粘结剂对超音速火焰喷涂碳化钨涂层磨粒磨损性能的影响

采用超音速火焰喷涂(HVOF)工艺在35钢基体上制备了WC-10Ni涂层和WC-12Co涂层,研究了镍、钴这两种粘结剂对WC涂层的显微硬度、摩擦系数和抗磨粒磨损性能的影响,采用扫描电子显微镜观察涂层磨损前后的表面形貌,探讨了WC涂层的磨粒磨损机理。结果表明,以HVOF方法制备的2种WC涂层均有较高的显微硬度,WC-10Ni涂层和WC-12Co涂层与SiC砂纸摩擦副之间的干摩擦系数相差不大。2种涂层在低载荷下均有较好的抗磨粒磨损性能,但在较高载荷下WC-12Co涂层的抗磨性明显优于WC-10Ni涂层。2种涂层的磨粒磨损形式主要为均匀磨耗磨损,磨损机理以微切削和微剥落为主。WC-12Co涂层的磨损表面损伤较轻微,综合性能优于WC-10Ni涂层。     

Wet abrasive wear behavior of WC-based cermet coatings prepared by HVOF spraying

In this study, three kinds of WC-based cermet coatings including WC–CoCr coating, WC–Ni coating and WC–Cr₃C₂–Ni coating were prepared by the high-velocity oxygen-fuel (HVOF) spraying process. Scanning electron microscopy (SEM), energy disperse spectroscopy (EDS) and Vickers hardness tester were used to analyze the microstructure and mechanical properties of these coatings. The WC–CoCr coating presented the highest average microhardness of 1205 HV_0.3, and then followed by the WC–Cr₃C₂–Ni coating (1188 HV_0.3) and the WC–Ni coating (1105 HV_0.3). The abrasive wear behavior of the WC-based coatings under the conditions of different applied loads and sediment concentrations were studied by a wet sand-rubber wheel tester. The results indicated that the abrasive wear loss rates of all the coatings increased with the increment of applied load or sediment concentration. In addition, the coatings with higher microhardness appeared to have higher abrasive wear resistance. The abrasive wear resistance of the WC-based coatings was 4–90 times higher than that of AISI 304 stainless steel under the same testing condition. The abrasive wear mechanism of the WC-based coatings was deduced to be the extrusion and removal of binder phases, as well as the fragmentation and peel-off of hard phases.     

Tribological behavior of nanostructured high velocity oxy-fuel (HVOF) thermal sprayed WC-17NiCr coatings

In this research, the nanostructured WC-17NiCr cermet coatings were developed using the high velocity oxy-fuel (HVOF) thermal spraying processes on ACI CD4MCu cast duplex stainless steel substrates, widely used in pump industry for abrasive wear protection of surfaces. The coatings, sprayed by both robotic and manual methods, had two different fuel (methane) to oxygen ratios (FTOR), namely 0.68 and 0.62. Using different analytical and microstructural techniques, the microstructural characteristics of the powder particles and mechanical, microstructural, and tribological properties of the coatings were determined. Different morphologies were assigned to sprayable particles, namely spherical, apple, donut, irregular, and mixed. It was revealed that the rate of WC decarburization had increased with increasing the FTOR. In contrast, the scanning electron microscopy and image analyses showed that the lowest porosity percentage was obtained for the robotically-sprayed coating with 0.68 FTOR. The Vickers microhardness increased along with fracture toughness, which can be attributed to the effect of the ‘duplex structure’ associated with the particle outer coating of Co and is a novelty in the research. The pin-on-disk reciprocal sliding wear tests at various loadings had shown different wear rates in the coatings. It was inferred that the wear performance was improved with the microstructural homogeneity, hardness, and the fracture toughness in the coatings. In all coatings, lower coefficient of friction (COF) was observed at higher loads. Finally, the wear mechanisms involved in the wear processes were identified as deformation and removal of the binder, fracture and pullout of the carbide particles, and delamination and spallation of the splats.     

SiC强化镍基纳米复合电刷镀层的干摩擦磨损特性

采用电刷镀技术制备了快速镍和,n-SiC/Ni、n-SiC/Ni-W复合镀层,研究了镀层的干摩擦磨损特性,测定了镀层的显微硬度,采用扫描电子显微镜(SEM)观察分析了镀层磨痕形貌.结果表明:纳米粒子的加入可以显著地提高镀层的耐磨性.纳米复合镀层的磨损机制以磨粒磨损为主,而纯镍镀层以粘着磨损和磨粒磨损为主.     

