Spraying material as well as preparation method and use method thereof

Abstract

The invention relates to a spraying material as well as a preparation method and a use method thereof. The spraying material comprises organic resin, ceramic powder, irregular ceramic particles, ceramic balls and an organic amine curing agent; the mass ratio of the organic resin to the ceramic powder is 10: (0.5-4); the mass ratio of the irregular ceramic particles to the spraying material is (3-5): 10; and the mass ratio of the ceramic balls to the spraying material is (4-6): 10. The spraying material with excellent spraying fluidity, impact strength and wear resistance is obtained by using a specific amount of ceramic powder, irregular ceramic particles and ceramic balls in the spraying material.

Description

Technical Field

[0001] This invention relates to the field of ceramic matrix composite materials technology, to a spraying material and its preparation and application methods, and particularly to a sprayable ceramic matrix anti-corrosion and wear-resistant composite coating material. Background Technology

[0002] In metallurgy, mining, and environmental protection, the flow-through components of equipment are typically in direct contact with fluids. The ores, slags, waste materials, and acid / alkali slurries carried by these fluids can cause corrosion, erosion, and wear on these components. In actual production, to minimize downtime caused by equipment maintenance and replacement, ceramic-based anti-corrosion and wear-resistant coatings are often used to repair and mend damaged equipment.

[0003] For example, CN115700291A discloses a composite coating for zinc pot roller bushings with strong corrosion resistance and wear resistance, which solves the technical problems in production sites where zinc pot roller bushings require higher corrosion resistance, wear resistance, and longer service life, further improving the productivity and product quality of hot-dip galvanized product production lines. CN105568263A discloses a method for preparing SiOC ceramic coatings using CO2 laser pyrolysis of polysiloxane materials. The preparation cycle is short, the ceramic surface is smooth and has low porosity, and the resulting ceramic coating has good corrosion resistance and wear resistance properties.

[0004] However, the existing ceramic-based anti-corrosion and wear-resistant coating construction process usually involves scraping, brushing, or manual application, which can easily lead to uneven coating thickness and long construction time, thus affecting the quality and progress of equipment repair and maintenance, and increasing production costs.

[0005] Therefore, how to provide a sprayable material that has good impact resistance and wear resistance after curing has become an urgent problem to be solved. Summary of the Invention

[0006] To address the aforementioned technical problems, the present invention aims to provide a spraying material, its preparation method, and its application method. The spraying material of the present invention uses organic resin as the main binder phase, ceramic powder as the main filler phase, irregular ceramic particles as a shear phase to improve the overall fluidity of the material and facilitate spraying, and ceramic beads as the main wear-resistant phase to enhance the overall wear resistance of the material. It is cured with an organic amine curing agent. The spraying material prepared by the present invention can be applied to the surface of materials such as metals and ceramics to form a ceramic-based wear-resistant composite coating. It has good spraying fluidity, is resistant to acid, alkali solutions, and aerosol corrosion, and does not reduce the impact strength and wear resistance of the material itself after curing. It is more suitable for large-area operations on large-size equipment, and can compensate for the limited means of wear-resistant repair and patching materials in actual production and use, significantly improving the efficiency of wear-resistant coating material operations, ensuring the comprehensive performance of the material, producing a more uniform coating thickness, and effectively reducing costs.

[0007] To achieve this objective, the present invention adopts the following technical solution: In a first aspect, the present invention provides a spraying material comprising organic resin, ceramic powder, irregular ceramic particles, ceramic beads, and organic amine curing agent; The mass ratio of the organic resin to the ceramic powder is 10:(0.5-4), for example, it can be 10:1, 10:1.5, 10:2, 10:2.5, 10:3 or 10:3.5, etc.; The mass ratio of the irregular ceramic particles to the spraying material is (3-5):10, for example, it can be 3.3:10, 3.5:10, 4:10, 4.5:10 or 4.8:10, etc.; The mass ratio of the ceramic beads to the spraying material is (4-6):10, for example, it can be 4.5:10, 4.8:10, 5:10, 5.5:10 or 5.8:10, etc.

