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CN-121977961-A - Wear-resistant composite coating performance test method for axial flow stirrer

CN121977961ACN 121977961 ACN121977961 ACN 121977961ACN-121977961-A

Abstract

The invention belongs to the technical field of coating performance test, and particularly relates to a wear-resistant composite coating performance test method of an axial flow stirrer. And extracting thickness variation and abrasive tracks to generate a dynamic wear rate curve, integrating multiple data to form a staged analysis data set, analyzing the mechanical properties of micro-areas to construct a failure mechanism map, and supplementing test data to output a full life cycle data set. And verifying the effectiveness by combining the retired blade failure trace, determining an acceleration factor to construct a flow field parameter quantization correlation model, extrapolating the service life of the coating, and predicting the energy consumption trend to form a dynamic performance evolution report. According to the invention, by constructing simulation working conditions, a multidimensional data system and a closed-loop analysis flow, the complex service environment of the blade is re-carved, the fit between the test and the actual service height is realized, the accurate data support and engineering guidance are provided for the evaluation and optimization of the coating performance, and the test scientificity and practicability are improved.

Inventors

  • LI LEI
  • GONG QIAN
  • ZHANG XINAN

Assignees

  • 江苏新合诚化工装备有限公司

Dates

Publication Date
20260505
Application Date
20260403

Claims (10)

