真空压力浸渗制备SiCp/AZ91复合材料的显微组织、力学性能和磨损行为

采用真空压力浸透法制备SiC_p/AZ91复合材料,研究其显微组织、力学性能和耐磨性。结果表明,SiC颗粒均匀分布于金属基体中,并与基体界面结合良好。Mg₁₇Al₁₂相在SiC颗粒附近优先析出,SiC与AZ91基体的热膨胀系数失配导致高密度位错的产生,加速基体的时效析出。与AZ91合金相比,SiC颗粒的加入提高了复合材料的硬度和抗压强度,这主要是由于载荷传递强化和晶粒细化强化机制。此外,由于SiC具有优异的耐磨性,在磨损过程中形成稳定的支撑面保护基体。     

Effect of Spraying Powders Size on the Microstructure,Bonding Strength,and Microhardness of MoSi2 Coating Prepared by Air Plasma Spraying

Molybdenum disilicide (MoSi₂) coatings were deposited on carbon steel by air plasma spraying technology with different feedstock powder sizes (i.e., powder A: ?15 + 2.5 μm, powder B: ?30 + 15 μm, powder C: ?54 + 30 μm, powder D: ?74 + 54 μm and powder E: ?106 + 74 μm). Phase composition and microstructure of coatings were characterized by x-ray diffraction (XRD) and scanning electron microscope. The bonding strength and microhardness of coatings were also evaluated. The XRD results show that there exists mutual transformation between T-MoSi₂ and H-MoSi₂ phase and part of Mo-rich phases are formed because of oxidization during the spraying process. With the increase of spraying powders size, the content of Mo-rich phases (Mo or Mo₅Si₃) and molybdenum oxide (MoO₃) in coatings decreases, and that of disilicide-rich phase (MoSi₂) in coatings increases. The oxidation degree of MoSi₂ particle gradually decreases during the spraying process with the increase of spraying powders size. The MoSi₂ is the main phase of the as-sprayed coatings when the spraying powders size is beyond 30 μm. With the increase of spraying powders size, the porosity of the as-sprayed coating increases, and the bonding strength of the coating gradually decreases. The hardness of coatings first increases and then decreases with the increase of spraying powders size.     

Co-electrodeposition and characterization of Cu-Si3N4 composite coatings

Smooth copper coatings containing well-distributed silicon nitride particles were obtained by co-electrodeposition in acidic sulfate bath. The cathodic current density did not show significant influence on incorporated particle volume fraction, whereas the increase of particle concentration in the bath led to its decrease. The increase of stirring rate increased the amount of embedded particles. The microhardness of the composite layers was higher than that of pure copper deposits obtained under the same conditions due to dispersion-strengthening and copper matrix grain refinement and increased with the increase of incorporated particle volume fraction. The microhardness of composites also increased with the increase of current density due to copper matrix grain refining. The composite coatings presented higher strength but lower ductility than pure copper layers. Pure copper and composite coatings showed the same corrosion resistance in 0.5 wt.% H₂SO₄ solution at room temperature.     

Properties and microstructure of Al-11Si/SiCp composite coatings fabricated by thermal spray

Thermal spraying has been used to coat 6082-T6 aluminium alloy with aluminium matrix composites. Mixtures of Al-11Si powder and 20 vol.% SiC and 40 vol.% SiC particles in the powder feeder were used as spraying material. In some conditions, SiC particles were coated with a sol-gel silica coating, which acts as an active barrier enhancing the wettability of the reinforcement by molten aluminium reducing the porosity of the composite coatings and inhibiting the formation of aluminium carbide. Coatings with a reinforcement volume fraction up to 17 vol.% (for 20 vol.% SiC in feeder) and 27 vol.% (for 40 vol.% SiC in feeder) were obtained with porosities below 1.0%. In all cases, the incorporation of sol-gel silica coatings on SiC particles reduced the porosity and increased the reinforcement volume fraction and the hardness of the coatings. The role played by the different spraying parameters has been also studied.     