[0008] In this invention, a sprayable material with excellent performance can be prepared by using a combination of filler phase nano-ceramic powder, shear phase ceramic particles, and wear-resistant phase ceramic beads. The shear phase ceramic particles can interrupt or shear the continuity of the composite material, reducing the material viscosity and giving it overall fluidity, making it suitable for spraying operations.

[0009] In this invention, the amounts of ceramic powder, irregular ceramic particles, and ceramic beads need to be controlled within specific ranges. If too much irregular ceramic particle is used, the overall continuity of the material is too low, affecting the curing effect of the binder phase, deteriorating the material's curing performance, and reducing its strength. If too much ceramic powder is used, the viscosity increases significantly, drastically reducing the spraying effect and affecting the final curing performance, causing the coating to powder. If too much ceramic beads are used, the overall density of the material increases significantly, affecting the spraying effect, resulting in poor material flowability, easy detachment, and making operation difficult.

[0010] Preferably, the mass ratio of the organic resin to the organic amine curing agent is 10:(2-3.5), for example, it can be 10:2.3, 10:2.5, 10:2.8, 10:3 or 10:3.3, etc.

[0011] In this invention, the amount of organic amine curing agent needs to be controlled within a specific range. If the amount of curing agent is too large, the curing speed will be too fast, which will easily cause uneven curing, affect the overall performance of the final material, and also easily lead to thermal runaway in the curing process, resulting in excessively fast curing.

[0012] Preferably, the organic resin includes any one or a combination of at least two of bisphenol A type epoxy resin, bisphenol B type epoxy resin, bisphenol F type epoxy resin, E48 type phenolic epoxy resin, E50 type phenolic epoxy resin, E51 type phenolic epoxy resin, or phenolic resin.

[0013] Preferably, the ceramic powder comprises any one or a combination of at least two of nano-silicon carbide, nano-silicon nitride, nano-silicon dioxide, nano-alumina, or nano-zirconia.

[0014] Preferably, the median particle size of the ceramic powder is 10-100 nm, for example, it can be 20 nm, 30 nm, 40 nm, 50 nm, 60 nm, 70 nm, 80 nm or 90 nm, and more preferably 30-50 nm.

[0015] Preferably, the irregular ceramic particles include any one or a combination of at least two of the following: corundum sand particles, brown corundum particles, diamond particles, zirconium corundum particles, zircon sand particles, quartz sand particles, corundum particles, or silicon carbide particles.

[0016] Preferably, the median particle size of the irregular ceramic particles is 0.4-0.5 mm, for example, it can be 0.42 mm, 0.44 mm, 0.45 mm, 0.46 mm or 0.48 mm, etc.

[0017] In this invention, the median particle size is the D50 of the equivalent area diameter.

[0018] Preferably, the irregular ceramic particles have a shape that includes any one or a combination of at least two of the following: sharp, blocky, or polygonal.

[0019] Preferably, the average aspect ratio of the irregular ceramic particles is not higher than 0.7 (e.g., it can be 0.1, 0.2, 0.3, 0.5 or 0.6, etc.), and the standard deviation is not higher than 0.2 (e.g., it can be 0.05, 0.1, 0.12, 0.15 or 0.18, etc.).

[0020] Preferably, the average aspect ratio is obtained by testing with a particle size and shape analyzer and a dynamic image method.

[0021] In this invention, the aspect ratio is D50.

[0022] Preferably, the bluntness of the irregular ceramic particles is not higher than 0.6 (e.g., it can be 0.1, 0.2, 0.3, 0.4 or 0.5, etc.), and the standard deviation is not higher than 0.15 (e.g., it can be 0.03, 0.05, 0.08, 0.1 or 0.12, etc.).

[0023] Preferably, the bluntness is obtained by testing using a dynamic image method.

[0024] In this invention, the bluntness is D50.

[0025] In this invention, if the median particle size of the irregular ceramic particles is too large, they will not have a shearing effect; if they are too small, they will have a binding effect. If the aspect ratio is too large, they will not have a shearing effect (similar to ceramic balls). If the bluntness is too high, the shearing effect will be poor and the viscosity cannot be effectively reduced.

