Method and apparatus for manufacturing an anti-corrosion coating by spray forming

Abstract

A manufacturing method and device for an anti-corrosion coating by spray forming, specifically including the following steps: Step 1, melting a prefabricated metal alloy block into alloy liquid, and the temperature of the melted alloy liquid is between 1550 degrees Celsius and 1750 degrees Celsius; Step 2, using a tundish to carry the melted alloy liquid; Step 3, starting the atomizing nozzle, atomizing the flowing alloy liquid by using the kinetic energy of an inert gas, and spraying the atomized metal liquid particles onto the surface of the processing object in the spray chamber to form an anti-corrosion layer on the surface of the processing object. The present invention adopts a process of atomizing alloy liquid flow into fine droplets by an inert gas, flying and cooling under a high-speed gas flow, and depositing into a blank before being completely solidified. The coating dilution rate is low, the coating material composition is uniform, the structure is refined, there is no macroscopic segregation, and the oxygen content is low, which is much better than the existing manufacturing methods of anti-corrosion coatings and has a broad market prospect.

Description

Technical Field

[0001] The present invention relates to the technical field of anti-corrosion coatings, and more specifically, particularly relates to a manufacturing method and device for a spray-formed anti-corrosion coating. Background Art

[0002] As the core heat transfer component of a boiler, the membrane water wall has long faced the problem of tube explosion caused by high-temperature corrosion. With the increase in the boiler operation temperature requirement, the traditional surface protection technology for alloy steel pipes has become insufficient. The current mainstream technology adopts the surfacing process to achieve anti-corrosion by surfacing stainless steel materials or superalloy materials on the substrate surface.

[0003] However, the surfacing technology has significant defects. On the one hand, it is necessary to pre-process the materials into powder or wire materials in advance, resulting in an increase in raw material costs; secondly, a relatively high dilution rate is generated during the surfacing process, resulting in segregation of the coating tissue composition and a decrease in corrosion resistance; at the same time, the multi-layer surfacing process has extremely low efficiency and is difficult to meet the continuous production requirements of large boilers. The improvement directions of the existing technology mostly focus on optimizing the surfacing material formula or adjusting the process parameters, but they have not been able to break through the inherent limitations of the surfacing technology, and there are problems such as dendritic coarsening and element segregation in the microstructure of the surfacing layer, which directly affect the service life of the coating.

[0004] In the actual production process, not only the membrane water wall tube rows, but also materials such as marine pipelines, compressed air energy devices, and coal storage devices require surface material anti-corrosion.

[0005] Therefore, the problems existing in the existing technology need to be further improved and developed. Summary of the Invention

[0006] (1) Invention Objective: To solve the problems existing in the above-mentioned existing technology, the objective of the present invention is to provide a manufacturing method and device for a spray-formed anti-corrosion coating to improve the efficiency of alloy spraying.

[0007] (2) Technical Solution: To solve the above technical problems, the present technical solution provides a manufacturing device for a spray-formed anti-corrosion coating, which includes an atomization workshop. The atomization workshop includes a spray chamber for accommodating the processing object and the operation unit of the processing object, and a spraying unit is arranged at the top of the atomization workshop;

[0008] Melting a prefabricated metal alloy block into alloy liquid;

[0009] The spraying unit includes a tundish for carrying the melted alloy liquid, and the temperature of the melted alloy liquid is between 1550 degrees Celsius and 1750 degrees Celsius;

[0010] The injection unit further includes an atomizing nozzle. One end of the atomizing nozzle is connected to the tundish, and the other end extends into the spraying chamber. The atomizing nozzle is also connected to an inert gas input device;

[0011] When the atomizing nozzle is activated, the kinetic energy of the inert gas is used to atomize the flowing alloy liquid. The atomized metal liquid particles are sprayed onto the surface of the processing object in the spraying chamber, forming an anti-corrosion layer on the surface of the processing object.

[0012] In the manufacturing device of the anti-corrosion coating by spray forming, the diameter distribution range of the atomized metal particles is 15um - 200um.

