Aluminum-based ceramic gradient structure antiskid coating and preparation method and application thereof

Abstract

The invention discloses an aluminum-based ceramic gradient structure antiskid coating and a preparation method and application thereof, and belongs to the technical field of coatings. The aluminum-based ceramic gradient-structure anti-skid coating consists of an aluminum-titanium alloy bonding bottom layer, a middle layer with low aluminum oxide content and a surface layer with high aluminum oxide content. The method effectively solves the bottleneck problems that a traditional resin-based anti-skid coating and an existing metal-based anti-skid coating are prone to aging, poor in binding force, unstable in friction coefficient, insufficient in durability and high-temperature resistance and the like, and solves the technical problems that a traditional electric arc spraying aluminum oxide / aluminum composite coating is prone to corrosion, abrasion, stripping and the like in a severe service environment. And the method can be used for manufacturing and operation maintenance of key parts of equipment in large ship flight deck areas serving under extreme working conditions and in the fields of aerospace, water conservancy ocean, national defense science and technology and the like.

Description

Technical Field

[0001] The invention relates to an aluminum-based ceramic gradient structure anti-slip coating and a preparation method and application thereof, belonging to the technical field of coatings. Background Art

[0002] The flight deck is a bridge connecting large ships and carrier-based aircraft, and is the key to achieving the core combat effectiveness of ships. In harsh marine environments, the flight deck is not only subject to strong corrosive atmosphere, high temperature and humidity, sunlight exposure, alternating dry and wet seawater, and pollution erosion by chemical media, but also has to bear the interaction of multiple complex factors such as huge impact loads during takeoff and landing of carrier-based aircraft and high-temperature tail flame scouring and burns. The flight deck anti-skid coating is a multiplier for improving the combat effectiveness of large ships. However, in harsh service environments, the commonly used resin-based anti-skid coating is no longer competent for the high-frequency continuous impact and high-temperature tail flame scouring of new carrier-based aircraft. Its failure behavior has become a "bottleneck" problem that restricts the development and combat effectiveness of large ships. Ensuring the long-term attendance and integrity of the flight deck anti-skid coating is a core technical problem that needs to be overcome.

[0003] In comparison, metal-based anti-slip coatings have inherent advantages over resin-based anti-slip coatings: they are not easy to age and degrade, have a long service life, and have corrosion resistance of more than 15 years; the friction coefficient can be stable at more than 0.9 for a long time; they have high wear resistance, which is more than 5 times that of resin-based anti-slip coatings; they do not produce toxic gases during construction and at high temperatures, and are green and environmentally friendly; they have high bonding strength with the substrate, which can reach more than 30MPa. With the increasing demand for anti-slip coating performance on the flight decks of new-generation large ships, it is imperative to use metal-based anti-slip coatings for the protection of carrier-based aircraft flight decks. However, existing metal-based anti-slip coatings have poor anti-slip and impact resistance, and are not resistant to long-term erosion and burns from the high-temperature tail flames of carrier-based aircraft.

[0004] In summary, the existing resin-based anti-skid coatings are difficult to meet the increasingly stringent marine service conditions. Therefore, it is urgent to optimize and improve the materials, structures and processes of the anti-skid coatings, and then provide a multifunctional integrated metal-based anti-skid coating with high density, high bonding strength, wear resistance, corrosion resistance, high temperature resistance, impact resistance, and the like, and a preparation method thereof. Summary of the invention

[0005] In order to solve the technical problems of easy aging, poor bonding force, unstable friction coefficient, insufficient durability and high temperature resistance of resin-based anti-slip coatings and existing metal-based anti-slip coatings, the purpose of the present invention is to provide an aluminum-based ceramic gradient structure anti-slip coating with multifunctional integration such as wear resistance, corrosion resistance, anti-slip and impact resistance, and high temperature resistance. In order to achieve its multifunctionality, in the coating structure design, an aluminum-titanium alloy with a self-propagating exothermic reaction is adopted as the bonding base layer to improve the bonding strength and corrosion resistance of the composite anti-slip coating, and the surface layer structure with a high alumina particle content is optimized to achieve the coating with excellent anti-slip, high temperature resistance and wear resistance. At the same time, an intermediate layer structure with a low alumina content is designed, so that the coating as a whole presents a strong outer appearance and internal toughness. The anti-skid coating has high hardness and good impact resistance; in addition, the core-shell structure nickel-coated alumina particles obtained by surface modification of alumina particles are intended to promote a self-propagating exothermic reaction between a small amount of metal nickel and the outer skin of the aluminum alloy through rapid dynamic physical and chemical metallurgy in the high-temperature arc zone of arc spraying, thereby expanding the range of the solid phase and liquid phase interval, improving the wettability of the interface between aluminum and alumina ceramics and forming an interface with the alumina ceramic phase, while improving the bonding strength between the ceramic particles and the metal matrix, reducing splashing, allowing more alumina ceramic particles to be deposited in the coating, and improving the density of the coating, thereby achieving a further improvement in the bonding strength, corrosion resistance, and wear resistance of the composite coating. Therefore, the present invention provides an aluminum-based ceramic gradient structure anti-skid coating that has the properties of wear resistance, corrosion resistance, anti-skid resistance, and high temperature resistance.

[0006] At the same time, the present invention provides a method for preparing an aluminum-based ceramic gradient structure anti-slip coating.

[0007] At the same time, the present invention provides an application of an aluminum-based ceramic gradient structure anti-slip coating.

[0008] In order to solve the above technical problems, the technical solution adopted by the present invention is:

[0009] The aluminum-based ceramic gradient structure anti-slip coating consists of an aluminum-titanium alloy bonding base layer, a middle layer with a low aluminum oxide content, and a surface layer with a high aluminum oxide content.

