钛合金磨料流光整加工表面完整性研究

目的 研究磨料流光整加工钛合金格栅表面完整性。方法 用电火花加工制备钛合金试样,通过磨料粒径、加工压力、加工次数的单因素试验,来研究其对试样表面粗糙度和表面形貌的影响规律,选用三种初始粗糙度不同的钛合金试样来进行磨料流光整加工效果试验,对比分析磨料流光整加工对试样表面残余应力的影响,进行加工次数的单因素试验研究磨料流加工过程中其对工件表面显微硬度的影响。结果 对于钛合金试样来说,磨料粒径和加工压力越大,表面抛光效果越明显,表面粗糙度就越低。当磨料粒径从38 μm增加到420 μm时,相对应的表面粗糙度值Ra从5.815 μm降低到0.824 μm;当加工压力从8 MPa增加到24 MPa时,相对应的表面粗糙度值Ra从4.314 μm降低到1.398 μm。而随着加工次数的增加,表面粗糙度值Ra从整体上呈现下降趋势,最后趋于稳定,当加工次数从10增加到80时,相对应的表面粗糙度值Ra从5.925 μm降低到0.307 μm,并且最后稳定在0.300 μm附近。钛合金试样经磨料流光整加工之后,表面残余应力由原来的拉应力变成了压应力。随着加工次数的增加,钛合金试样表面显微硬度整体上呈现先减小后增大的趋势,当加工次数从10增加到50时,显微硬度值从532.83HV降到357.73HV,当加工次数从50增加到90时,显微硬度值从357.73HV上升到393.48HV,试样表面显微硬度的均匀性也显著增加。结论 增大磨料粒径和加工压力或者增加加工次数,都能降低工件表面粗糙度,钛合金工件经过磨料流光整加工之后,表面完整性有较大改善。     

SiC和Al2O3颗粒对Ti-25Nb-3Mo-3Zr-2Sn合金微磨损行为的影响

本文研究了SiC和Al₂O₃颗粒对生物医用植入材料Ti-25Nb-3Mo-3Zr-2Sn合金的微磨损行为的影响。在文中研究了合金的比磨损率、摩擦系数、磨损机制以及微磨损与腐蚀之间的协同作用。研究结果显示,合金的比磨损率随磨粒尺寸的增加而增加。由于SiC磨粒的硬度和切削性均优于Al₂O₃磨粒,由此在同尺寸磨粒下SiC磨粒所造成的材料的损失比Al₂O₃磨粒造成的要大。摩擦系数的结果显示,在同一种磨粒作用下,Hank’s溶液中所获得的摩擦系数的平均值大于蒸馏水中所获得的摩擦系数平均值,且由于Hank’s溶液的腐蚀性所致在Hank’s溶液中获得的摩擦系数的稳定性要比在蒸馏水中的稳定性差;在同尺寸磨粒下,Al₂O₃磨粒所造成的摩擦系数要大于SiC磨粒所造成的。随磨粒尺寸的减小,磨损机制由三体磨损转变为混合磨损之后再转变为二体磨损。从磨损机制图中可以看出腐蚀对材料损失的贡献是不容小视的,磨损机制为以磨损为主的磨损腐蚀。     

电火花强化工艺制造金刚石镀层实验研究

为实现金刚石工具的快速制造和在线快速修复,探索了一种简单快速的金刚石表面强化工艺方法的可行性。以金刚石颗粒和钴颗粒为主要成分,采用压制工艺制作电极,并用该电极在基体材料304不锈钢板上进行电火花强化实验,探究电极的压制压力、金刚石含量、加工电流和加工时间等参数对实验效果的影响规律。用镀钛金刚石电极加工5 min,可得到表面上金刚石颗粒的表面积分数为13.5%、厚度为400μm的强化层,且该强化层具有很好的磨削性能。     

The microstructure of composite cermet coatings produced by carbo-vibroarc surfacing

The results of investigation of the microstructure of composite coatings produced by carbo-vibroarc surfacing using cermet pastes are presented. It is shown that the composite cermet coating consists of two zones – the main and transition. The main zone of the coating contains the Fe₂B hardening phase with nickel and chromium atoms implanted in the crystal lattice of the phase. The zone is situated in the matrix of the solid solution of iron and nickel Ni₃Fe. The transition zone of the coating is formed by the mutual diffusion of the coating and the substrate and consists of the (Fe, Ni)₂B hardening phase and the Ni₃Fe matrix. It is also shown that the hardening phases form plate-shaped grains with thicknesses of 1–4 μm and more than 100 μm long, distributed in the form of colonies throughout the entire volume of the coating zone. In the direction to the transition zone, the shape of the structural components changes to circular with the diameter of up to 5 μm.     

