铝青铜减摩粉体涂层及摩擦磨损性能
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摘要
铝青铜合金具有高强度、优良塑性、耐磨耐蚀性等优点,已成功应用于拉伸冲压模具当中。为了进一步将该合金拓广应用于表面工程领域,本文讨论了用以Cu-14Al-X合金为基础制备的铝青铜减摩粉体,该粉体材料是由氮气雾化法制备的。材料主要成分为Cu70～80%,Al12～16%,Fe2.0～4.0%,其余为Mn、Ni、Co、Re等微量元素。
分别采用等离子喷焊技术和激光熔敷技术两种表面熔敷工艺在45#钢基材表面制备了铝青铜减摩粉体涂层。借助X射线衍射仪(XRD)、扫描电子显微镜(SEM)、电子探针(EPMA)、场发射扫描电子显微镜(FESEM)、能谱仪(EDS)及摩擦磨损试验机等研究分析了两种涂层的微观组织结构特征及其形成过程、涂层与基体在界面附近的结合组织特征以及结合强度、涂层宏观硬度和显微硬度及其摩擦磨损性能等,以及不同粉末粒度对喷焊层性能的影响,最终得出适合于铝青铜(Cu-14Al-X)减摩粉体涂层的表面处理工艺。结果表明,制备工艺的不同对涂层的组织形貌、涂层成分、硬度影响明显。1.激光熔敷层和等离子喷焊层的物相组成相同,都为α+γ2+β?+K相,但组织形貌差别显著。激光熔敷层组织细小、致密,没有明显的晶界,硬质K相弥散分布于α+γ2+β?构成的基体相之中,等离子喷焊层的硬质K相尺寸相对较大且分布不均匀。2.等离子喷焊层和激光熔敷层的元素含量也有较大差异,尤其是Fe元素的含量差异明显。等离子喷焊层中的Fe元素含量达到了11.30%,而激光熔敷层中的Fe元素含量只有3.83%。3.激光熔敷层的表面硬度也远高于等离子喷焊层。激光熔敷层的表面硬度达到了362.5HV,而等离子喷焊层的表面硬度只有304HV。4.不同粉末粒度对等离子喷焊层的性能有较大的影响。
在RFT-III型摩擦磨损试验机上测试了等离子喷焊层和激光熔敷层的摩擦磨损性能,结果表明在边界润滑条件下:1.等离子喷焊层与激光熔敷层的摩擦磨损机理有明显差异;等离子喷焊层在低载荷下以轻微的磨粒磨损为主要磨损形式,在高载荷条件下转变为较严重的粘着磨损并伴随有轻度的磨粒磨损;激光熔敷层则以磨粒磨损为主。2.等离子喷焊层在低载荷条件下表现出了优良的摩擦磨损性能,但在高载荷下,磨损量和摩擦系数都会剧烈增加,摩擦性能不如激光熔敷层稳定。
在相同摩擦条件下,将激光熔敷层、等离子喷焊层和Cu-14Al-X合金的摩擦磨损性能进行了对比。结果表明:1.激光熔敷层和Cu-14Al-X合金均以磨粒磨损为主要磨损方式,而等离子喷焊层的磨损方式以粘着磨损为主。2.等离子喷焊层在低载荷下摩擦性能优于Cu-14Al-X合金和激光熔敷层,但在高载荷下,耐磨损性能下降很快,摩擦稳定性不好。3.激光熔敷层的摩擦性能和Cu-14Al-X合金大致相当,磨损量略高于Cu-14Al-X合金,但摩擦稳定性优于Cu-14Al-X合金。
含Ce与不含Ce的铝青铜减摩粉体涂层主要组织相同,加入适量的Ce细化了涂层的组织,改变黑色硬质相(K相)的形貌、尺寸大小,使黑色硬质相(K相)的数量增加,分布更均匀,抑制合金元素的偏聚,并促进涂层与基体之间的原子扩散,有利于元素的合金化,从而形成组织致密的冶金熔合区。
Aluminum bronze alloys which have high strength, excellent plasticity, wear and corrosion resistance and so on have been successfully applied to stretching and pressing tools. In order to widen its application in surface engineering, this paper discussed the self-lubricate aluminum bronze (Cu-14Al-X) powder which was made by nitrogen atomization. The main composition of the powder is: Cu 70 ~ 80%, Al 12 ~16%, Fe 2.0 ~ 4.0% and the rest is other microelements, for example, Mn, Co, Ni and Re.
