HVAS硼化物金属复合陶瓷涂层性能与工艺参数研究
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摘要
表面工程技术是先进制造技术的重要组成部分,同时又为制造业的技术创新提供重要的技术支撑。表面技术在材料的表面防护、表面修复和表面改性等方面具有独特的优势,超音速电弧喷涂技术是表面技术的一种,随着热喷涂技术和喷涂材料的不断发展,超音速电弧喷涂(HVAS)涂层以其优于基体材料的性能,提高了零件的使用寿命,节约了资源。
本文针对工程实际中应用广泛的循环硫化床锅炉水冷壁管表面抗冲蚀磨损的需求,研究了超音速电弧喷涂(HVAS)工艺、超音速电弧喷涂(HVAS)材料以及相关的辅助工艺,以Q235钢为基体材料,选择HDS-88A型高耐磨丝材,其主要成分为:硼化物金属复合陶瓷、Ni、Cr、Mo、Al及稀土,采用超音速电弧喷涂(HVAS)技术在Q235钢基体试件材料上制备了硼化物金属复合陶瓷涂层。
采用正交试验设计的方法,确定喷涂电流、喷涂电压和喷涂距离,进而运用二次回归方法确定喷涂电流、喷涂电压和喷涂距离对涂层的磨损量、硬度及孔隙率之间的相关关系。
分别运用MM200型摩擦磨损试验机和MLS-225型湿砂橡胶磨损试验机对硼化物金属复合陶瓷涂层在干摩擦条件下和冲蚀磨损条件下进行了磨损实验,实验结果表明,硼化物金属复合陶瓷涂层的摩擦磨损性能优于Q235钢基体材料。
利用HV-1000型维氏硬度仪对涂层的硬度也进行了检测,并运用DT2000图像分析软件和金相显微镜XJZ100对涂层的孔隙率进行了检测,结果表明涂层维氏硬度达700HV,孔隙率低于5%。
利用数理统计方法,通过二次回归正交实验设计,确定了合适的工艺参数,建立了二次回归方程,建立了喷涂电流、喷涂电压和喷涂电流与涂层的磨损量、硬度及孔隙率之间的数学模型,并找出了最佳的喷涂工艺参数。本文研究表明,超音速电弧喷涂(HVAS)硼化物金属复合陶瓷涂层质量较高,并具有良好的耐磨损性能。
Surface engineering technology is the important part of the advanced manufacture technology, and which afford technology support innovation of the advanced manufacture technology. Surface engineering technology is particular advantage on surface protected, surface repair, changing the performance of surface etc. High Velocity Arc spraying is one of surface engineering technology, with the development of thermal spraying technique and materials, High Velocity Arc spraying coating extend the range of material applications, enhance the work life of parts, saving the sources.
Aimed at the actual works in the curing cycle bed boiler erosion of the surface wear resistance requirements, researching the technique, material and supporting technology of High Velocity Arc spray. Used Q235 steel as basic material, select the HDS-88A wear-resistance high-wire material, and its basis: ceramic composite metal borides, Ni, Cr, Al, thulium. Adopt the High Velocity Arc spraying the coating on the Q235 steel.
Make sure the current、voltage and distance of the High Velocity Arc spraying under the method of orthogonal design theory, and the current、voltage and distance impact of wear, hardness and tiny-hole of coating.
MM200 respectively use friction and wear test machine and MLS-225 wet-sand rubber wear tester of composite ceramic coating metal borides in the dry friction conditions and erosion wear under conditions of the experiments wear, the result indicate that the coating's wear-resistance under the dry friction much better than under the erosion friction.
The hardness of coating also be tested under Huayin Vickers hardness-HV-1000, and the tiny-hole of coating be tested under DT200 image analysis software and metallographic microscope XJ100.
The use of mathematical statistics, through orthogonal design to determine the appropriate parameters, the establishment of quadratic regression methods, and established the Spraying current, voltage, and distance and wear between the mathematical model and identify the best process parameters. The research of experiments indicate that High Velocity Arc spraying metal borides composite ceramic coating quality is good and has good wear resistance, the use of mathematical statistics.
