An aluminum-based ceramic composite coating, its preparation method and application

Abstract

The present invention discloses an aluminum-based ceramic composite coating, a preparation method thereof and an application thereof, belonging to the technical field of material surface engineering and remanufacturing. The preparation method comprises the following steps: Step 1, subject alumina ceramic particles and titanium powder to acoustic resonance mixing to obtain a metal-coated ceramic composite powder with a core-shell structure; Step 2, wrap the above composite powder with an aluminum alloy outer skin and obtain an aluminum-based ceramic cored wire by a drawing process; Step 3, spray the above cored wire by using a high-speed arc spraying technique, and obtain an aluminum-based ceramic composite coating through an arc-zone dynamic metallurgical self-propagating exothermic reaction. The present invention effectively solves the technical problems of easy corrosion, wear and spalling and other failures of traditional arc-sprayed alumina / aluminum composite coatings under severe service environments, and can be used for the manufacturing and operation and maintenance of key components of equipment in fields such as aerospace, water conservancy and ocean, and national defense science and technology that serve in extreme working conditions.

Description

Technical Field

[0001] The present invention relates to an aluminum-based ceramic composite coating, a preparation method and an application thereof, and particularly relates to a method, a coating and an application for improving the bonding strength of an aluminum-based ceramic composite coating based on a dynamic metallurgical self-propagating exothermic reaction, belonging to the technical field of material surface engineering and remanufacturing. Background Art

[0002] Marine engineering equipment is a material prerequisite for expanding marine space and developing marine resources. However, marine equipment serves in a harsh marine environment for a long time, and it is inevitable to suffer from corrosion damage, abrasion failure and biofouling, which brings huge economic losses. The advanced high-speed arc spraying technology is one of the key technologies for realizing large-area corrosion protection of marine engineering. By preparing high-performance coatings, the surface performance of key components of marine engineering equipment can be improved and the service life can be extended, which is an important way to improve the overall level of China's marine engineering equipment. However, the marine environment involves complex factors in multiple fields such as meteorology, fluid, physics, chemistry and biology. With the continuous expansion of China's marine cause towards "ocean-going and deep-sea", the traditional thermal spraying aluminum and aluminum alloy coatings are difficult to meet the long-life protection system of engineering components in a harsh marine environment due to their low bonding strength (≤18 MPa), poor wear resistance (hardness ≤ 60 HV), insufficient corrosion resistance (neutral salt spray resistance < 380 h), etc. The comprehensive performance can be improved by adding ceramic reinforcing phases. Al2O3 ceramic is a material with high strength, high hardness and excellent corrosion resistance, and is often used in many fields such as aerospace, machinery, chemical industry, etc. Although the Al2O3 / Al composite coating has high hardness and friction coefficient, due to the presence of a large number of hard ceramic phases in the coating, during the spraying heating and cooling process, the coating will generate large thermal stress, resulting in low toughness of the coating. At the same time, there are disadvantages such as large linear expansion coefficient and poor wettability between the Al2O3 ceramic and the Al metal matrix, resulting in low bonding strength of the coating (≤20 MPa); and due to the presence of a weak metal phase in the coating, the metal phase is still the weak link of the cermet coating wear. Especially in a heavy load, corrosion, high-temperature alternating wear environment, due to the insufficient bonding strength between the Al2O3 ceramic and the Al metal matrix, and the weak strength and corrosion resistance of the Al metal phase, the wear, corrosion, tearing and peeling effects on the coating are significantly aggravated, thus restricting the service life of the composite coating. Therefore, how to improve the bonding strength of the aluminum-based ceramic coating to improve the overall mechanical properties of the coating has become an urgent technical problem in this field. Summary of the Invention

[0003] In order to solve the technical problem of poor bonding strength between aluminum alloy coatings and aluminum / aluminum oxide ceramic composite coatings, the object of the present invention is to provide a preparation method for aluminum-based ceramic composite coatings. To achieve this idea, starting from the core-shell structure of micro-nano titanium metal-coated alumina ceramics, the aim is to promote a self-propagating exothermic reaction between nano-titanium in the cored wire and the aluminum alloy outer skin through rapid dynamic physical and chemical metallurgy in the high-temperature arc zone of arc spraying. This expands the solid and liquid phase ranges, improves the wettability at the interface between aluminum and alumina ceramics, forms an interface with the alumina ceramic phase, while enhancing the bonding strength between ceramic particles and the metal matrix, reducing splashing, enabling more alumina ceramic particles to be deposited in the coating, and increasing the coating density, thereby further enhancing the bonding strength, corrosion resistance, and wear resistance of the composite coating. Therefore, the aluminum-based ceramic coating prepared by the method of the present invention can obtain high cohesive bonding strength and interfacial bonding strength, and at the same time has anti-slip and excellent wear and corrosion resistance properties.

[0004] Meanwhile, the present invention provides an aluminum-based ceramic composite coating, which can obtain high cohesive bonding strength and interfacial bonding strength, and at the same time has anti-slip and excellent wear and corrosion resistance properties.

[0005] Meanwhile, the present invention provides an application of the aluminum-based ceramic composite coating in key components of aerospace, water conservancy and ocean, and national defense equipment.