[0010] The aluminum-based ceramic gradient structure anti-skid coating is composed of an aluminum-titanium alloy bonding bottom layer, aluminum oxide particles with a ceramic content of 10-20 vol% and an aluminum-magnesium alloy middle layer, and aluminum oxide particles with a ceramic content of 40-55 vol% and an aluminum-magnesium alloy surface layer.

[0011] A method for preparing an aluminum-based ceramic gradient structure anti-slip coating comprises the following steps:

[0012] Step 1, pretreatment of alumina ceramic particles: the alumina ceramic particles are evenly divided into two parts, one part is added to a sodium hydroxide solution containing 50-60% and subjected to ultrasonic (frequency of 20-30kHz) coarsening treatment for 5-10 minutes, and then cleaned to obtain large-sized alumina ceramic particles, and the other part is added to a sodium hydroxide solution containing 70-80% and subjected to ultrasonic (frequency of 20-30kHz) coarsening treatment for 15-20 minutes, and then cleaned to obtain small-sized alumina ceramic particles, and then the coarsened large-sized alumina ceramic particles and small-sized alumina ceramic particles are mixed, dried and plated, and the alumina ceramic particles to be plated are obtained;

[0013] Step 2, nickel plating: put the alumina ceramic particles to be plated into a stirred reactor with a volume greater than 1L, add 1L of a solution containing 50-100g / L nickel chloride or nickel sulfate, 30-50g / L sodium hypophosphite, 5-10mg / L sodium dodecyl sulfate and 1-3mg / L thiourea, heat in a water bath to 70-85°C, control the pH value to 4-6, and react for 20-30min to obtain a nickel-coated alumina composite powder with a thickness of 1-2μm through an autocatalytic reaction;

[0014] Step 3, using 5054 aluminum alloy to wrap 10-20 vol% and 40-55 vol% of the above nickel-coated alumina composite powder respectively, and obtaining two aluminum-based ceramic powder core wires with different alumina contents through a drawing process;

[0015] When the outer skin of 5054 aluminum alloy is wrapped with 10-20 vol% nickel-coated alumina composite powder, the balance is 80-90 vol% AlMg alloy, which is an existing alloy and contains 5 wt% Mg and 95 wt% Al. The diameter of the 10-20 vol% aluminum-based ceramic powder core wire obtained after drawing is 2 mm. The filling rate of the 10-20 vol% aluminum-based ceramic powder core wire is 10-20%.

[0016] When the outer skin of 5054 aluminum alloy is wrapped with 40-55 vol% nickel-coated alumina composite powder, the balance is 45-60 vol% AlMg alloy, which is an existing alloy and contains 5 wt% Mg and 95 wt% Al. The diameter of the 40-55 vol% aluminum-based ceramic powder core wire obtained after drawing is 3 mm. The filling rate of the 40-55 vol% aluminum-based ceramic powder core wire is 40-55%.

[0017] Step 4, using high-speed arc spraying technology, first spray aluminum-titanium alloy wire to prepare a bonding base layer with a thickness of 100-150μm, then spray aluminum-based ceramic powder core wire with a ceramic content of 10-20vol% to prepare an intermediate layer with a thickness of 200-300μm, and finally spray aluminum-based ceramic powder core wire with a ceramic content of 40-55vol% to prepare a surface layer with a thickness of 300-500μm; wherein, each 50μm thick coating is bombarded with particles with elastic-plastic strain energy under a separate gas jet until the coating thickness reaches 600-950μm, so that an aluminum-based ceramic gradient structure anti-slip coating with strong bonding, impact resistance, high wear resistance, corrosion resistance, and resistance to long-term erosion by high-temperature flame flow can be obtained.

[0018] Preferably, in step 1, the particle size of the alumina ceramic particles is 150-300 μm; the particle size of the large-sized alumina ceramic particles is 140-280 μm; and the particle size of the small-sized alumina ceramic particles is 50-100 μm. During the wire drawing and extrusion process, the particle size of the large-sized alumina ceramic particles and the small-sized alumina ceramic particles will be partially broken and deformed.

[0019] Preferably, in step four, the main component of the aluminum-titanium alloy wire is Al97Ti3, the diameter is 2 mm, and the spraying process parameters are: spraying voltage 32-36 V, current 150-200 A, spraying pressure 0.65-0.7 MPa, and spraying distance 100-150 mm.

[0020] The spraying process of the aluminum-based ceramic intermediate layer and surface layer with different alumina contents is: spraying voltage 40-46V, current 350-420A, spraying pressure 0.65-0.7MPa, and spraying distance 150-200mm.

[0021] Preferably, in step 4, the particles with elastic-plastic strain energy are 0.8-1.2 mm spherical steel shots or iron shots, the air flow pressure is 0.45-0.55 MPa, and the bombardment distance is 150-200 mm.

[0022] The aluminum-based ceramic gradient structure anti-skid coating of the present invention has a coating bonding strength of ≥36MPa, an average hardness of ≥770HV0.1, a porosity of ≤1%, and a neutral salt spray resistance of ≥3000h; the friction coefficient between the coating and the tire is ≥1.1 in both dry and artificial seawater wet states, and the friction coefficient between the coating and the tire is ≥0.92 under lubricating oil conditions; the mass loss of the coating after being worn by the arresting cable is ≤5%; the number of failure points of the coating after being impacted by a falling ball is ≤2; and the neutral salt spray resistance of the coating after being washed by a 1500°C oxyacetylene flame for 45s is ≥1000h.

