Application of Titanium Alloy Nano Coatings in the Machinery Industry
2013-07-05
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1. The machinery and equipment industry has become a leading industry with fruitful results in China and has entered its best development period
The machinery industry is closely related to the growth rate of fixed asset investment. It is expected that during the "11th Five-Year Plan" period, China will maintain a relatively high economic growth rate. Driven by the revitalization policy for equipment manufacturing and strong export growth, the machinery industry will continue to develop healthily in an upward direction. It is expected that in the next five years, the industry's compound growth rate will remain above 18%, and machinery and equipment will enter its best development period. With the transfer of global manufacturing, China is gradually becoming the world's processing factory. The United States, Germany, Japan, South Korea and other countries have entered the high-tech-intensive and microelectronics era of industrialization, and heavy industries such as steel, machinery, and chemicals are gradually shifting to developing countries. The next 10 years will be the best period for the development of China's machinery industry. With the advancement of China's heavy and chemical industry process, the scale of Chinese enterprises, product technology, and quality will all be greatly improved. The international competitiveness of domestic machinery products will increase, gradually replacing imports and accelerating exports. At present, some sub-sectors of the machinery industry, such as shipbuilding, railway, containers and container crane manufacturing, have already benefited from international industrial transfer and will continue to benefit; power station equipment, construction machinery, machine tools, etc. will benefit from industrial transfer and accelerate the export process. In 2006, the total output value of China's machinery industry exceeded the 5 trillion yuan mark, reaching 5,471.777 billion yuan, a year-on-year increase of 30.06%; industrial added value was 1,437.083 billion yuan, a year-on-year increase of 32.12%. The entire industry has maintained rapid and steady development at a rate of over 20% for four consecutive years. According to statistics, the main business income of the machinery industry was 5,298.469 billion yuan, a year-on-year increase of 29.57%; the product sales rate was 97.63%, indicating good production-sales coordination. Among the 95 main products counted, 84 products had output exceeding the previous year, accounting for 88.42%, of which 65 products grew at double-digit rates, accounting for 68.42%. China's machinery and equipment industry is accelerating its expansion into the international market, and the machinery and equipment industry has become the main sector for China's foreign exchange earnings from exports.
According to the 2007 economic operation press conference of the China Machinery Industry Federation, in 2001 China's machinery and equipment self-sufficiency rate was 71%. Over the years, this indicator has continued to develop, and by the end of 2007 it had exceeded 82%. In addition, since 2006, China's machinery industry has changed from a net importer to a net exporter. In 2007, China's machinery industry foreign trade exports grew by 40.74%, 20.67% higher than the import growth rate. According to reports, in the first 11 months, China's machinery industry achieved a trade surplus of 22.5 billion US dollars, accounting for 9.43% of the national foreign trade surplus during the same period. After Zoomlion signed a 100-million-yuan order with ABG, a major Indian engineering general contracting company, breaking the record for the largest single product export in China's heavy machinery industry, domestic well-known construction machinery manufacturers such as Sany Heavy Industry, Sunward Intelligent, and Sany Heavy Industry have reported good news, with products frequently entering foreign markets. Previously, the machinery industry had always been one of the largest deficit industries in China's foreign trade. Although overall lagging behind developed countries, China's machinery products have obvious cost-effectiveness advantages in the low-to-medium end, and there is great room for export.
2. The performance of anti-corrosion coatings for exported equipment and machinery in harsh environments such as marine and mining environments needs to be improved
At present, the performance and environmental adaptability of heavy-duty anti-corrosion coatings in China are relatively poor. There are very few products that can achieve corrosion resistance for more than 10 years, and there is a big gap compared with foreign products, with low technical content. Exported mechanical equipment, marine engineering equipment, and large steel structures have high and urgent requirements for heavy-duty anti-corrosion coatings, but the technical performance and construction performance of domestic heavy-duty anti-corrosion coatings cannot meet user needs, and even serious quality problems have occurred. For example, an exported equipment from a construction machinery company in Changsha, due to coating problems, after marine transportation to Germany, the coating peeled off and the substrate rusted, resulting in compensation of 570,000 US dollars.
At present, the heavy-duty anti-corrosion coatings required for many major engineering projects in China are controlled by foreign-funded enterprises and foreign coatings, causing great passivity. Some construction machinery exports are forced to adopt measures such as wax sealing.