[0006] To solve the above technical problems, the technical solution adopted by the present invention is as follows:

[0007] A preparation method for an aluminum-based ceramic composite coating, comprising the following steps:

[0008] Step 1: Sonic resonance mix alumina ceramic particles and titanium powder to obtain a metal-coated ceramic composite powder with a core-shell structure;

[0009] Step 2: Wrap the above composite powder with an aluminum alloy outer skin and obtain an aluminum-based ceramic cored wire through a drawing process;

[0010] Step 3: Spray the above cored wire using high-speed arc spraying technology, and obtain an aluminum-based ceramic composite coating through dynamic metallurgical self-propagating exothermic reaction in the arc zone.

[0011] Preferably, in Step 1, the particle sizes of the titanium powder and the alumina ceramic particles are 30-50 nm and 150-200 μm respectively; the mass ratio is (0.1-1):(99.9-99).

[0012] Preferably, in step one, the method of acoustic resonance mixing is as follows: First, set the acceleration at 50 - 60 g, adjust the vibration frequency to 50 - 60 Hz, then increase it from 50 - 60 Hz to 120 - 140 Hz at a rate of 14 - 30 Hz / min within 3 - 5 min, then decrease it to 0 Hz at a rate of 30 - 50 Hz / min, stop for 1 - 2 min, then adjust it to 50 - 60 Hz within 30 s, then increase it from 50 - 60 Hz to 120 - 140 Hz at a rate of 14 - 30 Hz / min within 3 - 5 min, then decrease it to 0 Hz at a rate of 30 - 50 Hz / min, stop for 1 - 2 min, and repeat this process until the total time is 15 - 30 min.

[0013] Preferably, in step two, the outer skin of the powder core is an aluminum alloy strip, the filling rate of the powder core wire is 45% - 55%; the diameter of the powder core wire is 3 ± 0.1 mm.

[0014] Preferably, the aluminum alloy strip is 5054 aluminum alloy strip.

[0015] Preferably, in step three, the spraying process is as follows: spraying voltage 35 - 45 V, current 250 - 350 A, spraying pressure 0.6 - 0.7 MPa, spraying distance 100 - 200 mm.

[0016] For the aluminum - based ceramic composite coating obtained by using the preparation method of an aluminum - based ceramic composite coating of the present invention, the volume fraction of alumina ceramic in the coating ≥ 45 vol%.

[0017] For the aluminum - based ceramic composite coating of the present invention, the coating bonding strength ≥ 35 MPa, the average hardness ≥ 650 HV0.1, the porosity ≤ 1%, the neutral salt spray resistance performance ≥ 3000 h; the coating friction coefficient is ≥ 1.05 both in the dry state and the artificial seawater wet state, and the coating friction coefficient ≥ 0.9 under lubricating oil conditions; after being scoured by an oxy - acetylene flame flow at 1500 °C for 20 s, the neutral salt spray resistance performance of the coating ≥ 800 h.

[0018] The application of the aluminum - based ceramic composite coating of the present invention in key components of aerospace, water conservancy and ocean, and national defense equipment, the key components include ship flight decks, hulls and drilling platforms; the ship flight deck includes the take - off and landing area of carrier - based aircraft on large - ship flight decks.

[0019] A ship flight deck is prepared by using the aluminum - based ceramic composite coating of the present invention.

[0020] Specifically, for a method for preparing an aluminum-based ceramic composite coating of the present invention, first, nano titanium metal powder and alumina ceramic particles are weighed and packaged separately at room temperature, dried in a vacuum drying oven at 100-120°C for 2-3 hours, and then naturally cooled and stored in a dry environment. The packaged nano titanium metal powder and alumina ceramic particles are placed in an acoustic resonance mixing container according to a mass percentage of (0.1-1):(99.9-99). Among them, the particle size of the nano titanium metal powder is 30-50 nm, the particle size of the alumina ceramic is 150-200 μm, and the capacity of the mixing container is 500 ml. After the mixing container is filled with argon gas, frequency conversion-intermittent acoustic resonance mixing is carried out at room temperature. After the acoustic resonance mixing is completed, the processed powder is collected, evacuated and sealed for storage, and the nano titanium metal-coated alumina ceramic composite powder with a core-shell structure is obtained. Secondly, the 5054 aluminum alloy strip is tied into a U shape, and the above composite powder is added into the U-shaped groove with a filling rate of 45%-55%; the U-shaped groove is closed to wrap the powder in it, and then gradually reduced in diameter to a finished wire of Φ3±0.1 mm through a wire drawing die. Finally, a high-speed arc spraying technique is used to prepare an aluminum-based composite ceramic coating on a steel substrate after sandblasting and roughening.

[0021] Beneficial effects: Compared with the prior art, the present invention has the following advantages:

[0022] (1) Aiming at the technical problem of low bonding strength of the traditional arc-sprayed aluminum / alumina ceramic composite coating, based on the fact that self-propagating exothermic reaction can occur between aluminum and titanium metals (generating -142.25 KJ / mol of heat), the present invention proposes to add a small amount of titanium metal to the powder core material, and realize the self-propagating exothermic reaction between titanium and aluminum metals in the rapid dynamic physical and chemical metallurgical process in the high-temperature arc zone of arc spraying to expand the liquid phase and solid phase intervals, improve the wettability between the liquid metal and the ceramic particles and between the coating and the substrate, and promote the bonding between the metal and the ceramic phase to enhance the bonding strength. The design idea realizes the preparation of an aluminum-based ceramic coating with high bonding strength.

[0023] (2) By designing the "core-shell structure of nano titanium metal-coated alumina ceramic", the problems of mechanical distribution between traditional cermets and the uniform distribution of trace additives after ball milling are effectively avoided, while improving the bonding strength of the aluminum-based ceramic composite coating, the overall service life is also improved; and all the process flows can be completed by using the low-cost high-speed arc spraying technique, which greatly improves the preparation production efficiency and is beneficial to industrialization development.

