低压等离子喷涂射流特性及金属基涂层组织性能研究
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摘要
热喷涂技术是以热源的不断更新而发展的,随着等离子喷涂技术(APS)的发展,近年来超低压等离子喷涂技术(VLPPS)倍受瞩目。这种技术使用大功率等离子喷枪,在50～100Pa的超低压条件下,等离子射流达到超音速状态,可以制备出区别于传统层状组织的特殊结构涂层,具有良好的应用前景。
目前,对低压条件下等离子射流特性以及涂层形成机理的研究还处于初级阶段。研究等离子射流的特性,对获得良好的涂层组织有重要意义。本课题首先利用热焓探针系统,研究了低压条件下等离子射流的压力、比焓、温度、速度和努森数的分布,结果表明喷嘴出口附近射流的温度和速度较高,可分别达到10950K和2024m/s,努森数在1.0左右,等离子体的平均自由程与粉末颗粒的尺寸相当,对粉体的加热能力降低,使用内送粉喷涂方式可弥补这一不足。
根据射流特性的研究结果确定喷涂参数,选择316L不锈钢粉末和FeAl金属间化合物粉末作为研究对象,讨论低压等离子喷涂制备的涂层的组织和性能,得到在较高的喷涂能量和基体温度时,可以制备出等轴晶结构的316L不锈钢涂层,相比大气等离子喷涂制备的层状结构涂层,等轴晶涂层中几乎不存在孔隙及氧化物,并具有较低的显微硬度以及较高的耐腐蚀性。
尽管FeAl金属间化合物的熔点低于316L不锈钢,但使用得到等轴晶结构316L不锈钢涂层的喷涂参数制备的FeAl涂层依然为层片状组织,相比缺陷较多的大气等离子喷涂和超音速火焰喷涂涂层,低压等离子喷涂FeAl涂层组织十分致密,氧化物含量少,具有较高的显微硬度、弹性模量以及较低的断裂韧性,表现出特殊的性能。
Development of the thermal spray technology is usually accompanied with improving of the heat source. Recently, as compared with atmospheric plasma spray (APS) technique, very low pressure plasma spray (VLPPS) becomes attracting much attention. Currently, in the process of VLPPS, a high power plasma gun is adopted principally. The plasma jet is expanded, and jet velocity can reach an ultrasonic regimen at the pressure of50～100Pa. Under such conditions, the unique coating could be deposited and its applications would be more expected.
The technologies for the characteristics of plasma jet and how to deposite unique coatings still have a great many unbeknown problems. It's very significant to study the characteristics of plasma jet for manufacturing perfect coatings. In this work, distribution of pressure, temperature, velocity and Knudsen number of the plasma jet are investigated as a function of distance from nozzle exit by using enthalpy probe system under reduced chamber pressure. The results show that the temperature and velocity of plasma jet near the nozzle exit can reach10950K and2024m/s, and the Knudsen number is about1.0. This indicates the heat transfer from high temperature plasma to powder particles is decreased at exit of the nozzle. However, the internal powder feed torch we designed can remedy the decreased heating ability of plasma.
Meanwhile,316L stainless steel coating and FeAl intermetallic compound coating are deposited by low pressure plasma spray, and their microstructures and properties are also investigated. The results indicate that the equiaxed316L stainless steel coatings with clear grain boundary could be deposited at optimized parameters when spraying power and substrate temperature are carefully controlled. Compared with lamellar coating deposited by APS, the equiaxed coating shows less oxides and pores, and has much lower microhardness and higher corrosion resistance.
Though the melting temperature of FeAl is lower than that of316L stainless steel, but FeAl coating deposited at the same parameters as equiaxed316L stainless steel coating still exhibits lamellar microstructure. Furthermore, the FeAl coating deposited by LPPS presents special mechanical properties such as higher microhardness and elastic modulus as well as lower fracture toughness, when compared with those by atmospheric plasma spray or high velocity oxy-fuel spray.
目前,对低压条件下等离子射流特性以及涂层形成机理的研究还处于初级阶段。研究等离子射流的特性,对获得良好的涂层组织有重要意义。本课题首先利用热焓探针系统,研究了低压条件下等离子射流的压力、比焓、温度、速度和努森数的分布,结果表明喷嘴出口附近射流的温度和速度较高,可分别达到10950K和2024m/s,努森数在1.0左右,等离子体的平均自由程与粉末颗粒的尺寸相当,对粉体的加热能力降低,使用内送粉喷涂方式可弥补这一不足。
根据射流特性的研究结果确定喷涂参数,选择316L不锈钢粉末和FeAl金属间化合物粉末作为研究对象,讨论低压等离子喷涂制备的涂层的组织和性能,得到在较高的喷涂能量和基体温度时,可以制备出等轴晶结构的316L不锈钢涂层,相比大气等离子喷涂制备的层状结构涂层,等轴晶涂层中几乎不存在孔隙及氧化物,并具有较低的显微硬度以及较高的耐腐蚀性。
尽管FeAl金属间化合物的熔点低于316L不锈钢,但使用得到等轴晶结构316L不锈钢涂层的喷涂参数制备的FeAl涂层依然为层片状组织,相比缺陷较多的大气等离子喷涂和超音速火焰喷涂涂层,低压等离子喷涂FeAl涂层组织十分致密,氧化物含量少,具有较高的显微硬度、弹性模量以及较低的断裂韧性,表现出特殊的性能。
Development of the thermal spray technology is usually accompanied with improving of the heat source. Recently, as compared with atmospheric plasma spray (APS) technique, very low pressure plasma spray (VLPPS) becomes attracting much attention. Currently, in the process of VLPPS, a high power plasma gun is adopted principally. The plasma jet is expanded, and jet velocity can reach an ultrasonic regimen at the pressure of50～100Pa. Under such conditions, the unique coating could be deposited and its applications would be more expected.
The technologies for the characteristics of plasma jet and how to deposite unique coatings still have a great many unbeknown problems. It's very significant to study the characteristics of plasma jet for manufacturing perfect coatings. In this work, distribution of pressure, temperature, velocity and Knudsen number of the plasma jet are investigated as a function of distance from nozzle exit by using enthalpy probe system under reduced chamber pressure. The results show that the temperature and velocity of plasma jet near the nozzle exit can reach10950K and2024m/s, and the Knudsen number is about1.0. This indicates the heat transfer from high temperature plasma to powder particles is decreased at exit of the nozzle. However, the internal powder feed torch we designed can remedy the decreased heating ability of plasma.
Meanwhile,316L stainless steel coating and FeAl intermetallic compound coating are deposited by low pressure plasma spray, and their microstructures and properties are also investigated. The results indicate that the equiaxed316L stainless steel coatings with clear grain boundary could be deposited at optimized parameters when spraying power and substrate temperature are carefully controlled. Compared with lamellar coating deposited by APS, the equiaxed coating shows less oxides and pores, and has much lower microhardness and higher corrosion resistance.
Though the melting temperature of FeAl is lower than that of316L stainless steel, but FeAl coating deposited at the same parameters as equiaxed316L stainless steel coating still exhibits lamellar microstructure. Furthermore, the FeAl coating deposited by LPPS presents special mechanical properties such as higher microhardness and elastic modulus as well as lower fracture toughness, when compared with those by atmospheric plasma spray or high velocity oxy-fuel spray.
引文
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