Antifriction coat

FIELD: chemistry.

SUBSTANCE: antifriction coat can be used in gear pumps for reducing friction and wear resulted from corrosion or mechanical effects in tribojoints under effects of chemically active reagents, high temperature and loads on engaged parts to ensure required stable gaps between the said parts. The antifriction coat consists of three layers, i.e. inner, intermediate and upper layers. Note here that the inner layer represents a composition comprising 90 wt % of a polyimide varnish and 10 wt % of chromophosphatealuminic bond, the intermediate layer being made from 100 wt % of a pure polyimide varnish. Finally, the top layer represents a composition containing 90 wt % of polyimide varnish, 8 wt % of colloid graphite and 2 wt % of lecithin. Thickness of the aforesaid inner layer is within the limits of from 8 up to 10 mcm, thickness of the intermediate layer is within the limits of from 16 up to 20 mcm, thickness of the top layer is within the limits of from 24 up to 30 mcm, while the required thickness of the coat is provided by grinding the top layer.

EFFECT: longer life of friction assembly units and parts operated in chemically active environments.

2 tbl

 

The invention relates to the field of engineering, namely, anti-friction coatings used in gear pumps to reduce friction and corrosion and mechanical wear between the drive shaft and the pump casing and in other tribocharging when exposed to the mating parts of chemically active reagents, high temperatures and loads, and the need to safeguard the stability of the gaps in tribocharging.

Known antifriction self-lubricating material used for coating, which is used as a binder of epoxy resin and fillers are polyamide and silica fabric, molybdenum disulfide, bronze powder and polytetrafluoroethylene (see patent RU No. 2155198, CL F16C 33/20, 27.08.2000).

The main disadvantage of such coatings is the high coefficient of friction.

Known anti-friction coating containing a solid lubricant is molybdenum disulfide, graphite, boron nitride and a binder based on epoxy resin, in the following ratio of components, parts by weight: molybdenum disulfide - 25-58, graphite - 25-58, boron nitride 7-16, binder - 30-70, when this coating is applied on the metal surface a thin film of a mixture of solid lubricant and a binder (see US patent No. 5482637, CL F02B 77/02, 09.01.1996).

This composition may be used in which the quality of anti-friction wear-resistant coatings in the nodes mechanisms, operated in the regime of dry friction at loads up to 10 kg/mm2. However, this coating has a high porosity and does not protect the metal substrate from corrosion during operation of the mechanism in aggressive environments.

Closest to the invention to the technical essence and the achieved result is an anti-friction coating containing a solid lubricant is molybdenum disulfide and graphite, molybdenum and binder based on epoxy resin, and the coating consists of three layers, the lower of which is adjacent to the metal substrate made of molybdenum, an intermediate layer made of a binder without fillers, and the upper layer made of a binder, in which, as the solid lubricant introduced graphite (see patent RU 2211260, CL SS 28/00, 27.08.2003).

This coating provides excellent wear resistance and low coefficient of friction of adjacent pairs, the shear strength when working in non-aggressive environments. However, this coverage does not reduce corrosion and mechanical wear of friction pairs in the operation of the mechanism in aggressive environments, such as alkali and hydrochloric acid. Along with this, the floor, as previous analogs having a relatively low hardness, very poorly mechanical grinding and polishing, which does not allow to use it for promyshlennogo the manufacture of precision parts of friction, for example, gear pumps, pumping aggressive solutions.

Task to be solved by the present invention is directed, is the improvement of tribological characteristics of the coating and give it the properties of a corrosion inhibitor conjugate coated metal friction pairs, with high hardness, toughness and adhesion to the metal substrate.

The technical result is to increase the durability of anti-friction coatings, durability counterface and, respectively, of the friction mechanism as a whole.

This problem is solved and the technical result is achieved due to the fact that the anti-friction coating consists of three layers - the inner, intermediate, and upper, and the inner layer is made of a composition containing a polyimide varnish - 90 parts by weight and alumbramiento bunch - 10 parts by weight, the intermediate layer is made of pure polyimide varnish - 100 parts by weight and the upper layer is made of a composition containing a polyimide varnish - 90 parts by weight, colloidal graphite - 8 parts by weight and lecithin - 2 parts by weight, the thickness of the inner layer is in the range from 8 to 10 μm, the thickness of the intermediate layer is ranging from 16 to 20 μm, and the thickness of the upper layer is in the range from 24 to 30 μm. The top layer is polished to the desired thickness.

