Microstructure and oxidation resistance of reactive plasma clad Cr7 C3/γ-Fe ceramic composite coating

A new type oxidation resistance in situ Cr7 C3/γ-Fe ceramic composite coating was fabricated on hardened and tempered grade C steel by reactive plasma clad with Fe-Cr-C alloy powders. The oxidation resistance of the ceramic composite coating was investigated under the test condition of 900 ℃ and 50 hours. The results indicate that the coating has a rapidly solidified microstructure consisting of blocky primary Cr7 C3 and the inter-blocky Cr7 C3/γ-Fe eutectics and is metallurgically bonded to the hardened and tempered grade C steel substrate. The high temperature oxidation resistance of the coating is up to 1.9 times higher than that of grade C steel. The oxidation kinetics curve of the coating is conforming to the parabolic-rate law equation. The excellent oxidation resistance of the coating is mainly attributed to the continuous oxide films which consist of Cr203 and Fe203. The continuous oxide films can prevent the inner part of the coating from being further oxidized.     

Microstructure characterization and mechanical properties of thermal sprayed Ni-20wt.%Al coating

Thermal sprayed Ni-20wt. % Al coating is fabricated on 6061-T6 aluminum alloy substrates by twin-wire arc spraying （TWAS）. Experimental results present that the average bonding strength is around 53 MPa and the average hardness reaches 325 HV. The Vickers microhardness of NiAl and Ni3Al intermetaUic compounds is larger than that of the substrate, which is beneficial for improving the wear property. Wear mechanism exhibits features of adhesive wear. Friction and wear test results indicate that the wet friction coefficient is higher than the coefficient of dry friction after 200 cycles, and variations of the wet friction coefficient are relatively smaller.     

热喷涂制备非晶合金涂层的研究状况

非晶合金是一种极具发展潜力的新兴金属材料.用热喷涂方法制备非晶合金涂层是将非晶推向工程应用的有效方法.从分析非晶合金及其制备特性入手,阐述了非晶合金热喷涂涂层的特性及目前制备非晶合金涂层的两类热喷涂技术路线,展望了热喷涂制备非晶合金涂层未来的发展趋势.     

钛基RuO2-Ta2O5涂层电极材料的电容性能分析

采用热分解方法在钛基体上制备了(36%)RuO2-(64%)Ta2O5混合氧化物涂层。采用X射线衍射(XRD)、扫描电镜(SEM)、循环伏安(CV)以及恒流充放电测试研究了涂层电极的组织结构、表面形貌以及电容性能。结果表明:(36%)RuO2-(64%)Ta2O5涂层以非晶氧化物为基体,带有少量纳米微晶RuO2的组织结构。在酸性溶液中,在50～900 mV/s的扫描速度下,Ti/(36%)RuO2-(64%)Ta2O5涂层电极的伏安曲线都具有近似矩形形状,表现出良好的电容特性和功率特性。以5 mA/cm2和10 mA/cm2放电,比电容分别为525.5 F/g和495.1 F/g。在经历2000次循环充放电后,电极的电荷储存能力仍未衰减,显示其优异的循环稳定性。     

自保护堆焊工艺制备的铁基含非晶合金涂层

研制了一种含Fe,Cr,Ni等元素的自保护药芯焊丝,通过自保护堆焊工艺在45号钢基体上制备了铁基堆焊层。对堆焊层的宏观形貌和堆焊工艺条件进行简单评估,并对堆焊层的物相组成和微观组织结构进行了表征,对堆焊层的硬度、耐磨性、耐蚀性、热稳定性、抗裂性、自保护性能等进行了研究。结果表明:堆焊层为含非晶涂层,具有较好的耐磨、抗裂、耐蚀性能,且热稳定性良好,各项焊接工艺性能也较为理想,综合性能优异。     

