细粉粉末涂料流动性能的表征研究

为了更好地解决细粉及超细粉末涂料颗粒在加工、气流输送、喷涂等工艺中遇到的问题,本文对影响细粉粉末涂料流动性能的各粒径参数进行了实验研究和回归分析。研究发现:工业上通常应用中粒径(D50)来表征细粉涂料流动性并不够准确。通过对不同特征粒径以及粒径分布跨度等因素的考察,本文提出了一种由代表粒径大小和粒径分布的D10-D50-D90多变量关联模型来表征细粉粉末涂料流动性的方法,使细粉涂料流动性的预测更为可靠和准确,为细粉涂料特别是超细粉末涂料的工业应用提供理论指导。     

Properties of Ultrafine Aluminum Powder Stabilized by Aluminum Diboride

The paper studies properties of an ultrafine aluminum powder produced by electric explosions of conductors, whose particles are stabilized by coating with aluminum diboride immediately during the synthesis of the powder. The ultrafine aluminum powder stabilized in such a manner has special properties: narrow particle size distribution, increased dispersity, and higher resistance to oxidation upon heating.     

高频氢等离子体增强还原制备超细铜粉

利用高频感应热氢等离子体强化还原制备超细铜粉,考察了加料速率、还原氢气流量、氢气分布位置、反应区空间、冷却温度等因素对铜粉颗粒性能的影响,对制备的铜粉颗粒进行氧含量、XRD晶体结构、松装密度、粒度分布和比表面积的表征。结果表明,优化的工艺条件为反应区内径100 mm,加料速率4 g/min,淬火气氩气气量500 L/h,氢气气量500 L/h并通入少量载气,由氢等离子电离产生的氢自由基可强化反应实现瞬时还原,不仅可控制铜粉形貌,还能有效控制铜粉颗粒大小;利用该方法制备出粒径分布100?200 nm、分散性好的超细球形铜粉颗粒。该方法操作简便、产品纯度高、气氛可控、对环境污染小。     

反溶剂重结晶法制备超细碳酸氢钾粉体

采用反溶剂重结晶法进行了碳酸氢钾微粉化实验研究,通过正交实验确定了影响粉体粒径的因素,如溶液初始浓度、搅拌转速和溶剂反溶剂体积比,对优选条件进行了验证,并采用XRD和激光粒度分析仪对粒子的晶相及粒度分布进行了表征。实验结果表明,当碳酸氢钾水溶液初始质量浓度为100 g/L,搅拌转速为700 r/min,溶剂反溶剂体积比为1∶10时,可制备出平均粒径为491.9 nm且粒度分布较窄的碳酸氢钾超细粉体。     

Ferrochromium slag as a protective coating material against oxidation for caster rolls

In this study, ferrochromium (FeCr) slag, which is available as an industrial waste, is proposed as a protective surface coating material particularly for protection of continuous casting rolls against oxidation. FeCr slag was successfully deposited with atmospheric plasma spray (APS) method. Before the coating process, FeCr slag powder prepared in the particle size range of 5‐38 μm, was investigated using conventional characterization methods (XRD, SEM, TGA etc.). Thermal Barrier Coating (TBC) system was used as a basis for deposition processes. Accordingly, NiCoCrAlY (Amdry, ?45 + 5 μm) was firstly deposited as metallic bond coat layer onto the surface of AISI 420 substrate, and then FeCr slag layer was deposited as the top coating layer. After the deposition of FeCr slag powder, the resulting coating layer was found to have low porosity with a homogeneous microstructure. The deposited FeCr slag coatings were subjected to isothermal oxidation tests at different temperatures and test durations for determination of their oxidation behavior and upper operating temperature limits. The results obtained from this study indicate that FeCr slag can be considered as an alternative protective coating material for caster rolls which are subjected to high temperatures up to 800°C.     

Computational study of particle in-flight behavior in the HVOF thermal spray process

A computational framework is developed for the multiphase flow in a high velocity oxygen-fuel (HVOF) thermal spray coating process with steel powders as the feedstock. The numerical model includes continuum-type differential equations that describe the evolution of gas dynamics and multi-dimensional tracking of particle trajectories and temperature histories in the turbulent reacting flow field. The numerical study shows that the particle temperature is strongly affected by the injection position while the particle velocity is less dependent on this parameter. Moreover, both particle velocity and temperature at impact are strongly dependent on particle size, although the spatial variation of these two variables on the substrate is minimal. It is also found that not all the particles are deposited on the substrate perpendicularly (even if the spray angle is 90°), due to substantial radial fluid velocities near the stagnation point. A statistical distribution of particle velocity, temperature, impinging angle and position on the substrate as well as particle residence time is obtained in this work through independent random tracking of numerous particles by accounting for the distributed nature of particle size in the feedstock and injection position as well as the fluctuations in the turbulent gas flow.     

