Zinc-copper composite plated corrosion-resistant card clothing steel wire and processing technology thereof

Abstract

The invention provides a zinc-copper composite plated corrosion-resistant card clothing steel wire and a processing technology thereof.The processing technology comprises the steps that after drawing and heat treatment are completed, the card clothing steel wire is taken, unwound, cleaned to remove oil dirt on the surface and dried, and then a processed primary wire is obtained; the machined primary wire is immersed in a first electroplating bath for galvanization treatment to form a zinc plating layer, and a galvanized steel wire body is obtained; the galvanized steel wire body is subjected to surface roughening treatment after being cleaned, so that a bonding surface is formed on the surface of the galvanized steel wire body; immersing the galvanized steel wire body subjected to surface roughening treatment into a second electroplating bath for copper layer pre-plating treatment to form an intermediate bonding layer to obtain a first intermediate; carrying out alloying heat treatment on the first intermediate to form a copper-zinc composite layer to obtain a second intermediate; immersing the second intermediate into a third electroplating bath for copper plating treatment to form a copper plating layer to obtain a composite steel wire body; and coating anti-corrosion oil, and rolling into a disc to obtain a finished product. The strength and corrosion resistance of the card clothing steel wire can be effectively improved.

Description

Technical Field

[0001] This invention relates to the field of needle cloth steel wire technology, and in particular to a zinc-copper composite plated corrosion-resistant needle cloth steel wire and its processing technology. Background Technology

[0002] Card cloth is a core material in the textile industry for manufacturing combed cotton, wool, linen, silk, and synthetic fibers. As the surface coating of carding machines, card cloth is divided into two categories: metallic card cloth and elastic card cloth. Metallic card cloth is mainly used for rough spinning, opening, and impurity removal; elastic card cloth is mainly used for fine carding. With the increasing production demands of the textile industry, the required service life of carding machines has also greatly increased, thus placing higher demands on the strength and corrosion resistance of the card cloth wire. While traditional stainless steel card cloth wire has good corrosion resistance, its strength is relatively low and its carding effect is poor, while galvanized card cloth wire suffers from insufficient flatness and abrasion resistance. Summary of the Invention

[0003] In view of the shortcomings of the prior art described above, the purpose of this invention is to provide a zinc-copper composite plated corrosion-resistant needle cloth wire and its processing technology, which has the advantages of effectively improving the strength and corrosion resistance of the needle cloth wire.

[0004] To achieve the above and other related objectives, the present invention provides the following technical solution:

[0005] The first aspect of the present invention discloses a processing technology for zinc-copper composite coated corrosion-resistant needle wire, comprising:

[0006] After the needle cloth steel wire that has been drawn and heat-treated is unwound, it is cleaned to remove surface oil and dried to obtain the initial processed wire.

[0007] The raw wire is immersed in the first electroplating tank for zinc plating to form a zinc coating and obtain galvanized steel wire.

[0008] After the galvanized steel wire is cleaned, a surface roughening treatment is performed to form a bonding surface on the surface of the galvanized steel wire.

[0009] The galvanized steel wire, after surface roughening treatment, is immersed in the second electroplating tank for copper pre-plating treatment to form an intermediate bonding layer and obtain the first intermediate body.

[0010] The first intermediate is subjected to alloying heat treatment at 400-450°C under a protective atmosphere to bond the zinc coating with the intermediate bonding layer to form a copper-zinc composite layer, thus obtaining the second intermediate.

[0011] The second intermediate is immersed in the third electroplating tank for copper plating to form a copper plating layer, thus obtaining the composite steel wire.

[0012] After the composite steel wire is cleaned and dried, it is coated with anti-corrosion oil and then rolled into a coil to obtain the finished product.

[0013] In one embodiment of the present invention, the step of immersing the processed raw wire in a first electroplating bath for zinc plating to form a zinc coating and obtain galvanized steel wire specifically includes:

[0014] The raw wire is immersed in the zinc plating solution in the first electroplating tank. The pH value is controlled at 2.5-3, the plating solution temperature is controlled at 35-50℃, and the current density is controlled at 16-20 A / dm² for zinc plating treatment. The zinc coating thickness is controlled to reach 0.6-1μm to obtain galvanized steel wire.

