表面处置简介防腐.ppt

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style,*,表面处置简介_防腐,目录,表面处理的分类,金,属腐蚀的介绍,防腐表,面处理方,式分类,发黑,防锈剂,热浸锌,电镀,钝化,磷化,电泳,达克罗及环保达克罗,喷,漆表面处理方式,防腐能力排序,表面处理的分类,按照表面处理的功用，大致可以分为以下三类,：,防腐表面处,理,表面处理方式的目的是为了减缓基层材料的腐蚀速度。主要的处理方式如下：,发黑,/,蓝；,涂,油；,磷,化；,电,镀；,铬酸盐钝化；,电,泳；,达克,罗。,美观,表面处,理,表面处理方式的目的是为,了增加基材的颜色及表面光泽度。,主要的处理方式如下：,镏金；,面漆；,达克罗；,铬酸盐钝化,。,改变物体特性,表面处,理,表面处理方式的目的是为,了改善基,材,的物理特性（硬度，摩擦系数，导电性等）。,主要的处理方式如下：,渗碳,渗氮,磷,化,电,镀金,/,银,金属腐蚀的介绍,金属的腐蚀的过程是金属和周围介质作用转变成金属化合物的过程，实际上就是金属和介质之间发生氧化还原反应。,根据反应条件的不同可分为：,化学腐蚀：氧化剂直接与金属表面的原子碰撞、化合而形成腐蚀产物。即氧化还原在反应粒子相碰撞的瞬间直接于相碰撞的反应点上完成。,电化学腐蚀：金属表面与电解质溶液接触发生电化学反应，反应有着两个同时进行却又相对独立的过程。金属放出自由电子成为阳离子的反应称为阳极反应。接受电子的反应称为阴极反应。原电池的电化学过程是由阳极的氧化过程、阴极的还原过程以及电子的转移过程组成。,腐蚀过程演示,析氢腐蚀,吸氧腐蚀,条件,水膜呈酸性,水膜呈中性或酸性很弱,电极反应,负极,正极,总反应,Fe-2e=Fe,2+,2H,+,+2e=H,2,Fe+2H+=Fe,2+,H,2,2Fe-4e=2Fe,2+,O,2,+2H,2,O+4e=4OH,-,2Fe+2H,2,O+O,2,=2Fe(OH),2,4Fe(OH),2,+2H,2,O+O,2,=4Fe(OH),3,钢铁的析氢腐蚀和吸氧腐蚀比较,金属腐蚀的介绍,防腐表面处理方式分类,根据金属腐蚀的原理，我们可以从,阻断金属材料与氧化剂,/,电解质接触,和,提供足量的电子,两方面阻断腐蚀的发生。,根据处理方式的不同，可以将防腐处理方式大致分为以下三类：,化学处理,化学处理是指用化学方法使金属表面生成化合物保护膜，已达到防腐目的的方法,。,生,产中常用的有以下两种：,发,蓝处理（发黑）,磷,化（磷酸盐处理,）,铬酸,盐钝化,电化学处,理（阴极防护）,电化学处,理是,指选择电极电位低的金属，安装在被保护的金属上，或用导线与被保护的金属相连。当发生电化学腐蚀时，电位低的金属（阳极）被腐蚀，被保护的金属（阴极）不会腐蚀。此法也称阴极保护法。,阳,极材料一般是锌、铝、镁等活泼金属,。,阴极保护法常用于船体外壳、锅炉、海底设备和地下管道等,。,生,产中常用,的是,ICCP,（,Impressed,C,urrent Cathodic Protective),外加阴极防护：,覆盖,法,覆盖法是指在金属表面覆盖一层耐蚀材料（金属或非金属），以达到防腐目的的方法,。,金,属覆盖法,金属覆盖法是将活泼性很小，有较高抗蚀能力的金属覆盖在被保护的金属表面，以达到防腐目的的方法。常用的方法有以下几种,：,电,镀法,热,镀法,包,渡法,非金属覆盖法,涂,料涂装法,涂,防锈油法,ICCP,防腐表面处理方式分类,化学处,理,发蓝处理（发黑）,磷,化；,铬酸盐钝化,；,电化学处,理（阴极防护,/,李代桃僵,）,覆,盖,法,金,属覆盖,法,热浸（,镀）锌,机械锌（包镀锌）,电镀锌,/,铝,/,锡,/,镍,/,铜,/,铬,达克罗（久美特，美加力，德尔肯）,非,金属覆盖,法,涂料涂装法,涂防锈油法,Anti-rust,Anti-corrosion treatment Y 7000,Y 7000,STD 121-0009,Anti-rust treatment Y 700,Y 700,STD 5771,7,Not for new design,Catholically,protective,Cathodically protective for Tubes and Tube fittings Y 400,Y 400,STD 