外送陶瓷粉电弧喷涂复合涂层的研究
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摘要
电弧喷涂是快速发展的材料加工技术,在防磨损、防腐和磨损部件的修复等行业中应用广泛。电弧喷涂材料主要包括实心丝材和粉芯丝材。实心丝材易于操作且效率也高,但成分不容易调节,难以获得高性能复合涂层。粉芯丝材可以根据实际需要调节粉末成分以得到各种特殊性能的涂层,但是其具有成本较高、拉拔困难、成分较难调节等缺点。
本实验提出外送粉电弧喷涂的概念,即在电弧喷涂实心丝材的基础上辅以外送陶瓷粉末,进而制备金属基陶瓷复合涂层。本文研究了两种外送陶瓷粉方式和电弧喷涂工艺,并利用扫描电子显微镜(SEM)、能谱仪(EDAX)、X射线衍射仪(XRD)等测试方法研究了电弧喷涂涂层的显微组织结构和涂层的性能,其研究成果如下:
当采用陶瓷粉靠近基体的方式外送SiO_2和TiO_2粉时,涂层中含有部分陶瓷颗粒,而外送Al_2O_3粉时,几乎没有陶瓷颗粒进入涂层。当采用陶瓷粉靠近起弧区的方式外送SiC粉和SiC铁铝球磨粉时,一部分SiC粉以原始颗粒形态镶嵌在涂层中,另一部分SiC颗粒在高温下发生了分解,生成了石墨和SiO_2并沉积到涂层中,对涂层的硬度和耐磨性有一定的提高。
在无外送粉电弧喷涂时,工艺参数对复合涂层显微硬度的影响由主到次依次为:喷涂电流、雾化空气压力、喷涂电压,其最优工艺参数组合为喷涂电压为30V,喷涂电流为220A,雾化空气压力为0.7MPa。
采用第一种送粉方案外送SiO_2粉时,涂层在干摩擦条件下的主要机制是粘着磨损,并伴随着一定量的磨粒磨损。采用第二种送粉方案外送SiC粉和SiC铁铝球磨粉时,涂层在干摩擦条件下主要为磨粒磨损,并伴随着发生一定的粘着磨损。
Arc spraying is a rapid-developing material processing technology, anti-wear, anti-corrosion and parts repairments are widely used. Arc spraying materials include solid wire and cored wire. Solid wire is easy to operate and high efficiency, but the composition is not easy to adjust, it is difficult to obtain high-performance coatings. Cored wire can be adjusted according to actual needs in order to get all kinds of special powder composition of the coating performance, but it has some shortcomings, such as high cost, hard to make, composition more difficult to adjust.
In this study, the concept of arc spraying feeding ceramic powders from outside is proposed. Solid wire and ceramic powders from outside combine to get a composite coating. Two kinds of feeding ceramics from outside methods are studied. Scanning electron microscopy (SEM), energy dispersive spectroscopy (EDAX), X-ray diffraction (XRD) test methods are used in the study. The results are as follows:
When ceramic powders of SiO_2 and TiO_2 are close to the substrate for sending, the coating contains part of the ceramic particles. Al_2O_3 powder is used, almost no ceramic particles come into the coating. When ceramic powder are close to the arc zone by using SiC powders or SiC Fe-Al mill powders, part of the powders embed in the coating at the original shape, the other part of SiC particles have decomposed so that C elements and SiO_2 deposit to the coating. In hardness and wear resistance of the coating has improved to some extent.
Process parameters on the hardness of composite coatings from the main to the secondary were: spray current, atomizing air pressure, spray voltage. The optimum process parameters for the spray voltage of 30V, Spraying current of 220A, atomizing air pressure is 0.7MPa. When ceramic powders of SiO_2 are close to the substrate, the abrasive wear and along with adhesive wear are the main wear style in dry friction. When ceramic powder are close to the arc zone by using SiC powders or SiC Fe-Al mill powders, the abrasive wear are the main wear style along with adhesive wear in dry friction.
本实验提出外送粉电弧喷涂的概念,即在电弧喷涂实心丝材的基础上辅以外送陶瓷粉末,进而制备金属基陶瓷复合涂层。本文研究了两种外送陶瓷粉方式和电弧喷涂工艺,并利用扫描电子显微镜(SEM)、能谱仪(EDAX)、X射线衍射仪(XRD)等测试方法研究了电弧喷涂涂层的显微组织结构和涂层的性能,其研究成果如下:
当采用陶瓷粉靠近基体的方式外送SiO_2和TiO_2粉时,涂层中含有部分陶瓷颗粒,而外送Al_2O_3粉时,几乎没有陶瓷颗粒进入涂层。当采用陶瓷粉靠近起弧区的方式外送SiC粉和SiC铁铝球磨粉时,一部分SiC粉以原始颗粒形态镶嵌在涂层中,另一部分SiC颗粒在高温下发生了分解,生成了石墨和SiO_2并沉积到涂层中,对涂层的硬度和耐磨性有一定的提高。
在无外送粉电弧喷涂时,工艺参数对复合涂层显微硬度的影响由主到次依次为:喷涂电流、雾化空气压力、喷涂电压,其最优工艺参数组合为喷涂电压为30V,喷涂电流为220A,雾化空气压力为0.7MPa。
采用第一种送粉方案外送SiO_2粉时,涂层在干摩擦条件下的主要机制是粘着磨损,并伴随着一定量的磨粒磨损。采用第二种送粉方案外送SiC粉和SiC铁铝球磨粉时,涂层在干摩擦条件下主要为磨粒磨损,并伴随着发生一定的粘着磨损。
Arc spraying is a rapid-developing material processing technology, anti-wear, anti-corrosion and parts repairments are widely used. Arc spraying materials include solid wire and cored wire. Solid wire is easy to operate and high efficiency, but the composition is not easy to adjust, it is difficult to obtain high-performance coatings. Cored wire can be adjusted according to actual needs in order to get all kinds of special powder composition of the coating performance, but it has some shortcomings, such as high cost, hard to make, composition more difficult to adjust.
