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

Abstract

The application discloses an aluminum-based ceramic gradient structure anti-skid 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 is composed of an aluminum-titanium alloy bonding bottom layer, an intermediate layer with low alumina content and a surface layer with high alumina content. The application effectively solves the bottleneck problems of the traditional resin-based anti-skid coating and the existing metal-based anti-skid coating, such as easy aging, poor bonding force, unstable friction coefficient, insufficient durability and high-temperature resistance and the like, and the failure technical problems of the traditional arc-sprayed alumina / aluminum composite coating, such as easy corrosion, wear and peeling in a severe service environment, and the like, and can be used for manufacturing and operation and maintenance of key parts of equipment in the fields of large ship flight decks in extreme working conditions, aerospace, water conservancy and ocean and the like.

Description

Technical Field

[0001] This invention relates to an aluminum-based ceramic gradient structure anti-slip coating, its preparation method and application, belonging to the field of coating technology. Background Technology

[0002] The flight deck serves as the bridge connecting large warships and carrier-based aircraft, and is crucial for realizing the core combat capabilities of a warship. In the harsh marine environment, the flight deck not only suffers from highly corrosive atmospheres, high temperatures and humidity, direct sunlight, alternating wet and dry seawater conditions, and chemical contamination, but also endures the immense impact loads of aircraft takeoffs and landings, as well as the scorching heat from high-temperature exhaust plumes. The anti-skid coating on the flight deck is a multiplier for enhancing the combat effectiveness of large warships. However, under the harsh service environment, commonly used resin-based anti-skid coatings are no longer sufficient to withstand the high-frequency continuous impacts and high-temperature exhaust plumes of new carrier-based aircraft. Their failure behavior has become a problem restricting the development and combat effectiveness of large warships. Ensuring the long-term availability and integrity of the flight deck anti-skid coating is a core technical challenge that urgently needs to be overcome.

[0003] In comparison, metal-based anti-slip coatings have inherent advantages over resin-based anti-slip coatings: they are less prone to aging and degradation, have a longer service life, and their corrosion resistance can reach over 15 years; their coefficient of friction can remain stable above 0.9 for a long period; their wear resistance is more than 5 times that of resin-based anti-slip coatings; they do not produce toxic gases during construction and at high temperatures, making them environmentally friendly; and they have high bonding strength with the substrate, reaching over 30 MPa. With the increasing demand for anti-slip coating performance on the flight decks of new-generation large ships, the application of metal-based anti-slip coatings for the protection of carrier-based aircraft flight decks is imperative. However, existing metal-based anti-slip coatings suffer from poor anti-slip and impact resistance, and are not resistant to prolonged scouring and burning from the high-temperature exhaust plumes of carrier-based aircraft.

[0004] In summary, existing resin-based anti-slip coatings are insufficient to meet the increasingly demanding marine service conditions. Therefore, there is an urgent need to optimize and improve the materials, structure, and processes of anti-slip coatings, and to provide a multifunctional integrated metal-based anti-slip coating and its preparation method that combines high density, high bonding strength, wear resistance, corrosion resistance, high temperature resistance, and impact resistance. Summary of the Invention

[0005] To address the technical challenges of resin-based and existing metal-based anti-slip coatings, such as easy aging, poor adhesion, unstable friction coefficient, and insufficient durability and high-temperature resistance, this invention aims to provide a multi-functional aluminum-based ceramic gradient structure anti-slip coating that integrates wear resistance, corrosion resistance, anti-slip and impact resistance, and high-temperature resistance. To achieve this multi-functionality, the coating structure design utilizes an aluminum-titanium alloy with a self-propagating exothermic reaction as the bonding underlayer to enhance the bonding strength and corrosion resistance of the composite anti-slip coating. An optimized surface layer structure with high alumina particle content achieves excellent anti-slip, high-temperature resistance, and wear resistance. Simultaneously, a low-alumina content intermediate layer structure is designed, resulting in an overall coating exhibiting external strength and internal toughness. Yes, the anti-slip coating achieves both high hardness and excellent impact resistance. Furthermore, the core-shell structure of nickel-coated alumina particles obtained through surface modification of alumina particles aims to induce a self-propagating exothermic reaction between a small amount of metallic nickel and the aluminum alloy outer layer through rapid dynamic physicochemical metallurgy in the high-temperature arc zone of arc spraying. This expands the solid-liquid phase range, improves the wettability of the aluminum-alumina ceramic interface, and forms an interface with the alumina ceramic phase. This enhances the bonding strength between the ceramic particles and the metal matrix while reducing spatter, allowing more alumina ceramic particles to deposit into the coating and increasing its density. Therefore, this invention provides an aluminum-based ceramic gradient structure anti-slip coating that combines wear resistance, corrosion resistance, anti-slip and impact resistance, and high-temperature resistance.

[0006] Meanwhile, this invention provides a method for preparing an aluminum-based ceramic gradient structure anti-slip coating.