[0026] Preferably, the ceramic beads include any one or a combination of at least two of zirconia ceramic beads, alumina ceramic beads, silicon nitride ceramic beads, or silicon carbide ceramic beads.

[0027] Preferably, the median particle size of the ceramic beads is 0.1-4 mm, for example, it can be 0.5 mm, 1 mm, 1.5 mm, 2 mm or 3 mm, etc.

[0028] Preferably, the organic amine curing agent includes an organic amine epoxy curing agent.

[0029] Preferably, the organic amine curing agent includes any one or a combination of at least two of the following: type 593 diethylenetriaminebutyl glycidyl ether curing agent, type T31 phenolic amine curing agent, type 630 polyamide curing agent, type 631 polyamide curing agent, or 2,4,6-tris(dimethylaminomethyl)phenol.

[0030] Preferably, the spraying material further includes organic additives.

[0031] Preferably, the mass ratio of the organic resin to the organic additive is 10:(1.5-3), for example, it can be 1:1.8, 1:2, 1:2.3, 1:2.5 or 1:2.8, etc.

[0032] Preferably, the organic additive includes any one or a combination of at least two of the following: dispersant, leveling agent, or defoamer.

[0033] Preferably, the dispersant comprises any one or a combination of at least two of oleic acid, stearic acid, sodium stearate, zinc stearate, or AFCONA-4401.

[0034] Preferably, the leveling agent includes any one or a combination of at least two of BYK-W985, NANOBYK-3620, or NANOBYK-3611.

[0035] Preferably, the defoamer includes any one or a combination of at least two of BYK-110, BYK-141, or ethanol.

[0036] Preferably, the mass ratio of the dispersant to the ceramic powder is (0.02-0.4):10, for example, it can be 0.05:10, 0.1:10, 0.2:10, 0.25:10 or 0.3:10, etc.

[0037] Preferably, the mass ratio of the leveling agent to the organic resin is (1-2.5):10, for example, it can be 1.2:10, 1.5:10, 1.8:10, 2:10 or 2.3:10, etc.

[0038] Preferably, the mass ratio of the defoamer to the organic resin is (0.05-0.5):10, for example, it can be 0.1:10, 0.2:10, 0.25:10, 0.3:10 or 0.4:10, etc.

[0039] In a second aspect, the present invention provides a method for preparing a spraying material as described in the first aspect, the method comprising the following steps: (1) The ceramic powder, irregular ceramic particles, ceramic beads and optional organic additives are each divided into two separate portions; (2) Mix the first part of organic additive with organic resin, then add the first part of ceramic powder and the first part of irregular ceramic particles, degas, then add the first part of ceramic beads, degas, and obtain component A; The second part of organic additive is mixed with organic amine curing agent, then the second part of ceramic powder and the second part of irregular ceramic particles are added, degassing is performed, then the second part of ceramic beads are added, degassing is performed, and component B is obtained. (3) Mix component A and component B to obtain the spraying material.

[0040] Preferably, the degassing is performed in a vacuum degassing machine.

[0041] Preferably, the first portion of ceramic powder accounts for 50%-100% of the total mass of ceramic powder, for example, it can be 60%, 70%, 75%, 80% or 90%, etc.

[0042] Preferably, the first portion of irregular ceramic particles accounts for 50%-100% of the total mass of irregular ceramic particles, for example, it can be 60%, 70%, 75%, 80% or 90%, etc.

[0043] Preferably, the first batch of ceramic beads accounts for 50%-100% of the total mass of the ceramic beads, for example, it can be 60%, 70%, 75%, 80% or 90%, etc.

[0044] Preferably, the first portion of organic additive accounts for 50%-100% of the total mass of organic additive, for example, it can be 60%, 70%, 75%, 80% or 90%, etc.

[0045] Preferably, the speed of the vacuum degassing machine is 1000-2000 rpm, for example, it can be 1200 rpm, 1400 rpm, 1500 rpm, 1600 rpm or 1800 rpm.

