Triple-wire flame spray apparatus and triple flame spray layer produced by same

Abstract

The present invention relates to a triple-wire flame spray apparatus and a triple flame spray layer produced by same. One aspect of the present invention is to provide a triple-wire flame spray apparatus and a triple flame spray layer produced by same.

Description

Triple wire flame sprayer and triple flame spray layer produced thereby

[0001] The present invention relates to a triple wire flame sprayer and a triple flame spray layer produced thereby.

[0002] Recently, the installation of solar power plants has been expanding in accordance with eco-friendly policies. There is a trend of these solar power plants shifting from land-based locations to harsh environments such as reclaimed land, abandoned salt fields, and deserts; in particular, as they move to saline environments like water, problems regarding vulnerability to corrosion are emerging.

[0003] Generally, structures such as square tubes are used for the installation of solar power plants, and galvanized steel sheets are mainly used as the material for these structures to ensure corrosion resistance.

[0004] However, galvanized steel sheets face a problem where they become locally more vulnerable to corrosion as the plating layer is lost during processes such as forming or welding.

[0005] Accordingly, there is a need for measures to prevent the deterioration of corrosiveness caused by the loss of the plating layer on galvanized steel sheets.

[0006] Meanwhile, recently manufactured galvanized steel sheets feature a plating layer containing multiple alloying elements rather than a single alloy. If a loss occurs in such a plating layer, it is desirable to form a coating layer having a composition similar to that of the plating layer in the loss area.

[0007] However, currently commercially available thermal spray wires have the disadvantage of not having a composition similar to that of a plating layer. In addition, even when using a conventional flame sprayer, it is necessary to perform two or more stages of spraying to control the composition to be similar to that of a plating layer. Even with two or more stages of spraying, it is not easy to control the composition and thickness of the spray coating layer, and consequently, there is a problem where corrosion resistance is actually reduced.

[0008] One aspect of the present invention is to provide a triple wire flame sprayer and a triple flame spray layer produced thereby.

[0009] A preferred aspect of the present invention is to provide a triple wire flame sprayer having excellent corrosion resistance and easy modification of the composition of the sprayed layer, and a triple flame sprayed layer produced thereby.

[0010] The problems of the present invention are not limited to those described above. A person skilled in the art to which the present invention pertains will have no difficulty understanding additional problems of the present invention from the overall contents of this specification.

[0011] One embodiment of the present invention provides a triple wire flame sprayer comprising: a first feeding device for feeding a first wire; a second feeding device for feeding a second wire; a third feeding device for feeding a third wire; a first control device for controlling the feeding speed of the first wire; a second control device for controlling the feeding speed of the second wire; and a third control device for controlling the feeding speed of the third wire; wherein the first wire, the second wire, and the third wire are provided at the same or similar points and are simultaneously melted by a flame.

[0012] The first, second, and third control devices can each variably control the feed speeds of the first, second, and third wires, respectively, so as to have a ratio of the desired thermal spray layer composition.

[0013] The above triple wire flame sprayer may additionally include a heat source device that provides flames to the first wire, the second wire, and the third wire.

[0014] The above triple wire flame sprayer may additionally include a first nozzle, a second nozzle, and a third nozzle so that the first wire, the second wire, and the third wire are each fed into the flame.

[0015] The first nozzle, second nozzle, and third nozzle may have an angle of 0 to 20° with respect to the vertical axis.

[0016] The above triple wire flame sprayer may additionally include a gas nozzle that supplies gas to the flame.

[0017] The above triple wire flame sprayer may additionally include an oxygen nozzle that supplies oxygen to the flame.

[0018] The first wire is composed of a first element, the second wire is composed of a second element, and the third wire is composed of a third element, and the triple wire flame sprayer can control the target composition of the spray layer using the following relationship 1.

[0019] [Relationship 1] X = αX1 + βX2 + γX3

[0020] (wherein X is the triple thermal spray layer composition, α is A / (A+B+C)×100, β is B / (A+B+C)×100, γ is C / (A+B+C)×100, A is ρ1×v1×s1, B is ρ2×v2×s2, C is ρ3×v3×s3, ρ1 is the welding efficiency (%) of the first wire, v1 is the feeding speed of the first wire (cm / min), and s1 is the cross-sectional area of ​​the first wire (cm²) 2 ), above ρ2 is the welding efficiency (%) of the second wire, above v2 is the feeding speed (cm / min) of the second wire, above s2 is the cross-sectional area (cm²) of the second wire 2 ), above ρ3 is the welding efficiency (%) of the third wire, above v3 is the feed speed (cm / min) of the third wire, and above s3 is the cross-sectional area (cm²) of the third wire. 2 ), above X1 means a component of the first element, above X2 means a component of the second element, and above X3 means a component of the third element.)

