钨涂层面对等离子体材料出气性能的研究

钨由于高熔点、低溅射率等优点而被广泛的认为是最有希望的核聚变装置面对等离子体材料.然而考虑到等离子体约束和边界气体再循环,钨涂层面对等离子体材料在真空中的出气性能的研究是十分重要的.研究结果显示钨涂层主要出气种类为H2,H2O,O2,CO/N2和CO2.在300℃、经过4小时的烘烤,涂层出气率有明显的降低,特别是H2O和CO/N2;继续烘烤对涂层出气率改善效果不显著,因此真空等离子体喷涂钨涂层在用作面对等离子体材料时,仍需要烘烤、放电清洗等壁处理手段.     

聚变堆装置中面向等离子体材料钨涂层的研究进展

钨具有高的熔点、不与氚发生共沉积、与等离子体好的兼容性和低的腐蚀率等优点,是最有前景的一种面向等离子体材料.为了解决面向等离子体材料的制备及其与热沉材料连接问题,涂层技术在实验聚变堆装置中得到广泛应用.评述了目前实验聚变堆装置中面向等离子体材料钨涂层的研究进展.     

嬗变元素Re、Os对聚变装置面向等离子体钨材料性能的影响

钨(W)由于具有高熔点、高密度、低热膨胀系数、低氚滞留、低溅射产额等优异性能,被认为是最有潜力的聚变装置面向等离子体材料.氘氚聚变反应产生的14 MeV中子会导致W中嬗变元素铼(Re)、锇(Os)的产生,随着服役时间的延长,嬗变元素不断累积.这两种嬗变元素的产生势必会影响到W材料的微观组织结构,进而对W材料的性能产生影响.本文全面介绍了W嬗变元素Re、Os对聚变装置面向等离子体W材料的关键服役性能的影响,包括对力学性能、抗辐照性能、热学性能以及钨中氢同位素输运行为的影响.结果表明,W嬗变元素Re、Os能对W材料的性能造成较大的改变,但目前相关的研究都不够系统化,未来还需进行更为系统的研究来全面地对中子辐照条件下聚变装置面向等离子体W材料的性能进行评估.     

钨用作核聚变装置面对等离子体材料可行性分析

通过与碳材料比较,分析钨作为核聚变面对等离子体材料的可行性。研究结果显示,钨是最有前景的面对等离子体材料,氢及其同位素滞留量小、热能和粒子反射率高、溅射率低、杂质聚集可控等,除此之外,钨具有熔点高、热力学性能优异等优点。     

不同辐照粒子下钨及钨合金辐照损伤行为的研究进展

研究核聚变、准稳态等离子体下面向等离子体材料的辐照行为,发展适合于先进实验超导托卡马克(EAST)、国际热核聚变实验堆(ITER)和中国聚变工程实验堆(CFETR)长脉冲高参数运行乃至未来聚变反应堆稳态运行的高性能面向等离子体材料是当前核聚变研究一项艰巨而又紧迫的任务。钨因具有高熔点、高导热率、低溅射腐蚀速率、高自溅射阀值以及低蒸气压和低氚滞留等优异性能,被认为是聚变装置最具有前景的面向等离子体材料。综合评述了钨及钨合金在不同辐照粒子下损伤行为的最新研究进展。粒子辐照造成的微观缺陷在钨及钨合金内部累积,辐照造成缺陷的形成和数量与钨基材料颗粒微观结构、第二相成分等密切相关,辐照缺陷情况各异。同时,辐照粒子种类、能量、剂量和温度等辐照条件都会对钨材料辐照后的形貌特征和缺陷产生重要影响。     

核聚变钨铜面对等离子体材料研究

介绍了钨用作核聚变面对等离子体材料的制备技术以及钨材料的微观结构以及基本性能,包括真空/大气等离子体喷涂钨涂层,超高压电阻烧结技术制备W/Cu梯度材料,粉末冶金TiC、La_2O_3弥散增强钨合金材料。研究发现,钨涂层柱状晶结构能有效地增强整体系统传热,涂层气孔率7.4%、与基体结合良好、热导率80 W/(m·K),能够承受10 MW/m~2的稳态热负荷;5层W/Cu梯度材料无裂纹、孔洞等缺陷存在,表现出优异的热力学性能;La_2O_3和TiC在钨合金中起到"钉扎"作用,大大改善了钨材料晶界力较小,脆性等缺点,提高了冶金材料的性能。     

