直流等离子喷枪的研究现状及发展趋势

直流等离子喷枪是等离子喷涂系统中最为核心的部件,决定了粒子的熔融软化沉积效果和涂层性能。总结 了阴极、阳极 ( 喷嘴 ) 和气体分配环等关键部件的结构特征对等离子射流的影响。进一步介绍了直流等离子喷枪 的结构优化发展,重点从等离子体射流稳定性和涂层沉积效率提升等角度进行阐述,介绍了级联等离子喷枪对射 流稳定性的优化,以及送粉方式对涂层沉积效率的提升,并展望了未来的发展趋势。     

Ultradisperse and nano structures in plasma coatings hardened by electromechanical treatment

For the example of PRFBKh6-2 alloy and P6M5 steel powders, the structure of plasma coatings after electromechanical treatment is investigated by scanning probe microscopy. After such treatment, ultradisperse and nano hardening phases are formed in the coating. These phases are formed by the decomposition of the coating’s initial fast-quenched structure in high-speed treatment. The formation of characteristic structural zones hardened by nanoparticles and ultradisperse particles is analyzed; the proportions of nanoparticles and ultradisperse particles are determined by the parameters of the sprayed powder and the conditions of plasma spraying and subsequent electromechanical treatment.     

热喷涂 WC-MoB-Co 金属陶瓷涂层的耐腐蚀性能研究

本文采用团聚烧结法制备了 WC-MoB-Co 金属陶瓷喷涂粉末, 使用超音速火焰喷涂技术在 316L 不锈钢基 材上制备了 WC-MoB-Co 涂层; 采用 SEM、 XRD 表征了 WC-MoB-Co 粉末和腐蚀前后涂层的微观形貌及物相组成; 测试了 WC-MoB-Co 涂层耐熔融锌铝腐蚀性能。 研究结果表明, 制备的 WC-MoB-Co 金属陶瓷复合粉末粒度集中、 流动性好、 松装密度高; WC-MoB-Co 涂层结合强度高、 孔隙率低; WC-MoB-Co 涂层具有良好的耐腐蚀性能, 随着腐蚀时间的延长, 涂层中的 WC 颗粒逐渐参与反应。     

The cytogenetic study of established Syrian hamster cell lines. II. A comparative analysis of the karyotypes of cell lines HaK, CER and BHK-21 (C-13)

Hydroxyapatite (HA) coatings were prepared by three thermal spraying methods: flame spraying, high velocity oxygen fuel spraying and plasma spraying. The HA was then examined by Rietveld analysis using the General Structure Analysis Software package (GSAS) and the results compared with those for the precursor powder. A comparison between HA before and after spraying showed that all three spraying methods caused a distortion in the unit cell in the form of a unit cell a-axis length decrease and a c-axis increase. Overall unit cell volumes showed a difference between the three thermal methods, with flame spraying and high velocity oxygen fuel methods giving a unit cell volume increase and the air plasma spraying method showing a decrease, compared to the starting powders. The two different starting powders used each showed a high oxygen occupancy for the hydroxyl oxygen. When thermally sprayed, both powders gave a reduction in occupancy, which suggested carbonate substitution for the OH group, but this was subsequently removed when thermally processed. The spraying also formed oxyapatite, indicated both by spectral analysis showing a reduction in the hydroxyl peak and by the hydroxyl oxygen occupancy falling to a level below 0.5. Major differences between the three spraying methods could be seen in the distortion index calculations. The thermal spraying techniques gave an increase in the distortion index, but it was significantly higher for the plasma-sprayed coating.     

Fabrication of TiC/Fe–Ni cermet coatings by reactive thermal spraying of Fe–Ti–Ni–C composite powder

Abstract

A mixture of ferrotitanium, nickel powders and sucrose was heated with an intention of carbonising the sucrose. The tiny ferrotitanium, nickel particles are bound by the carbon obtained from pyrolysis of the sucrose to form a unique structure of Fe–Ti–Ni–C composite powder for reactive thermal spraying. The carbon is a reactive constituent as well as the binder in the composite powder. TiC/Fe–Ni cermet coating was prepared by reactive plasma spraying of this powder. A mass of TiC particles were in situ synthesised and uniformly distributed in the Fe–Ni alloy matrix without residuals of raw materials in the coating. The coating is consisted of two different areas: one is the composite area, where lots of spherical fine TiC particles (100–500 nm) are homogeneously distributed within the Fe–Ni alloy matrix; the other is a small fraction of TiC accumulation. The volume fraction of composite area is >87%.     

