响应面分析法在绿色快速磷化工艺研发中的应用  

Application of Response Surface Analysis in the Research on the Green and Rapid Phosphating Process

作　　者：石西尧 朱志平[1] 曹洁 汤甜 武梦婷 SHI Xiyao;ZHU Zhiping;CAO Jie;TANG Tian;WU Mengting(School of Chemistry and Chemical Engineering,Changsha University of Technology,Changsha 410114,China)

机构地区：[1]长沙理工大学化学化工学院,长沙410114

出　　处：《中国表面工程》2023年第3期223-234,共12页China Surface Engineering

基　　金：湖南省科技计划重点资助项目(2013GK2016)。

摘　　要：长期处于户外的输电杆塔容易遭受锈蚀而受损,传统的涂料涂覆处理无法起到同时除锈和防腐的作用,因此亟须探索一种适合输电杆塔的绿色磷化处理工艺。基于电化学与响应面分析法,以磷酸与氧化锌为基础磷化液,研究植酸、复合钝化剂BM1、硝酸锰三种促进剂的浓度对锌系磷化膜成膜质量的影响,以硫酸铜点滴时间评判其耐蚀性。采用扫描电子显微镜观察添加不同促进剂的磷化液所形成磷化膜的表面形貌。通过响应面分析法对磷化液的成膜耐腐蚀效果进行优化,得到硫酸铜点滴时间的二次响应方程。各因素影响次序为硝酸锌>复合钝化剂(BM1)>植酸>硝酸锰,通过优化获得硫酸铜点滴时间为101 s的磷化液配方,即氧化锌15 g/L、磷酸100 g/L、复合钝化剂BM11.7 g/L、植酸11.7 mL/L、硝酸锌52.4 g/L、硝酸锰5.9 g/L、OP-10乳化剂适量。通过响应面优化参数得到的磷化液配方在具有除锈功能的同时能有效提高Q235低碳钢的耐腐蚀性能,可为磷化液新配方的性能预测和浓度优化提供方法与理论指导。Although transmission towers have been in use outdoors for a long time,they are easily damaged by corrosion,especially in areas with heavy industrial pollution.Additionally,traditional coating treatments cannot simultaneously remove rust and prevent corrosion.However,the use of a phosphating film can inhibit the formation of microbatteries on the steel surface,improve the corrosion resistance of steel,extend the service life,and significantly improve the adhesion between the substrate and coating.Nonetheless,most traditional phosphating methods employ high-or medium-temperature phosphating,which consumes a lot of fossil energy and promotes environmental pollution.To ensure safety during power transmission and distribution,it is crucial to develop a fast and green phosphating process suitable for the high-altitude operations on transmission towers.Based on electrochemical and response surface analyses,a phosphating coating was prepared on Q235 low-carbon steel using a mixture of phosphoric acid and zinc oxide as the basic phosphating solution.The effect of the concentration of phytic acid,composite passivation agent BMi,and manganese nitrate on the quality of zinc-based phosphating films was then studied,and the corrosion resistance of the coating was evaluated based on the time of copper sulfate test.The fixed phosphating process conditions were as follows:the pH value of the phosphating solution was 2.3-3.0,phosphating temperature was 25℃,and phosphating time was 40 min.The corrosion resistance of the phosphating film was analyzed using an electrochemical polarization curve and electrochemical impedance spectroscopy,and the results showed that the phosphating film had a better corrosion resistance when an accelerant was added to the phosphating solution.Moreover,the current density was less than half of that of the pure phosphating solution,and the maximum coating resistance was 25612:cm²,which was approximately 4 times higher than that of the pure phosphating solution.With an increase in the accelerator conc

关 键 词：绿色磷化 耐蚀性 锰系磷化膜 磷化工艺 响应曲面法 

分 类 号：TG174[金属学及工艺—金属表面处理]