2. Before the stainless steel layer is formed, a resin layer and an alloy layer are sequentially formed on the surface of the substrate, which improves the connection strength between the stainless steel layer and the substrate and makes the formation of the stainless steel layer more stable.

[0029] 3. Through targeted optimization and improvement of the process, the resin layer and alloy layer are further assisted to provide a strong connection between the stainless steel layer and the substrate. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 FIG. 1 is a schematic diagram of the hierarchical structure of a carbon fiber workpiece according to an embodiment of the present invention.

[0031] In the figure, 101 is a carbon fiber matrix, 102 is a resin layer, 103 is an alloy layer, and 104 is a stainless steel layer. DETAILED DESCRIPTION

[0032] The following describes the embodiments of the present invention by means of specific embodiments. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments. The various details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of the present invention. It should be noted that, in the absence of conflict, the features in the following embodiments and embodiments can be combined with each other. In the embodiments of the present invention, all methods used are conventional methods unless otherwise specified.

[0033] Example 1

[0034] This embodiment provides a carbon fiber roller with a stainless steel coating sprayed on its surface, comprising a carbon fiber roller core, a resin layer disposed on the surface of the carbon fiber roller core, a transition layer formed on the surface of the resin layer, and a stainless steel layer formed on the surface of the transition layer. The roller is prepared as follows:

[0035] S1. Clean the surface of the carbon fiber roller core and sandblast to form a sand layer. Use 30-50 mesh white corundum for sandblasting.

[0036] S2. A resin layer is formed on the surface of the sand layer by spraying. The resin is epoxy resin, and the thickness of the formed resin layer is 100 microns.

[0037] S3. On the surface of the resin layer, an alloy transition layer is formed by spraying. The alloy transition layer uses aluminum alloy powder and has a thickness of 150 microns.

[0038] S4. On the surface of the alloy transition layer, a stainless steel layer is formed by spraying. The stainless steel layer is made of 304 stainless steel powder and is formed by spraying with a thickness of 250 microns.

[0039] Example 2

[0040] This embodiment provides a carbon fiber roller with a stainless steel coating sprayed on its surface, comprising a carbon fiber roller core, a resin layer disposed on the surface of the carbon fiber roller core, a transition layer formed on the surface of the resin layer, and a stainless steel layer formed on the surface of the transition layer. The roller is prepared as follows:

[0041] S1. Clean the surface of the carbon fiber roller core and sandblast to form a sand layer. Use 30-50 mesh white corundum for sandblasting.

[0042] S2. A resin layer is formed on the surface of the sand layer by spraying. The resin is water-based polyurethane, and the thickness of the formed resin layer is 120 microns.

[0043] S3. On the surface of the resin layer, an alloy transition layer is formed by spraying. The alloy transition layer uses aluminum alloy powder and has a thickness of 200 microns.

[0044] S4. On the surface of the alloy transition layer, a stainless steel layer is formed by spraying. The stainless steel layer is made of 304 stainless steel powder and is formed by spraying with a thickness of 280 microns.

[0045] Example 3

[0046] This embodiment provides a carbon fiber roller with a stainless steel coating sprayed on its surface, comprising a carbon fiber roller core, a resin layer disposed on the surface of the carbon fiber roller core, a transition layer formed on the surface of the resin layer, and a stainless steel layer formed on the surface of the transition layer. The roller is prepared as follows:

[0047] S1. Clean the surface of the carbon fiber roller core and sandblast to form a sand layer. Use 30-50 mesh white corundum for sandblasting.

[0048] S2. A resin layer is formed on the surface of the sand layer by spraying. The resin is epoxy resin, and the thickness of the formed resin layer is 100 microns.

[0049] S3. On the surface of the resin layer, an alloy transition layer is formed by spraying. The alloy transition layer uses aluminum alloy powder and has a thickness of 150 microns.