PS-PVD 热障涂层显微结构对耐侵蚀性能的影响研究

采用等离子喷涂物理气相沉积 ( PS-PVD ) 技术开展了热障涂层梯度结构调控研究，通过调整喷涂送粉速率， 在底部、中间和顶部沉积阶段制备了五种不同的热障涂层，对热障涂层的显微组织、粗糙度、孔隙率、耐熔盐腐 蚀和耐粒子冲蚀性能进行表征，阐明了显微结构变化对热障涂层耐侵蚀性能的影响。研究表明：送粉速率的变化 对PS-PVD热障涂层羽柱状结构的沉积有显著的影响，低送粉速率下，涂层底部结构比较致密，当送粉速率增大时， 由于粉末颗粒在喷涂过程气化不充分，未熔粒子增加，羽柱状顶部结构趋向致密结构转变，涂层顶部孔隙率下降， 表面粗糙度降低。送粉速率由底至顶梯度递增制备的涂层表现出较高的耐熔盐腐蚀性能和耐粒子冲蚀性能。     

不同复合形式对AlSi／BN粉末及其涂层组织性能的影响

本文通过对两种组元的粒度设计,制备出BN与AlSii团聚、BN包裹AlSi、AlSi包裹BN三种形态的AlSi／BN复合粉末,通过大气等离子喷涂制备AlSi／BN可磨耗封严涂层,对粉末及涂层组织性能的研究结果表明,BN与AlSi团聚复合粉末涂层的BN含量最高,热稳定性最好。AlSi包裹BN复合粉末形成的涂层具有最高的硬度,其BN的损失特性为烧损和冲击型损失。     

等离子喷涂制备铁基非晶合金涂层的结构及其耐腐蚀性能的研究

选用铁基非晶合金粉末(含有Cr,Mo,Ni,P,B,Si)采用等离子喷涂方法在Q235低碳钢和不锈钢基体上制备合金涂层,通过金相显微镜、X射线衍射和扫描电子显微镜研究分析了涂层的相组成和显微结构。研究结果表明:该涂层与基体结合紧密,涂层均匀致密度高,涂层主要由非晶组成;涂层由变形成条带状的粒子相互搭接而成,其中含有少量未熔粒子和氧化物。所制备的铁基非晶涂层气孔率约2.5%,硬度为750～850 HV0.1。通过在H_2SO_4、HCl和NaOH溶液中进行浸泡腐蚀和三电极电化学分析,表明该涂层具有优异的耐腐蚀能力。     

柱状晶对等离子YSZ涂层性能的影响

本文选用微米级YSZ粉末和纳米级YSZ粉末喂料,采用等离子喷涂技术制备了两种YSZ涂层,并通过扫描电镜(SEM)对涂层的微观组织和结构进行了研究。结果表明:微米级YSZ粉末制备涂层内部柱状晶的尺寸较短,长度在1～3μm之间;纳米级YSZ粉末制备涂层内部柱状晶的尺寸较长,长度在8～12μm之间;这种组织结构特征的差异是导致YSZ涂层结合强度和热震性能不同的主要原因。     

Formation and Characterization of Plasma Sprayed Photocatalytic TiO2- ZnO Nano- Compounded Coatings

Two kinds of TiO2-ZnO nano-compounded powders aggregated by spray-drying process and evaporation method were used to deposit photocatalytic coatings by atmospheric plasma spraying technique. The phase compositions, morphologies of the agglomerated TiO2-ZnO powders and the as-sprayed coating were characterized using X-ray diffraction (XRD) and field emission scanning electron microscope (FESEM) respectively. Furthermore, roughness measurements were carried out on their surfaces of the plasma sprayed TiO2-ZnO nano-comPounded coatings. Compared with the TiO2ZnO nano-compounded coating deposited from the spray-dried powder, it was found that the TiO2-ZnO nano-compounded coating deposited from the evaporated powder possesses higher anatase phase. It is ascribed to the existing of partially melted or non-melted microstructure in the TiO2-ZnO coating deposited from the evaporated powder. The partially-meltedor non-melted microstructure was retained from the starting agglomerated powder. This microstructure is beneficial to improve the photocatalytic properties of plasma sprayed TiO2-ZnO nano-compounded coatings.     