The use of nano-scale pigments and fillers in coating production has been a hot topic of research and development in recent years. There are many related reports at home and abroad, but few reports on actual industrialization. Therefore, it is very urgent and necessary to explore through experiments a high-performance anti-corrosion coating made from titanium-tantalum alloy nano-materials, titanium alloy nano-materials and other nano-materials to improve the performance and self-sufficiency rate of China's heavy-duty anti-corrosion coatings.
From the development trend, although the production cost of nano-coatings is higher than that of ordinary coatings, their comprehensive performance shows special excellence compared with ordinary coatings. Their good cost-effectiveness indicates potential economic value. Modifying anti-corrosion coatings through nanotechnology is currently the most effective technical means to improve the anti-corrosion effect of coatings. Nano-coatings have become the best choice for delaying corrosion.
Mechanical equipment, especially construction machinery equipment, often needs to face relatively harsh working environments. The surface of mechanical equipment needs to be coated with coatings that can withstand extreme harsh conditions such as acid and alkali, salt spray, seawater, wear, and impact, in order to delay the corrosion of mechanical equipment and extend the service life of the equipment.
3. Features and advantages of Kexing nano products
The product combines the dual excellent characteristics of titanium (titanium-tantalum) alloy and nano-materials. It has excellent comprehensive technical performance such as corrosion resistance, wear resistance, weather resistance, aging resistance, oil resistance, pollution resistance, strong adhesion, high strength, high toughness, and high thermal stability (see Table 1 for details). Among them, the main technical indicators such as salt spray resistance, acid and alkali salt resistance, seawater resistance, and wear resistance have reached and exceeded the advanced level of similar international products. It is also easy to construct and apply: low requirements for coating surface treatment, can be applied at room temperature with rust, wet surface construction, strong adhesion to rust, wet and old paint surfaces, can achieve primer and topcoat in one, fast coating and recoating, improve work efficiency, reduce coating costs, and still meet harsh environmental conditions. It also has good compatibility with the human body and the environment: completely non-toxic, antibacterial, pollution-resistant, UV-resistant, anti-static, thus it is an excellent high-efficiency, long-lasting, non-toxic special anti-corrosion coating. Its comprehensive performance is fully comparable to similar high-performance foreign products, but its price (conservatively estimated) is only one-third to one-fifth of theirs, with much higher cost-effectiveness. The wear resistance of a pure titanium nano-polymer (amorphous) coating from a foreign research institute is difficult to compare with our company's product (especially indicators such as adhesion under heat conditions), while the unit price is 80% higher. Our company's titanium alloy nano-coating has been appraised by academicians Shi Changxu, Xie Sishen and others as the main appraisal experts as "a domestic and international first, reaching the international advanced level, with anti-corrosion performance superior to currently known heavy-duty anti-corrosion coating brands." Therefore, this product has very obvious competitive advantages in domestic and foreign markets and fully has the possibility of replacing imports and exporting.
Since the successful development of our company's nano heavy-duty anti-corrosion coating, it has been widely welcomed by the market due to its high anti-permeability, corrosion resistance, wear resistance, enhanced surface strength, and lower price than foreign high-end products. It was rated as a national key new product in 2005. Articles coated with nano anti-corrosion materials can withstand boiling water and can be immersed in seawater for 10 years without damage. It is currently the most ideal and promising anti-corrosion coating for marine hull anti-corrosion coatings. It has been widely used in machinery equipment industries such as Sany Heavy Industry, Sunward Intelligent, Zoomlion, Chenliang Machinery, Saier Fan, Shandong Yanguang, etc. Especially because Sunward Intelligent has coated nearly 10,000 excavators and exported thousands of them, it received high praise at the Paris Expo. Sunward's evaluation of our coating is: "Since August 2005, our company has used rare metal titanium alloy nano-materials and coatings produced by Changsha Kexing Nano Company, mainly for coating and anti-corrosion of exported construction machinery and port machinery. After more than a year of application practice, we believe that rare metal titanium alloy nano-materials and coatings have unique anti-corrosion performance, especially acid resistance, alkali resistance, salt spray resistance and other properties are greatly superior to ordinary heavy-duty anti-corrosion coatings, and are fully capable of withstanding the heavy responsibility of resisting marine corrosion. They have been well received by our customers (especially European customers). The product has good development prospects."
The superior corrosion resistance of titanium alloy nano-coating is because, as a highly corrosion-resistant active additive, it gives the coating the anti-corrosion advantages of nano-particles and titanium alloy, and at the same time has a special network structure.
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