Preparation method of wear-resistant, corrosion-resistant and toxic ion escape-resistant coating for laryngoscope and endoscope aluminum alloy disinfection box
The three-layer composite coating structure solves the problems of corrosion and ion escape of aluminum alloy sterilization boxes under high temperature and high pressure sterilization and near-shore overseas training environments, achieving high wear resistance and corrosion resistance, and ensuring the safety and service life of medical devices.
Patent Information
- Application Number
- CN202511545442.9
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-10-28
- Publication Date
- 2026-01-23
AI Technical Summary
Existing aluminum alloy sterilization boxes are prone to corrosion and oxide film peeling under high-temperature and high-pressure steam sterilization and near-shore overseas training environments, resulting in the release of metal ions, which affects service life and medical safety.
A three-layer composite coating is adopted, including an AlSi10Mg base layer, a carrier layer of nano-TiC and rare earth oxides, and a nano-ceramic functional layer. The coating is formed by laser cladding process to form a metallurgical bond, which relieves thermal stress, improves hardness and corrosion resistance, and blocks the migration of metal ions.
It significantly improves the wear resistance and corrosion resistance of aluminum alloy disinfection boxes, extends their service life, ensures medical safety, and maintains long-term stability, especially in high humidity and high salt spray environments.
Smart Images
Figure CN121380941A_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The present application relates to the technical field of medical instrument research and development and material coating preparation, and particularly relates to a preparation method of a wear-resistant, corrosion-resistant and anti-toxic ion escape coating of a laryngoscope and endoscope aluminum alloy disinfection box. BACKGROUND
[0002] Aluminum alloy becomes an ideal material for manufacturing laryngoscopes and endoscopes and their supporting storage devices due to its low density, high specific strength, good processing performance and good thermal conductivity. Laryngoscopes and endoscopes are important medical instruments commonly used in clinical otolaryngology, respiratory department and surgery, and play an irreplaceable role in disease diagnosis, treatment and operation. A laryngoscope is a medical instrument used to expose the laryngeal and vocal cord regions under general anesthesia or local anesthesia, so as to facilitate the doctor to perform minimally invasive surgery, biopsy or tumor resection. An endoscope uses an optical imaging system to enter the human body through a natural body cavity or a minimally invasive incision, so as to realize direct observation and operation of a lesion. Such instruments are precise in structure, high in value, and directly or indirectly in contact with the body cavity, and usually need to be matched with special storage and disinfection equipment to ensure the sterility and functional integrity during use.
[0003] In clinical practice, high-temperature and high-pressure steam sterilization is often used as the main disinfection method for supporting laryngoscopes and endoscopes. The commonly used conditions are 120 DEG C, 0.25 MPa, and 15-45 min. Although high-temperature and high-pressure steam sterilization can effectively kill bacteria, fungi and viruses, it can cause significant thermal stress and corrosion load on the structural materials of the instruments and their storage and disinfection boxes, especially on light metal substrates such as aluminum alloy, which can easily cause problems such as oxidation film peeling, pitting corrosion, crevice corrosion, stress corrosion cracking and continuous escape of metal ions. These problems not only shorten the service life of the disinfection box, but also may cause contamination of the instruments, endangering the safety of patient treatment.
[0004] In addition, aluminum alloy is prone to local corrosion under high humidity, high salt fog and high temperature and high pressure environments, especially in marine climates or coastal areas where the air humidity is high and the salt content is high. Salt deposition can significantly reduce the stability of the natural oxidation film, accelerate the development of pitting and crevice corrosion. In addition, under the long-term action of strong acid, strong alkali, chlorine-containing disinfectants and high-temperature water vapor, the surface protective film of the aluminum alloy will gradually dissolve, causing 、 and other metal ions to migrate outward. Such ion escape constitutes a serious safety hazard in the field of medical instruments, because metal ions entering the patient's tissues or body fluids can cause local inflammatory reactions, cytotoxicity and even systemic toxic side effects.
[0005] Furthermore, this problem is particularly pronounced in coastal training environments. Coastal areas have high salt content in the air, drastic temperature and humidity fluctuations, and are accompanied by corrosive gases such as chlorides and trace amounts of sulfides. Simultaneously, medical devices undergoing overseas training must withstand frequent, short-interval disinfection cycles and may even be exposed to dust particles and high humidity in the field. These factors collectively exacerbate the risk of aluminum alloy surface corrosion and coating failure. Traditional surface protection measures often struggle to maintain stable performance under such high-intensity service environments.