一种新型经济高效非晶涂层的制备与性能表征

利用火焰喷涂技术喷涂自制的气雾化合金粉末取代非晶粉末,制备了NiFeBSiNb非晶纳米晶涂层。分别对粉末和涂层的微观组织结构和热力学性能进行了表征。结果表明,自制的合金粉末球形度较好,大多为球形或椭球形;主要为晶体结构,由Nb₂Ni₂₁B₆晶体相和(Ni,Fe)₂₃B₆固溶体组成。而经过火焰喷涂制备的涂层,形成了非晶相和纳米晶相。通过公式计算此合金体系粉末和涂层形成非晶相的临界冷却速率分别为6.01×10₅K/s和4.56×10₃K/s,解释了在粉末制备过程中较难形成非晶相而喷涂过程中形成非晶结构比较容易。对涂层的摩擦磨损性能进行了测试,涂层摩擦系数仅为0.17,具有优异的耐磨性能。     

Microstructure and thermal expansion of copper-based amorphous alloys during structural relaxation

(Cu43Zr48Al9)98Y2 amorphous alloy bar was prepared by the arc melting copper mold absorption casting method,and then,the amorphous alloy was annealed at different temperatures for different times.The influence of heating rate on thermal expansion and thermal stability was studied by thermomechanical analysis(TMA),and the microstructure evolution of the amorphous alloy during structural relaxation and crystallization was studied by XRD and TEM.Results show that the structural evolution behavior of the(Cu43Zr48Al9)98Y2 amorphous alloy can be divided into five different stages(structural relaxation preparation stage,structural relaxation stage,first crystallization stage,second crystallization stage,and grain growth stage).When the heating rate is 20 K/min,the amorphous alloy has the smallest thermal expansion coefficient and the best thermal stability.The width of the supercooled liquid region is 66.42 K.Samples with different relaxation states were prepared by annealing at the heating rate of 20 K/min.The structural evolution of amorphous alloys with different relaxation states is as follows:amorphous→CuZr2+AlCu2Zr7→CuZr2+AlCu2Zr7+CuZr(B2)+CuZr(M)+Cu10Zr7→CuZr2+AlCu2Zr7+CuZr(B2)+CuZr(M).After annealing at 706 K and 726 K(in the supercooled liquid region)for 1.5 h,the amorphous-nanocrystalline composites were obtained.When the annealing temperature is 706 K,the crystallization process of the sample is as follows:amorphous→Cu10Zr7→Cu10Zr7+CuZr,and for the sample at 726 K,it is as follows:amorphous→CuZr2+AlCu2Zr7+Cu10Zr7→Cu10Zr7+CuZr2→CuZr2+CuZr(B2)+Cu10Zr7.     

热喷涂Fe基非晶涂层耐腐蚀性与孔隙率研究进展

热喷涂Fe基非晶合金涂层的综合性能优异,特别是在耐磨、耐腐蚀方面具有传统晶体材料无可比拟的优势,因而广泛应用于材料表面的防护领域。然而热喷涂涂层为典型的层状结构,涂层内部会存在一定量的孔隙,致使涂层耐腐蚀性能下降。首先介绍了热喷涂Fe基非晶涂层的腐蚀机理及其影响因素,总结了热喷涂涂层孔隙产生的机制、分类和影响因素。接着重点介绍了孔隙与热喷涂Fe基非晶涂层耐腐蚀性之间关系的研究进展。最后,通过对热喷涂涂层的形成过程与孔隙形成机理进行分析,粒子铺展变形能力差是显著影响涂层形成时粒子相互嵌套叠加和变形能力的主要原因。所以,Fe基非晶涂层可以从改变喷涂粉末成分和粒度、第二项粒子加入及喷涂工艺参数优化等措施,来改善粒子铺展变形能力,提高致密度。采用激光快速表面重熔技术对涂层微表层进行快速重熔处理,同样可以达到降低涂层孔隙率、提高涂层耐腐蚀性的目的。     

Comparison of a cold-sprayed and plasma-sprayed Fe25Cr20Mo1Si amorphous alloy coatings on 40Cr substrates