冷喷涂SiC/Al纳米复合涂层的组织结构与性能

为制备基体相晶粒细小、增强相均匀分布的SiC/Al纳米复合涂层,以Al、SiC为原料,采用高能球磨法获得SiC颗粒弥散分布的纳米晶Al基复合材料粉末,利用冷喷涂技术低温成型制备了SiC/Al纳米复合涂层,分析了SiC含量对复合涂层相结构、晶粒尺寸、微观结构、硬度及磨损性能的影响规律。结果表明：冷喷涂可实现球磨纳米晶复合粉末结构的原位移植,所制备SiC/Al纳米复合涂层组织致密,微米及亚微米级SiC弥散分布在纳米晶Al（约80 nm）基体之上;SiC颗粒对Al基体有明显强化作用,冷喷涂SiC/Al纳米复合涂层的硬度随SiC体积分数的增加而显著增加,50% SiC/Al纳米复合涂层的硬度高达515 HV_0.3,约为Al块材的13倍;冷喷涂SiC/Al纳米复合涂层的耐磨损性能随着SiC含量增加而显著提高,涂层磨损失效机制为磨粒对基体的切削犁沟变形。     

Effect of Tool Rotation Speed on Microstructure and Microhardness of Friction-Stir-Processed Cold-Sprayed SiCp/Al5056 Composite Coating

SiC-particle-reinforced Al5056-matrix composite coatings were deposited onto Al2024 substrates by cold spraying using a powder mixture having 15 vol.% SiC. To investigate the effects of friction stir processing (FSP) parameters on the microstructure and microhardness of the as-sprayed coating, the as-sprayed composite coating was then subjected to FSP using a stir tool having a threaded pin with rotation speed of 600 rpm and 1400 rpm. Results showed that the coatings presented Al and SiC phases before and after FSP treatment, and no other diffraction peaks were detected. Fine grains were produced in the Al5056 matrix due to severe plastic deformation during FSP, and the refined SiC particles exhibited a homogeneous distribution in the FSPed coating. In addition, an evident reduction of porosity (from 0.36% to 0.08% at 600 rpm or 0.09% at 1400 rpm) occurred, and a dramatic size reduction of the reinforcement from 12.5 µm to 6.5 µm at 600 rpm or 7.0 µm at 1400 rpm was achieved. Nevertheless, the microhardness profile presented general softening and a decrease from 143.9 HV to about 110 HV.     

Distribution of SiC particles in semisolid electromagnetic-mechanical stir-casting Al-SiC composite

The distribution of SiC particles in Al-SiC composite can greatly influence the mechanical performances of Al-SiC composite. To realize the homogeneous distribution of SiC particles in stir-casting Al-SiC composite, semisolid stir casting of Al-4.25 vol.%SiC composite was conducted using a special electromagneticmechanical stirring equipment made by our team, in which there are three uniformly-distributed blades with a horizontal tilt angle of 25 ° to mechanically raise the SiC particles by creating an upward movement of slurry under electromagnetic stirring. The microstructure of the as-cast Al-SiC composites was observed by Scanning Electron Mcroscopy(SEM). The volume fraction of SiC particles was measured by image analysis using the Quantimet 520 Image Processing and Analysis System. The tensile strength of the Al-4.25 vol.%SiC composites was measured by tensile testing. Results show that the Al-4.25 vol.%SiC composites with the homogeneous distrbutin of SiC particles can be obtained by the electromagnetic-mechanical stirring casting with the speed of 300 and 600 r·min-1 at 620 °C. The differences between the volume fraction of Si C particles at the top of ingot and that at the bottom are both ~0.04 vol.% with the stirring speed of 300 and 600 r·min-1, which are so small that the distribution of SiC particles can be seen as the homogeneous. The tensile strength of the Al matrix is enhanced by 51.2% due to the uniformly distributed SiC particles. The porosity of the composite mainly results from the solidification shrinkage of slurry and it is less than 0.04 vol.%.     

沉积时间对AZ91D合金表面Ni-P-SiC复合镀层性能的影响

目的提高镁合金的耐蚀性和耐磨性。方法以AZ91D镁合金为基体,采用SiC颗粒质量浓度为3 g/L的Ni-P化学镀溶液,在其表面沉积不同时间,制备Ni-P-SiC复合镀层。通过扫描电子显微镜(SEM)、显微硬度测试、粗糙度仪、电化学腐蚀和磨损等试验来分析和评价Ni-P-SiC复合镀层的厚度、表面粗糙度、显微硬度、耐腐蚀性能和耐磨性能。结果 Ni-P-SiC复合镀层的厚度和表面粗糙度随沉积时间增加而增加,沉积时间为150 min时,镀层厚度可达53μm,表面粗糙度为2.5μm。沉积时间为120 min时,镀层的显微硬度最高,为641HV,此时复合镀层的耐蚀性和耐磨性最好,自腐蚀电位高达-0.73 V,腐蚀电流密度为0.78μA/cm~2,磨损体积最小,为1.04×10~(-3)mm~3。与AZ91D镁合金基体相比,沉积复合镀层后的样品更耐蚀,说明复合镀层有效改善了镁合金基体的耐蚀性。结论沉积时间对Ni-P-SiC复合镀层的性能有一定影响,在沉积时间为120 min时获得的复合镀层具有较好的耐蚀性和耐磨性。     