[0006] Current protective measures for the surface of aluminum alloy disinfection boxes mainly employ single-layer coatings and single-method modifications, including anodizing, nickel electroplating, electroless plating, ceramic spraying, and organic coating treatments. Anodizing can form a dense coating on the aluminum alloy surface. Oxide layers improve corrosion and wear resistance, but these films are prone to hydration, cracking, and peeling in high-temperature, high-pressure steam and high-chlorine environments, leading to a decrease in protective performance. Electroplating or electroless nickel plating can improve surface hardness and corrosion resistance, but during high-temperature, high-pressure sterilization, the large difference in thermal expansion coefficients between the plating layer and the substrate can easily generate microcracks. Furthermore, nickel poses a potential biocompatibility risk. Organic coatings (such as epoxy and polyurethane) perform well in inhibiting ion migration, but they are prone to aging, softening, or decomposition under high-temperature, high-pressure sterilization, and their adhesion is significantly reduced under humid conditions. Ceramic spraying (such as plasma spraying)... or While it offers high hardness and high-temperature resistance, its bond with the aluminum alloy substrate is mostly mechanical, resulting in limited bonding strength. This makes it prone to peeling under thermal cycling and mechanical impact. Furthermore, the pores in the sprayed coating can easily become channels for corrosive media to penetrate, thus weakening its long-term protective effect. Summary of the Invention
[0007] The purpose of this invention is to provide a method for preparing a wear-resistant, corrosion-resistant, and toxic ion-resistant coating for aluminum alloy disinfection boxes for laryngoscopes and endoscopes, so as to overcome the above-mentioned defects in the prior art.
[0008] A method for preparing a wear-resistant, corrosion-resistant, and toxic ion-resistant coating for an aluminum alloy disinfection box for laryngoscopes and endoscopes includes the following steps: S1. Substrate Pretreatment: Medical aluminum alloy sterilization boxes are selected as the substrate material. First, mechanical grinding is performed to remove the natural oxide film on the surface and any pitting or corrosion marks. Then, acetone and anhydrous ethanol are used for cleaning in sequence to thoroughly remove surface oil and residual impurities. After cleaning, the substrate needs to be dried at low temperature in a vacuum drying oven to ensure that there is no moisture residue on the surface. The purpose of the pretreatment process is to ensure the cleanliness and activity of the substrate surface, provide good interface conditions for subsequent laser cladding and alloying processes, and reduce the formation of metallurgical defects such as porosity and inclusions. S2, Preparation of the primer layer: On the surface of the pretreated aluminum alloy substrate, a primer layer of AlSi10Mg alloy is prepared by laser cladding process, with a thickness of 0.1-0.4mm; Among them, the main function of the primer layer is: I. Buffering interlayer stress: Since the subsequent load-bearing layer and functional layer contain a large number of high-hardness ceramic particles, the thermal expansion coefficient is quite different from that of the aluminum alloy substrate, and stress concentration is easily generated in the cold and hot cycle. AlSi10Mg as the primer layer can absorb and relieve stress through its good plasticity and toughness.
[0009] II. Enhance metallurgical bonding: During the cladding process, the primer layer and the aluminum alloy substrate achieve metallurgical bonding through local melting, thereby forming a firm interface and improving the bonding strength of the overall coating.
[0010] III. Improve interface quality: It is conducive to the formation of good interface performance between the substrate and the primer layer, and conducive to the formation of good metallurgical bonding with the subsequent load-bearing layer.
[0011] S3, Interlayer cleaning: After the preparation of the primer layer, steel brushes are used to repeatedly brush off the slag forming materials and oxide films that may exist on the surface of the primer layer, which is conducive to the formation of good wettability between the molten alloy powder droplets and the load-bearing layer during the preparation process.
[0012] S4, Preparation of the load-bearing layer: On the surface of the primer layer, a load-bearing layer composed of nanoscale ceramic, rare earth oxide and AlSi10Mg is prepared by laser cladding process; Among them, the main function of the load-bearing layer is: I. Improve hardness and wear resistance: Nanoscale TiC particles are dispersedly strengthened in the cladding layer, significantly improving the hardness and wear resistance of the load-bearing layer. Meanwhile, the relatively smaller nanoscale TiC particles have relatively smaller plowing effect than micron-scale TiC particles.
[0013] II. Improve corrosion resistance: Nanoscale TiC particles not only act as a physical barrier to hinder the diffusion of corrosive media, but also improve the overall density through interface effect, reducing the corrosion channels.
[0014] III. Rare earth fine-grain strengthening effect: As a rare earth oxide, it can refine grains, purify grain boundaries, reduce the formation of segregation and brittle phases, and promote the stability of the passivation film, thereby improving the salt spray resistance and corrosion resistance of the load-bearing layer. Meanwhile, the nanoscale can also reduce the plowing effect on the coating.
[0015] IV. Relieve the tendency of thermal cracks: It can also optimize the dynamic behavior of the molten pool during the cladding process, reduce the sensitivity of thermal cracks, and make the load-bearing layer structure more stable.