[0024] (3) By improving the interfacial bonding state between the aluminum matrix and alumina ceramics, utilizing the load-bearing effect of high-hardness alumina ceramic particles and the high-toughness metal aluminum matrix to absorb the impact and frictional forces on the coating to inhibit and reduce the initiation and development of coating cracks, and with the good matching of their physical and chemical properties, the integration of high strength and toughness of the coating with high ceramic content is achieved, which can be used for the manufacturing and operation and maintenance of key components of equipment in the fields of aerospace, water conservancy and ocean, national defense science and technology, etc. serving in extreme working conditions, and has important economic value and popularization significance.

[0025] (4) The aluminum-based ceramic composite coating obtained by the present invention can be used in normal-temperature strong corrosion areas such as ship decks, hulls and drilling platforms, and can also be used in the take-off and landing areas of carrier-based aircraft on the flight decks of large ships. The anti-slip coating of the present invention can not only withstand the scouring of high-temperature tail flame flow during the take-off and landing of carrier-based aircraft, but also has the functions of strong corrosion resistance, high-temperature alternating wear and corrosion resistance, and can significantly improve the service life of the flight decks of large ships.

[0026] The present invention discloses an aluminum-based ceramic composite coating, its preparation method and application, including the following steps: First, alumina ceramic particles and titanium powder are subjected to acoustic resonance mixing to obtain a metal-coated ceramic composite powder with a core-shell structure; secondly, the above composite powder is wrapped with an aluminum alloy outer skin and obtained an aluminum-based ceramic cored wire through a drawing process; finally, the above cored wire is sprayed using high-speed arc spraying technology under preset process parameters, and through the dynamic metallurgical self-propagating exothermic reaction in the arc zone, the preparation of an aluminum-based ceramic composite coating with high bonding strength is realized. Based on the self-propagating exothermic chemical reaction between metal aluminum and titanium, the present invention proposes a design idea of an aluminum-based cored wire with a core-shell structure of nano-titanium metal-coated alumina ceramics, and uses the high-temperature arc zone of high-speed arc spraying for rapid dynamic physical and chemical metallurgy to promote an exothermic reaction between each component, improving the wettability between metal aluminum and alumina ceramics and forming an interfacial bond with it. While improving the bonding strength of the aluminum-based ceramic composite coating, the ceramic content and density in the coating are increased, and the wear resistance and corrosion resistance of the aluminum-based ceramic composite coating are further improved. The present invention effectively solves the technical problems of easy corrosion, wear and peeling of traditional arc-sprayed alumina / aluminum composite coatings in harsh service environments, and can be used for the manufacturing and operation and maintenance of key components of equipment in the fields of aerospace, water conservancy and ocean, national defense science and technology, etc. serving in extreme working conditions. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 is the appearance morphology diagram of the core-shell type composite powder prepared in Example 1;

[0028] Figure 2 is the cross-sectional morphology diagram of the coating prepared in Example 2;

[0029] Figure 3 is the X-ray diffraction pattern of the coating prepared in Example 3;

[0030] Figure 4 It is the surface morphology diagram of the coating prepared in Example 3 after the neutral salt spray test;

[0031] Figure 5 It is the average hardness distribution of the coating prepared in Example 4;

[0032] Figure 6 It is the bonding strength distribution diagram of the coating prepared in Example 5;

[0033] Figure 7 It is the potentiodynamic polarization curve diagram of the coating prepared in Example 6. Detailed implementation manners

[0034] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. The following embodiments are only used to illustrate the present invention and are not used to limit the scope of the present invention.

[0035] Unless otherwise specified, other materials and raw materials used in the present invention are all conventional raw materials that can be purchased from the market. The technical means used are conventional means well known to those skilled in the art.

[0036] The test methods adopted in the embodiments are as follows:

[0037] (1) Use an X-ray diffractometer to determine the phase structure of the prepared sample.

[0038] (2) Use a scanning electron microscope to observe the morphology of the prepared powder.

[0039] (3) Use a Vickers hardness tester to measure the microhardness of the coating.

[0040] (4) Use an electrochemical workstation to measure the electrochemical corrosion performance of the coating.

[0041] (5) Use a tensile bonding strength test to measure the bonding strength of the coating.

[0042] (6) Use a salt spray test chamber to test the neutral salt spray resistance of the coating.

[0043] Example 1

[0044] A method for preparing an aluminum-based ceramic composite coating, the steps of the method are as follows: First, weigh and package nano titanium metal powder and alumina ceramic particles respectively at room temperature, dry them in a vacuum drying oven at 120 °C for two hours and then cool naturally and store them in a dry environment. Place the packaged nano titanium metal powder and alumina ceramic particles in a sonic resonance mixing container according to a mass percentage of 0.1:99.9. Among them, the particle size of the nano titanium metal powder is 50 nm, the particle size of the alumina ceramic is 200 μm, and the capacity of the mixing container is 500 ml. After filling the mixing container with argon gas, perform sonic resonance mixing in a room temperature environment. The process of sonic resonance mixing is: first set the acceleration of sonic resonance to 50 g, then adjust the vibration frequency to 50 Hz, then increase from 50 Hz to 120 Hz at a rate of 14 Hz / min within 5 min, then decrease to 0 Hz at a rate of 30 Hz / min, stop for 1 min, then adjust to 50 Hz within 30 s, then increase from 50 Hz to 120 Hz at a rate of 14 Hz / min within 5 min, then decrease to 0 Hz at a rate of 30 Hz / min, stop for 1 min, and repeat this process until the total time is 30 min. After completion, collect the processed powder, evacuate and seal it for storage to obtain a core-shell structured nano titanium metal-coated alumina ceramic composite powder. Secondly, tie a 5054 aluminum alloy strip into a U shape, add the above composite powder into the U-shaped groove, and the filling rate is 50%; close the U-shaped groove so that the powder is coated therein, and then gradually reduce the diameter to a Φ3 mm finished wire through a wire drawing die. Finally, use the high-speed arc spraying technology to prepare an aluminum-based composite ceramic coating on a steel substrate after sandblasting roughening. The spraying process parameters are: spraying voltage is 35 V, spraying current is 280 A, spraying distance is 200 mm, and spraying air pressure is 0.7 MPa.