121-0006,Non-electrolytically applied zincflake coating,separately or in combination with organic coating Y 530,Y530,STD 5752,53,Cathodically protective with friction requirement Y 1000,Y 1000,STD 121-0003,not for new design,Cathodically protective without friction requirement Y 2000,Y 2000,STD 121-0004,Flake cathodic protective surface treatment with friction requirements,Y 1200,Y 1200,STD 121-0012,Electrolytic cathodic protective surface treatment with friction requirements,Y 1300With or without sealer,Y 1300,STD 121-0013,Electro-,Chromium Plating Y 110,Y 110,STD 5732,11,not for new design,Chromium Plating Y 120,Y 120,STD 5732,12,Nickel plating Y 109,Y 109,STD 5732,109,Electro coat paint(EC paint)98121,EC painting,STD 1281,21,Electroplated coating of Tin Y 108,Y 108,STD 5732,108,Electroplated coating of Zinc with chromating Y 105,Y 105,STD 5732,105,Not for new design,Electroplated coatings of,zinc-iron with chromating,Fe/Zn-Fe C,STD 5732,104,Not for new design,Phosphating,Phosphating Y 104,Y104,STD 5742,104,Painting,Painting Y 520Zinc-chromate metal and organic coating,Y 520,STD 5752,52,not for new design,painting Y 500,Y 500,5751,5,not for new design,painting Y 511,Y 511,STD 5751,511,painting Y 550,Y 550,STD 5751,55,not for new design,painting Y 600,Y 600,STD 121-0001,painting Y 650,Y 650,STD 121-0002,K1,K2,K3,K4,K1,2,3,4,STD 5751,51,Not for new design,Hot dip,Hot dip galvanized coatings Y 111,Y 111,STD 5733,111,Not for new design,沃尔沃标准,将经过清洗的钢在空气、水蒸气或含有,NaOH,、,NaNO2,等氧化性介质中加热，使钢表面生成一层致密的蓝色（,550,）,或黑色（,130,）的,Fe3O4,氧化膜，以改善钢的耐蚀性和外观，这种工艺称为发蓝处理（发黑）。,能否把铁氧化成致密、光滑的,Fe3O4,关键是选择好强的氧化剂。强氧化剂是由氢氧化钠,(NaOH),、亚硝酸钠,(NaNO2),、磷酸三钠,(Na3PO4),组成。发蓝时用它们的熔融液去处理工件；发黑是用它们的水溶液去处理工件。