Disclosure of Invention
The technical problem to be solved is as follows: aiming at the problem of corrosion and abrasion failure of key parts of marine equipment in a severe marine environment, the invention provides a super-hydrophobic corrosion-resistant antifouling aluminum-based amorphous coating and a preparation method thereof in order to further improve the corrosion-resistant antifouling performance of the aluminum-based amorphous coating. The method can prepare the super-hydrophobic surface on a large area of various metal workpiece substrates with complex structures, and has the advantages of simple manufacturing process, high preparation efficiency, suitability for field construction, low cost and the like. The hydrophobic surface prepared by the method not only has excellent super-hydrophobic performance and self-cleaning effect, but also has the wear-resisting and corrosion-resisting properties of the amorphous coating, and has a certain anti-icing function.
The technical scheme is as follows: the preparation method of the super-hydrophobic corrosion-resistant antifouling aluminum-based amorphous coating comprises the following steps:
s1 pretreatment of substrate surface
The surface of a sample is polished by sand paper to remove oxides, the polished sample is ultrasonically cleaned for 5-15min by absolute ethyl alcohol and acetone respectively to remove surface particle impurities and oil stains, and after natural air drying, in order to ensure good bonding force between a coating and a base material, the surface of the sample is subjected to sand blasting by adopting a sand blasting process to improve the surface roughness of the sample;
s2 preparation of aluminum-based amorphous coating
Carrying out multi-pass spraying on the surface of the pretreated base material by utilizing a high-speed electric arc spraying technology to prepare the aluminum-based amorphous coating with the micron-sized coarse structure;
s3, coating surface chemical etching
Etching the aluminum-based amorphous coating prepared in the step S2 in an alkaline solution, establishing a micro-nano composite rough structure on the surface of the coating, activating the surface of the coating, taking out the coating, ultrasonically cleaning the coating in absolute ethyl alcohol for 5-15min, removing surface residual liquid and etching products, and naturally drying the coating;
s4 modification of Low surface energy substance
And modifying the coating treated by the S3 in a low surface energy substance, taking out and drying the modified coating, and cooling the modified coating to room temperature to obtain the super-hydrophobic corrosion-resistant antifouling aluminum-based amorphous coating.
Preferably, the parameters of the sand blasting process in the step S1 are as follows: the compressed air pressure is 0.7MPa, the relative distance is 100mm, the angle is 70-90 degrees, and the granularity of the white corundum sand for sand blasting is 20 meshes.
Preferably, in S2, the substrate is made of pure aluminum coating powder core, the powder core is made of FeSi powder, alloy powder which contains 75 wt.% of Si, Fe powder and has the purity of 99.9 wt.%, the filling rate of the powder core is 40-43%, and the diameter of the powder core wire is 2 mm.
Preferably, the spraying process parameters in S2 are: spraying voltage is 34V, spraying current is 150A, compressed air pressure is 0.7MPa, and relative distance is 200 mm.
Preferably, the alkali solution in S3 is a sodium hydroxide aqueous solution with the concentration of 0.01-1mol/L, the etching time is 30S-6min, and the etching is carried out in a static water state or an ultrasonic bath environment.
Preferably, the low surface energy substance in S4 is trimethoxy (1H,1H,2H, 2H-heptadecafluorodecyl) silane-ethanol solution with concentration of 1 wt.% to 5 wt.%, modification temperature is room temperature to 80 ℃, and modification time is 2H to 12H; the drying temperature is room temperature-120 deg.C, and the drying time is 30min-2 h.
The super-hydrophobic corrosion-resistant antifouling aluminum-based amorphous coating prepared by any one of the methods.
The principle of the method of the invention is that: the corrosion resistance of the coating is greatly improved by utilizing the synergistic effect of the amorphous alloy with excellent corrosion resistance and the super-hydrophobic surface structure with low adhesion and excellent self-cleaning property. Compared with crystalline materials, the unique atomic structure of the amorphous alloy endows the amorphous alloy with more uniform structure, no crystal defects such as crystal boundary, segregation and the like, has the properties of high strength, high hardness, excellent corrosion resistance and the like, and is a metal material with the highest strength and the best corrosion resistance which is discovered at present; therefore, the aluminum-based amorphous coating with high corrosion resistance can be prepared on the substrate by using a low-cost and high-efficiency electric arc spraying process. In order to further improve the corrosion resistance of the aluminum-based amorphous coating, a chemical method is utilized to construct a micro-nano structure on the surface of the aluminum-based amorphous coating and reduce the surface free energy to obtain the super-hydrophobic surface coating with excellent self-cleaning property. The corrosion resistance of the coating can be obviously improved through the synergistic effect of the self-cleaning super-hydrophobic structure and the amorphous structure, and meanwhile, the electric arc spraying technology and the chemical surface treatment process adopted by the invention are simple, high in efficiency and suitable for field construction, and can be used for large-area preparation on a non-planar complex structure substrate, such as parts with complex structures, such as right angles, curved surfaces and the like.
