Novel pretreatment of hard metal substrate for better performance of diamond coated cutting tools

A surface engineering approach for a novel pretreatment of hard metal tool substrate for optimum adhesion of diamond coatings is presented. Firstly, an alkaline solution was used to etch the WC grains to generate a rough surface for better mechanical interlocking. Subsequently, surface Co was removed by etching in acid solution. Then the hard metal substrate was boronized to form a compound interlayer which acted as an efficient diffusion barrier to prevent the outward diffusion of Co. Novel nano-microcrystalline composite diamond film coatings with a very smooth surface was deposited on the surface engineering pretreated hard metal surface. Promising results of measurement in adhesion strength as well as field cutting tests have been obtained.     

基底厚度对蒸发液滴表面温度分布的影响

蒸发液滴的表面温度分布对液滴的液体流动和颗粒沉积有着重要的影响。获得液滴表面温度目前主要采用数值计算方法。针对有限厚度基底上的蒸发液滴,分析了网格划分对液滴表面温度计算结果的影响。结果表明,相比于液滴边缘附近区域,液滴中心区域网格的细化对计算结果影响不大;而在接触线附近,相比于网格尺寸,网格细化区域大小对计算结果的影响也很小。利用数值方法研究了基底厚度对蒸发液滴表面温度分布特性的影响,发现随着基底厚度的改变液滴表面出现3种温度分布模式:(1)从液滴顶点到边缘处表面温度逐渐升高;(2)液滴表面温度非单调变化;(3)从液滴顶点到边缘处表面温度逐渐降低。考虑热传导路径长度和蒸发制冷的共同作用,对不同表面温度分布模式进行了解释,并获得了(h_R,q)坐标平面上的表面温度分布模式相图。本文结果将有助于对液滴蒸发过程的理解,并为蒸发诱导自组装、喷墨印刷等技术提供理论依据。     

PcBN刀具车削淬硬高速钢的切削力与温度研究

应用正交试验设计,研究了PcBN刀具车削淬硬高速钢的切削力、切削温度以及切屑形态。结果表明：切削深度和进给量的增加而引起切削力的增大,切削速度的增加而引起了切削力的减小,切屑具有绝热加工形成的锯齿形态特点。     

Applicability of DLC and WC/C low friction coatings on Al2O3/TiCN mixed ceramic cutting tools for dry machining of hardened 52100 steel

The present work examines the applicability of DLC and WC/C low friction coatings on Al₂O₃/TiCN based mixed ceramic cutting tools for the dry and hard turning of AISI 52100 steel (62 HRC). The characterization of coated tools reveals that the coatings retain very low values of surface roughness, whereas the DLC coating exhibits much higher microhardness when compared to the WC/C coating. On the other hand, the WC/C coating exhibit a coarse surface morphology virtually due to the tungsten doping. Later, continuous turning tests were executed with the help of coated and uncoated cutting tools under dry cutting conditions, and their performance was investigated in terms of machining forces, cutting temperature and tool wear. Coating delamination by flaking and peeling is quite prominent in the case of both the coatings; however, it is less severe for the WC/C coated tool. The coatings help to reduce machining forces, cutting temperatures and tool wear, but the performance of coated tools converge towards uncoated tool as the cutting speed, and feed rate is increased. Both the coatings prevent the development of cracks near the cutting edge with WC/C coating exhibiting superior wear behavior basically due to its multilayered structure and better thermal stability. Moreover, the tested low friction coatings don't serve as thermal barriers and only the lubrication generated due to graphitization at the chip-tool interface is mostly responsible for the improved machining performance.     