[0023] The aluminum-based ceramic gradient structure anti-slip coating of the present invention can be used in key components of aerospace, water conservancy, ocean, and national defense equipment. Key components include ship flight decks, hulls, drilling platforms, and steel structure towers in marine environments; ship flight decks include the take-off and landing area of ​​carrier-based aircraft on large ship flight decks.

[0024] The anti-skid coating of the flight deck of a large ship, especially the vertical take-off and landing area, can be prepared by using the aluminum-based ceramic gradient structure anti-skid coating of the present invention.

[0025] Specifically, the preparation method of the aluminum-based ceramic gradient structure anti-slip coating of the present invention is:

[0026] First, the alumina ceramic particles are weighed at room temperature and pretreated: the alumina ceramic particles are divided into two equal parts, one part is added to a 50-60% sodium hydroxide solution for ultrasonic roughening treatment for 5-10 minutes and then cleaned to obtain large-sized alumina ceramic particles, and the other part is added to a 70-80% sodium hydroxide solution for ultrasonic roughening treatment for 15-20 minutes and then cleaned to obtain small-sized alumina ceramic particles, and then the roughened large-sized alumina ceramic particles and the small-sized alumina ceramic particles are mixed. The ceramic particles are mixed and dried to be plated, so as to obtain the alumina ceramic particles to be plated; the alumina ceramic particles to be plated are placed in a stirred reactor with a volume of more than 1L, and 1L of a solution containing 50-100g / L nickel chloride or nickel sulfate, 30-50g / L sodium hypophosphite, 5-10mg / L sodium dodecyl sulfate and 1-3mg / L thiourea is added, and the solution is heated to 70-85°C in a water bath, the pH value is controlled to be 4-6, and the reaction time is 20-30min, and a nickel-coated alumina composite powder with a thickness of 1-2μm is obtained through an autocatalytic reaction. 10-20vol% and 40-55vol% of the above composite powders are wrapped with a 5054 aluminum alloy material skin and two aluminum-based ceramic powder core wires with different alumina contents are obtained through a drawing process for standby use.

[0027] Secondly, on the steel substrate after sandblasting roughening, high-speed arc spraying technology is used to spray an aluminum-titanium alloy wire with a diameter of 2 mm under the conditions of spraying process parameters of voltage 32-36 V, current 150-200 A, spraying pressure 0.65-0.7 MPa, and spraying distance 100-150 mm to obtain a bonding base layer with a thickness of 100-150 μm, wherein each 50 μm thick coating is bombarded with a spherical steel shot or iron shot with a diameter of 0.8-1.2 mm at an airflow pressure of 0.45-0.55 MPa and a distance of 150-200 mm.

[0028] Finally, high-speed arc spraying technology is used on the aluminum-titanium alloy bonding base layer. Under the conditions of spraying process parameters of voltage 40-46V, current 350-420A, spraying pressure 0.65-0.7MPa, and spraying distance 150-200mm, aluminum-based ceramic powder core wire with a ceramic content of 10-20vol% is sprayed in sequence to prepare an intermediate layer with a thickness of 200-300μm and an aluminum-based ceramic powder core wire with a ceramic content of 40-55vol% is sprayed to prepare a surface layer with a thickness of 300-500μm. Among them, every 50μm thick coating is bombarded with spherical steel shots or iron shots with a diameter of 0.8-1.2mm under an airflow pressure of 0.45-0.55MPa and a distance of 150-200mm until the overall thickness of the coating reaches 600-950μm, so that an aluminum-based ceramic gradient structure anti-slip coating with strong bonding, impact resistance, high wear resistance, corrosion resistance, and resistance to high-temperature flame erosion can be obtained.

[0029] Beneficial effects: Compared with the prior art, the present invention has the following advantages:

[0030] (1) The present invention aims to solve the technical problems of resin-based anti-skid coatings and existing metal-based anti-skid coatings, such as easy aging, poor bonding, unstable friction coefficient, insufficient durability and high temperature resistance. In terms of material design, based on the self-propagating exothermic reaction between aluminum-nickel alloys, the present invention first proposes a "shell-core structure of chemically nickel-plated alumina ceramics". The present invention also uses the self-propagating exothermic reaction between nickel and aluminum metals in the rapid dynamic physical and chemical metallurgical process of the high-temperature arc zone of arc spraying to expand the liquid phase and solid phase interval, improve the wettability between liquid metal and ceramic particles and between coating and substrate, and promote the bonding between metal and ceramic to improve the bonding strength, thereby realizing the preparation of aluminum-based ceramic coatings with high bonding strength.

[0031] (2) In terms of structural design, the exothermic reaction between aluminum and titanium is used as the bonding base layer of the aluminum-based ceramic coating to improve the bonding strength between the ceramic composite coating and the substrate; an intermediate layer structure with a low alumina content is designed to make the coating as a whole strong on the outside and tough on the inside, so that the anti-slip coating has good impact resistance; at the same time, a surface layer structure with a high alumina particle content is adopted to achieve excellent anti-slip, high temperature and wear resistance of the coating; at the same time, by improving the interface bonding state between the aluminum substrate and the alumina ceramic, the bearing effect of the high-hardness alumina ceramic particles and the high-toughness metal aluminum substrate are used to absorb the impact and friction of the coating to inhibit and reduce the initiation and development of cracks in the coating. In addition, the two have good physical and chemical properties matching to achieve a strong and tough integration of the high-ceramic content coating.

