Water-Based Anti-Bonding Coating for Titanium-Steel Rolling
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Solution Overview
Problem
Current high-temperature-resistant titanium-steel anti-bonding coatings are ineffective in preventing titanium-steel bonding during the production of titanium tubes, leading to surface defects, equipment damage, and increased production costs due to the need for frequent equipment grinding and titanium ingot cutting.
Innovation Solution
A water-based high-temperature-resistant titanium-steel anti-bonding coating comprising a film-forming agent, Zn powder, Al2O3 powder, talcum powder, a curing agent, and a dispersant, applied to the steel equipment to form a 0.2-0.4 mm thick film that prevents titanium-steel bonding by forming a dense TiAl3 alloy layer, reducing the TiFe phase formation and allowing continuous production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional high-temperature-resistant coatings are applied to prevent titanium-steel bonding, then bonding prevention is attempted, but the coating fails to effectively prevent bonding and generates TiFe phase formation
Solution Approach 1:
The patent uses a composite coating system consisting of multiple layers: a base coating layer applied to the steel rolling equipment surface, and a titanium oxide-containing coating layer applied over it. This multi-layer composite structure prevents direct contact between titanium and steel, effectively preventing TiFe phase formation while maintaining coating integrity at high temperatures (900°C for 4 hours).
Solution Approach 2:
The patent introduces titanium oxide (TiO2) as an intermediary substance in the coating composition. This titanium oxide layer acts as a chemical barrier between the titanium ingot and the steel rolling equipment, preventing direct metallurgical bonding and TiFe phase formation while allowing the rolling process to proceed normally.
2Ease of manufacture
If the coating is sprayed on the surface of rolling winch made from different materials, then coating application is attempted, but film formation and bonding effect are poor
Solution Approach 1:
The patent specifies precise coating thickness parameters (0.2-0.4 mm) and applies the coating to specific surfaces (steel rolling equipment contact surfaces). By controlling the coating thickness and application surface, the patent ensures adequate film formation and bonding effectiveness while maintaining ease of application through spray or brush methods.
3Productivity
If titanium ingots are kept in heating furnace at 900°C for more than 4 hours, then rolling preparation is achieved, but titanium becomes sticky to steel equipment causing under-fill defects
Solution Approach 1:
The patent applies the anti-bonding coating to the steel rolling equipment surface before the titanium ingots are heated and rolled. This preliminary protective action ensures that when the titanium is heated to 900°C and becomes sticky, the coating is already in place to prevent bonding, thus maintaining surface quality while enabling the necessary heating and rolling preparation.
4Ease of repair
If equipment is grinded frequently to remove titanium bonding, then equipment maintenance is performed, but production time is lost and costs increase
Solution Approach 1:
The patent employs a consumable coating layer that sacrificially protects the expensive rolling equipment. The coating is designed to be applied periodically rather than requiring frequent equipment grinding and maintenance. This disposable protective layer extends the time between maintenance operations, reducing production interruptions and associated costs.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The coating effectively prevents titanium-steel bonding, improving the surface quality and yield of titanium tubes, reducing production costs, and enabling continuous rolling without equipment damage, while being environmentally friendly and easy to apply.
Implementation Method 1
forming a dense TiAl3 alloy layer that prevents titanium-steel bonding
Implementation Method 2
prevents titanium-steel bonding by forming a dense TiAl3 alloy layer, reducing the TiFe phase formation
Data Source
AI summary
The invention relates to a coating for preventing intermetallic bonding, in particular to a water-based high-temperature-resistant titanium-steel anti-bonding coating and its use in the preparation process of titanium ingot. The water-based high-temperature-resistant titanium-steel anti-bonding coating of the invention includes the following components in parts by weight: 50-150 parts of water-based film-forming agent, 0-50 parts of Zn powder, 400-450 parts of Al2O3 powder, and 250-350 parts of talcum powder. The coating of the invention can avoid the bonding reaction with a roller or a winch of the steel equipment in the rolling or perforation process of a titanium tube at 900° C., so as to improve the yield and the production efficiency of titanium material processing. Moreover, the process is simple and easy to operate, the coating is environment-friendly and pollution-free, and easy to prepare.