[0046] Preferably, the degassing time is 30 s-10 min, for example, it can be 1 min, 2 min, 3 min, 5 min or 8 min, etc.

[0047] Preferably, the mixing in step (3) includes any one or a combination of at least two of manual stirring, mechanical stirring or centrifugal stirring.

[0048] Thirdly, the present invention provides a method of using the spraying material as described in the first aspect, the method comprising the following steps: The coating material is sprayed onto the surface of the substrate, compacted, and cured to obtain a coating.

[0049] Preferably, the diameter of the spray nozzle is 3-10 mm, for example, it can be 4 mm, 5 mm, 6 mm, 7 mm, 8 mm or 9 mm, etc.

[0050] Preferably, the thickness of the coating is 2-20 mm, for example, it can be 5 mm, 8 mm, 10 mm, 15 mm or 18 mm.

[0051] Preferably, the curing includes room temperature curing and / or heat curing, wherein the room temperature curing temperature is 10-40℃ (e.g., 15℃, 20℃, 25℃, 30℃, 35℃ or 39℃, etc.), and the heat curing temperature is 40-120℃ (e.g., 41℃, 50℃, 70℃, 90℃, 100℃ or 110℃, etc.).

[0052] Compared with the prior art, the present invention has at least the following beneficial effects: The spraying material of this invention can be sprayed onto the surface of materials such as metals and ceramics, preventing corrosion from acid and alkali solutions and their aerosols. It has good spraying fluidity and does not reduce the mechanical properties and wear resistance of the material itself after curing, making it more suitable for large-area operations on large-size equipment. It can solve the problem of limited means of wear-resistant repair and patching materials in actual production and use, greatly improve the efficiency of wear-resistant coating materials, ensure the comprehensive performance of the material, make the coating thickness more uniform, and effectively reduce costs. Attached Figure Description

[0053] Figure 1 This describes the microstructure of the irregular ceramic particles in Embodiment 1 of the present invention.

[0054] Figure 2This is a particle image of the irregular ceramic particles in Embodiment 1 of the present invention and its equivalent area diameter.

[0055] Figure 3 This is a diagram of the coating material prepared in Example 1 of the present invention before it is cured and applied to the surface of a workpiece.

[0056] Figure 4 This is a diagram showing the compacted spraying material prepared in Example 1 of the present invention applied to the surface of a workpiece.

[0057] Figure 5 This is a diagram showing the cured coating material prepared in Example 1 of the present invention applied to the surface of a workpiece. Detailed Implementation

[0058] The technical solution of the present invention will be further described below with reference to the accompanying drawings and specific embodiments. However, the following examples are merely simplified examples of the present invention and do not represent or limit the scope of protection of the present invention. The scope of protection of the present invention is determined by the claims.

[0059] The sources of some of the raw materials used in the preparation of the embodiments and comparative examples of this invention are as follows: The organic resin is a bisphenol A type epoxy resin, with the grade name 128; The ceramic powder is nano-silica, purchased from Maclean, grade S876025, CAS number 60676-86-0; The irregular ceramic particles are corundum sand particles with a median particle size of 0.482 mm, an aspect ratio of 0.628, and a bluntness of 0.528. The ceramic beads are made of zirconia ceramic. The organic amine curing agent is type 593 diethylenetriaminebutyl glycidyl ether curing agent; The dispersant is AFCONA-4401; The leveling agent is NANOBYK-3620; The defoamer is BYK-141.

[0060] Example 1 This invention provides a spraying material comprising 10 parts organic resin, 2 parts ceramic powder, 68 parts irregular ceramic particles, 85 parts ceramic beads, 3 parts organic amine curing agent, and 2 parts organic additive. The organic additive is a mixture of 0.08 parts dispersant, 1.5 parts leveling agent, and 0.42 parts defoamer.

