冷喷涂涂层的结合机理

冷喷涂技术在我国和一些发达国家得到了高度重视和发展,研究工作已经在多个方面展开.总结了有关涂层结合机理的研究方法;讨论了绝热剪切失稳现象以及由此可能导致的几种结合方式;分析了粒子临界沉积速度、冲蚀速度与有效结合的关系;介绍了影响涂层质量的因素以及结合强度、显微硬度等力学性能的测试结果.     

挤压态Mg—Gd—Y系合金中的绝热剪切带

在经钢球高速侵彻后的挤压态Mg-Gd-Y系合金板材中发现有绝热剪切带生成.这些剪切带经腐蚀后在光学显微镜下呈亮白色,平均宽度约为10μm,带内的显微硬度明显高于周围基体,属于典型的绝热剪切带.剪切带只出现在稳定塑性侵彻阶段.整个侵彻过程中只有数条剪切带形成,这表明该合金具有较好的抗热塑失稳的能力.     

沉积入射角度对热障涂层形貌和性能的影响

采用真空电弧镀（ARC）技术在DZ125合金基体上制备NiCrAlYSi(HY3)金属粘结层,然后采用电子束物理气相沉积（EB-PVD）技术,分别以0°、20°、40°、60°和80°五种入射角度沉积氧化钇稳定氧化锆（6～8YSZ）陶瓷涂层,研究了入射角度对涂层形貌和性能的影响。结果表明：五种入射角度的热障涂层均能形成柱状晶结构,随着入射角度增加,孔隙率和柱状晶倾斜角度均逐渐增加,涂层厚度逐渐减小;对带涂层试样进行结合强度测试,入射角度0°～40°时涂层的结合强度均在55MPa以上,入射角度增加到80°时,结合强度降低到15.7MPa;热冲击条件下,陶瓷面层和基体之间形成TGO,由于不同入射角度下涂层孔隙率不同,TGO生长速度不一致,导致其热冲击寿命存在明显差异,入射角度为0°～40°时涂层的热冲击寿命均超过4000次,入射角度为60°时涂层的热冲击寿命为3371次,入射角度为80°时涂层的热冲击寿命最短,仅为1836次。     

局部晶序分析方法研究团簇沉积后的晶格结构

在冷喷涂过程中,喷涂粒子被超音速气流加热到较高速度,在低于喷涂材料熔点的温度下撞击基体发生剧烈的塑性变形而沉积形成涂层.通过径向分布函数和局部晶序方法研完了粒子沉积后形成涂层的晶格结构,发现粒子沉积后形成了类似于基体的fcc晶格结构.     

冷喷涂临界速度及其影响因素

综述了冷喷涂过程中粒子速度和临界速度的模拟计算及实际测定的方法,分析了冷喷涂中影响临界速度的因素,指出合理利用数值计算方法并结合粒子和基体本身的物理性质来设计喷管几何结构、优化涂层制备工艺参数以提高涂层性能将是冷喷涂发展的主要方向之一。     

碳基材料超高速粒子侵蚀的数值模拟

应用动力学理论建立了碳基材料超高速粒子侵蚀的数学模型。在模型中引入了表征材料抵抗侵蚀破坏能力的参数: 冲击破坏侵蚀能和剪切破坏侵蚀能。通过定义多重碰撞修正因子β, 给出了多粒子侵蚀材料体积损失的理论计算公式。计算了石墨和C/ C 靶材在Al₂O₃粒子撞击下, 体积损失比随粒子入射角及入射速度的变化规律。结果表明, 脆性碳基材料在超高速粒子撞击作用下, 冲击破坏与剪切破坏同时发生, 冲击破坏在材料体积损失中起主导作用。计算结果与已有的实验值吻合较好。      