The purpose of this paper is to examine whether cold spraying is capable of manufacturing high-quality ferrous-based amorphous alloy coatings by comparing the performance of a cold-sprayed with a plasma-sprayed Fe25Cr20Mo1Si amorphous coating on a 40Cr substrate. The hardness, microstructure, wear resistance, and corrosion resistance of the two coatings were determined with potentiodynamic polarization curves, neutral salt spray tests, scanning electron microscopy, energy dispersive spectroscopy, and X-ray diffraction and their performance differences were examined. The results show that the cold-sprayed Fe25Cr20Mo1Si coating has an amorphous content of 97.63%, which is slightly higher than that for the raw powder (97.24%) and plasma-sprayed coating (96.55%). The coating hardness ranges from 720 HV to 1,030 HV, which is higher than plasma-sprayed coating (590–610 HV) and decreases the wear rate to about 2/3. The average porosity is 2.97 ± 0.59%, which is lower than that of the plasma-sprayed coating (4.95 ± 0.13%). The cold-sprayed Fe25Cr20Mo1Si coating can pass the 3,000 hr neutral salt spraying test, while the plasma-sprayed coating fails within 120 hr. The corrosion current in 3.5% NaCl solution reached to its stable value about 1.66 A/cm², which is about 1/4 of the plasma-sprayed coating (5.81 A/cm²). Upon analyzing the properties and the anticorrosion performance, it was found that there are no through-thickness pores in the cold-sprayed coating that impact its long-term anticorrosion performance. Cold spraying can be used to fabricate ferrous-based amorphous coatings instead of traditional thermal spraying technologies to obtain high-quality ferrous-based amorphous coatings.     

热喷涂制备Fe基非晶合金涂层的研究进展

从非晶形成理论、热喷涂制备Fe基非晶涂层两个方面对热喷涂制备Fe基合金涂层研究进行了综述,并对热喷涂制备该涂层未来的发展进行了展望.     

热喷涂制备非晶态合金耐蚀涂层及其在电力设施防护中的应用研究进展

非晶态合金涂层材料因其组织结构均一、耐蚀性优异的特性,在电力材料防护领域有着重要应用价值,热喷涂制备的非晶态合金涂层是电力设施防护方法的重要发展方向。 对相关研究进行了综述。 首先介绍几种重要的非晶态合金材料体系, 引用近年来国内外基于热喷涂等技术的非晶态合金涂层材料的制备方法。 然后分析涂层防腐蚀、防冲蚀效果与机理,重点介绍应用上较重要的铁基、镍基、铝基防腐蚀非晶材料体系的研究进展。 最后,对热喷涂法制备铁基、镍基非晶态涂层材料在电力设施防腐蚀方面的应用及未来发展进行展望。     

Deposition of HVAF-sprayed Ni-based amorphous metallic coatings

Ni₅₃Nb₂₀Ti₁₀Zr₈Co₆Cu₃ (at.%) amorphous alloy with high glass forming ability (GFA), capable of forming a wholly amorphous rod of 3 mm diameter by casting, was adopted to deposit amorphous metallic coatings by high velocity air fuel (HVAF) thermal spraying. The effects of powder feed rate and spraying distance on amorphous phase content and porosity of the coatings were investigated. It was indicated that an appropriate powder feed rate was desirable to produce a coating with high amorphous fraction, whereas a larger spraying distance led to a more dense coating. The corrosion resistance of the sprayed coatings was also examined in 1 M HCl aqueous solution.     

Enhancement of adhesion bonding between titanium metal and electrodeposited calcium phosphate

A novel hydroxyapatite/rutile coating was prepared on a titanium substrate. Initially, an amorphous calcium phosphate coating layer was electrochemically deposited on a Ti substrate. The surface morphology, chemical composition and phase identification of the coatings were investigated by the X-ray diffraction and scanning electron microscopy associated with an energy dispersive spectrometer. Annealing at 700°C for 3 hrs. transforms the amorphous calcium phosphate layer into well-crystallized hydroxyapatite (HAP) and the Ti metal surface into rutile. The developed HAP/rutile composite surface layer became denser and better adhering with the substrate than the initially formed amorphous calcium phosphate. The adhesion bond strength and the hardness of the coating were extremely raised by thermal annealing.     