Reliability analysis of ceramic cutting tools in continuous and interrupted hard turning

Reliability analysis was carried out for ceramic cutting tools used in continuous and interrupted hard turning. On the basis of micromechanics and damage mechanics, statistical characteristics of the original defects in the tool material microstructure were evaluated and analyzed. A new tool performance indicator was proposed considering the combined effects of the original damage of the tool material microstructure, the macro-mechanical properties of the tool material and the external loads on the cutting tool. Statistical analysis of the tool performance indicator was performed for continuous and interrupted turning. The relationship between tool reliability and the probability distribution of tool performance indicator was identified. It was found that the original damage of the ceramic tool material followed a weibull distribution. The probability density of the original damage decreased as the original damage increased. When interrupted turning was adopted, tool performance indicator was relatively low and the indicator decreased as cutting length ratio became smaller. The indicator followed a weibull distribution and this was invariable when turning condition changed. Relatively low shape parameter and scale parameter in probability density function of tool performance indicator appeared when the tool was tested in interrupted turning and relatively small cutting length ratio was applied. Similar to tool performance indicator, tool lives obtained under different cutting conditions also followed a weibull distribution. When turning condition varied, shape parameter and scale parameter in probability density function of tool life changed in a similar way to those parameters in probability density function of tool performance indicator. Both the probability density function of tool life and that of tool performance indicator first increased and then decreased as the independent variable increased. Shape parameter for tool performance indicator can be used in the calculation of tool reliability when the cutting length ratio in interrupted turning was relatively small.     

改性纳米TiO_2对纸张涂料及涂布纸性能的影响

研究了改性纳米TiO2对纸张涂料流变行为和涂布纸性能的影响。研究发现,在同一剪切速率下,随着改性纳米TiO2用量的增加,纸张涂料的表观黏度逐渐增大,且含改性纳米TiO2的纸张涂料具有较高的弹性模量和黏性模量,相位角则较低;随着改性纳米TiO2的用量在0~10%范围内增加,涂布纸的光学性能和印刷适性持续改善,且涂层表面结构的SEM和AFM观察显示,含改性纳米TiO2的纸张涂层表面具有较优的微观孔隙结构。     

硬质合金刀具类金刚石涂层的摩擦磨损性能

以等离子体化学气相沉积技术在硬质合金刀具表面制备了类金刚石(DLC)涂层.研究了DLC涂层刀具和无涂层刀具的硬度,不同载荷、不同转速下两种刀具的摩擦磨损性能,以及在水润滑和油润滑条件下DLC涂层刀具的滑动摩擦行为.结果表明,DLC涂层刀具的平均硬度为2 099.9 HV,比无涂层刀具提高了48.3%;DLC涂层刀具的摩擦因数明显低于无涂层刀具,其磨损率随着载荷的增加而增大,随转速的增大而减小;油润滑比水润滑能更有效减缓摩擦作用.     

Influence of hot-pressing temperature on physical and electrochemical performance of catalyst coated membranes for direct methanol fuel cells

The physical and electrochemical performance of a direct methanol fuel cell (DMFC) are improved by optimizing the hot-pressing temperature for fabricating the catalyst coated membrane (CCM) through the decal transfer method. SEM and XRD tests show that the morphology of the catalyst layer and the growth of Pt particles can be greatly influenced by the hot-pressing temperature. The CCM hot-pressed at 185 °C displays the best output performance due to the increase in electrochemical surface area (ESA), and the improved contact between the catalyst layer and the membrane. Although high hot-pressing temperature favors decreased methanol crossover, the performance of the CCM is subject to serious Pt agglomeration and slow mass transport.     

Design and optimization of the coating thickness on chopped carbon fibers and sintering temperature for ZrB2-SiC-Cf composites prepared by hot pressing

Interface designation and low-temperature densifying were expected to inhibit the performance attenuation of fiber in the preparation of ceramic matrix composites. Nevertheless, the optimization of interface thickness and sintering temperature were still rarely investigated systematically. Herein, the performance of carbon fiber varied with coating thickness and the heat-treat temperatures were investigated by quantitatively. The tensile strength of carbon fibers degraded dramatically (≥30%) when coating thickness above a critical value. A larger dimension and ordered graphite crystallite structure resulted in the severe performance deterioration of carbon fibers as the sintering temperature exceeding 1500 ℃. The PyC coatings with an appropriate thickness acted as a critical role of changing the fracture mode of the ZrB₂-SiC-C_f and noticeably increased the fracture strain of the composite. The regular trend provided a general design strategy in construction of ZrB₂-SiC-C_f composite with optimal properties and could be extended to other ceramic matrix composites.     