[0007] Meanwhile, this invention provides an application of an aluminum-based ceramic gradient structure anti-slip coating.

[0008] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows:

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

[0010] The aluminum-based ceramic gradient structure anti-slip coating consists of an aluminum-titanium alloy bonding base layer, an aluminum-magnesium alloy intermediate layer with a ceramic content of 10-20 vol%, and an aluminum-magnesium alloy top layer with a ceramic content of 40-55 vol%.

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

[0012] Step 1, Pretreatment of alumina ceramic particles: Divide the alumina ceramic particles into two equal parts. Add one part to a solution containing 50-60% sodium hydroxide and roughen it with ultrasonic treatment (frequency 20-30kHz) for 5-10 minutes, then clean it to obtain large-sized alumina ceramic particles. Add the other part to a solution containing 70-80% sodium hydroxide and roughen it with ultrasonic treatment (frequency 20-30kHz) for 15-20 minutes, then clean it to obtain small-sized alumina ceramic particles. Then mix the roughened large-sized alumina ceramic particles and small-sized alumina ceramic particles evenly, dry them, and wait for plating to obtain the alumina ceramic particles to be plated.

[0013] Step 2, nickel plating: Place the alumina ceramic particles to be plated into a stirred reactor with a volume > 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℃, control the pH value to 4~6, and the reaction time is 20~30min. Obtain nickel-coated alumina composite powder with a thickness of 1~2μm through autocatalytic reaction;

[0014] Step 3: Using 5054 aluminum alloy, 10-20 vol% and 40-55 vol% of the above-mentioned nickel-coated alumina composite powder are respectively wrapped with a sheath and then drawn to obtain two aluminum-based ceramic powder core wires with different alumina contents.

[0015] When 5054 aluminum alloy is used to coat 10-20 vol% of nickel-coated alumina composite powder, the remainder is 80-90 vol% of AlMg alloy. AlMg alloy is an existing alloy containing 5 wt% Mg and 95 wt% Al. After drawing, a 10-20 vol% aluminum-based ceramic powder core wire with a diameter of 2 mm is obtained. The filling rate of the 10-20 vol% aluminum-based ceramic powder core wire reaches 10-20%.

[0016] When 5054 aluminum alloy is used to coat 40-55 vol% of nickel-coated alumina composite powder, the balance is 45-60 vol% of AlMg alloy. The AlMg alloy is an existing alloy containing 5 wt% Mg and 95 wt% Al. After drawing, a 3 mm diameter aluminum-based ceramic powder core wire is obtained. The filling rate of the 40-55 vol% aluminum-based ceramic powder core wire reaches 40-55%.

[0017] Step four involves using high-speed arc spraying technology. First, an aluminum-titanium alloy wire is sprayed to prepare a bonding underlayer with a thickness of 100-150 μm. Second, an aluminum-based ceramic powder core wire with a ceramic content of 10-20 vol% is sprayed to prepare an intermediate layer with a thickness of 200-300 μm. Finally, an aluminum-based ceramic powder core wire with a ceramic content of 40-55 vol% is sprayed to prepare a surface layer with a thickness of 300-500 μm. During this process, every 50 μm of coating thickness, microparticles with elastic-plastic strain energy are used to bombard the deposited coating under a separate gas jet until the coating thickness reaches 600-950 μm. This process yields a strong-bonded, impact-resistant, highly wear-resistant, corrosion-resistant, and high-temperature flame-flow-resistant aluminum-based ceramic gradient structure anti-slip coating.

[0018] Preferably, in step one, the alumina ceramic particles have a particle size of 150~300μm; the large-size alumina ceramic particles have a particle size of 140~280μm; and the small-size alumina ceramic particles have a particle size of 50~100μm. During the wire drawing and extrusion process, the large-size alumina ceramic particles and the small-size alumina ceramic particles will partially break and deform.

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

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

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

[0022] The aluminum-based ceramic gradient structure anti-slip coating of this invention has a coating bonding strength ≥36MPa, an average hardness ≥770HV0.1, a porosity ≤1%, and a neutral salt spray resistance ≥3000h. The coefficient of friction between the coating and the tire is ≥1.1 under both dry and artificial seawater wet conditions, and ≥0.92 under lubricated oil conditions. The coating mass loss after arresting cable wear is ≤5%. The coating has ≤2 failure points after falling ball impact. After being subjected to a 1500℃ oxyacetylene flame jet for 45s, the coating's neutral salt spray resistance is ≥1000h.

[0023] The aluminum-based ceramic gradient structure anti-slip coating of the present invention can be applied in key components of aerospace, water conservancy and marine engineering, including ship flight decks, hulls, drilling platforms and steel structure towers in marine environments; ship flight decks include the take-off and landing areas of carrier-based aircraft on large ships.

