高压阀门密封面超音速等离子喷涂操作人员量化技能评价体系构建与工程验证

Construction and Engineering Verification of a Quantitative Skill Evaluation System for Supersonic Plasma Spray Operators on Sealing Surfaces of High-Pressure Valves

摘要: 国内热喷涂行业对喷涂作业人员能力考核长期依赖企业内部定性评价，缺少适配高压阀门密封面严苛服役工况的成套量化评价方案，普遍存在重理论、轻实操，考核指标与成品涂层性能脱节，缺乏喷涂故障应急处置考核，工艺可追溯性未纳入人员能力评价等工程痛点。本文依托KJ(Y)202631项目L₃₂(4¹⁰)多因素正交喷涂试验结果，结合项目自研喷涂工艺评定记录模板、实操量化评分细则与理论考核题库，系统辨识超音速等离子喷涂全流程岗位技能要素，构建实操权重60%、理论权重40%的喷涂操作人员量化技能评价体系。该体系划分为设备调试、工艺参数调控、喷涂精度与成品涂层质量控制、故障应急处置四大实操模块，配套标准化闭卷理论考核、全流程工艺归档模板与双重合格判定准则；将设备校准偏差、工艺参数波动、涂层厚度均匀性、涂层缺陷管控、工艺记录时效精度、质量溯源准确率转化为可量化考核指标。通过对20名不同从业年限喷涂人员开展试点考核验证，结果表明：经本评价体系筛选的合格操作人员，可将人为因素诱发的涂层质量缺陷占比控制在5%以内，喷涂批次间涂层性能波动 ≤ 5%，工艺记录完整率达100%，质量问题溯源准确率 ≥ 90%。本研究弥补了高压阀门密封面喷涂岗位人员能力量化评价的技术空白，可为阀门制造企业人员技能培训、岗位准入资质管理及行业团体标准编制提供成套工程化技术方案与数据支撑。

Abstract: The ability assessment of spray operators in the domestic thermal spray industry has long relied on qualitative, in-house evaluations within enterprises. There is a lack of a comprehensive quantitative evaluation scheme adapted to the demanding service conditions of high-pressure valve sealing surfaces. Prominent engineering pain points prevail, including an overemphasis on theory over hands-on operation, a disconnect between assessment indicators and finished coating performance, the absence of assessments covering spray fault emergency response, and the failure to incorporate process traceability into personnel capability evaluation. Based on the results of the L₃₂(4¹⁰) multi-factor orthogonal spray test of Project KJ(Y)202631, and combined with the self-developed spray process qualification record template, hands-on quantitative scoring rules, and theoretical examination question bank, this paper systematically identifies the job skill elements throughout the entire spray process and constructs a quantitative skill evaluation system for supersonic plasma spray operators, with hands-on operation weighted at 60% and theory at 40%. The system is divided into four hands-on operation modules—equipment commissioning, process parameter regulation, spray accuracy and finished coating quality control, and fault emergency response—supported by a standardized closed-book theoretical examination, a full-process process archival template, and dual pass criteria. It converts equipment calibration deviation, process parameter fluctuation, coating thickness uniformity, coating defect control, process recording time accuracy, and quality traceability accuracy into quantifiable assessment indicators. Through pilot assessment and verification conducted on 20 spray personnel with different years of experience, the results show that qualified operators selected by this evaluation system can control the proportion of coating quality defects induced by human factors within 5%, keep coating performance fluctuation between spray batches ≤ 5%, achieve a 100% process record completeness rate, and attain a quality problem traceability accuracy ≥ 90%. This study fills the technical gap in quantitative capability evaluation for spray personnel on high-pressure valve sealing surfaces, and can provide a complete set of engineering-ready technical solutions and data support for personnel skill training in valve manufacturing enterprises, post-entry qualification management, and the compilation of industry group standards.