[0032] (3) In terms of preparation technology, during the thermal spraying process, the elastic-plastic strain energy characteristics of the bombarding particles are used to synchronously bombard the deposited coating surface. While achieving effective deposition and thickening of aluminum-based ceramic materials, the bombarding particles produce a "compacting" effect, which improves the residual stress distribution inside the coating, that is, reduces the residual tensile stress and increases the residual compressive stress within a reasonable range, thereby significantly weakening the adverse effects of sudden cooling stress (tensile stress) induced by coating deposition. The overall quality and performance of the coating are improved and enhanced, and the intrinsic and service life of the coating are greatly improved; and the entire process can be integrated using low-cost high-speed arc spraying technology, which greatly improves the preparation and production efficiency, is conducive to industrial development, and can be used for the manufacture and operation and maintenance of key components of equipment in the fields of aerospace, water conservancy, ocean, national defense science and technology, etc. that serve under extreme working conditions. It has important economic value and promotion significance.

[0033] (4) The present invention performs batch coarsening treatment on alumina ceramic particles to obtain large-sized alumina ceramic particles and small-sized alumina ceramic particles. After the mixed alumina ceramic particles to be plated are nickel-plated and drawn into wires, the wire filling rate can be as high as 55%. The filling rate is high, and through the gradient structure design, the bonding strength, impact resistance, wear resistance, corrosion resistance, and high-temperature flame flow resistance of the coating are finally significantly improved.

[0034] The present invention effectively solves the bottleneck problems of traditional resin-based anti-slip coatings and existing metal-based anti-slip coatings, such as easy aging, poor bonding strength, unstable friction coefficient, insufficient durability and high temperature resistance, as well as the technical failure problems of traditional arc sprayed alumina / aluminum composite coatings that are prone to corrosion, wear and peeling under harsh service environments. The present invention can be used for the manufacture and operation and maintenance of key components of flight deck areas of large ships serving in extreme working conditions, as well as in the fields of aerospace, water conservancy, ocean, national defense science and technology, etc. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] Figure 1 is a schematic diagram of the structure of the coating prepared in Example 1;

[0036] Figure 2 is a cross-sectional morphology of the coating prepared in Example 1;

[0037] Figure 3 This is the appearance morphology of the core-shell composite powder prepared in Example 1;

[0038] Figure 4 is the average hardness distribution of the coating prepared in Example 1;

[0039] Figure 5 is a potentiodynamic polarization curve diagram of the coating prepared in Example 1;

[0040] Figure 6This is a surface morphology of the coating prepared in Example 1 after the neutral salt spray test. DETAILED DESCRIPTION

[0041] The present invention will be further described in detail below in conjunction with the accompanying drawings and specific embodiments. The following embodiments are only used to illustrate the present invention and are not intended to limit the scope of the present invention.

[0042] Unless otherwise specified, other materials and raw materials used in the present invention are 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.

[0043] The test method used in the embodiment is as follows:

[0044] (1) The physical structure of the prepared samples was determined using an X-ray diffractometer.

[0045] (2) The morphology of the prepared powders was observed using a scanning electron microscope.

[0046] (3) The microhardness of the coating was measured using a Vickers hardness tester.

[0047] (4) The electrochemical corrosion performance of the coating was measured using an electrochemical workstation.

[0048] (5) The bonding strength of the coating was measured using a tensile bonding strength test.

[0049] (6) Use a salt spray test chamber to test the neutral salt spray resistance of the coating.

[0050] Example 1

[0051] The preparation method of the aluminum-based ceramic gradient structure anti-slip coating comprises the following steps: first, the alumina ceramic particles are weighed at room temperature, and the alumina ceramic particles are pretreated: the alumina ceramic particles with a particle size of about 250 μm are evenly divided into two parts, one part is added to a 55% sodium hydroxide solution for ultrasonic roughening treatment for 5.5 minutes, and then cleaned to obtain large-sized alumina ceramic particles; the other part is added to a 75% sodium hydroxide solution for ultrasonic roughening treatment for 18 minutes, and then cleaned to obtain small-sized alumina ceramic particles; and then the roughened large-sized alumina ceramic particles are Aluminum ceramic particles (particle size of about 200 μm) and small-size alumina ceramic particles (particle size of about 75 μm) are mixed and dried for plating to obtain alumina ceramic particles to be plated; the alumina ceramic particles to be plated are placed in a stirred reactor with a volume of more than 1L, and 1L of a solution containing 75g / L nickel chloride, 40g / L sodium hypophosphite, 7mg / L sodium dodecyl sulfate and 2mg / L thiourea is added, and the solution is heated to 80°C in a water bath, the pH value is controlled to 5, and the reaction time is 25min, and a nickel-coated alumina composite powder with a thickness of about 1.5μm is obtained through an autocatalytic reaction. 15vol% and 50vol% of the above composite powders are wrapped with a 5054 aluminum alloy material skin and two aluminum-based ceramic powder core wires with different alumina contents are obtained through a drawing process for standby use (the filling rate of the aluminum-based ceramic powder core wire with a ceramic content of 15vol% is 15%, and the filling rate of the aluminum-based ceramic powder core wire with a ceramic content of 50vol% is 50%).

[0052] Secondly, high-speed arc spraying technology was used on the steel substrate after sandblasting roughening. The spraying process parameters were voltage 35V, current 180A, spraying pressure 0.68MPa, and spraying distance 125mm. A 2mm diameter aluminum-titanium alloy wire was sprayed to obtain a bonding base layer with a thickness of 120μm. Spherical steel shots with a diameter of 1.0mm were used to bombard the deposited aluminum-titanium alloy coating at an airflow pressure of 0.5MPa and a distance of 180mm for each 50μm thick coating.