[0016] S5, interlayer cleaning: after the preparation of the bearing layer, the steel brush is repeatedly brushed to remove the slag forming materials, oxide film and adhered nano TiC particles on the surface of the bearing layer, which is beneficial to the formation of good wettability between the bearing layer and the molten alloy powder droplets in the preparation process of the bearing layer; S6, functional layer preparation: a 0.4-0.8 mm thick nano alloyed ceramic layer is formed on the top of the bearing layer by laser alloying method. The main function of the functional layer is: I. Surface protection: directly resist the thermal stress impact in the high temperature and high pressure steam sterilization process, and prevent the direct intrusion of external medium into the bearing layer.
[0017] II. Excellent chemical corrosion resistance: The ceramic layer has strong chemical stability to , corrosive ions and can prevent their penetration and diffusion.
[0018] III. Block toxic ion migration: the functional layer effectively inhibits the escape of , metal ions, avoiding their entry into the medical environment to cause potential toxic side effects.
[0019] IV. Improve wear resistance: the dense layer has high hardness and can maintain surface integrity under the action of frequent wiping, friction and sand scouring, preventing scratches and surface failure.
[0020] S7, heat preservation and slow cooling: heat preservation cotton is used for heat preservation, and slow cooling to room temperature in the environment air to avoid cracks caused by rapid cooling.
[0021] Preferably, the chemical composition of the primer layer in step S2 includes the following components by weight percentage: 9.0%-11.0% Si, 0.2%-0.45% Mg, 0.02%-0.22% Fe, 0.02%-0.05% Cu, 0.22%-0.45% Mn, and the balance of Al.
[0022] Preferably, the powder of the bearing layer in step S4 includes the following components by weight percentage: 85%-90% AlSi10Mg, 8%-15% nano TiC, and 2%-5% nano .
[0023] Preferably, in the bearing layer powder, the particle size of the nano TiC particles is 30-50 nm, and the particle size of the nano particles is 8-15 nm.
[0024] Preferably, in step S4, ball milling or ultrasonic dispersion is used to uniformly distribute the nano-ceramic particles to prevent agglomeration. Spherical nano-ceramic particles are selected to improve flowability and powder feeding uniformity.
[0025] Preferably, the laser cladding process parameters during the preparation of the underlayer and the carrier layer are as follows: laser power of 2.4 to 2.8 kW, scanning speed of 4 to 8 mm / s, carrier gas flow rate of 5 to 10 L / min, powder feeding rate of 7 to 14 g / min, argon gas is used as the powder feeding carrier gas and the protective gas for the molten pool, and the cladding powder feeding is carried out in a ring-shaped manner.
[0026] Preferably, in step S6, before preparation, anhydrous ethanol is used with... Mix the coating material at a molar ratio of 2:8 and dry it at 150°C for 2 hours. Apply the coating material evenly to the surface of the substrate with a brush, with a thickness of about 0.1 to 0.3 mm.
[0027] Preferably, the process parameters for preparing the functional layer in step S6 are: laser power 2.4–2.6 kW, scanning speed 5–10 mm / s, and carrier gas flow rate 5–10 L / min, to perform laser alloying and ensure... The particles form a dense alloy layer with the matrix, avoiding pores or microcracks.
[0028] Preferably, during the preparation of the underlayer, the load-bearing layer, and the functional layer, the surface to be treated is treated by surface blackening to reduce the reflectivity of the aluminum alloy to the laser and improve the laser energy absorption efficiency.
[0029] Preferably, during the preparation of the base layer, the support layer, and the functional layer, the oxygen content of the environment surrounding the processing area is controlled to be 20–200 ppm to improve the preparation performance of each layer.
[0030] The beneficial effects achieved by this invention are as follows: (1) Layered gradient structure achieves multiple protections, significantly improving the overall service performance of the coating. This invention adopts a three-layer composite structure of bottom layer-bearing layer-functional layer, forming a multi-synergistic protection mode of "bottom layer buffer-middle layer reinforcement-outer layer barrier", effectively solving the multi-source failure problem of aluminum alloy disinfection boxes in critical overseas training environments. The bottom layer AlSi10Mg serves as a buffer layer, with a thermal expansion coefficient close to that of the substrate. It can absorb the thermal stress generated by alternating hot and cold temperatures during multiple high-temperature and high-pressure steam sterilization cycles, avoiding interlayer cracking, and forming a strong metallurgical bonding interface with the substrate. The middle layer introduces nano-TiC and Through dispersion strengthening, grain refinement, and interface purification, it not only significantly improves hardness and wear resistance but also markedly enhances corrosion resistance in salt spray environments. The outermost dense nano-layer... The functional layers directly resist high-temperature steam, salt spray ions, and dust erosion, providing the first line of defense for the overall coating. Unlike traditional single-layer coatings, this structure, through a progressive division of functions, ensures the overall mechanical stability of the coating while avoiding the "weakest link" failure mode of a single coating in complex environments. Therefore, this invention enables the disinfection box to maintain long-term stability under harsh conditions such as high humidity, high salt spray, and multiple sterilization cycles, improving overall service performance by more than 2 times compared to traditional coatings.
