An adaptive multi-layer wear resistant coating structure for scouring environments

Abstract

This utility model discloses a multi-layer wear-resistant coating structure that adapts to scouring environments, belonging to the field of wear-resistant coating technology. The key technical points include a substrate with a wear-resistant protective layer on its surface. This protective layer consists of a first transition layer, an intermediate buffer layer, a second transition layer, and an outer rigid protective layer, arranged sequentially from the inside out. The substrate and the first transition layer are coated and bonded after sandblasting pretreatment. The first transition layer and the intermediate buffer layer are bonded by hot-pressing curing. This solves the problems of existing multi-layer wear-resistant structures, which often use direct coating or simply grind carbon steel substrates without targeted pretreatment, leading to easy peeling and detachment under long-term scouring. Furthermore, the interlayer bonding often uses a single curing process, failing to match the characteristics of different coating materials, resulting in gaps and cracks between layers, easy crack propagation along the interlayer boundaries, poor elasticity of the transition layer material, lack of self-healing design in the outermost layer, and no reasonable surface texture, resulting in weak wear resistance and damage resistance.

Description

Technical Field

[0001] This utility model relates to the field of wear-resistant coating technology, and in particular to a multi-layer wear-resistant coating structure that adapts to scouring environments. Background Technology

[0002] In fields such as water conservancy projects, oil transportation, and mining, the flow-through components of equipment are subjected to the scouring of media such as sandy water flow and slurry for a long time. Although the core base material carbon steel is widely used due to its low cost and high strength, its surface wear resistance is poor and it is easily damaged by the abrasion and impact of solid particles, resulting in failure. Frequent replacement of parts is required, which increases the operation and maintenance costs and creates potential safety hazards.

[0003] Existing multi-layer wear-resistant structures mostly use direct coating or simply grinding of carbon steel substrates without targeted pretreatment. Under long-term scouring, they are prone to peeling and falling off. The interlayer bonding between coatings mostly uses a single curing process, which does not match the characteristics of different coating materials. Voids and cracks are easily generated between layers, and cracks are easy to extend along the interlayer. The transition layer material has poor elasticity, and the outermost layer lacks self-healing design and has no reasonable surface texture, resulting in weak wear resistance and damage resistance.

[0004] To address this, a multi-layer wear-resistant coating structure that adapts to scouring environments is proposed. Utility Model Content

[0005] The purpose of this invention is to provide a multi-layer wear-resistant coating structure that adapts to the scouring environment. This addresses the problems of existing multi-layer wear-resistant structures, which often use direct coating or simply grinding of carbon steel substrates without targeted pretreatment. These structures are prone to peeling and detachment under long-term scouring, and the interlayer bonding often uses a single curing process that does not match the characteristics of different coating materials. This results in gaps and cracks between layers, with cracks easily propagating along the interlayer. The transition layer material has poor elasticity, and the outermost layer lacks a self-healing design and a reasonable surface texture, leading to weak wear resistance and damage resistance.

[0006] To achieve the above objectives, this utility model provides the following technical solution: a multi-layer wear-resistant coating structure that adapts to scouring environments, comprising a substrate, wherein a wear-resistant protective layer is disposed on the surface of the substrate, and the wear-resistant protective layer is provided with a first transition layer, an intermediate buffer layer, a second transition layer and an outer rigid protective layer in sequence from the inside to the outside; the substrate and the first transition layer are coated and bonded after sandblasting pretreatment; the first transition layer and the intermediate buffer layer are bonded by hot pressing and curing; the intermediate buffer layer and the second transition layer are bonded by coating and curing at room temperature; and the second transition layer and the outer rigid protective layer are bonded by coating and curing by heating.

[0007] Preferably, the substrate is made of carbon steel.

[0008] Preferably, the first transition layer is made of nitrile rubber, and the coating of the first transition layer is carried out by a spraying process.

[0009] Preferably, the intermediate buffer layer is a linear starch hydrogel layer, and the intermediate buffer layer is coated using a blade coating process.

[0010] Preferably, the intermediate buffer layer contains modified particles, which are mixed into the amylose hydrogel by an ultrasonic dispersion process.

[0011] Preferably, the material of the second transition layer is silane-modified epoxy resin, and the coating of the second transition layer is performed by roller coating process.

