Patent Application
20240042469
This application claims foreign priority of Chinese Patent Application No. 202210944611.6, filed on Aug. 8, 2022 in the China National Intellectual Property Administration, the disclosures of all of which are hereby incorporated by reference.
The present invention belongs to the technical filed of plasma spraying guns, and more particularly, relates to a small-size axial powder feeding inner hole plasma spraying gun.
Cylinder, hole, ring, pipe and other inner hole parts are key parts of power, transmission, manipulation and transportation systems in mechanical equipment, and are also short service life parts subjected to extremely harsh service conditions and prone to various damages and failures. The research and development of a coating technology for strengthening/modification/life prolongation of inner wall surfaces of equipment parts is an important way to improve a service reliability of equipment, prolong a service life of equipment, and reduce operation and maintenance costs of whole life cycle of equipment.
For example, an internal combustion engine is used in automobile industry, aerospace industry, shipbuilding industry and machinery industry, and is one of the most critical parts. However, a reciprocating motion of a piston causes fatigue wear on a surface of the piston, thus reducing a service life of a cylinder liner of the internal combustion engine. Experiments have proved that the wear resistance of a cylinder block can be improved by spraying a layer of wear-resistant coating on an inner wall of an air cylinder. For another example, in order to improve the corrosion resistance of a petroleum pipeline, it is necessary to spray a corrosion-resistant coating on an inner surface of the petroleum pipeline, and in order to improve the wear resistance of a coupling of the petroleum pipeline, it is necessary to spray a wear-resistant and anti-adhesion coating on an inner surface of the coupling.
A method for preparing a thermal spraying coating on a surface of an inner hole comprises flame spraying, electric arc spraying and plasma spraying. The flame spraying and the electric arc spraying have a long spraying distance, few sprayable material types and a low coating performance. The plasma spraying has a coating performance better than those of the flame spraying and the electric arc spraying, and a small spraying distance, thus being easy to realize coating spraying on an inner surface of a small hole channel.
In reality, some pipelines, couplings and engine cylinder blocks are small in size and belong to semi-blind holes or blind holes, so that a special inner hole plasma spraying gun is needed for spraying an inner wall and a hole bottom. The smaller the inner diameter of the hole is, the smaller the spraying gun capable of being used for spraying a coating on the inner wall is. In the prior art, when a size of the spraying gun is reduced, a maximum power capable of being reached is reduced, which is not conducive to spraying a metal or ceramic coating with a high melting point and good wear resistance. Moreover, most small-size inner hole spraying guns adopt an external powder feeding method, which is more unfavorable to the melting and acceleration of a sprayed material, thus being not easy to obtain a high-performance coating in the inner hole. Even though some inner hole spraying guns adopt an internal powder feeding method, since a powder feeding position is not in a high temperature zone of a plasma flame flow, energy utilization is insufficient, the spraying distance is too small, and a flying time of the powder in a jet flow is too short, there are defects of insufficient powder melting, low powder utilization rate, low spraying efficiency and serious dust pollution in the coating.
Existing inner hole plasma spraying guns mainly have the following problems:
(1) A gun body thickness of the spraying gun is too large. The gun body thickness of the spraying gun is great than or equal to 40 mm (the gun body thickness of the spraying gun refers to a distance between a front edge of a gun body in a direction of a jet flow outlet and a rear edge of a tail portion of the gun body), and a thickness of a common spraying gun ranges from 60 mm to 70 mm. The smaller the thickness of the spraying gun is, the smaller the diameter of the sprayable inner hole is.
(2) Spraying gun without axial powder feeding inner hole. Most of the spraying guns adopt the external powder feeding method, with a low plasma flame temperature at the powder feeding position, which is unfavorable to the melting and acceleration of the sprayed material, thus being not easy to obtain a high-performance coating in the inner hole. Even though some inner hole spraying guns adopt the internal powder feeding method, since the powder feeding position is not in the high temperature zone of the plasma flame flow, the energy utilization is insufficient, the spraying distance is too small, and the flying time of the powder in the jet flow is too short, there are defects of insufficient powder melting, low powder utilization rate, low spraying efficiency and serious dust pollution in the coating.