TiC/Ti3AlC2–Co plasma-sprayed coatings with excellent high-temperature tribological properties

In this work, TiC/Ti₃AlC₂–Co cermet coatings with varying amounts of Ti₃AlC₂ were deposited by atmospheric plasma spraying (APS) process and their wear-resistant properties were discussed. The friction coefficients and wear rates at high-temperatures were measured through a ball-on-disk type friction test at 600 °C. In addition, the corresponding wear mechanisms were elucidated through the observation of phase changes and surface microstructural evolution of the coatings. The results indicated that the as-prepared coatings consisted of TiC, Ti, TiO₂, Al₂O₃, Co and CoO phases, which were produced by the decomposition and oxidation of TiC and Ti₃AlC₂. Compared with other samples, the sample with 30 wt% Ti₃AlC₂ addition displayed the smallest friction coefficient and least wear rate. Its wear rate was about 1.26 times lower than that of reported TiC–Co cermet material and about 10 times lower than that of the typically used TiC–Ni cermet material, suggesting outstanding wear resistance at elevated temperature. The addition of Ti₃AlC₂ reduced the friction coefficient of the coating by producing more TiC and Al₂O₃ hard phases and a consequent reduction of coating porosity. When the amount of Ti₃AlC₂ in the coating was less than 30 wt%, the main wear mechanism was abrasive wear. As the content of Ti₃AlC₂ was increased in the coating, the wear mechanism changed from abrasive wear to adhesive wear and the wear pattern of the coating gradually transformed from the furrows to the debris. This transformation of mechanism was related to the synergistic effect of hardness and porosity of the coating, which resulted from the remaining content and the special layered structure of Ti₃AlC₂.     

Corrosive wear behavior of HVOF-sprayed micro-nano-structured Cr3C2–NiCr cermet coatings under aqueous media

A novel micro-nano-structured Cr₃C₂–NiCr cermet coating was prepared on 316L stainless steel by high-velocity oxygen fuel spraying technology (HVOF). Cermet coatings with different contents of micro-and nano-sized Cr₃C₂ particles as the hard phase and a NiCr alloy matrix as the bonding phase were prepared and characterized in terms of porosity, microhardness, and corrosive wear resistance in a 3.5% NaCl solution and artificial seawater. Compared to nanostructured coatings, micro-nano-structured coatings avoid decarburization and reduce nanoparticle agglomeration during the spray process, and mechanical and electrochemical properties were improved in comparison with those of conventional coatings. The micro-nano-structured Cr₃C₂–NiCr coating rendered low porosity (≤0.34%) and high microhardness (≥1105.0HV_0.3). The coating comprising 50% nano-sized Cr₃C₂ grains exhibited the best corrosive wear resistance owing to its densest microstructure and highest microhardness. Furthermore, compared to static corrosion, the dynamic corrosion of the coatings led to more severe mechanical wear, because corrosion destroyed the coating surface and ions promoted corrosion to invade coatings through the pores during corrosion wear.     

Tribological Characterization of WC–Co Plasma Sprayed Coatings

Atmospheric plasma spraying of WC coatings is typically characterized by increased decarburization, with a consequent reduction of their wear resistance. Indeed, high temperature and oxidizing atmosphere promote the appearance of brittle crystalline and amorphous phases. However, by using a high helium flow rate in a process gas mixture, plasma spraying may easily be optimized by increasing the velocity of sprayed particles and by reducing the degree of WC dissolution. To this purpose, a comparative study was performed at different spray conditions. Both WC–Co powder and coating phases were characterized by X-ray difraction. Their microstructure was investigated by scanning electron microscopy. Mechanical, dry sliding friction, and wear tests were also performed. The wear resistance was highly related to both microstructural and mechanical properties. The experimental data confirmed that high-quality cermet coatings could be manufactured by using optimized Ar–He mixtures. Their enhanced hardness, toughness, and wear resistance resulted in coatings comparable to those sprayed by high velocity oxygen-fuel.     