Preparation and magnetic properties of amorphous Co–Zr–B alloy nano-powders

The magnetic Co–Zr–B amorphous alloy powders, having a nearly spherical morphology with diameters <50 nm, were obtained successfully by the reduction of an aqueous solution of zirconium sulphate and cobalt chloride with an aqueous solution of sodium borohydride. XRD, selected-area electron diffraction (SAED) and differential scanning calorimetry (DSC) studies showed that the resultant were partially amorphous together with a tiny volume fraction of crystalline phases, and the main amorphous phase consisted of the Zr-based amorphous particles and the Co-based Zr-containing amorphous particles. It is found that the Co/Zr ratio in the powders was indistinguishably equal to the Co²⁺/Zr⁴⁺ ratio in the original mixed solution and the boron content of the samples increased along with the addition rate of NaBH₄ solution. The crystallization temperatures of the resultant powders were in the range of 765.1–771.3 K. The thermal stability of amorphous Co–Zr–B powder increased with increasing the zirconium content. When the Co/Zr ratio in the samples increased from 1.94 to 5.14, the saturation magnetization increased monotonously from 4.76 to 8.87 emu/g, but the coercivity increased irregularly from 15.98 to 26.81 Oe.     

Laser surface coating of Fe-Cr-Mo-Y-B-C bulk metallic glass composition on AISI 4140 steel

Fe-based bulk metallic glasses exhibit very high hardness, elastic modulus/limit and wear/corrosion resistance. In the present investigation, an attempt has been made to develop an amorphous coating with Fe₄₈Cr₁₅Mo₁₄Y₂C₁₅B₆ bulk metallic glass on AISI 4140 substrate by laser surface processing. Following coating, the microstructure and phase aggregate were analyzed by scanning electron microscope and X-ray diffraction, respectively. Microhardness and wear resistance were assessed using Vickers microhardness tester and ball-on-plate wear testing machine, respectively. The coating thickness varied directly with incident laser power and interaction time. Despite trials with wide range of process parameters, the present experiments were unable to retain complete amorphous surface microstructure after laser surface coating. Numerical prediction of the thermal profile and related parameters suggest that the cooling rate and thermal gradient experienced by the coated zone were fairly high. Yet failure to retain amorphous/glassy microstructure of an otherwise bulk metallic glassy alloy suggests that compositional changes (solute redistribution) within the coated zone and across the coating-substrate interface are responsible for nucleation and growth of crystalline phases from the melt. However, correlation between coating parameters and surface microstructure and properties allowed determination of the optimum conditions that ensured fine grained uniform microstructure with a significant improvement in hardness and wear resistance.     

Electrochemical Properties of Pulse Plating Amorphous Ni-Mo-W Alloy Coating in Alkaline Medium

采用脉冲电镀技术获得了高活性Ni-Mo-W析氢合金阴极。以析氢反应过电位为考察指标,确定了脉冲镀Ni-Mo-W合金的最佳电镀条件,如Na2WO4·2H2O浓度、平均电流密度和占空比等。同时,系统研究了Mo和W含量对Ni-Mo-W合金镀层成分和组成的影响规律。结果表明,在二元合金中添加W能有效提高电极的析氢反应活性(η200＝80 mV);非晶态Ni-Mo-W合金的组织结构主要取决于Mo含量;与非晶态Ni-Mo合金镀层相比,Ni-Mo-W合金析氢阴极的电化学稳定性得到一定程度的提高。     