[0012] Preferably, the outer rigid protective layer is made of bisphenol A type epoxy resin, and the outer rigid protective layer is coated using a high-pressure airless spraying process.

[0013] Preferably, microcapsules are embedded in the outer rigid protective layer, and the microcapsules contain epoxy resin repair agents. The microcapsules are mixed in bisphenol A type epoxy resin by mechanical stirring.

[0014] Preferably, the outer surface of the outer rigid protective layer is provided with a surface texture, which is a strip groove, and the strip groove is processed by mechanical milling.

[0015] Preferably, the outer rigid protective layer also contains nano-alumina particles, which are added to the bisphenol A epoxy resin through a ball milling mixing process.

[0016] Compared with the prior art, the beneficial effects of this utility model are:

[0017] This application utilizes a wear-resistant protective layer on the substrate surface. The outer rigid protective layer is prepared by high-pressure airless spraying of bisphenol A type epoxy resin, resulting in a dense and uniform structure with evenly dispersed nano-alumina particles, significantly improving hardness and wear resistance. This effectively resists abrasion from solid particles in the scouring medium. Microcapsules rupture upon contact with cracks, releasing a repair agent for self-repair. Striped grooves reduce the contact area with the medium, lowering impact pressure and resistance, further mitigating outer layer wear. The outer layer and the second transition layer are bonded tightly through heat curing, preventing peeling. The second transition layer combines rigidity and toughness, buffering impact forces to prevent direct impact on the inner layer. The second transition layer and the intermediate buffer layer are cured at room temperature, ensuring stable bonding without damaging the hydrogel structure. The hydrogel efficiently absorbs impact energy. Modified particles are ultrasonically dispersed to enhance their strength and prevent excessive wear. When deformation and breakage occur, the intermediate buffer layer and the first transition layer are hot-pressed together. The nitrile rubber can buffer the remaining energy a second time. Furthermore, the first transition layer is coated and bonded to the pre-treated carbon steel substrate, which significantly improves the interfacial bonding force and prevents the coating from peeling off completely. The materials and processes of each layer work together to form a complete anti-erosion protection system, which can effectively protect the carbon steel substrate and adapt to long-term erosion environment. This solves the problems of existing multi-layer wear-resistant structures, which mostly use direct coating or simply grind the carbon steel substrate without targeted pretreatment, making them prone to peeling off under long-term erosion. The interlayer bonding between coatings mostly uses a single curing process, which does not match the characteristics of different coating materials, making it easy for gaps and cracks to form between layers. Cracks are easy to extend along the interlayer. The transition layer material has poor elasticity, and the outermost layer lacks self-healing design and reasonable surface texture, resulting in weak wear resistance and damage resistance. Attached Figure Description

[0018] Figure 1 This is an overall structural diagram of the multi-layer wear-resistant coating structure for adaptive scouring environment of this utility model;

[0019] Figure 2 This is a cross-sectional view of the substrate and the wear-resistant protective layer in this utility model;

[0020] Figure 3 This is a cross-sectional view of the intermediate buffer layer in this utility model;

[0021] Figure 4 This is a cross-sectional view of the outer rigid protective layer in this utility model;

[0022] Figure 5 This is a three-dimensional structural diagram of the outer rigid protective layer in this utility model.

[0023] In the figure, 1 is the substrate; 2 is the wear-resistant protective layer; 3 is the first transition layer; 4 is the intermediate buffer layer; 5 is the second transition layer; and 6 is the outer rigid protective layer. Detailed Implementation

[0024] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0025] Please see Figure 1-5 The present invention provides the following technical solution:

[0026] A multi-layer wear-resistant coating structure adaptable to scouring environments includes a substrate 1, a wear-resistant protective layer 2 disposed on the surface of the substrate 1, and a first transition layer 3, an intermediate buffer layer 4, a second transition layer 5, and an outer rigid protective layer 6 disposed sequentially from the inside to the outside of the wear-resistant protective layer 2. The substrate 1 and the first transition layer 3 are coated and bonded after sandblasting pretreatment. The first transition layer 3 and the intermediate buffer layer 4 are bonded by hot pressing and curing. The intermediate buffer layer 4 and the second transition layer 5 are bonded by coating and curing at room temperature. The second transition layer 5 and the outer rigid protective layer 6 are bonded by coating and curing by heating.