(3) When an inner wall of a hole with an inner diameter less than Φ175 mm is sprayed, only the small-size inner hole spraying gun can be used, and the power of the small-size inner hole spraying gun cannot reach more than 35 kW. The larger the power is, the more fully the sprayed material melts, which is more conductive to obtaining a high-performance coating.
Aiming at the defects of the prior art, the present invention aims to provide a small-size axial powder feeding inner hole plasma spraying gun, which adopts an axial powder feeding method, and effectively reduces a thickness of the spraying gun by reasonably setting a structure of the spraying gun, thus improving power of the spraying gun.
The present invention provides the technical solutions as follows.
A small-size axial powder feeding inner hole plasma spraying gun comprises:
Preferably, the cooling channel comprises a water inlet channel, a first annular water cavity, a water passing channel, a second annular water cavity and a water outlet channel which are communicated in sequence;
Preferably, the spray hole channel comprises a compression section, a throat and an expansion section in sequence in an axial direction; and
Preferably, the insulator is provided with an annular air inlet groove on one side facing the front gun body, and the air inlet groove is communicated with the air inlet channel and arranged around the second through hole;
Preferably, the air guide grooves are arranged in a radial direction of the annular bulge.
Preferably, an included angle is formed between an axial direction of the guide air grooves and a radial direction of the annular bulge, so that gas entering from the guide air grooves deviates from a center of the second annular groove.
Preferably, the insulator is connected with the front gun body and the rear gun body at the same time through a gun body fixing bolt;
Preferably, a gun body thickness of the spraying gun ranges from 28 mm to 32 mm.
Preferably, the small-size axial powder feeding inner hole plasma spraying gun further comprises determination of sizes of parts of the spraying gun according to the following formula:
The present invention has the beneficial effects as follows.
The present invention is further described in detail hereinafter with reference to the drawings, so that those skilled in the art are able to implement according to the text of the specification.
As shown in
The front gun body 2 is provided with a first through hole 2a. One end of the nozzle 1 is fixed on an outside of the front gun body 2 through the nozzle gland 3, and the other end of the nozzle extends to an inside of the front gun body 2 through the first through hole 2a, and is flush with the inside of the front gun body 2. The nozzle gland 3 is partially embedded in the front gun body 2 and connected to the front gun body 2 through a plurality of nozzle gland fixing bolts 22. A spray hole channel la is coaxially arranged in the nozzle 1. An O-shaped ring M1 and an O-shaped ring M2 are respectively arranged between a front end and a rear end of the nozzle 1 and the front gun body 2. According to the present invention, a space size of the spraying gun is reduced by designing the gland-type fixed nozzle. According to existing nozzles, a pressing cap is fixed on the front gun body through a thread, but the biggest problem of this design is that a larger size is needed in an axial direction. According to the present invention, the nozzle 1 is fixed through the nozzle gland 3, and the nozzle gland 3 does not need the design of thread. The nozzle gland 3 is fixed on the front gun body 2 through the gland fixing bolts 22 at four corners, which saves a large space in the axial direction for the nozzle 1, thus effectively reducing the thickness of the spraying gun.
The insulator 4 is arranged between the front gun body 2 and the rear gun body 5, and fixedly connected with the front gun body 2 and the rear gun body 5 at the same time. The insulator 4 is provided with a second through hole 4a, and the rear gun body 5 is provided with a third through hole 5a; and the first through hole 2a, the second through hole 4a and the third through hole 5a are coaxially arranged.
The powder feeding frame 7 is fixedly connected to an outside of the rear gun body 5 through a plurality of powder feeding frame fixing bolts 21. An interior of the powder feeding frame 7 is provided with a powder inlet channel 7a, and one side of the powder feeding frame 7 close to the rear gun body 5 is provided with a powder feeding joint 71. One end of the powder inlet channel 7a is communicated with a channel in the powder feeding joint 71, and the other end of the powder inlet channel is communicated with a power inlet pipe F1. An O-shaped ring M3 is arranged between the powder feeding frame 7 and the rear gun body 5, and the O-shaped ring M3 is arranged around the third through hole 5a.