[0015] In one embodiment of the present invention, the surface roughening treatment performed after cleaning the galvanized steel wire to form a bonding surface on the surface of the galvanized steel wire specifically includes:

[0016] After the galvanized steel wire is cleaned and dried, it is introduced into the sandblasting chamber and moved forward at a constant speed.

[0017] The galvanized steel wire is sandblasted to achieve surface roughening and form a bonding surface by controlling the abrasive particle size to be 0.3-0.6mm, the air pressure to be 0.35-0.55MPa, the sandblasting distance to be 85-120mm, and the sandblasting angle to be 65-75°.

[0018] In one embodiment of the present invention, the step of immersing the galvanized steel wire, after surface roughening treatment, into a second electroplating bath for copper pre-plating to form an intermediate bonding layer and obtain a first intermediate body specifically includes:

[0019] After the galvanized steel wire has undergone surface roughening treatment and cleaning, it is pickled and activated with a 3%-10% dilute acid solution to remove the surface oxide layer.

[0020] After being cleaned and dried again, the galvanized steel wire is placed in the second electroplating tank and electroplated in the pyrophosphate electroplating solution system to achieve copper pre-plating treatment to form an intermediate bonding layer. The pH value of the pyrophosphate electroplating solution system is controlled at 8.2-8.8, the temperature at 38-45℃, the current density at 5-10 A / dm², and the thickness of the intermediate bonding layer at 0.25-0.4μm.

[0021] After thoroughly cleaning to remove residual plating solution, the galvanized steel wire that forms the intermediate bonding layer is immersed in passivation solution for passivation treatment to obtain the first intermediate.

[0022] In one embodiment of the present invention, during alloying heat treatment, the temperature is increased according to a temperature gradient of 80-100℃, 150-200℃, 280-320℃, and 400-450℃.

[0023] In one embodiment of the present invention, the step of immersing the second intermediate in a third electroplating bath for copper plating to form a copper plating layer to obtain the composite steel wire specifically includes:

[0024] After cooling the second intermediate to room temperature, it is immersed in the third electroplating bath in a pyrophosphate electroplating solution system. The pH value is controlled at 8.4-8.8, the temperature at 38-45℃, and the current density at 20-25 A / dm² for copper plating treatment. The thickness of the copper plating layer is controlled at 0.5-1μm to obtain the composite steel wire.

[0025] In one embodiment of the present invention, the method further includes: before coating the surface with anti-corrosion oil:

[0026] After thoroughly cleaning to remove the plating solution remaining on the surface of the composite steel wire, the composite steel wire is immersed in a passivation solution for a secondary passivation treatment.

[0027] In one embodiment of the present invention, anti-corrosion oil is coated onto the surface of the composite steel wire by spraying.

[0028] In one embodiment of the present invention, it further includes:

[0029] After being coiled into a coil, the steel wire is kept at a temperature of 180-220℃ for 3-5 hours to eliminate hydrogen embrittlement.

[0030] The second aspect of the present invention discloses a zinc-copper composite corrosion-resistant needle wire, which is manufactured using the processing technology described in the first aspect.

[0031] As described above, the present invention has the following beneficial effects:

[0032] This invention provides a zinc-copper composite-plated corrosion-resistant needle-cloth steel wire and its processing technology. A zinc coating is formed on the surface of the steel wire through galvanizing, followed by copper pre-plating and copper plating to form an outer copper coating. This creates a protective layer structure with an inner zinc and an outer copper layer. The outer copper coating improves the overall conductivity of the steel wire, effectively dissipating static electricity and reducing the risk of fiber entanglement, dust adhesion, and sparks. Furthermore, the copper coating has superior wear resistance compared to the zinc coating, protecting the zinc coating and effectively extending its service life. The zinc coating is only consumed after the copper coating is damaged. The zinc coating acts as the anode and is preferentially corroded after the copper coating is damaged, thus effectively protecting the steel wire substrate. Surface roughening treatment improves the adhesion between the pre-plated copper and zinc coatings, reducing the likelihood of separation during use. A copper-zinc composite layer is then formed through alloying heat treatment, further enhancing the bonding strength between the coatings. Subsequent copper plating thickens the copper coating, ensuring sufficient adhesion while effectively guaranteeing the performance of the copper coating. Finally, anti-corrosion oil is applied to the steel wire surface for corrosion protection, effectively extending the service life of the steel wire. Detailed Implementation