Two kinds of self-lubricate aluminum bronze coatings on AISI-1045 steel were respectively prepared by plasma spraying and laser cladding technology. By using X-ray diffraction (XRD), scanning electron microscopy (SEM), electron probe micro-analyzer (EPMA), field emission scanning electron microscopy (FESEM), energy dispersive spectrometer (EDS) and friction and wear test machine, microstructure, forming process, interface between substrate and coating, bonding strength, macrohardness, microhardness and friction and wear properties were studied. The effect of different particle size of powder on them was also analysed. Finally, surface treatment technology fitting to self-lubricate aluminum bronze (Cu-14Al-X) coating was gained. The results showed different preparing technologies has different influences on morphology, composition and hardness. 1. The phases of the two coatings are same, includingα,γ2,β? and K. The structure of laser cladding coating is finer, denser without clear grain boundaries and the hard K phases disperse in the substrate, While those in the plasma spraying coating is large and distributes unevenly. 2. The element contents of them are different, especially Fe. The content Fe in plasma spraying coating is up to 11.30%, while that in laser cladding coating is only 3.83%. 3. The hardness of laser cladding coating which is 362.5HV is higher than that of plasma spraying coating which is only 304HV. 4. The effect of different particle size of powders on properties of the plasma spraying coating is obvious.
Friction and wear properties of plasma spraying coating and laser cladding coating were performed on RFT-III friction and wear test machine under boundary lubricant condition. The results are as follows: 1. Friction and wear mechanism of the two coatings is various. That of the plasma spraying coating is slight abrasive abrasion under low load, while serious adhesion abrasion under high load with slight abrasive abrasion. That of laser cladding coating is mainly abrasive abrasion. 2. Plasma spraying coating possesses excellent wear resistance under low load, but wear loss and friction coefficient increase violently under high load, which illustrates its tribological properties is less stable than that of the laser cladding coating.
In the same test conditions, tribological properties of laser cladding coating, plasma spraying coating and Cu-14Al-X alloys were studied. 1. The wear mechanism of laser cladding coating and Cu-14Al-X alloys is mainly abrasive abrasion, but plasma spraying coating is adhesion abrasion. 2. Tribological performance of plasma spraying coating under low load is better than that of Cu-14Al-X alloys and laser cladding coating, but under high load, wear resistance decreased rapidly, which indicates its tribological stability is not good. 3. Laser cladding coating and Cu-14Al-X alloys have similar tribological properties, but wear loss of laser cladding coating is slightly higher than that of Cu-14Al-X alloys. Friction stability of laser cladding coating is better than that of Cu-14Al-X alloys.
The structure of the self-lubricate aluminum bronze coatings with and without Ce is same. Adding moderate Ce can refine the structure, change the morphology, size of the K phases, increase their quantities and make them disturb more evenly. Ce can also restrain segregation of alloy elements and accelerate atomic diffusion which is benefit for alloying, thus form dense fusing zone.
分别采用等离子喷焊技术和激光熔敷技术两种表面熔敷工艺在45#钢基材表面制备了铝青铜减摩粉体涂层。借助X射线衍射仪(XRD)、扫描电子显微镜(SEM)、电子探针(EPMA)、场发射扫描电子显微镜(FESEM)、能谱仪(EDS)及摩擦磨损试验机等研究分析了两种涂层的微观组织结构特征及其形成过程、涂层与基体在界面附近的结合组织特征以及结合强度、涂层宏观硬度和显微硬度及其摩擦磨损性能等,以及不同粉末粒度对喷焊层性能的影响,最终得出适合于铝青铜(Cu-14Al-X)减摩粉体涂层的表面处理工艺。结果表明,制备工艺的不同对涂层的组织形貌、涂层成分、硬度影响明显。1.激光熔敷层和等离子喷焊层的物相组成相同,都为α+γ2+β?+K相,但组织形貌差别显著。激光熔敷层组织细小、致密,没有明显的晶界,硬质K相弥散分布于α+γ2+β?构成的基体相之中,等离子喷焊层的硬质K相尺寸相对较大且分布不均匀。2.等离子喷焊层和激光熔敷层的元素含量也有较大差异,尤其是Fe元素的含量差异明显。等离子喷焊层中的Fe元素含量达到了11.30%,而激光熔敷层中的Fe元素含量只有3.83%。3.激光熔敷层的表面硬度也远高于等离子喷焊层。激光熔敷层的表面硬度达到了362.5HV,而等离子喷焊层的表面硬度只有304HV。4.不同粉末粒度对等离子喷焊层的性能有较大的影响。
在RFT-III型摩擦磨损试验机上测试了等离子喷焊层和激光熔敷层的摩擦磨损性能,结果表明在边界润滑条件下:1.等离子喷焊层与激光熔敷层的摩擦磨损机理有明显差异;等离子喷焊层在低载荷下以轻微的磨粒磨损为主要磨损形式,在高载荷条件下转变为较严重的粘着磨损并伴随有轻度的磨粒磨损;激光熔敷层则以磨粒磨损为主。2.等离子喷焊层在低载荷条件下表现出了优良的摩擦磨损性能,但在高载荷下,磨损量和摩擦系数都会剧烈增加,摩擦性能不如激光熔敷层稳定。