In this study, the concept of arc spraying feeding ceramic powders from outside is proposed. Solid wire and ceramic powders from outside combine to get a composite coating. Two kinds of feeding ceramics from outside methods are studied. Scanning electron microscopy (SEM), energy dispersive spectroscopy (EDAX), X-ray diffraction (XRD) test methods are used in the study. The results are as follows:
When ceramic powders of SiO_2 and TiO_2 are close to the substrate for sending, the coating contains part of the ceramic particles. Al_2O_3 powder is used, almost no ceramic particles come into the coating. When ceramic powder are close to the arc zone by using SiC powders or SiC Fe-Al mill powders, part of the powders embed in the coating at the original shape, the other part of SiC particles have decomposed so that C elements and SiO_2 deposit to the coating. In hardness and wear resistance of the coating has improved to some extent.
Process parameters on the hardness of composite coatings from the main to the secondary were: spray current, atomizing air pressure, spray voltage. The optimum process parameters for the spray voltage of 30V, Spraying current of 220A, atomizing air pressure is 0.7MPa. When ceramic powders of SiO_2 are close to the substrate, the abrasive wear and along with adhesive wear are the main wear style in dry friction. When ceramic powder are close to the arc zone by using SiC powders or SiC Fe-Al mill powders, the abrasive wear are the main wear style along with adhesive wear in dry friction.
引文
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[13] H.L. Liao,Size distribution of particles from individual wires and the effects of nozzle geometry in twin wire arc spraying[J].Surface & Coatings Technology,200 (2005):2123– 2130
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[30]秦颢.高硬度耐磨粉芯线材的研制[D].北京:北京工业大学,1999
[31]张书辉,郦剑.电弧喷涂粉芯丝材的研究与应用[J].热处理,2010,05(025)
[32]付东兴,徐滨士,李庆芬,等.高速电弧喷涂技术在防腐工程领域的研究现状[J].材料导报, 2007, 21(3): 94-96.
[33]韦福水,蒋伯平,汪行愷,等.热喷涂技术[M].北京:机械工业出版社, 1986: 1-34
[34] Drzeniek H, et al. Introduction of cored wires to arc spraying[J].International Thermal Spraying Conference 10th, 1983: 136~138
[35]邓世均.高科技时代的热喷涂技术[J].材料保护,1995, 28(8):32~36
[36] Borisov Y, et al. Composite flux cored wires for thermal spraying[J].Proceeding of ITSC 95.kobe, 1995, 5: 1115~1118
[37] Elliot Sampson. Advances in thermal spray coatings broaden their applications[J].Welding Journal, 1993, 7: 39~41
[38] Hallum D L. Metal-cored wires : what you should know[M].Welding Design & Fabrication, 1992, 10: 22~28
[39]杨建桥,杨保兴.热喷涂纳米结构涂层研究现状与展望[J].腐蚀与防护, 2008, 29(5): 290-294.
[40]贺定勇,张发云,蒋建敏,等.铁基含TiC陶瓷粉电弧喷涂粉芯丝材的研究[J].中国表面工程, 2006, 19(5): 41-44.
[41]汤顺意.电弧喷涂制备铁基耐磨陶瓷涂层的工艺优化[J].工艺装备,2007, 5(4):26~28
[42]贺定勇.电弧喷涂粉芯丝材及涂层的磨损特性研究[D].北京:北京工业大学, 2004.