[0033] The technical solutions in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0034] The first aspect of this invention provides a processing technology for zinc-copper composite coated corrosion-resistant needle wire, comprising:

[0035] S100. After the drawn and heat-treated needle wire is unwound, it is cleaned to remove surface oil and dried to obtain the initial processed wire. The needle wire can be an existing needle wire of appropriate size and model. The needle wire after drawing can reach the appropriate size, and the needle wire after heat treatment can effectively improve the strength of the needle wire. Of course, the drawing process and heat treatment process can use existing processes, such as austenitizing heat treatment.

[0036] During the unwinding process of the needle cloth steel wire, oil stains on the surface of the steel wire can be removed by chemical degreasing. Chemical degreasing can be carried out at 80°C with a mixed solution of 50-80 g / L sodium hydroxide, 30-50 g / L sodium carbonate and 20-40 g / L sodium phosphate, followed by rinsing with clean water and drying with hot air to ensure the reliability of subsequent electroplating. Of course, in some embodiments, the oxide layer on the surface of the steel wire can also be removed by soaking in a 10%-15% hydrochloric acid solution at room temperature for 5-10 minutes to improve the adhesion of the coating.

[0037] In one specific embodiment, the drawn and heat-treated needle-cloth steel wire is passively fed through a rotating wire rack. During the feeding process, ultrasonic alkaline washing, six-stage water washing, and ultrasonic sulfuric acid washing are used to remove oxide scale and residual soap powder and grease from the surface of the steel wire. The six-stage water washing uses a series of water rinsing to thoroughly clean the steel wire to avoid cross-contamination of the tank solutions, while ultrasonic sulfuric acid washing can reduce wastewater treatment pressure and effectively reduce operating costs. The steel wire is fed in a straight-line manner, with a maximum of 16 steel wires processed. The spacing between steel wires is controlled at 30 mm, the span between steel wires is controlled at 450 mm, the diameter of the processed steel wire is φ0.20-0.50 mm, and the feeding speed is controlled at 65-70 m / min.

[0038] S200: The initial wire is immersed in the first electroplating tank for galvanizing treatment to form a zinc coating and obtain galvanized steel wire.

[0039] Specifically, S200 involves immersing the initial wire in the zinc plating solution of the first electroplating tank, controlling the pH value to 2.5-3, the solution temperature to 35-50℃, and the current density to 16-20 A / dm² for zinc plating, and controlling the zinc coating thickness to reach 0.6-1μm to obtain the galvanized steel wire. The zinc plating solution can be zincate zinc plating solution, chloride zinc plating solution, etc. The thickness of the zinc coating can be controlled by controlling the wire's moving speed, thereby controlling the electroplating time. The coating thickness and electroplating time can typically be calculated using the following formula:

[0040] ;

[0041] Where d represents the target coating thickness (μm), t represents the electroplating time (min), and D k η represents the cathode current density (A / dm²). k The value represents the cathode current efficiency (%), C represents the electrochemical equivalent of zinc, taken as 1.22 g / (A·h), and ρ represents the density of zinc, taken as 7.14 g / cm³.

[0042] After calculating the electroplating time based on the target coating thickness using the above formula, and then calculating the required moving speed of the steel wire, effective electroplating deposition can be achieved.

[0043] In one specific example, the first electroplating tank and the zinc plating tank use soluble anodes. Zinc is replenished through another auxiliary tank, in which zinc is slowly dissolved by the solution. The pH value of the solution needs to be controlled to be maintained at about 2.0. A pump is used to circulate the solution in the zinc plating tank and the auxiliary tank, and the concentration is controlled by the pH value. The purpose is to ensure that the zinc ion concentration in the zinc solution is stable.

[0044] S300. After cleaning the galvanized steel wire, a surface roughening treatment is performed to form a bonding surface on the surface of the galvanized steel wire.

[0045] Specifically, the S300 includes:

[0046] S301. After cleaning and drying, the galvanized steel wire is introduced into the sandblasting chamber and moved forward at a constant speed. Specifically, it can be cleaned with water or dried with hot air. The sandblasting chamber is a relatively sealed structure, and the abrasive material will not splash out when the steel wire passes through the sandblasting chamber for sandblasting treatment.