The cathode 6 is arranged in the second through hole 4a and the third through hole 5a at the same time. As shown in
A powder feeding hole channel 6a is coaxially arranged in the cathode 6, one end (an inlet end of the cathode seat 61) of the powder feeding hole channel 6a is communicated with the channel in the powder feeding joint 71, and the other end (an outlet end of the cathode head 62) of the powder feeding hole channel is communicated with the spray hole channel 1a. The powder feeding hole channel 6a is coaxially arranged with the spray hole channel 1a.
The spraying gun provided by the present invention adopts axial powder feeding, and a high-melting-point powder material may be sprayed in a small-size inner hole under a small spraying distance. A powder outlet for axial powder feeding in the spraying gun is the cathode head 62, where a temperature of a plasma flame is high, which can reach more than 8,000° C., thus being conducive to rapid heating and melting of the powder material.
Further preferably, the cathode 6 is provided with four mounting propelling holes 6b. The four mounting propelling holes 6b are matched with a special tool. By using the special tool on the four mounting propelling holes 6b, it is convenient for propelling rotation of the cathode 6, so as to fix the cathode on the powder feeding frame 7.
As shown in
As shown in
The plasma spraying gun further comprises a cooling channel with an interior introduced with cooling water, so that the cooling water enters through the front gun body 2, flows through an outside area of the nozzle 1 and an outside area of the cathode 6 in a surrounding manner in sequence, and then flows out from the rear gun body 5. An outside of the cathode 6 is provided with an annular radiating fin 63 at the corresponding cooling channel. The arrangement of the annular radiating fin 63 is conductive to heat dissipation of the cathode, thus improving ablation resistance of the cathode and prolonging a service life of the cathode, so that the cathode is capable of bearing higher power.
As shown in
The water inlet channel W2 is formed in the front gun body 2, an upper end of the water inlet channel is connected to the water inlet pipe W1, and a lower end of the water inlet channel is connected to the first annular water cavity W3. The first annular water cavity W3 is arranged in the front gun body 2 and arranged around an outer wall of the nozzle 1. In the embodiment, the first annular water cavity W3 is formed by enclosing a groove formed at a periphery of the first through hole 2a and the outer wall of the nozzle 1. The first annular water cavity W3 is arranged corresponding to middle and rear portions of the nozzle 1, the outer wall of the nozzle 1 is coaxially provided with an annular cooling groove 1c, and an opening of the cooling groove 1c faces an outlet end of the nozzle 1 and is communicated with the first annular water cavity W3. The arrangement of the cooling groove 1c on the nozzle 1 can greatly reduce a temperature of a groove area of a rubber ring, thus prolonging a service life of the rubber ring, and ensuring high-power operation of the spraying gun.
The water passing channel consists of a water outlet channel W4 of the front gun body, a water inlet channel W6 of the rear gun body and a connecting channel W5 penetrating through the insulator. The water outlet channel W4 of the front gun body is formed in the front gun body 2 and has an upper end communicated with the first annular water cavity W3, the connecting channel W5 is arranged perpendicular to the insulator 4, and the water inlet channel W6 of the rear gun body is formed in the rear gun body 5. Two ends of the connecting channel W5 are respectively communicated with lower ends of the water outlet channel W4 of the front gun body and the water inlet channel W6 of the rear gun body. The second annular water cavity W7 is arranged in the rear gun body 5, and the annular radiating fin 63 is located in the second annular water cavity W7. An upper end of the water inlet channel W6 of the rear gun body is communicated with the second annular water cavity W7. The water outlet channel W8 is formed in the rear gun body 2, an upper end of the water outlet channel W8 is connected to a water outlet pipe W9, and a lower end of the water outlet channel is communicated with the second annular water cavity W7.