超导托卡马克EAST限制器材料的腐蚀与沉积的研究

在磁约束聚变实验装置托卡马克中,第一壁材料直接面对高温等离子体,承受高能粒子的轰击。随着聚变装置等离子体存在时间的延长及辅助加热功率的增加,第一壁材料腐蚀和沉积将会越来越严重。材料的腐蚀一方面会污染等离子体影响聚变等离子体的品质,另一方面将危害装置的安全运行。为了提高材料的物理和化学溅射阈值,超导托卡马克东方超环(EAST)装置上选用掺杂碳化硅涂层石墨作为第一壁材料。本实验通过离子束表面分析方法,研究了EAST装置中限制器石墨材料的腐蚀与沉积特性,结果显示在累计大约36000s的等离子体实验中,安装在限制器上的标记瓦块近1μm的碳涂层基本被腐蚀,其腐蚀速率超过0.0278 nm/s。     

钼基体上真空等离子体喷涂钨涂层的研究

采用真空等离子体喷涂(VPS)技术制备出厚度超过0.8 mm的金属钨涂层,并对涂层进行了高温热处理.结果显示:金属钨涂层主要呈层状结构,其密度可达到理论密度的98%以上;工艺参数对喷涂涂层性能有较大影响,特别是对涂层密度、结合强度有影响;高温热处理引起界面结构变化,形成钨钼混合层,且再结晶形成细小的晶粒;和CVD方法以及常压等离子体喷涂方法制备的钨涂层相比,低压等离子体喷涂具有明显的优势.     

中国的超导托卡马克装置HT—7U用炭基面对等离子体材料的研究

聚变能作为一种潜在的替代能源,可以为将来提清洁和无穷尽的能源供给,引起中国政府的高度重视。一项国家大科学工程“超导托卡马克HT－7U的建造”目前正在中国科学院合肥等离子体物理研究所实施。考虑到HT－7U将运行在高热负荷和近稳态的工作条件下,研究和选取面对等离子体候选材料就显得极为重要。中国科学院山西煤炭化学研究所和合肥等离子体物理研究所合作致力于HT－7U用炭基面对等离子体材料的研究和开发。本文主要介绍了聚变能的优点,有关聚变研究的一些基本概念如托卡马克,等离子体,面对等离子体材料,壁材料和等离子体间的相互作用行为等。给出了HT－7U炭基面对等离子体材料的主要结果。相关的具体研究结果将在后续文章中给予报道。     

钨基面对等离子体材料的制备和性能

利用等离子体喷涂技术和弥散增强粉末冶金方法制备钨基面对等离子体材料,并对其基本物理属性进行了分析,包括气孔率及其分布、硬度、抗弯强度、结合强度。同时,利用电子束实验装置对钨基复合材料高热负荷性能进行了研究。研究发现,VPS-W涂层能够承受10MW/m~2、100s的热负荷沉积,涂层开裂、分层是其失效原因;TiC和La_2O_3弥散相增强了钨基复合材料性能,在表面温度控制在1500℃以下可作为面对等离子体材料。     

等离子喷涂工艺对钽/钨复合涂层组织结构的影响

采用等离子喷涂方法制备了Ta/W复合涂层,研究了喷涂距离和喷涂功率对Ta/W涂层密度、沉积效率、化学成分和组织结构的影响.结果表明,Ta/W涂层组织致密,钽、钨涂层之间没有明显的界面,涂层密度分别达到14.27 g/mm3和16.86 g/mm3;喷涂功率对钨粉的沉积效率影响较大,喷涂功率低于40 kW以下时钨粉的沉积效率极低;涂层中的氧含量较低,氧化主要发生在熔融粒子飞行过程中,采用惰性气体保护可以减少涂层中的氧含量.     