[0053] Finally, high-speed arc spraying technology was used on the aluminum-titanium alloy bonding base layer. Under the conditions of spraying process parameters of voltage 45V, current 400A, spraying pressure 0.68MPa, and spraying distance 180mm, aluminum-based ceramic powder core wire with a ceramic content of 15vol% was sprayed in sequence to prepare a middle layer with a thickness of 250μm and aluminum-based ceramic powder core wire with a ceramic content of 50vol% was sprayed to prepare a surface layer with a thickness of 400μm. Every 50μm thick coating, spherical steel shots with a diameter of 1.0mm were used to bombard the deposited coating under the conditions of airflow pressure of 0.5MPa and distance of 180mm until the overall thickness of the coating reached 770μm.

[0054] like Figure 1As shown, the aluminum-based ceramic gradient structure anti-slip coating obtained in this embodiment is composed of an aluminum-titanium alloy bonding base layer, an aluminum oxide particle with a ceramic content of 15 vol% and an aluminum-magnesium alloy middle layer, and an aluminum oxide particle with a ceramic content of 50 vol% and an aluminum-magnesium alloy surface layer.

[0055] like Figure 2 As shown, this is the cross-sectional morphology of the coating prepared in this embodiment. Figure 2 It can be seen that the coating has a compact structure and is well bonded to the substrate. The entire coating is divided into two areas: gray and gray-black. The gray area is the aluminum-magnesium alloy substrate, and the gray-black block and long strip substances are aluminum oxide particles. It can be found that in the upper part of the coating, the aluminum oxide particle content is more than that in the middle and bottom areas of the coating, which also confirms the gradient structural distribution of aluminum oxide in the coating.

[0056] Figure 3 The appearance morphology of the core-shell composite powder prepared in Example 1 shows 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 gradient structure anti-slip coating is 782HV (such as Figure 4 As shown), the porosity is 0.9% and the average bonding strength is 38MPa. Figure 5 The potentiodynamic polarization curves of the coating prepared in this example and the pure aluminum coating after being immersed in 3.5% NaCl solution for 70 days show that the self-corrosion potential of the aluminum-based ceramic gradient coating is significantly higher than that of the pure aluminum coating; its self-corrosion current density is two orders of magnitude smaller than that of the pure aluminum coating, indicating that the aluminum-based ceramic gradient coating has excellent corrosion resistance. Neutral salt spray resistance ≥ 3000h (such as Figure 6 The friction coefficient between the coating and the tire is 1.2 in both dry and artificial seawater wet states, and 0.95 under lubricating oil conditions; the coating mass loss is 2.5% after being worn by the arresting cable; there is one failure point after the impact of a falling ball; the neutral salt spray resistance of the coating is ≥1000h after being washed by 1500℃ oxyacetylene flame for 45s.

[0057] The aluminum-based ceramic gradient structure anti-slip coating of this embodiment can be used in key components of aerospace, water conservancy, ocean, and national defense equipment. Key components include ship flight decks, hulls, drilling platforms, and steel structure towers in marine environments; ship flight decks include large ship flight decks and carrier-based aircraft take-off and landing areas.

[0058] The anti-skid coating of the flight deck of a large ship, especially the vertical take-off and landing area, can be prepared by using the aluminum-based ceramic gradient structure anti-skid coating of this embodiment.

[0059] Example 2

[0060] The preparation method of the aluminum-based ceramic gradient structure anti-slip coating comprises the following steps: first, the alumina ceramic particles are weighed at room temperature, and the alumina ceramic particles are pretreated: the alumina ceramic particles with a particle size of about 300 μm are evenly divided into two parts, one part is added to a 50% sodium hydroxide solution for ultrasonic roughening treatment for 5 minutes and then cleaned to obtain large-sized alumina ceramic particles, and the other part is added to a 70% sodium hydroxide solution for ultrasonic roughening treatment for 15 minutes and then cleaned to obtain small-sized alumina ceramic particles, and then the roughened large-sized alumina ceramic particles are Aluminum ceramic particles (particle size of about 280 μm) and small-size alumina ceramic particles (particle size of about 100 μm) are mixed and dried for plating to obtain alumina ceramic particles to be plated; the alumina ceramic particles to be plated are placed in a stirred reactor with a volume of more than 1L, and 1L of a solution containing 50g / L nickel sulfate, 30g / L sodium hypophosphite, 5mg / L sodium dodecyl sulfate and 1mg / L thiourea is added, and the solution is heated to 70°C in a water bath, the pH value is controlled to 4, and the reaction time is 20min, and a nickel-coated alumina composite powder with a thickness of 1μm is obtained through an autocatalytic reaction. 10vol% and 40vol% of the above composite powders are wrapped with a 5054 aluminum alloy material skin and two aluminum-based ceramic powder core wires with different alumina contents are obtained through a drawing process for standby use (the filling rate of the aluminum-based ceramic powder core wire with a ceramic content of 10vol% reaches 10%, and the filling rate of the aluminum-based ceramic powder core wire with a ceramic content of 40vol% reaches 40%).

[0061] Secondly, high-speed arc spraying technology was used on the sandblasted steel substrate with a spraying process parameter of voltage 32V, current 150A, spraying pressure 0.65MPa, and spraying distance 100mm to spray an aluminum-titanium alloy wire with a diameter of 2mm to obtain a bonding base layer with a thickness of 100μm. Spherical iron shots with a diameter of 0.8mm were used to bombard the deposited aluminum-titanium alloy coating at an airflow pressure of 0.45MPa and a distance of 150mm for each 50μm thick coating.

[0062] Finally, high-speed arc spraying technology was used on the aluminum-titanium alloy bonding base layer. Under the conditions of spraying process parameters of voltage 40V, current 350A, spraying pressure 0.65MPa, and spraying distance 150mm, aluminum-based ceramic powder core wire with a ceramic content of 10vol% was sprayed in sequence to prepare a 200μm thick intermediate layer and a 300μm thick surface layer made of aluminum-based ceramic powder core wire with a ceramic content of 40vol%. Every 50μm thick coating, spherical iron shots with a diameter of 0.8mm were used to bombard the deposited coating under the conditions of airflow pressure of 0.45MPa and distance of 150mm until the overall thickness of the coating reached 600μm.