[0027] In this embodiment: When the multi-layer wear-resistant coating structure of this adaptive scouring environment is in operation, the outer rigid protective layer 6 directly contacts the scouring medium such as sand-containing water flow and slurry. It is prepared by high-pressure airless spraying of bisphenol A type epoxy resin. This process ensures that the coating is dense and uniform. The ball-milled and mixed nano-alumina particles in the coating greatly improve the hardness and wear resistance of the outer layer, resisting the abrasion of solid particles. If microcracks occur in the outer layer, the mechanically stirred and dispersed microcapsules rupture, releasing epoxy resin repair agent to fill the cracks. The strip grooves mechanically milled on the outer surface reduce the contact area of ​​the medium, reducing impact and resistance. The outer layer and the second transition layer 5 are heat-cured and bonded together, promoting chemical cross-linking and preventing peeling. The second transition layer 5 has both rigidity and toughness to buffer impact force. The second transition layer 5 is cured and bonded to the intermediate buffer layer 4 at room temperature. The intermediate buffer layer 4, composed of linear starch hydrogel, absorbs energy, while the modified particles, dispersed by ultrasound, enhance its strength. The intermediate buffer layer 4 is hot-pressed and cured together with the first transition layer 3. The nitrile rubber of the first transition layer 3 provides further buffering and is coated and bonded to the pre-treated carbon steel substrate 1 to prevent coating peeling. The layers work together to form an anti-erosion system, protecting the carbon steel substrate 1 to withstand long-term erosion. This solves the problems of existing multi-layer wear-resistant structures, which often use direct coating or simply sanding the carbon steel substrate without targeted pretreatment, making them prone to peeling and falling off under long-term erosion. The interlayer bonding often uses a single curing process, which does not match the characteristics of different coating materials, making it easy for voids and cracks to form between layers. Cracks are easy to propagate along the interlayer. The transition layer material has poor elasticity, and the outermost layer lacks self-healing design and reasonable surface texture, resulting in weak wear resistance and damage resistance.

[0028] Specifically, such as Figure 1 As shown, the material of substrate 1 is carbon steel.

[0029] Specifically, such as Figure 2 As shown, the first transition layer 3 is made of nitrile rubber, and the coating of the first transition layer 3 is carried out by spraying.

[0030] In this embodiment: the substrate 1 is made of carbon steel, which takes into account both low cost and high strength, and is suitable for the basic performance requirements of the flow-through components of equipment in the fields of water conservancy and mining. The first transition layer 3 is made of nitrile rubber and is coated by spraying. The elasticity of nitrile rubber can initially buffer the impact of scouring. The spraying process can ensure that the thickness of the transition layer is uniform and that it is tightly bonded to the substrate 1, thereby improving the overall bonding stability of the coating and preventing subsequent layer peeling.

[0031] Specifically, such as Figure 2 As shown, the intermediate buffer layer 4 is a linear starch hydrogel layer, and the intermediate buffer layer 4 is coated by a scraping process.

[0032] Specifically, such as Figure 3 As shown, modified particles are dispersed in the intermediate buffer layer 4. The modified particles are mixed in the amylose hydrogel by ultrasonic dispersion process.

[0033] In this embodiment: the intermediate buffer layer 4 is a linear starch hydrogel layer and is coated by a scraping process. The high elastic deformation capacity of the linear starch hydrogel can efficiently absorb the scouring energy. The scraping process can precisely control the thickness of the buffer layer. The modified particles in the buffer layer are mixed by an ultrasonic dispersion process, which can avoid particle agglomeration and ensure that the particles are evenly dispersed to enhance the strength of the hydrogel structure, prevent the buffer layer from being damaged due to excessive deformation, and extend the life of the buffer function.

[0034] Specifically, such as Figure 2 As shown, the material of the second transition layer 5 is silane-modified epoxy resin, and the coating of the second transition layer 5 is carried out by roller coating process.

[0035] In this embodiment: the second transition layer 5 is made of silane-modified epoxy resin and coated by roller coating process. The silane-modified epoxy resin has both rigidity and toughness, which can effectively connect the intermediate buffer layer 4 and the outer rigid protective layer 6, balance the stress transmission between the inner and outer layers. The roller coating process can make the transition layer dense and without gaps, further strengthen the interlayer bonding, and avoid interlayer cracking under the action of scouring.