[0045] The volume fraction of alumina ceramic in the coating is 45 vol%.

[0046] Figure 1 For the appearance morphology diagram of the core-shell composite powder prepared in Example 1, it can be seen that the composite powder has a core-shell structure and the metal coating layer is dense and complete. The average hardness of the aluminum-based ceramic composite coating is 661 HV, the porosity is 0.9%, the average bonding strength is 35 MPa, and the coating has a neutral salt spray resistance of 3000 h; the friction coefficient of the coating is 1.05 both in the dry state and the artificial seawater wet state, and the friction coefficient of the coating under lubricating oil conditions is 0.9; after being flushed by an oxyacetylene flame flow at 1500 °C for 20 s, the neutral salt spray resistance of the coating is 800 h.

[0047] An aluminum-based ceramic composite coating obtained by using the method for preparing an aluminum-based ceramic composite coating of this example.

[0048] The application of the aluminum-based ceramic composite coating of this embodiment in key components of aerospace, water conservancy and ocean, and national defense equipment, where the key components include ship flight decks, hulls and drilling platforms; the ship flight deck includes the takeoff and landing area of carrier-based aircraft on large ship flight decks.

[0049] A ship flight deck is prepared by using the aluminum-based ceramic composite coating of this embodiment.

[0050] Example 2

[0051] A preparation method of an aluminum-based ceramic composite coating, the steps of the method are as follows: First, weigh and package nano titanium metal powder and alumina ceramic particles respectively at room temperature, dry them in a vacuum drying oven at 120°C for two hours and then cool naturally and store them in a dry environment. Place the packaged nano titanium metal powder and alumina ceramic particles in a sonic resonance mixing container according to a mass percentage of 0.3:99.7. Among them, the particle size of the nano titanium metal powder is 40nm, the particle size of the alumina ceramic is 180μm, and the capacity of the mixing container is 500ml. After filling the mixing container with argon gas, perform sonic resonance mixing in a room temperature environment. The process of sonic resonance mixing is: first set the acceleration of sonic resonance to 60g, then adjust the vibration frequency to 50Hz, then increase it from 50Hz to 140Hz at a rate of 30Hz / min within 3min, then decrease it to 0Hz at a rate of 50Hz / min, stop for 2min, then adjust it to 50Hz within 30s, then increase it from 50Hz to 140Hz at a rate of 30Hz / min within 3min, then decrease it to 0Hz at a rate of 50Hz / min, stop for 2min, and repeat this process until the total time is 20min. After completion, collect the processed powder, vacuumize and seal it for storage to obtain the core-shell structured nano titanium metal-coated alumina ceramic composite powder. Second, tie the 5054 aluminum alloy strip into a U shape, add the above composite powder into the U-shaped groove, and the filling rate is 45%; close the U-shaped groove to wrap the powder in it, and then gradually reduce the diameter to Φ3mm finished wire through a wire drawing die. Finally, use the high-speed arc spraying technology to prepare an aluminum-based composite ceramic coating on the steel substrate after sandblasting roughening. The spraying process parameters are spraying voltage of 35V, spraying current of 250A, spraying distance of 150mm, and spraying air pressure of 0.65MPa.

[0052] The volume fraction of alumina ceramic in the coating is 48vol%.

[0053] Figure 2For the preparation of the cross-sectional morphology diagram of the coating in Example 2, it can be seen that the composite coating has a compact structure, dense organization, and good bonding with the substrate. After testing, the average porosity of the coating is 0.75%, the coating bonding strength is 38.2 MPa, and the average hardness of the coating is 673 HV. The coating has a neutral salt spray resistance performance of 3500 h; the friction coefficients of the coating are 1.09 and 1.06 under dry and artificial seawater wet conditions respectively, and the friction coefficient of the coating under lubricating oil conditions is 0.92; after being flushed by an oxyacetylene flame flow at 1500 °C for 20 s, the neutral salt spray resistance performance of the coating is 880 h.

[0054] An aluminum-based ceramic composite coating obtained by using the preparation method of an aluminum-based ceramic composite coating of this example.

[0055] The application of the aluminum-based ceramic composite coating of this example in key components of aerospace, water conservancy and ocean, and national defense equipment, and the key components include ship flight decks, hulls, and drilling platforms; the ship flight deck includes the carrier aircraft takeoff and landing area of a large ship flight deck.

[0056] A ship flight deck prepared by using the aluminum-based ceramic composite coating of this example.

