Fe-Al复合涂层电弧喷涂工艺及组织性能的研究
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摘要
本文在对国内外电弧喷涂技术的发展及现状进行一定研究分析的基础上，把逆变交流电源应用到电弧喷涂工艺中；对电弧喷涂的工艺原理进行了较为深入的理论分析；利用正交试验对电弧喷涂工艺进行了优化；对用优化工艺喷涂的Fe-Al系合金涂层的结合机理、耐热磨损机理进行了深入的分析。为电弧喷涂工艺方法、耐热磨损涂层在生产中的推广应用提供了理论依据。
对电弧喷涂过程中高速气流对熔滴的力学作用进行了一定的理论探讨，得出气流流场对电弧喷涂涂层质量影响的定性分析结果。通过分析电弧喷涂条件下电弧的热稳定过程，提出利用逆变方波交流电源作为电弧喷涂的电源；对逆变方波交流电弧喷涂过程中电弧区的动态行为进行了一定试验分析，得出逆变方波交流电源是理想的电弧喷涂电源。
根据对电弧喷涂工艺原理的研究，利用正交设计的方法对工艺参数进行了优化选择试验，得出最佳工艺参数；通过分析，得出各个工艺参数对涂层性能影响的定性结果，在可得到涂层的工艺范围内，喷涂电流对涂层性能的影响最大。
利用透射电子显微镜(TEM)、扫描电子显微镜(SEM)、X-射线衍射仪(XRD)、能谱仪(EDS)等现代分析手段研究了电弧喷涂Fe-Al涂层的微观结构，探讨了涂层中Fe-Al金属间化合物形成的机理，研究了复合涂层在一定温度下的磨损机理。为Fe-Al金属间化合物复合涂层的生产应用提供了一定的理论基础。
In this paper, inverter power source is applied to the arc spraying process based on the current state and development of arc spraying technology at home and aboard. Further theoretical analysis is conducted on the principle of arc spraying process optimized by orthogonal experimental design. Combination mechanism and hot-wearability mechanism of coatings prepared by arc spraying process are studied, which provides the theoretical basis for the extensive application of the process optimized and coatings with hot wearability.
The qualitative analysis in terms of the effect of gas flow field on the coatings is obtained through the discussion in theory about the force of high-velocity gas flow on the droplets in the arc spraying process. Square wave inverter power source is proposed in arc spraying process through analyzing the heat stability of arc. It is also proved to be the ideal power source for arc spraying process according to the experimental analysis of the dynamic behavior in arc.
Optimum process parameters optimized by orthogonal experimental design are acquired following the principle of arc spraying process. It is concluded that the coating performance depends most on the current through the qualitative analysis of the effect of process parameters on the coating performance.
The microstructure of iron aluminide coatings is investigated by transmission electron microscope(TEM), scanning electron microscope(SEM), X-ray analysis(XRD) and energy dispersive spectrometer(EDS). The formation mechanism of iron aluminide intermetallic composite discussed and abrasion mechanism of composite coatings studied under specific temperature in this paper provide the theoretical basis for the application and production of iron aluminide intermetallic coatings.
对电弧喷涂过程中高速气流对熔滴的力学作用进行了一定的理论探讨，得出气流流场对电弧喷涂涂层质量影响的定性分析结果。通过分析电弧喷涂条件下电弧的热稳定过程，提出利用逆变方波交流电源作为电弧喷涂的电源；对逆变方波交流电弧喷涂过程中电弧区的动态行为进行了一定试验分析，得出逆变方波交流电源是理想的电弧喷涂电源。
根据对电弧喷涂工艺原理的研究，利用正交设计的方法对工艺参数进行了优化选择试验，得出最佳工艺参数；通过分析，得出各个工艺参数对涂层性能影响的定性结果，在可得到涂层的工艺范围内，喷涂电流对涂层性能的影响最大。
利用透射电子显微镜(TEM)、扫描电子显微镜(SEM)、X-射线衍射仪(XRD)、能谱仪(EDS)等现代分析手段研究了电弧喷涂Fe-Al涂层的微观结构，探讨了涂层中Fe-Al金属间化合物形成的机理，研究了复合涂层在一定温度下的磨损机理。为Fe-Al金属间化合物复合涂层的生产应用提供了一定的理论基础。
In this paper, inverter power source is applied to the arc spraying process based on the current state and development of arc spraying technology at home and aboard. Further theoretical analysis is conducted on the principle of arc spraying process optimized by orthogonal experimental design. Combination mechanism and hot-wearability mechanism of coatings prepared by arc spraying process are studied, which provides the theoretical basis for the extensive application of the process optimized and coatings with hot wearability.
The qualitative analysis in terms of the effect of gas flow field on the coatings is obtained through the discussion in theory about the force of high-velocity gas flow on the droplets in the arc spraying process. Square wave inverter power source is proposed in arc spraying process through analyzing the heat stability of arc. It is also proved to be the ideal power source for arc spraying process according to the experimental analysis of the dynamic behavior in arc.
Optimum process parameters optimized by orthogonal experimental design are acquired following the principle of arc spraying process. It is concluded that the coating performance depends most on the current through the qualitative analysis of the effect of process parameters on the coating performance.