高温相变材料胶囊化及应用研究进展

高温相变材料因具有较高的相变温度,且单位体积的潜热值较大,将其胶囊化用于高温领域（＞120℃）具有较大的应用前景。本文介绍了高温相变材料的种类及其胶囊化技术,对不同类型的高温相变胶囊制备方法进行了阐述。指出了目前高温相变胶囊制备过程中存在的问题,如金属大胶囊的芯材与壁材的相容性、微/纳胶囊易破碎等。重点论述了溶胶-凝胶法、水热法制备高温相变微/纳胶囊过程中囊壁材料、热处理温度等对胶囊性能的影响。针对上述因素引起的胶囊热循环性能差、过冷大等问题,提出了解决方案。最后阐述了高温相变胶囊的相关应用情况,并提出未来在寻找与芯材相容性好的壁材、优化微/纳胶囊制备方式、抑制胶囊过冷等方面需要进一步探索。     

Corrosion‐resistant coating development with potential application in equipment of low‐temperature waste heat recovery

In order to improve corrosion resistance of a condensing heat exchanger, a fluoropolymer, perfluoroalkoxy alkane (PFA), fine powder in 30 wt% aqueous slurry was coated on metal coupons and a coating of high quality finish was obtained. The coating was characterized by microscopy and thickness measurements. The thickness of the coating can be controlled by the number of layers used for the application of wet spray. Hot acid bath corrosion tests showed that the coated coupon possesses the highest adhesion strength and excellent corrosion resistance (1.8–6.7 × 10^?3 mm/year), comparable to super alloys such as Inconel (1.1–26.2 × 10^?3 mm/year) and Hastelloy (0.3–19.8 × 10^?3 mm/year). A heat transfer coefficient analysis showed that across a heat transfer metal tube coated with PFA, the heat transfer resistance of the gas side film is one order of magnitude larger than the resistance from the coated layer. The developed coating could provide an alternative material solution for condensing heat exchangers used in low‐grade waste heat recovery.     

Computer-aided modeling for predicting layer thickness of a duplex treated ceramic coating on tool steels

Five different tool steels (DIN 1.2080, 1.2210, 1.2344, 1.2510 and 1.3343) have been targeted for a duplex surface treatment consisted of nitriding followed by vanadium thermo-reactive diffusion (TRD). TRD process was performed in molten salt bath at 575, 650 and 725 °C for 1 to 15 h. A duplex ceramic coating of vanadium carbonitride (VCN) with a thickness up to 10.2 μm was formed on tool steel substrates. Characterization of the ceramic coating by means of scanning electron microscopy (SEM) and X-ray diffraction analysis (XRD) indicated that the diffused compact and dense layers mainly consisted of V(C,N) and V₂(C,N) phases. Layer thickness of duplex coating has been modeled by gene expression programming (GEP). Recently, application of GEP as a computer-aided technique has got appreciable attraction especially for modeling and to formulate engineering demands. For GEP approaches, chemical composition of steel substrates along with different bath and processing parameters totally composed of 17 different parameters were considered as inputs to establish mathematical correlations. Finally, the training and testing results in models have shown strong potential for predicting the layer thickness of duplex treated ceramic coating on tool steels.     

电场对竖直矩形微槽群润湿及表面温度的影响

微槽群在热流密度较大时会达到其毛细极限,可通过主动换热方式之一——电水动力学效应对其进行强化。本文为了研究电场对微槽群表面润湿特性和温度分布的影响,采用平板电极提供电场,蒸馏水作为工质,使用高速相机拍摄微槽内液体润湿长度,测量误差为2.97%～7.46%;使用红外热像仪拍摄电场作用下微槽群表面温度分布,测量误差为2.1%～2.39%。热流密度测量误差范围是9.66%～11.11%。结果表明：电场通过驱动微槽内流体向加热区域流动而提升其润湿性能,且较低热流密度下提升更好。因润湿性能的提升,微槽表面温度得以下降。随着电场增强,微槽横向温度分布的“波峰”、“波谷”差别加大,微槽纵向温度明显降低。当热流密度加大时,温降更为显著,1.4W/cm²热流密度、6kV电压下温降可达到30℃以上。温降的增加反映了电场对微槽的强化润湿进一步提升了微槽换热性能,且电场对较高热流情形下的微槽换热有着更为显著的强化效果。     