[0057] Example 3

[0058] A method for preparing an aluminum-based ceramic composite coating, the method steps are as follows: First, weigh and package nano titanium metal powder and alumina ceramic particles respectively at room temperature, dry them in a vacuum drying oven at 100 °C for 3 hours, then cool naturally and store them in a dry environment. Place the packaged nano titanium metal powder and alumina powder in a sound resonance mixing container according to a mass percentage of 1:99. Among them, the particle size of the nano titanium metal powder is 30 nm, the particle size of the alumina ceramic is 200 μm, and the capacity of the mixing container is 500 ml. After filling the mixing container with argon gas, perform sound resonance mixing at room temperature. The process of sound resonance mixing is: first set the acceleration of sound resonance to 50 g, then adjust the vibration frequency to 60 Hz, then increase from 60 Hz to 140 Hz at a rate of 26.7 Hz / min within 3 min, then decrease to 0 Hz at a rate of 40 Hz / min, stop for 1.5 min, then adjust to 60 Hz within 30 s, then increase from 60 Hz to 140 Hz at a rate of 26.7 Hz / min within 3 min, then decrease to 0 Hz at a rate of 40 Hz / min, stop for 1.5 min, and repeat this process until the total time is 25 min. After completion, collect the processed powder, evacuate and seal it for storage, and obtain the core-shell structured nano titanium metal-coated alumina ceramic composite powder. Second, tie the 5054 aluminum alloy strip into a U shape, add the above composite powder into the U-shaped groove, and the filling rate is 55%; close the U-shaped groove to wrap the powder in it, and then gradually reduce the diameter to Φ3 mm finished wire through a wire drawing die. Finally, use the high-speed arc spraying technology to prepare an aluminum-based composite ceramic coating on the steel substrate after sandblasting roughening. The spraying process parameters are spraying voltage of 45 V, spraying current of 300 A, spraying distance of 180 mm, and spraying air pressure of 0.7 MPa.

[0059] The volume fraction of alumina ceramic in the coating is 47 vol%.

[0060] Figure 3 For the X-ray diffraction pattern of the coating prepared in Example 3, it can be seen that the microstructure of the pure aluminum coating is mainly composed of α-Al, while the microstructure of the aluminum-based ceramic coating is mainly composed of α-Al and α-Al2O3. After testing, the average porosity of the aluminum-based ceramic composite coating is 0.5%, the coating bonding strength is 41.3 MPa, the average hardness of the coating is 726 HV; the coating has a neutral salt spray resistance of 3000 h; the friction coefficients of the coating are 1.08 and 1.06 under dry and artificial seawater wet conditions respectively, and the friction coefficient of the coating under lubricating oil conditions is 0.95; after being flushed by an oxyacetylene flame flow at 1500 °C for 20 s, the neutral salt spray resistance of the coating is 950 h.

[0061] Figure 4It is the surface morphology diagram of the coating prepared in Example 3 after the neutral salt spray test. The arc-sprayed zinc-aluminum coating is used as a comparative coating. It can be seen that there is a large amount of white rust on the surface of the zinc-aluminum coating after 144 hours of the neutral salt spray test, indicating that serious corrosion behavior has occurred in the coating at this time; however, after 3000 hours of the neutral salt spray test on the aluminum-based ceramic composite coating prepared in this example, there are no failure phenomena such as white rust and bulging on the surface of the coating, indicating that the aluminum-based ceramic coating prepared in this example has excellent corrosion resistance.

[0062] The aluminum-based ceramic composite coating obtained by using the preparation method of an aluminum-based ceramic composite coating of this example.

[0063] The application of the aluminum-based ceramic composite coating of this example in key components of aerospace, water conservancy and ocean, and national defense equipment. The key components include ship flight decks, hulls and drilling platforms; the ship flight decks include the take-off and landing areas of carrier-based aircraft on large ship flight decks.

[0064] A ship flight deck obtained by using the aluminum-based ceramic composite coating of this example.

[0065] Example 4

[0066] A preparation method of an aluminum-based ceramic composite coating, the method steps are as follows: First, weigh and package nano titanium metal powder and alumina ceramic particles respectively at room temperature, dry them in a vacuum drying oven at 120 °C for two hours and then cool naturally and store in a dry environment. Place the packaged nano titanium metal powder and alumina ceramic particles in a sonic resonance mixing container according to a mass percentage of 0.8:99.2. Among them, the particle size of the nano titanium metal powder is 50 nm, the particle size of the alumina ceramic is 200 μm, and the capacity of the mixing container is 500 ml. After filling the mixing container with argon gas, conduct sonic resonance mixing in a room temperature environment. The process of sonic resonance mixing is: first set the acceleration of sonic resonance to 50 g, then adjust the vibration frequency to 55 Hz, then increase from 55 Hz to 130 Hz at a rate of 18.75 Hz / min within 4 min, then decrease to 0 Hz at a rate of 45 Hz / min, stop for 1 min, then adjust to 55 Hz within 30 s, then increase from 55 Hz to 130 Hz at a rate of 18.75 Hz / min within 4 min, then decrease to 0 Hz at a rate of 45 Hz / min, stop for 1 min, and repeat this process until the total time is 30 min. After completion, collect the processed powder, evacuate and seal it for storage to obtain the core-shell structured nano titanium metal-coated alumina ceramic composite powder. Secondly, tie the 5054 aluminum alloy strip into a U shape, add the above composite powder into the U-shaped groove, and the filling rate is 48%; close the U-shaped groove to wrap the powder in it, and then gradually reduce the diameter to Φ3 mm finished wire through a wire drawing die. Finally, use the high-speed arc spraying technology to prepare an aluminum-based composite ceramic coating on the steel substrate after sandblasting roughening. The spraying process parameters are spraying voltage of 42 V, spraying current of 350 A, spraying distance of 120 mm, and spraying air pressure of 0.6 MPa.