TC4和DT4合金的绝热剪切行为

采用分离式Hopkinson压杆装置对TC4钛合金和DT4电磁纯铁的帽形试样进行动态冲击实验,以研究两种材料高应变率下的绝热剪切行为,并分析材料热物理性能和力学性能对其绝热剪切敏感性的影响。实验所得流变应力-时间的关系曲线以及微观的金相分析都表明:尽管两种材料都发生了绝热剪切失效,但是TC4材料中的绝热剪切过程比较短暂,在失稳后的几个微秒之内材料就丧失了承载能力,并且带旁基体无明显塑性流变;而DT4材料中绝热剪切带的形成和扩展过程却要经历约60μs的时间,而带旁边的基体材料沿剪切方向发生了明显的塑性流变。通过对比两种材料绝热剪切带的扩展能,揭示了材料的比热、热导率和动态强度等参数对绝热剪切过程的影响。     

低能He+、Ar+、Xe+轰击SiC的蒙特卡诺模拟

应用蒙特卡诺程序SRIM对He 、Ar 、Xe 轰击SiC的微观过程进行了模拟.对不同能量(100～500eV)以及不同角度(0～85°)下He 、Ar 、Xe 轰击SiC引起的溅射率、溅射原子分布、溅射原子能量以及入射离子在SiC中的分布情况进行了分析比较.结果表明对于原子量较小的He 入射SiC所引起的溅射主要是由进入表面之下的背散射离子产生的碰撞级联造成的,溅射原子具有较高的能量;对于原子量较大的Ar 、Xe 入射所引起的溅射主要是由进入SiC内部的离子直接产生的碰撞级联产生,溅射原子的能量相对较低.随着离子入射角度的逐渐增加,SiC的溅射率逐渐增加,在70°左右达到溅射峰值,随着入射角度的继续增加,入射离子的背散射不能使碰撞级联充分扩大,反冲原子的生成效率急剧降低,导致溅射率开始急剧下降.     

基于设计地震动的斜入射波时程确定方法对土石坝地震响应的影响

基于设计地震动的斜入射波时程确定方法对土石坝的地震响应有显著影响,分析了斜入射P波和SV波时程按均质岩体在平坦地表水平向设计地震动1/2调幅,获得这种常用方法及其适用性。在P波和SV波组合斜入射前提下,考虑两者对半无限空间自由场的共同作用,建立了空间任意点自由场分量表达式,基于控制点自由场分量与设计地震动分量相同的原则,建立了入射波时程与入射角度的函数关系,提出了基于两向设计地震动的入射波时程确定方法。分析了在按垂直入射假定确定斜入射波时程时半无限空间地表自由场和基岩-覆盖层-土石坝系统地震响应相对于该方法的偏差。结果表明:在任意非垂直入射角度下,控制点自由场响应偏离设计地震动较严重,获得的土石坝坝顶加速度大小随入射角度变化规律包含地震动强度变化的贡献,不是设计地震动作用下的结果;该方法获得的地表自由场位移与设计地震动水平和竖直分量均吻合良好,能够正确反映斜入射角度引起的非一致运动,可以在保持设计地震动强度不变的前提下,分析斜入射角度对土石坝地震响应的影响。     

喷涂距离对粒子飞行特征及变形程度的影响

测量了不同喷涂距离下粒子的飞行速度和温度,观察了等离子喷涂ZrO2粒子的变形程度,分析喷涂距离对粒子飞行特征及变形程度的影响.结果表明,粒子速度沿轴向先加速后减速,而粒子温度沿轴向逐渐降低,粒子撞击基体后的变形程度是粒子温度和速度共同作用的结果,当喷涂距离为80mm时,粒子的变形最佳,呈圆盘形.     

THE EFFECT OF MATERIAL MICROSTRUCTURE ON MICROCUTTING PROCESSES

In the machining of mirror-like surfaces, a typical cutting depth of a few micrometers is common. With such a small depth of cut, chip formation takes place within individual grains of polycrystalline materials. In this article, orthogonal cutting of single copper crystals was performed in order to investigate the dependency of cutting deformation and surface quality on the crystallographic orientation of the substrate material. The experimental results show that the crystallographic orientation of the workpiece exerts a significant influence on the shear angle and the machined surface roughness. Cutting force variation with crystallographic orientation was analyzed on the basis of a microplasticity model. The trend in the variation of theoretical values of an effective Taylor factor (the shear strength) compares well with that of published experimental data on cutting forces.     

