ABRASION-RESISTANT ANTI-CORROSIVE COATING, AND PREPARATION METHOD AND USE THEREOF

Abstract

Disclosed are an abrasion-resistant anti-corrosive coating, and a preparation method and a use thereof. The abrasion-resistant anti-corrosive coating is prepared from a component A and a component B. In the component A, a polyurethane (PU) resin is used as a film-forming material in combination with a corrosion inhibitor, an abrasion-resistant filler, and a body filler. On the basis of the abrasion resistance of the PU resin, the corrosion inhibition of the corrosion inhibitor and the high abrasion resistance of the abrasion-resistant filler improve the abrasion resistance of a coating layer. The use of the body filler reduces a cost of the coating. A thixotropic agent makes the coating have high storage stability. The coating does not include metal components, which avoids an electrochemical potential difference between a coating layer and an alloy, such that the corrosion of the alloy can be effectively controlled.

Claims

1. An abrasion-resistant anti-corrosive coating made from a component A and a component B, wherein in parts by weight, the component A comprises: polyurethane resin: 10 to 60 parts; abrasion-resistant filler: 1 to 60 parts; thixotropic agent: 0.5 to 1 part; body filler: 5 to 15 parts; corrosion inhibitor: 0.5 to 2 parts; and solvent: 20 to 80 parts; the component B comprises a curing agent; and a mass ratio of the component A to the component B is 1:(1-2).

2. The abrasion-resistant anti-corrosive coating according to claim 1, wherein the abrasion-resistant filler is silicon nitride and/or boron nitride; the thixotropic agent is lipophilic fumed silica; the body filler is mica and/or ground calcium carbonate; the corrosion inhibitor is N-nitrosophenylhydramine and/or hexamethylenetetramine (HMTA); and the solvent is selected from the group consisting of X-10, xylene, and ethylene glycol monoethyl ether acetate.

3. The abrasion-resistant anti-corrosive coating according to claim 1, wherein the curing agent is a modified alkyd resin.

4. The abrasion-resistant anti-corrosive coating according to claim 2, wherein the silicon nitride and the boron nitride each have a particle size of 1 μm to 20 μm; the lipophilic fumed silica has a particle size of 20 nm to 100 nm; and the mica or the ground calcium carbonate has a particle size of 2 μm to 30 μm.

5. A preparation method of the abrasion-resistant anti-corrosive coating according to claim 1, comprising the following steps: 1) preparation of the component A: thoroughly mixing the polyurethane resin, the abrasion-resistant filler, the thixotropic agent, the body filler, the corrosion inhibitor, and the solvent, and grinding a resulting mixture for dispersion to obtain the component A; and 2) mixing the component A with the component B, and thoroughly stirring a resulting mixture to obtain the abrasion-resistant anti-corrosive coating.

6. The preparation method according to claim 5, wherein the component A has a fineness degree of 10 μm to 30 μm.

7. The preparation method according to claim 5, wherein the grinding for dispersion is conducted at a rotational speed of 1,500 rpm to 3,000 rpm for 30 min to 60 min.

8. A method for preparation of an abrasion-resistant anti-corrosive coating layer for a steel material, aluminum alloy, titanium alloy, and/or magnesium alloy component, comprising using the abrasion-resistant anti-corrosive coating according to claim 1.

9. The method according to claim 8, comprising the following steps: applying the abrasion-resistant anti-corrosive coating on a surface of the component through spray-coating, brush-coating, or dip-coating, with two adjacent layers being applied at an interval of 10 min to 20 min, and curing at room temperature for 24 h or more to obtain an abrasion-resistant anti-corrosive coating layer.

10. A preparation method of the abrasion-resistant anti-corrosive coating according to claim 2, comprising the following steps: 1) preparation of the component A: thoroughly mixing the polyurethane resin, the abrasion-resistant filler, the thixotropic agent, the body filler, the corrosion inhibitor, and the solvent, and grinding a resulting mixture for dispersion to obtain the component A; and 2) mixing the component A with the component B, and thoroughly stirring a resulting mixture to obtain the abrasion-resistant anti-corrosive coating.