[0013] In the manufacturing device of the anti-corrosion coating by spray forming, a heating and heat preservation unit is arranged around the tundish, and the heating and heat preservation unit is used to maintain the temperature of the alloy liquid between 1550 degrees Celsius and 1750 degrees Celsius.

[0014] In the manufacturing device of the anti-corrosion coating by spray forming, the nozzle body of the atomizing nozzle has a metal solution channel in the vertical direction. The middle part of the nozzle body in the horizontal direction has a protrusion arranged on the metal solution channel, and a metal solution narrowing component is arranged above the protrusion.

[0015] In the manufacturing device of the anti-corrosion coating by spray forming, a first inert gas channel and a second inert gas channel are respectively arranged on the left and right sides of the nozzle body in the horizontal direction; an annular air channel in the horizontal direction is arranged in the middle of the nozzle body, and the first inert gas channel and the second inert gas channel are connected to the annular air channel; the inner side of the annular air channel close to the metal solution channel has a first gas channel in the vertical direction; a horizontal second gas channel and a vertical third gas channel are formed between the lower side of the metal solution narrowing component and the protrusion; the first gas channel, the second gas channel and the third gas channel are connected to form a spraying channel.

[0016] In the manufacturing device of the anti-corrosion coating by spray forming, the atomizing nozzle sprays inert gas into the spraying chamber from the first inert gas channel and the second inert gas channel on the left and right sides at a flow rate of 1000 - 3000 cubic meters per hour and a pressure of 1.5 - 3.5 MPa through the spraying channel.

[0017] A manufacturing method of an anti-corrosion coating by spray forming specifically includes the following steps:

[0018] Step 1: Melting the metal alloy block of the prefabricated components into alloy liquid, and the temperature of the melted alloy liquid is between 1550 degrees Celsius and 1750 degrees Celsius;

[0019] Step 2: Use a tundish to hold the molten alloy liquid.

[0020] Step 3: Start the atomizing nozzle, use the kinetic energy of the inert gas to atomize the flowing alloy liquid, and spray the atomized metal liquid particles onto the surface of the processing object in the spray chamber to form an anti-corrosion layer on the surface of the processing object.

[0021] In the described manufacturing method of a spray-formed anti-corrosion coating, the atomizing nozzle injects inert gas into the spray chamber from the first inert gas channel and the second inert gas channel on the left and right sides at a flow rate of 1000 - 3000 cubic meters per hour and a pressure of 1.5 - 3.5 MPa.

[0022] In the described manufacturing method of a spray-formed anti-corrosion coating, inert gas is introduced through the first inert gas channel and the second inert gas channel respectively arranged on the left and right sides in the horizontal direction of the nozzle body; the inert gas passes through the annular air channel in the middle of the nozzle body, and then through the first gas channel in the vertical direction connected to the annular air channel; the metal solution narrowing part and the lower protrusion form a horizontal second gas channel and a vertical third gas channel and spray out.

[0023] In the described manufacturing method of a spray-formed anti-corrosion coating, the alloy liquid is atomized into metal liquid particles with a size of 15um - 200um.

[0024] (III) Beneficial effects: The manufacturing method and device of a spray-formed anti-corrosion coating provided by the present invention have high production efficiency. It directly customizes metal alloy blocks with the required components, uses the metal melting liquid of the metal alloy block as the raw material, atomizes the alloy liquid flow into fine droplets with inert gas, flies and cools under high-speed air flow, and deposits into a blank before it is completely solidified. It does not require powders and wires needed for welding processes, has low costs; in addition, the coating dilution rate is low; finally, the coating material has uniform composition, refined structure, no macroscopic segregation, low oxygen content, is much better than the existing manufacturing methods of anti-corrosion coatings, and has broad market prospects. Brief Description of the Drawings

[0025] Figure 1 is a schematic structural diagram of a manufacturing device of a spray-formed anti-corrosion coating of the present invention;

[0026] Figure 2 is a schematic structural diagram of the atomizing nozzle of the present invention;

[0027] Figure 3 is a schematic structural diagram of the hollow area on the rotating unit of the operation unit of the present invention located on the processing object;

[0028] Figure 4It is a schematic structural diagram of the covered area on the rotating unit of the operation unit of the present invention located on the processing object;

[0029] Figure 5 It is a schematic flow diagram of a manufacturing method of an anti-corrosion coating by spray forming according to the present invention.