[0067] The volume fraction of alumina ceramic in the coating is 49 vol%.

[0068] Figure 5 For the average hardness distribution of the coating prepared in Example 4, it can be seen that the average hardness of the aluminum-based ceramic coating is 721 HV, which is much higher than that of the pure aluminum coating. After testing, the average porosity of the aluminum-based ceramic composite coating is 0.68%, and the coating bonding strength is 36.5 MPa. The coating's resistance to neutral salt spray is 3500 h; the friction coefficients of the coating in the dry state and the artificial seawater wet state are 1.1 and 1.08 respectively, and the friction coefficient of the coating under lubricating oil conditions is 0.97; after being flushed by an oxyacetylene flame flow at 1500 °C for 20 s, the coating's resistance to neutral salt spray is 850 h.

[0069] An aluminum-based ceramic composite coating obtained by using the preparation method of an aluminum-based ceramic composite coating of this example.

[0070] The application of the aluminum-based ceramic composite coating of this embodiment in key components of aerospace, water conservancy and ocean, and national defense equipment, where the key components include ship flight decks, hulls, and drilling platforms; the ship flight deck includes the takeoff and landing area of carrier-based aircraft on large ship flight decks.

[0071] A ship flight deck is prepared by using the aluminum-based ceramic composite coating of this embodiment.

[0072] Example 5

[0073] A preparation method of an aluminum-based ceramic composite coating, the steps of the method are as follows: First, weigh and package nano titanium metal powder and alumina ceramic particles respectively at room temperature, dry them in a vacuum drying oven at 120 °C for two hours and then cool naturally and store them in a dry environment. Place the packaged nano titanium metal powder and alumina ceramic particles in a sono-resonance mixing container according to a mass percentage of 0.5:99.5. Among them, the particle size of the nano titanium metal powder is 50 nm, the particle size of the alumina ceramic is 150 μm, and the capacity of the mixing container is 500 ml. After filling the mixing container with argon gas, perform sono-resonance mixing in a room temperature environment. The process of sono-resonance mixing is: first set the acceleration of sono-resonance to 50 g, then adjust the vibration frequency to 60 Hz, then increase from 60 Hz to 120 Hz at a rate of 20 Hz / min within 3 min, then decrease to 0 Hz at a rate of 50 Hz / min, stop for 1 min, then adjust to 60 Hz within 30 s, then increase from 60 Hz to 120 Hz at a rate of 20 Hz / min within 3 min, then decrease to 0 Hz at a rate of 50 Hz / min, stop for 1 min, and repeat this process until the total time is 15 min. After completion, collect the processed powder, vacuumize and seal it for storage to obtain the core-shell structured nano titanium metal-coated alumina ceramic composite powder. Second, tie a 5054 aluminum alloy strip into a U shape, add the above composite powder into the U-shaped groove, and the filling rate is 52%; close the U-shaped groove to wrap the powder in it, and then gradually reduce the diameter to Φ3 mm finished wire through a wire drawing die. Finally, use the high-speed arc spraying technology to prepare an aluminum-based composite ceramic coating on a steel substrate after sandblasting roughening. The spraying process parameters are spraying voltage of 44 V, spraying current of 290 A, spraying distance of 100 mm, and spraying air pressure of 0.7 MPa.

[0074] The volume fraction of alumina ceramic in the coating is 48 vol%.

[0075] Figure 6The bonding strength distribution diagram of the coating prepared in Example 5. It can be seen that the average bonding strength of the aluminum-based ceramic coating is 39.2 MPa, which is 3.1 times that of the pure aluminum coating. After testing, the average porosity of the aluminum-based ceramic composite coating is 0.82%, the average hardness of the coating is 752 HV, and the neutral salt spray resistance of the coating reaches more than 3000 h. The friction coefficients of the aluminum-based ceramic composite coating are 1.12 and 1.09 under dry and artificial seawater wet conditions respectively, and the friction coefficient of the coating is 0.98 under lubricating oil conditions; after being flushed by an oxyacetylene flame flow at 1500 °C for 20 s, the neutral salt spray resistance of the coating is 910 h.

[0076] An aluminum-based ceramic composite coating obtained by using the preparation method of an aluminum-based ceramic composite coating in this example.

[0077] The application of the aluminum-based ceramic composite coating in this example in key components of aerospace, water conservancy and ocean, and national defense equipment. The key components include ship flight decks, hulls and drilling platforms; the ship flight deck includes the carrier aircraft takeoff and landing area of a large ship flight deck.

[0078] A ship flight deck prepared by using the aluminum-based ceramic composite coating in this example.