Producing hardfacing composite materials for ecologically safe technologies

The application of hardfacing materials for producing high-strength coatings on components working in abrasive wear conditions is one of the important directions of research into increasing the service life of road construction, agricultural and other types of equipment. However, in producing this equipment, the ecological safety requirements are sometimes ignored and this results in negative effects on the environment and the health of personnel. This article describes the results of scientific and research investigations of the team of authors to develop a cladding powder by the method of chemical gas phase deposition of nickel tetracarbonyl on the surface of aluminium oxide particles and application of the powder for producing wear-resistant coatings. The powder materials are deposited in a closed cycle excluding contact of the personnel with toxic substances and emission of contaminants into the atmosphere, resulting in a safe process. Plasma coatings with the required physical–mechanical properties have been produced. This confirms the efficiency of the approaches used in this case and increases the service life of working sections of machines subjected to abrasive wear.     

Feasibility study of a flexible grinding method for precision machining of the TiAl-based alloy

This study presents detailed experimental investigations on precision machining of the TiAl-based alloy with an abrasive belt flexible grinding method. Subsequently, the feasibility of this precision machining method is evaluated with respect to the material removal rate, abrasive wear, machined surface roughness, and residual stress. The material removal rate and surface roughness were determined as experimental indicators and were measured via a three-coordinate measuring instrument and surface profiler, respectively. Micro-morphologies of the machined surface and worn abrasive belt were investigated via a scanning electron microscope. The residual stress distributions in the machined surface layer were detected by using an X-ray diffractometer. The experimental results revealed that the aforementioned evaluation indicators satisfied the desired requirements, thereby indicating that the abrasive belt flexible grinding technique was suitable for precision machining of the TiAl-based alloy. Additionally, the optimal combinations of grinding parameters were determined to obtain desirable material removal rate and machined surface roughness. The basic wear processes and characteristics of the abrasive belt were thoroughly examined. The formation of desirable residual compressive stresses in the machined surface layer was mainly attributed to low frequency and small amplitude vibration knocking at the grinding interface.     

颗粒增强钢基耐磨复合材料的制备、组织与性能

采用铸渗法成功制备出ZTA(ZrO2增韧A12O3)陶瓷颗粒增强合金钢基耐磨复合材料.制备方法:将陶瓷颗粒与自制粘结剂混合填充到具有一定型腔的模具中,加压凝固后获得多孔连通的陶瓷预制体;将预制体固定到铸型中,浇注合金钢,浇注温度1 500--1 560℃,金属液铸渗预制体获得局部复合的耐磨复合材料.结果表明:铸渗效果良好,陶瓷颗粒与合金钢基体界面结合紧密,无缩孔、裂纹等缺陷;陶瓷颗粒在复合材料中的体积分数为42％～56％;在三体磨料磨损条件下,ZTA/合金钢复合材料的抗三体磨料磨损性能是合金钢基体的4.37倍.     

钒钛微合金化对铸态中锰钢组织和性能的影响

通过试验研究,探讨添加钒钛微合金化对铸态中锰钢的组织性能的影响,确定钒钛微合金的合适加入量,实验表明经添加V质量分数为0．1％。0．2％或Ti0．15％与稀土和硅钙合金的复合处理后的铸态中锰钢,在中低冲击载荷下耐磨性能优于高锰钢,实现铸态中锰钢在中低冲击载荷下使用具有良好的耐磨性,该项目的研究具有良好的经济与社会效益。     

超声振动对GCr15/45钢摩擦副油润滑下的摩擦磨损性能影响

在超声振动摩擦磨损实验仪上考察了超声振动对GCr15/45钢摩擦副油润滑下的减摩抗磨性能影响,初步探讨了在超声振动下摩擦磨损机制。结果表明,超声振动作用下45钢表面的质点会产生振动,减小了摩擦副间的正压力,破坏了表面油膜的形成影响摩擦副间的减摩抗磨性能。在所选试验载荷范围内,超声振动均可以不同程度的改善摩擦副的减摩抗磨性能,其中载荷为40 N时,超声振动对摩擦副的减摩抗磨性能改善最显著,摩擦因数和磨损体积比没有超声振动时分别降低了10%和49%。超声振动没有改变GCr15/45钢摩擦副的磨损机制,但可以减轻磨粒磨损程度。     

大型钛合金复合板材恒压砂带磨削关键技术研究

文章针对大型钛合金复合板材砂带磨削过程中出现的问题,提出了自适应模糊-PID复合控制方案,有效地解决了钛合金复合板材砂带磨削加工过程中存在的磨削不均匀问题.通过恒压力接触被磨工件,使磨头磨具能有效地跟随板材型面起伏变化,不仅保证了磨削深度尺寸而且改善了板材的表面加工质量.在对被控对象进行仿真的基础上,进行了磨削试验研究,结果表明:采用自适应模糊-PID复合控制方案对钛合金板材进行磨削,试件表面各处的材料去除厚度基本在0.1～0.16mm之间平稳浮动,取得了良好的控制效果.