[0030] Reference numerals: spraying unit 100, tundish 110, heating and heat preservation unit 120, atomizing nozzle 130, nozzle body 131, molten metal channel 132, protrusion 133, molten metal narrowing member 134, first inert gas channel 135, second inert gas channel 136, annular air channel 137, spraying channel 138, first gas channel 138-1, second gas channel 138-2, third gas channel 138-3, funnel-shaped nozzle 139, atomizing working chamber 200, spraying cavity 210, processing object 220, operation unit 230, rotating unit 240, covering plate 2401, covered area 2401a, hollowed area 2401b, crawler power sub-module 2402, crawler 2403, motor 250. Detailed embodiments

[0031] The following further describes the present invention in detail with reference to preferred embodiments. More details are elaborated in the following description for a full understanding of the present invention. However, the present invention can obviously be implemented in many other ways different from this description. Those skilled in the art can make similar extensions and deductions according to the actual application situation without departing from the connotation of the present invention. Therefore, the protection scope of the present invention should not be limited by the content of this specific embodiment.

[0032] The attached drawings are schematic diagrams of embodiments of the present invention. It should be noted that this attached drawing is only for illustration and is not drawn under the condition of equal proportion, and should not be used to limit the actual claimed protection scope of the present invention.

[0033] A manufacturing device for an anti-corrosion coating by spray forming provided by the present invention, as Figure 1 shown, includes an atomizing working chamber 200. The atomizing working chamber includes a spraying cavity 210. The spraying cavity 210 is used to accommodate the processing object 220 and the operation unit 230 of the processing object. The operation unit 230 is used for automatic operations such as fixing, rotating, feeding into the spraying cavity, and outputting from the spraying cavity of the processing object, so that the processing object 220 can be position-adjusted in the spraying cavity 210 according to anti-corrosion requirements. The spraying cavity 210 of the present invention can be oval or square, etc., which will not be elaborated here.

[0034] Melting a prefabricated metal alloy block into an alloy liquid. The alloy liquid is a superalloy liquid, and the temperature of the superalloy liquid is between 1550 °C and 1750 °C.

[0035] At the top of the atomization workshop 200, a spraying unit 100 is provided. The spraying unit 100 includes a tundish 110 which is used to hold the molten alloy liquid. The temperature of the molten alloy liquid is between 1550 °C and 1750 °C. A heating and heat preservation unit 120 is arranged around the tundish 110, and the heating and heat preservation unit 120 is used to maintain the temperature of the alloy liquid between 1550 °C and 1750 °C to meet the temperature required for alloy liquid atomization. The spraying unit 100 further includes an atomizing nozzle 130. One end of the atomizing nozzle 130 is connected to the tundish 110, and the other end extends into the spraying cavity 210. At the same time, the atomizing nozzle 130 is also connected to an inert gas input device. When the atomizing nozzle 130 is started, the kinetic energy of the inert gas is used to atomize the alloy liquid. The diameter distribution range of the atomized metal particles is 15um - 200um. Subsequently, the atomizing nozzle 130 sprays the atomized metal particles into the spraying cavity 210.

[0036] In the present invention, an alloy material of a metal alloy block is used as the raw material before melting. The metal alloy block can be a metal alloy block customized according to anti-corrosion requirements, such as a chromium alloy block. When the anti-corrosion requirement is a nickel-based alloy, the composition of the nickel-based alloy has the preferred embodiments in Table 1:

[0037] Table 1

[0038]

[0039] The atomizing nozzle 130, as Figure 2 shown, includes a nozzle body 131. The nozzle body 131 is columnar or in other shapes. It further includes a metal solution channel 132 in the vertical direction of the nozzle body 131. In the middle part of the horizontal direction of the nozzle body 131, there is a protrusion 133 on the metal solution channel 132. An upper-wide and lower-narrow metal solution narrowing member 134 is embedded in the upper part of the protrusion 133, and the metal solution narrowing member 134 is arranged above the protrusion 133. Below the connection of the inert gas channel and the metal solution narrowing member 134 is a narrowing-up and widening-down atomization outlet, and the atomization outlet is arranged below the protrusion 133.