钨铜聚能粒子流的侵彻特性研究

为研究钨铜聚能粒子流的侵彻特性,对钨铜多孔药型罩和紫铜板药型罩的侵彻性能进行了试验研究,测试了钨铜聚能粒子流侵彻铝板的穿深与时间关系曲线。试验结果表明:在1倍装药口径炸高下,钨铜聚能粒子流侵彻铝靶的穿深比紫铜板射流侵彻铝靶的穿深要提高31%。利用最小二乘法对穿深与时间关系曲线进行拟合,拟合结果表明穿深与时间的关系呈乘幂形式。结合侵彻试验结果,确定了钨铜聚能粒子流的最后侵彻速度为1657.8m/s。这为多孔药型罩聚能装药的设计提供一定的指导意义。     

Residual stress induced by cold spray coating of magnesium AZ31B extrusion

Aluminum particles were successfully sprayed on wrought magnesium AZ31B extrusion using the cold spray technology. Cold spray high impact velocity of particles colliding with the substrate induced beneficial compressive residual stresses. Magnitude of the residual stress at the surface and its distribution through the thickness were measured using X-ray diffraction. With particle spraying velocity of 400 m/s, the residual stress was measured to be −25 MPa at the surface. The process of collision and development of residual stress was then modeled using LS-DYNA software to study the effect of the cold spray process parameters on the residual stress profile. Various models were employed to simulate the impact of the single and multiple particles. An asymmetric material model that considers the strain rate effect was employed to model AZ31B different behavior in tension and compression. Results of simulations for impact of multiple particles were compared with the results of XRD measurements on the substrate surface and through the depth of the substrate. After the validation of the models, a parametric study was performed on the impact of a single particle to find the optimum cold spray particle velocity, size, shape, incident angle, and friction parameters. Parameters leading to the optimum residual stress profile are introduced herein.     

Adiabatic shear instability based mechanism for particles/substrate bonding in the cold-gas dynamic-spray process

Particles/substrate interactions during the cold-gas dynamic-spray deposition process are studied using a dynamic axisymmetric thermo-mechanical finite element analysis. In addition, the particles/substrate bonding mechanism has been investigated using a one-dimensional thermo-mechanical model for adiabatic strain softening and the accompanying adiabatic shear localization. The results obtained show that the minimal impact particles velocity needed to produce shear localization at the particles/substrate interface correlates quite well with the critical velocity for particles deposition by the cold-gas dynamic-spray process in a number of metallic materials. This finding suggests that the onset of adiabatic shear instability in the particles/substrate interfacial region plays an important role in promoting particle/substrate adhesion and, thus, particles/substrate bonding during the cold-gas dynamic-spray process.     

Wachstum von TiN-Schichten bei periodisch wechselnden Einfallswinkelverhältnissen der schichtbildenden Teilchen

Preferably, the magnetron sputtering process is used for the deposition of hard coatings in the low temperature range. The bombardement of energetical particles as well as the angular distribution of particle incidence onto the substrate are well known to influence the growth of the film substantielly. Especielly, layers with open columnar microstructure grow if the film-forming particles arrive the substrate at a large angle against the normal of the substrate. These films are unsuitable for tribological protection. For thickness homogenization and for effective utilization of the deposition chamber, a motion of the substrates is nessesary. This motion causes time dependent variations of the angle of the particles incidence. The microstructure of the films will be shown to deteriorate due to the amount of particles arriving the substrate at a large angle against the normal of the substrate. The possibility to suppress the formation of the open columnar microstructure during deposition of hard coatings on substrates (e.g. tools) by suitable procedures is discussed.     