,化学反应机理：,钢铁浸入溶液后，在氧化剂和碱的作用下，表面生成,Fe3O4,氧化膜，该过程包括以下三个阶段：,钢铁表面在热碱溶液和氧化剂（亚硝酸钠）的作用下生成亚铁酸钠,3Fe+,NaNO2+5NaOH=3Na2FeO2+H2O+NH3,亚,铁酸钠进一步与溶液中的氧化剂反应生成铁酸,钠,6Na2FeO2+NaNO2+5H2O=3Na2Fe2O4+7NaOH+NH3,铁,酸钠,（,Na2Fe2O4,）,与亚铁酸钠,（,Na2FeO2,）,相互作用生成磁性氧化,铁,Na2Fe2O4+Na2FeO2+2 H2O=Fe3O4+4NaOH,在钢铁表面附近生成,的,Fe3O4,，,其在浓碱性溶液中的溶解度极小，很快就从溶液中,结晶,析出，并在钢铁表面形成晶核，而后晶核逐渐长大形成一层连续致密的黑色氧化膜,。,发,蓝（发黑）的操作过程,：,工件装夹去油清洗酸洗氧化清洗皂化热水煮洗检查。,应用特点：,发蓝,/,黑工艺，操作简单，成本低。被应用于转运，暂储。如捆带钢,又称包装用钢带。,发蓝时，工件的尺寸和光洁度对质量影响不大。故常用于精密仪器、光学仪器、工具、硬度块及机械行业中的标准件等。,发黑,/,蓝,金属加工件在生产加工及运输的过程中，很容易生锈，这就需要使用防锈油在金属表面形成一层薄膜，防止金属锈蚀的化学品。,防锈剂是一种超级高效的合成渗透剂，它能强力渗入铁锈、腐蚀物、油污内从而轻松地清除掉螺丝、螺拴上的锈迹和腐蚀物，具有渗透除锈、松动润滑、抵制腐蚀、保护金属等性能。并可在部件表面上形成并贮存一层润滑膜，可以抑制湿气及许多其它化学成份造成的腐蚀。,防锈剂可分为,工序间,与,工序后,的防锈剂，,工序间的称为防锈剂，,工序后的,称为,防锈封闭剂,。,防锈,剂分类：,溶剂型防锈,剂。,溶,剂蒸发后，形成一层软的脂膜,。,水基防锈,剂,水溶性防锈化合,物,(,亚硝酸盐）、,水溶性助剂、溶剂和水组,成。,油性防锈剂,产品采用精制程度较高的矿物油为基础油，并添加防锈、抗氧,化,等,多种进口添加剂依日本精湛配方研制而成,。,VCI,气相防锈膜,气相防锈膜,1,系列产品是将现代薄膜技术与气相防锈（,VCI,）,技,术结合，以,PE,树脂与,VCI,经特殊工艺共混共挤吹塑而成,。,蜡膜防锈,剂,由成膜剂和高效缓蚀剂以及基础油调配而成的稀释型防锈油,。,其他漆状及凡士林类,防锈剂应用特点：,操,作,方便，可浸泡操,作。,具,有良好防锈功能。,水,基型溶液，无毒无味，安全不起火。,使,用与废液处理方便、绝对环保。,对,工件无影响，保持工件原有面貌。,Materials in classes-1 to-4 are intended for,protection during transportation and/or as a,supplementary corrosion prevention.,Materials in classes-5 and-6 are intended for,long-term use and are thus not intended to be,removed.,Materials in class-11 are intended for long-term,use and are thus not intended to be removed.,Y7000-1,shall be indicated for materials subjected to marginal corrosion,e.g.indoors,where temperature and humidity fluctuate(risk of condensation).,Test duration 3,months.,Outdoors,under roof,no salt sprayGeneral corrosion Ri1 Acc.to STD 420-0002,STD 1027,1372Accelerated outdoor exposure,Y7000-2,is reserved for future needs.,-,Y7000-3,shall be indicated for materials subjected to intensive corrosion,e.g.outdoors in coastal regions,outdoorsin industrialized areas with aggressive air,in large urban areas or covered transportation by sea.,Accelerated corrosion test,Test duration 1 weekGeneral corrosion