[0040] A first inert gas channel 135 and a second inert gas channel 136 are respectively arranged on the left and right sides of the horizontal direction of the nozzle body 131, and the first inert gas channel 135 and the second inert gas channel 136 are preferably symmetrically arranged left and right.

[0041] A horizontal annular air channel 137 is provided in the middle of the spray head body 131, and the first inert gas channel 135 and the second inert gas channel 136 are connected to the annular air channel 137. The annular air channel in the middle of the spray head body 131 has a vertical first gas channel 138-1 on the inner side close to the metal solution channel 132. The upper-wide and lower-narrow metal solution narrowing member 134 and the protrusion 133 form a horizontal second gas channel 138-2 and a vertical third gas channel 138-3. The channel formed by the communication of the first gas channel 138-1, the second gas channel 138-2 and the third gas channel 138-3 is called a spray channel 138. The first gas channel 138-1, the second gas channel 138-2 and the third gas channel 138-3 are connected. The width of the first gas channel 138-1 is higher than that of the second gas channel 138-2, and the width of the second gas channel 138-2 is higher than that of the third gas channel 138-3. That is, the high-pressure inert gas propagates vertically upward from the first gas channel 138-1, horizontally from the second gas channel 138-2, and vertically downward from the third gas channel 138-3. Preferably, the third gas channel 138-3 is a high-pressure inert gas channel with a gradually narrowing outlet, and the third gas channel 138-3 has an inclination angle of about 15 degrees with the vertical direction. Preferably, the first gas channel 138-1 and the second gas channel 138-2 both have gradually narrowing outlets in the gas propagation direction.

[0042] Preferably, the annular air channel 137 has a vertical first gas channel 138-1 and a horizontal second gas channel 138-2 on the inner side close to the metal solution channel 132. The outlet of the second gas channel 138-2 and the upper-wide and lower-narrow metal solution narrowing member 134 form a vertical third gas channel 138-3. The channel formed by the communication of the first gas channel 138-1, the second gas channel 138-2 and the third gas channel 138-3 is the spray channel 138.

[0043] The inert gas in the present invention is a high-temperature and high-pressure inert gas, and the temperature of the high-temperature and high-pressure inert gas is controlled between 1550 °C and 1750 °C, and the pressure is controlled between 1.5 - 3.5 MPa.

[0044] The spray head body 131 of the present invention makes high-pressure gas spray out from the spray channel 138 with a gradually narrowing outlet. A funnel-shaped nozzle 139 is arranged on the inner wall of the atomization outlet. The falling high-temperature molten metal solution is instantaneously atomized into powdered liquid metal particles by the high-pressure gas through the funnel-shaped nozzle 139. The angle of the funnel-shaped nozzle 139 of the present invention preferably can be a divergence angle of about 15 degrees, and there is no specific limitation. The divergence angle of the funnel-shaped nozzle 139 of the present invention can be adjusted to adjust the spraying range of the powdered liquid metal particles.

[0045] The inert gas of the present invention includes inert gases such as nitrogen N2 and argon Ar, and there is no specific limitation. The atomizing spray head 130 inputs the inert gas into the spray chamber 210 at a very large flow rate. At a flow rate of 1000 - 3000 cubic meters per hour and a pressure of 1.5 - 3.5 MPa, the large-flow inert gas is input into the spray chamber 210 and discharged from the exhaust holes at the bottom of the spray chamber 210, and the air in the spray chamber 210 overflows through the exhaust holes, so that the spray chamber 210 is in an inert gas atmosphere. The high-temperature molten solution produced by the present invention is in an inert gas atmosphere during the process of being atomized into particles and from high-temperature liquid state to solidification, and will not be oxidized or incorporated with other impurity gases, thereby improving the quality of the anti-corrosion coating on the processing object 220.