[0061] The preparation method of the spray coating material includes the following steps: (1) Mix 1 part of organic additive with organic resin, then add 1 part of ceramic powder and 34 parts of irregular ceramic particles, degas in a vacuum degassing machine at 1200 rpm for 10 min, then add 45 parts of ceramic beads, degas in a vacuum degassing machine at 1500 rpm for 5 min to obtain component A. (2) Mix 1 part of organic additive with organic amine curing agent, then add 1 part of ceramic powder and 34 parts of irregular ceramic particles, degas in a vacuum degassing machine at 1800 rpm for 1 min, then add 40 parts of ceramic beads, degas in a vacuum degassing machine at 1800 rpm for 3 min to obtain component B. (3) Mix component A and component B to obtain the spraying material.

[0062] Example 2 This invention provides a spraying material comprising 10 parts organic resin, 2 parts ceramic powder, 68 parts irregular ceramic particles, 85 parts ceramic beads, 3 parts organic amine curing agent, and 2 parts organic additive. The organic additive is a mixture of 0.08 parts dispersant, 1.5 parts leveling agent, and 0.42 parts defoamer.

[0063] The preparation method of the spray coating material includes the following steps: (1) Mix 1.1 parts of organic additive with organic resin, then add 1.1 parts of ceramic powder and 35 parts of irregular ceramic particles, degas in a vacuum degassing machine at 1200 rpm for 10 min, then add 50 parts of ceramic beads, degas in a vacuum degassing machine at 1500 rpm for 5 min to obtain component A. (2) Mix 0.9 parts of organic additives with organic amine curing agent, then add 0.9 parts of ceramic powder and 33 parts of irregular ceramic particles, degas in a vacuum degassing machine at 1800 rpm for 1 min, then add 35 parts of ceramic beads, degas in a vacuum degassing machine at 1800 rpm for 3 min to obtain component B; (3) Mix component A and component B to obtain the spraying material.

[0064] Example 3 This invention provides a spraying material comprising 10 parts organic resin, 2 parts ceramic powder, 68 parts irregular ceramic particles, 85 parts ceramic beads, 3 parts organic amine curing agent, and 2 parts organic additive. The organic additive is a mixture of 0.08 parts dispersant, 1.5 parts leveling agent, and 0.42 parts defoamer.

[0065] The preparation method of the spray coating material includes the following steps: (1) Mix 1.2 parts of organic additives with organic resin, then add 1.2 parts of ceramic powder and 40 parts of irregular ceramic particles, degas in a vacuum degassing machine at 1200 rpm for 10 min, then add 55 parts of ceramic beads, degas in a vacuum degassing machine at 1500 rpm for 5 min to obtain component A. (2) Mix 0.8 parts of organic additives with organic amine curing agent, then add 0.8 parts of ceramic powder and 28 parts of irregular ceramic particles, degas in a vacuum degassing machine at 1800 rpm for 1 min, then add 30 parts of ceramic beads, degas in a vacuum degassing machine at 1800 rpm for 3 min to obtain component B; (3) Mix component A and component B to obtain the spraying material.

[0066] Example 4 This invention provides a spraying material comprising 10 parts organic resin, 2 parts ceramic powder, 68 parts irregular ceramic particles, 85 parts ceramic beads, 3 parts organic amine curing agent, and 2 parts organic additive. The organic additive is a mixture of 0.08 parts dispersant, 1.5 parts leveling agent, and 0.42 parts defoamer.

[0067] The preparation method of the spray coating material includes the following steps: (1) Mix 1.3 parts of organic additives with organic resin, then add 1.3 parts of ceramic powder and 45 parts of irregular ceramic particles, degas in a vacuum degassing machine at 1200 rpm for 10 min, then add 60 parts of ceramic beads, degas in a vacuum degassing machine at 1500 rpm for 5 min to obtain component A. (2) Mix 0.7 parts of organic additives with organic amine curing agent, then add 0.7 parts of ceramic powder and 23 parts of irregular ceramic particles, degas in a vacuum degassing machine at 1800 rpm for 1 min, then add 25 parts of ceramic beads, degas in a vacuum degassing machine at 1800 rpm for 3 min to obtain component B; (3) Mix component A and component B to obtain the spraying material.