Ri1 Acc.to STD 420-0002,STD 423-0014 Accelerated corrosion test Atmospheric corrosion,Y7000-4,shall be indicated for visible parts on complete vehicle that are not surface treated in some other way,e.g.painted and not subjected to mechanical wear.Showroomappearance required at delivery.,Accelerated corrosion test,Test duration 1 weekGeneral corrosion Ri0 Acc.to STD 420-0002,STD 423-0014 Accelerated corrosion test Atmospheric corrosion,Y7000-5,shall be indicated for materials which in addition to extensive corrosion are also subjected to mechanical wear,e.g.the underbody of vehicles.,Tested on relevant substrates 6 weeksSubstrate 8 mm,Zinc-coated 4 mm,STD 423-0014 Accelerated corrosion test Atmospheric corrosion,Y7000-6,shall be indicated for materials which in addition to extensive corrosion are also subjected to severe mechanical wear,such as striking gravel,e.g.on the inside of the wheel housing.,Tested on relevant substrates 6 weeksSubstrate 8 mm,Zinc-coated 4 mm,STD 423-0014 Accelerated corrosion test Atmospheric corrosion,Y7000-11,shall be indicated when it is necessary for the material to have good penetration properties,e.g.in crevices and cavities.,Tested on relevant,Accelerating corrosion testGeneral corrosion Ri0 Acc.to STD 420-0002,STD 423-0014 Accelerated corrosion test Atmospheric corrosion,Anti-rust,Y 7000,STD 121-0009,Y 700,STD 5771,7,Not for new design,沃尔沃防锈剂标准,防锈剂,防锈剂,应用,“山泉”牌,E99-1,汽车表面防护,蜡,E99-1,汽车表面防护蜡涂布性好，易喷涂，对各种漆膜和金属有很好的附着力，形成的保护膜均匀细腻、连续密实，保护膜耐热性好（耐热,80,以上）、耐候性好，耐酸碱性好，耐盐雾性好，且此保护膜去除工艺简单。,E99-1,汽车表面防护蜡主要用于汽车、工程机械、农业机械等大型设备在贮存运输过程中的漆膜保护，特别是海运出口时的漆膜防护。,技术性能参数：,1.,外观,:,乳白色可摇溶液体,2.,粘度,(,涂,-4,杯,25,):12-18s,3.,不挥发分含量,:13-18%,7,.,耐盐雾性,:,膜厚,10-15um,：被涂底材为未处理钢板：,96h,无,锈蚀,被涂底材为氨基醇酸漆板：,192h,无锈蚀,长,期防锈,剂,MSDS-LONG#2 Spray,外观：半褐色,气味：淡甜味,Ph,：,无资料,水溶解性：不溶解,沸点：,104,熔点：无信息,饱和蒸汽压,(mmHg/20,),：无资料,比重,(H2O=1),：,0.80,0.05,蒸汽密度,(Air=1),：无资料,蒸发率,(Ether=1),：无资料,PDS-LONG#2,长期防锈剂,强力防锈剂（室内：,3,年，室外：,2,年）,可形成强力的蜡状皮膜。