[0031] (2) Nano-ceramic reinforcement and rare earth oxide grain refinement effect improve wear resistance and corrosion resistance. The bearing layer adopts an AlSi10Mg matrix to introduce nano-TiC and nano-... Uniform dispersion of TiC particles is achieved through laser cladding. The nano-TiC particles, with a diameter of 30–50 nm, possess a large specific surface area and strong interfacial bonding, enabling the formation of a continuous reinforcing phase network. This avoids surface scratches caused by the ploughing effect of traditional micron-sized ceramic particles, thus achieving a balance between high hardness and low damage during friction and wear. Furthermore, TiC exhibits excellent chemical stability, serving as a physical barrier to the diffusion of corrosive media, effectively blocking... , The plasma transport path in the coating reduces the corrosion rate. The rare earth effect further enhances the coating's density and corrosion resistance by purifying grain boundaries, refining grains, and reducing segregation and the formation of brittle phases. It also promotes the formation and repair of a surface passivation film during corrosion. This dual effect results in excellent stability of the support layer under salt spray corrosion and humid heat coupling environments. Comparative tests show that the neutral salt spray corrosion resistance time can be extended to over 100 hours, far superior to anodic oxidation or single-phase ceramic coatings. Therefore, this invention achieves a comprehensive improvement in the support layer's high hardness, high wear resistance, and strong corrosion resistance through the synergistic mechanism of nano-ceramic strengthening and rare earth element grain refinement.
[0032] (3) The dense functional layer barrier effectively inhibits the escape of toxic metal ions, ensuring medical safety. This invention prepares nano-sized layers through laser alloying on the outermost layer. The ceramic functional layer is highly dense and chemically inert. The interface between the functional layer and the aluminum alloy substrate achieves a continuous transition through metallurgical bonding, with no obvious pores or cracks, effectively blocking the penetration of corrosive media and the migration of metal ions. Under high-temperature and high-pressure sterilization cycles, the functional layer exhibits excellent thermal stability, without softening or decomposition, thus maintaining its barrier properties. Therefore, this invention not only improves the corrosion resistance of the sterilization box but also has significant implications for medical safety, addressing the technical shortcoming of existing coatings that "improve corrosion resistance but lack biosafety." Attached Figure Description
[0033] Figure 1 A microhardness comparison chart for different coatings of the present application.
[0034] Figure 2 A comparison chart of ion release concentration for different coatings of the present application.
[0035] Figure 3 A comparison chart of salt spray corrosion resistance for different coatings of the present application.
[0036] Figure 4 A chart of friction coefficient and wear loss of the present application. DETAILED DESCRIPTION
[0037] In order to make the objects, technical solutions and advantages of the embodiments of the present application clearer, the technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only some of the embodiments of the present application, rather than all the embodiments of the present application. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative work fall within the scope of protection of the present application.
[0038] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the present application belongs; the terminology used in the specification of the present application is only for the purpose of describing specific embodiments and is not intended to limit the present application; the terms "comprise" and "have" and any variations thereof in the specification and claims of the present application and the description of the drawings are intended to cover non-exclusive inclusion.
[0039] Reference herein to "an embodiment" means that a particular feature, structure, or characteristic described in connection with the embodiment can be included in at least one embodiment of the present application. The appearance of the phrase "in an embodiment" in various places in the specification does not necessarily all refer to the same embodiment, nor is it necessarily mutually exclusive of other embodiments. It is explicitly and implicitly understood that the embodiments described herein are capable of combination.
[0040] Embodiment 1: The embodiment provides a preparation method of a laryngoscope and endoscope aluminum alloy disinfection box wear-resistant corrosion-resistant and anti-toxic ion release coating, and steps are as follows: (1) substrate pretreatment: select a medical aluminum alloy disinfection box material (AlSi10Mg) as the substrate. First, sequentially polish with 400# and 800# sandpaper to remove the surface natural oxide film, pitting and corrosion marks; then ultrasonically clean with acetone and anhydrous ethanol for 5 min each, and dry and then place in a vacuum drying oven (60°C, 1 h) to ensure that the surface is clean, free of oil stains and moisture residues.