11. A preparation method of the abrasion-resistant anti-corrosive coating according to claim 3, comprising the following steps: 1) preparation of the component A: thoroughly mixing the polyurethane resin, the abrasion-resistant filler, the thixotropic agent, the body filler, the corrosion inhibitor, and the solvent, and grinding a resulting mixture for dispersion to obtain the component A; and 2) mixing the component A with the component B, and thoroughly stirring a resulting mixture to obtain the abrasion-resistant anti-corrosive coating.

12. A preparation method of the abrasion-resistant anti-corrosive coating according to claim 4, comprising the following steps: 1) preparation of the component A: thoroughly mixing the polyurethane resin, the abrasion-resistant filler, the thixotropic agent, the body filler, the corrosion inhibitor, and the solvent, and grinding a resulting mixture for dispersion to obtain the component A; and 2) mixing the component A with the component B, and thoroughly stirring a resulting mixture to obtain the abrasion-resistant anti-corrosive coating.

13. A method for preparation of an abrasion-resistant anti-corrosive coating layer for a steel material, aluminum alloy, titanium alloy, and/or magnesium alloy component, comprising using the abrasion-resistant anti-corrosive coating according to claim 2.

14. A method for preparation of an abrasion-resistant anti-corrosive coating layer for a steel material, aluminum alloy, titanium alloy, and/or magnesium alloy component, comprising using the abrasion-resistant anti-corrosive coating according to claim 3.

15. A method for preparation of an abrasion-resistant anti-corrosive coating layer for a steel material, aluminum alloy, titanium alloy, and/or magnesium alloy component, comprising using the abrasion-resistant anti-corrosive coating according to claim 4.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0040] To describe the technical solutions in the examples of the present disclosure or in the prior art more clearly, the accompanying drawings required for describing the examples or the prior art will be briefly described below. Apparently, the accompanying drawings in the following description show merely some examples of the present disclosure, and those of ordinary skill in the art may still derive other drawings from these accompanying drawings without creative efforts.

[0041] FIG. 1 is an electrochemical impedance spectroscopy (EIS) spectrum of the magnesium alloy AZ91D with an abrasion-resistant anti-corrosive coating layer in Example 1 of the present disclosure after being soaked in a 3.5% NaCl solution for 3,000 h;

[0042] FIG. 2 shows a mass loss of the magnesium alloy AZ91D with an abrasion-resistant anti-corrosive coating layer in Example 1 of the present disclosure;

[0043] FIG. 3 shows macroscopic morphologies of the magnesium alloy AZ31 with an abrasion-resistant anti-corrosive coating layer in Example 2 of the present disclosure that undergoes humid heat corrosion for 1,000 h, where the left panel shows a macroscopic morphology of the sample undergoing a humid heat test for 1,000 h (GJB 150.9A-2009), and the right panel shows the original morphology of a coating layer;

[0044] FIG. 4 shows a macroscopic morphology of a magnesium alloy ME20M with an abrasion-resistant anti-corrosive coating layer in Example 4 of the present disclosure that undergoes neutral salt spray corrosion for 2,000 h (GJB 150.11A-2009); and

[0045] FIG. 5 shows EIS spectra of a magnesium alloy AZ91D with an abrasion-resistant anti-corrosive coating layer in Example 5 of the present disclosure when soaked in a 10% HCl solution.

DETAILED DESCRIPTION

[0046] In order to make the objectives, features, and advantages of the present disclosure more comprehensible, the technical solutions in the examples of the present disclosure will be clearly and completely described below. Apparently, the examples described below are merely some rather than all of the examples of the present disclosure. All other examples obtained by those of ordinary skill in the art based on the examples of the present disclosure without creative efforts should fall within the protection scope of the present disclosure.

[0047] In the examples of the present disclosure, the PU resin and the curing agent are from a TS01-3 two-component PU coating of the Tianjin Lighthouse Coatings Industry Development Co., Ltd.; and the X-10 solvent is purchased from the Tianjin Lighthouse Coatings Industry Development Co., Ltd., and the X-10 solvent is a mixed solvent composed of 60 parts of anhydrous toluene, 25 parts of butyl acetate, and 15 parts of cyclohexanone.