[0046] Existing anti-corrosion technologies use alloy powder materials or alloy wire materials as the raw materials for spraying. The present invention directly uses metal alloy blocks as the raw materials for spraying. The high-temperature molten metal solution after melting the metal alloy blocks is directly atomized into powdered state by high-pressure inert gas, and the powdered liquid alloy particles are directly sprayed on the surface of the processing object for anti-corrosion spraying. The present invention omits the process of remelting and spraying the powdered metal again, reduces the pollution of the anti-corrosion raw materials, has good purity of the anti-corrosion materials, does not require secondary heating, and saves energy.

[0047] The spray chamber 210 of the present invention has an inlet and an outlet for the processing object, and exhaust holes at the bottom. The exhaust holes are used for exhausting the inert gas during the spraying and forming process of the anti-corrosion coating, and at the same time solidifying the alloy liquid particles that have not been deposited on the membrane wall into solid particles, and discharging them out of the spray chamber 210 with the inert gas flow for recycling. Preferably, an alloy powder recovery unit is arranged outside the exhaust holes.

[0048] In a preferred embodiment of the spray chamber 210 of the present invention, the spray chamber 210 is cylindrical, and the size of the cylindrical spray chamber 210 is about 8 m to 15 m in height and about 1.5 m to 3 m in diameter. The present invention can adjust the size of the spray chamber 210 according to requirements, and the spray chamber of the present invention can process large processing objects. The anti-corrosion coating of the processing object 220 can be sprayed in one pass. The grains of the anti-corrosion coating are fine, the structure is uniform, and rapid solidification technologies such as inhibition of macrosegregation can be achieved. In addition, the thickness of the coating sprayed on the processing object by the present invention is controllable, the coating production efficiency is high, there is no need for secondary heating like surfacing and spraying, and it is low-carbon and environmentally friendly.

[0049] Preferably, the processing object 220 of the present invention is a membrane wall tube bank, an offshore pipeline, a compressed air energy device, a coal storage device, etc. The rotating unit 240 includes supporting rollers on both sides of the membrane wall, and the supporting rollers fix both ends of the membrane wall tube bank, so that the membrane wall tube bank passes through the spray chamber 210 at a set rate and position, and the atomized alloy liquid particles are deposited on the membrane wall tube bank and solidify and accumulate into an anti-corrosion coating.

[0050] Preferably, the thickness of the anti-corrosion coating of the present invention is 0.5 mm to 3 mm.

[0051] In order to improve the control of the thickness and uniformity of the anti-corrosion coating, the present invention also provides a thickness detection unit and a processing object cooling unit in the spray chamber 210. The thickness detection unit, the processing object cooling unit, the operation unit 230, and the funnel-shaped nozzle adjustment unit are all connected to the main control unit. The processing object cooling unit can be a water-cooled circulation cooling device that penetrates the membrane wall tube bank or is arranged under the membrane wall tube bank. The main control unit of the present invention controls the circulation frequency of the water-cooled circulation cooling device according to the detection data of the thickness detection unit, and increases the circulation frequency according to the increase in the thickness of the anti-corrosion coating to inhibit macrosegregation.

[0052] The present invention provides a thickness detection unit on the inner wall of the top in the spray chamber 210. During the process of spraying the anti-corrosion coating on the processing object 220, the thickness detection unit monitors the thickness of the anti-corrosion coating in real time, and adjusts the thickness of the anti-corrosion coating by adjusting the spraying angle of the funnel-shaped nozzle and the position of the processing object 220 by the operation unit 230, so as to obtain a uniform anti-corrosion coating that meets the set thickness.

[0053] The annular air passage 137 on the nozzle body 131 of the present invention is a storage space for inert gas, which can make the pressure of the inert gas more uniform. In addition, the process of the spray passage 138 gradually narrowing is also a process of pressurizing the inert gas.

[0054] Preferably, the thickness detection unit of the present invention may be an infrared detection device, and the principle of thickness detection of the anti-corrosion coating is not limited here.

[0055] The operation unit 230 of the present invention includes an operation table, a translation module fixed on the operation table, and a rotation unit surrounding the operation table. The rotation unit includes a cover plate 2401, a crawler 2403 for driving the cover plate to rotate, a roller, and a motor 250. The processing object 220 is fixed on the operation table, and the rotation unit rotates around the processing object 220.