Direct coarse powder aqueous slip casting and pressureless sintering of highly transparent AlON ceramics

Direct coarse powder aqueous slip casting was proposed to prepare AlON green body for pressureless sintering of highly transparent AlON ceramics. It was reported that anti-hydrolysis treatment to AlON powder before aqueous slip casting was essential due to hydrolysis reaction between AlON and water. However, both XRD of hydrolyzed powder and pH value of aqueous slurry indicate that the hydrolyzate amount is positively correlating with hydrolysis reaction area, i.e., surface area of powder. Therefore, replacing fine particle with coarse one to reduce surface area of powder is an efficient hydrolyzates reduction scheme by lessening hydrolysis reaction sites. As a result, the hydrolyzate in green body of direct slip casting coarse AlON powder (91 vol% of particles have a size of >1.0 μm) was successfully reduced to an insignificant amount so that the sintered ceramics had a high transmittance (84.1% at ~3750 nm), which also verified the effectiveness of the proposed hydrolyzate-reduction scheme.     

Dense Nanostructured Hydroxyapatite Coating on Titanium by Aerosol Deposition

In order to improve biocompatibility of Ti metal substrates, 1-μm-thick nanostructured hydroxyapatite (HAp) coatings were deposited on the substrates through aerosol deposition, which sprays HAp powder with an average particle size of 3.2 μm at room temperature in vacuum. The original HAp particles were fractured into nanoscale fragments to form highly dense coating during the deposition process. Density of the HAp coating was 98.5% theoretical density (TD). Transmission electron microscopy observation revealed that the as-deposited coating consisted of HAp crystallites with average grain size of 16.2 nm and amorphous phase. Tensile adhesion strength between the coating and the substrate was 30.5±1.2 MPa. Annealing up to 500°C in air increased crystallinity and grain size in the coating without any delamination or crack according to X-ray diffraction analysis and electron microscopy. MTS assay and alkaline phosphatase activity measurements with MC3T3-E1 preosteoblast cell revealed that the biocompatibility was greatly improved by postdeposition heat treatment at 400°C in air due to well-crystallized HAp with average grain size of 29.3 nm. However, further heat treatment at 500°C deteriorated biocompatibility due to rapid growth of HAp grains to average size of 99 nm. Cross section of the coating on a commercially available Ti dental implant revealed full coverage of the surface with HAp.     

A Model of Deposition of Hygroscopic Particles in the Human Lung

Many aerosols in the environment are hygroscopic and grow in size once inhaled into the humid respiratory tract. The deposited amount and the distribution of the deposited particles among airways differ from insoluble particles of the same initial diameter. As particles grow in size, diffusive behavior tends to diminish while impaction and sedimentation effects increase. A multiple-path model for deposition of hygroscopic particles in the respiratory tract was developed for symmetric and asymmetric lung geometries by implementing particle size change in a model of insoluble particle deposition in lungs. Particle growth by molecular diffusion of water vapor to the particle surface was formulated. The growth model included temperature depression, solute, Kelvin, and Fuchs effects. Particle growth during travel time in each lung airway was computed. Average loss efficiency per airway was calculated by incorporating contributions from particles of various sizes acquired in that airway. A mass balance on the number of particles that entered, exited, deposited, or remained suspended was performed per airway to obtain regional and local deposition fractions of particles in the lung. The deposition fractions calculated for salt particles showed a drop for submicrometer particles in the tracheobronchial region and a significant increase in deposition for micrometer particles or larger. Consequently, very few fine and coarse salt particles reached the alveolar region to be available for deposition. Overall, lung deposition of ultrafine particles decreased for salt particles. Deposition for fine and coarse salt particles in the lung was larger than that of insoluble particles of the same initial particle size.     

Formation of vertical cracks in air plasma sprayed YSZ coatings using unpyrolyzed powder

Thick thermal barrier coatings (TTBCs) with vertical cracks deposited by air plasma spray (APS) and solution precursor plasma spray (SPPS) techniques have been widely investigated to achieve good thermal insulation along with reasonable service life. In this study, synthesized unpyrolyzed YSZ powder was air plasma sprayed in order to produce segmentation crack TTBCs. The microstructure and hardness of the deposits were then compared with those of the conventional TTBCs and dense vertically cracked (DVC)TTBCs. In this regard, spraying parameters were optimized to achieve deposits with the appropriate amount of unpyrolyzed particles in them to assist inducing vertical cracks in the deposited layers. The effect of the unpyrolyzed particles on microstructure, porosity, and microhardness of plasma sprayed coatings were also evaluated and compared. The new fabricated coating showed a bimodal structure combining non-molten sub-micron size particles and conventional splats along with segmentation cracks with higher amount of porosity and lower hardness compared to those of the DVC coatings. The results implied that, depositing unpyrolyzed powder by APS, as a new approach for achieving segmentation crack TTBCs, is very promising.     