等离子沉积氧化锆涂层显微组织及性能研究

目的以氧化锆粉末作为喷涂材料,使用等离子喷涂的方式制备出性能优异的氧化锆涂层。方法通过不同的工艺参数来对涂层的显微组织及性能进行优化,分别利用扫描电镜(SEM)、X射线衍射分析仪(XRD)等方法,研究了工艺参数对涂层显微组织影响,并通过高温氧化测试来研究涂层的抗高温性能。结果在其他喷涂条件固定的情况下,涂层的厚度与喷涂时送粉量有关,送粉量越高则涂层厚度越大;当改变喷涂距离时,涂层的致密度则随着喷涂距离的增加而降低;在高温氧化40h后,涂层表面没有发生明显变化。结论通过等离子喷涂制备的氧化锆涂层具有较好的致密度,孔隙率最低仅为3.24%;涂层具有良好的热稳定性,能够长时间在高温下稳定使用。     

Nitridation of aluminum particles and formation process of aluminum nitride coatings by reactive RF plasma spraying

Nitridation of aluminum particles and formation process of aluminum nitride coatings by reactive RF plasma spraying was investigated by collecting splat and depositions and fabrication of the coating. Nitriding reaction of aluminum particles during flight in the plasma and after deposit on the substrate was confirmed by the observation of splats and the deposition morphologies, respectively. However, as nitriding reaction of aluminum particles easily forms brittle agglomerates on the substrate, the formation of sound coating was difficult. Though the coating was fabricated with the spraying condition of RF power of 5 kW, it was impossible to fabricate the coatings with RF power of 6 kW. In order to fabricate aluminum nitride coatings by reactive RF plasma spraying, it is necessary to control the plasma and the substrate temperature for the suitable conditions with changing RF power and nitrogen gas flow rate.     

大气等离子喷涂工艺参数对Al2O3涂层性能的影响

为了提高燃烧器工艺烧嘴的使用寿命,在UMCo-50基材表面大气等离子喷涂Al2O3层。采用正交试验法对喷涂工艺参数进行了优化,运用微观形貌分析、X射线衍射分析并结合强度及显微硬度等测试方法,系统研究了喷涂主气流量、功率和送粉量对AI2O3涂层综合性能的影响规律。结果表明:喷涂主气流量、功率和送粉量对Al2O3涂层性能具有交互性影响,在40L/min Ar,48 kW和30g/min条件下可以获得性能较好的Al2O3涂层,极大地提高了UMCo-50基材的抗高温氧化和耐磨性能,使之具有广阔的应用前景。     

Effects of shroud gas injection on material properties of tungsten layers coated by plasma spraying

Coated tungsten layers on stainless steel substrates were are produced by atmosphere plasma spraying. A shroud gas injection method was employed to reduce the ambient air entrainment into the plasma jets. The effects of shroud gas on the material properties of the tungsten layers were investigated by finding the dependence of oxide content, coating thickness and porosity on the injection velocity, shielding width, and mass flux of the shroud gas. The high injection velocity was more effective than thick shroud shielding in protecting the plasma jets from ambient air engulfment, and the mass flux of the shroud gas showed negligibly small effects on the suppression of air entrainment. Therefore, in order to produce a thick tungsten coating with low porosity and oxide contents, high injection velocity with a limited flow rate is a desirable operating condition for shroud gas injection in atmospheric plasma spraying.     

正交试验设计优化等离子喷涂纳米Al2O3-13%TiO2涂层工艺参数

为了深入研究等离子喷涂纳米Al2O3-13%TiO2(质量分数)工艺参数与涂层性能之间的关系,采用正交试验设计法,针对等离子喷涂过程中喷涂距离、喷涂电流、主气压力及辅气压力等4个主要参数,选用L9(34)正交表,以涂层结合强度为指标开展制备工艺参数的优化。结果表明,影响涂层结合强度的因素主次顺序是喷涂电流、喷涂距离、主气压力、辅气压力;等离子喷涂纳米Al2O3-13%TiO2最佳工艺参数为:喷涂距离110mm,喷涂电流870A,主气压力0.31MPa,辅气压力0.97MPa,优化工艺喷涂的涂层结合强度达到31.5MPa。     