[0024] The anti-slip coating for the flight deck of large ships, especially the vertical take-off and landing area, can be prepared using the aluminum-based ceramic gradient structure anti-slip 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 as follows:

[0026] First, after weighing the alumina ceramic particles at room temperature, the alumina ceramic particles are pretreated as follows: The alumina ceramic particles are divided into two equal parts. One part is added to a sodium hydroxide solution containing 50-60% and ultrasonically roughened for 5-10 minutes, then cleaned to obtain large-sized alumina ceramic particles. The other part is added to a sodium hydroxide solution containing 70-80% and ultrasonically roughened for 15-20 minutes, then cleaned to obtain small-sized alumina ceramic particles. Then, the roughened large-sized and small-sized alumina ceramic particles are... The ceramic particles are mixed evenly and dried for plating to obtain alumina ceramic particles to be plated. These particles are then placed in a stirred reactor with a volume >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. The mixture is heated in a water bath to 70-85℃, the pH is controlled at 4-6, and the reaction time is 20-30 minutes. Through autocatalytic reaction, a nickel-coated alumina composite powder with a thickness of 1-2μm is obtained. Two types of aluminum-based ceramic core wires with different alumina contents are obtained by wrapping 10-20 vol% and 40-55 vol% of the above composite powder with 5054 aluminum alloy and then drawing them.

[0027] Secondly, on the roughened steel substrate after sandblasting, a high-speed arc spraying technique is used to spray aluminum-titanium alloy wire with a diameter of 2 mm under the following spraying process parameters: voltage 32-36V, current 150-200A, spraying pressure 0.65-0.7MPa, and spraying distance 100-150mm. This results in a bonding underlayer with a thickness of 100-150μm. Every 50μm of coating thickness, spherical steel shot or iron shot with a diameter of 0.8-1.2mm is used to bombard the deposited aluminum-titanium alloy coating under the following conditions: airflow pressure 0.45-0.55MPa, and distance 150-200mm.

[0028] Finally, on the aluminum-titanium alloy bonding substrate, high-speed arc spraying technology is used to sequentially spray an intermediate layer with a ceramic powder core wire containing 10-20 vol% ceramic material to prepare a thickness of 200-300 μm, and a top layer with a ceramic powder core wire containing 40-55 vol% ceramic material to prepare a thickness of 300-500 μm, under the following spraying process parameters: voltage 40-46V, current 350-420A, spraying pressure 0.65-0.7MPa, and spraying distance 150-200mm. Every 50μm of coating thickness, spherical steel shot or iron shot with a diameter of 0.8-1.2mm is used to bombard the deposited coating under the following conditions: airflow pressure 0.45-0.55MPa, and distance 150-200mm, until the overall coating thickness reaches 600-950μm. This results in a strong-bonded, impact-resistant, highly wear-resistant, corrosion-resistant, and high-temperature flame erosion-resistant aluminum-based ceramic gradient structure anti-slip coating.

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

[0030] (1) This invention addresses the technical challenges of 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. In terms of material design, based on the self-propagating exothermic reaction between aluminum and nickel alloys, the invention first proposes a "shell-core structure of chemically plated nickel-coated alumina ceramic". It utilizes the self-propagating exothermic reaction between nickel and aluminum metals during the rapid dynamic physicochemical metallurgical process of electric arc spraying at high temperature to expand the liquid and solid phase intervals, improve the wettability between liquid metal and ceramic particles and between coating and substrate, and promote the bonding between metal and ceramic phases to enhance the bonding strength. This invention achieves 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 layer of aluminum-based ceramic coating, which improves the bonding strength between ceramic composite coating and substrate; a low alumina content intermediate layer structure is designed, which makes the coating exhibit strong exterior and tough interior, giving the anti-slip coating good impact resistance; at the same time, a surface layer structure with high alumina particle content is adopted, which realizes that the coating has excellent anti-slip, high temperature resistance and wear resistance; at the same time, by improving the interface bonding state between aluminum substrate and alumina ceramic, the bearing effect of high hardness alumina ceramic particles and the absorption of impact and friction force on the coating by high toughness aluminum substrate are used to suppress and reduce the initiation and development of coating cracks. In addition, the two have good physical and chemical properties matching, realizing the high ceramic content coating with integrated strength and toughness.

[0032] (3) In terms of preparation process, during the thermal spraying process, the elasto-plastic strain energy characteristics of the bombarding particles are used to bombard the surface of the deposited coating simultaneously. While achieving effective deposition and thickening of aluminum-based ceramic materials, the bombarding particles generate a "compacting" effect, which improves the distribution of residual stress inside the coating, that is, reduces residual tensile stress and increases residual compressive stress within a reasonable range. This significantly weakens the adverse effects of coating deposition-induced rapid cooling stress (tensile stress), and the overall quality and performance of the coating are improved and strengthened. The intrinsic properties and service life of the coating are greatly improved. Moreover, the entire process can be completed in one integrated manner using low-cost high-speed electric arc spraying technology, which greatly improves the preparation and production efficiency, is conducive to industrial development, and can be used for the manufacturing and operation and maintenance of key components of equipment in aerospace, water conservancy and marine fields that serve under extreme conditions. It has important economic value and promotion significance.