化学法制备电极用超细铜粉

以CuSO4溶液为原料,采用NaOH沉淀-葡萄糖预还原-水合肼还原工艺（简称两步液相还原法）制得了粒度均匀可控、分散性好、适用于陶瓷电容器电极的球形超细铜粉。实验研究了葡萄糖预还原、水合肼的添加方式以及添加剂聚乙烯吡咯烷酮（PVP）和NH4Cl对超细铜粉粒度和形貌的影响。结果表明,葡萄糖预还原和水合肼的分步添加均有利于超细铜粒子的均匀生长,适量PVP的加入有助于超细铜粉粒径均匀并使其形貌趋于一致,NH4Cl可使铜粉的粒径变小,当Cu与NH4Cl的摩尔比为1∶1时铜粉的形貌会由类球形向正多面体转变。     

Development and Validation of a Simple Numerical Model for Estimating Workplace Aerosol Size Distribution Evolution Through Coagulation,Settling, and Diffusion

Recent research has indicated that the toxicity of inhaled ultrafine particles may be associated with the size of discrete particles deposited in the lungs. However, it has been speculated that in some occupational settings rapid coagulation will lead to relatively low exposures to discrete ultrafine particles. Investigation of likely occupational exposures to ultrafine particles following the generation of aerosols with complex size distributions is most appropriately addressed using validated numerical models. A numerical model has been developed to estimate the size-distribution time-evolution of compact and fractal-like aerosols within workplaces resulting from coagulation, diffusional deposition, and gravitational settling. Good agreement has been shown with an analytical solution to lognormal aerosol evolution, indicating good compatibility with previously published models. Validation using experimental data shows reasonable agreement when assuming spherical particles and coalescence on coagulation. Assuming the formation of fractal-like particles within a range of diameters led to good agreement between modeled and experimental data. The model appears well suited to estimating the relationship between the size distribution of emitted well-mixed ultrafine aerosols, and the aerosol that is ultimately inhaled where diffusion loses are small.     

Numerical Study of the Effect of Particle Size on the Coating Efficiency and Uniformity of an Electrostatic Powder Coating Process

This paper reports on a research project that studies the effect of particle size on the coating efficiency and coating uniformity in a powder coating system using the computational fluid dynamics as a modelling tool. The numerical simulations are conducted for different particle sizes with different distances between the spray gun and the coating part and different positions of the powder spray gun pattern adjuster sleeve (PAS). This study can provide detailed information on air flow pattern and particle trajectories inside the powder coating booth, and the coating film thickness on the coated part as well as the particle transfer efficiency (PTE). In numerical simulations, the air flow field is obtained by solving three‐dimensional Navier‐Stokes equations with standard κ‐ϵ turbulence model and non‐equilibrium wall function. The second phase, the coating powder, consists of spherical particles that are dispersed in the continuous phase, the air. In addition to solving transport equations for the air, the trajectories of the particles are calculated by solving the particle motion equations using the Lagrangian method. It is assumed that particle‐particle interaction can be neglected. The electrostatic field is modelled by solving the Laplace equation.     

纳米SiC－Si_3N_4复合超细粉末的研制

用热化学气相反应法制备了纳米级Ｓｉｃ－Ｓｉ＿３Ｎ＿４复合超细粉末，讨论了工艺参数对复合超细粉末颗粒度、组成、结构等的影响，并制备出颗粒呈球形、颗粒尺寸均匀、分散性好、最小颗粒尺寸为８９Ａ的纳米级ＳｉＣ－Ｓｉ＿３Ｎ＿４复合超细粉末。     

粉末涂料粒径对涂装产品质量的影响

介绍了用激光粒度分布仪检测粉末涂料粒径的原理,分析了粉末涂料的粒径对涂料的流平性、上粉率、稳定性、回收率及涂装产品质量外观等的影响,结合实际生产经验,根据涂装产品质量的要求,提出了控制粉末涂料粒径的生产工艺参数。     

纳米SiO2复合粒子/有机硅低聚物透明超疏水复合涂层的制备及其性能

本文以Stober法制备的胶体SiO2粒子与粉体SiO2粒子结合的SiO2复合粒子在玻璃基底构建粗糙表面,以三乙氧基甲基硅烷（MTES）与正硅酸乙酯（TEOS）为前聚体制备的酸性有机硅低聚物作为粘接剂,使用偶联剂KH540与氟硅烷PFDT进行改性,通过喷涂法在玻璃基底上制备出SiO2复合粒子/酸性有机硅低聚物复合透明超疏水涂层,然后探究SiO2复合粒子、酸性有机硅低聚物、偶联剂KH540以及氟硅烷PFDT对复合涂层的影响。研究表明：当SiO2复合粒子由粒径为110 nm的胶体SiO2粒子与粒径为50 nm的粉体SiO2粒子两种粒子组成,SiO2复合粒子溶液与酸性有机硅稀释液的混合质量比为4:1,添加偶联剂KH540与氟硅烷PFDT的质量比为混合液的1%时,复合涂层在可见光波长范围内透光率可达88%,静态接触角能达155°,在800目砂纸上磨损60 cm后仍能保持超疏水性能,具有良好的自清洁性,为透明超疏水涂层的制备提供一种简便、低成本方案。     