[0041] (2) Preparation of the underlayer: An AlSi10Mg underlayer was prepared on the pretreated substrate surface using a four-way coaxial powder feeding laser cladding method. The mass fraction of the powder used was: Si 10.0%, Mg 0.35%, Fe 0.1%, Cu 0.03%, Mn 0.3%, with the balance being Al. Cladding process parameters: laser power 2.5 kW, scanning speed 6 mm / s, powder feeding rate 10 g / min, carrier gas (argon) flow rate 8 L / min. A dense cladding layer with a thickness of 0.30 mm was formed.
[0042] (3) Interlayer cleaning (underlayer preparation): After the underlayer preparation is completed, immediately stop powder feeding and laser irradiation, and use a steel brush to repeatedly brush away residual slag, oxides and spatter particles from its surface; then wipe the surface with anhydrous ethanol to ensure cleanliness. This step ensures that the powder droplets can fully wet the underlayer and achieve metallurgical bonding during the cladding process of the bearing layer.
[0043] (4) Preparation of the support layer: An AlSi10Mg-based nano-ceramic composite support layer was prepared by laser cladding on the cleaned substrate surface. The mass fraction of the mixed powder used was: 87% AlSi10Mg, 10% nano-TiC, and 3% nano-TiC. The cladding process parameters were: laser power 2.5 kW, scanning speed 6 mm / s, powder feed rate 10 g / min, and carrier gas flow rate 8 L / min. This resulted in a 0.8 mm thick support layer.
[0044] (5) Interlayer cleaning (bearing layer): After the bearing layer is formed, use a steel brush to repeatedly remove any oxide slag, unmelted particles and attached ceramic particles that may exist on the surface; then blow away the floating slag with high-purity argon gas, and wipe the surface with anhydrous ethanol. This step avoids defect inclusions and helps to form a good metallurgical bond in the subsequent functional layers.
[0045] (6) Functional layer preparation: Laser alloying is used to introduce functional layers onto the surface of the load-bearing layer. Functional layer. First, [the following will be done] The powder and anhydrous ethanol were mixed and stirred evenly at a mass ratio of 8:2, and then uniformly brushed onto the surface of the carrier layer to a thickness of 0.2 mm. After drying at 150℃ for 2 h, it was ready for use. Subsequently, a laser alloying process was used with the following parameters: laser power 2.5 kW, scanning speed 10 mm / s, and carrier gas flow rate 8 L / min, forming a functional layer with a thickness of approximately 0.4 mm.
[0046] (7) Slow cooling treatment: After alloying, immediately cover with insulation cotton and let it cool slowly to room temperature to avoid cracks or residual stress concentration caused by rapid cooling.
[0047] Example 2: The embodiment provides a preparation method of a wear-resistant, corrosion-resistant and anti-toxic ion release coating of a laryngoscope and endoscope aluminum alloy disinfection box, and steps are as follows: (1) substrate pretreatment: select a medical aluminum alloy disinfection box material (AlSi10Mg) as the substrate. First, sequentially polish with 400# and 800# sandpaper to remove the natural oxide film, pitting and corrosion marks on the surface; then ultrasonically clean with acetone and anhydrous ethanol for 5 min each, and after drying, place in a vacuum drying box (60°C, 1 h) to ensure that the surface is clean, free of oil stains and moisture residues.
[0048] (2) preparation of the primer layer: on the surface of the pretreated substrate, an AlSi10Mg primer layer is prepared by using a four-way coaxial powder feeding laser cladding method. The mass fraction of the powder used is: Si 10.0%, Mg 0.35%, Fe 0.1%, Cu 0.03%, Mn 0.3%, and the balance is Al. The cladding process parameters are: laser power 2.4 kW, scanning speed 4 mm / s, powder feeding rate 7 g / min, and carrier gas (argon) flow rate 5 L / min. A dense cladding layer with a thickness of 0.30 mm is formed.
[0049] (3) interlayer cleaning (primer layer): after the preparation of the primer layer is completed, stop powder feeding and laser irradiation immediately, and repeatedly brush the surface with a steel brush to remove residual slag, oxides and splashed particles; then wipe the surface with anhydrous ethanol to ensure cleanliness. This step ensures that the powder droplets can fully wet the primer layer and achieve metallurgical bonding during the cladding process of the bearing layer.
[0050] (4) preparation of the bearing layer: on the surface of the cleaned primer layer, an AlSi10Mg-based nanoceramic composite bearing layer is prepared by laser cladding. The mass fraction of the mixed powder used is: 87% AlSi10Mg, 10% nanometer TiC and 3% nanometer . The cladding process parameters are: laser power 2.4 kW, scanning speed 4 mm / s, powder feeding rate 7 g / min, and carrier gas flow rate 5 L / min. Finally, a bearing layer with a thickness of 0.8 mm is formed.