[0021] Another embodiment of the present invention provides a triple flame spray layer produced by the aforementioned triple wire flame sprayer.

[0022] According to one aspect of the present invention, a triple wire flame sprayer and a triple flame spray layer produced thereby can be provided.

[0023] According to a preferred aspect of the present invention, a triple wire flame sprayer having excellent corrosion resistance and easy modification of the composition of the spray layer, and a triple flame spray layer produced by the same can be provided.

[0024] FIG. 1 is a schematic diagram of a triple wire flame sprayer according to one embodiment of the present invention.

[0025] Figure 2 is a schematic diagram of the AA region of Figure 1 viewed from the top.

[0026] Preferred embodiments of the present invention will be described below with reference to the attached drawings. However, embodiments of the present invention may be modified in various other forms, and the scope of the present invention is not limited to the embodiments described below.

[0027] In addition, embodiments of the present invention are provided to more fully explain the present invention to those with average knowledge in the relevant technical field.

[0028] In drawings, the shapes and sizes of elements may be exaggerated for clearer explanation.

[0029] In describing the embodiments of the present invention, if it is determined that a detailed description of known technology related to the present invention may unnecessarily obscure the essence of the present invention, such detailed description will be omitted. Furthermore, the terms described below are defined considering their functions in the present invention, and these may vary depending on the intentions or conventions of the user or operator. Therefore, such definitions should be based on the content throughout this specification. The terms used in the detailed description are merely for describing the embodiments of the present invention and should not be limited in any way. Unless explicitly stated otherwise, expressions in the singular form include the meaning of the plural form.

[0030] In this description, expressions such as “include” or “equipped” are intended to refer to certain characteristics, numbers, steps, actions, elements, parts or combinations thereof, and should not be interpreted to exclude the existence or possibility of one or more other characteristics, numbers, steps, actions, elements, parts or combinations thereof other than those described.

[0031] In this specification, terms such as 'top', 'upper', 'upper surface', 'lower', 'lower surface', 'lower surface', and 'side surface' are based on the drawings and may actually vary depending on the direction in which the elements or components are arranged.

[0032] Additionally, throughout the specification, when it is said that one part is 'connected' to another part, this includes not only cases where they are 'directly connected,' but also cases where they are 'indirectly connected' with other elements in between.

[0033] The present invention will be described in detail below through each embodiment or example of the invention. It should be noted that each embodiment or example described in this specification is not limited to a single embodiment or example, but may also be combined with other embodiments or examples. Accordingly, the citation of claims in the patent claims is merely an example of an embodiment, and the technical concept of the present invention should not be interpreted as being limited only to a combination with the cited claims; rather, combinations with various claims are also included within the scope of the technical concept of the present invention.

[0034] FIG. 1 is a schematic diagram of a triple wire flame sprayer according to an embodiment of the present invention. FIG. 2 is a schematic diagram of the AA region of FIG. 1 viewed from above. Hereinafter, a triple wire flame sprayer according to an embodiment of the present invention will be described with reference to FIG. 1 and FIG. 2.

[0035] The triple wire flame sprayer (100) of the present invention includes a first feeding device (10) for feeding a first wire (1), a second feeding device (20) for feeding a second wire (2), and a third feeding device (30) for feeding a third wire (3). The first feeding device (10), the second feeding device (20), and the third feeding device (30) may have various types or shapes, but as an example, they may have the shape of rollers, thereby enabling continuous spraying. At this time, the first wire (1), the second wire (2), and the third wire (3) may be of the same type or different types. When the first wire (1), the second wire (2), and the third wire (3) are of different types, the composition of the spray layer can be varied. For example, the first wire, the second wire, and the third wire may each be Zn-based, Al-based, and Mg-based wires.

[0036] The triple wire flame sprayer (100) of the present invention includes a first control device (12) for controlling the feeding speed of the first wire, a second control device (22) for controlling the feeding speed of the second wire, and a third control device (32) for controlling the feeding speed of the third wire. By controlling the speeds of the first feeding device (10), the second feeding device (20), and the third feeding device (30) through the first control device (12), the second control device (22), and the third control device (32), the composition of the spray layer can be varied, and the thickness of the spray layer can be appropriately controlled. For example, the first control device, the second control device, and the third control device can each variably control the feeding speeds of the first wire, the second wire, and the third wire, respectively, so as to have a ratio of the desired spray layer composition.

