【作者】 刘秀生；

【导师】 高万振；

【作者基本信息】 机械科学研究总院 ， 机械设计及理论， 2011， 博士

【摘要】 钢结构表面的防腐蚀耐磨涂料通常由防腐蚀底漆、过渡中间漆和功能性面漆等组成,形成防腐耐磨涂层体系。本论文在查阅大量文献资料、开展理论分析与实验研究的基础上,针对研制涂层的物理机械、耐介质、防腐蚀、耐老化、防霉菌、抗磨损、减流阻和抗空泡腐蚀等性能要求,研究配套的涂料体系,进行性能评价与考核,取得了一定研究成果。底漆研究以涂层湿膜附着力破坏理论为基础,将有机涂层的粘接破坏这一极其复杂的热动力学过程进行优化和典型化,探讨了磷酸盐的防锈机理,研究了一种用于替代含铅、铬及镉等重金属的防锈底漆。该底漆由改性复合无毒防锈颜料、高性能环氧树脂、无苯溶剂、助剂和新型固化剂等组成,具有干燥速度快,物理机械性能好和耐蚀性能优良等特点。无溶剂耐磨中间涂层采用丁腈橡胶增韧改性的低分子量环氧树脂为主要成膜物,添加经表面改性处理的片状颜料、活性稀释剂、防沉剂及其它助剂等与固化剂混合后制成。评价了涂层的抗渗透、耐盐雾、耐湿热、耐老化、耐介质和耐磨耗性能,筛选出了综合性能优异的无溶剂涂料产品,比较了不同涂层的抗蚀和耐磨性能。研制的无溶剂涂层的耐磨耗性能比环氧面漆和聚氨酯面漆的耐磨耗性能提高了20%-50%。对比分析了不同厂家氟碳树脂的室外耐候性和室内紫外加速老化(QUV)性能,筛选出性能优异的耐候性氟碳树脂,与耐候性颜填料、研制的防霉剂、分散剂、助剂和固化剂等制成常温固化氟碳涂料。评价了涂层的耐候、防霉、耐盐雾和耐化学介质等性能。研制涂层的耐霉菌等级为0级(即无霉菌生长),耐QUV老化5000h保光率≥90%,户外暴露48个月涂层性能无明显变化。针对常温固化氟碳涂料,尤其是无光或半光氟碳涂料耐沾污性能较差等问题,分别研制疏水化添加剂和亲水化添加剂,用于改善涂料的抗沾污性能。研制的两种添加剂均能将无光涂层(60°光泽≤10°)的清洁率提高到75%以上,其中亲水添加剂的抗沾污性能更好,且不影响涂层的重涂性。研究了低表面能涂层表面能、紫外光照时间与涂层摩擦系数的关系,发现低表面能涂层在紫外光照射下表面能会升高,随之最大静摩擦系数也会增大；滑动摩擦系数变化不大。可能原因是涂层表面平整度对滑动摩擦系数的影响程度要超过涂层表面能对其的影响。利用研制的专用流阻测试设备,比较分析不同品种与表面形貌涂层的减水流阻效果,进行了理论解释。研制的低表面能涂层减阻效果达到20%以上。针对涂层的防空泡腐蚀要求,研制了高强度粘接底层、高韧性过渡中间层和抗空泡腐蚀弹性体面层的涂层体系,评价了不同涂层的抗空蚀性能。弹性体涂层在保证粘接强度的基础上,具有比硬质合金更好的抗空蚀效果；探讨了满足大型薄壁件抗空蚀要求的涂层体系设计方案,硬质合金与弹性体涂层配合使用,形成的复合涂层具有更优异的抗空蚀效果。研制了一种无溶剂厚浆双组份反应固化型苯氧基树脂改性环氧树脂涂料,探讨了苯氧基树脂对涂料性能的影响。研究成功管内壁有机厚涂层离心自流平涂覆工艺,设计并制造了专用的管内壁有机厚涂层离心自流平涂覆机及相应工装,实现了研制涂料在大型圆管内壁的精密控制涂装,单道次涂装的涂层厚度可达2mm,涂层尺寸精度、形位公差和表面粗糙度均可达到精密机械加工零件水平。针对天然气管道输送要求,计算了涂覆商用环氧涂料和采用离心自流平工艺涂覆研制涂料的内涂管道与无内涂管道相比的减阻效果。结果表明,研制的新型管内壁涂层具有比商用管内壁环氧涂层更优异的减阻性能。更多还原