Microstructure and Wear Behavior of Plasma‐Sprayed Nanostructured WC–Co Coatings

Atmospheric plasma spraying of WC–Co particles with standard gas mixtures (Ar–H₂) typically results in largely decarburized coatings with relatively low wear resistance. To fabricate cermet coatings with enhanced tribological properties, nanostructured WC–Co coatings were plasma sprayed using two different process gas mixtures. Phase composition and microstructure were investigated by X‐ray diffraction and scanning electron microscopy, respectively. Microhardness increased by increasing the amount of retained WC grains in coating microstructure. Friction and wear properties, measured under dry sliding conditions, strongly depended on the degree of decarburization. They were comparable to those of conventional coatings produced using identical conditions.     

Combustion‐thermal‐sprayed recycled poly(ethylene terephthalate)

Thermal‐sprayed polymer coatings have been used as protection against corrosion and wear. In this study, poly(ethylene terephthalate) (PET) powder, which was obtained from postconsumer beverage bottles, was deposited on 1020 steel by low‐velocity flame‐spray technology. The chemical and structural changes in PET due to the thermal‐spray processing were investigated with Fourier transform infrared spectroscopy and X‐ray diffraction. Changes in tribological behavior were examined by pin‐on‐disk testing and three‐dimensional profilometry. The results show that coatings had the same functional groups as the PET beverage bottles. However, the degree of crystallinity was modified. These changes were rationalized in terms of possible structural modifications of the PET polymer. The study showed evidence that the pin‐on‐disk wear developed by an abrasion process through a ploughing mechanism, although a fatigue mechanism could not be disregarded. A low friction coefficient between PET and steel was confirmed. In the as‐sprayed condition, the PET coatings showed higher friction, likely because of a higher coarse debris production rate during the pin‐on‐disk testing. Heat treating the as‐sprayed coating to increase the amorphous PET content improved the sliding behavior by increasing wear resistance. © 2004 Wiley Periodicals, Inc. J Appl Polym Sci 92: 3159–3166, 2004     

Al2O3-CoCrAlY 复合陶瓷激光熔覆层的组织与性能

研究了Ａｌ２Ｏ３－ＣｏＣｒＡｌＹ复合陶瓷涂层的组织结构、成分分布及其耐磨性能。结果表明：等离子喷涂层的组织呈层片状,面层由α－Ａｌ２Ｏ３和少量的γ－Ａｌ２Ｏ３组成,层间为机械结合界面,涂层平均硬度为８９７ＨＶ０．２。经激光重熔后的组织为单一的α－Ａｌ２Ｏ３柱状晶,在ＣｏＣｒＡｌＹ与基体间有界面相形成,其界面为冶金结合,层间存在着平缓的成分过渡;Ａｌ２Ｏ３与ＣｏＣｒＡｌＹ间的界面结合状况得到了明显的     

Surface and cross–section characteristics and friction–wear properties of high velocity oxy fuel sprayed WC–12Co coating

A WC–12Co coating was sprayed on H13 hot work mould steel using a high velocity oxy fuel (HVOF). The surface and cross–section morphologies, chemical compositions, and phases of obtained coatings were analyzed using a field emission scanning electron microscope (FESEM), energy dispersive spectrometer (EDS), and X–ray diffraction (XRD), respectively. The friction–wear properties were investigated using a wear test, the wear mechanism of WC–12Co coating was also discussed. The results show that the WC–12Co coating primarily is composed of WC hard phase with high hardness and Co as a binder, which is evenly distributed on the coating surface, no atom–rich zones. There is no W₃O phase appearing in the HVOF spraying, showing that the WC–12Co coating has high oxidation resistance, the new phases of W₂C and C are produced due to the decarburization of WC. The coating thickness is ~200 μm, which is combined the substrate with the mechanical binding and local micro–metallurgical bonding. The average coefficient of friction (COF) of WC–12Co coating is 0.272, showing good friction performance, the wear mechanism is primarily abrasive wear, accompanied with fatigue wear.     

Microstructure,adhesion, and tribological properties of conventional plasma-sprayed coatings on steel substrate

A variety of metallic and oxide coatings were deposited under various conditions on 1020 mild steel substrate by conventional plasma spraying. The coating thickness, microhardness, cohesion and adhesion failure loads, friction coefficient, and abrasive wear resistance were evaluated. The coatings were classified as follows, in order of decreasing microhardness and wear resistance: alumina, chromia, 316 stainless steel, Ni-5% Al, elemental aluminum and aluminum-polyester. Wear resistance increased with increasing microhardness and decreasing friction coefficient. The microhardness and wear resistance of high-velocity oxy-fuel (HVOF) diamond jet (DJ)-sprayed aluminum were found to be superior to those of plasma-sprayed aluminum. Plasma or flame-sprayed metallic coatings adhered well to the substrate. The cohesion, adhesion, microhardness, and wear resistance of alumina coatings exceeded those of equally thick chromia coatings.     