Effect of the powder particle structure and substrate hardness during vacuum cold spraying of Al2O3

In this paper, the effect of the powder particle structure and substrate hardness during vacuum cold spraying (VCS) of Al₂O₃ is investigated. Our results help understand the underlying deposition mechanism during VCS in more detail and enable the tailoring and improving of the resulting coatings. Two structurally different alumina feedstocks were used for this study. We find that the loosely agglomerated powder bonds to the substrate primarily through coordinated deformation of the nano-sized powder particles. The sintered powder, on the other hand, bonds to the substrate through severe fracture and deformation of the particles. High-resolution transmission electron microscopy (HR-TEM) was employed to observe details in the interfacial microstructure of the coatings on the two substrates with differing hardness. The hard steel substrate facilitates particle fracture, which leads to cohesive particle/particle-bonding in the coating region close to the substrate. The softer aluminum substrate leads to strong interfacial coating/substrate-bonding because the particles are embedded into the substrate. In summary, the fracture and deformation of the feedstock as well as the substrate hardness affect both adhesion (coating/substrate bonding) and cohesion (particle/particle bonding) considerably.     

电沉积Ni-S-Co/ZrO_2复合电极及其催化析氢性能

在镀液中悬浮粒径为200～400 nm的ZrO2固体颗粒,以电沉积方法制备了Ni-S-Co/ZrO2复合电极。XRD和SEM测试结果表明,沉积层由非晶态的Ni、Co、S和单斜晶型的ZrO2粒子组成。镀层表面呈团粒状结构,无裂隙,与基体结合牢固。电化学测试结果表明,25℃时,Ni-S-Co/ZrO2复合电极在质量分数28%NaOH水溶液中,在电流密度100 mA/cm2下的超电势为145 mV,与未复合纳米ZrO2粒子的Ni-S-Co电极相比降低了50 mV。表明超细ZrO2的掺入有效提高了电极对析氢反应的催化效果。实验表明,沉积的最佳电流密度为70 mA/cm2,最适宜的ZrO2用量为15 g/L,采用Ni-S-Co作为过渡层可以显著改善复合镀层与基体的结合。     

Unmelted particles in plasma sprayed coatings

A technique is described for investigation of unmelted particles in plasma spraying and for porosity investigation in coatings. A study of unmelted particles is made. The technique is based on large area section (LAS) images, superimposed to obtain a densely packed “column” of images as a 3-D map of a certain volume of the plasma sprayed coating. Optical micrographs of a polished cross section of the coating were used. The LAS technique combines two parameters—magnification and field size. Such a combination is normally beyond the range of optical microscopy. The method makes it necessary to polish the sample again and again and after each polishing step align precisely the new LAS with the previous one. The unmelted particles are considered to have been spheroidized in the plasma plume during plasma spraying, but to have cooled below the melting point before reaching the substrate. Such particles are embedded in the coating as previously solidified, i.e. with globular shape. The 3-D map makes it possible to observe their distribution inside the coating. These globular particles represent defects in the deposited coating. Moreover they have a tendency to behave isotropically under the influence of stress or other physical factors and in this way serve in the anisotropic structure of the coating as centers of secondary defects deteriorating the functional properties of the coatings.     

TiB2–ZrB2–SiC composite ceramic coating with the formation of solid-phase (TixZr1-x)B2 deposited by atmospheric plasma spraying as a barrier to molten cryolite-based salt

TiB₂, ZrB₂, and SiC powders with particles measuring several micrometers were first agglomerated and then deposited onto the substrate of a porous carbon block as a barrier to molten cryolite-based salt. Scanning electron microscopy, X-ray diffraction, and transmission electron microscopy were conducted to investigate the fine microstructure of the obtained ceramic coating and to elucidate the evolution of agglomerated powder from sprayed particles in plasma jet to splats on a substrate. Results indicated that a highly dense ceramic coating consisting of a solid solution (Ti_xZr_1-x)B₂, residual TiB₂, and ZrB₂ was obtained. The compactness of the coating and the formation of a solid solution phase was mainly caused by a SiC-rich liquid phase, as determined from a boride and silicon carbide pseudodiagram. After being submerged in molten cryolite-based salt for 8 h, the ceramic coating was firmly bonded to a carbon block. No molten slat permeated the ceramic coating.