[0050] S4. The roller core having the alloy transition layer formed thereon is placed in a sealed environment at 200° C. and 2 atmospheres for 25 minutes.

[0051] S5. On the surface of the alloy transition layer, a stainless steel layer is formed by spraying. The stainless steel layer is made of 304 stainless steel powder and is formed by spraying with a thickness of 250 microns.

[0052] Example 4

[0053] This embodiment provides a carbon fiber roller with a stainless steel coating sprayed on its surface, comprising a carbon fiber roller core, a resin layer disposed on the surface of the carbon fiber roller core, a transition layer formed on the surface of the resin layer, and a stainless steel layer formed on the surface of the transition layer. The roller is prepared as follows:

[0054] S1. Clean the surface of the carbon fiber roller core and sandblast to form a sand layer. Use 30-50 mesh white corundum for sandblasting.

[0055] S2. A resin layer is formed on the surface of the sand layer by spraying. The resin is polyurethane and the thickness of the formed resin layer is 100 microns.

[0056] S3. On the surface of the resin layer, an alloy transition layer is formed by spraying. The alloy transition layer uses aluminum alloy powder and has a thickness of 150 microns.

[0057] S4. The roller core having the alloy transition layer formed thereon is placed in a sealed environment at 120° C. and 3 atmospheres for 20 minutes.

[0058] S5. On the surface of the alloy transition layer, a stainless steel layer is formed by spraying. The stainless steel layer is made of 304 stainless steel powder and is formed by spraying with a thickness of 250 microns.

[0059] Example 5

[0060] The optimization and improvement based on Example 4 is different from Example 4 in that magnetic nano-ferroferric oxide particles are added to the alloy powder forming the alloy transition layer in S3, and the added mass ratio of aluminum alloy powder to magnetic nano-ferroferric oxide particles is 5:1.

[0061] Example 6

[0062] The optimization and improvement based on Example 4 is different from Example 4 in that magnetic nano-ferroferric oxide particles are added to the alloy powder forming the alloy transition layer in S3.

[0063] Prepared as follows:

[0064] S1. Clean the surface of the carbon fiber roller core and sandblast to form a sand layer. Use 30-50 mesh white corundum for sandblasting.

[0065] S2. A resin layer is formed on the surface of the sand layer by spraying. The resin used is polybutylene terephthalate (PBT), and the thickness of the formed resin layer is 100 microns.

[0066] S3. On the surface of the resin layer, an alloy transition layer is formed by spraying. The alloy transition layer uses aluminum alloy powder and has a thickness of 150 microns.

[0067] S4. On the surface of the alloy transition layer, a magnetic layer is formed by spraying, using magnetic nano-ferroferric oxide particles with a thickness of 30 microns.

[0068] S5. Place the roller core having the alloy transition layer formed thereon in a sealed environment at 120° C. and 3 atmospheres for treatment for 20 minutes.

[0069] S6. On the surface of the alloy transition layer, a stainless steel layer is formed by spraying. The stainless steel layer is made of 304 stainless steel powder and is formed by spraying with a thickness of 250 microns.

[0070] Comparative Example 1

[0071] This comparative example provides a carbon fiber roller with a stainless steel coating sprayed on its surface, comprising a carbon fiber roller core, a resin layer disposed on the surface of the carbon fiber roller core, and a stainless steel layer formed on the surface of the resin layer. The preparation method is as follows:

[0072] S1. Clean the surface of the carbon fiber roller core and sandblast to form a sand layer. Use 30-50 mesh white corundum for sandblasting.

[0073] S2. A resin layer is formed on the surface of the sand layer by spraying. The resin is polyurethane and the thickness of the formed resin layer is 100 microns.

[0074] S3. A stainless steel layer is formed on the surface of the resin layer by spraying. The stainless steel layer is made of 304 stainless steel powder and is formed by spraying with a thickness of 250 microns.

[0075] The difference from Example 1 is that no alloy transition layer is provided.