An O-shaped ring M6 is arranged between the front gun body 2 and the insulator 4, and an O-shaped ring M7 and the O-shaped ring M6 are arranged between the rear gun body 5 and the insulator 4. The O-shaped ring M6 and the O-shaped ring M7 are both arranged around the connecting channel W5, and the O-shaped ring M6 and the O-shaped ring M7 are symmetrically arranged on two sides of the insulator 4. An O-shaped ring M8 is used for forming sealed connection between the second through hole 4a and the third through hole 5a.
Further preferably, as shown in
In the embodiment, four guide air grooves G4 are provided and uniformly distributed in a circumferential direction of the bulge 41 to divide the bulge 41 into four equal parts in structure. An axis of the air guide groove G4 is arranged in an radial direction of the annular bulge 41, which means that gas is sprayed towards a center of the second annular groove G5 through the air guide grooves G4. The gas is in a non-rotating state when entering the second annular groove G5 (the back pressure air chamber) through the air guide grooves G4. A plasma jet flow formed by a non-rotating air flow has a low velocity, which is suitable for spraying a high-melting-point powder material.
In another embodiment, an included angle of route deviation is formed between an axial direction of the guide air grooves G4 and a radial direction of the annular bulge 41, so that gas entering from the guide air grooves G4 deviates from a center of the second annular groove G5. At the moment, the gas is in a rotating state when entering the second annular groove G5 (the back pressure air chamber) through the air guide grooves G4. A plasma jet flow formed by a rotating air flow has a higher velocity, which is suitable for spraying a low-melting-point powder material. The included angle of deviation may be set as 30° maximumly.
As shown in
The front gun body 2 and the rear gun body 5 are insulated by using the insulating gasket 23 and the screw insulating bushing 8 at a joint of the spraying gun fixing bolt 20. There is no straight-through gap between the front gun body 2 and the rear gun body 5 at a connected area of the spraying gun fixing bolt 20 after mounting, and all seams or gaps are labyrinth-type In arc ignition or plasma spraying work, an electric arc will not be ignited in the connected area of the spraying gun fixing bolt 20 due to a slit effect to cause a burning loss of the spraying gun. A short-circuit burning loss in a connected area of a spraying gun fixing bolt of an existing inner hole spraying gun is a common damage form. According to the present invention, there is good insulation between the front gun body 2 and the rear gun body 5, which can effectively avoid accidental short-circuit ablation in the area.
In the embodiment, a space size of the spraying gun in an axial direction is saved by adopting designs of the gland-type fixed nozzle, the air groove of the insulator, the axial powder feeding and the labyrinth-type gap in the connected area of the spraying gun fixing bolt 20, so that a minimum thickness of the spraying gun is 28 mm. The small-thickness spraying gun provides a premise for spraying the small-size inner hole.
According to the small-size axial powder feeding inner hole plasma spraying gun provided by the present invention, sizes of parts of the spraying gun may be determined according to the following formula to obtain a better spraying effect:
In practical application, specifications and models of several nozzles may be determined in advance, and then the model of the nozzle is quickly selected by calculating the reference value m for selection according to a melting point, a particle size and a density of a material to be sprayed, so as to improve an optimization efficiency of spraying process, and prevent the powder material from being melted and adhered to the inner wall of the hole channel of the nozzle when the nozzle is mistakenly selected to affect a jet flow quality and a coating quality. When the nozzle is mistakenly selected, the nozzle and the spraying gun may even be burnt due to blockage of the hole channel. A specific method for selecting the model is shown in Table 1.
Preferably, the nozzle 1 is made of chromium zircomium copper alloy. The front gun body 2, the rear gun body 5, the powder feeding frame 7, the air inlet pipe G1, the water inlet pipe W1 and the water outlet pipe W9 are all made of brass alloy. The cathode head 62 is made of tungsten alloy. The cathode seat 61 is made of red copper or brass alloy. The nozzle gland 3 is made of stainless steel. The insulator 4, the insulating bushing 8, the insulating gasket 23 and the insulating gasket 24 are made of a resin material, which may be polyimide resin, phenolic resin, bismaleimide resin and other resins.