【Abstract】 A covering system possessing wear resistance and corrosion resistance on steel structure surface is usually made up of different coatings with relevant functions, such as anti-corrosion primer, intermediate coating and functional finish, etc. On the basis of a great deal of document data, theory analyses and experimental work, the dissertation studied on a set of matching coating system catering to different requirements of coatings’properties, such as physical and mechanical properties, tolerance of chemical mediator, corrosion prevention, anti-aging, anti-mildew, wear resistance, drag reduction and anti-cavitations. Evaluation and assessment of the performances of the matching coating show that some research results have been achieved.Based on the theory for adhesion strength failure of wet film the extremely complicated thermodynamic process of organic coatings’bonding failure was typified and optimized in the dissertation. The antirust mechanism of phosphate is discussed in detail. Based on the above theoretic work a new kind of anti-corrosive primer was developed to replace those traditional primers consisting of heavy metals, such as lead, chromium and cadmium. This kind of primer consists of epoxy resin with high performances, non-benzene solvent, auxiliary materials, new type curing agents and inert fillers, such as zinc phosphate, aluminum tripolyphosphate, zinc oxide as well as composite antirust pigment, iron oxide red and mica powder. It is nontoxic and characterized by fast drying speed, good mechanical property, excellent salted water resistance, high resistance against boiling water and long life when tested by salt spray test, etc.Anti-wear intermediate coatings were prepared with a developed solvent-free anti-wear paint. The paint was concocted by using low molecular weight epoxy resin toughened with butadiene acrylonitrile rubber as main film-former, surface modified flake pigments as additives, reactive diluents and anti-settling agents as viscosity-and-homogeneous degree modifier, curing agent as well as other auxiliary materials. A solvent-free paint product with the best comprehensive properties was screened through testing coatings’performances, such as anti-permeability, resistance against salt spray, resistance against heat and humidity, tolerance of chemical mediator, anti-aging and wear resistance. Results show that wear resistance and corrosion resistance of the developed solvent-free coating are 20%～50% higher than that of epoxy or polyurethane top finishes. A kind of fluorocarbon resin with the best outdoor weather ability and the longest life when tested by QUV are selected by comparing and analyzing with other different fluorocarbon resin producers. It was used as main film-former and together with weather-resistant fillers, self-made antifungal agents, dispersants, anti-settling agents, anti-foaming agents, flatting agents, smooth agents and curing agents for preparing a new kind of air-drying fluorocarbon coating. Performance tests were carried out to evaluate weather ability, anti-fungal ability, resistance against salt spray and tolerance of chemical mediator of the coating. Results show that its fungus-resistant degree is zero, i.e. no moulds growth, life is 5000h when tested by QUV, gloss retention is above 90% and other properties has not changed obviously after 48-month outdoor exposure.Hydrophobic and hydrophilic additives were respectively developed to solve the regular problems of poor dirt resistance for traditional air-drying fluorocarbon coatings, especially for matt or semi-matt ones. The two kind of additives developed can both increase the cleaning rate of matt fluorocarbon coatings by 75%. Hydrophilic additives’ dirt resistance is better. And recoat ability of fluorocarbon coatings modified with the both additives is not affected.The varieties of low surface energy coatings’friction coefficient with surface energy and UV-light irradiation time were investigated. Results show that the surface energy of such coatings increased when exposed under UV-light, so did their static friction coefficient. Nevertheless, their dynamic friction coefficient had not changed obviously under the same condition. The possible reason of that might be that the influence of coatings’smoothness on their dynamic friction coefficient was higher than that of coatings’surface energy.The flow reduction effects of coatings with different varieties and surface topography were compared each other with specially self-made flow resistance test equipment. And theoretical analyses were given to explain the cause of these different effects. Flow resistance tests proved that flow reduction rate of the low surface energy coatings prepared reached above 20%.According to the requirements of cavitation erosion resistance for coatings, a new coating system made up of a bottom layer with high binding strength, an intermediate layer with high toughness and an elastomeric top finish with good cavitation erosion resistance was developed. Its cavitation erosion resistance was compared with that of other coatings including organic coatings and cemented carbide coatings and high-strength steel. Under the condition of fine binding strength, the coating system developed had better cavitation erosion resistance than cemented carbide coating. To meet large thin wall parts’requirements of cavitation erosion resistance, a design scheme of a composite coating system made up of a thermal spraying cemented carbide coating as bottom coat and an elastomeric organic top finish was discussed. The discuss result shows that such composite coating system may have better cavitation erosion resistance than both single elastomeric organic coating system and single thermal spraying cemented carbide coating system.A new kind of two-component solvent-free thick paste curing reaction epoxy coating material modified with phenoxy resin was developed, and the effects of the phenoxy resin on coating material’s performance were investigated. A new centrifuging and self-leveling technique for the application of organic thick coating to inner wall of pipes has been successfully developed. A set of special paint coating equipment for preparing thick organic coatings on the inner wall of pipes with centrifuging and self-leveling technique and corresponding tooling and jigs were designed and manufactured. A precision control for the application of developed coating to inner wall of large pipes became true. The thickness of the coating obtained by only one application could reach 2mm, and its dimensional precision, geometric tolerance and surface roughness could reach a high level of precision machining.For the requirements of natural gas pipeline transportation, effects of drag reduction of the developed coating prepared on inner wall of gas pipeline were calculated and compared to that of coating-free pipeline and the commercial epoxy coatings prepared on inner wall of gas pipelines. Results show that the effects of drag reduction of the developed coating are better than that of the commercial epoxy coatings for their application to gas pipeline.更多还原