[0068] Example 5 This invention provides a spraying material comprising 10 parts organic resin, 2 parts ceramic powder, 68 parts irregular ceramic particles, 85 parts ceramic beads, 3 parts organic amine curing agent, and 2 parts organic additive. The organic additive is a mixture of 0.08 parts dispersant, 1.5 parts leveling agent, and 0.42 parts defoamer.

[0069] The preparation method of the spray coating material includes the following steps: (1) Mix 1.4 parts of organic additives with organic resin, then add 1.4 parts of ceramic powder and 50 parts of irregular ceramic particles, degas in a vacuum degassing machine at 1200 rpm for 10 min, then add 65 parts of ceramic beads, degas in a vacuum degassing machine at 1500 rpm for 5 min to obtain component A. (2) Mix 0.6 parts of organic additives with organic amine curing agent, then add 0.6 parts of ceramic powder and 18 parts of irregular ceramic particles, degas in a vacuum degassing machine at 1800 rpm for 1 min, then add 20 parts of ceramic beads, degas in a vacuum degassing machine at 1800 rpm for 3 min to obtain component B; (3) Mix component A and component B to obtain the spraying material.

[0070] Example 6 This invention provides a spraying material comprising 10 parts organic resin, 2 parts ceramic powder, 68 parts irregular ceramic particles, 85 parts ceramic beads, 3 parts organic amine curing agent, and 2 parts organic additive. The organic additive is a mixture of 0.08 parts dispersant, 1.5 parts leveling agent, and 0.42 parts defoamer.

[0071] The preparation method of the spray coating material includes the following steps: (1) Mix 1.5 parts of organic additives with organic resin, then add 1.5 parts of ceramic powder and 55 parts of irregular ceramic particles, degas in a vacuum degassing machine at 1200 rpm for 10 min, then add 70 parts of ceramic beads, degas in a vacuum degassing machine at 1500 rpm for 5 min to obtain component A. (2) Mix 0.5 parts of organic additive with organic amine curing agent, then add 0.5 parts of ceramic powder and 13 parts of irregular ceramic particles, degas in a vacuum degassing machine at 1800 rpm for 1 min, then add 15 parts of ceramic beads, degas in a vacuum degassing machine at 1800 rpm for 3 min to obtain component B. (3) Mix component A and component B to obtain the spraying material.

[0072] Example 7 This embodiment provides a spraying material, which differs from Embodiment 1 only in that the amount of the organic amine curing agent is 1.5 parts.

[0073] Example 8 This embodiment provides a spraying material, which differs from Embodiment 1 only in that the irregular ceramic particles are corundum sand particles with a median particle size of 0.4-0.5 mm, an aspect ratio of 0.6-0.7, and a bluntness of 0.5-0.6.

[0074] Example 9 This embodiment provides a spraying material, which differs from Embodiment 1 only in that the irregular ceramic particles are corundum sand particles with a median particle size of 0.6-0.7 mm, an aspect ratio of 0.6-0.7, and a bluntness of 0.5-0.6.

[0075] Example 10 This embodiment provides a spraying material, which differs from Embodiment 1 only in that the irregular ceramic particles are corundum sand particles with a median particle size of 0.4-0.5 mm, an aspect ratio of 0.7-0.8, and a bluntness of 0.5-0.6.

[0076] Example 11 This embodiment provides a spraying material, which differs from Embodiment 1 only in that the irregular ceramic particles are corundum sand particles with a median particle size of 0.4-0.5 mm, an aspect ratio of 0.6-0.7, and a bluntness of 0.6-0.7.

[0077] Comparative Example 1 This embodiment provides a spraying material, which differs from Embodiment 1 only in that the amount of ceramic beads used is 55 parts, and the weight ratio of ceramic beads in component A and component B is the same as in Embodiment 1.

[0078] Comparative Example 2 This embodiment provides a spraying material, which differs from Embodiment 1 only in that the amount of ceramic powder used is 5 parts, and the weight ratio of ceramic powder in component A and component B is the same as in Embodiment 1.