  1. 1. The method for testing the performance of the wear-resistant composite coating of the axial-flow stirrer is characterized by comprising the following steps of: S1, collecting initial bonding strength, surface roughness and friction coefficient of a coating, introducing multiphase abrasive fluid, applying periodic pulsating load matched with axial-flow rotational flow frequency, simulating coupling working conditions of rotational flow scouring, centrifugal shearing and load fluctuation of a stirrer blade, and outputting a multi-dimensional dynamic test data set; S2, extracting thickness variation data and an abrasive collision track from the multi-dimensional dynamic test data set, generating a dynamic abrasion rate curve by using a fractal dimension algorithm, and performing space-time correlation integration on the dynamic abrasion rate curve, the strength retention rate, the three-dimensional morphology and the roughness data by using a regional abrasion contribution rate algorithm to form a staged analysis data set; S3, analyzing the mechanical property distribution of the micro-region of the coating by using the dynamic wear rate curve and the stepwise analysis data set, constructing a failure mechanism map, supplementing the cyclic wear-resistance test data and outputting a full life cycle change data set; s4, comparing the rotational flow scouring characteristic area failure trace of the retired blade with a failure mechanism map, dynamic abrasion data and a full life cycle change data set to verify effectiveness, and determining an acceleration factor by taking flow field shearing force as a variable to construct a flow field parameter quantization correlation model; S5, according to the acceleration factor, the failure mechanism map and the flow field parameter quantization association model, associating the cycle number, the impedance and the wear rate, extrapolating the service life and predicting the energy consumption trend, and forming a coating dynamic performance evolution report.
  2. 2. The method for testing the performance of the wear-resistant composite coating of the axial-flow stirrer according to claim 1, wherein in the step S1, the specific step of outputting the multi-dimensional dynamic test data set is as follows: s11, collecting initial bonding strength, surface roughness and friction coefficient of a coating, calibrating basic performance of a coating sample by a standardized detection means, and integrating after eliminating abnormal data points to form an initial performance data set; S12, selecting a performance standard sample in the initial performance data set, introducing multiphase abrasive fluid, applying periodic pulsating load matched with the rotational flow frequency of the axial flow, and simulating the coupling working conditions of rotational flow flushing, centrifugal shearing and load fluctuation of the blades of the stirrer; And S13, acquiring dynamic response data of the coating under the load according to the coupling working condition, carrying out association calibration on the dynamic data and an initial performance data set, and outputting a multi-dimensional dynamic test data set.
  3. 3. The method for testing the performance of the wear-resistant composite coating of the axial-flow stirrer according to claim 1, wherein in the step S2, the specific steps of forming the stepwise analysis data set are as follows: S21, screening real-time data of each monitoring point position of the coating according to the multi-dimensional dynamic test data set, extracting thickness variation time sequence data and abrasive collision track coordinate data, and forming a standardized monitoring data set; S22, matching the thickness variation, the collision track distribution and the flow field parameters according to the standardized monitoring data set, analyzing the quantitative association rule of the thickness variation, the collision track distribution and the abrasion loss through correlation, and outputting a quantitative association equation and characteristic parameters; S23, correcting the wear rate according to the quantized correlation equation, the characteristic parameters and the track distribution, and fitting to generate a dynamic wear rate curve by taking time as a horizontal axis and the wear amount as a vertical axis; s24, retesting the retention rate of the bonding strength of the coating according to key time nodes in the dynamic wear rate curve, and acquiring three-dimensional morphology and roughness data of the surface at the moment to form a matching performance data set; and S25, integrating the dynamic wear rate curve, the intensity retention rate and the three-dimensional morphology roughness data according to the time and the two-dimensional correlation of the monitoring point position, and archiving after calibrating the data deviation to form a staged analysis data set.
  4. 4. The method for testing the performance of the wear-resistant composite coating of the axial-flow stirrer according to claim 3, wherein in the step S23, the specific step of generating the dynamic wear rate curve is as follows: calculating theoretical abrasion loss of coating layers of different time nodes according to the quantized correlation equation, the characteristic parameters and the track distribution data, and calculating deviation by combining characteristic parameter calibration to obtain corrected abrasion loss basic data; according to the corrected abrasion loss basic data and the area difference of the abrasive collision track distribution, a weight coefficient is given to the abrasion rate of the monitoring point, and area abrasion rate correction is carried out; And according to the corrected abrasion rate of each point, fitting the data points in a nonlinear fitting mode by taking the test time as a horizontal axis and the corrected abrasion quantity as a vertical axis to form a dynamic abrasion rate curve.
  5. 5. The method for testing the performance of a wear-resistant composite coating of an axial-flow mixer according to claim 3, wherein in step S25, the step of forming the stepwise analysis data set comprises the steps of: The time node and the monitoring point of the dynamic wear rate curve are taken as a reference frame, the strength retention rate, the acquisition time of the three-dimensional morphology roughness data and the monitoring point are matched with the reference frame one by one, so that three types of data form a one-to-one association relationship in the space-time dimension, and space-time matching data are output; Establishing a data deviation calibration model according to the working condition parameters of the coating test, substituting the space-time matching data into the data deviation calibration model, correcting the data deviation value, and outputting calibration multisource data; and carrying out structured sorting on the data deviation calibration model, classifying and archiving the data according to time sequences and monitoring point positions, establishing a unified data index and storage format, and outputting a staged analysis data set.
  6. 6. The method for testing the performance of the wear-resistant composite coating of the axial-flow stirrer according to claim 1, wherein in the step S3, the specific step of outputting the full life cycle change data set is as follows: S31, extracting hardness and elastic modulus of different monitoring points and different time nodes from the time-space change characteristics and the stepwise analysis data of the dynamic wear rate curve to form coating time-space distribution data; S32, dividing abrasion, peeling and cracking of the coating and corresponding space-time areas by associating the evolution rule of the dynamic wear rate with the degradation characteristics of the surface morphology of the coating space-time distribution data, and drawing a coating failure mechanism map; S33, determining the load and the frequency of a cyclic wear-resistance test according to the coating failure mechanism map, and collecting wear amount and resistance change data in different failure stages to form cyclic wear-resistance supplementary test data; And S34, combing the coating failure mechanism map, the dynamic wear rate curve, the staged analysis data set and the cyclic wear-resistance supplement test data according to the time sequence of the full service period of the coating, calibrating the data consistency, and outputting the full life period change data set of the coating.
  7. 7. The method for testing the performance of the wear-resistant composite coating of the axial-flow stirrer according to claim 6, wherein in the step S32, the specific steps of drawing the coating failure mechanism map are as follows: extracting the variation trend of hardness and elastic modulus of different hollow nodes in the coating space-time distribution data, corresponding to the dynamic wear rate evolution rule, associating surface morphology degradation characteristics, establishing an intrinsic causal relationship, and forming multidimensional coupling analysis data; Defining failure judgment standards of abrasion, peeling and cracking according to the multidimensional coupling analysis data, and determining failure time nodes and monitoring point location areas; And combing the evolution sequences and associated logics of different failure types according to the failure time nodes and the monitoring point location areas, adopting a visual map to present failure distribution, evolution paths and causes, and drawing a coating failure mechanism map.
  8. 8. The method for testing the performance of the wear-resistant composite coating of the axial-flow stirrer according to claim 1, wherein in the step S4, the specific steps of constructing a flow field parameter quantization correlation model are as follows: S41, extracting coating failure types, space-time distribution and performance attenuation rules according to the failure mechanism map, dynamic wear data and full life cycle change data set, and comparing the coating failure types, space-time distribution and performance attenuation rules with actual failure marks of the rotational flow scouring feature areas of the retired blades to obtain a verification effective map; s42, designing a multi-gradient shear force test working condition according to the verification effective map and the full life cycle change data set, combining the wear rate data, quantitatively calculating acceleration factors corresponding to different shear forces, and outputting an acceleration factor value result; S43, integrating failure inducement in the failure mechanism map and performance parameters in full life cycle data according to the acceleration factor value result, and constructing a flow field parameter quantization association model.
  9. 9. The method for testing the performance of the wear-resistant composite coating of the axial-flow stirrer according to claim 8, wherein in the step S42, the specific step of establishing the association relation between the shearing force and the acceleration factor is as follows: According to the working condition range of the verification effective map and the full life cycle change data set, disassembling the shearing force interval of the actual service flow field, and dividing a plurality of shearing force test gears according to gradients to form a multi-gradient shearing force test working condition scheme; according to the multi-gradient shear force test working condition scheme, working condition abrasion rate and failure period data in the full life cycle change data set are verified, failure time sequence characteristics of an effective map are verified, and a corresponding relation between shear force and abrasion rate and test period is established; And according to the corresponding relation, calculating acceleration factors under different shear force gears by adopting a quantization fitting algorithm, removing abnormal data, calibrating calculation deviation, and outputting an acceleration factor value result.
  10. 10. The method for testing the performance of the wear-resistant composite coating of the axial-flow stirrer according to claim 1, wherein in the step S5, the specific steps for forming a report of the evolution of the dynamic performance of the coating are as follows: S51, according to the acceleration factor, the failure mechanism map and the flow field parameter quantization association model, the cycle number, the electrochemical impedance and the wear rate data in the full life cycle data are called, corresponding association of the three is established, and a multi-parameter association data set is formed; s52, according to the failure critical threshold defined by the multi-parameter association data set and the failure mechanism map, deducing a coating performance attenuation track under different working conditions by using a flow field parameter quantization association model, converting actual service time by an acceleration factor, extrapolating service life of the coating to reach the failure critical state, and predicting energy consumption change trend in different service life stages; and S53, carding the dynamic performance evolution characteristics of the coating according to the energy consumption change trend and the failure cause analysis of the failure mechanism map to form a dynamic performance evolution report of the coating covering the performance change rule, the service life evaluation and the energy consumption prediction.