非等温液-液对置撞击面温度分布均匀性

对不同条件下非等温过程液-液对置撞击后形成的气液混合撞击面的温度分布均匀性进行了研究。以温度不均匀系数和撞击面温度分布作为评价标准,利用Mixture模型数值模拟撞击过程,并基于平面激光诱导荧光（PLIF）技术进行可视化测量实验验证计算模型。通过对不同的喷嘴出口速度（v）、喷嘴对置间距（L）以及湍动能等条件下撞击面温度分布进行研究。结果表明,喷嘴直径和喷嘴对置间距一定时,增加喷嘴的出口流速,则温度不均匀系数整体呈下降趋势;喷嘴直径和喷嘴出口流速一定时,非等温液-液对置撞击后形成区域温度场分布随喷嘴间距的增加,其温度分布区间呈减小趋势。L=3D时,温度的分布区间最小,温度场分布最均匀。湍动能的分布曲线越平稳,液-液对置撞击后形成的气液混合撞击面的温度分布越均匀。     

A numerical approach to the heat transfer in monolithic and SiC reinforced HfB2, ZrB2 and TiB2 ceramic cutting tools

Cutting tools are widely used in industry and must be hard enough for machining processes, which should work appropriately at low temperatures to improve cutting speed and productivity. In this research, a numerical method was employed to calculate the temperature distribution in the cutting tools made of different diborides. Monolithic and SiC reinforced HfB₂, ZrB₂ and TiB₂ ceramics were selected for investigation and comparison studies. In this regard, 3-dimensional heat conduction equation was solved in a cutting tool with radiative, convective and heat flux boundary conditions by finite element method using COMSOL Multiphysics. This study clarifies that the maximum temperature in the tools made of ZrB₂ and TiB₂ among the monolithic ceramics is lower than that of HfB₂. Moreover, the temperature variation slope versus time is the highest in HfB₂. All composite materials reinforced with SiC showed lower maximum temperature than the monolithic ones. The thermal performance of TiB₂–SiC and ZrB₂–SiC composites was acquired to be better than that of the other investigated materials. The dominant heat transfer mechanism in the cutting tools was conduction.     

Preparation and high-temperature oxidation resistance of multilayer MoSi2/MoB coating by spent MoSi2-based materials

Spent MoSi₂ and MoB were used as raw materials to prepare multilayer MoSi₂/MoB coating on molybdenum by the two-step method of slurry deposition and spark plasma sintering. The results showed dense MoSi₂/MoB coating after sintering while penetrated cracks appeared in MoSi₂ coating due to coefficient of thermal expansion mismatch between the Mo substrate and coating. After the sintering of MoSi₂/MoB coatings, MoB and Mo₂B diffusion layers were formed between MoB transition layer and Mo substrate without defects, exhibiting good metallurgical bonding. The high-temperature oxidation behavior of coatings (1500°C) was also explored. After oxidation of 50 h at 1500°C, lowest mass gain (0.035 mg/cm²) was obtained for MoSi₂/MoB coating, and the oxide scale was dense and complete without voids, making the oxygen diffusion at elevated temperature inhibited. Compared with MoSi₂ coating under the same oxidation conditions, relatively thinner silica oxide scale was acquired by MoSi₂/MoB coating because of the reduction of cracks, and the multilayer coating exhibits better anti-oxidation properties at high temperature.     

Ablation behavior of HfC coating with different thickness for carbon/carbon composites at ultra-high temperature

The thickness of the different HfC coatings from 20 μm to 50 μm were prepared on the surface of carbon/carbon (C/C) composites by low pressure chemical vapor deposition (LPCVD). The microstructure and thermal stress of the coatings after ablation were investigated, as well as the effect of thickness and thermal stress on the ablation resistance of the HfC coating was analyzed. After being ablated at a heat flux of 2.4 MW/m² for 60 s, the thermal stress gradually increased at first and then rapidly increased with the increasing thickness of coating. The results indicated that the moderate coating thickness can effectively release the thermal stress generated during the ablation process. The 40 μm-thick HfC coating showed the best ablation resistance with the mass ablation rate and line ablation rate were only 0.13 mg/s and 0.09 μm/s, respectively.     