[0079] Comparative Example 3 This embodiment provides a spraying material, which differs from Embodiment 1 only in that the amount of irregular ceramic particles used is 40 parts, and the weight ratio of the irregular ceramic particles in component A and component B is the same as in Embodiment 1.

[0080] Comparative Example 4 This embodiment provides a spraying material, which differs from Embodiment 1 only in that the amount of irregular ceramic particles used is 105 parts, and the weight ratio of the irregular ceramic particles in component A and component B is the same as in Embodiment 1.

[0081] Comparative Example 5 This embodiment provides a spraying material, which differs from Embodiment 1 only in that the amount of the irregular ceramic particles is 0 parts.

[0082] Application Example 1 This application example provides a coating, the preparation method of which includes the following steps: The coating material of Example 1 was sprayed onto the surface of the cast iron substrate, compacted, and cured at 80°C for 30 minutes to obtain the coating.

[0083] The diameter of the spray nozzle is 10 mm.

[0084] Application Example 2 This application example provides a coating, the preparation method of which includes the following steps: The coating material of Example 2 was sprayed onto the surface of the cast iron substrate, compacted, and cured at 30°C for 24 hours to obtain the coating.

[0085] The diameter of the spray nozzle is 8 mm.

[0086] Application Example 3-11, Comparison with Application Example 1-5 Application Examples 3-11 and Comparative Application Examples 1-5 each provide a coating, the only difference from Application Example 1 being that the spraying materials are from Examples 3-11 and Comparative Examples 1-5, respectively.

[0087] The test results are shown in Table 1.

[0088] Table 1 The test results show that: (1) As can be seen from Examples 1-11, the present invention obtains a spraying material with excellent spraying fluidity, impact strength and wear resistance by using a specific amount of ceramic powder, irregular ceramic particles and ceramic beads in the spraying material.

[0089] (2) A comparison between Example 1 and Example 7 shows that the present invention improves the performance of the sprayed material by further limiting the amount of organic amine curing agent. If the amount of curing agent is too small, the corrosion resistance will decrease.

[0090] A comparison of Example 1 with Examples 8-11 reveals that the present invention improves the performance of the spraying material by further limiting the median particle size, aspect ratio, and bluntness of the irregular ceramic particles.

[0091] (3) By comparing Example 1 with Comparative Examples 1-5, it can be seen that if irregular ceramic particles are missing in the spraying material, or if the amounts of ceramic powder, irregular ceramic particles and ceramic beads are not within a specific range, a spraying material with excellent spraying fluidity, impact strength and wear resistance cannot be obtained.

[0092] In summary, by designing the components of the spraying material, the present invention produces a spraying material that not only has good spraying fluidity and is resistant to acid, alkali solutions and aerosol corrosion, but also does not reduce the material's impact strength and wear resistance after curing.

[0093] The applicant declares that the above description is only a specific embodiment of the present invention, but the protection scope of the present invention is not limited thereto. Those skilled in the art should understand that any changes or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention fall within the protection and disclosure scope of the present invention.

Claims

1. A spray coating material, characterized in that, The spraying material includes organic resin, ceramic powder, irregular ceramic particles, ceramic beads, and organic amine curing agent; The mass ratio of the organic resin to the ceramic powder is 10:(0.5-4); The mass ratio of the irregular ceramic particles to the spraying material is (3-5):10; The mass ratio of the ceramic beads to the spraying material is (4-6):

10.

2. The spraying material according to claim 1, characterized in that, The mass ratio of the organic resin to the organic amine curing agent is 10:(2-3.5).

3. The spraying material according to claim 1 or 2, characterized in that, The organic resin includes any one or a combination of at least two of the following: bisphenol A type epoxy resin, bisphenol B type epoxy resin, bisphenol F type epoxy resin, E48 type phenolic epoxy resin, E50 type phenolic epoxy resin, E51 type phenolic epoxy resin, or phenolic resin.