喷涂参数对内送粉等离子喷枪制备YSZ涂层微观结构和性能的影响

为了进一步提高大气等离子喷涂YSZ热障涂层性能并降低其成产成本,开发了内送粉等离子喷枪.本文采用Spray Watch 2i在线监测系统测量了YSZ粉末粒子温度和飞行速度,采用实验室手段表征了涂层的微观结构、结合强度、弯曲性能和抗热震性能.研究结果表明,内送粉方式下喷涂距离对涂层微观结构和性能的影响规律与外送粉相似,而电流和主气流量表现出了独特的作用效果：随电流的增大,涂层综合性能先增加后降低,高电流下制备的涂层结合强度较低;在30～50 L/min范围内,增大主气流量可显著提高涂层结合强度.与外送粉最优参数制备YSZ涂层相比,内送粉时的功率消耗大幅降低,但粒子熔化效果明显增强,相同送粉速率下粉末沉积效率略有增加,涂层热循环寿命有所提高.     

镁基六铝酸镧喷涂粉末制备及其热处理工艺研究

采用固相反应法合成热障涂层用镁基六铝酸镧（LaMgAl₁₁O₁₉）,通过离心喷雾干燥造粒制备LaMgAl₁₁O₁₉粉末,并对粉末进行热处理研究,将未热处理和热处理后的粉末通过等离子喷涂制备LaMgAl₁₁O₁₉涂层并在1100℃高温氧化1 h。通过场发射扫描电子显微镜、霍尔流量计、X射线衍射等方法对LaMgAl₁₁O₁₉粉末的微观形貌、流动性、松装密度、物相和涂层形貌进行了分析。结果表明:离心喷雾干燥造粒工艺获得了粒径均匀、流动性好的LaMgAl₁₁O₁₉球形粉末,但粉末颗粒内部结构疏松不致密;热处理能明显改善LaMgAl₁₁O₁₉球形粉末的流动性和致密度,并能有效的避免涂层分解、改善涂层成分、提高涂层的性能。本试验中的最佳热处理温度为1450℃,与未热处理粉末相比,经过1450℃热处理后粉末的流动性为12.1 s·50 g-1,流动时间缩短了19.9%,松装密度提高了83.4%;制备的涂层孔隙率更低,结构更为致密,有效的降低了喷涂过程中涂层非晶相的形成。     

组元粒度对AlSi包覆BN涂层组织性能的影响

本文制备三种不同粒度配比的AlSi包覆BN复合粉末,通过大气等离子喷涂制备AlSi/BN可磨耗封严涂层,对涂层的硬度,结合强度及涂层组织进行了研究,并通过试验研究了不同形态颗粒在喷涂沉积过程中的演变行为,试验表明,较细的AlSi包覆较小粒径的BN颗粒在喷涂过程中具有最好的沉积效果,BN损失最少,核心BN颗粒粗大的粉末沉积效果差,BN损失严重。     

超音速等离子喷涂制备细密柱晶结构热障涂层研究进展

本文介绍了最新开发的超音速大气等离子喷涂（SAPS）技术制备细密柱晶结构热障涂层系统（SAPS-TBCs）的一些研究进展。由于SAPS喷涂15～45μm粒径的8YSZ氧化锆球形粉末在等离子射流中飞行速度约为400-450m/s,是普通大气等离子（APS：130～220m/s）2～3倍,可方便制备出体积分数达80%以上的...     

NiCoCrAlY合金粉体形态及粒度分布对超音速等离子喷涂制备合金涂层氧化行为的影响研究

以不同粒度分布的四种NiCoCrAlY合金粉体为原料,采用最新开发出的高效能超音速等离子喷涂技术制备合金涂层。分别对合金涂层进行＂1000℃、8h预氧化＋1100℃、100h氧化＂及直接＂1100℃、120h＂高温氧化试验。对喷涂及氧化试验后的涂层进行SEM观察及EDX分析,结果表明：四种合金涂层在形成过程中,均发生了...     