[0051] (5) interlayer cleaning (bearing layer): after the formation of the bearing layer, a steel brush is used to repeatedly brush the surface to remove possible oxidation slag, unmelted particles and attached ceramic particles; then blow off the dross with high-purity argon, and then wipe the surface with anhydrous ethanol. This step avoids defect inclusions and helps the subsequent functional layer to form good metallurgical bonding.
[0052] (6) preparation of the functional layer: on the surface of the bearing layer, a functional layer is introduced by laser alloying. First, a functional layer is introduced by laser alloying. First, a The powder is mixed with anhydrous ethanol at a mass ratio of 8:2, stirred uniformly, and uniformly brushed on the surface of the bearing layer with a coating thickness of 0.2 mm. After drying at 150°C for 2 h, it is ready for use. Then, a laser alloying process is used for treatment with the following parameters: laser power 2.4 kW, scanning speed 5 mm / s, and carrier gas flow 5 L / min. A functional layer with a thickness of about 0.4 mm is formed.
[0053] (7) Slow cooling treatment: After alloying, cover the heat preservation cotton immediately, and slowly cool to room temperature with the environment to avoid cracks or residual stress concentration caused by rapid cooling.
[0054] Example 3: The present embodiment provides a preparation method of a laryngoscope and endoscope aluminum alloy disinfection box wear-resistant, corrosion-resistant and anti-toxic ion release coating, and the steps are as follows: (1) Substrate pretreatment: Select medical aluminum alloy disinfection box material (AlSi10Mg) as the substrate. First, sequentially polish with 400# and 800# sandpaper to remove the natural oxide film, pitting and corrosion marks on the surface; then ultrasonic clean with acetone and anhydrous ethanol for 5 min each, and dry in a vacuum drying oven (60°C, 1 h) to ensure that the surface is clean, free of oil stains and moisture residues.
[0055] (2) Preparation of primer layer: On the surface of the pretreated substrate, an AlSi10Mg primer layer is prepared by four-way coaxial powder feeding laser cladding. The mass fraction of the powder used is: Si 10.0%, Mg 0.35%, Fe 0.1%, Cu 0.03%, Mn 0.3%, and the balance is Al. The cladding process parameters are: laser power 2.8 kW, scanning speed 8 mm / s, powder feeding rate 14 g / min, carrier gas (argon) flow 10 L / min, forming a dense cladding layer with a thickness of 0.30 mm.
[0056] (3) Interlayer cleaning (primer layer): After the preparation of the primer layer is completed, stop the powder feeding and laser irradiation immediately, and use a steel brush to repeatedly brush the surface to remove residual slag, oxides and splashed particles; then wipe the surface with anhydrous ethanol to ensure cleanliness. This step ensures that the powder droplets can fully wet the primer layer and achieve metallurgical bonding during the cladding process of the bearing layer.
[0057] (4) Preparation of bearing layer: On the surface of the cleaned primer layer, an AlSi10Mg-based nanometer ceramic composite bearing layer is prepared by laser cladding. The mass fraction of the mixed powder used is: 87% AlSi10Mg, 10% nanometer TiC, and 3% nanometer . The cladding process parameters are: laser power 2.8 kW, scanning speed 8 mm / s, powder feeding rate 14 g / min, and carrier gas flow 10 L / min. Finally, a bearing layer with a thickness of 0.8 mm is formed.
[0058] (5) Interlayer cleaning (bearing layer): After the bearing layer is formed, use a steel brush to repeatedly remove any oxide slag, unmelted particles and attached ceramic particles that may exist on the surface; then blow away the floating slag with high-purity argon gas, and wipe the surface with anhydrous ethanol. This step avoids defect inclusions and helps to form a good metallurgical bond in the subsequent functional layers.
[0059] (6) Functional layer preparation: Laser alloying is used to introduce functional layers onto the surface of the load-bearing layer. Functional layer. First, [the following will be done] The powder and anhydrous ethanol were mixed and stirred evenly at a mass ratio of 8:2, and then evenly brushed onto the surface of the carrier layer to a thickness of 0.2 mm. After drying at 150℃ for 2 h, it was ready for use. Subsequently, a laser alloying process was used to form a functional layer with a thickness of approximately 0.4 mm. The parameters were: laser power 2.6 kW, scanning speed 10 mm / s, and carrier gas flow rate 10 L / min.
[0060] (7) Slow cooling treatment: After alloying, immediately cover with insulation cotton and let it cool slowly to room temperature to avoid cracks or residual stress concentration caused by rapid cooling.