4. The spraying material according to any one of claims 1-3, characterized in that, The ceramic powder includes any one or a combination of at least two of nano-silicon carbide, nano-silicon nitride, nano-silicon dioxide, nano-alumina, or nano-zirconia. Preferably, the median particle size of the ceramic powder is 10-100 nm; Preferably, the irregular ceramic particles include any one or a combination of at least two of the following: corundum sand particles, brown corundum particles, diamond particles, zirconium corundum particles, zircon sand particles, quartz sand particles, corundum particles, or silicon carbide particles. Preferably, the median particle size of the irregular ceramic particles is 0.4-0.5 mm; Preferably, the irregular ceramic particles have a shape that includes any one or a combination of at least two of the following: sharp, blocky, or polygonal. Preferably, the average aspect ratio of the irregular ceramic particles is not higher than 0.7, and the standard deviation is not higher than 0.

2. Preferably, the bluntness of the irregular ceramic particles is not higher than 0.6 and the standard deviation is not higher than 0.

15.

5. The spraying material according to any one of claims 1-4, characterized in that, The ceramic beads include any one or a combination of at least two of the following: zirconia ceramic beads, alumina ceramic beads, silicon nitride ceramic beads, or silicon carbide ceramic beads. Preferably, the median particle size of the ceramic beads is 0.1-4 mm; Preferably, the organic amine curing agent includes an organic amine epoxy curing agent; Preferably, the organic amine curing agent includes any one or a combination of at least two of the following: type 593 diethylenetriaminebutyl glycidyl ether curing agent, type T31 phenolic amine curing agent, type 630 polyamide curing agent, type 631 polyamide curing agent, or 2,4,6-tris(dimethylaminomethyl)phenol.

6. The spraying material according to any one of claims 1-5, characterized in that, The spraying material also includes organic additives; Preferably, the mass ratio of the organic resin to the organic additive is 10:(1.5-3); Preferably, the organic additive includes any one or a combination of at least two of dispersants, leveling agents, or defoamers; Preferably, the dispersant comprises any one or a combination of at least two of oleic acid, stearic acid, sodium stearate, zinc stearate, or AFCONA-4401; Preferably, the leveling agent includes any one or a combination of at least two of BYK-W985, NANOBYK-3620, or NANOBYK-3611; Preferably, the defoamer includes any one or a combination of at least two of BYK-110, BYK-141, or ethanol; Preferably, the mass ratio of the dispersant to the ceramic powder is (0.02-0.4):10; Preferably, the mass ratio of the leveling agent to the organic resin is (1-2.5):10; Preferably, the mass ratio of the defoamer to the organic resin is (0.05-0.5):

10.

7. A method for preparing a spraying material as described in any one of claims 1-6, characterized in that, The preparation method includes the following steps: (1) The ceramic powder, irregular ceramic particles, ceramic beads and optional organic additives are each divided into two separate portions. (2) Mix the first part of organic additive with organic resin, then add the first part of ceramic powder and the first part of irregular ceramic particles, degas, then add the first part of ceramic beads, degas, and obtain component A; The second part of organic additive is mixed with organic amine curing agent, then the second part of ceramic powder and the second part of irregular ceramic particles are added, degassing is performed, then the second part of ceramic beads are added, degassing is performed, and component B is obtained. (3) Mix component A and component B to obtain the spraying material.

8. The preparation method according to claim 7, characterized in that, The degassing is performed in a vacuum degassing machine; Preferably, the speed of the vacuum degassing machine is 1000-2000 rpm; Preferably, the degassing time is 30 s-10 min.

9. The preparation method according to claim 7 or 8, characterized in that, The mixing in step (3) includes any one or a combination of at least two of manual stirring, mechanical stirring or centrifugal stirring.

10. A method of using a spraying material as described in any one of claims 1-6, characterized in that, The method of use includes the following steps: The coating material is sprayed onto the surface of the substrate, compacted, and cured to obtain a coating. Preferably, the diameter of the spray nozzle is 3-10 mm; Preferably, the thickness of the coating is 2-20 mm; Preferably, the curing includes room temperature curing and / or heat curing, wherein the room temperature curing temperature is 10-40℃ and the heat curing temperature is 40-120℃.

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