[0063] The aluminum-based ceramic gradient structure anti-slip coating obtained in this embodiment is composed of an aluminum-titanium alloy bonding base layer, an aluminum oxide particle with a ceramic content of 10 vol% and an aluminum-magnesium alloy middle layer, and an aluminum oxide particle with a ceramic content of 40 vol% and an aluminum-magnesium alloy surface layer.

[0064] The average hardness of the aluminum-based ceramic gradient structure anti-skid coating is 771HV, the porosity is 0.91%, and the average bonding strength is 36MPa. The neutral salt spray resistance is ≥3000h; the friction coefficient between the coating and the tire is 1.1 in both dry and artificial seawater wet states, and the friction coefficient between the coating and the tire is 0.92 under lubricating oil conditions; the coating mass loss is 5% after being worn by the arresting cable; the coating has 2 failure points after being impacted by a falling ball; the neutral salt spray resistance of the coating is ≥1000h after being washed by 1500℃ oxyacetylene flame for 45s.

[0065] The aluminum-based ceramic gradient structure anti-slip coating of this embodiment can be used in key components of aerospace, water conservancy, ocean, and national defense equipment. Key components include ship flight decks, hulls, drilling platforms, and steel structure towers in marine environments; ship flight decks include large ship flight decks and carrier-based aircraft take-off and landing areas.

[0066] The anti-skid coating of the flight deck of a large ship, especially the vertical take-off and landing area, can be prepared by using the aluminum-based ceramic gradient structure anti-skid coating of this embodiment.

[0067] Example 3

[0068] The preparation method of the aluminum-based ceramic gradient structure anti-slip coating comprises the following steps: first, the alumina ceramic particles are weighed at room temperature, and the alumina ceramic particles are pretreated: the alumina ceramic particles with a particle size of about 150 μm are evenly divided into two parts, one part is added to a 60% sodium hydroxide solution for ultrasonic roughening treatment for 10 minutes and then cleaned to obtain large-sized alumina ceramic particles, and the other part is added to an 80% sodium hydroxide solution for ultrasonic roughening treatment for 20 minutes and then cleaned to obtain small-sized alumina ceramic particles, and then the roughened large-sized alumina ceramic particles are Porcelain particles (particle size of about 150 μm) and small-size alumina ceramic particles (particle size of about 50 μm) are mixed and dried to be plated, so as to obtain alumina ceramic particles to be plated; the alumina ceramic particles to be plated are placed in a stirred reactor with a volume of more than 1L, and 1L of a solution containing 100g / L nickel chloride or nickel sulfate, 50g / L sodium hypophosphite, 10mg / L sodium dodecyl sulfate and 3mg / L thiourea is added, and the solution is heated to 85°C in a water bath, the pH value is controlled to 6, and the reaction time is 30min, and a nickel-coated alumina composite powder with a thickness of 2μm is obtained through an autocatalytic reaction. 20vol% and 55vol% of the above composite powders are wrapped with a 5054 aluminum alloy material skin and two aluminum-based ceramic powder core wires with different alumina contents are obtained through a drawing process for standby use (the filling rate of the aluminum-based ceramic powder core wire with a ceramic content of 20vol% reaches 20%, and the filling rate of the aluminum-based ceramic powder core wire with a ceramic content of 55vol% reaches 55%).

[0069] Secondly, high-speed arc spraying technology was used on the steel substrate after sandblasting roughening. The spraying process parameters were voltage 36V, current 200A, spraying pressure 0.7MPa, and spraying distance 150mm. A bonding base layer with a thickness of 150μm was obtained. Spherical steel shots with a diameter of 1.2mm were used to bombard the deposited aluminum-titanium alloy coating at an airflow pressure of 0.55MPa and a distance of 200mm for each 50μm thick coating.

[0070] Finally, high-speed arc spraying technology was used on the aluminum-titanium alloy bonding base layer. Under the conditions of spraying process parameters of voltage 46V, current 420A, spraying pressure 0.7MPa, and spraying distance 200mm, aluminum-based ceramic powder core wire with a ceramic content of 20vol% was sprayed in sequence to prepare a 300μm thick intermediate layer and a 55vol% aluminum-based ceramic powder core wire with a ceramic content of 500μm was prepared. The surface layer, wherein every 50μm thick coating, a spherical steel shot with a diameter of 1.2mm was used to bombard the deposited coating under the conditions of airflow pressure of 0.55MPa and a distance of 200mm until the overall thickness of the coating reached 950μm.

[0071] The aluminum-based ceramic gradient structure anti-slip coating obtained in this embodiment is composed of an aluminum-titanium alloy bonding base layer, an aluminum oxide particle with a ceramic content of 20 vol% and an aluminum-magnesium alloy middle layer, and an aluminum oxide particle with a ceramic content of 55 vol% and an aluminum-magnesium alloy surface layer.

[0072] The average hardness of the aluminum-based ceramic gradient structure anti-skid coating is 789HV, the porosity is 0.87%, and the average bonding strength is 41MPa. The neutral salt spray resistance is ≥3000h; the friction coefficient between the coating and the tire is 1.27 in both dry and artificial seawater wet states, and the friction coefficient between the coating and the tire is 0.98 under lubricating oil conditions; the coating mass loss is 3% after being worn by the arresting cable; the coating has 0 failure points after being impacted by a falling ball; the neutral salt spray resistance of the coating is ≥1000h after being washed by 1500℃ oxyacetylene flame for 45s.