[0079] Example 6

[0080] A preparation method of an aluminum-based ceramic composite coating, the method steps are as follows: First, weigh and package nano titanium metal powder and alumina ceramic particles respectively at room temperature. After drying in a vacuum drying oven at 120 °C for two hours and then naturally cooling, store them in a dry environment. Place the packaged nano titanium metal powder and alumina powder in a sound resonance mixing container according to a mass percentage of 0.4:99.6. Among them, the particle size of the nano titanium metal powder is 50 nm, the particle size of the alumina ceramic is 200 μm, and the capacity of the mixing container is 500 ml. After filling the mixing container with argon gas, conduct sound resonance mixing at room temperature. The process of sound resonance mixing is: first set the acceleration of sound resonance to 50 g, then adjust the vibration frequency to 60 Hz, then increase from 60 Hz to 140 Hz at a rate of 16 Hz / min within 5 min, then decrease to 0 Hz at a rate of 30 Hz / min, stop for 1 min, then adjust to 60 Hz within 30 s, then increase from 60 Hz to 140 Hz at a rate of 16 Hz / min within 5 min, then decrease to 0 Hz at a rate of 30 Hz / min, stop for 1 min, and repeat this process until the total time is 25 min. After completion, collect the processed powder, vacuumize and seal it for storage, and obtain a core-shell structured nano titanium metal-coated alumina ceramic composite powder. Secondly, tie a 5054 aluminum alloy strip into a U shape, add the above composite powder into the U-shaped groove, and the filling rate is 53%; close the U-shaped groove to wrap the powder in it, and then gradually reduce the diameter to a Φ3 mm finished wire through a wire drawing die. Finally, use the high-speed arc spraying technology to prepare an aluminum-based composite ceramic coating on a steel substrate after sandblasting and roughening. The spraying process parameters are: spraying voltage is 40 V, spraying current is 270 A, spraying distance is 180 mm, and spraying air pressure is 0.65 MPa.

[0081] Figure 7 The potentiodynamic polarization curve of the coating prepared in Example 6 after soaking in 3.5 wt% NaCl solution for 10 days. It can be seen that the self-corrosion current density of the aluminum-based ceramic coating is 1.132×10 -6 μA / cm 2 , the self-corrosion current density of the pure aluminum coating is 34.92×10 -6 μA / cm 2 , the self-corrosion current density of the aluminum-based ceramic coating is improved by one order of magnitude compared with the pure aluminum coating, showing higher corrosion resistance; the self-corrosion potentials of the pure aluminum coating and the aluminum-based ceramic coating are -1.283 V and -1.069 V respectively. After testing, the volume fraction of alumina ceramic in the coating is 50 vol%.

[0082] The average porosity of the aluminum-based ceramic composite coating is 0.76%, the average hardness of the coating is 734 HV, and the neutral salt spray resistance of the aluminum-based ceramic coating reaches more than 3000 h. The average bonding strength of the aluminum-based ceramic coating is 42.8 MPa. The friction coefficients of the aluminum-based ceramic composite coating are 1.11 and 1.09 under dry and artificial seawater wet conditions respectively, and the friction coefficient of the coating is 0.98 under lubricating oil conditions; after being flushed by an oxyacetylene flame flow at 1500 °C for 20 s, the neutral salt spray resistance of the coating is 900 h.

[0083] An aluminum-based ceramic composite coating obtained by using the preparation method of an aluminum-based ceramic composite coating of this embodiment.

[0084] The application of the aluminum-based ceramic composite coating of this embodiment in key components of aerospace, water conservancy and ocean, and national defense equipment. The key components include ship flight decks, hulls and drilling platforms; the ship flight deck includes the takeoff and landing area of carrier-based aircraft on large ship flight decks.

[0085] A ship flight deck prepared by using the aluminum-based ceramic composite coating of this embodiment.

[0086] Comparative Example 1

[0087] The difference between this comparative example and Example 1 is only that:

[0088] The resonance frequency of acoustic resonance mixing is 120 Hz; the acceleration is 50 g, and the mixing time is 30 min.

[0089] The volume fraction of alumina ceramic in the coating obtained in this comparative example is 30 vol%. The coating bonding strength is 22 MPa, the average hardness is 350 HV0.1, the porosity is 1.79%, and the neutral salt spray resistance is 1000 h; the friction coefficients of the coating are 0.96 and 0.9 under dry and artificial seawater wet conditions respectively, and the friction coefficient of the coating is 0.80 under lubricating oil conditions; after being flushed by an oxyacetylene flame flow at 1500 °C for 20 s, the neutral salt spray resistance of the coating is 240 h.

[0090] Comparative Example 2

[0091] The difference between this comparative example and Example 1 is only that: the process of acoustic resonance mixing is: first set the acceleration to 50 g, then adjust the vibration frequency to 40 Hz, then increase from 40 Hz to 150 Hz at a rate of 36.7 Hz / min within 3 min, then decrease to 0 Hz at a rate of 20 Hz / min, stop for 0.5 min, then adjust to 40 Hz within 30 s, then increase from 40 Hz to 150 Hz at a rate of 36.7 Hz / min within 3 min, then decrease to 0 Hz at a rate of 20 Hz / min, stop for 0.5 min, and repeat this process until the total time is 30 min.

[0092] The volume fraction of alumina ceramics in the coating obtained in this comparative example is 36 vol%. The coating bonding strength is 25 MPa, the average hardness is 590 HV0.1, the porosity is 1.55%, and the neutral salt spray resistance is 2000 h; the friction coefficients of the coating are 0.97 and 0.95 under dry and artificial seawater wet conditions respectively, and the friction coefficient of the coating under lubricating oil conditions is 0.82; after being scoured by an oxyacetylene flame flow at 1500 °C for 20 s, the neutral salt spray resistance of the coating is 600 h.

[0093] Comparative Example 3

[0094] The difference between this comparative example and Example 1 is only that: the process of acoustic resonance mixing is as follows: first set the acceleration to 50 g, then adjust the vibration frequency to 50 Hz, then increase it from 50 Hz to 120 Hz at a rate of 14 Hz / min within 5 min, then decrease it to 0 Hz at a rate of 30 Hz / min, then adjust it to 50 Hz within 30 s, then increase it from 50 Hz to 120 Hz at a rate of 14 Hz / min within 5 min, then decrease it to 0 Hz at a rate of 30 Hz / min, and repeat this process until the total time is 30 min.