According to the small-size axial powder feeding inner hole plasma spraying gun provided by the present invention, the gun body thickness of the spraying gun may be controlled to range from 28 mm to 32 mm. A minimum diameter of a sprayable inner hole is 55 mm, and a maximum diameter of the sprayable inner hole is unlimited. The design of axial powder feeding, the small-thickness inner hole gun and the high power ensure the preparation of a high-performance coating in the small-size inner hole under a small spraying distance.
In the present invention, a high-pressure gas mode is used, wherein a maximum pressure of argon is 1.2 MPa, a maximum pressure of hydrogen is 1.0 MPa, and a maximum pressure of nitrogen is 1.0 MPa. Moreover, the nozzle has a De-Laval structure of small hole channel, so that the nozzle has a higher cooling efficiency. Therefore, a compression effect of a plasma arc is improved. Therefore, a maximum working voltage can reach 100 V, the plasma jet flow has a better stability, the plasma arc has a better rigidity, and the jet flow has a higher velocity.
Maximum power of the spraying gun is 40 kW, and corresponding electrical parameters comprise a current of 400 A and a voltage of 100 V; or a current of 450 A and a voltage of 90 V. Interiors of the front gun body 2 and the rear gun body 5 both adopt the design of maximum-diameter water channel, a water flow channel in an interior of the spraying gun is simple without complicated cooling holes, and a water flow flows smoothly in the interior of the spraying gun and has low pressure drop. The cooling water cools exteriors of the throat of the nozzle and the expansion section of the hole channel which have the highest temperature and are most prone to the burning loss in the spraying gun first. A rear portion of the cathode 6 is provided with the radiating fin, which can greatly improve a heat dissipation effect of the cathode 6. The nozzle 1 is provided with the cooling groove 1c, which can greatly reduce the temperature in the groove area of the rubber ring, and the arrangement of the structure above ensures improvement of power of the spraying gun.
A working process of the small-size axial powder feeding inner hole plasma spraying gun provided by the present invention is as follows: the cooling water enters the interior of the spraying gun from the water inlet pipe and flows out from the water outlet pipe to cool the spraying gun, and meanwhile, the water inlet pipe is connected to a positive pole of a power supply, and the water outlet pipe is connected to a negative pole of the power supply. Plasma working gas (generally comprising a mixed gas of argon and hydrogen, or a mixed gas of argon and nitrogen) enters the interior of the spraying gun from the air inlet pipe, enters the nozzle 1 from the annular cavity 1b, and is sprayed out from the outlet of the nozzle 1. After the spraying gun is powered on, the working gas in an interior of the nozzle becomes the plasma jet flow after high-frequency arc ignition. A gas-powder mixture enters the plasma jet flow in the nozzle. After the plasma jet flow is heated and sprayed on a surface of a workpiece at an accelerated velocity, the powder is cooled to form the coating.
A working principle of the interior of the spraying gun is as follows.
Water route: as shown in
Gas route: as shown in
Electric circuit: the water inlet hole is connected to the positive pole of the power supply, and the water outlet hole is connected to the negative pole of the power supply. The nozzle 1, the nozzle gland 3 and the front gun body 2 of the spraying gun form the positive pole. The cathode 6, the powder feeding frame 7 and the rear gun body 5 of the spraying gun form the negative pole. The insulator 4 separates the positive and negative poles to prevent short circuit.
Powder route: the gas-powder mixture enters the powder feeding frame 7 from the powder inlet pipe F1, passes through the powder inlet channel 7a in the powder feeding frame 7, the powder feeding joint 71 and the hole channel in the cathode 6, enters the throat of the nozzle 1 to merge with the working gas, and finally is sprayed out from the outlet of the nozzle 1.
Although the implementation of the present invention has been disclosed above, it is not limited to the applications listed in the specification and the embodiments, and can be fully applied to various fields suitable for the present invention, and additional modifications can be easily implemented by those skilled in the art. Therefore, the present invention is not limited to the specific details and illustrations shown and described herein without departing from the general concept defined by the claims and the equivalent scope.
| Number | Date | Country | Kind |
|---|---|---|---|
| 202210944611.6 | Aug 2022 | CN | national |