[0033] (4) The present invention roughens alumina ceramic particles in batches to obtain large-size alumina ceramic particles and small-size alumina ceramic particles. After the alumina ceramic particles to be plated are mixed and nickel-plated and drawn into wires, the wire filling rate can reach up to 55%. The high filling rate, through gradient structure design, ultimately achieves significantly improved coating bonding strength, impact resistance, wear and corrosion resistance, and resistance to long-term erosion by high-temperature flame flow.

[0034] This 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 adhesion, unstable friction coefficient, insufficient durability and high temperature resistance. It also solves the technical problems of traditional arc-sprayed alumina / aluminum composite coatings, which are prone to corrosion, wear and peeling in harsh service environments. It can be used for the manufacturing and operation and maintenance of key components of equipment in the flight deck area of ​​large ships serving in extreme conditions, as well as in aerospace, water conservancy and marine fields. Attached Figure Description

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

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

[0037] Figure 3 Here are the morphological images of the core-shell composite powder prepared in Example 1;

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

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

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

[0041] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments. The following embodiments are for illustrative purposes only and are not intended to limit the scope of the invention.

[0042] Unless otherwise specified, all other materials and raw materials used in this 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 testing methods used in this embodiment are as follows:

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

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

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

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

[0048] (5) The bonding strength of the coating is measured by tensile bond strength test.

[0049] (6) The coating’s resistance to neutral salt spray was tested using a salt spray test chamber. Example 1

[0050] The preparation method of the aluminum-based ceramic gradient structure anti-slip coating is as follows: First, after weighing the alumina ceramic particles at room temperature, the alumina ceramic particles are pretreated: the alumina ceramic particles with a particle size of about 250 μm are divided into two equal parts. One part is added to a 55% sodium hydroxide solution for ultrasonic roughening for 5.5 min and then cleaned to obtain large-sized alumina ceramic particles. The other part is added to a 75% sodium hydroxide solution for ultrasonic roughening for 18 min and then cleaned to obtain small-sized alumina ceramic particles. Then the roughened large-sized alumina ceramic particles are... Alumina ceramic particles (approximately 200 μm in diameter) and small-sized alumina ceramic particles (approximately 75 μm in diameter) are mixed, dried, and then plated to obtain alumina ceramic particles to be plated. These alumina ceramic particles are placed in a stirred reactor with a volume >1 L, and 1 L of a solution containing 75 g / L nickel chloride, 40 g / L sodium hypophosphite, 7 mg / L sodium dodecyl sulfate, and 2 mg / L thiourea is added. The mixture is heated in a water bath to 80 °C, the pH is controlled at 5, and the reaction time is 25 min. Through autocatalytic reaction, a nickel-coated alumina composite powder with a thickness of approximately 1.5 μm is obtained. Two types of aluminum-based ceramic core wires with different alumina contents are obtained by wrapping 15 vol% and 50 vol% of the above composite powder with 5054 aluminum alloy and then drawing them (the 15 vol% aluminum-based ceramic core wire has a 15% filling rate, and the 50 vol% aluminum-based ceramic core wire has a 50% filling rate).

[0051] Secondly, on the roughened steel substrate after sandblasting, high-speed arc spraying technology was used to spray aluminum-titanium alloy wire with a diameter of 2mm under the following spraying process parameters: voltage 35V, current 180A, spraying pressure 0.68MPa, and spraying distance 125mm, to obtain a bonding underlayer with a thickness of 120μm. Every 50μm of coating thickness, spherical steel shot with a diameter of 1.0mm was used to bombard the deposited aluminum-titanium alloy coating under the following conditions: airflow pressure 0.5MPa and distance 180mm.

[0052] Finally, on the aluminum-titanium alloy bonding substrate, a high-speed arc spraying technique was used to sequentially spray an intermediate layer with a ceramic powder core wire with a ceramic content of 15 vol% to prepare a thickness of 250 μm, and a top layer with a ceramic powder core wire with a ceramic content of 50 vol% to prepare a thickness of 400 μm on the aluminum-titanium alloy bonding substrate. Every 50 μm of coating thickness, spherical steel shot with a diameter of 1.0 mm was used to bombard the deposited coating under the conditions of airflow pressure of 0.5 MPa and distance of 180 mm until the overall coating thickness reached 770 μm.

[0053] like Figure 1As shown, the aluminum-based ceramic gradient structure anti-slip coating obtained in this embodiment consists of an aluminum-titanium alloy bonding underlayer, an aluminum oxide particle and aluminum-magnesium alloy intermediate layer with a ceramic content of 15 vol%, and an aluminum oxide particle and aluminum-magnesium alloy surface layer with a ceramic content of 50 vol%.