Wear behavior of Fe3Al-TiN-TiB2 HVOF coatings: A comparative study between in situ and ex situ powder processing routes

In the present study, the tribological properties of High Velocity Oxy-Fuel (HVOF) coatings prepared from Fe₃Al-based composite powders were investigated. The iron aluminide matrix of the composite powders was reinforced with TiN and TiB₂ particles made using two different processing routes: a) an in situ method where fine ceramic particles were formed in the matrix by the reaction between Ti and BN, and b) an ex situ method where preformed coarse TiN and TiB₂ particles were added to the matrix. The tribomechanical performance of the coatings was assessed using indentations and pin-on-disc wear tests. Compared to ex situ samples, the Fe₃Al-based coatings strengthened with in situ ceramic particles exhibit higher microhardness and wear resistance regardless of the sliding velocity. The presence of voids, cracks and scratches/grooves in the wear track of the in situ coatings and the coating material transferred to the corresponding counterpart suggest that coatings with fine reinforcing particles fail predominantly via delamination and adhesive wear mechanisms. In the case of the ex situ coatings, the presence of a significant amount of hard ceramic particles within the wear track indicates that abrasive wear plays a dominant role in the degradation mechanism. Oxidation wear also contributed to material removal at high sliding velocity since transfer materials inside the wear track contain a high oxygen content compared to the unworn region regardless of the coating type.     

电镀银/钯/硬金组合耐磨镀层工艺研究

为了提高镀硬金导电环的耐磨性,在黄铜基材上电镀铜/钯/硬金、镍/钯/硬金和银/钯/硬金三种组合镀层,通过工艺实验,组合镀层的外观、厚度、结合力、硬度、接触电阻及表面微观形貌等性能测试,以及装配后耐磨性能考核试验,发现银/钯/硬金组合镀层耐磨性最好。结果表明,该镀层耐磨可达100万次,能够满足产品抗磨性要求。     

Comparative study on wear behavior of plasma sprayed Al2O3 coatings sliding against different counterparts

Although the friction and wear behavior of plasma sprayed aluminum matrix ceramic coatings have been extensively discussed in the last decades, only few researches have been carried out the wear mechanisms sliding against different pairs. The tribological behaviors of plasma sprayed Al₂O₃ coating sliding against ZrO₂, Si₃N₄, Al₂O₃ and stainless steel balls in air were comparatively investigated in this study. It was showed that Al₂O₃ coating sliding against different counterparts exhibited diverse tribological behaviors, which could be mainly ascribed to the different mechanical properties of counterparts. Meanwhile, the tribochemical reactions influenced the friction performances significantly. Moreover, the transform of γ-Al₂O₃ to α-Al₂O₃ occurred during the friction, which was closely related to the coefficient of friction and thermal conductivities of counterparts. The main wear of Al₂O₃ coating sliding against ceramic materials resulted from the brittle fracture and abrasive wear. While it was dominated by adhesive wear when sliding against stainless steel, and accompanied with abrasive wear.     

Electrochemical measurements to evaluate the damage due to abrasion on organic protective system

Organic coatings are the most commonly used system for protection of metals from corrosion. In several applications organic coatings have to show, in addition to the protection properties and a good aesthetic appearance, good resistance to impact and abrasion. In fact, the mechanical damage can remarkably decrease the protection properties, even in the case of a very protective organic coating.

To evaluate the abrasion resistance of organic coatings the Taber Abraser test is frequently used. The mechanical damage is determined by measuring the mass loss without considering the form of damage (morphology and influence on corrosion protection performances).

The aim of this work is to evaluate the degradation of protection properties, caused by abrasion in Taber tests, using electrochemical methods.

Polyester powder coated steels were studied. Several parameters were considered such as the number of cycles, hardness of abrasive grinders and imposed weight.

By considering the resistance and capacitance of the organic coatings, obtained by fitting the electrochemical impedance data, it is possible to evaluate the trend of damage evolution as a function of the number of cycles and of the test parameters.

These EIS technique can distinguish the slight difference in aggressiveness of the two types of grinders used. The CS10 grinders produce debris which show the tendency to stick to the grinder itself and to the paint, reducing the abrasive action. Nevertheless, in this case the abrasion of the coating appears more uniform. In contrast, CS17 grinders increase the tendency to produce localised defects, which reduces the performance of the paint.