本文针对工程实际中应用广泛的循环硫化床锅炉水冷壁管表面抗冲蚀磨损的需求,研究了超音速电弧喷涂(HVAS)工艺、超音速电弧喷涂(HVAS)材料以及相关的辅助工艺,以Q235钢为基体材料,选择HDS-88A型高耐磨丝材,其主要成分为:硼化物金属复合陶瓷、Ni、Cr、Mo、Al及稀土,采用超音速电弧喷涂(HVAS)技术在Q235钢基体试件材料上制备了硼化物金属复合陶瓷涂层。
采用正交试验设计的方法,确定喷涂电流、喷涂电压和喷涂距离,进而运用二次回归方法确定喷涂电流、喷涂电压和喷涂距离对涂层的磨损量、硬度及孔隙率之间的相关关系。
分别运用MM200型摩擦磨损试验机和MLS-225型湿砂橡胶磨损试验机对硼化物金属复合陶瓷涂层在干摩擦条件下和冲蚀磨损条件下进行了磨损实验,实验结果表明,硼化物金属复合陶瓷涂层的摩擦磨损性能优于Q235钢基体材料。
利用HV-1000型维氏硬度仪对涂层的硬度也进行了检测,并运用DT2000图像分析软件和金相显微镜XJZ100对涂层的孔隙率进行了检测,结果表明涂层维氏硬度达700HV,孔隙率低于5%。
利用数理统计方法,通过二次回归正交实验设计,确定了合适的工艺参数,建立了二次回归方程,建立了喷涂电流、喷涂电压和喷涂电流与涂层的磨损量、硬度及孔隙率之间的数学模型,并找出了最佳的喷涂工艺参数。本文研究表明,超音速电弧喷涂(HVAS)硼化物金属复合陶瓷涂层质量较高,并具有良好的耐磨损性能。
Surface engineering technology is the important part of the advanced manufacture technology, and which afford technology support innovation of the advanced manufacture technology. Surface engineering technology is particular advantage on surface protected, surface repair, changing the performance of surface etc. High Velocity Arc spraying is one of surface engineering technology, with the development of thermal spraying technique and materials, High Velocity Arc spraying coating extend the range of material applications, enhance the work life of parts, saving the sources.
Aimed at the actual works in the curing cycle bed boiler erosion of the surface wear resistance requirements, researching the technique, material and supporting technology of High Velocity Arc spray. Used Q235 steel as basic material, select the HDS-88A wear-resistance high-wire material, and its basis: ceramic composite metal borides, Ni, Cr, Al, thulium. Adopt the High Velocity Arc spraying the coating on the Q235 steel.
Make sure the current、voltage and distance of the High Velocity Arc spraying under the method of orthogonal design theory, and the current、voltage and distance impact of wear, hardness and tiny-hole of coating.
MM200 respectively use friction and wear test machine and MLS-225 wet-sand rubber wear tester of composite ceramic coating metal borides in the dry friction conditions and erosion wear under conditions of the experiments wear, the result indicate that the coating's wear-resistance under the dry friction much better than under the erosion friction.
The hardness of coating also be tested under Huayin Vickers hardness-HV-1000, and the tiny-hole of coating be tested under DT200 image analysis software and metallographic microscope XJ100.
The use of mathematical statistics, through orthogonal design to determine the appropriate parameters, the establishment of quadratic regression methods, and established the Spraying current, voltage, and distance and wear between the mathematical model and identify the best process parameters. The research of experiments indicate that High Velocity Arc spraying metal borides composite ceramic coating quality is good and has good wear resistance, the use of mathematical statistics.
引文
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[7]徐滨士,刘世参.表面工程[M].北京:机械工业出版社,2001
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[10]J.L.Lin,H.K.Ma.A DEPOSITION MODEL APPLIED IN A THERMAL SORAY PROCESS[J].Heat Mass Transfer,2004,31(4):323-332
[11]邓世均.迎接热喷涂工业的兴起[J].材料保护,2000,33(1):78-82
[12]Bob Irving.Improving the density of the thermal spray coat by HVIF[J].Welding Journal,2000,(2):42-44
[13]宋仁国,何望昭,黄卫东等.激光表面重熔对热喷涂铝涂层微观结构及其阻氢性能的影响[J].中国有色金属学报,2000,10(1):179-184
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