[0047] After galvanizing, the steel wire can be directly wound up, and then unwound. The constant speed can be controlled according to actual needs. Alternatively, it can be passed directly through the cleaning tank and drying box into the sandblasting chamber without being wound up, and the constant speed is consistent with the moving speed required for electroplating.

[0048] S302. The abrasive particle size is controlled at 0.3-0.6mm, the air pressure at 0.35-0.55MPa, the blasting distance at 85-120mm, and the blasting angle at 65-75° to blast galvanized steel wire to achieve surface roughening and form a bonding surface. The abrasive can be selected from quartz sand, steel grit, glass beads, etc. The abrasive is sprayed out by a spray gun. The blasting distance is the distance between the spray gun nozzle and the surface of the steel wire, and the blasting angle is the angle between the axis of the spray gun nozzle and the extension of the steel wire.

[0049] The purpose of surface roughening is to give the zinc coating a certain roughness to improve the bonding strength with subsequent coatings. After sandblasting, the minimum thickness of the zinc coating must be not less than 0.2 μm.

[0050] S400. The galvanized steel wire, after surface roughening treatment, is immersed in the second electroplating tank for copper pre-plating treatment to form an intermediate bonding layer and obtain the first intermediate body.

[0051] Specifically, the S400 includes:

[0052] S401. After cleaning the galvanized steel wire that has undergone surface roughening treatment, surface pickling and activation are performed using a 3%-10% dilute acid solution to remove the surface oxide layer. The dilute acid solution can be dilute hydrochloric acid or dilute sulfuric acid. When performing surface activation, the concentration of the dilute acid solution and the treatment time must be strictly controlled to avoid excessive corrosion. In this embodiment, the treatment time is controlled to be 5-10 minutes.

[0053] S402. After cleaning and drying again, the galvanized steel wire is put into the second electroplating tank and electroplated in the pyrophosphate electroplating solution system to achieve copper pre-plating treatment to form an intermediate bonding layer. The pH value of the pyrophosphate electroplating solution system is controlled to be 8.2-8.8, the temperature is 38-45℃, the current density is 5-10 A / dm², and the thickness of the intermediate bonding layer is 0.25-0.4μm.

[0054] The pyrophosphate electroplating solution system may specifically include: 80-90 g / L of copper pyrophosphate (Cu2P2O7) to provide copper ions; 320-380 g / L of potassium pyrophosphate (K4P2O7) as the main complexing agent to stabilize copper ions; 20-25 g / L of ammonium citrate ((NH4)2HC6H5O7) as an auxiliary complexing agent to improve coating quality; and 2-3 ml / L of ammonia (NH4OH) to adjust the pH and improve coating gloss. The method for controlling the electroplating time is the same as in step S200.

[0055] S403. After thoroughly cleaning and removing residual plating solution, immerse the galvanized steel wire that forms the intermediate bonding layer in a passivation solution for passivation treatment to obtain the first intermediate. The passivation solution can be, for example, benzotriazole solution, and the immersion time is usually controlled at 5-8 minutes.

[0056] S500, the first intermediate is subjected to alloying heat treatment at a temperature of 400-450°C under a protective atmosphere to bond the zinc coating with the intermediate bonding layer to form a copper-zinc composite layer, thereby obtaining the second intermediate.

[0057] Specifically, before alloying heat treatment, the surface of the steel wire must be cleaned and dried. The protective atmosphere can be, for example, nitrogen. During alloying heat treatment, the temperature is increased in gradients of 80-100℃, 150-200℃, 280-320℃, and 400-450℃, so that the steel wire can be gradually heated. During operation, the steel wire can be passed through heating furnace sections with different temperature gradients. The steel wire is gradually heated as it moves slowly. The slow movement speed of the steel wire should ensure that each part of the steel wire is kept in the heating furnace section at 400-450℃ for 15-20 minutes, so that a metallurgically bonded copper-zinc composite layer is formed through atomic diffusion.

[0058] S600, the second intermediate is immersed in the third electroplating tank for copper plating to form a copper plating layer and obtain a composite steel wire.