EXAMPLE 1

[0048] In this example, in parts by mass, 20 parts of silicon nitride powder with a particle size of 10 μm, 0.8 part of fumed silica with a particle size of 20 nm, 10 parts of muscovite mica powder with a particle size of 12 μm, and 0.9 part of N-nitrosophenylhydroxylamine were weighed and sequentially added to 30 parts of PU resin, then 30 parts of an X-10 solvent were weighed and added, and a resulting mixture was thoroughly stirred, then put into a stirring and grinding machine together with 50 parts of grinding beads having a particle size of 1 mm, ground at 2,000 rpm for 40 min, and then taken out and filtered through a 120-mesh stainless steel mesh to obtain a component A of 10 μm to 30 μm; and 15 parts of modified alkyd resin (curing agent, component B) were weighed and thoroughly mixed with the component A (a mass ratio of the component A to the component B was 1:(1-2)) to obtain an abrasion-resistant anti-corrosive coating.

[0049] The abrasion-resistant anti-corrosive coating was spray-coated on a surface of a sand-blasted magnesium alloy AZ91D for a first time, then the surface was dried for 15 min, the abrasion-resistant anti-corrosive coating was spray-coated for a second time, and a resulting sample was cured for 24 h in a dry room-temperature environment to obtain an abrasion-resistant anti-corrosive coating layer with a thickness of 65 μm.

[0050] In this example, performance parameters of the abrasion-resistant anti-corrosive coating layer were as follows:

[0051] The magnesium alloy AZ91D with the abrasion-resistant anti-corrosive coating layer was soaked in a 3.5% NaCl solution for 3,000 h. As shown in FIG. 1, after the soaking, an impedance of the coating layer was remained at 10.sup.9 Ω cm.sup.2, indicating that the coating layer in this example exhibited excellent corrosion resistance.

[0052] As shown in FIG. 2, a mass loss of the magnesium alloy with the coating layer after being abraded for 30 min under a load of 1,000 g was 47 times lower than that of the magnesium alloy AZ91D, indicating that the coating layer in this example exhibited excellent abrasion resistance.

Comparative Example 1

[0053] In this comparative example, a coating was prepared by the same process as in Example 1, except that a zinc powder was used as the corrosion inhibitor and an alumina powder was used as the abrasion-resistant filler. The coating was coated on a surface of a magnesium alloy AZ91D to obtain a coating layer. Since the higher potential of zinc than the magnesium alloy AZ91D promoted the corrosion of the magnesium alloy, after the coating layer was soaked for 520 h, an impedance of the coating layer dropped to 10.sup.5 Ω cm.sup.2, indicating that the coating layer lost its protective effect. Under the same friction and abrasion conditions, a mass loss of the magnesium alloy with the coating layer was only 15 times lower than that of the magnesium alloy AZ91D.

EXAMPLE 2

[0054] In this example, in parts by mass, 30 parts of boron nitride powder with a particle size of 15 μm, 1 part of fumed silica with a particle size of 50 nm, 8 parts of GCC with a particle size of 25 μm, and 1.5 parts of HMTA were weighed and sequentially added to 50 parts of PU resin, then 35 parts of xylene were weighed and added, and a resulting mixture was thoroughly stirred, then put into a stirring and grinding machine together with 60 parts of grinding beads having a particle size of 2 mm, ground at 3,000 rpm for 30 min, and then taken out and filtered through a 300-mesh stainless steel mesh to obtain a component A of 10 μm to 30 μm; and 25 parts of a curing agent (component B) were weighed and thoroughly mixed with the component A (a mass ratio of the component A to the component B was 1:(1-2)) to obtain an abrasion-resistant anti-corrosive coating.

[0055] The abrasion-resistant anti-corrosive coating was spray-coated on a surface of a sand-blasted magnesium alloy AZ31 for a first time, then the surface was dried for 10 min, the abrasion-resistant anti-corrosive coating was spray-coated for a second time, and a resulting sample was cured for 24 h in a dry room-temperature environment to obtain an abrasion-resistant anti-corrosive coating layer with a thickness of 70 μm.

[0056] In this example, performance parameters of the abrasion-resistant anti-corrosive coating layer were as follows:

[0057] The magnesium alloy AZ31 with the abrasion-resistant anti-corrosive coating layer was subjected to a humid heat corrosion test for 1,000 h. As shown in FIG. 3, after the 1,000 h of test, the coating layer was intact, and did not undergo damage such as blistering and peeling.