Has the advantages that:
(1) the method has the advantages of simple process, high efficiency, suitability for field construction and low cost, and can be used for large-area preparation on a non-planar complex structure substrate;
(2) the aluminum-based amorphous coating prepared by adopting the high-speed electric arc spraying technology has the advantages of low oxide content, uniform components, compact structure, porosity of less than 2%, good combination with a substrate, amorphous content of more than 80 vol%, and excellent wear resistance and corrosion resistance;
(3) the contact angle of the super-hydrophobic aluminum-based amorphous coating prepared by the method is more than 150 degrees, the rolling angle is less than 10 degrees, the super-hydrophobic aluminum-based amorphous coating has good hydrophobicity, excellent waterproof, self-cleaning and corrosion resistance performances are shown, and the super-hydrophobic aluminum-based amorphous coating has high wear resistance of the amorphous coating;
(4) the super-hydrophobic aluminum-based amorphous coating prepared by the invention can be applied to various occasions such as the outer surfaces of various industrial parts, the inner walls of pipelines and the like, which need self-cleaning, corrosion resistance, anti-icing, energy-saving fluid transportation and the like.
Detailed Description
The following examples further illustrate the present invention but are not to be construed as limiting the invention. Modifications and substitutions to methods, procedures, or conditions of the invention may be made without departing from the spirit and substance of the invention. Unless otherwise specified, the technical means used in the examples are conventional means well known to those skilled in the art.
Example 1:
the preparation method of the super-hydrophobic corrosion-resistant antifouling aluminum-based amorphous coating specifically comprises the following steps:
(1) pretreatment of substrate surfaces
And (3) polishing the surface of the sample by using sand paper to remove oxides, and ultrasonically cleaning the polished sample by using absolute ethyl alcohol and acetone for 10min respectively to remove surface particle impurities and oil stains. After natural air drying, in order to ensure that the coating and the base material have good binding force, the surface of the sample is subjected to sand blasting treatment by adopting a sand blasting process so as to improve the surface roughness, wherein the sand blasting process parameters are as follows: the compressed air pressure is 0.7MPa, the relative distance is 100mm, the angle is 70-90 degrees, and the granularity of the white corundum sand for sand blasting is 20 meshes.
(2) Preparation of aluminum-based amorphous coating
The aluminum-based amorphous coating is prepared on the surface of the coarsened substrate by utilizing a high-speed electric arc spraying technology, the powder core wire for spraying is prepared by coating a powder core with a pure aluminum sheath, the powder core is alloy powder formed by mixing FeSi (75 wt.% Si) powder and Fe (99.9 wt.%), the filling rate of the powder core is 40-43%, and the diameter of the powder core wire is 2 mm. The spraying process parameters are as follows: spraying voltage is 34V, spraying current is 150A, compressed air pressure is 0.7MPa, and relative distance is 200 mm.
(3) Chemical etching of coating surfaces
Etching the aluminum-based amorphous coating in a static sodium hydroxide aqueous solution with the concentration of 1mol/L for 30s-6min, establishing a micro-nano composite rough structure on the surface of the coating, simultaneously improving the surface activity of the coating, taking out the coating, ultrasonically cleaning the coating in absolute ethyl alcohol for 10min, removing surface residual liquid and etching products, and naturally drying the coating.
(4) Low surface energy substance modification
And (3) soaking the etched coating in a 1 wt.% trimethoxy (1H,1H,2H, 2H-heptadecafluorodecyl) silane-ethanol solution at room temperature for 12H, taking out, and air-drying at room temperature for 2H to obtain the super-hydrophobic aluminum-based amorphous coating.