[0054] like Figure 2 The image shown is a cross-sectional morphology diagram of the coating prepared in this embodiment. Figure 2 It can be seen that the coating structure is compact and 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 blocky and strip-shaped substances are alumina particles. It can be found that the alumina particle content is higher in the upper part of the coating than in the middle and bottom areas, which confirms the gradient structure distribution of alumina in the coating.

[0055] Figure 3 The image shows the morphology 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 is dense and complete. The average hardness of the aluminum-based ceramic gradient structure anti-slip coating is 782 HV (e.g., ...). Figure 4 As shown in the figure, the porosity is 0.9% and the average bonding strength is 38 MPa. Figure 5 The potentiodynamic polarization curves of the coating prepared in this embodiment and the pure aluminum coating after immersion in 3.5% NaCl solution for 70 days are shown. It can be seen 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 lower than that of the pure aluminum coating, indicating that the aluminum-based ceramic gradient coating has excellent corrosion resistance. Neutral salt spray resistance ≥3000h (e.g., Figure 6 (As shown); the coefficient of friction between the coating and the tire is 1.2 in both dry and artificial seawater wet conditions, and 0.95 in lubricated oil conditions; the coating mass loss is 2.5% after abrasion by the arresting cable; there is one failure point in the coating after a falling ball impact; the coating's resistance to neutral salt spray is ≥1000h after being sprayed by a 1500℃ oxyacetylene flame for 45s.

[0056] The aluminum-based ceramic gradient structure anti-slip coating of this embodiment can be applied to key components in aerospace, water conservancy and marine engineering. 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 areas of carrier-based aircraft on large ships.

[0057] The anti-slip coating for the flight deck of large ships, especially the vertical take-off and landing area, can be prepared using the aluminum-based ceramic gradient structure anti-slip coating of this embodiment. Example 2

[0058] The preparation method of the aluminum-based ceramic gradient structure anti-slip coating includes the following steps: First, after weighing the alumina ceramic particles at room temperature, the alumina ceramic particles are pretreated as follows: Alumina ceramic particles with a particle size of about 300 μm are divided into two equal parts. One part is added to a 50% sodium hydroxide solution for ultrasonic roughening for 5 minutes and then cleaned to obtain large-sized alumina ceramic particles. The other part is added to a 70% sodium hydroxide solution for ultrasonic roughening for 15 minutes and then cleaned to obtain small-sized alumina ceramic particles. Then, the roughened large-sized alumina ceramic particles are... Alumina ceramic particles (approximately 280 μm in diameter) and small-sized alumina ceramic particles (approximately 100 μm in diameter) are mixed, dried, and then plated to obtain alumina ceramic particles to be plated. These alumina ceramic particles are placed in a stirred reactor with a volume >1 L, and 1 L of a solution containing 50 g / L nickel sulfate, 30 g / L sodium hypophosphite, 5 mg / L sodium dodecyl sulfate, and 1 mg / L thiourea is added. The mixture is heated in a water bath to 70 °C, the pH is controlled at 4, and the reaction time is 20 min. A nickel-coated alumina composite powder with a thickness of 1 μm is obtained through an autocatalytic reaction. Two types of aluminum-based ceramic core wires with different alumina contents are obtained by wrapping 10 vol% and 40 vol% of the above composite powder with 5054 aluminum alloy and then drawing them (the 10 vol% aluminum-based ceramic core wire has a filling rate of 10%, and the 40 vol% aluminum-based ceramic core wire has a filling rate of 40%).

[0059] Secondly, on the roughened steel substrate after sandblasting, high-speed electric arc spraying technology was used to spray aluminum-titanium alloy wire with a diameter of 2mm under the following spraying process parameters: voltage 32V, current 150A, spraying pressure 0.65MPa, and spraying distance 100mm, to obtain a bonding underlayer with a thickness of 100μm. Every 50μm of coating thickness, 0.8mm diameter spherical iron shot was used to bombard the deposited aluminum-titanium alloy coating under the following conditions: airflow pressure 0.45MPa and distance 150mm.

[0060] Finally, on the aluminum-titanium alloy bonding substrate, a high-speed arc spraying technique was used to sequentially spray an intermediate layer with a ceramic powder core wire with a ceramic content of 10 vol% to prepare a thickness of 200 μm and a top layer with a ceramic powder core wire with a ceramic content of 40 vol% to prepare a thickness of 300 μm on the substrate. Every 50 μm of coating thickness, 0.8 mm diameter spherical iron shot was used to bombard the deposited coating under a gas flow pressure of 0.45 MPa and a distance of 150 mm until the overall coating thickness reached 600 μm.

[0061] The aluminum-based ceramic gradient structure anti-slip coating obtained in this embodiment consists of an aluminum-titanium alloy bonding base layer, an aluminum oxide particle and aluminum-magnesium alloy intermediate layer with a ceramic content of 10 vol%, and an aluminum oxide particle and aluminum-magnesium alloy surface layer with a ceramic content of 40 vol%.