Comparative Example 2

[0058] In this comparative example, a coating was prepared by the same process as in Example 2, except that a polyamide (PA) powder with a molecular weight of 19,000 was used as the thixotropic agent. The coating was coated on a surface of a magnesium alloy AZ31 to obtain a coating layer. Due to the poor compatibility of PA with the coating, the coating layer had many pores. After undergoing humid heat corrosion for 830 h, the coating layer had blisters and exhibited reduced protection performance.

EXAMPLE 3

[0059] In this example, in parts by mass, 10 parts of silicon nitride powder with a particle size of 20 μm, 15 parts of boron nitride powder with a particle size of 15 μm, 1.2 parts of fumed silica with a particle size of 100 nm, 5 parts of muscovite mica powder with a particle size of 2 μm, 7 parts of GCC with a particle size of 20 μm, 0.8 part of N-nitrosophenylhydroxylamine, and 1 part of HMTA were weighed and sequentially added to 60 parts of PU resin, then 40 parts of an X-10 diluent and 40 parts of xylene were weighed and added, and a resulting mixture was thoroughly stirred, then put into a stirring and grinding machine together with 80 parts of grinding beads having a particle size of 0.5 mm, ground at 1,500 rpm for 60 min, and then taken out and filtered through a 120-mesh stainless steel mesh to obtain a component A of 10 μm to 30 μm; and 30 parts of a curing agent (component B) were weighed and thoroughly mixed with the component A (a mass ratio of the component A to the component B was 1:(1-2)) to obtain an abrasion-resistant anti-corrosive coating. The abrasion-resistant anti-corrosive coating was spray-coated on a surface of a sand-blasted magnesium alloy ME20M for a first time, then the surface was dried for 20 min, the abrasion-resistant anti-corrosive coating was spray-coated for a second time, and a resulting sample was cured for 24 h in a dry room-temperature environment to obtain an abrasion-resistant anti-corrosive coating layer with a thickness of 75 μm.

[0060] In this example, performance parameters of the abrasion-resistant anti-corrosive coating layer were as follows:

[0061] The magnesium alloy ME20M with the abrasion-resistant anti-corrosive coating layer was subjected to neutral salt spray corrosion for 2,000 h, and as shown in FIG. 4, the coating layer underwent no blistering, peeling, and cracking, indicating that the coating layer had excellent salt spray corrosion resistance.

Comparative Example 3

[0062] In this comparative example, a coating was prepared by the same process as in Example 3, except that kaolin was used as the body filler. The coating was coated on a surface of a magnesium alloy ME20M to obtain a coating layer, and the magnesium alloy with the coating layer was subjected to salt spray corrosion for 560 h. Because the kaolin had a high iron content and thus easily corroded the magnesium alloy, the magnesium alloy matrix was corroded after the salt spray corrosion.

EXAMPLE 4

[0063] In this example, in parts by mass, 60 parts of silicon nitride powder with a particle size of 20 μm, 0.6 part of fumed silica with a particle size of 30 nm, 10 parts of muscovite mica powder with a particle size of 5 μm, 5 parts of GCC with a particle size of 10 μm, 0.1 part of N-nitrosophenylhydroxylamine, and 0.7 part of HMTA were weighed and sequentially added to 40 parts of PU resin, then 40 parts of the diluent ethylene glycol monoethyl ether acetate were weighed and added, and a resulting mixture was thoroughly stirred, then put into a stirring and grinding machine together with 60 parts of grinding beads having a particle size of 1 mm, ground at 2,500 rpm for 50 min, and then taken out and filtered through a 220-mesh stainless steel mesh to obtain a component A of 10 μm to 30 μm; and 40 parts of a curing agent (component B) were weighed and thoroughly mixed with the component A (a mass ratio of the component A to the component B was 1:(1-2)) to obtain an abrasion-resistant anti-corrosive coating. The abrasion-resistant anti-corrosive coating was spray-coated on a surface of a sand-blasted magnesium alloy AZ91D for a first time, then the surface was dried for 12 min, the abrasion-resistant anti-corrosive coating was spray-coated for a second time, and a resulting sample was cured for 24 h in a dry room-temperature environment to obtain an abrasion-resistant anti-corrosive coating layer with a thickness of 60 μm.