Description

Wear-resistant composite coating performance test method for axial flow stirrer Technical Field The invention belongs to the technical field of coating performance test, and particularly relates to a wear-resistant composite coating performance test method of an axial flow stirrer. Background The traditional axial flow stirrer wear-resistant composite coating performance testing method has obvious limitations, adopts a plane sample to simulate the shape of a blade, only applies a single load and introduces homogeneous abrasive fluid, and cannot restore the complex working conditions of actual solid-liquid-gas three-phase flushing, flow field shearing force and load fluctuation, so that the testing scene is disjointed from actual service. The data acquisition dimension is single, the space-time dimension alignment and the accurate calibration are lacked, the quantitative association between the flow field parameters and the abrasion loss is not established, only basic performance data can be obtained, and the non-uniform abrasion characteristics of the coating can not be reflected. And only simple performance detection is performed, partitioned micro-area mechanical test and in-situ failure tracking are not performed, accelerated test effectiveness verification is not performed, a corrosion-abrasion coupling failure mechanism cannot be excavated, the service life of the coating cannot be extrapolated, the energy consumption is predicted, only basic performance judgment can be performed, and targeted engineering guidance cannot be provided for coating optimization. Disclosure of Invention In order to make up the defects of the prior art, the invention provides a method for testing the performance of the wear-resistant composite coating of an axial-flow stirrer. The method is mainly used for solving the problems that the conventional test working condition has low fitting degree, the data lacks quantitative association, and the failure essence and the extrapolated service life cannot be accurately analyzed. The invention provides a method for testing the performance of a wear-resistant composite coating of an axial flow stirrer, which comprises the following steps of S1, collecting initial bonding strength, surface roughness and friction coefficient of the coating, introducing multiphase abrasive fluid, applying periodic pulsating load matched with axial flow rotational flow frequency, simulating the coupling working conditions of rotational flow scouring, centrifugal shearing and load fluctuation of a blade of the stirrer, and outputting a multi-dimensional dynamic test data set. S2, extracting thickness change data and an abrasive collision track from the multi-dimensional dynamic test data set, and generating a dynamic wear rate curve by using a fractal dimension algorithm. And carrying out space-time correlation integration on the dynamic wear rate curve, the strength retention rate, the three-dimensional morphology and the roughness data by using a regional abrasion contribution rate algorithm to form a staged analysis data set. And S3, analyzing the mechanical property distribution of the micro-region of the coating by using the dynamic wear rate curve and the stepwise analysis data set, constructing a failure mechanism map, supplementing the cyclic wear-resistance test data, and outputting a full life cycle change data set. S4, comparing the rotational flow scouring characteristic area failure trace of the retired blade with a failure mechanism map, dynamic abrasion data and a full life cycle change data set to verify effectiveness, determining an acceleration factor by taking flow field shearing force as a variable, and constructing a flow field parameter quantization correlation model. S5, quantifying a correlation model according to the acceleration factor, the failure mechanism map and the flow field parameter, correlating the cycle number, the impedance and the wear rate, extrapolating the service life and predicting the energy consumption trend to form a coating dynamic performance evolution report. According to the method for testing the performance of the wear-resistant composite coating of the axial-flow stirrer, in the step S1, the specific steps of outputting a multi-dimensional dynamic test data set are as follows: And S11, collecting initial bonding strength, surface roughness and friction coefficient of the coating, calibrating basic performance of a coating sample by a standardized detection means, and integrating after eliminating abnormal data points to form an initial performance data set. S12, selecting a performance standard sample in the initial performance data set, introducing multiphase abrasive fluid, applying periodic pulsating load matched with the rotational flow frequency of the axial flow, and simulating the coupling working conditions of rotational flow flushing, centrifugal shearing and load fluctuation of the blades of the stirrer. And S13, acquiring dynamic response dat