[0037] More specifically, for example, when the first wire is an Al wire, the second wire is a Zn wire, and the third wire is a Mg wire, and the target composition of the thermal spray layer is Al:Zn:Mg = 1:1:1 in weight%, the first control device, the second control device, and the third control device can control the first feeding device, the second feeding device, and the second feeding device so that the feeding speed of the first wire, the second wire, and the third wire is determined based on the densities of Al, Zn, and Mg.

[0038] For example, when the first wire is composed of a first element, the second wire is composed of a second element, and the third wire is composed of a third element, the triple wire flame sprayer of the present invention can control the target composition of the spray layer using the following Equation 1. That is, the composition of the spray layer can be determined by the ratio of the welding efficiency, cross-sectional area, and feeding speed of the first wire, the second wire, and the third wire. Meanwhile, the composition of the actual spray layer formed may not necessarily match the following Equation 1, and may have an error of, for example, ±10%.

[0039] [Relationship 1] X = αX1 + βX2 + γX3

[0040] (wherein X is the triple thermal spray layer composition, α is A / (A+B+C)×100, β is B / (A+B+C)×100, γ is C / (A+B+C)×100, A is ρ1×v1×s1, B is ρ2×v2×s2, C is ρ3×v3×s3, ρ1 is the welding efficiency (%) of the first wire, v1 is the feeding speed of the first wire (cm / min), and s1 is the cross-sectional area of ​​the first wire (cm²) 2 ), above ρ2 is the welding efficiency (%) of the second wire, above v2 is the feeding speed (cm / min) of the second wire, above s2 is the cross-sectional area (cm²) of the second wire 2 ), above ρ3 is the welding efficiency (%) of the third wire, above v3 is the feed speed (cm / min) of the third wire, and above s3 is the cross-sectional area (cm²) of the third wire. 2 ), above X1 means a component of the first element, above X2 means a component of the second element, and above X3 means a component of the third element.)

[0041] Meanwhile, the above-mentioned welding efficiency can be defined as the ratio of the weight of the weld metal to the weight of the welding wire consumed. For example, the welding efficiency can be calculated by measuring the weight of the consumed thermal spray material and the weight of the thermal spray material deposited on the test specimen. As an example, the weight of the thermal spray material deposited on the test specimen can be calculated by first measuring the weight of the test specimen, performing thermal spraying on the specimen, and then measuring the change in weight, while the weight of the consumed thermal spray material can be calculated by measuring the feed speed and feed time of the thermal spray material. At this time, the weight of the thermal spray layer formed on the test specimen can be converted into the weight of each element using an EDS device.

[0042] The triple wire flame sprayer (100) of the present invention may additionally include a heat source device (40) that provides flames to the first wire, the second wire, and the third wire. The present invention does not specifically limit the type of the heat source device, but as an example, the heat source device may be a torch.

[0043] The triple wire flame sprayer (100) of the present invention is characterized in that the first wire, the second wire, and the third wire are provided at the same or similar point and are simultaneously melted by the flame. Through this, the composition of the sprayed layer can be controlled to become uniform. Meanwhile, the same or similar point may be an area where the flame is generated, and since it is sufficient for the first wire, the second wire, and the third wire to be simultaneously melted by the flame, the present invention does not specifically limit it. However, as an example, the similar point may be an area within a radius of 5 mm from the target point. If the area of ​​the similar point exceeds a radius of 5 mm from the target point, uniform melting does not occur, making it difficult to obtain the desired plating layer composition. It is more advantageous for the similar point to be an area within a radius of 4 mm from the target point, and more advantageous for it to be 3 mm.

[0044] The triple wire flame sprayer (100) of the present invention may additionally include a first nozzle (14), a second nozzle (24), and a third nozzle (34) so ​​that the first wire, the second wire, and the third wire are each fed into the flame. Through the first nozzle (14), the second nozzle (24), and the third nozzle (34), the first wire, the second wire, and the third wire can be fed directly into the flame, thereby making it easier to control the composition of the spray layer.

