The world's thermal spraying has a history of 100 years, and China's thermal spraying has a history of nearly 50 years. Especially in the past two decades, China's thermal spraying has made great progress and development. Below, we will briefly introduce the overall level and status, equipment and materials, applications, research and development.
1. Overall level and status
According to incomplete statistics, during the “Eighth Five-Year Plan†period (1991-1995, including 1996), the total output value of China's thermal spraying industry was about 300 million yuan (including thermal spraying equipment, materials, construction and technical services, auxiliary equipment materials, etc.). ). In 1996, China’s national economic output value was about 7.5 trillion yuan (about 910 billion US dollars), and thermal spray production value accounted for about 0.39/10000>.
According to the basic situation of the association, there are about 3,000 people in the national thermal spraying industry (excluding temporary workers in the construction team), and the units engaged in thermal spraying work are 300~350, including thermal spraying equipment, materials, auxiliary machines and auxiliary materials production plants. , thermal spraying construction, technical service units, as well as research, teaching, development units and trading companies engaged in thermal spraying.
The thermal spraying unit is still a small unit (<30 people), accounting for more than 90% of the total. The per capita output value of the thermal spraying industry is about 100,000 yuan per person per year, which is among the best in the machinery industry (premium level).
According to foreign materials, in recent years, the total output value of thermal spray in the United States is about 2 billion US dollars, and Japan is 80 billion yen, accounting for 3.6/10000 and 2.3/10000 of its gross national product (GNP), respectively. The ratio of the thermal spray production value to the GNP weight is an important indicator of the development of thermal spray in the country. This ratio in China is only 11% in the US and 17% in Japan. This shows that China's thermal spraying is still in the development stage, far from reaching the stage of maturity and saturation. For this reason, thermal spraying has a vast market in China, and there are many opportunities and development prospects.
2. Thermal spraying equipment and materials
After decades of independent development and introduction, and drawing on advanced foreign technology, China has been able to develop and produce vacuum plasma, atmospheric plasma, explosive spraying, plasma surfacing, arc spraying, flame powder coating, flame wire spraying equipment, and metal production. Powder (Ni, Co, Fe based, total about 300t / year), ceramics, cermet powder (Al2O3, Al2O3 + TiO2, Cr2O3, WC-Co, etc., total about 200t / year), wire (Al, Zn, Cu, Stainless steel, etc., totaling about 1000t/year). Although the overall level of equipment is still not high, there are still some quality problems in the material, but China has become one of the few countries in the world that can be self-sufficient in thermal spraying equipment and materials, basically meeting the needs of the thermal spraying industry. . At the same time, about 10% of equipment and materials still need to be imported.
3. Application of thermal spraying technology
At present, thermal spraying technology has been widely used in China. The main application fields are aviation, aerospace, steel, petrochemical, steel structure anti-corrosion, machinery, light industry, textile, paper, energy, ship, etc., with a total output value of about 200 million. Yuan/year. China's thermal spray applications have the following characteristics:
(1) It has a wide range of applications and has a fairly high level in certain fields, such as aero engines (cooperating with Boeing), annealing furnace bottom rolls, galvanized guide rolls (steel industry), valves (petrochemical industry), wire drawing rolls, towers Wheels, drawing rings, etc. (textile industry), high-grade glass molds (light industry), valves (automobile industry), etc.
(2) A wide range of processes and materials are used. Almost all the thermal spraying processes and materials used in the world are used in China, such as vacuum plasma spraying, atmospheric plasma spraying, explosive spraying, supersonic flame spraying, arc spraying, flame powder spraying, plasma. Surfacing, laser remelting, vacuum (protective atmosphere) remelting, etc.
(3) Enterprises engaged in thermal spray application (Job Shop) are mainly small and medium-sized enterprises (<30 people), accounting for 2/3 of the total, and the output value accounts for more than 75% of the total output value. Share-holding cooperative enterprises, private enterprises, and collective enterprises accounted for a considerable proportion, and joint and sole proprietorship enterprises began to appear.
(4) The maintenance methods of thermal spraying as equipment and components are relatively developed. For medium and small thermal spraying enterprises, more than half of the work is aimed at repairing.
(5) Research institutes and research institutes of research institutes, universities and colleges, such as welding (more than half), materials, surface processing and other professions, actively enter the domestic thermal spray market. The main technical force of thermal spraying in China is also in the above units.
At present, the main problems in application are small scale, uneven levels, lack of unified management and standards, and the inability to form leading thermal spray companies at home and abroad (such as Tocal in Japan, Praxair in the US, and France). SNMI, etc.).
4. Research and development of thermal spraying technology
The main force of research and development of thermal spray technology in China is still the institutes and universities. The overall level of thermal spray research and development in China (team, R&D conditions and equipment, R&D results, paper level and quantity) is second only to Japan in Asia, and belongs to the second square in the world (Russia, Rui, France, and English). The first square is for the United States, Germany, and Japan. The 14th International Thermal Spraying Conference published 16 papers, ranking fourth. The 15th International Thermal Spraying Conference is expected to publish 15 papers, which is also in the forefront.
In terms of equipment, R&D mainly focuses on the development of vacuum plasma spraying, supersonic flame spraying (HVOF), supersonic arc spraying equipment, development of explosive spraying, plasma spraying, flame plastic spraying equipment; in the process, focusing on composite processes, such as spraying +Laser remelting/induction calming/vacuum remelting, self-propagating process (such as core wire, MCrAlY, etc.) spraying process of new materials; material research on ceramic powder, such as Al2O3+TiO2 powder production process, and McrAlY, 50Cr50Ni , bio-engineering materials, rare earth elements, etc.; in coating design, performance, organization, testing, evaluation and control, focus on TBC coating, high temperature resistant cermet coating, bioengineered coating composition, stress Research on the role of distribution, organization, and interface.
The problems in R&D are mainly insufficient funds, research equipment aging, repeated topic selection, few international frontier research topics, high-tech research and high-tech information research, and low level of “pure†academic research topics, oriented to applications and markets. The research and development topics are not well integrated due to the combination of demand, "high should not, low is not", the above problems urgently need to be resolved.
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