Effect of liquid layer on the motion of particle during oblique wet collision

Collisions between particles and the wall covered by a liquid layer play an important role in many different industrial processes (e.g., chemical, pharmaceutical, and transportation). Understanding the rebound motion law of the collision between particles and the wall covered by a liquid layer is vital to ensure the high efficiency of processes such as wet granulation and fluid catalytic cracking. In the present study, we investigated the influence of different collision angles on the liquid bridge geometry, particle motions, particle energy, and other collision details based on the oblique collisions between particles and the target plate covered by a liquid layer. Results showed that the collision angle of particles has a great effect on the liquid bridge geometry. Moreover, the liquid bridge caused by different collision angles initially increases the particle deflection angle difference and then decreases, and this influence gradually increases with the increase of the collision angle. In addition, the collision angle greatly affects the particle’s energy.     

Ultrasonic assisted fabrication of particle reinforced bonds joining aluminum metal matrix composites

This paper presents a method of producing uniform particle strengthened bonds between pieces of aluminum metal matrix composite (Al-MMCs), of strength equal to that of the substrate material. SiC particle reinforced Zn-based filler metals were fabricated by mechanical stir casting and ultrasonic treatment, and then used to join pieces of SiC_p/A356 composite with the aid of ultrasonic vibration. The filler metals made by mechanical stirring were porous and contained many particle clusters. Ultrasonic vibration was used to disperse the agglomerates and prevent further coagulation of SiC particles during joining, but the method failed to eliminate the porosity, resulting in a highly porous bond. The filler metal treated by ultrasonic vibration was free of defects and produced a non-porous bond strengthened with uniform particles between pieces of SiC_p/A356 composite. The presence of surface oxide films at the bonding interface significantly degraded the performance of SiC particle reinforced bond. Removal of this oxide film by at least 4 s of ultrasonic vibration significantly increased the bond strength, reaching a value equal to that of the substrate metal.     

Numerical prediction of particle erosion of pipe bends

In the present study the Euler/Lagrange approach in combination with a proper turbulence model and full two-way coupling is applied for erosion estimation due to particle conveying along a horizontal to vertical pipe bend. Particle tracking considers both particle translational and rotational motion and all relevant forces such as drag, gravity/buoyancy and transverse lift due to shear and particle rotation were accounted for Laín and Sommerfeld (2012). Moreover, models for turbulent transport of the particles, collisions with rough walls and inter-particle collisions using a stochastic approach are considered Sommerfeld and Laín (2009). In this work, the different transport effects on spherical solid particle erosion in a pipe bend of a pneumatic conveying system are analysed. For describing the combined effect of cutting and deformation erosion the model of Oka et al. (2005) is used. Erosion depth was calculated for two- and four-way coupling and for mono-sized spherical glass beads as well as a size distribution of particles with the same number mean diameter (i.e. 40?μm). Additionally, particle mass loading was varied in the range from 0.3 to 1.0. The erosion model was validated on the basis of experiments by Mazumder et al. (2008) for a narrow vertical to horizontal pipe system with high conveying velocity. Then a 150?mm pipe system with 5?m horizontal pipe, pipe bend and 5?m vertical pipe with a bulk velocity of 27?m/s was considered for further analysis. As a result inter-particle collisions reduce erosion although the wall collision frequency is enhanced Sommerfeld and Laín (2015); additionally, considering a particle size distribution with the same number mean diameter as mono-sized particles yields much higher erosion depth. Finally, when particle mass loading is increased, bend erosion is reduced due to modifications of particle impact velocity and angle, although wall collision frequency grows.     

氧化铝悬浮液剪切流变特性的研究

分析了柠檬酸铵(TAC,分散剂)稳定的氧化铝悬浮液的剪切流变行为,研究了TAC加入比例及颗粒大小对流变特性的影响.认为静态时悬浮液中存在由于颗粒布朗运动而形成的热力学颗粒簇,剪切变稀是在剪切作用下热力学颗粒簇分解的结果,而剪切稠化源于剪切作用下水力学颗粒簇的形成.通过悬浮液中颗粒成簇势垒概念的引入,提出悬浮液的低剪粘度和高剪粘度分别取决于氧化铝颗粒表面的ζ电位和Stern电位,通过加入过量的柠檬酸铵可以抑制悬浮液的剪切稠化,推导出了剪切稠化临界剪切速率与颗粒粒径关系的数学表达式.