[0073] The aluminum-based ceramic gradient structure anti-slip coating of this embodiment can be used in key components of aerospace, water conservancy, ocean, and national defense equipment. Key components include ship flight decks, hulls, drilling platforms, and steel structure towers in marine environments; ship flight decks include large ship flight decks and carrier-based aircraft take-off and landing areas.

[0074] The anti-skid coating of the flight deck of a large ship, especially the vertical take-off and landing area, can be prepared by using the aluminum-based ceramic gradient structure anti-skid coating of this embodiment.

[0075] Example 4

[0076] The only difference between this embodiment and embodiment 1 is that the aluminum-based ceramic gradient structure anti-slip coating is composed of an aluminum-titanium alloy bonding base layer, alumina particles with a ceramic content of 10 vol% and an aluminum-magnesium alloy intermediate layer, and alumina particles with a ceramic content of 55 vol% and an aluminum-magnesium alloy surface layer.

[0077] The aluminum-based ceramic gradient structure anti-skid coating obtained in this embodiment has an average hardness of 785HV, a porosity of 0.9%, an average bonding strength of 37MPa, and a neutral salt spray resistance of ≥3000; the friction coefficient between the coating and the tire is 1.2 in both dry and artificial seawater wet states, and the friction coefficient between the coating and the tire is 0.94 under lubricating oil conditions; the coating mass loses 2.8% after wear by the arresting cable; the coating has one failure point after being impacted by a falling ball; the neutral salt spray resistance of the coating is ≥1000h after being eroded by a 1500°C oxyacetylene flame for 45s.

[0078] Example 5

[0079] The only difference between this embodiment and Embodiment 1 is that the aluminum-based ceramic gradient structure anti-slip coating is composed of an aluminum-titanium alloy bonding base layer, alumina particles with a ceramic content of 20 vol% and an aluminum-magnesium alloy intermediate layer, and alumina particles with a ceramic content of 40 vol% and an aluminum-magnesium alloy surface layer.

[0080] The aluminum-based ceramic gradient structure anti-skid coating obtained in this embodiment has an average hardness of 795HV, a porosity of 0.92%, an average bonding strength of 40MPa, and a neutral salt spray resistance of ≥3000; the friction coefficient between the coating and the tire is 1.2 in both dry and artificial seawater wet states, and the friction coefficient between the coating and the tire is 0.97 under lubricating oil conditions; the coating mass loses 1.6% after wear by the arresting cable; the coating has 0 failure points after being impacted by a falling ball; the coating's neutral salt spray resistance is ≥1000h after being eroded by a 1500°C oxyacetylene flame for 45s.

[0081] Comparative Example 1

[0082] The difference between this comparative example and Example 1 is that the alumina ceramic particles are weighed at room temperature, added into a 75% sodium hydroxide solution for ultrasonic roughening treatment for 5 minutes, cleaned, dried and plated to obtain the alumina ceramic particles to be plated.

[0083] Comparative Example 2

[0084] The only difference between this comparative example and Example 1 is that the intermediate layer is aluminum oxide particles and aluminum-magnesium alloy with a ceramic content of 5 vol%.

[0085] Comparative Example 3

[0086] The only difference between this comparative example and Example 1 is that the intermediate layer is aluminum oxide particles and aluminum-magnesium alloy with a ceramic content of 25 vol%.

[0087] Comparative Example 4

[0088] The only difference between this comparative example and Example 1 is that no spherical steel shot or iron shot is used to bombard the deposited coating during the coating preparation process.

[0089] The performance data of Examples 1 to 5 and Comparative Examples 1 to 4 are shown in Table 1 below.

[0090] Table 1 Performance data table

[0091]

[0092] It should be understood that in order to streamline the present disclosure and aid in understanding one or more of the various inventive aspects, in the above description of exemplary embodiments of the present invention, various features of the present invention are sometimes grouped together into a single embodiment, figure, or description thereof. However, this disclosed method should not be interpreted as reflecting the intention that the claimed invention requires more features than those expressly recited in each claim. Rather, as reflected in the claims, inventive aspects lie in less than all of the features of the previously disclosed embodiments. Therefore, the claims that follow the detailed description are hereby expressly incorporated into the detailed description, with each claim itself serving as a separate embodiment of the present invention.

[0093] Although the present invention has been described according to a limited number of embodiments, it will be apparent to those skilled in the art, with the benefit of the above description, that other embodiments may be envisioned within the scope of the invention thus described. In addition, it should be noted that the language used in this specification is selected primarily for readability and teaching purposes, rather than for explaining or defining the subject matter of the present invention. Therefore, many modifications and variations will be apparent to those skilled in the art without departing from the scope and spirit of the appended claims. The disclosure of the present invention is illustrative, not restrictive, with respect to the scope of the present invention, which is defined by the appended claims.

[0094] The above is only a preferred embodiment of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the principle of the present invention. These improvements and modifications should also be regarded as the scope of protection of the present invention.

Claims

1. Aluminum-based ceramic gradient structure anti-slip coating, characterized in that: It consists of an aluminum-titanium alloy bonding base layer, an intermediate layer with low aluminum oxide content, and a surface layer with high aluminum oxide content.

2. The aluminum-based ceramic gradient structure anti-slip coating according to claim 1, characterized in that: The intermediate layer with low alumina content comprises alumina particles with a ceramic content of 10-20 vol% and the balance of aluminum-magnesium alloy.

3. The aluminum-based ceramic gradient structure anti-slip coating according to claim 1, characterized in that: The surface layer with high alumina content includes: alumina particles with a ceramic content of 40-55 vol% and the balance of aluminum-magnesium alloy.