Influences of interface morphology and thermally grown oxide thickness on residual stress distribution in thermal barrier coating system

Calculation of residual stress with finite element method is a basic work in failure mechanism investigation in thermal barrier coating (TBC) system because the residual stress is main driving force for crack nucleation and propagation. In this work, a complicated cosine curve with gradually increasing amplitude was used to simulate interface morphologies between layers so as to study the residual stress behavior during the cooling process in air plasma spraying TBC system by finite element method. The substrate, thermally grown oxide (TGO) and top coat (TC) are considered to be elastic and bond coat (BC) elastic-perfectly plastic. The material properties are all temperature dependent. The stress result comparison between models with and without substrate shows the effect of substrate on the residual stress distribution around layers interfaces should not be ignored as the substrate influences the value of normal residual stress as well as the stress distribution along undulating interfaces. Then the model with substrate was used to study the residual stress evolution along interfaces during cooling down from the temperature of 1000 °C to room temperature. The influences of the thickness of TGO and the amplitude and wavelength of interface on the residual stress distributions near interfaces were considered. The results show that these influences are very complicated. Meanwhile, it's found that the hybrid roughness parameter containing information for height and spacing is more suitable to describe the interface complicacy. The results facilitate understanding the failure mechanism relevant to interface morphology and TGO thickness.     

传热模型对近临界工况CO2干气密封温压分布和稳态性能影响

干气密封流体膜与密封环间传热模型的合理选取对于准确求解密封温压分布和稳态性能至关重要。在CO₂近临界工况下,对比研究了密封环等温模型、绝热模型和共轭热传递模型对超临界CO₂干气密封端面温度、压力分布和开启力、泄漏率等稳态性能的影响,探讨了不同膜厚和转速条件下密封环等温模型和绝热模型的适用性,并基于共轭热传递模型研究了超临界CO₂和空气介质干气密封的温压分布和稳态性能差异。结果表明：以共轭热传递模型计算结果为基准,密封环等温模型假设适用于小膜厚低速流动工况,不过开启力偏低而泄漏率偏高,绝热模型假设适用于大膜厚高速流动工况;相较于空气介质干气密封,超临界CO₂干气密封在小膜厚下的温度分布和大膜厚下的压力分布基本接近,不过小膜厚下的温度更低,而在大膜厚下的压力更高。     

板式换热器Ni-P-TiO2复合纳米镀层微生物污垢特性

换热器微生物污垢问题普遍存在于能源化工领域,污垢的聚集会导致设备的流动阻力、燃料消耗和维护成本支出大幅度增加。本文采用复合纳米镀层来抑制和减轻换热表面的微生物污垢的附着和沉积。首先采用化学镀的方式,在板式换热器的不锈钢316板上镀覆 Ni-P-TiO₂复合纳米镀层和对照性的Ni-P 镀层。基于板式换热器的微生物污垢在线监测实验系统,研究了镀覆Ni-P-TiO₂复合纳米镀层的板式换热器微生物污垢特性。结果表明,清洁状态下,镀覆两种镀层的板式换热器其摩擦系数（f）和Nusselt数（Nu）相较未镀覆板式换热器均略有增加;微生物污垢实验后,相比较未镀覆的板式换热器,镀覆Ni-P镀层的板式换热器污垢热阻减少了8.36%~23.07%,而镀覆Ni-P-TiO₂复合纳米镀层的板式换热器污垢热阻减少了16.6%~30.96%;在相同微生物污垢实验工况下,镀覆Ni-P-TiO₂复合纳米镀层的板式换热器的摩擦系数（f）相比Ni-P镀层的低2.54%~11.82%,但Nu却明显高于Ni-P镀层达8.47%~9.45%,并且污垢热阻明显小于Ni-P镀层达10.66%~18.18%,镀覆Ni-P-TiO₂复合纳米镀层的板式换热器展现了优异的强化传热性能和抑垢性能。