The microstructure of iron aluminide coatings is investigated by transmission electron microscope(TEM), scanning electron microscope(SEM), X-ray analysis(XRD) and energy dispersive spectrometer(EDS). The formation mechanism of iron aluminide intermetallic composite discussed and abrasion mechanism of composite coatings studied under specific temperature in this paper provide the theoretical basis for the application and production of iron aluminide intermetallic coatings.
引文
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2．徐滨士等．表面工程的理论与技术．北京：国防工业出版社，1999
3. Merican Welding Society. Thermal spraying: Practice, theory and application. Academic Press,1985
4. H.Zatt. A quarter of a century of plasma spraying. Ann. Rev. Mater. Sci.. 1983, 13:9～12
5. Kassabji, J.P. Durand, G.Jacq. Thermal spray applications for the next millennium: A business development. Proceedings of the 15th ITSC, Nice, France, 1998:1677～1680
6．田保红．高速电弧喷涂Fe_3A1／WC复合涂层高温冲蚀行为研究．[博士学位论文]．沈阳：中国科学院金属研究所，20003
7. M.U.Schoop. A new process for the production of metallic coatings. Chem. Met. Eng..1920,(8):404～406
8. M.L.Thorpe.Thermal spray: Industry in transition. Advanced Materials&Processes.1993,(5):50～61
9. H.Drzeniek, H.D.Steffens. Cored wires for arc and flame spraying. Proceedings of the 1th NTSC, Orlando, 1987:33～40
10. E.R.Sampson. Cored Wire Application Using Electric Are Spray[C]. Proceedings of the 15th ITSC, Nice, France, 1998:133～137
11. H.D.Steffens, Z.Babiak. Wear resistant composite coatings produced by arc spraying using cored wires. Proceedings of the 4th NTSC, Pittsburgh, 1991:331～336
12. Z.Liu, W. Gao, F. Wang. Oxidation behavior of FeA1 intermetallic coatings produced by magnetron sputter deposition. Scripta Materilla.. 1998, 39(11): 1497～1502
13. S.W. Banovic, J.N.Dupont and A.R.Marder. Experimental evaluation of Fe-Al claddings in high-temperature sulfdising environments. Welding Research. 2001,(3)63～70
14. H.D.Steffens, Z.Babiak and M.Wewel. Recent developments in arc spraying. IEEE Transactions on Plasma Science. 1990,18(6):974～979
15. J.R.Blackford, R.A.Buckley, H.Jones. Spray deposition of an iron aluminide. J.Mater. Sci..1998,33:4417～4421
16．温瑾林，耿维生，刘爱华．管状丝材料的电弧喷涂。沈阳工业大学学报，1997，19(2)1～6
17. K.Wira et al. Microstructure and wear properties of arc sprayed tungsten carbide coatings.Proceedings of the 14th ITSC, Kobe, Japan, 1995:465～470
18. R.H.unger, V.E.Belashchenko, W.R.Kratochvil. A new arc spray system to spray high density,low oxide coatings. Proceedings of the 15th ITSC, Nice, France, 1998:1489～1493
19. I.N.Karp, S.V. Petrove, A.P. Rudoy, A.N.Arjakin. Electric arc spraying in supersonic steams.
Proceedings of the 5th NTSC, Anaheim, 1993:185～190
20. R.W. Kincaid, F.D.Witherspoon. High velocity pulsed wire-arc spray. Proceedings of the 16th ITSC, Montreal, Canada, 2000:663～668
21. H.Drzeniek, H.D.Steffens. Cored wires for arc and flame spraying. Proceedings of the 1th NTSC, Orlando, 1987:33～40
22. E.R.Sampson, M.P. Zwetsloot. Arc spray process for the aircraft and stationary of turbine industry. Journal of Thermal Spray Technology. 1997,6(2)254～259
23. H.D.Steffens. Arc and plasma spraying today and in the 90th. Transactions of JWRI.1998,17(1):57～70
24．王震林、韩勇、许晋生，金属热喷涂技术及其应用，纺织工业出版社，1992．1，p40
25. J.J.Kaiser, R.A.Miller. Inert gas improves arc sprayed coatings. Advanced Materials&Processes. 1989,(12):37～40
26. S.W. Banovic, J.N.Dupont and A.R.Marder. Experimental evaluation of Fe-A1 claddings in high-temperature sulfdising environments. Welding Research. 2001,(3)63～70
27. H.D.Steffens, K.Nassenstein, S.Keller, G. Barbezet. The sonarc process: Combining the advantages of arc and HVOF spraying. Journal of Thermal Spray Technology. 1994,3(4):398～403
28．徐滨士等．高速电弧喷涂粒子速度和雾化特性研究[J]．机械工程学报．2000．36(1)：36-40．
29．张建民，张瑞林．Fe-A1系金属间化合物本征脆性的电子理论。材料研究学报。1996，10(3)34～38
30．孙祖庆，黄原定．Fe_3A1基金属间化合物合金强韧化途径探索．金属学报，1993，29(8)：35～38
31．杜国维，王政，肖纪美．Fe-28A1合金中的相转变．金属学报．1995，31(4)：A151～155
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