浅海海缆钢丝铠装层防腐蚀工艺优化
Optimization of Anti-Corrosion Process for Steel Wire Armor Layer in Shallow Sea Submarine Cables
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摘要: 针对浅海环境高盐、微生物、机械应力引发海缆钢丝铠装腐蚀失效问题,以及传统热镀锌与普通涂料工艺存在的镀层容易生锈、屏蔽防护不足、防护时效短等不足,文中提出以锌铝镁合金镀层替代传统热镀锌,以石墨烯复合涂料替代传统涂料,并优化热浸镀与喷涂工艺参数的方案,通过多组对比试验,结合电化学测试、盐雾试验与微观形貌分析验证工艺优化效果。结果表明,优化后的铠装层在模拟浅海环境中的腐蚀速率降低38.5%,盐雾试验耐蚀时长提升至1 200 h以上,镀层与基材结合力提高56%,涂料与镀层结合力提高37.5%。铝镁合金镀层与石墨烯复合涂料的双重防护体系配合精准管控的热浸镀与喷涂工艺,可显著提升浅海海缆钢丝铠装层的耐蚀性能,满足浅海海缆防腐需求。Abstract: To address the corrosion failure of steel wire armor in submarine cables induced by high salinity, microorganisms, and mechanical stress in shallow sea environments, and to overcome the shortcomings of traditional hot-dip zinc coating and ordinary organic coating process, such as susceptibility to rust, inadequate shielding protection, and short service life, a scheme involving the replacement of the traditional hot-dip zinc coating with a Zn-Al-Mg alloy coating, the conventional paint with a graphene-composite coating, and the optimization of the process parameters of hot-dipping and spraying was proposed. Effectiveness of the optimized process was verified through multiple sets of comparative experiments, combined with electrochemical testing, salt spray testing, and microscopic morphology analysis. Results showed that the optimized armor layer exhibited a 38.5% reduction in corrosion rate in a simulated shallow sea environment, the salt spray corrosion resistance was extended to over 1 200 h, a 56% increase in adhesion between the coating and the substrate, and a 37.5% improvement in adhesion between the paint and the coating. It was demonstrated that the dual protection system consisting of the Zn-Al-Mg alloy coating and graphene-composite coating, together with precisely controlled hot-dipping and spraying processes, could significantly enhance corrosion resistance of steel wire armor layer for shallow sea submarine cables and meet the anti-corrosion requirements for long-term service.
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