[0056] The cover plate 2401 includes a flexible steel outer frame, which is divided into two regions, a covering region 2401a and a hollow region 2401b. The covering region 2401a has a plurality of grid surfaces, which can be placed horizontally or vertically. By adjusting the position of the grid surfaces, the covering position of the covering region 2401a can be dynamically adjusted. When the processing object 220 is installed, the hollow region 2401b is located above the processing object 220, as Figure 3 shown. The main control unit first controls a plurality of specified grid surfaces of the cover plate 2401 to adjust their positions to the vertical direction, and then the motor 250 rotates the covering region 2401a of the cover plate 2401 to the surface of the processing object 220 through the crawler 2403 and the roller.

[0057] The operation unit 230 can translate the processing object 220, or can rotate the cover plate 2401 around the processing object 220 through the rotation unit 240. The rotation unit 240 is connected to the main control unit, and rotates at a rotation moment, speed and rotation position according to the control of the main control unit, and the translation moment, translation speed and translation position of the operation unit 230, so that the processing object 220 obtains the most uniform anti-corrosion coating.

[0058] The rotation unit 240 of the present invention may further include a crawler 2403, a crawler power sub-module 2402 and a motor 250. The motor 250 drives the rotation of the crawler power sub-module 2402, and the crawler power sub-module 2402 drives the crawler 2403 to rotate.

[0059] The translation speed of the operation unit 230 of the present invention matches the set thickness of the processing object 220, that is, the translation speed makes the product of the residence time of the processing object 220 and the spraying rate of the funnel-shaped nozzle 139 meet the threshold value of the set thickness of the processing object.

[0060] The inner wall of the covering plate 2401 is a crawler structure. An outer frame is arranged on the outer wall of the crawler structure. A cross-shaped grid is arranged in the covering area 2401a of the outer frame. A grid surface is arranged on each grid. The grid surface can be placed horizontally or vertically around the engaging part on the rotating shaft. The cross-shaped grid arranged in the area is called the first grid.

[0061] The infrared detection device measures the surface coating thickness distribution of the processing object by using non-contact coating non-destructive testing technology and sends the detected data to the control unit. The control unit sets a grid positioning map on the image surface of the processing object 220 according to the detection image of the infrared detection device. The grid positioning map corresponds to the thickness distribution map on the surface of the processing object 220. The grid on the grid positioning map is called the second grid. The control unit compares the grid positioning map of the processing object 220 with the thickness distribution map to determine the serial numbers of the second grids on the grid positioning map with a thickness less than the threshold. Preferably, in the present invention, the area of the first grid can be smaller than that of the second grid. The control unit sends the serial numbers of the first grids covered by the second grid to the rotating unit 240. The rotating unit 240 controls the corresponding serial number of the first grid to be adjusted from the horizontal position to the vertical position, and then rotates and covers it on the grid positioning map of the processing object 220, as Figure 4 shown.

[0062] In the present invention, the atomizing nozzle 130 continues to spray the processing object covered by the covering plate 2401, so that the anti-corrosion coating on the surface of the processing object 220 reaches a uniform state.

[0063] The present invention provides a manufacturing method for a spray-formed anti-corrosion coating, which specifically includes the following steps, as Figure 5 shown:

[0064] Step 1: Melting a prefabricated metal alloy block into alloy liquid, and the temperature of the melted alloy liquid is between 1550 °C and 1750 °C;

[0065] Step 2: Using the tundish 110 to carry the melted alloy liquid;

[0066] Step 3: Starting the atomizing nozzle 130, atomizing the flowing alloy liquid by using the kinetic energy of inert gas, and spraying the atomized metal liquid particles onto the surface of the processing object 220 in the spray chamber 210 to form an anti-corrosion layer on the surface of the processing object 220.