致密化工艺对氧化钛粉末及等离子喷涂涂层性能影响研究

采用喷雾干燥法制备了一种球形氧化钛团聚粉末, 并通过高温烧结及感应等离子球化工艺对团聚粉末进行 致密化处理。 利用扫描电子显微镜 (SEM)、 霍尔流速计和粉末颗粒强度仪对粉末性能进行了表征, 研究了不同致 密化处理工艺对粉末颗粒强度、 松装密度及流动性的影响。 采用大气等离子喷涂 (APS) 工艺制备了氧化钛涂层, 并对涂层的微观组织进行研究。 研究结果表明, 高温烧结工艺及等离子球化工艺均可有效提升氧化钛团聚粉末 的致密度, 经过高温烧结工艺后氧化钛粉末内部的细小颗粒呈现烧结熔融的趋势, 而采用等离子球化处理后的 团聚粉末直接形成了致密球体结构。 相比于高温烧结工艺, 等离子球化工艺对氧化钛粉末的致密化效应更为明 显, 粉末的颗粒强度可达 187.86 MPa, 松装密度可由 0.79 g/cm3 提升至 1.69 g/cm3, 流动性由 163.22 s/50g 加快 至 100.27 s/50g。 该粉末经过大气等离子喷涂沉积形成的氧化钛涂层孔隙率为 2.8 %, 与未经致密化工艺处理的氧 化钛团聚粉末相比, 制备的涂层致密化水平有了较大程度的提升, 涂层的平均显微硬度值由 434.18 HV0.3 提升至 744.37 HV0.3, 涂层的结合强度均值由 11.07 MPa 提升至 29.93 MPa。     

纳米ZrO_2粉末感应等离子体球化处理工艺研究

采用液体送粉技术及感应等离子体球化技术对纳米YSZ(6%~8%Y2O3-ZrO2)粉末进行了团聚、球化处理,研究了感应等离子体球化处理工艺参数对于粉体球化率的影响,采用三维景深显微镜、场发射扫描电镜、X射线衍射(XRD)研究了球化处理前后纳米YSZ粉末的表面形貌、截面形貌及其相结构。结果表明,采用液体送粉感应等离子球化处理技术,可同时对纳米YSZ粉末进行团聚及其致密化处理,得到的粉末为表面光洁、致密的实心球或空心球粉末,其粒径分布范围为40~100μm;YSZ粉末的相结构在处理前后没有发生变化。     

Melting metal powder particles in an inductively coupled r.f. plasma torch

A numerical model is developed for the prediction of melting metal powder particles in an inductively coupled r.f. plasma torch. The model is developed for dilute spray conditions where the gas phase flow is not affected by the loading condition. The governing equation for the gas phase flow contains the source terms from the electromagnetic field. The theoretical calculations have shown that particle thermal history and its velocity are greatly affected by the plasma operating conditions (i.e., carrier gas flow rate, injector location, and power level,etc.). Without the proper control of particle trajectories, particles may bounce around the fireball and exit the torch as unmelted or resolidified solid particles. With the insertion of an injector or injecting particles with a high carrier gas flow rate, the predictions show that even relatively small size particles can be directed into the fireball and maintained in the molten state before they impact on the substrate. Consequently, more uniform and dense deposits can be achieved.     

Melting metal powder particles in an inductively coupled r.f. plasma torch

A numerical model is developed for the prediction of melting metal powder particles in an inductively coupled r.f. plasma torch. The model is developed for dilute spray conditions where the gas phase flow is not affected by the loading condition. The governing equation for the gas phase flow contains the source terms from the electromagnetic field. The theoretical calculations have shown that particle thermal history and its velocity are greatly affected by the plasma operating conditions (i.e., carrier gas flow rate, injector location, and power level,etc.). Without the proper control of particle trajectories, particles may bounce around the fireball and exit the torch as unmelted or resolidified solid particles. With the insertion of an injector or injecting particles with a high carrier gas flow rate, the predictions show that even relatively small size particles can be directed into the fireball and maintained in the molten state before they impact on the substrate. Consequently, more uniform and dense deposits can be achieved.