In anti-friction coating each SL the St and its components have its own function.

First of all, the use of polyimide varnish PAK as the matrix of the coating layers allows the floor to work in the friction nodes used in chemically active environments at temperatures up to 300°C.

High physical-mechanical properties of polyimides in comparison with other polymers, including hardness and ultimate tensile strength, allow for mechanical grinding and polishing polyimide coatings. This, in turn, allows the manufacture of industrial parts precision machinery, such as pumps, with a steadily recurring dimension of the gaps in tribocharging.

High wetting properties of polyimide varnish and related uniform thickness allow the coating process by using conventional methods, for example by dipping, brush or spray gun.

The inner layer of the cover - "adhesive" is used to increase the adhesion of the polymer coating to the metal surface such as the surface of the drive shaft gear pump. Introduction alumbramiento ligaments related to inorganic adhesives, polyimide matrix helped to create the inner layer with high adhesion to the metal substrate that can withstand up to 300°and stores in the high hardness. This layer by its physical-mechanical properties, including compressive strength, tensile, impact and Flexural significantly higher than the characteristics of other organic coatings.

The intermediate layer coating - "compensation", made entirely of polyimide varnish, plays the role of a pressure compensator in the case of a temperature increase in tribojunction, for example, when the temperature of the pumped by the pump environment.

The top layer of the coating is "anti-friction" that performs multiple functions. The composition of colloidal graphite s-1 with a polyimide varnish gives the coating properties salesmanagement. Introduction in the polyimide matrix method, which is a corrosion inhibitor, allows you to create friction on the surface of the counterface thin film that prevents corrosion and mechanical wear, such as wear of the gear housing of the dosing pump when rotating in him the drive shaft on the floor. It is the top layer of the coating is subjected to mechanical precision grinding, and precision products polishing to achieve the rated accuracy of the dimensions of the cover and roughness of its surface.

During the performed tests indicate that the physico-mechanical and tribological characteristics of the thickness of each layer of antifriction pok is itia. The best results were achieved when the thickness of the inner layer was in the range of from 8 to 10 μm, the thickness of the intermediate layer was in the range of from 16 to 20 μm, and the thickness of the upper layer ranged from 24 to 20 microns.

The main elements of technology for anti-friction coatings are:

- preparation of the compositions of the layers;

- the formation of layers on steel surfaces with step thermoimidization intermediate layers;

- high-temperature heat treatment;

- precision grinding of the upper layer (in the case of manufacturing precision products - polishing).

The preparation of the composition of the inner layer of the coating comprises combining and mixing 90 parts by weight of polyimide varnish and 10 parts by weight of alumbramiento ligaments in the stirrer vane type liquid polymers with a characteristic viscosity of 0.6...1.2 V for 10-15 min until complete homogenization.

The preparation of the composition of the top layer includes combining and mixing 90 parts by weight of polyimide varnish, 8 parts by weight of graphite and 2 parts by weight of lecithin in the mixer of the same type for 15-20 min until complete homogenization.

The formation of the inner layer of the coating is carried out by applying the composition with a brush on the metal surface, the exposure to full spreading and termoemcali at 427°C for 1 h is CA. The thickness of the layer is in the range of 8 to 10 μm.

The formation of the intermediate coating layer is 2 to receive:

- application 1-layer net polyimide lacquer brush on the surface of the inner layer of the coating, exposure to full spreading and termoemcali at 427°C for 1 hour. The thickness of the 1st layer is in the range of 8 to 10 μm;

- drawing 2-layer polyimide lacquer brush on the surface of the 1st layer, the exposure to full spreading and termoemcali at 427°C for 1 hour. The thickness of the 2nd layer is in the range of 8 to 10 μm, and the thickness of the intermediate coating layer is in the range 16...20 microns.