4. The aluminum-based ceramic gradient structure anti-slip coating according to claim 1, characterized in that: The thickness of the aluminum-titanium alloy bonding bottom layer is 100-150 μm, the thickness of the middle layer with low aluminum oxide content is 200-300 μm, and the thickness of the surface layer with high aluminum oxide content is 300-500 μm.

5. The aluminum-based ceramic gradient structure anti-slip coating according to claim 1, characterized in that: The coating bonding strength is ≥36MPa, the average hardness is ≥770HV0.1, the porosity is ≤1%, and the neutral salt spray resistance is ≥3000h; the friction coefficient between the coating and the tire is ≥1.1 in both dry and artificial seawater wet states, and the friction coefficient between the coating and the tire is ≥0.92 under lubricating oil conditions; The coating mass loss after the arresting cable is worn is ≤5%; the coating failure points after the falling ball impact are ≤2; After being blasted with 1500℃ oxyacetylene flame for 45s, the neutral salt spray resistance of the coating shall be ≥1000h.

6. The method for preparing the aluminum-based ceramic gradient structure anti-slip coating according to any one of claims 1 to 5, characterized in that: The following steps are involved: Step 1, pretreatment of alumina ceramic particles: the alumina ceramic particles are evenly divided into two parts, one part is added to a sodium hydroxide solution containing 50-60% for ultrasonic roughening treatment for 5-10 minutes and then cleaned to obtain large-sized alumina ceramic particles, and the other part is added to a sodium hydroxide solution containing 70-80% for ultrasonic roughening treatment for 15-20 minutes and then cleaned to obtain small-sized alumina ceramic particles, and then the roughened large-sized alumina ceramic particles and the small-sized alumina ceramic particles are mixed, dried and plated, and the alumina ceramic particles to be plated are obtained; Step 2, nickel plating: put the alumina ceramic particles to be plated into a stirred reactor with a volume greater than 1L, add 1L of a solution containing 50-100g / L nickel chloride or nickel sulfate, 30-50g / L sodium hypophosphite, 5-10mg / L sodium dodecyl sulfate and 1-3mg / L thiourea, heat in a water bath to 70-85°C, control the pH value to 4-6, and react for 20-30min to obtain a nickel-coated alumina composite powder with a thickness of 1-2μm through an autocatalytic reaction; Step 3, using 5054 aluminum alloy material to wrap 10-20 vol% and 40-55 vol% of the above nickel-coated alumina composite powder respectively, and obtaining 10-20 vol% aluminum-based ceramic powder core wire and 40-55 vol% aluminum-based ceramic powder core wire through a drawing process; Step 4, using high-speed arc spraying technology, first spray aluminum-titanium alloy wire to prepare an aluminum-titanium alloy bonding base layer with a thickness of 100-150μm, then spray 10-20vol% aluminum-based ceramic powder core wire to prepare a middle layer with a thickness of 200-300μm, and finally spray 40-55vol% aluminum-based ceramic powder core wire to prepare a surface layer with a thickness of 300-500μm; wherein, each 50μm thick coating is bombarded with particles with elastic-plastic strain energy under a separate gas jet until the coating thickness reaches 600-950μm, so that an aluminum-based ceramic gradient structure anti-slip coating with strong bonding, impact resistance, high wear resistance, corrosion resistance, and resistance to long-term erosion by high-temperature flame flow can be obtained.

7. The preparation method according to claim 6, characterized in that: In step 1, the particle size of the alumina ceramic particles is 150-300 μm; the particle size of the large-sized alumina ceramic particles is 150-280 μm; and the particle size of the small-sized alumina ceramic particles is 50-100 μm.

8. The preparation method according to claim 6, characterized in that: In step three, the diameter of the 10-20 vol% aluminum-based ceramic powder core wire is 2 mm; the diameter of the 40-55 vol% aluminum-based ceramic powder core wire is 3 mm.

9. The preparation method according to claim 6, characterized in that: In step 4, a high-speed arc spraying technology is used on the steel substrate after sandblasting roughening. The spraying process parameters are voltage 32-36V, current 150-200A, spraying pressure 0.65-0.7MPa, and spraying distance 100-150mm. The aluminum-titanium alloy wire with a diameter of 2mm is sprayed to obtain an aluminum-titanium alloy bonding bottom layer with a thickness of 100-150μm, wherein each 50μm thick coating is bombarded with a spherical steel shot or iron shot with a diameter of 0.8-1.2mm at an airflow pressure of 0.45-0.55MPa and a distance of 150-200mm. High-speed arc spraying technology is used on the aluminum-titanium alloy bonding base layer. Under the spraying process parameters of voltage 40-46V, current 350-420A, spraying pressure 0.65-0.7MPa, and spraying distance 150-200mm, 10-20vol% aluminum-based ceramic powder core wire is sprayed in sequence to prepare an intermediate layer with a thickness of 200-300μm and 40-55vol% aluminum-based ceramic powder core wire is sprayed to prepare a surface layer with a thickness of 300-500μm. Spherical steel shots or iron shots with a diameter of 0.8-1.2mm are used to bombard the deposited coating at each 50μm thick coating under the conditions of airflow pressure of 0.45-0.55MPa and a distance of 150-200mm.

10. Application of the aluminum-based ceramic gradient structure anti-slip coating according to any one of claims 1 to 5 in key parts of aerospace, water conservancy, ocean, and national defense equipment, characterized in that: Key components include ship flight decks, hulls, drilling platforms and steel structure towers in marine environments; ship flight decks include the take-off and landing area of ​​large ship flight decks for carrier-based aircraft.

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