[0064] In this example, performance parameters of the abrasion-resistant anti-corrosive coating layer were as follows:

[0065] After the magnesium alloy AZ91D with the abrasion-resistant anti-corrosive coating layer was soaked in a 10% HC1 solution for 2,163 h, the coating layer did not undergo blistering, peeling, and cracking, and as shown in FIG. 5, an impedance of the coating layer remained at 10.sup.9 Ω cm.sup.2, indicating that the coating layer exhibited excellent acid corrosion resistance.

Comparative Example 4

[0066] In this comparative example, a coating was prepared by the same process as in Example 4, except that a ferrophosphorus powder was used as the corrosion inhibitor. The coating was coated on a surface of a magnesium alloy AZ91D, and the magnesium alloy with a coating layer was soaked in a 10% HCl solution for 843 h. After the soaking, the magnesium alloy matrix was corroded.

EXAMPLE 5

[0067] In this example, in parts by mass, 5 parts of silicon nitride powder with a particle size of 1 μm, 0.7 part of fumed silica with a particle size of 20 nm, 5 parts of muscovite mica powder with a particle size of 15 μm, 0.2 part of N-nitrosophenylhydroxylamine, and 1.2 parts of HMTA were weighed and sequentially added to 15 parts of PU resin, then 35 parts of xylene were weighed and added, and a resulting mixture was thoroughly stirred, then put into a stirring and grinding machine together with 25 parts of grinding beads having a particle size of 0.8 mm, ground at 1800 rpm for 40 min, and then taken out and filtered through a 150-mesh stainless steel mesh to obtain a component A of 10 μm to 30 μm; and 10 parts of a curing agent (component B) were weighed and thoroughly mixed with the component A (a mass ratio of the component A to the component B was 1:(1-2)) to obtain an abrasion-resistant anti-corrosive coating. The abrasion-resistant anti-corrosive coating was spray-coated on a surface of a sand-blasted magnesium alloy AZ31 for a first time, then the surface was dried for 13 min, the abrasion-resistant anti-corrosive coating was spray-coated for a second time, and a resulting sample was cured for 24 h in a dry room-temperature environment to obtain an abrasion-resistant anti-corrosive coating layer with a thickness of 80 μm.

[0068] In this example, performance parameters of the abrasion-resistant anti-corrosive coating layer were as follows:

[0069] The magnesium alloy AZ31 with the abrasion-resistant anti-corrosive coating layer was subjected to a friction and abrasion test under a load of 1,000 g for 30 min, and after the friction and abrasion test, a mass loss of the magnesium alloy with the coating layer was 52 times lower than that of the magnesium alloy AZ31. The magnesium alloy was soaked in artificial sea water for 2,000 h, and after the soaking, the coating layer did not undergo damage such as blistering, peeling, and cracking and still could play a prominent protective role, such that the magnesium alloy below the coating layer was not corroded.

Comparative Example 5

[0070] In this comparative example, a coating was prepared by the same process as in Example 5, except that 90 parts of PU resin were used in the component A. The coating was coated on a surface of a magnesium alloy AZ31. Then the magnesium alloy with a coating layer was subjected to a friction and abrasion test, and after the friction and abrasion test, a mass loss of the magnesium alloy with the coating layer was only 13 times lower than that of the magnesium alloy AZ31. The magnesium alloy with the coating layer was soaked in artificial sea water for 796 h, and after the soaking, the magnesium alloy matrix was corroded.

[0071] The results of the examples show that an abrasion-resistant anti-corrosive coating layer of a magnesium alloy obtained by the process significantly improves the abrasion resistance and corrosion resistance of the magnesium alloy, and the process is easy to control and is suitable for industrial production.

[0072] The above examples are used only to describe the technical solutions of the present disclosure, and are not intended to limit the present disclosure. Although the present disclosure is described in detail with reference to the above examples, those of ordinary skill in the art should understand that they can still modify the technical solutions described in the above examples, or make equivalent substitutions to some technical features therein. These modifications or substitutions do not make the essence of the corresponding technical solutions depart from the spirit and scope of the technical solutions of the examples of the present disclosure.