FIG. 1(a) shows the cross-sectional morphology of the coating, the coating thickness is 654 μm, and the porosity is 1.4%. Fig. 1(b) is a coating XRD pattern, and it can be seen that there is a broad diffuse scattering peak between 30 ° and 50 ° 2 θ, representing typical amorphous characteristics, and the amorphous content is calculated to be 80.4 ± 4.6 vol.%. FIG. 2 shows the spray-coated coating and the static water contact angle thereof after etching in 1mol/L sodium hydroxide aqueous solution for 30s-6min and modification, the spray-coated coating contact angle is 134.8 degrees, the spray-coated coating contact angle reaches 140.8 degrees after modification by low surface energy substances, and the spray-coated coating belongs to the hydrophobic category. When the surface of the coating is etched by the alkali solution for 30s, the contact angle of the coating rises to 151.9 degrees, the super-hydrophobic range is reached, the contact angle is increased firstly and then slightly reduced along with the prolonging of the etching time, and the maximum value is reached after 4min of etching and is 157.4 degrees. FIG. 3 is the surface morphology of the as-sprayed coating and after 4min etching with an aqueous alkali, it can be seen that the metal melted by the arc is atomized into micro-droplets under the action of high-pressure gas and is accelerated to be sprayed onto the substrate to be flattened, and the edge shows a micro-convex characteristic due to the splashing effect to form a micro-scale coarse structure; after chemical etching, the surface roughness of the coating is increased, and a micro-nano multilevel rough structure is formed.
Example 2:
the preparation method of the super-hydrophobic corrosion-resistant antifouling aluminum-based amorphous coating specifically comprises the following steps:
(1) pretreatment of substrate surfaces
And (3) polishing the surface of the sample by using sand paper to remove oxides, and ultrasonically cleaning the polished sample by using absolute ethyl alcohol and acetone for 10min respectively to remove surface particle impurities and oil stains. After natural air drying, in order to ensure that the coating and the base material have good binding force, the surface of the sample is subjected to sand blasting treatment by adopting a sand blasting process so as to improve the surface roughness, wherein the sand blasting process parameters are as follows: the compressed air pressure is 0.7MPa, the relative distance is 100mm, the angle is 70-90 degrees, and the granularity of the white corundum sand for sand blasting is 20 meshes.
(2) Preparation of aluminum-based amorphous coating
The aluminum-based amorphous coating is prepared on the surface of the coarsened substrate by utilizing a high-speed electric arc spraying technology, the powder core wire for spraying is prepared by coating a powder core with a pure aluminum sheath, the powder core is alloy powder formed by mixing FeSi (75 wt.% Si) powder and Fe (99.9 wt.%), the filling rate of the powder core is 40-43%, and the diameter of the powder core wire is 2 mm. The spraying process parameters are as follows: spraying voltage is 34V, spraying current is 150A, compressed air pressure is 0.7MPa, and relative distance is 200 mm.
(3) Chemical etching of coating surfaces
Etching the aluminum-based amorphous coating in a sodium hydroxide aqueous solution with the concentration of 1mol/L for 30s-6min, establishing a micro-nano composite rough structure on the surface of the coating, simultaneously improving the surface activity of the coating, taking out the coating, ultrasonically cleaning the coating in absolute ethyl alcohol for 10min, removing surface residual liquid and etching products, and naturally drying the coating.
(4) Low surface energy substance modification
And (3) soaking the etched coating in a 1 wt.% trimethoxy (1H,1H,2H, 2H-heptadecafluorodecyl) silane-ethanol solution at the temperature of 80 ℃ for 2H, taking out, and air-drying at room temperature for 2H to obtain the super-hydrophobic aluminum-based amorphous coating.
As can be seen from fig. 4, in case 2, the contact angle of the aluminum-based amorphous coating after chemical etching for 30s and modification reaches 152.2 °, and fig. (a) shows that the coating surface is in a fully immersed state, and the coating surface shows a reflective characteristic due to the formation of air pockets between the aqueous solution and the hydrophobic layer. The figure (b) is a jet flow experiment on the surface of the coating, and can be seen that the surface of the coating shows good water repellency and has higher stability under high-speed water flow. The figure (c) is a water drop bounce experiment, and it can be seen that the liquid drops are separated from the coating surface after multi-stage bounce, and the excellent waterproof performance is shown.
Example 3:
the preparation method of the super-hydrophobic corrosion-resistant antifouling aluminum-based amorphous coating specifically comprises the following steps:
(1) pretreatment of substrate surfaces
And (3) polishing the surface of the sample by using sand paper to remove oxides, and ultrasonically cleaning the polished sample by using absolute ethyl alcohol and acetone for 10min respectively to remove surface particle impurities and oil stains. After natural air drying, in order to ensure that the coating and the base material have good binding force, the surface of the sample is subjected to sand blasting treatment by adopting a sand blasting process so as to improve the surface roughness, wherein the sand blasting process parameters are as follows: the compressed air pressure is 0.7MPa, the relative distance is 100mm, the angle is 70-90 degrees, and the granularity of the white corundum sand for sand blasting is 20 meshes.