Grain-Refined AZ92 Alloy with Superior Strength and Ductility

Grain-refined AZ92 (GR-AZ92) alloy with superior tensile properties is developed by adding 1 wt% Zn and a very small amount of SiC (0.17 wt%) to commercial AZ91 alloy for enhancing the solid-solution strengthening effect and refining the crystal grains, respectively. The homogenized GR-AZ92 alloy with an average grain size of 91 μm exhibits a tensile yield strength (TYS) of 125 MPa, ultimate tensile strength (UTS) of 281 MPa, and elongation of 12.1%, which are significantly higher than those of AZ91 alloy with a grain size of 420 μm (TYS of 94 MPa, UTS of 192 MPa, and elongation of 7.0%). The peak-aging time of GR-AZ92 alloy (8 h) is significantly shorter than that of AZ91 alloy (32 h) owing to a larger amount of grain boundaries in the former, which serve as nucleation sites of Mg₁₇Al₁₂ precipitates. A short-aging treatment for less than 1 h of the GR-AZ92 alloy causes an effective improvement in its strength without a significant reduction in its ductility. The 30-min-aged GR-AZ92 alloy has an excellent combination of strength and ductility, with a TYS of 142 MPa, UTS of 304 MPa, and elongation of 8.0%.     

Comparison of 10 μm and 20 nm Al-Al2O3 Metal Matrix Composite Coatings Fabricated by Low-Pressure Cold Gas Dynamic Spraying

Cold-gas dynamic spraying (“cold spraying”) was used to deposit aluminum-alumina (Al-Al₂O₃) metal-matrix composite (MMC) coatings onto 6061 Al alloy. The powders consisted of ?45 μm commercially pure Al that was admixed with either 10 μm or agglomerated 20 nm Al₂O₃ in weight fractions of 25, 50, 75, 90, and 95 wt.%. Scanning electron microscopy (SEM), Vickers microhardness testing, and image analysis were conducted to determine the microstructure, properties, and the volume fractions of reinforcing particles in the coatings, which was then converted to weight fractions. As the weight fraction of the Al₂O₃ in the coatings increased, the hardness values of the MMC coatings increased. A maximum hardness of 96 ± 10 HV_0.2 was observed for the MMC coating that contained the agglomerated 20 nm Al₂O₃ particles, while a maximum hardness of 85 ± 24 HV_0.2 was observed for the coatings with the 10 μm Al₂O₃ particles. The slight increase in hardness of the coating containing the agglomerated 20 nm Al₂O₃ particles occurred in a coating of Al₂O₃ content that was lower than that in the coating that contained the 10 μm reinforcing Al₂O₃ particles. The increased hardness of the MMC coatings that contained the agglomerated 20 nm Al₂O₃ particles and at lower reinforcing particle content was attributed to the increased spreading of the nanoagglomerated particles in the coating, which increased load-sharing and reinforcement capability of the particles. These results suggest that the use of nanoagglomerated, reinforcing hard-phase particles in cold-sprayed MMC coatings may be a more efficient alternative to the use of conventional micronsized reinforcing particles.     

SiC_p/AZ91镁基复合材料的热挤压

采用搅拌铸造法制备SiC体积分数为5%、10%和15%的颗粒增强AZ91镁基复合材料（SiCp/AZ91）。复合材料经过T4处理后,于350°C以固定挤压比12：1进行热挤压。在铸态复合材料中,颗粒在晶间微观区域发生偏聚。热挤压基本上消除了这种偏聚并有效地改善颗粒分布。另外,热挤压有效地细化基体的晶粒。结果表明：热挤压明显提高复合材料的力学性能。在挤压态复合材料中,随着SiC颗粒含量的升高,基体的晶粒尺寸减小,强度和弹性模量升高,但是伸长率降低。     

Influence of FeCrAl Content on Microstructure and Bonding Strength of Plasma-Sprayed FeCrAl/Al<Subscript>2</Subscript>O<Subscript>3</Subscript> Coatings

Low-power plasma-sprayed FeCrAl/Al₂O₃ composite coatings with 1.5 mm thickness have been fabricated for radar absorption applications. The effects of FeCrAl content on the coating properties were studied. The FeCrAl presents in the form of a few thin lamellae and numerous particles, demonstrating relatively even distribution in all the coatings. Results show that the micro-hardness and porosity decrease with the increase in FeCrAl content. With FeCrAl content increasing from 28 to 47 wt.%, the bonding strength of the coatings with 1.5 mm thickness increases from 10.5 to 27 MPa, and the failure modes are composed of cohesive and adhesive failure, which are ascribed to the coating microstructure and the residual stress, respectively.     