铁基非晶增强碳化钨涂层的微观结构与性能

采用超音速火焰喷涂技术制备了WC-CoCr/铁基非晶复合涂层。比较研究了复合涂层和WC-CoCr的微观形貌、硬度、耐磨性能、高温氧化性能和腐蚀性能。XRD分析和SEM观察表明,复合涂层主要由WC相、W2C相和铁基非晶相组成。与WC-CoCr涂层相比,复合涂层的硬度有所降低,但是两者没有显著性差异。由于硬度下降,导致复合涂层的耐磨性能略低于WC-CoCr涂层。800℃高温氧化测试表明,复合涂层在800℃具有良好的热稳定性,这归因于氧化过程中生成了一层致密的氧化膜。此外,复合涂层在3.5%氯化钠溶液中的耐腐蚀性能也优于WC-CoCr涂层。     

Microstructure and Thermal Properties of Atmospheric Plasma-Sprayed Yb<Subscript>2</Subscript>Si<Subscript>2</Subscript>O<Subscript>7</Subscript> Coating

In the present work, Yb₂Si₂O₇ powder was synthesized by solid-state reaction using Yb₂O₃ and SiO₂ powders as starting materials. Atmospheric plasma spray technique was applied to fabricate Yb₂Si₂O₇ coating. The phase composition and microstructure of the coating were characterized. The density, open porosity and Vickers hardness of the coating were investigated. Its thermal stability was evaluated by thermogravimetry and differential thermal analysis (TG-DTA). The thermal diffusivity and thermal conductivity of the coating were measured. The results showed that the as-sprayed coating was mainly composed of crystalline Yb₂Si₂O₇ with amorphous phase. The coating had a dense structure containing defects, such as pores, interfaces and microcracks. The TG-DTA results showed that there was almost no mass change from room temperature to 1200 °C, while a sharp exothermic peak appeared at around 1038 °C in DTA curve, which indicated that the amorphous phase crystallized. The thermal conductivity of the coating decreased with rise in temperature up to 600 °C and then followed by an increase at higher temperatures. The minimum value of the thermal conductivity of the Yb₂Si₂O₇ coating was about 0.68 W/(m K).     

Novel In Situ Transformable Coating for Elevated-Temperature Applications

This article presents a new glass forming twin wire-arc thermal spray coating which is applicable to elevated temperature environments involving erosion and corrosion. When sprayed using conventional twin wire-arc spray technology, primarily amorphous coating is obtained containing an amorphous matrix with very small nanocrystalline precipitates that are less than 10 nm in size. The as-sprayed coating is found to be very hard and abrasion resistant. However, during elevated temperature exposure such as in coal-fired or biomass boiler environments, the coating may devitrify into fully nanocrystalline state consisting of α-Fe and M₂(BC)₁ phases. When this occurs the microhardness is found to increase dramatically by over 200 kg/mm² which leads to an increase in abrasion resistance by a factor of 3.5 with an analogous increase in erosion resistance. Due to the significance of these beneficial changes in coating behavior, the kinetics of the devitrification transformation was investigated using isothermal experiments and modeled with classical nucleation theory. Predictive behavior was then enabled through the development of a time-temperature-transformation diagram to model the devitrification transformation under specific thermal exposures, which was additionally confirmed by experimentation.     

CO2气氛和喷涂距离对电弧喷涂铁基非晶涂层组织及耐蚀性能的影响

为提高电弧喷涂铁基非晶涂层的非晶含量及耐蚀性,以CO₂为载流气体代替空气进行电弧喷涂试验,并研究喷涂距离对涂层组织与耐蚀性的影响。结果表明,喷涂层的厚度约为200 μm,涂层均主要由结晶相与非晶相构成。相比于空气介质,CO₂抑制了晶化,从而提高了涂层中的非晶含量。同时,喷涂距离对涂层的组织及耐蚀性能有较大影响。随着喷涂距离的增加,涂层中的非晶含量减少。当喷涂距离为100 mm时,涂层具有最高的开路电位-0.498 V(vs SCE)及最小的自腐蚀电流密度4.281 μA/cm²,耐蚀性能最好;当喷涂距离为150 mm时,涂层的耐蚀性最差。提高非晶含量和组织的均匀性可增强该涂层的耐蚀性能。