[0059] Specifically, the S600 is as follows:

[0060] After cooling the second intermediate to room temperature, it is immersed in the third electroplating bath in a pyrophosphate electroplating solution system. The pH value is controlled at 8.4-8.8, the temperature at 38-45℃, and the current density at 20-25 A / dm² for copper plating treatment. The thickness of the copper plating layer is controlled at 0.5-1μm to obtain the composite steel wire.

[0061] The pyrophosphate electroplating solution system is the same as in step S402. By controlling different current densities and electroplating times, the thickness of the copper plating layer is controlled to be greater than the thickness of the intermediate bonding layer.

[0062] Furthermore, in some embodiments, the method further includes: S601, thoroughly cleaning and removing the plating solution remaining on the surface of the composite steel wire, then immersing the composite steel wire in a passivation solution for a secondary passivation treatment, wherein the secondary passivation treatment is the same as the initial passivation treatment.

[0063] After cleaning, steel wire usually has some moisture on its surface. Therefore, it needs to be dried after cleaning to ensure that the surface of the steel wire is dry. Electric drying can usually be used to make the temperature inside the drying oven reach about 120℃.

[0064] S700 After cleaning and drying the composite steel wire, apply anti-corrosion oil to the surface and roll it into a coil to obtain the finished product. The anti-corrosion oil is applied to the surface of the composite steel wire by spraying, preferably by electrostatic spraying.

[0065] In some embodiments, it further includes: S800, after being wound into a coil, the steel wire is kept at a temperature of 180-220°C for 3-5 hours to eliminate hydrogen embrittlement. This step is usually carried out within 2 hours after the copper plating process is completed. This step can effectively maintain the toughness and strength of the steel wire, and at the same time, it can facilitate the curing of the anti-corrosion oil.

[0066] The second aspect of the present invention provides a zinc-copper composite corrosion-resistant needle cloth steel wire, which is manufactured using the processing technology described in the first aspect.

[0067] This invention forms a zinc coating on the surface of a steel wire through galvanizing, followed by copper pre-plating and copper plating to form an outer copper coating, thus creating a protective layer structure with inner zinc and outer copper. The outer copper coating improves the overall conductivity of the steel wire, effectively dissipating static electricity and reducing the risk of fiber entanglement, dust adhesion, and sparks. Furthermore, the copper coating has superior wear resistance compared to the zinc coating, protecting it and extending its lifespan. The zinc coating is only consumed after the copper coating is damaged, whereas the zinc coating is consumed only after the copper coating is damaged. The steel wire substrate is then preferentially corroded as an anode, effectively protecting it. Surface roughening treatment improves the adhesion between the pre-plated copper and zinc layers, reducing the likelihood of separation during use. A copper-zinc composite layer is then formed through alloying heat treatment, further enhancing the bonding strength between the layers. Copper plating is then applied to thicken the copper layer, ensuring sufficient adhesion while maintaining the performance of the copper coating. Finally, anti-corrosion oil is applied to protect the steel wire surface from corrosion, effectively extending its service life.

[0068] The above embodiments merely illustrate several implementation methods of the present invention, and their descriptions are relatively specific and detailed, but they should not be construed as limiting the scope of the invention patent. It should be noted that, for those skilled in the art, several modifications and improvements can be made without departing from the concept of the present invention. These are all equivalent modifications and improvements made to the above embodiments based on the essential technology of the present invention, and all of these fall within the protection scope of the present invention.

Claims

1. A processing technology for zinc-copper composite coated corrosion-resistant needle-cloth steel wire, characterized in that, include: After the needle cloth steel wire that has been drawn and heat-treated is unwound, it is cleaned to remove surface oil and dried to obtain the initial processed wire. The raw wire is immersed in the first electroplating tank for zinc plating to form a zinc coating and obtain galvanized steel wire. After the galvanized steel wire is cleaned, a surface roughening treatment is performed to form a bonding surface on the surface of the galvanized steel wire. The galvanized steel wire, after surface roughening treatment, is immersed in the second electroplating tank for copper pre-plating treatment to form an intermediate bonding layer and obtain the first intermediate body. The first intermediate is subjected to alloying heat treatment at 400-450°C under a protective atmosphere to bond the zinc coating with the intermediate bonding layer to form a copper-zinc composite layer, thus obtaining the second intermediate. The second intermediate is immersed in the third electroplating tank for copper plating to form a copper plating layer, thus obtaining the composite steel wire. After the composite steel wire is cleaned and dried, it is coated with anti-corrosion oil and then rolled into a coil to obtain the finished product.