[0061] Comparative Example 1: To verify the key role of the functional layer in the overall composite coating, the same substrate material and preparation process as in Example 1 were used. The difference is that this comparative example only prepared up to the load-bearing layer and did not perform the laser alloying step of the functional layer. The specific process is as follows: (1) Substrate pretreatment: Medical aluminum alloy disinfection box material (AlSi10Mg) was selected as the substrate. First, 400# and 800# sandpaper were used to grind the surface in sequence to remove the natural oxide film, pitting and corrosion marks; then, acetone and anhydrous ethanol were used for ultrasonic cleaning for 5 min each, and after drying, the surface was placed in a vacuum drying oven (60℃, 1 h) to ensure that the surface was clean and free of oil and moisture residue.
[0062] (2) Preparation of the underlayer: An AlSi10Mg underlayer was prepared on the pretreated substrate surface using a coaxial annular powder feeding laser cladding method. The mass fraction of the powder used was: Si 10.0%, Mg 0.35%, Fe 0.1%, Cu 0.03%, Mn 0.3%, with the balance being Al. Cladding process parameters: laser power 2.5 kW, scanning speed 6 mm / s, powder feeding rate 10 g / min, carrier gas (argon) flow rate 8 L / min. A dense cladding layer with a thickness of 0.30 mm was formed.
[0063] (3) Interlayer cleaning (primer layer): After the preparation of the primer layer, stop powder feeding and laser irradiation immediately, and use a steel brush to repeatedly brush the surface to remove residual slag, oxides and splashed particles; then wipe the surface with anhydrous ethanol to ensure cleanliness. This step ensures that the powder droplets can fully wet the primer layer and achieve metallurgical bonding during the cladding process of the bearing layer.
[0064] (4) Bearing layer preparation: On the surface of the cleaned primer layer, an AlSi10Mg-based nanometer ceramic composite bearing layer is prepared by laser cladding. The mass fraction of the mixed powder used is: 87% AlSi10Mg, 10% nanometer TiC, and 3% nanometer . The cladding process parameters are: laser power 2.5 kW, scanning speed 6 mm / s, powder feeding rate 10 g / min, and carrier gas flow rate 8 L / min. A bearing layer with a thickness of 0.8 mm is finally formed.
[0065] Comparative Example 2: (1) Substrate pretreatment: A medical aluminum alloy sterilization box material (AlSi10Mg) is selected as the substrate. First, 400# and 800# sandpaper are used in sequence to polish and remove the surface natural oxide film, pitting and corrosion marks; then acetone and anhydrous ethanol are used for ultrasonic cleaning for 5 min each, and after drying, the substrate is placed in a vacuum drying oven (60°C, 1 h) to ensure surface cleanliness, no oil stains and moisture residues.
[0066] (2) Primer layer preparation: On the surface of the pretreated substrate, an AlSi10Mg primer layer is prepared by using a ring-shaped coaxial powder feeding laser cladding method. The mass fraction of the powder used is: Si 10.0%, Mg 0.35%, Fe 0.1%, Cu 0.03%, Mn 0.3%, and the balance is Al. The cladding process parameters are: laser power 2.5 kW, scanning speed 6 mm / s, powder feeding rate 10 g / min, and carrier gas (argon) flow rate 8 L / min. A dense cladding layer with a thickness of 0.30 mm is formed.
[0067] Comparative Example 3: A medical aluminum alloy sterilization box material (AlSi10Mg) is used as the substrate.
[0068] The test is carried out at room temperature without lubrication using an MDW-02 friction and wear tester. The friction pair uses Gr15 hard alloy balls with a diameter of 6 mm. The wear resistance test sample size is 20x10x10 mm. The test parameters are selected as follows: wear frequency of 3 Hz, load of 20 N, and friction time of 10 min. The test data are as follows: The average friction coefficient of the AlSi10Mg substrate is 0.5504, and the wear amount is 2.8 mg; The average friction coefficient of the base layer (AlSi10Mg cladding layer) is 0.5984, slightly higher than that of the AlSi10Mg substrate, and the wear amount is 1.7 mg, 1.1 mg lower than that of the AlSi10Mg substrate; The average friction coefficient of the bearing layer (87% AlSi10Mg+10% TiC+3% Cladding layer) is 0.5117, and the wear amount is 1.4 mg, lower than that of the AlSi10Mg base layer; The average friction coefficient of the functional layer ( Alloying) is 0.4042, and the wear amount is 1.0 mg, further reduced compared with the bearing layer.
[0069] In addition, the performance comparison of the prepared coating and anodic oxidation, electroplated nickel and organic coating is shown in Table 1: Table 1
[0070] The above-mentioned embodiments of the present application do not constitute a limitation on the protection scope of the present application. Any modification, equivalent replacement and improvement made within the spirit and principle of the present application shall be included in the protection scope of the claims of the present application.