[0036] Specifically, such as Figure 2 As shown, the outer rigid protective layer 6 is made of bisphenol A type epoxy resin, and the outer rigid protective layer 6 is coated using a high-pressure airless spraying process.

[0037] Specifically, such as Figure 4 As shown, microcapsules are embedded in the outer rigid protective layer 6, and epoxy resin repair agent is encapsulated inside the microcapsules. The microcapsules are mixed in bisphenol A type epoxy resin by mechanical stirring.

[0038] In this embodiment: the outer rigid protective layer 6 is made of bisphenol A epoxy resin and coated by high-pressure airless spraying process. Bisphenol A epoxy resin has high hardness and excellent wear resistance. High-pressure airless spraying can ensure that the outer layer is dense and uniform, resisting the abrasion of solid particles in the scouring medium. The microcapsules in the outer layer are evenly dispersed by mechanical stirring. When cracks occur, they can release epoxy resin repair agent to achieve self-repair, prevent crack propagation, and maintain the integrity of the outer protective layer.

[0039] Specifically, such as Figure 5 As shown, the outer surface of the outer rigid protective layer 6 is provided with a surface texture, which is a strip groove. The strip groove is processed by mechanical milling.

[0040] Specifically, such as Figure 4 As shown, the outer rigid protective layer 6 also contains nano-alumina particles, which are added to the bisphenol A epoxy resin through a ball milling mixing process.

[0041] In this embodiment: the outer surface of the outer rigid protective layer 6 is machined with strip grooves to reduce the contact area between the scouring medium and the outer layer, thereby reducing the impact pressure and scouring resistance and reducing the wear of the outer layer. The nano alumina particles added to the outer layer are evenly dispersed by ball milling, which can further improve the hardness and wear resistance of the outer layer. The ball milling process ensures that the particles do not agglomerate and are tightly bonded to the resin matrix, significantly enhancing the scouring resistance of the outer layer.

[0042] Working Principle: In operation, this multi-layered wear-resistant coating structure, designed to withstand scouring environments, first comes into direct contact with the scouring medium, such as sand-laden water or slurry, via the outer rigid protective layer 6. This outer rigid protective layer 6 is prepared using bisphenol A epoxy resin through a high-pressure airless spraying process. This process ensures a dense and uniform coating. Simultaneously, the uniformly dispersed nano-alumina particles within the coating, achieved through ball milling, significantly enhance the hardness and wear resistance of the outer layer, effectively resisting the abrasive action of solid particles in the scouring medium. When the outer rigid protective layer 6 develops microcracks due to scouring, the microcapsules embedded within, uniformly distributed through mechanical stirring, rupture as the cracks propagate. The epoxy resin repair agent encapsulated within is released and fills the cracks, preventing further crack extension and maintaining the integrity of the outer protective layer. Furthermore, the strip grooves machined by mechanical milling on the outer surface of the outer rigid protective layer 6 reduce the contact area between the scouring medium and the coating surface, thereby reducing the impact pressure and scouring resistance of the medium on the coating and further mitigating wear on the outer layer. The outer rigid protective layer 6 and the second transition layer 5 are bonded together by heat curing. The heat curing process promotes the chemical cross-linking between the bisphenol A epoxy resin and the silane-modified epoxy resin, ensuring a tight bond between the two and preventing interlayer delamination. At the same time, the silane-modified epoxy resin material of the second transition layer 5 has both rigidity and toughness, which can buffer the scouring impact force transmitted from the outer layer and prevent the impact force from acting directly on the inner layer. The second transition layer 5 and the intermediate buffer layer 4 are bonded together by room temperature curing. Room temperature curing can be carried out without destroying the linear starch hydrogel structure. To achieve a stable bond between the two, the amylose hydrogel in the intermediate buffer layer 4 possesses excellent elastic deformation capability, effectively absorbing the impact energy transmitted through the second transition layer 5 and weakening the impact of scouring load on the substrate 1. Furthermore, the modified particles uniformly dispersed in the buffer layer through ultrasonic dispersion enhance the structural strength of the hydrogel, preventing damage to the buffer layer itself due to excessive deformation. The intermediate buffer layer 4 and the first transition layer 3 are bonded together through hot-pressing curing. Hot-pressing ensures a tight bond between the nitrile rubber first transition layer 3 and the amylose hydrogel. The nitrile rubber in the first transition layer 3 possesses good elasticity and flexibility, further buffering the remaining impact energy. Simultaneously, it is bonded to the pre-treated carbon steel substrate 1 through coating. The pre-treatment of sandblasting removes oil stains from the surface of the substrate 1 and enhances its elasticity. By increasing surface roughness, the interfacial bonding force between the first transition layer 3 and the substrate 1 is significantly improved, preventing the coating from peeling off the substrate 1 surface as a whole. Ultimately, through the synergistic effect of the material properties of each layer and the appropriate bonding process, a complete anti-erosion protection system is formed. This system effectively protects the carbon steel substrate 1, adapting to long-term erosion environments. It solves the problems of existing multi-layer wear-resistant structures that often use direct coating or simple grinding of the carbon steel substrate without targeted pretreatment, leading to easy peeling and detachment under long-term erosion. Furthermore, the interlayer bonding often uses a single curing process that does not match the different coating material properties, resulting in gaps and cracks between layers, which can easily propagate along the interlayer boundaries.The transition layer material has poor elasticity, the outermost layer lacks a self-healing design and has no reasonable surface texture, resulting in weak wear resistance and damage resistance.