2. The processing technology of zinc-copper composite corrosion-resistant needle-cloth steel wire according to claim 1, characterized in that, The process of immersing the raw wire in the first electroplating bath for zinc plating to form a zinc coating and obtain galvanized steel wire specifically includes: The raw wire is immersed in the zinc plating solution in the first electroplating tank. The pH value is controlled at 2.5-3, the plating solution temperature is controlled at 35-50℃, and the current density is controlled at 16-20 A / dm² for zinc plating treatment. The zinc coating thickness is controlled to reach 0.6-1μm to obtain galvanized steel wire.

3. The processing technology of zinc-copper composite corrosion-resistant needle-cloth steel wire according to claim 1 or 2, characterized in that, The process of roughening the surface of the galvanized steel wire after cleaning to form a bonding surface specifically includes: After the galvanized steel wire is cleaned and dried, it is introduced into the sandblasting chamber and moved forward at a constant speed. The galvanized steel wire is sandblasted to achieve surface roughening and form a bonding surface by controlling the abrasive particle size to be 0.3-0.6mm, the air pressure to be 0.35-0.55MPa, the sandblasting distance to be 85-120mm, and the sandblasting angle to be 65-75°.

4. The processing technology of zinc-copper composite corrosion-resistant needle-cloth steel wire according to claim 3, characterized in that, The step of immersing the surface-roughened galvanized steel wire in a second electroplating bath for copper pre-plating to form an intermediate bonding layer and obtain the first intermediate body specifically includes: After the galvanized steel wire has undergone surface roughening treatment and cleaning, it is pickled and activated with a 3%-10% dilute acid solution to remove the surface oxide layer. After being cleaned and dried again, the galvanized steel wire is placed in the second electroplating tank and electroplated in the pyrophosphate electroplating solution system to achieve copper pre-plating treatment to form an intermediate bonding layer. The pH value of the pyrophosphate electroplating solution system is controlled at 8.2-8.8, the temperature at 38-45℃, the current density at 5-10 A / dm², and the thickness of the intermediate bonding layer at 0.25-0.4μm. After thoroughly cleaning to remove residual plating solution, the galvanized steel wire that forms the intermediate bonding layer is immersed in passivation solution for passivation treatment to obtain the first intermediate.

5. The processing technology of zinc-copper composite corrosion-resistant needle-cloth steel wire according to claim 4, characterized in that, When performing alloying heat treatment, the temperature is increased according to the temperature gradient of 80-100℃, 150-200℃, 280-320℃, and 400-450℃.

6. The processing technology of zinc-copper composite corrosion-resistant needle-cloth steel wire according to claim 1, characterized in that, The step of immersing the second intermediate in a third electroplating bath for copper plating to form a copper plating layer and obtaining the composite steel wire specifically includes: After cooling the second intermediate to room temperature, it is immersed in the third electroplating bath in a pyrophosphate electroplating solution system. The pH value is controlled at 8.4-8.8, the temperature at 38-45℃, and the current density at 20-25 A / dm² for copper plating treatment. The thickness of the copper plating layer is controlled at 0.5-1μm to obtain the composite steel wire.

7. The processing technology of zinc-copper composite corrosion-resistant needle-cloth steel wire according to claim 1, characterized in that, Before applying anti-corrosion oil to the surface, the following steps are also included: After thoroughly cleaning to remove the plating solution remaining on the surface of the composite steel wire, the composite steel wire is immersed in a passivation solution for a secondary passivation treatment.

8. The processing technology of zinc-copper composite corrosion-resistant needle-cloth steel wire according to claim 1, characterized in that, Anti-corrosion oil is applied to the surface of the composite steel wire by spraying.

9. The processing technology of zinc-copper composite corrosion-resistant needle-cloth steel wire according to claim 1, characterized in that, Also includes: After being coiled into a coil, the steel wire is kept at a temperature of 180-220℃ for 3-5 hours to eliminate hydrogen embrittlement.

10. A zinc-copper composite corrosion-resistant needle-cloth steel wire, characterized in that, It is prepared by any one of the processing techniques described in claims 1-9.