[0067] Preferably, in a method for manufacturing an anti-corrosion coating by spray forming according to the present invention, the atomizing nozzle 130 injects inert gas into the spray chamber 210 from the first inert gas passage 135 and the second inert gas passage 136 on the left and right sides at a flow rate of 1000 - 3000 cubic meters per hour and a pressure of 1.5 - 3.5 MPa. In this way, the kinetic energy of the inert gas is used to atomize the flowing alloy liquid into metal liquid particles with a size of 15um - 200um. In addition, a large amount of inert gas overflows the air in the spray chamber 210, so that the processing object 220 and the metal liquid particles are in an environment without oxygen, water, and other impurity gases, preventing the metal liquid particles from being oxidized during the process from high-temperature liquid state to solid state. The present invention makes the anti-corrosion coating on the surface of the processing object 220 have fine grains, uniform structure, controllable coating thickness, and can inhibit macro-segregation. The method of the present invention has high coating production efficiency, does not require secondary heating like surfacing and spraying, and is low-carbon and environmentally friendly.

[0068] In a method for manufacturing an anti-corrosion coating by spray forming according to the present invention, inert gas is introduced through the first inert gas passage 135 and the second inert gas passage 136 respectively provided on the left and right sides in the horizontal direction of the nozzle body 131; the inert gas first passes through the annular air passage 137 in the middle of the nozzle body 131, and then passes through the first gas passage 138-1 in the vertical direction communicating with the annular air passage 137; finally, it is ejected from the horizontal second gas passage 138-2 formed by the metal solution narrowing member 134 and the protrusion 133 and the third gas passage 138-3 in the vertical direction. The spraying method of the present invention makes the pressure of the ejected inert gas more uniform, which is beneficial to forming an anti-corrosion coating material with uniform composition.

[0069] In a method for manufacturing an anti-corrosion coating by spray forming according to the present invention, the purity of the anti-corrosion coating is good, secondary heating is not required, and a large-scale spraying device can be made to spray and process large-scale processing objects.

[0070] A method and device for manufacturing an anti-corrosion coating by spray forming provided by the present invention have high production efficiency. A metal alloy block with the required components is directly customized, and the metal melting liquid of the metal alloy block is used as the raw material. Inert gas is used to atomize the alloy liquid flow into fine droplets, which fly and cool under high-speed air flow and deposit into a blank before completely solidifying. Powders and wires required for the welding process are not used, and the cost is low; in addition, the coating dilution rate is low; finally, the coating material has uniform composition, refined structure, no macro-segregation, and low oxygen content, which is much better than the existing methods for manufacturing anti-corrosion coatings and has broad market prospects.

[0071] The above content is an illustration of the preferred embodiments of the present invention, which can help those skilled in the art to more fully understand the technical solutions of the present invention. However, these embodiments are merely examples and it cannot be determined that the specific implementation manners of the present invention are limited to the descriptions of these embodiments. For those of ordinary skill in the technical field to which the present invention pertains, without departing from the concept of the present invention, several simple deductions and transformations can still be made, and all should be regarded as falling within the protection scope of the present invention.

Claims

1. A manufacturing device for an anti-corrosion coating by spray molding, characterized in that, It includes an atomization workshop, and the atomization workshop includes a spraying chamber which is used to accommodate the processing object and the operation unit of the processing object. A spraying unit is arranged at the top of the atomization workshop; Melting the prefabricated metal alloy block into alloy liquid; The spraying unit includes a tundish which is used to hold the melted alloy liquid, and the temperature of the melted alloy liquid is between 1550 °C and 1750 °C; The spraying unit further includes an atomizing nozzle. One end of the atomizing nozzle is connected to the tundish, and the other end extends into the spraying chamber. The atomizing nozzle is also connected with an inert gas input device; When the atomizing nozzle is started, the kinetic energy of the inert gas is used to atomize the flowing alloy liquid, and the atomized metal liquid particles are sprayed onto the surface of the processing object in the spraying chamber to form an anti-corrosion layer on the surface of the processing object; The operation unit includes an operating table, a translation module fixed on the operating table, and a rotating unit surrounding the operating table; the rotating unit includes a cover plate, a crawler belt driving the cover plate to rotate, a roller and a motor; the processing object is fixed on the operating table, and the rotating unit rotates around the processing object; The cover plate includes a flexible steel outer frame which is divided into two areas, a covering area and a hollow area; the covering area has a plurality of grid surfaces which are placed horizontally or vertically, and the covering position of the covering area is dynamically adjusted by adjusting the position of the grid surfaces.

