Patent technology of phosphating coated wire rope, referred to as phosphating wire rope, phosphating wire rope. Phosphating film makes the surface of steel wire more wear-resistant and improves its corrosion resistance. The porous structure of phosphating film can increase the storage of grease on the surface of steel wire rope, reduce the friction coefficient, promote sliding, delay the occurrence of fretting damage on the surface of steel wire rope and inhibit the initiation of fatigue microcracks, thus greatly prolonging the service life of steel wire rope.
Chinese name
phosphorized coating steel wire rope
Foreign name
phosphorized coating steel wire rope
1. overview of phosphating coated steel wire rope technology
Patent technology of phosphating coated wire rope, referred to as phosphating wire rope, phosphating wire rope. Phosphating film makes the surface of steel wire more wear-resistant and improves its corrosion resistance. The porous structure of phosphating film can increase the storage of grease on the surface of steel wire rope, reduce the friction coefficient, promote sliding, delay the occurrence of fretting damage on the surface of steel wire rope and inhibit the initiation of fatigue microcracks, thus greatly prolonging the service life of steel wire rope [1]?
Phosphating technology is mainly used for reducing friction, improving wear resistance, bonding mesophase, electrical insulation and surface decoration in corrosion protection and cold working of steel materials. Among them, the phosphating process with the main function of improving the wear resistance of steel materials, reducing friction and improving lubrication is widely used in friction bearing parts in automobile, light industry, chemical industry, electrical appliances, national defense and other fields. Phosphating technology is applied to wear resistance, friction reduction and rust prevention of steel wire in steel wire rope. The composite effect of phosphating film and grease on steel wire surface is far better than any grease currently used [1]?
Wear is the most common damage mode of wire rope, which is generally divided into three situations: external wear, deformation wear and internal wear [2]. For wire rope products, in order to prolong the service life of wire rope, technical measures can only be taken to prevent the wear caused by fretting under the condition that fretting between wires cannot be eliminated [3]. Fretting fatigue damage is closely related to the surface properties of materials. Using surface engineering technology can improve the fretting fatigue resistance of traditional materials and enhance the fretting fatigue resistance of new materials. Through surface modification, the fretting damage resistance, wear resistance and fretting damage resistance of materials can be effectively improved. Taking these surface protection measures is conducive to weakening or blocking the harm caused by friction when the steel wire slides relatively, thus inhibiting and delaying the occurrence of fretting damage on the steel wire surface and greatly prolonging the service life of the steel wire [1]?
Phosphating film itself has good electrical insulation, which can effectively inhibit the formation of micro-batteries on the surface of steel wire; The combination of phosphating film and grease can greatly improve the lubrication effect between steel wires and improve the corrosion resistance and oxidation resistance of steel wires. The patented technology of phosphating coated steel wire rope is to phosphatize the rope-making steel wire, and control the film weight between 3g/m2 and 60g/m2, including carbon steel wire, alloy steel wire, galvanized steel wire, aluminized steel wire and zinc-aluminum alloy coated steel wire [1].
2. Comparison of production process between phosphating coated steel wire rope and smooth steel wire rope (Note: phosphating coated steel wire rope and smooth steel wire rope are completely different products)
Production technology of phosphating coated steel wire rope;
Wire → pickling → washing → zinc phosphating → washing → drying → cold drawing → heat treatment → pickling → washing → cold drawing → making rope steel wire → alkali washing → washing → pickling → washing → manganese wear-resistant phosphating → washing → drying → twisting steel core → inspection → packaging [4]
Production technology of smooth steel wire rope;
Wire rod → pickling → water washing → zinc phosphating → water washing → drying → cold drawing → heat treatment → pickling → water washing → zinc phosphating → water washing → drying → cold drawing → rope making steel wire → twisting steel core → rope combining → inspection → packaging [4]?
The rope-making steel wire is made of high-quality carbon structural steel hot-rolled wire rod, which should be cold-drawn to the specified diameter and meet certain physical performance requirements. The rope-making steel wire produced by the above process is smooth steel wire, and the rope-making steel wire can be directly used for twisting or steel core without any surface treatment after cold drawing, which is smooth steel wire rope [5]?
3. The service life of phosphating steel wire rope is 2-3 times that of smooth steel wire rope, and it is an ideal substitute for smooth steel wire rope.
The phosphating treatment of rope steel wire is mainly manganese series or zinc-manganese series phosphating. The phosphatized steel wire is directly twisted with the phosphatized steel wire. Because the phosphating coating makes the surface of steel wire rope more wear-resistant and corrosion-resistant, the service life of phosphating steel wire rope is 2-3 times longer than that of smooth steel wire rope, and the fatigue life of steel wire rope is greatly improved. With the in-depth study of the formula of wear-resistant and corrosion-resistant phosphating solution, the fatigue life may be greatly improved. Phosphating steel wire rope is not only an ideal substitute for smooth steel wire rope, but also completely.
4. Scope of application of phosphating steel wire rope.
Some materials of steel wire will dissolve during phosphating. When the weight of phosphating film is 3g/m2~ 15g/m2, the diameter of steel wire after phosphating is almost unchanged. When the weight of phosphating film exceeds 20g/m2, the increase of steel wire diameter is very limited, and the mechanical properties of steel wire have no obvious change before and after phosphating (hydrogen should be removed to prevent hydrogen embrittlement). This feature makes phosphating wire rope technology suitable for almost all kinds of wire rope products, especially those with strict requirements on fatigue resistance, such as elevator wire rope, wire rope for port loading and unloading door machine, mine wire rope, aircraft wire rope for pumping unit and various crane wire ropes. And there is no conflict with all current national standards for wire ropes, that is, phosphating coated wire ropes can completely meet the technical requirements of current national standards or industry standards for wire ropes. [ 1]?
5. Determination of film weight of phosphating film
The type and weight of phosphating film is the decisive technical index to identify the authenticity of phosphating coated steel wire rope. The film weight of phosphating coated steel wire rope is 3-60 g/m2 (in this range, using a larger film weight is beneficial to improve fatigue life, such as 15-30 g/m2), and manganese phosphating and zinc-manganese phosphating are the best production processes.
The weight of phosphating film is less than 3g/m2, which is not phosphating coated steel wire rope.
According to the corresponding national standard GB/T9792-2003 "Determination of film quality per unit area of conversion film of metal materials", the phosphating film quality of phosphating steel wire for phosphating steel wire rope was tested. For the split test of phosphating film weight of twisted phosphating steel wire rope products, the grease coated on the surface of steel wire can be thoroughly cleaned with organic solvent first, and then the weight of phosphating film can be determined according to the above standard weight method after drying. [ 1]?