Microstructures and mechanical properties of Al 2519 matrix composites reinforced with Ti-coated SiC particles

Ti-coated SiC_p particles were developed by vacuum evaporation with Ti to improve the interfacial bonding of SiC_p/Al composites. Ti-coated SiC particles and uncoated SiC particles reinforced Al 2519 matrix composites were prepared by hot pressing, hot extrusion and heat treatment. The influence of Ti coating on microstructure and mechanical properties of the composites was analyzed by scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS). The results show that the densely deposited Ti coating reacts with SiC particles to form TiC and Ti₅Si₃ phases at the interface. Ti-coated SiC particle reinforced composite exhibits uniformity and compactness compared to the composite reinforced with uncoated SiC particles. The microstructure, relative density and mechanical properties of the composite are significantly improved. When the volume fraction is 15%, the hardness, fracture strain and tensile strength of the SiC_p reinforced Al 2519 composite after Ti plating are optimized, which are HB 138.5, 4.02% and 455 MPa, respectively.     

Corrosion of Magnesium-Aluminum Alloys with Al-11Si/SiC Thermal Spray Composite Coatings in Chloride Solution

Depositions of Al-11Si coatings reinforced with 5, 15, and 30 vol.% SiC particles (SiCp) were performed onto AZ31, AZ80, and AZ91D magnesium alloys. The influence of substrate composition and SiCp proportion on the anti-corrosion properties of composite coatings was evaluated using DC and AC electrochemical measurements in 3.5 wt.% NaCl solution at 22 °C. The as-sprayed coatings were permeable to the saline solution, and galvanic corrosion occurred at the substrate/coating interface after immersion in the saline solution for a few hours. The addition of SiCp yielded coatings with higher porosity and less effectiveness against corrosion. The application of a cold-pressing post-treatment produced denser coatings with reduced surface roughness, improved hardness, and superior corrosion resistance. However, galvanic corrosion was observed after several days of immersion because of penetration of the 3.5 wt.% NaCl solution through the remaining pores in the coatings.     

Volume Fraction Effect of V8C7 Particulates on Impact Toughness and Wear Performance of V8C7/Fe Monolithic Composites

The V₈C₇ particulates-reinforced iron-based metal matrix composite with 8-33 vol.% V₈C₇ was produced by infiltration casting process with subsequent heat treatment at 1164 °C for 3 h. With increasing the volume fraction of V₈C₇ in the composite, microhardness of the composite increases, while its impact toughness decreases. Relative wear resistance of the composite with different volume fractions of V₈C₇ was also investigated in this study. The composite with 24 vol.% V₈C₇ shows the highest relative wear resistance, which is much higher than that of gray cast iron. Microcracking, microploughing, and the fragmentation of particulates are found to be the dominant wear mechanisms.     

Mechanical Behavior of a Magnesium Alloy Nanocomposite Under Conditions of Static Tension and Dynamic Fatigue

In this paper, the intrinsic influence of nano-alumina particulate (Al₂O_3p) reinforcements on microstructure, microhardness, tensile properties, tensile fracture, cyclic stress-controlled fatigue, and final fracture behavior of a magnesium alloy is presented and discussed. The unreinforced magnesium alloy (AZ31) and the reinforced composite counterpart (AZ31/1.5 vol.% Al₂O₃) were manufactured by solidification processing followed by hot extrusion. The elastic modulus, yield strength, and tensile strength of the nanoparticle-reinforced magnesium alloy were noticeably higher than the unreinforced counterpart. The ductility, quantified by elongation-to-failure, of the composite was observably lower than the unreinforced monolithic counterpart (AZ31). The nanoparticle-reinforced composite revealed improved cyclic fatigue resistance over the entire range of maximum stress at both the tested load ratios. Under conditions of fully reversed loading (R = ?1) both materials showed observable degradation in behavior quantified in terms of cyclic fatigue life. The conjoint influence of reinforcement, processing, intrinsic microstructural features and loading condition on final fracture behavior is presented and discussed.     