[0062] The aluminum-based ceramic gradient structure anti-slip coating has an average hardness of 771 HV, a porosity of 0.91%, and an average bond strength of 36 MPa. It exhibits neutral salt spray resistance ≥3000 h; the coefficient of friction between the coating and tire is 1.1 under both dry and artificial seawater wet conditions, and 0.92 under lubricated oil conditions; the coating experiences a 5% mass loss after being worn by arresting gear; two failure points are found after a falling ball impact test; and the coating's neutral salt spray resistance is ≥1000 h after being subjected to a 1500℃ oxyacetylene flame for 45 s.

[0063] The aluminum-based ceramic gradient structure anti-slip coating of this embodiment can be applied to key components in aerospace, water conservancy and marine engineering. 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 areas of carrier-based aircraft on large ships.

[0064] The anti-slip coating for the flight deck of large ships, especially the vertical take-off and landing area, can be prepared using the aluminum-based ceramic gradient structure anti-slip coating of this embodiment. Example 3

[0065] The preparation method of the aluminum-based ceramic gradient structure anti-slip coating includes the following steps: First, after weighing the alumina ceramic particles at room temperature, the alumina ceramic particles are pretreated as follows: Alumina ceramic particles with a particle size of approximately 150 μm are divided into two equal parts. One part is added to a 60% sodium hydroxide solution for ultrasonic roughening for 10 minutes and then cleaned to obtain large-sized alumina ceramic particles. The other part is added to an 80% sodium hydroxide solution for ultrasonic roughening for 20 minutes and then cleaned to obtain small-sized alumina ceramic particles. Then, the roughened large-sized alumina ceramic particles are... Ceramic particles (approximately 150 μm in diameter) and small-sized alumina ceramic particles (approximately 50 μm in diameter) are mixed and dried for plating to obtain the alumina ceramic particles to be plated. These particles are then placed in a stirred reactor with a volume >1 L, and 1 L of a solution containing 100 g / L nickel chloride or nickel sulfate, 50 g / L sodium hypophosphite, 10 mg / L sodium dodecyl sulfate, and 3 mg / L thiourea is added. The mixture is heated in a water bath to 85°C, the pH is controlled at 6, and the reaction time is 30 min. A nickel-coated alumina composite powder with a thickness of 2 μm is obtained through an autocatalytic reaction. Two types of aluminum-based ceramic core wires with different alumina contents are obtained by wrapping 20 vol% and 55 vol% of the above composite powder with 5054 aluminum alloy and then drawing them (the 20 vol% ceramic core wire has a filling rate of 20%, and the 55 vol% ceramic core wire has a filling rate of 55%).

[0066] Secondly, on the roughened steel substrate after sandblasting, high-speed arc spraying technology was used to spray aluminum-titanium alloy wire with a diameter of 2mm under the following spraying process parameters: voltage 36V, current 200A, spraying pressure 0.7MPa, and spraying distance 150mm, to obtain a bonding underlayer with a thickness of 150μm. Every 50μm of coating thickness, spherical steel shot with a diameter of 1.2mm was used to bombard the deposited aluminum-titanium alloy coating under the following conditions: airflow pressure 0.55MPa and distance 200mm.

[0067] Finally, on the aluminum-titanium alloy bonding substrate, a high-speed arc spraying technique was used to sequentially spray an intermediate layer with a ceramic powder core wire with a ceramic content of 20 vol% to prepare a thickness of 300 μm and a top layer with a ceramic powder core wire with a ceramic content of 55 vol% to prepare a thickness of 500 μm on the aluminum-titanium alloy bonding substrate. Every 50 μm of coating thickness, spherical steel shot with a diameter of 1.2 mm was used to bombard the deposited coating at a gas flow pressure of 0.55 MPa and a distance of 200 mm until the overall coating thickness reached 950 μm.

[0068] The aluminum-based ceramic gradient structure anti-slip coating obtained in this embodiment consists of an aluminum-titanium alloy bonding base layer, an aluminum oxide particle and aluminum-magnesium alloy intermediate layer with a ceramic content of 20 vol%, and an aluminum oxide particle and aluminum-magnesium alloy surface layer with a ceramic content of 55 vol%.

[0069] The aluminum-based ceramic gradient structure anti-slip coating has an average hardness of 789 HV, a porosity of 0.87%, and an average bond strength of 41 MPa. It exhibits neutral salt spray resistance ≥3000 h; the coefficient of friction between the coating and tire is 1.27 in both dry and artificial seawater wet conditions, and 0.98 under lubricated oil conditions; the coating experiences a 3% mass loss after being worn by arresting gear; there are 0 failure points after a falling ball impact test; and the coating's neutral salt spray resistance is ≥1000 h after being subjected to a 1500℃ oxyacetylene flame for 45 s.