[0045] The first nozzle, the second nozzle, and the third nozzle may have an angle (α) of 0 to 20° with respect to the vertical axis. If the angle exceeds 20°, the volume of the sprayer may become excessively large. The first nozzle, the second nozzle, and the third nozzle may be arranged symmetrically with respect to the vertical axis, but are not limited thereto. Additionally, the first nozzle, the second nozzle, and the third nozzle may be arranged to be tilted at the same angle with respect to the vertical axis, but are not limited thereto. Furthermore, the present invention does not specifically limit the angle (β) between the first nozzle, the second nozzle, and the third nozzle, but more advantageously, it may have an angle of 120°. Meanwhile, the above α represents the angle (acute angle) between the vertical axis and the nozzle when the sprayer is viewed from the front as shown in FIG. 1, and the above β represents the respective angles (acute angles) between the first nozzle, the second nozzle, and the third nozzle when the sprayer is viewed from the top as shown in FIG. 2.

[0046] The triple wire flame sprayer (100) of the present invention may additionally include a gas nozzle (50) that provides gas to the flame. The gas may not only help in generating the flame but also help in controlling the area where the flame is generated. The present invention does not specifically limit the type of gas, but as an example, it may be propane gas (C3H8 gas).

[0047] The triple wire flame sprayer (100) of the present invention may further include an oxygen nozzle (60) that provides oxygen to the flame. The oxygen can help raise the temperature of the flame, thereby making it easier to melt the first wire, the second wire, and the third wire.

[0048] Another embodiment of the present invention provides a triple flame sprayed layer produced by the aforementioned triple wire flame sprayer. The sprayed layer of the present invention provided in this manner has the advantage of having a uniform composition while also being easy to control. Accordingly, as an example, it can be preferably applied to a plating layer loss area having various compositions. Furthermore, since it can be controlled to have a composition similar to that of a plating layer, superior corrosion resistance can be secured. Meanwhile, the present invention does not specifically limit the type of plating layer, but as an example, it may be a Zn-Al-Mg-based plating layer.

[0049] The present invention will be described in detail below through examples. However, it should be noted that the examples described below are intended merely to illustrate and embody the present invention and are not intended to limit the scope of the present invention. This is because the scope of the present invention is determined by the matters described in the patent claims and matters reasonably inferred therefrom.

[0050] (Example)

[0051] First, a substrate steel plate was prepared with a Zn-Al-Mg-based (Al: 12 wt%, Mg: 5 wt%, remainder Zn) plating layer formed on one side. Subsequently, a thermal spray layer was formed by thermal spraying using the triple wire flame sprayer of the present invention under the conditions described in Tables 1 and 2 below. The composition of the thermal spray layer was measured at 10 random locations using EDS (Energy Dispersive Spectroscopy) and is shown in Table 2 below. Meanwhile, the welding efficiency was calculated by measuring the ratio of the weight of the thermal spray material deposited on the test specimen to the weight of the thermal spray material consumed. The weight of the thermal spray material deposited on the test specimen was calculated by first measuring the weight of the test specimen, performing thermal spraying on the specimen, and then measuring the change in weight, while the weight of the thermal spray material consumed was calculated by measuring the feeding speed and feeding time of the thermal spray material.

[0052] Classification 1st Wire 2nd Wire Component (s1) Welding Efficiency (ρ1) (%) Cross-sectional Area (s1) (cm² 2 ) Feed rate (v1) (cm / min) Component (s2) Welding efficiency (ρ2) (%) Cross-sectional area (s2) (cm 2 Feeding speed (v2) (cm / min) Example 1 Al 9 0.01 13250 Z n 9 70.01 13250 Example 2 Al 9 70.01 13300 Z n 9 70.01 13250 Example 3 Al 9 70.01 13350 Mg 9 70.01 13250 Example 4 Al 9 70.01 13150 Mg 9 70.01 13300 Example 5 Mg 9 70.01 13100 Al 9 70.01 13120 [Equation 1] X = αX1 + βX2 + γX3 (wherein X is the triple thermal spray layer composition, α is A / (A+B+C)×100, β is B / (A+B+C)×100, and γ is C / (A+B+C)×100, where A represents ρ1×v1×s1, B represents ρ2×v2×s2, and C represents ρ3×v3×s3.