[0043] The above are merely preferred embodiments of the present utility model and are not intended to limit the present utility model. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A multi-layer wear resistant coating structure adapted to a scouring environment, comprising a substrate (1), characterized in that: The surface of the substrate (1) is provided with a wear-resistant protective layer (2). The wear-resistant protective layer (2) is provided with a first transition layer (3), an intermediate buffer layer (4), a second transition layer (5) and an outer rigid protective layer (6) from the inside to the outside. The substrate (1) and the first transition layer (3) are coated and bonded after sandblasting pretreatment. The first transition layer (3) and the intermediate buffer layer (4) are bonded by hot pressing and curing. The intermediate buffer layer (4) and the second transition layer (5) are bonded by coating and curing at room temperature. The second transition layer (5) and the outer rigid protective layer (6) are bonded by coating and curing by heating.

2. A multi-layer wear resistant coating structure that is adaptive to a scouring environment according to claim 1, characterized in that: The substrate (1) is made of carbon steel.

3. The multi-layer wear-resistant coating structure for adaptive scouring environments according to claim 1, characterized in that: The first transition layer (3) is made of nitrile rubber, and the coating of the first transition layer (3) is carried out by spraying process.

4. A multi-layer wear resistant coating structure that self-adapts to a scouring environment according to claim 1, wherein: The intermediate buffer layer (4) is a linear starch hydrogel layer, and the intermediate buffer layer (4) is coated by a scraping process.

5. A multi-layer wear resistant coating structure that self-adapts to a scouring environment according to claim 4, characterized in that: The intermediate buffer layer (4) contains modified particles, which are mixed into the amylose hydrogel by ultrasonic dispersion.

6. A multi-layer wear resistant coating structure that self-adapts to a scouring environment according to claim 1, wherein: The material of the second transition layer (5) is silane-modified epoxy resin, and the coating of the second transition layer (5) is carried out by roller coating process.

7. A multi-layer wear resistant coating structure that self-adapts to a scouring environment according to claim 1, wherein: The outer rigid protective layer (6) is made of bisphenol A type epoxy resin, and the outer rigid protective layer (6) is coated using a high-pressure airless spraying process.

8. A multi-layer wear resistant coating structure that self-adapts to a scouring environment according to claim 7, characterized in that: Microcapsules are embedded in the outer rigid protective layer (6), and the interior of the microcapsules contains epoxy resin repair agent. The microcapsules are mixed in bisphenol A type epoxy resin by mechanical stirring.

9. The multilayer wear-resistant coating structure for adaptive scouring environments according to claim 1, characterized in that: The outer surface of the outer rigid protective layer (6) is provided with a surface texture, which is a strip groove, and the strip groove is processed by mechanical milling.

10. A multi-layer wear resistant coating structure that self-adapts to a scouring environment according to claim 7, wherein: The outer rigid protective layer (6) also contains nano-alumina particles, which are added to bisphenol A epoxy resin by ball milling and mixing.

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