[0070] The aluminum-based ceramic gradient structure anti-slip coating of this embodiment can be applied in aerospace, water conservancy and marine engineering, and key components. 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 areas of carrier-based aircraft on large ships.

[0071] The anti-slip coating for the flight deck of large ships, especially the vertical take-off and landing area, can be prepared using the aluminum-based ceramic gradient structure anti-slip coating of this embodiment. Example 4

[0072] The only difference between this embodiment and Embodiment 1 is that the aluminum-based ceramic gradient structure anti-slip coating consists of an aluminum-titanium alloy bonding base layer, an aluminum oxide particle layer with a ceramic content of 10 vol% and an aluminum-magnesium alloy intermediate layer, and an aluminum oxide particle layer with a ceramic content of 55 vol% and an aluminum-magnesium alloy surface layer.

[0073] The aluminum-based ceramic gradient structure anti-slip coating obtained in this embodiment has an average hardness of 785 HV, a porosity of 0.9%, an average bonding strength of 37 MPa, and a neutral salt spray resistance of ≥3000. The coefficient of friction between the coating and the tire is 1.2 under both dry and artificial seawater wet conditions, and 0.94 under lubricated oil conditions. The coating mass loss is 2.8% after being worn by the arresting cable. There is one failure point in the coating after being impacted by a falling ball. After being scourd by a 1500℃ oxyacetylene flame for 45 seconds, the coating's neutral salt spray resistance is ≥1000 h. Example 5

[0074] The only difference between this embodiment and Embodiment 1 is that the aluminum-based ceramic gradient structure anti-slip coating consists of an aluminum-titanium alloy bonding base layer, an aluminum oxide particle layer with a ceramic content of 20 vol% and an aluminum-magnesium alloy intermediate layer, and an aluminum oxide particle layer with a ceramic content of 40 vol% and an aluminum-magnesium alloy surface layer.

[0075] The aluminum-based ceramic gradient structure anti-slip coating obtained in this embodiment has an average hardness of 795 HV, a porosity of 0.92%, an average bonding strength of 40 MPa, and a neutral salt spray resistance of ≥3000. The coefficient of friction between the coating and the tire is 1.2 under both dry and artificial seawater wet conditions, and 0.97 under lubricated oil conditions. The coating mass loss is 1.6% after being worn by the arresting cable. There are 0 failure points in the coating after being impacted by a falling ball. After being scourd by a 1500℃ oxyacetylene flame for 45 seconds, the coating's neutral salt spray resistance is ≥1000 h.

[0076] Comparative Example 1

[0077] The only difference between this comparative example and Example 1 is that: after weighing the alumina ceramic particles at room temperature, they are added to a solution containing 75% sodium hydroxide for ultrasonic roughening treatment for 5 minutes, then cleaned, dried and ready for plating, thus obtaining the alumina ceramic particles to be plated.

[0078] Comparative Example 2

[0079] The only difference between this comparative example and Example 1 is that the intermediate layer consists of alumina particles with a ceramic content of 5 vol% and an aluminum-magnesium alloy.

[0080] Comparative Example 3

[0081] The only difference between this comparative example and Example 1 is that the intermediate layer consists of alumina particles with a ceramic content of 25 vol% and an aluminum-magnesium alloy.

[0082] Comparative Example 4

[0083] The only difference between this comparative example and Example 1 is that the deposited coating was not bombarded with spherical steel shot or iron shot during the coating preparation process.

[0084] The performance data of Examples 1-5 and Comparative Examples 1-4 are shown in Table 1 below.

[0085] Table 1 Performance Data Sheet

[0086]

[0087] It should be understood that, in order to simplify this disclosure and aid in understanding one or more of the various aspects of the invention, features of the invention are sometimes grouped together in a single embodiment, figure, or description thereof in the above description of exemplary embodiments of the invention. However, this method of disclosure should not be interpreted as reflecting an intention that the claimed invention requires more features than expressly recited in each claim. Rather, as reflected in the claims, inventive aspects lie in fewer than all the features of the foregoingly disclosed embodiments. Therefore, the claims, following the detailed description, are hereby expressly incorporated into that detailed description, wherein each claim itself is a separate embodiment of the invention.

[0088] Although the invention has been described with reference to a limited number of embodiments, those skilled in the art will understand from the foregoing description that other embodiments are conceivable within the scope of the invention described herein. Furthermore, it should be noted that the language used in this specification has been chosen primarily for readability and instructional purposes, and not for the purpose of interpreting or limiting the subject matter of the 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 invention is illustrative and not restrictive, and the scope of the invention is defined by the appended claims.