The formation of the upper layer coating is carried out in 3 doses:

- application 1-layer composite brush on the surface of the intermediate layer coating, exposure to full spreading and termoemcali at 427°C for 1 hour. The thickness of the 1st layer is in the range of 8 to 10 μm;

- drawing 2-layer composite brush on the surface of the 1st layer, the exposure to full spreading and termoemcali at 427°C for 1 hour. The thickness of the 2nd layer is in the range of 8 to 10 μm;

- application of 3-layer composite brush on the surface of the 2nd layer, the exposure to full spreading and termoemcali at 427°C for 1 hour. The thickness of the 3rd layer is within the 8 to 10 μm, and the thickness of the top layer of the coating is within 24-30 ám.

This layering of paint and the compositions of the intermediate layers 8 to 10 μm and their thermoimidization at a temperature of 427°allows us to produce a coating with high physical-mechanical characteristics with virtually no internal stress after the heat treatment.

After formation of the coating is high temperature heat treatment by heating and aging of coatings in vacuum at temperatures of 250°C (1 hour)300°C (1 hour), 350°C (1 hour) and 400°With (30 min).

After cooling the product is covering up to 20±2°is made With precision grinding of the upper layer (in the case of manufacturing precision products - polishing).

If necessary, the coating on the body of rotation, for example on the shaft of gear pump, polyimide varnish and composition of the layers applied to the shaft of the brush, after which the shaft is installed on the device and is driven with a speed of 300 rpm With this method of molding is ensured uniformity and thickness of the coating layers to the extent necessary.

Performed laboratory and pilot testing of anti-friction coatings in comparison with its prototype.

Laboratory tests of the coating was carried out on the end machine friction. Covered the e was applied on a metal substrate of steel H, and as counterbody used gear pumps of the same steel. Sliding speed V=0.05 m/s, pressure P=15 MPa, Wednesday - acidic solution of aramid fibers, containing 1.5% hydrochloric acid. The floor of the prototype was applied in accordance with the description EN 2211260, CL SS 28/00, 27.08.2003. In table 1 and table 2 show the results of the tests. Linear wear was determined by the base points on optimate with multiplier 1 μm. 1, 2, 3 is the number of samples.

Table 1
FloorHardness, conventional units, GOST 5233-76Ultimate tensile strength, MPa
123123
Anti-friction coating0,760,710,73165178171
Floor-prototype0,480,520,53545962

Table 2
FloorThe coefficient of frictionThe wear rate of the coating, 1·10-9 The intensity of wear of the counterbody, 1·10-9
123123123
Antifriction0,040,030,041,92,11,82,12,12,2
floor
Floor-prototype0,050,050,042,62,62,34,8a 4.94,3

From the results of laboratory tests, it follows that the tribological characteristics of anti-friction coatings is higher than that of the prototype. This is especially noticeable in the analysis of the wear counterface, which confirms the effectiveness of the introduction of the coating of the corrosion inhibitor of lecithin. The hardness and ultimate tensile strength of the proposed coating is higher than that of the coating of the prototype, which probably allows the mechanical grind and Polish the proposed coverage.

Pilot testing of anti-friction coatings show is on gear pumps-dosing, pumping aggressive solutions aramid fibers at JSC "the company". Anti-friction coating and coating-the prototype was applied to the drive shaft of the pump, and operating time were determined their effectiveness. The counterbody was a cast iron housing. As a result, the operating time of the pump with the shaft, covered with anti-friction coating, amounted to 768 hours, coated prototype - 1778 hours.

Thus, the proposed anti-friction coating has a high level of properties and ensure the reliability and durability of the friction gear pumps and other machinery operating in harsh environments.

As can be seen from the description of the proposed anti-friction coating involves an inventive step and can be protected by a patent of the Russian Federation.

Anti-friction coating consisting of three layers: an inner, an intermediate and a top, wherein the inner layer is made of a composition containing a polyimide varnish 90 parts by weight and alumbramiento a bunch of 10 parts by weight, the intermediate layer is made of pure polyimide varnish 100 parts by weight and the upper layer is made of a composition containing a polyimide varnish 90 parts by weight, colloidal graphite 8 parts by weight and lecithin 2 parts by weight, and the thickness of the inner layer is in the range from 8 to 10 μm, the thickness of the intermediate layer is within 16 to 20 microns, the thickness of the upper layer is in the range from 24 to 30 μm, and the required thickness of the coating is achieved by grinding the top layer.



 

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