在相同摩擦条件下,将激光熔敷层、等离子喷焊层和Cu-14Al-X合金的摩擦磨损性能进行了对比。结果表明:1.激光熔敷层和Cu-14Al-X合金均以磨粒磨损为主要磨损方式,而等离子喷焊层的磨损方式以粘着磨损为主。2.等离子喷焊层在低载荷下摩擦性能优于Cu-14Al-X合金和激光熔敷层,但在高载荷下,耐磨损性能下降很快,摩擦稳定性不好。3.激光熔敷层的摩擦性能和Cu-14Al-X合金大致相当,磨损量略高于Cu-14Al-X合金,但摩擦稳定性优于Cu-14Al-X合金。
含Ce与不含Ce的铝青铜减摩粉体涂层主要组织相同,加入适量的Ce细化了涂层的组织,改变黑色硬质相(K相)的形貌、尺寸大小,使黑色硬质相(K相)的数量增加,分布更均匀,抑制合金元素的偏聚,并促进涂层与基体之间的原子扩散,有利于元素的合金化,从而形成组织致密的冶金熔合区。
Aluminum bronze alloys which have high strength, excellent plasticity, wear and corrosion resistance and so on have been successfully applied to stretching and pressing tools. In order to widen its application in surface engineering, this paper discussed the self-lubricate aluminum bronze (Cu-14Al-X) powder which was made by nitrogen atomization. The main composition of the powder is: Cu 70 ~ 80%, Al 12 ~16%, Fe 2.0 ~ 4.0% and the rest is other microelements, for example, Mn, Co, Ni and Re.
Two kinds of self-lubricate aluminum bronze coatings on AISI-1045 steel were respectively prepared by plasma spraying and laser cladding technology. By using X-ray diffraction (XRD), scanning electron microscopy (SEM), electron probe micro-analyzer (EPMA), field emission scanning electron microscopy (FESEM), energy dispersive spectrometer (EDS) and friction and wear test machine, microstructure, forming process, interface between substrate and coating, bonding strength, macrohardness, microhardness and friction and wear properties were studied. The effect of different particle size of powder on them was also analysed. Finally, surface treatment technology fitting to self-lubricate aluminum bronze (Cu-14Al-X) coating was gained. The results showed different preparing technologies has different influences on morphology, composition and hardness. 1. The phases of the two coatings are same, includingα,γ2,β? and K. The structure of laser cladding coating is finer, denser without clear grain boundaries and the hard K phases disperse in the substrate, While those in the plasma spraying coating is large and distributes unevenly. 2. The element contents of them are different, especially Fe. The content Fe in plasma spraying coating is up to 11.30%, while that in laser cladding coating is only 3.83%. 3. The hardness of laser cladding coating which is 362.5HV is higher than that of plasma spraying coating which is only 304HV. 4. The effect of different particle size of powders on properties of the plasma spraying coating is obvious.
Friction and wear properties of plasma spraying coating and laser cladding coating were performed on RFT-III friction and wear test machine under boundary lubricant condition. The results are as follows: 1. Friction and wear mechanism of the two coatings is various. That of the plasma spraying coating is slight abrasive abrasion under low load, while serious adhesion abrasion under high load with slight abrasive abrasion. That of laser cladding coating is mainly abrasive abrasion. 2. Plasma spraying coating possesses excellent wear resistance under low load, but wear loss and friction coefficient increase violently under high load, which illustrates its tribological properties is less stable than that of the laser cladding coating.
In the same test conditions, tribological properties of laser cladding coating, plasma spraying coating and Cu-14Al-X alloys were studied. 1. The wear mechanism of laser cladding coating and Cu-14Al-X alloys is mainly abrasive abrasion, but plasma spraying coating is adhesion abrasion. 2. Tribological performance of plasma spraying coating under low load is better than that of Cu-14Al-X alloys and laser cladding coating, but under high load, wear resistance decreased rapidly, which indicates its tribological stability is not good. 3. Laser cladding coating and Cu-14Al-X alloys have similar tribological properties, but wear loss of laser cladding coating is slightly higher than that of Cu-14Al-X alloys. Friction stability of laser cladding coating is better than that of Cu-14Al-X alloys.
The structure of the self-lubricate aluminum bronze coatings with and without Ce is same. Adding moderate Ce can refine the structure, change the morphology, size of the K phases, increase their quantities and make them disturb more evenly. Ce can also restrain segregation of alloy elements and accelerate atomic diffusion which is benefit for alloying, thus form dense fusing zone.
引文
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