Claims
1. A method for preparing a wear-resistant, corrosion-resistant, and toxic ion-resistant coating for an aluminum alloy disinfection box for laryngoscopes and endoscopes, characterized in that: Comprise the following steps: S1, substrate pretreatment: select medical aluminum alloy disinfection box as the substrate material, first to the surface of the disinfection box to be prepared for composite coating mechanical polishing, remove the surface oxide film and possible pitting, corrosion marks; then use acetone and anhydrous ethanol cleaning, to thoroughly remove the surface oil and residual corrosion; the cleaned disinfection box substrate needs to be dried in a vacuum drying oven, to ensure that the surface is free of moisture; S2, preparation of the primer layer: on the surface of the pretreated aluminum alloy substrate, AlSi10Mg alloy primer layer is prepared by laser cladding process, the thickness is 0.1-0.4mm; S3, interlayer cleaning: after the preparation of the primer layer, the slag forming material and the possible existing oxide film on the surface of the primer layer are repeatedly brushed off by tools; S4, preparation of the bearing layer: on the surface of the primer layer, a bearing layer composed of nano ceramic, rare earth oxide and AlSi10Mg is prepared by laser cladding process; S5, interlayer cleaning: after the preparation of the bearing layer, the slag forming material, oxide film and adhering particles on the surface of the bearing layer are repeatedly brushed off by tools; S6, function layer preparation: on the surface of the carrier layer, based on the laser alloying method, the micro alloying ceramic layer; S7, insulation and slow cooling: insulation cotton is used for insulation, and slow cooling to room temperature in air environment.
2. The laryngoscope and endoscope aluminum alloy sterilization box wear-resistant, corrosion-resistant and anti-toxic ion release coating preparation method according to claim 1, characterized in that: In steps S3 and S5, steel brushes are used to repeatedly brush off the surface of the primer layer and the surface of the bearing layer, respectively.
3. The method for preparing a wear-resistant, corrosion-resistant and anti-toxic ion release coating of a laryngoscope and endoscope aluminum alloy disinfection box according to claim 1, characterized in that: The powder of the bearing layer in step S4 comprises the following components in percentage by weight: 85-90% of AlSi10Mg, 8-15% of nano-TiC and 2-5% of nano-SiC .
4. The method for preparing a wear-resistant, corrosion-resistant and anti-toxic ion release coating of a laryngoscope and endoscope aluminum alloy disinfection box according to claim 3, characterized in that: The nano TiC particles in the bearing layer have a particle size of 30-50 nm, and the nano particles have a particle size of 8-15 nm.
5. The method of preparing a wear resistant, corrosion resistant and anti-toxic ion release coating for laryngoscope and endoscope aluminum alloy sterilization boxes according to claim 1, characterized in that: In step S4, ball milling or ultrasonic dispersion process is used to uniformly distribute the nano ceramic particles, and spherical particles are selected for the nano ceramic particles.
6. The method of preparing a wear and corrosion resistant and anti-toxic ion leaching coating for laryngoscope and endoscope aluminum alloy sterilization boxes according to claim 1, characterized in that: The process parameters for laser cladding in the preparation of the primer layer and the bearing layer are laser power 2.4-2.8 kW, scanning speed 4-8 mm / s, carrier gas flow 5-10 L / min, powder feeding rate 7-14 g / min, argon is used as the powder feeding carrier gas and the molten pool protection gas, and ring-shaped powder feeding mode is used for cladding powder feeding.
7. The method of preparing a wear resistant, corrosion resistant and anti-toxic ion release coating for a laryngoscope and endoscope aluminum alloy sterilization case according to claim 1, characterized in that: In step S6, before preparation, anhydrous ethanol is used to dissolve the functional coating, and the solution is applied on the surface of the carrier layer by brush coating, with a thickness of about 0.1-0.3 mm. The functional coating is stirred in a ratio of 2:8 by mole, dried at 150°C for 2 hours, and uniformly brushed on the surface of the carrier layer by brush coating, with a thickness of about 0.1-0.3 mm.
8. The method of preparing a wear and corrosion resistant and anti-toxic ion leaching coating for laryngoscope and endoscope aluminum alloy sterilization boxes according to claim 1, characterized in that: In step S6, the process parameters for the preparation of the functional layer are laser power 2.4-2.6 kW, scanning speed 5-10 mm / s, carrier gas flow 5-10 L / min.
9. The method of preparing a wear and corrosion resistant and anti-toxic ion leaching coating for laryngoscope and endoscope aluminum alloy sterilization boxes according to claim 1, characterized in that: During the preparation of the primer layer, the bearing layer and the functional layer, the surface blackening method is used to treat the surface to be treated.
10. The method for laryngoscope and endoscope aluminum alloy disinfection box wear-resistant, corrosion-resistant and anti-toxic ion release coating preparation according to claim 1, characterized in that: During the preparation of the primer layer, the bearing layer and the functional layer, the oxygen content of the environment around the processing area is controlled to be 20-200 ppm.