[43]温瑾林.管状丝材的电弧喷涂[J].沈阳工业大学学报,1997, 19(2):1~2
[44]田保红.电弧喷涂金属基复合材料涂层[J].洛阳工学院学报,1999, 20(4):14~15
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[2]刘新田.表面工程[M].河南:河南大学出版社,2000: 1~3
[3]徐滨士,李长久.表面工程与热喷涂技术及其发展[J].中国表面工程,1998,11(1):3-9
[4]吴和元,阂小兵.热喷涂技术在火电行业的应用[J].湖南电力,2002,4:56
[5]康东,彭焕荣.汽轮机曲轴的电弧喷涂修复[J].焊接技术,2009.7:38
[6]王志健,田欣利.超音速火焰喷涂理论与技术的研究进展[J].兵器材料科学与工程,2002.3:25
[7] Xiaochuan Wang. Investigation of two-wire arc spray process[D].University of Minnesota, 1998
[8]栗卓新,方建筠.国内外热喷涂涂层形成机理的研究进展[J].中国机械工程2006,11(06)
[9]张平.热喷涂材料[M].北京:国防工业出版社,2006: 178~180
[10]徐滨士,马世宁.电弧喷涂技术的应用和发展[J].铁道物资科学管理,1997,15(3):34~35
[11]熊腊森,刘松,吴丰顺.电弧喷涂枪的研究与设计[J].电焊机,2003,10(33)
[12] Y.L. Zhu,Characterization via image analysis of cross-over trajectories and inhomogeneity in twin wire arc spraying[J].Surface and Coatings Technology,162 (2003):301–308
[13] H.L. Liao,Size distribution of particles from individual wires and the effects of nozzle geometry in twin wire arc spraying[J].Surface & Coatings Technology,200 (2005):2123– 2130
[14]梁秀兵,徐滨士,马世宁.高速电弧喷涂特性测试与分析[J].机械工程学报,2002,35(2):57-60
[15] E Pfender. Fundamental studies assoeiated with the plasma spraying proeess[J]. Surf. Coat & Teehnol, 1998, 34: 8~14
[16] M Kelkar. Modeling of wire are spraying[D]. Thesis,University of Minnesota, 1998, 24:153~154
[17]徐滨士,朱绍华.表面工程的理论与技术[M].北京:国防工业出版社,1999
[18]徐滨士.表面工程与维修[M].北京:机械工业出版社,1996
[19]陈文威.金属表面涂层技术及应用[M].北京:人民交通出版社,1996: 195~198
[20]肖宏滨,朱锦洪.电弧喷涂工艺参数对涂层结合强度的影响[J].洛阳工学院学报,1999,01(20)
[21]董立先,王勇.电弧喷涂工艺参数对3Cr13涂层性能稳定性的影响[J].管道技术与设备,2005,1(13)
[22]袁子良,莫亚武.电弧喷涂工艺参数对涂层组织和性能的影响[J].表面技术,2005,03(014)
[23]黄国华,陈安军,电弧喷涂工艺参数对铝镁合金涂层结合强度的影响[J].热加工工艺,2009,06(035)
[24]魏琪,李辉,铝基粉芯线材电弧喷涂工艺参数优化研究[J].材料科学与工艺,2008,04(032)
[25]汪刘应,汉功,电弧喷涂不锈钢涂层结合强度研究[J].中国表面工程,1999,01(03)
[26]伞金福,杜智,毕志夫.电弧喷涂不锈钢涂层耐磨性的研究[J].摩擦学学报,1998,02(004)
[27]伞金福,杜智,毕志夫.电弧喷涂不锈钢工艺对涂层组织及碳烧损量的影响[J].材料保护,1998,31(10):3-6
[28]伞金福,杜智,毕志夫.电弧喷涂不锈钢工艺对涂层孔隙率和氧化物含量的影响[J].中国表面工程,1997,9(3):23-27.
[29]邓世钧.高性能陶瓷涂层[M].北京:化学工业出版社,2004.
[30]秦颢.高硬度耐磨粉芯线材的研制[D].北京:北京工业大学,1999
[31]张书辉,郦剑.电弧喷涂粉芯丝材的研究与应用[J].热处理,2010,05(025)
[32]付东兴,徐滨士,李庆芬,等.高速电弧喷涂技术在防腐工程领域的研究现状[J].材料导报, 2007, 21(3): 94-96.
[33]韦福水,蒋伯平,汪行愷,等.热喷涂技术[M].北京:机械工业出版社, 1986: 1-34
[34] Drzeniek H, et al. Introduction of cored wires to arc spraying[J].International Thermal Spraying Conference 10th, 1983: 136~138
[35]邓世均.高科技时代的热喷涂技术[J].材料保护,1995, 28(8):32~36
[36] Borisov Y, et al. Composite flux cored wires for thermal spraying[J].Proceeding of ITSC 95.kobe, 1995, 5: 1115~1118
[37] Elliot Sampson. Advances in thermal spray coatings broaden their applications[J].Welding Journal, 1993, 7: 39~41
[38] Hallum D L. Metal-cored wires : what you should know[M].Welding Design & Fabrication, 1992, 10: 22~28
[39]杨建桥,杨保兴.热喷涂纳米结构涂层研究现状与展望[J].腐蚀与防护, 2008, 29(5): 290-294.
[40]贺定勇,张发云,蒋建敏,等.铁基含TiC陶瓷粉电弧喷涂粉芯丝材的研究[J].中国表面工程, 2006, 19(5): 41-44.
[41]汤顺意.电弧喷涂制备铁基耐磨陶瓷涂层的工艺优化[J].工艺装备,2007, 5(4):26~28
[42]贺定勇.电弧喷涂粉芯丝材及涂层的磨损特性研究[D].北京:北京工业大学, 2004.
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