,优秀的水置换性。,防锈力：可在湿气、空气、酸、碱、盐或其蒸汽中形成强力的蜡状保护膜，维持强力的防锈力。其防锈时间为；屋内,3,年，屋外,2,年，可适用于船舶、航空机、各种化工厂。,润滑力：具有高度的耐磨耗、耐磨擦、耐热性，以优秀的渗透力可迅速渗透到细微的缝隙中发挥其防锈、润滑效果。并且其密着性好，不易被除去，保护水或海水中装备。,水置换力：表面张力小，渗透力强，并且发水及水置换力优秀，发挥良好的绝缘作用。,也适合用于电气系统的保护。,安定性：除盐系溶剂外不含硅类，因此不损伤塑料、橡胶、油漆、纤维、电线、镀金部位等。该产品是未使用破坏环境的氟利昂系喷射剂的环保性产品，可以使用在启动中的装备,。,4.,不挥发分滴点,:,80,5.,涂层状态,:,连续蜡状膜,6.,干燥时间,(,指干,):,1h,TOTAL OSYRIS DWX K 9000,USES,Developed for long term anti-rust of metal parts with hard wax as solvent dilution type rust preventive oil,Use for indoor and outdoot of all metal materials,Easy to remove the film with solvent type cleaner.Proper for parts for export and big parts required outdoor stored,PROPERTIES,Maintain good rust preventive performance for over 250hrs,indoor:3 year,Outdoor:12months,May be applied by Spraying,by Dipping,by Brushing,VCI,气相防锈,膜,热镀,的原,理及工艺,热镀锌,锌镀,层,的防护原理,热镀,锌产品的质量要求,Hot dip,Hot dip galvanized coatings Y 111,Y 111,STD 5733,111,Not for new design,沃尔沃标准,热浸锌（热镀锌）,热镀的原理及工艺,热镀法,是指将金属短时间浸入熔融耐蚀的金属液中，取出冷却后，在金属表面形成覆盖的方法。钢板、钢管、钢丝等经热镀锌，可防大气、水腐蚀；热镀法不会产生有毒盐，常用于制作食品罐头。热镀层与金属表面结合牢固，热镀法操作简单，生产率高，应用广泛。,热镀锌工艺过程,工件脱脂水洗酸洗水洗浸助镀溶剂烘干预热热镀锌整理冷却（钝化）漂洗干燥检验,镀前处理脱脂,清除在防锈处理、机械加工过程沾上的油脂,镀前处理酸洗,清除表面的铁的氧化物；硫酸,/,盐酸,水冷和钝化,水冷镀层光亮，方便运走整理；,钝化,-,目的是提高工件表面抗大气腐蚀性能，减少或延长白锈出现时间，保持镀层具有良好的外观。都用铬酸盐钝化。,钝化,热镀锌,酸洗,酸洗,热浸锌（热镀锌）,热浸锌,是由较古老的热镀方法发展而来的，自从,1836,年法国把热镀锌应用于工业以来，已经有一百七十多年的历史了。,热浸锌,是非常优良的一种防腐处理。它是在锌呈液体的状态下，经过了相当复杂的物理、化学作用之后，在钢铁上不仅镀上较厚的,纯锌层,，而且还生成一种,锌铁合金层,。,热镀锌层防护性能,通常电镀锌层厚度,5,15m,，而热镀锌层一般在,35m,以上，甚至高达,200m,。热镀锌覆盖能力好，镀层致密，无有机物夹杂。这使得热浸锌具备了电镀锌所无法相比拟的强耐蚀性。因此这种镀法特别适用于各种强酸、碱雾气等强腐蚀环境中。,优点具体表现如下：,镀层完整、均匀,：,整,个钢材表面均受到保护，无论在凹陷处管件内部，或任何其它涂层很难进入的角落，溶化锌容易均匀的覆盖上。,镀层坚硬,：,镀,锌层的硬度值比钢材还大。,独,特的边角保护,。,在,边角区，锌层往往比其它地方还厚，且有良好的韧性及抗磨耗性。而其它涂层在此边角处，往往是最薄、最不易施工且最易受伤害处，故常须再维护。,双,重保护,：,屏,障及牺牲阳极保护阴极。