等离子喷涂WC-12Co涂层的组织与性能

为了提高WC-12Co涂层的喷涂质量,采用大气等离子喷涂(APS)方法在Q235钢基体上制备WC-12Co复合涂层,探讨了不同工艺参数下涂层的组织与性能,用扫描电镜(SEM)、X射线衍射仪(XRD)和能谱仪(EDS)研究涂层形貌和微观组织及涂层成分演变规律,采用显微硬度计测试涂层显微硬度。结果表明:涂层主要由WC和W2C以及少量的Co3W3C和Co6W6C相组成;涂层主要以机械结合方式为主,厚度大约在300μm,粘结层厚度约为60μm。该试验最优工艺参数为电流300 A,送粉率50 g/min,喷涂距离110 mm;优化后涂层硬度为1 169HV0.5 N,孔隙率为3.6%。     

Influence of spraying conditions on thermal and velocity properties of plasma sprayed hydroxyapatite

Hydroxyapatite (HA), classified as a bioactive material, was proven to be well suitable for orthopaedic and dental applications due to its ability to integrate into bone structures and support bone ingrowth. Therefore it is used as a coating material for common metallic implant materials which carry most of the load. Covered by a layer of HA, the implants are much better accepted by surrounding tissues. To date, the only reliable method of applying HA coatings to metallic implants is plasma spraying. The aim of this research was to study the conditions to which the HA powder is exposed during spraying, which, in return, highly influence the resulting quality of the final coating. The two main characteristics describing and quantifying the plasma spraying process — temperature and velocity of the HA particles — were investigated. To study the changes of both characteristics under different spraying conditions, Taguchi design of experiment together with analysis of variance (ANOVA) method were utilized. Results showed the three main parameters influencing the powder particles' in-flight properties are gun power, main gas flow and spraying distance, while other parameters have a little (feed rate) or no effect (auxiliary gas).     

Effect of Zr on microstructure of metallic glass coatings prepared by gas tunnel type plasma spraying

Metallic glass is one of the most attractive advanced materials, and many researchers have conducted various developmental research works. Metallic glass is expected to be used as a functional material because of its excellent physical and chemical functions such as high strength and high corrosion resistance. However, the application for small size parts has been carried out only in some industrial fields. In order to widen the industrial application fields, a composite material is preferred for the cost performance. In the coating processes of metallic glass with the conventional deposition techniques, there is a difficulty to form thick coatings due to their low deposition rate. Thermal spraying method is one of the potential candidates to produce metallic glass composites. Metallic glass coatings can be applied to the longer parts and therefore the application field can be widened. The gas tunnel plasma spraying is one of the most important technologies for high quality ceramic coating and synthesizing functional materials. As the gas tunnel type plasma jet is superior to the properties of other conventional type plasma jets, this plasma has great possibilities for various applications in thermal processing. In this study, the gas tunnel type plasma spraying was used to form the metallic glass coatings on the stainless-steel substrate. The microstructure and surface morphology of the metallic glass coatings were examined using Fe-based metallic glass powder and Zr-based metallic glass powder as coating material. For the mechanical properties the Vickers hardness was measured on the cross section of both the coatings and the difference between the powders was compared.     

超音速等离子体喷涂MoSi2涂层工艺研究

涂层技术是C/C复合材料高温抗氧化与抗烧蚀的有效手段,单一的SiC涂层很难为C/C复合材料提供有效的长寿命保护。金属间化合物MoSi2高温时会形成一层致密的SiO2保护膜,具有特别优异的高温抗氧化性能,常作为C/C复合材料的高温抗氧化涂层。本文采用超音速等离子喷涂法在带SiC涂层的C/C复合材料表面制备了MoSi2涂层,主要研究了喷涂功率、主气(Ar)流量对粉料表面温度、飞行速度、沉积率以及对涂层表面微观结构和结合强度的影响。结果表明:喷涂功率在47.5~52.5 kW之间,既能使粒子有较高的速度和温度,还能保证粉末不过熔,在喷涂功率为50 kW时,粉料的沉积率最高,氧化不高,涂层表面致密性好,截面结合紧密,结合强度高;Ar流量为65 L/min时,能够保证MoSi2粉末有较高的表面温度与较快飞行速度,沉积率最高,氧化不高,涂层表面致密,几乎没有孔隙与裂纹。因此,调控超音速等离子体喷涂工艺参数能够在带SiC涂层的C/C复合材料表面得到致密且结合良好的MoSiO2涂层。