高铝粉煤灰空心微珠填充环氧树脂复合材料及其冲蚀磨损行为研究

Large amounts of fly ash generated from coal-fired power plants have caused serious pollution to the environment. Based on the direction of tribology research of fly ash cenospheres added in polymeric materials and the exploration and development of its more valuable approaches, and the epoxy resin matrix composites as erosion resistant protective coating has been used increasingly in the field of erosion wear, this project puts forward an industrial solid waste, high-alumina fly ash cenospheres, as a reinforcement to epoxy-based composites. The erosion wear behavior of fly ash cenospheres-epoxy composites will be drawn up, then the theory model of cenospheres size gradation will be established through the study on the distribution of particle size. Started with the modified mechanism of cenospheres and the interface bonding mechanism between cenospheres and epoxy-based composites, the functioning mechanism of cenospheres on the curing behavior of the epoxy resin will be studied. Then the relationship between the curing of cenospheres/ epoxy system, the interface bonding between cenospheres and epoxy-based composites, the mechanical properties and the slurry erosion wear resistance of cenospheres/ epoxy composites will be comprehensively analyzed. And the slurry erosion wear mechanisms of cenospheres/epoxy composites will be researched, so as to establish the theory model of erosion wear. The research results will not only have important theoretical significance to enrich the theory of tribology, but also improve the developing of the synthetical usage of fly ash by using the new approach. At the same time, it has important significance for our country to establish the energy-saving and environment-friendly society.

燃煤发电产生的大量粉煤灰已对环境造成严重污染。基于粉煤灰中空心微珠在聚合物材料摩擦学方向的研究及其更有价值的利用途径开始得到探索和开发，以及环氧树脂基复合材料作为耐冲蚀保护涂层在冲蚀磨损领域中的应用日益广泛，本项目提出利用工业固废高铝粉煤灰微珠填充环氧树脂材料，拟围绕粉煤灰微珠/环氧树脂复合材料的冲蚀磨损行为展开，通过研究颗粒级配效应，建立微珠粒径级配理论模型。从微珠表面改性机理、微珠与环氧树脂基体间界面结合机理入手，探讨微珠对环氧树脂固化行为的作用机理，综合分析微珠/环氧树脂体系的固化、微珠与环氧树脂基体间界面结合、微珠/环氧树脂复合材料的力学性能及其冲蚀磨损性能间的关系，研究微珠/环氧树脂复合材料冲蚀磨损机理，从而建立冲蚀磨损理论模型。本研究将对丰富摩擦学理论具有重要的理论研究意义，也为粉煤灰高附加值利用提出新途径，促进粉煤灰综合利用的发展，还对我国建立节能型、环保型社会有着重要意义。

本项目利用燃煤发电厂产生的粉煤灰微珠作填料，用环氧树脂为基体材料，综合研究了粉煤灰微珠/环氧树脂复合材料的耐冲蚀磨损性能，以期获得高值化利用工业废物的新方法和获得具有优良耐冲蚀磨损性能的环氧涂层材料，对环境保护也有重要意义。项目开展了粉煤灰微珠表面改性，微珠/环氧树脂体系固化工艺，微珠/环氧树脂复合材料的力学性能、耐磨性能以及耐冲蚀磨损性能的研究，本研究的特色在于粉煤灰的高附加值利用。研究结果表明：KH550硅烷偶联剂能有效改善微珠表面性能，提高微珠和树脂间相容性。粉煤灰微珠/环氧树脂体系的最佳固化工艺为80℃120min+120℃30min。微珠添加量为15phr时环氧树脂复合材料的力学性能最好，微珠粒径越小、级配比例越大，复合材料的力学性能越好。复合材料耐磨耗性主要受微珠含量、粒径、载荷、速度、固化剂含量以及固化工艺的影响。粉煤灰微珠/环氧树脂复合材料的耐冲蚀性能随微珠含量的增加呈先增加后下降的关系。微珠粒径越大耐磨耗能也越高。随浆料浓度和冲蚀速度的增加，复合材料的耐冲蚀磨损性能随之降低。建立了基于微珠含量、微珠粒径、冲蚀速度和浆料浓度四个主要影响因素的冲蚀磨损理论模型，可用来预测粉煤灰微珠/环氧基复合材料涂层在冲蚀磨损工况下的抗冲蚀磨损性能。本项目还拓展研究了粉煤灰微珠/环氧树脂复合涂层的腐蚀老化性能、短玻璃纤维和粉煤灰微珠混杂增强环氧树脂的力学性能以及涂层与钢板的结合强度、氧化石墨烯/粉煤灰微珠混杂增强环氧树脂的磨耗性能，结果表明，氧化石墨层状褶皱结构适合负载颗粒填料，可有效解决粉煤灰微珠在环氧树脂体系中的分散性和稳定性问题，氧化石墨烯也进一步提高了粉煤灰微珠/环氧树脂复合材料的耐磨性能。结合氧化石墨烯纳米片卓越的阻隔作用，这一研究为设计应用于海洋环境的新型防腐耐磨涂层提供了新思路。