AZ91D镁合金等离子喷涂Ni-Al/陶瓷涂层的组织和性能

以Ni-Al为粘结层,在AZ91D镁合金基体上等离子喷涂Ni-Al/Al2O3、Ni-Al/Al2O3-13%TiO2(Ni-Al/AT13)、Ni-Al/Al2O3-20%TiO2(Ni-Al/AT20)复合涂层及Ni-Al/Al2O3/Al2O3-13%TiO2/Al2O3-20%TiO2(Ni-Al/Al2O3/AT13/AT20)梯度涂层,利用SEM、EDS和XRD分析涂层的微观组织特征,通过硬度、拉伸和热震实验研究涂层硬度、结合强度和抗热震性能,并与直接喷涂Al2O3、AT20的涂层进行比较。结果表明:Ni-Al粘结层因"自粘结"效应与基体形成较为致密并具有冶金结合的界面,且与Al2O3、AT13和AT20陶瓷层互有渗透、交叉和啮合,涂层致密性及结合力大为提高,表现出优良的抗热震性能。Al2O3涂层主要由亚稳态γ-Al2O3组成,AT20涂层以Al2O3和Al2TiO5为主。镁合金表面喷涂Al2O3陶瓷层后硬度大幅提高,由于加入TiO2,AT13和AT20涂层的硬度略低于Al2O3涂层的。Ni-Al/Al2O3-TiO2复合陶瓷的涂层结合强度高于Ni-Al/Al2O3单一陶瓷涂层的,而Ni-Al/Al2O3/AT13/AT20梯度涂层的结合强度比Ni-Al/AT20涂层的更高。     

Microstructure,Mechanical Properties,and Two-Body Abrasive Wear Behavior of Cold-Sprayed 20 vol.% Cubic BN-NiCrAl Nanocomposite Coating

20 vol.% cubic boron nitride (cBN) dispersoid reinforced NiCrAl matrix nanocomposite coating was prepared by cold spray using mechanically alloyed nanostructured composite powders. The as-sprayed nanocomposite coating was annealed at a temperature of 750 °C to enhance the inter-particle bonding. Microstructure of spray powders and coatings was characterized. Vickers microhardness of the coatings was measured. Two-body abrasive wear behavior of the coatings was examined on a pin-on-disk test. It was found that, in mechanically alloyed composite powders, nano-sized and submicro-sized cBN particles are uniformly distributed in nanocrystalline NiCrAl matrix. Dense coating was deposited by cold spray at a gas temperature of 650 °C with the same phases and grain size as those of the starting powder. Vickers hardness test yielded a hardness of 1063 HV for the as-sprayed 20 vol.% cBN-NiCrAl coating. After annealed at 750 °C for 5 h, unbonded inter-particle boundaries were partially healed and evident grain growth of nanocrystalline NiCrAl was avoided. Wear resistance of the as-sprayed 20 vol.% cBN-NiCrAl nanocomposite coating was comparable to the HVOF-sprayed WC-12Co coating. Annealing of the nanocomposite coating resulted in the improvement of wear resistance by a factor of ~33% owing to the enhanced inter-particle bonding. Main material removal mechanisms during the abrasive wear are also discussed.     

Effect of the spraying process on the microstructure and tribological properties of bronze-alumina composite coatings

In the present paper, aluminum bronze-alumina composite coatings have been applied on mild steel substrate using conventional plasma spray and a new route based on cold spray techniques. The microstructure, phase distribution, microhardness, adhesion strength and tribological behavior of the composite coatings, consisting of alumina reinforcing phase distributed in a bronze matrix, were studied. Ball-on-disk dry sliding wear tests, Rubber Wheel tests and Erosion tests were conducted to examine the tribological behavior of the composite coatings. The tribological properties of the bronze coatings were improved by the addition of alumina. Friction coefficient of coatings depends strongly on the reinforcing particles content and spraying process. Wear mechanisms of the composite coatings, such as ploughing and particle delamination, were considered. In the case of abrasive wear test, the wear rate was greatly reduced due to the reinforcing ceramic particles. Relationships between size and volume fraction of the ceramic reinforcement Al₂O₃ and the wear rate are discussed. On the other hand, erosion wear behavior of coatings with higher bronze content showed the best results.     

Corrosion behaviour of Mg/Al alloys with composite coatings

The corrosion behaviour of aluminium/silicon carbide (Al/SiC) composite coatings deposited by thermal spray on AZ31, AZ80 and AZ91D magnesium-aluminium alloys was investigated by electrochemical and gravimetric measurements in 3.5 wt.% NaCl solution at 22 °C. Corrosion products were examined by scanning electron microscopy (SEM), energy dispersive X-ray (EDX) analysis and low-angle X-ray diffraction (XRD). Al/SiC composite coatings in the as-sprayed state revealed high level of porosity with poor bonding at the Al/SiC and coating/substrate interfaces, which facilitated degradation of the magnesium substrates by a mechanism of galvanic corrosion. Cold-pressing post-treatment produced more compact coatings with improved corrosion performance in 3.5 wt.% NaCl compared with as-sprayed coatings.