即使因受很大的机械伤害或其它原因，造成一小部份的锌层脱落，将铁基裸露。此时，周围锌层就会发挥牺牲阳极的功能，来保护此处钢铁，使其不受侵蚀。而其它涂层则刚好相反，铁锈会马上生成，且迅速漫延至涂层下面，引起涂层剥落。,锌,层在大气中的消耗非常缓,慢,锌层也会发生腐蚀，但腐蚀速率约为钢铁腐蚀速率的,1/17,至,1/18,，且是可预估,的。,热镀锌的防腐年限久远,热镀锌产品在不同的环境中防腐年限不一样：重工业区,13,年，海洋,50,年，郊外,104,年，城市,30,年。镀层寿命在某一特定的环境下，主要视镀层厚度而定,。,应用：,广泛运用于冷轧带钢，电力铁塔、通信铁塔、铁路、公路防护、路灯杆、船用构件、建筑钢结构构件、变电站附属设施、轻工业等。,锌镀层的防护原理,机械保护,在大气腐蚀条件下锌层表面有,ZnO,、,Zn(OH)2,及碱式碳酸锌保护膜，一定程度上减缓锌的腐蚀，这层保护膜,(,也称白锈,),受到破坏又会形成新的膜层。,电化学保护,当锌层破坏严重，危及到铁基体时，锌对基体产生电化学保护，锌的标准电位,-0.76V,，铁的标准电位,-0.44V,，锌与铁形成微电池时锌作为阳极被溶解，铁作为阴极受到保护。,锌层对钢铁腐蚀的保护过程,表,面的镀层完整，锌层对钢材进行物理保护，锌在大气中被腐蚀；,镀,层中的合金层暴露于大气中，锌层对钢材进行物理保护，由于电极电位的不同，纯锌层对合金层提供阳极保护而优先腐蚀；,纯,锌层腐蚀完毕，合金层完整，合金层对钢材提供物理保护，发生的腐蚀是,Zn-Fe,合金层在大气中的腐蚀；,镀,层部分破损使钢板局部裸露于大气中，由于,Zn,、,Fe,和,Zn-Fe,合金的电极电位分别为,-0.762v,、,-0.439v,和,-0.59-0.66v,，所以发生的腐蚀是,Zn,的电化学腐蚀，锌对钢基提供阳极保护；,纯,锌层腐蚀完毕，钢铁部分裸露在大气中，合金层对钢铁阳极,保护；,全部镀层消耗完毕，发生钢铁腐蚀。,热镀锌产品的质量要求,热镀锌产品质量主要包括如下四个部分,:,外观,镀件主要表面、内构面、连接部位等光滑整洁，色泽一致。不允许有磕碰、锌刺、锌瘤、积锌、锌灰、挂具痕迹、流痕、叠痕等异物及异形突起等外观缺陷存在；,构,件焊接部位、角棱、死角、结构内部等部位应无锌灰、积锌、返锈水现象等。如有，必需修复，否则不合格。,镀,件表面不能有打磨痕迹。,连,接部位：丝孔及连接面应无积锌、无锌瘤、锌刺等。,镀,件不允许变形。,锌,层厚,度,锌,层厚度直接决定了热镀锌产品的防腐蚀年,限；,锌,层附着,力,附着力主要是衡量镀件的锌层与基体金属结合牢固程度，镀锌层经锤击试验锌层不剥离、不凸起。,镀,层均匀,性,镀锌层应均匀，以防止局部过早腐蚀，影响钢制件的整体使用寿命。,微观,锌花,截面,灰暗镀层,漏镀,表面粒子,电镀的原理,电镀的工艺,电解液的组成,镀层的评价,电镀的种类,镀锌,Electro-,Chromium Plating Y 110,Y 110,STD 5732,11,not for new design,Chromium Plating Y 120,Y 120,STD 5732,12,Nickel plating Y 109,Y 109,STD 5732,109,Electrocoat paint(EC paint)98121,EC painting,STD 1281,21,Electroplated coating of Tin Y 108,Y 108,STD 5732,108,Electroplated coating of Zinc with chromating Y 105,Y 105,STD 5732,104STD 5732,105,Not for new design,Electroplated coatings ofzinc-iron with chromating,Fe/Zn-Fe C,STD 5732,104,Not for new design,沃尔沃标准,电镀,电镀的原理,电镀过程是镀液中的金属离子在外电场的作用下,经电极反应还原成金属原子并在阴极上进行金属沉积的过程。,完成电沉积过程必须经过以下三个步骤,液相传质,镀液中的水化金属离子或络离子从溶液内部向极界面迁移,到达阴极的双电层溶液一侧。,电化学反应,水化金属离子或络离子通过双电层,并去掉它周围的水化分子或配位体层,从阴极上得电子生成金属原子。,电结晶,金属原子