[0053] Classification 3rd Wire Relationship 1 Actual Thermal Spray Layer Composition (s3) Welding Efficiency (ρ3) (%) Cross-sectional Area (s3) (cm² 2Feeding speed (v3) (cm / min) Example 1 Mg 970.01 13300 31.25 Al + 31.25 Zn + 37.50 Mg 31.1 Al + 31.2 Zn + 37.7 Mg Example 2 Mg 970.01 13300 35.29 Al + 29.42 Zn + 35.29 Mg 35.0 Al + 29.7 Zn + 35.3 Mg Example 3 Zn 970.01 13300 38.89 A l+27.78Mg+33.33Zn39.1Al+27.6Mg+33.3ZnExample 4Zn970.011350015.79Al+31.58Mg+52.63Zn15.5Al+31.7Mg+52.8ZnExample 5Zn970.011360012.20Mg+14.63Al+73.17Zn12.0Mg+14.4Al+73.6Zn[Relationship 1] X = αX1 + βX2 + γX3 (where X is the triple thermal spray layer composition, α is A / (A+B+C)×100, β is B / (A+B+C)×100, γ is C / (A+B+C)×100, A is ρ1×v1×s1, B is ρ2×v2×s2, and C is ρ3×v3×s3.)

[0054] As can be seen from Tables 1 and 2 above, the composition of the thermal spray layer formed by the triple wire flame sprayer of the present invention follows the trend of Equation 1. Of course, the actual composition of the thermal spray layer does not match the composition of the thermal spray layer according to Equation 1, but it can be seen that it is within an error of ±10%.

[0055] [Explanation of the symbol]

[0056] 1: First wire

[0057] 2: Second wire

[0058] 3: Third wire

[0059] 10: First delivery device

[0060] 20: Second delivery device

[0061] 30: Third delivery device

[0062] 12: First control device

[0063] 22: Second control device

[0064] 32: Third control device

[0065] 14: First nozzle

[0066] 24: Second nozzle

[0067] 34: Third nozzle

[0068] 40: Heat source device

[0069] 50: Gas nozzle

[0070] 60: Oxygen nozzle

[0071] 100: Triple Wire Flame Warrior

Claims

1. A first feeding device for feeding the first wire; A second wire-fed device for feeding a second wire; A third wire-fed device for feeding a third wire; A first control device for controlling the feed speed of the first wire; A second control device for controlling the feed speed of the second wire; and A third control device for controlling the feed speed of the third wire; is included, The above-mentioned first wire, second wire, and third wire are provided at the same or similar points and are simultaneously melted by a flame in a triple wire flame sprayer.

2. In Paragraph 1, The above-mentioned first control device, second control device, and third control device are a triple wire flame sprayer capable of variably controlling the feeding speeds of the first wire, second wire, and third wire, respectively, so as to have a ratio of the desired spray layer composition.

3. In Paragraph 1, The above triple wire flame sprayer is a triple wire flame sprayer further comprising a heat source device that provides flames to the first wire, the second wire, and the third wire.

4. In Paragraph 1, The above triple wire flame sprayer is a triple wire flame sprayer further comprising a first nozzle, a second nozzle, and a third nozzle so that the first wire, the second wire, and the third wire are each fed into the flame.

5. In Paragraph 4, The above-mentioned first nozzle, second nozzle, and third nozzle are triple wire flame sprayers having an angle of 0 to 20° with respect to the vertical axis.

6. In Paragraph 1, The above triple wire flame sprayer is a triple wire flame sprayer that additionally includes a gas nozzle for supplying gas to the flame.

7. In Paragraph 1, The above triple wire flame sprayer is a triple wire flame sprayer that additionally includes an oxygen nozzle for supplying oxygen to the flame.

8. In Paragraph 1, The first wire is composed of a first element, the second wire is composed of a second element, and the third wire is composed of a third element. The above triple wire flame sprayer is a triple wire flame sprayer that controls the target composition of the spray layer using the following relationship 1. [Relationship 1] X = αX1 + βX2 + γX3 (wherein X is the triple thermal spray layer composition, α is A / (A+B+C)×100, β is B / (A+B+C)×100, γ is C / (A+B+C)×100, A is ρ1×v1×s1, B is ρ2×v2×s2, C is ρ3×v3×s3, ρ1 is the welding efficiency (%) of the first wire, v1 is the feeding speed of the first wire (cm / min), and s1 is the cross-sectional area of ​​the first wire (cm²) 2 ), above ρ2 is the welding efficiency (%) of the second wire, above v2 is the feeding speed (cm / min) of the second wire, above s2 is the cross-sectional area (cm²) of the second wire 2 ), above ρ3 is the welding efficiency (%) of the third wire, above v3 is the feed speed (cm / min) of the third wire, and above s3 is the cross-sectional area (cm²) of the third wire. 2 ), above X1 means a component of the first element, above X2 means a component of the second element, and above X3 means a component of the third element.) 9. A triple flame spray layer produced by a triple wire flame sprayer according to any one of claims 1 to 8.

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