Twin wire flame spray device and twin flame-sprayed layer manufactured using same

Abstract

The present invention relates to a twin wire flame spray device and a twin wire flame-sprayed layer manufactured using same. One aspect of the present invention is to provide a twin wire flame spray device and a twin flame-sprayed layer manufactured using same.

Description

Twin wire flame sprayer and twin flame spray layer manufactured thereby

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

[0009] A preferred aspect of the present invention is to provide a twin wire flame sprayer having excellent corrosion resistance and easy modification of the composition of the sprayed layer, and a twin 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 twin wire flame sprayer comprising: a first feeding device for feeding a first wire; a second feeding device for feeding a second wire; a first control device for controlling the feeding speed of the first wire; and a second control device for controlling the feeding speed of the second wire, wherein the first wire and the second wire are provided at the same or similar points and are simultaneously melted by a flame.

[0012] The first and second control devices can each variably control the feeding speeds of the first and second wires to have a ratio of the desired thermal spray layer composition.

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

[0014] The twin wire flame sprayer described above may additionally include a first nozzle and a second nozzle so that the first wire and the second wire are fed into the flame.

[0015] The first nozzle and the second nozzle may have an angle of -20 to 20°.

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

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

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

[0019] [Relationship 1] X = αX1 + βX2

[0020] (wherein X is the twin thermal spray layer composition, α is A / (A+B)×100, β is B / (A+B)×100, A is ρ1×v1×s1, B is ρ2×v2×s2, 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 X1 refers to a component of the first element, and above X2 refers to a component of the second element.)

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

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

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

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

[0025] Figure 2 is a photograph of a thermal spray layer formed by two-stage thermal spraying using a conventional flame sprayer, observed under an optical microscope.

[0026] Figure 3 is a photograph of a thermal spray layer formed using the twin flame sprayer of the present invention, observed under an optical microscope.

[0027] 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.

[0028] 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.

[0029] In drawings, the shapes and sizes of elements may be exaggerated for clearer explanation.

[0030] 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.

[0031] 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.

[0032] 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.

[0033] 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.

[0034] 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.

[0035] FIG. 1 is a schematic diagram of a twin-wire flame sprayer according to an embodiment of the present invention. Hereinafter, a twin-wire flame sprayer according to an embodiment of the present invention will be described with reference to FIG. 1.

[0036] The twin wire flame sprayer (100) of the present invention includes a first feeding device (10) for feeding a first wire (1) and a second feeding device (20) for feeding a second wire (2). The first feeding device (10) and the second feeding device (20) may have various types or shapes, but as an example, they may have the shape of a roller, thereby enabling continuous spraying. At this time, the first wire (1) and the second wire (2) may be of the same type or different types. If the first wire (1) and the second wire (2) are of different types, the composition of the spray layer can be varied. For example, the first wire and the second wire may each use one of a Zn-based, Al-based, or Mg-based wire. Meanwhile, as an example, if the composition of the thermal spray layer is a single component, either the first or second delivery device may be shut down.

[0037] The twin wire flame sprayer (100) of the present invention includes a first control device (12) for controlling the feeding speed of the first wire and a second control device (22) for controlling the feeding speed of the second wire. By controlling the speeds of the first feeding device (10) and the second feeding device (20) through the first control device (12) and the second control device (22), 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 and the second control device can each variably control the feeding speeds of the first wire and the second wire to have a desired ratio of the spray layer composition.

[0038] More specifically, for example, when the first wire is an Al wire and the second wire is a Zn wire, and the target composition of the thermal spray layer is Al:Zn=1:1 in weight%, the first control device and the second control device can control the first feeding device and the second feeding device so that the feeding speed of the first wire and the second wire is determined based on the densities of Al and Zn.

[0039] For example, when the first wire is composed of a first element and the second wire is composed of a second element, the twin 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 feed speed of the first wire and the second wire. Meanwhile, the composition of the actual spray layer formed may not necessarily match the following Equation 1, and may have, for example, an error of ±10%.

[0040] [Relationship 1] X = αX1 + βX2

[0041] (wherein X is the twin thermal spray layer composition, α is A / (A+B)×100, β is B / (A+B)×100, A is ρ1×v1×s1, B is ρ2×v2×s2, 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 X1 refers to a component of the first element, and above X2 refers to a component of the second element.)

[0042] 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.

[0043] The twin wire flame sprayer (100) of the present invention may further include a heat source device (30) that provides flames to the first wire and the second 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.

[0044] The twin wire flame sprayer (100) of the present invention is characterized in that the first wire and the second wire are provided at the same or similar point and are simultaneously melted by the flame. Through this, separation between the spray layers can be prevented, and the composition of the spray layer can be controlled to become uniform, thereby further improving plating adhesion. Meanwhile, the same or similar point may be an area where the flame is generated, and since it is sufficient for the first wire and the second 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.

[0045] The twin wire flame sprayer (100) of the present invention may additionally include a first nozzle (14) and a second nozzle (24) so ​​that the first wire and the second wire are each fed into the flame. Through the first nozzle (14) and the second nozzle (24), the first wire and the second wire can be fed directly into the flame, thereby making it easier to control the composition of the spray layer.