[0076] The hardness of the coating on the surface of the carbon fiber roller obtained in the above embodiments and comparative examples was tested, and the results are shown in Table 1.

[0077] Table 1 Microhardness of the carbon fiber roller surface coating obtained in each embodiment and comparative example

[0078] Carbon fiber roller Microhardness (HV0.1) Example 1 563 Example 2 568 Example 3 604 Example 4 610 Example 5 601 Example 6 606 Comparative Example 1 324

[0079] As can be seen from Table 1, the surface hardness of the coating without the alloy transition layer is lower than that of the solution with the alloy transition layer in each embodiment, which shows that the setting of the alloy transition layer can assist the surface stainless steel layer and improve the hardness of the coating.

[0080] In this embodiment, in order to study the stability of the stainless steel layer, its bonding strength was tested. The test scheme refers to the standard ASTM D4541. The test results are shown in Table 2.

[0081] Table 2 Bonding strength of carbon fiber roller surface coating obtained in each embodiment and comparative example

[0082] Carbon fiber roller Bonding strength (MPa) Example 1 24.4 Example 2 25.1 Example 3 36.4 Example 4 37.2 Example 5 40.1 Example 6 45.8 Comparative Example 1 16.6

[0083] As shown in Table 2, the bonding strength of the stainless steel layer in each embodiment of the present invention can reach over 24 MPa. In contrast, the coating bonding strength in Comparative Example 1, which lacks an alloy transition layer, is only 16.6 MPa, lower than that of the embodiment employing an alloy transition layer. This demonstrates that the provision of an alloy transition layer can help improve the bonding strength of the coating. A comparison of Examples 3 and 4 with Examples 1 and 2 reveals that high-temperature and high-pressure treatment after forming the alloy transition layer is beneficial for improving the bonding strength of the coating. Examples 5 and 6 demonstrate that the addition of magnetic particles further enhances the bonding strength of the coating. In particular, Example 6, in which the magnetic particle coating is formed independently, exhibits a greater improvement in the bonding strength of the coating than a mixture of magnetic particles and alloy powder.

Claims

1. A method for preparing a carbon fiber workpiece with a stainless steel coating sprayed on its surface, characterized in that: The steps include: S1. Providing a carbon fiber matrix; S2. Clean the substrate surface and sandblast to form a sand layer; S3 is formed on the surface of the substrate having a sand layer sprayed with a hot melt resin to form a resin layer; S4. Spraying alloy powder on the surface of the resin layer to form a transition layer; S5. On the surface of the alloy transition layer, a magnetic layer is formed by spraying, using magnetic nano-iron tetroxide particles with a thickness of 30 microns; S6. The workpiece is placed under high temperature and high pressure conditions for 20 to 40 minutes, wherein the high temperature and high pressure conditions are a temperature 10 to 35 degrees Celsius below the melting point of the resin and a pressure of 2 to 5 atmospheres; S7. Spray stainless steel powder on the surface of the transition layer to form a stainless steel layer.

2. The method for preparing a carbon fiber workpiece with a stainless steel coating sprayed on its surface according to claim 1, characterized in that: The raw material of the stainless steel layer is any one of 304 stainless steel powder, 304L stainless steel powder, 316 stainless steel powder, and 316L stainless steel powder, or a mixture of several of them.

3. The method for preparing a carbon fiber workpiece with a stainless steel coating sprayed on its surface according to claim 1, characterized in that: The thickness of the transition layer is greater than the thickness of the resin layer.

4. The method for preparing a carbon fiber workpiece with a stainless steel coating sprayed on its surface according to claim 1, characterized in that: A sand layer is further formed between the carbon fiber matrix and the resin layer.

5. The method for preparing a carbon fiber workpiece with a stainless steel coating sprayed on its surface according to claim 4, characterized in that: The sand layer is formed by spraying white corundum with a mesh size of 30 to 50.

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