[0089] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the principle of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A method for preparing an aluminum-based ceramic gradient structure anti-slip coating, characterized in that, The aluminum-based ceramic gradient structure anti-slip coating consists of an aluminum-titanium alloy bonding base layer, a low alumina content intermediate layer, and a high alumina content top layer. The preparation method includes the following steps: Step 1, Pretreatment of alumina ceramic particles: Divide the alumina ceramic particles into two equal parts. Add one part to a solution containing 50-60% sodium hydroxide and ultrasonically roughen it for 5-10 minutes, then clean it to obtain large-sized alumina ceramic particles. Add the other part to a solution containing 70-80% sodium hydroxide and ultrasonically roughen it for 15-20 minutes, then clean it to obtain small-sized alumina ceramic particles. Then mix the roughened large-sized alumina ceramic particles and small-sized alumina ceramic particles evenly, dry them, and wait for plating to obtain the alumina ceramic particles to be plated. Step 2, nickel plating: Place the alumina ceramic particles to be plated into a stirred reactor with a volume > 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℃, control the pH value to 4~6, and the reaction time is 20~30min. Obtain nickel-coated alumina composite powder with a thickness of 1~2μm through autocatalytic reaction; Step 3: 10-20 vol% of the above-mentioned nickel-coated alumina composite powder and the balance of 80-90 vol% AlMg alloy are wrapped with a 5054 aluminum alloy outer skin, and 10-20 vol% aluminum-based ceramic powder core wire is obtained by drawing process. The material is made of 5054 aluminum alloy, which encapsulates 40-55 vol% of the above-mentioned nickel-coated alumina composite powder and the balance of 45-60 vol% AlMg alloy. The aluminum-based ceramic powder core wire is obtained by drawing process. Step four involves using high-speed arc spraying technology. First, aluminum-titanium alloy wire is sprayed to prepare an aluminum-titanium alloy bonding underlayer with a thickness of 100-150 μm. Second, 10-20 vol% aluminum-based ceramic powder core wire is sprayed to prepare an intermediate layer with a thickness of 200-300 μm. Finally, 40-55 vol% aluminum-based ceramic powder core wire is sprayed to prepare a surface layer with a thickness of 300-500 μm. During this process, every 50 μm of coating thickness, microparticles with elastic-plastic strain energy are bombarded with the deposited coating under a separate gas jet until the coating thickness reaches 600-950 μm. This process yields an aluminum-based ceramic gradient structure anti-slip coating with strong bonding, impact resistance, high wear and corrosion resistance, and resistance to long-term erosion by high-temperature flame flow. In step three, the diameter of the aluminum-based ceramic powder core wire is 2 mm for 10-20 vol% aluminum-based ceramic powder core wire; and the diameter of the aluminum-based ceramic powder core wire is 3 mm for 40-55 vol% aluminum-based ceramic powder core wire. In step one, the particle size of alumina ceramic particles is 150~300μm; the particle size of large-sized alumina ceramic particles is 150~280μm; and the particle size of small-sized alumina ceramic particles is 50~100μm. The coating has a bonding strength ≥36MPa, an average hardness ≥770HV0.1, a porosity ≤1%, and a neutral salt spray resistance ≥3000h. The coefficient of friction between the coating and the tire is ≥1.1 under both dry and artificial seawater wet conditions, and ≥0.92 under lubricated oil conditions. The coating mass loss after arresting cable wear is ≤5%. The coating has ≤2 failure points after falling ball impact. The coating's neutral salt spray resistance is ≥1000h after being sprayed by a 1500℃ oxyacetylene flame for 45s.

2. The preparation method according to claim 1, characterized in that, In step four, high-speed arc spraying technology is used on the roughened steel substrate to spray aluminum-titanium alloy wire with a diameter of 2mm under the following spraying process parameters: voltage 32-36V, current 150-200A, spraying pressure 0.65-0.7MPa, and spraying distance 100-150mm. This results in an aluminum-titanium alloy bonding underlayer with a thickness of 100-150μm. Every 50μm of coating thickness, spherical steel shot or iron shot with a diameter of 0.8-1.2mm is used to bombard the deposited aluminum-titanium alloy bonding underlayer under the following conditions: airflow pressure 0.45-0.55MPa, and distance 150-200mm. On an aluminum-titanium alloy bonding substrate, a high-speed arc spraying technique was used to sequentially spray a 200-300 μm thick intermediate layer with 10-20 vol% aluminum-based ceramic powder core wire and a 300-500 μm thick top layer with 40-55 vol% aluminum-based ceramic powder core wire at a spraying process parameter of 40-46 V voltage, 350-420 A current, 0.65-0.7 MPa spraying pressure, and 150-200 mm spraying distance. Every 50 μm of coating thickness, spherical steel shot or iron shot with a diameter of 0.8-1.2 mm was used to bombard the deposited coating at a gas flow pressure of 0.45-0.55 MPa and a distance of 150-200 mm.

3. The application of the aluminum-based ceramic gradient structure anti-slip coating obtained by the preparation method according to any one of claims 1 to 2 in key components in the aerospace or marine engineering fields, characterized in that, Key components include ship flight decks, hulls, or steel structure towers in marine environments; ship flight decks are the take-off and landing areas for carrier-based aircraft on large ships.

Images