(2) Preparation of aluminum-based amorphous coating
The aluminum-based amorphous coating is prepared on the surface of the coarsened substrate by utilizing a high-speed electric arc spraying technology, the powder core wire for spraying is prepared by coating a powder core with a pure aluminum sheath, the powder core is alloy powder formed by mixing FeSi (75 wt.% Si) powder and Fe (99.9 wt.%), the filling rate of the powder core is 40-43%, and the diameter of the powder core wire is 2 mm. The spraying process parameters are as follows: spraying voltage is 34V, spraying current is 150A, compressed air pressure is 0.7MPa, and relative distance is 200 mm.
(3) Chemical etching of coating surfaces
In ultrasonic bath, etching the aluminum-based amorphous coating in a static sodium hydroxide aqueous solution with the concentration of 0.01mol/L for 30s-6min, establishing a micro-nano composite rough structure on the surface of the coating, simultaneously improving the surface activity of the coating, taking out the coating, ultrasonically cleaning the coating in absolute ethyl alcohol for 10min, removing surface residual liquid and etching products, and naturally airing the coating.
(4) Low surface energy substance modification
Soaking the etched coating in 5 wt.% trimethoxy (1H,1H,2H, 2H-heptadecafluorodecyl) silane-ethanol solution for 6H at room temperature, taking out, drying at 120 ℃ for 30min, and cooling to room temperature to obtain the super-hydrophobic aluminum-based amorphous coating.
As can be seen from FIG. 5, the contact angle of the aluminum-based amorphous coating chemically etched for 30s and modified in example 3 reaches 151.2 degrees, and the aluminum-based amorphous coating has good dirt-removing ability and excellent self-cleaning property.
Example 4:
the preparation method of the super-hydrophobic corrosion-resistant antifouling aluminum-based amorphous coating specifically comprises the following steps:
(1) pretreatment of substrate surfaces
And (3) polishing the surface of the sample by using sand paper to remove oxides, and ultrasonically cleaning the polished sample by using absolute ethyl alcohol and acetone for 10min respectively to remove surface particle impurities and oil stains. After natural air drying, in order to ensure that the coating and the base material have good binding force, the surface of the sample is subjected to sand blasting treatment by adopting a sand blasting process so as to improve the surface roughness, wherein the sand blasting process parameters are as follows: the compressed air pressure is 0.7MPa, the relative distance is 100mm, the angle is 70-90 degrees, and the granularity of the white corundum sand for sand blasting is 20 meshes.
(2) Preparation of aluminum-based amorphous coating
The aluminum-based amorphous coating is prepared on the surface of the coarsened substrate by utilizing a high-speed electric arc spraying technology, the powder core wire for spraying is prepared by coating a powder core with a pure aluminum sheath, the powder core is alloy powder formed by mixing FeSi (75 wt.% Si) powder and Fe (99.9 wt.%), the filling rate of the powder core is 40-43%, and the diameter of the powder core wire is 2 mm. The spraying process parameters are as follows: spraying voltage is 34V, spraying current is 150A, compressed air pressure is 0.7MPa, and relative distance is 200 mm.
(3) Chemical etching of coating surfaces
In ultrasonic bath, etching the aluminum-based amorphous coating in a static sodium hydroxide aqueous solution with the concentration of 0.01mol/L for 30s-6min, establishing a micro-nano composite rough structure on the surface of the coating, simultaneously improving the surface activity of the coating, taking out the coating, ultrasonically cleaning the coating in absolute ethyl alcohol for 10min, removing surface residual liquid and etching products, and naturally airing the coating.
(4) Low surface energy substance modification
And (2) soaking the etched coating in a 1 wt.% trimethoxy (1H,1H,2H, 2H-heptadecafluorodecyl) silane-ethanol solution at the temperature of 80 ℃ for 2H, taking out, drying at the temperature of 120 ℃ for 30min, and cooling to room temperature to obtain the super-hydrophobic aluminum-based amorphous coating.
As can be seen from fig. 6, in case 4, the contact angle of the aluminum-based amorphous coating after being chemically etched for 30s and modified reaches 154.6 °, and after being soaked in a 3.5 wt.% NaCl solution for 1h, the self-corrosion potential and the self-corrosion current density of the as-sprayed coating are respectively as follows: -0.750V and 7.20X 10-7A/cm2(ii) a The self-corrosion potential and the self-corrosion current density of the super-hydrophobic aluminum-based amorphous coating are respectively as follows: -0.608V and 1.33X 10-8A/cm2This shows that the super-hydrophobic aluminum-based amorphous coating has more excellent corrosion resistance.