[0046] The angle between the first nozzle and the second nozzle may be between 0 and 40°. The angle between them may be the angle between the center axis of the first nozzle and the center axis of the second nozzle when viewed from the front of the sprayer. The first nozzle and the second nozzle may be symmetrically arranged with respect to the vertical axis of the sprayer, but are not limited thereto. If the angle between them exceeds 40°, the volume of the sprayer may become excessively large. Meanwhile, the first nozzle and the second nozzle may have opposite angle ranges so that the first wire and the second wire can be melted simultaneously by the flame. That is, if the first nozzle has a positive angle, it is preferable for the second nozzle to have a negative angle. Although not limited thereto, for example, as shown in FIG. 1, when the angle (α) between the center axis of the first nozzle and the vertical axis of the sprayer is -10° when viewed from the front, the angle between the center axis of the second nozzle and the vertical axis of the sprayer may be 10°. Additionally, the first nozzle and the second nozzle may have the same angle value, but are not limited thereto and may have different angle values.

[0047] The twin wire flame sprayer (100) of the present invention may additionally include a gas nozzle (16, 26) 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).

[0048] The twin wire flame sprayer (100) of the present invention may additionally include an oxygen nozzle (18, 28) 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 and the second wire.

[0049] Another embodiment of the present invention provides a twin flame sprayed layer produced by the aforementioned twin 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.

[0050] Figure 2 is a photograph of a thermal layer formed by two-stage thermal spraying using a conventional flame sprayer, observed under an optical microscope. In this case, an Al wire was used for the first stage of thermal spraying, and a Zn wire was used for the second stage of thermal spraying, and the feeding speed of the Al wire and Zn wire was 4.6 m / min.

[0051] Figure 3 is a photograph of a thermal spray layer formed using the twin flame sprayer of the present invention, observed under an optical microscope. At this time, an Al wire was used as the first wire and a Zn wire was used as the second wire, and the feeding speed of the first wire and the second wire was 4.6 m / min.

[0052] As can be seen from Figures 2 and 3, when using a conventional flame sprayer, the sprayed layer is formed as a separated layer, whereas when using the twin wire flame sprayer of the present invention, it can be confirmed that it is formed as a single layer.

[0053] 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.

[0054] (Example)

[0055] 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 twin wire flame sprayer of the present invention under the conditions listed in Table 1 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 deposition 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 feed speed and feed time of the thermal spray material.

[0056] Classification 1st Wire 2nd Wire Relationship 1 Actual Welding Layer Composition 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 13 300 Zn 9 70.01 13 300 5 0.00 Al + 5 0.00 Zn 4 9.7 Al + 5 0.3 Zn Example 2 Al 9 70.01 13 3 5 0 Zn 9 70.01 13 300 5 3.85 Al + 4 6.15 Zn 5 3.6 Al + 4 6.4 Zn Example 3 Al 9 70.01 13 400 Zn 9 70 .011335053.33Al+46.67Zn53.8Al+46.2Zn Example 4 Zn970.0113450Al970.011335056.25Zn+43.75Al46.7Zn+43.3Al Example 5 Zn970.0113500Al970.011340055.56Zn+44.44Al55.1Zn+44.9Al [Equation 1] X = αX1+ βX2 (where X is the twin thermal spray layer composition, α is A / (A+B)×100, β is B / (A+B)×100, A is ρ1×v1×s1, and B is ρ2×v2×s2.)

[0057] As can be seen from Table 1 above, the composition of the thermal spray layer formed by the twin 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%.

[0058] [Explanation of the symbol]

[0059] 1: First wire

[0060] 2: Second wire

[0061] 10: First delivery device

[0062] 20: Second delivery device

[0063] 12: First control device

[0064] 22: Second control device

[0065] 14: First nozzle

[0066] 24: Second nozzle

[0067] 16, 26: Gas nozzle

[0068] 18, 28: Oxygen nozzle

[0069] 30: Heat source device

[0070] 100: Twin 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 first control device for controlling the feed speed of the first wire; and A second control device for controlling the feed speed of the second wire; is included, A twin wire flame sprayer in which the first wire and the second wire are provided at the same or similar points and melted simultaneously by a flame.

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

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

4. In Paragraph 1, The twin wire flame sprayer described above additionally includes a first nozzle and a second nozzle so that the first wire and the second wire are fed into the flame.

5. In Paragraph 4, The first nozzle and the second nozzle are twin wire flame sprayers having an angle of -20 to 20°.

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

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

8. In Paragraph 1, The first wire above is composed of a first element, and the second wire is composed of a second element, and The above twin wire flame sprayer is a twin wire flame sprayer that controls the target composition of the spray layer using the following relationship 1. [Relationship 1] X = αX1 + βX2 (wherein X is the twin thermal spray layer composition, α is A / (A+B)×100, β is B / (A+B)×100, A is ρ1×v1×s1, B is ρ2×v2×s2, 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 X1 refers to a component of the first element, and above X2 refers to a component of the second element.) 9. A twin flame spray layer produced by a twin wire flame sprayer according to any one of claims 1 to 8.

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