2. The manufacturing apparatus of an anti-corrosion coating by spray forming according to claim 1, characterized in that, The diameter distribution range of the atomized metal particles is 15μm - 200μm.

3. The manufacturing apparatus of an anti-corrosion coating by spray forming according to claim 1, characterized in that, A heating and heat preservation unit is arranged around the tundish, and the heating and heat preservation unit is used to maintain the temperature of the alloy liquid between 1550 °C and 1750 °C.

4. The manufacturing device of an anti-corrosion coating by spray forming according to claim 1, characterized in that, The nozzle body of the atomizing nozzle has a metal solution channel in the vertical direction. In the middle part of the nozzle body in the horizontal direction, there is a protrusion arranged on the metal solution channel, and a metal solution narrowing component is arranged above the protrusion.

5. The manufacturing device of an anti-corrosion coating by spray forming according to claim 4, characterized in that, A first inert gas channel and a second inert gas channel are respectively arranged on the left and right sides of the nozzle body in the horizontal direction; a horizontal annular air channel is arranged in the middle of the nozzle body, and the first inert gas channel and the second inert gas channel are connected to the annular air channel; the annular air channel has a first gas channel in the vertical direction on the inner side close to the metal solution channel; a horizontal second gas channel and a vertical third gas channel are formed between the lower side of the metal solution narrowing component and the protrusion; the first gas channel, the second gas channel and the third gas channel are connected to form a spraying channel.

6. The manufacturing device of an anti-corrosion coating by spray forming according to claim 1, characterized in that, The atomizing nozzle sprays inert gas into the spraying chamber from the first inert gas channel and the second inert gas channel on the left and right sides at a flow rate of 1000 - 3000 cubic meters per hour and a pressure of 1.5 - 3.5 MPa through the spraying channel.

7. A manufacturing method of a spray-molded anti-corrosion coating, applied to a manufacturing device of a spray-molded anti-corrosion coating according to any one of claims 1-6, characterized in that, Specifically, it includes the following steps: Step 1: Melting the prefabricated metal alloy block into alloy liquid, and the temperature of the melted alloy liquid is between 1550 °C and 1750 °C; Step 2: Using a tundish to hold the melted alloy liquid; Step 3: The atomizing nozzle starts, and the kinetic energy of the inert gas is used to atomize the flowing alloy liquid. The atomized metal liquid particles are sprayed onto the surface of the processing object in the spray chamber to form an anti-corrosion layer on the surface of the processing object. When the processing object is installed, the hollow area is located above the processing object. The main control unit first controls the positions of multiple grid surfaces specified by the cover plate to be adjusted to the vertical direction, and then the motor rotates the covered area of the cover plate to the surface of the processing object through the crawler and the idler roller. The operating unit translates the processing object or rotates the cover plate around the processing object through the rotating unit; the rotating unit is connected to the main control unit. According to the rotation time, speed, and rotation position of the rotating unit controlled by the main control unit, as well as the translation time, translation speed, and translation position of the operating unit, the processing object is coated with a uniform anti-corrosion layer.

8. A manufacturing method of an anti-corrosion coating by spray forming according to claim 7, characterized in that, The atomizing nozzle injects inert gas into the spray chamber from the first inert gas channel and the second inert gas channel on the left and right sides at a flow rate of 1000 - 3000 cubic meters per hour and a pressure of 1.5 - 3.5 MPa.

9. The manufacturing method of an anti-corrosion coating by spray forming according to claim 7, characterized in that, Inert gas is introduced through the first inert gas channel and the second inert gas channel respectively arranged on the left and right sides in the horizontal direction of the nozzle body; the inert gas passes through the annular air channel in the middle of the nozzle body, and then through the first gas channel in the vertical direction connected to the annular air channel; the metal solution narrowing part and the lower protrusion form a horizontal second gas channel and a vertical third gas channel and spray out.

10. A method for manufacturing an anti-corrosion coating by spray forming according to claim 7, characterized in that, The alloy liquid is atomized into metal liquid particles with a size of 15μm - 200μm.

Images