[0095] The volume fraction of alumina ceramics in the coating obtained in this comparative example is 39 vol%. The coating bonding strength is 28 MPa, the average hardness is 600 HV0.1, the porosity is 1.38%, and the neutral salt spray resistance is 2500 h; the friction coefficients of the coating are 0.98 and 0.96 under dry and artificial seawater wet conditions respectively, and the friction coefficient of the coating under lubricating oil conditions is 0.84; after being scoured by an oxyacetylene flame flow at 1500 °C for 20 s, the neutral salt spray resistance of the coating is 620 h.

[0096] It should be understood that, in order to streamline the present disclosure and assist in understanding one or more of the various inventive aspects, in the above description of the exemplary embodiments of the present invention, the various features of the present invention are sometimes grouped together into a single embodiment, figure, or description thereof. However, the disclosed method should not be construed as reflecting the intention that the claimed invention requires more features than are expressly recited in each claim. Rather, as reflected in the claims, the inventive aspects lie in less than all of the features of the previously disclosed embodiments. Thus, the claims following the detailed description are hereby expressly incorporated into the detailed description, where each claim stands on its own as a separate embodiment of the present invention.

[0097] Although the present invention has been described based on a limited number of embodiments, those skilled in the art in this technical field will understand, in light of the above description, that other embodiments can be envisioned within the scope of the present invention thus described. In addition, it should be noted that the language used in this specification is mainly selected for the purpose of readability and teaching, rather than for the purpose of explaining or limiting the subject matter of the present invention. Therefore, many modifications and variations will be obvious to those of ordinary skill in this technical field without departing from the scope and spirit of the appended claims. For the scope of the present invention, the disclosure of the present invention is illustrative rather than restrictive, and the scope of the present invention is defined by the appended claims.

[0098] The above are only the preferred embodiments of the present invention. It should be pointed out that for those of ordinary skill in the art in this technical field, without departing from the principle of the present invention, several improvements and refinements can still be made, and these improvements and refinements should also be regarded as the protection scope of the present invention.

Claims

1. A preparation method of an aluminum-based ceramic composite coating, characterized in that It includes the following steps: Step 1: Sonic resonance mixing of alumina ceramic particles and titanium powder to obtain a metal-coated ceramic composite powder with a core-shell structure; Step 2: Wrapping the above composite powder with an aluminum alloy outer skin and obtaining an aluminum-based ceramic cored wire by a drawing process; Step 3: Spraying the above cored wire by high-speed arc spraying technology, and obtaining an aluminum-based ceramic composite coating through the arc zone dynamic metallurgical self-propagating exothermic reaction; In Step 1, the method of sonic resonance mixing is as follows: First, set the acceleration at 50 - 60g to adjust the vibration frequency to 50 - 60Hz, then increase from 50 - 60Hz to 120 - 140Hz at a rate of 14 - 30Hz / min within 3 - 5min, then decrease to 0Hz at a rate of 30 - 50Hz / min, stop for 1 - 2min, then adjust to 50 - 60Hz within 30s, then increase from 50 - 60Hz to 120 - 140Hz at a rate of 14 - 30Hz / min within 3 - 5min, then decrease to 0Hz at a rate of 30 - 50Hz / min, stop for 1 - 2min, and repeat this process until the total time is 15 - 30min; The volume fraction of alumina ceramic in the coating is ≥45vol%; The coating bonding strength is ≥35MPa, the average hardness is ≥650HV0.1, the porosity is ≤1%, and the neutral salt spray resistance performance is ≥3000h; The coating friction coefficient is ≥1.05 both in the dry state and the artificial seawater wet state, and the coating friction coefficient is ≥0.9 under lubricating oil conditions; After being scoured by an oxyacetylene flame flow at 1500°C for 20s, the neutral salt spray resistance performance of the coating is ≥800h; The mass ratio of titanium powder to alumina ceramic particles is (0.1 - 1):(99.9 - 99).

2. The preparation method of an aluminum-based ceramic composite coating according to claim 1, characterized in that In Step 1, the particle sizes of titanium powder and alumina ceramic particles are 30 - 50nm and 150 - 200μm respectively.

3. The preparation method of an aluminum-based ceramic composite coating according to claim 1, characterized in that, In Step 2, the outer skin of the cored wire is an aluminum alloy strip, and the filling rate of the cored wire is 45% - 55%; The diameter of the cored wire is 3 ± 0.1mm.

4. The preparation method of an aluminum-based ceramic composite coating according to claim 3, characterized in that, The aluminum alloy strip is a 5054 aluminum alloy strip.

5. The preparation method of an aluminum-based ceramic composite coating according to claim 1, characterized in that In Step 3, the spraying process is as follows: spraying voltage 35 - 45V, current 250 - 350A, spraying pressure 0.6 - 0.7MPa, spraying distance 100 - 200mm.

6. An aluminum-based ceramic composite coating obtained by the preparation method of an aluminum-based ceramic composite coating according to any one of claims 1 - 5.

7. Use of the aluminum-based ceramic composite coating according to claim 6 in key components of aerospace, water conservancy and ocean, and national defense equipment, characterized in that, The key components include the flight deck of a ship, the hull, and a drilling platform; The flight deck of a ship includes the takeoff and landing area of carrier-based aircraft on the flight deck of a large ship.

8. A ship flight deck, characterized in that, Prepared by using the aluminum-based ceramic composite coating described in claim 6.

Images