A different degradation rate and morphology were observed: an initially high damage value, followed by a decrease was observed due to both the presence of debris and the progressive efficiency loss of the abrasive wheels. For this reason, polishing of the grinder after every 1000 cycles is necessary to maintain a constant abrasion efficiency.     

Formation of vertical cracks in air plasma sprayed YSZ coatings using unpyrolyzed powder

Thick thermal barrier coatings (TTBCs) with vertical cracks deposited by air plasma spray (APS) and solution precursor plasma spray (SPPS) techniques have been widely investigated to achieve good thermal insulation along with reasonable service life. In this study, synthesized unpyrolyzed YSZ powder was air plasma sprayed in order to produce segmentation crack TTBCs. The microstructure and hardness of the deposits were then compared with those of the conventional TTBCs and dense vertically cracked (DVC)TTBCs. In this regard, spraying parameters were optimized to achieve deposits with the appropriate amount of unpyrolyzed particles in them to assist inducing vertical cracks in the deposited layers. The effect of the unpyrolyzed particles on microstructure, porosity, and microhardness of plasma sprayed coatings were also evaluated and compared. The new fabricated coating showed a bimodal structure combining non-molten sub-micron size particles and conventional splats along with segmentation cracks with higher amount of porosity and lower hardness compared to those of the DVC coatings. The results implied that, depositing unpyrolyzed powder by APS, as a new approach for achieving segmentation crack TTBCs, is very promising.     

Friction behavior of PTFE-coated Si3N4/TiC ceramics fabricated by spray technique under dry friction

PTFE coatings were deposited on the Si₃N₄/TiC ceramic substrate by using spray technology. The surface and cross-section micrographs, adhesive force of coatings with substrate, surface roughness and micro-hardness of the coated ceramics were examined. The friction and wear behaviors of ceramic samples with and without coatings were investigated through carrying out dry sliding friction tests against WC/Co ball. The test results indicated that the coated ceramics exhibited rougher surface and lower micro-hardness, and the PTFE coatings can significantly reduce the surface friction and adhesive wear of ceramics. The friction performance of PTFE-coated sample was affected by applied load due to the lower surface hardness and shear strength of coatings, and the main wear failure mechanisms were abrasion wear, coating delamination and flaking. It can be considered that deposition of PTFE coatings is a promising approach to improve the friction and wear behavior of ceramic substrate.     

Exploring the influences of the counterpart materials on friction and wear behaviors of atmospheric plasma-sprayed YSZ coating

Sliding wear behaviors of atmospheric plasma-sprayed Yttria Stabilized Zirconia (YSZ) coating mated with four metallic or ceramic counterparts (Si₃N₄, Al₂O₃, GCr15 and ZrO₂) were investigated. It has been found that YSZ coatings in contact with Si₃N₄ and GCr15 show better tribological performances than the other cases, which is due to the formation of the tribolayer mainly consisting of Si₃N₄ and Fe₂O₃ respectively on the worn surfaces. In the case of YSZ coating-Al₂O₃ and YSZ coating-ZrO₂ tribopairs, the wear debris are more irregular and larger in size, resulting in severe abrasive wear and brittle fracture of debris particles. In particular, the specific wear rate of YSZ coating sliding against GCr15 is negative due to the significant material transfer of the tribo-oxide layer, while that of YSZ coating sliding against ZrO₂ is the highest. Amorphization of the wear particles appears in the four cases due to the repeated mechanical action. It has been demonstrated that the wear of YSZ coating deteriorates with the increased flash temperature between the contact surfaces during rubbing process.     

Tribological and corrosion behaviors of fluorocarbon coating reinforced with sodium iron titanate platelets and whiskers

A series of sodium iron titanate (NFTO)–fluorocarbon composite coatings have been prepared with the liquid-phase blending method. The effects of two types of NFTO, NFTO platelets, and NFTO whiskers, on the tribological and corrosion behaviors of the composite coatings, are systematically studied. The results show that the addition of NFTO can significantly enhance the friction-reducing and wear resistance performances of the fluorocarbon coating. Under dry sliding, the minimum specific wear rate is 1.67 × 10⁻⁴ mm³/Nm for the platelet-filled composite coatings and 1.15 × 10⁻⁴ mm³/Nm for the whisker-filled composite coatings, respectively, showing a decrease of 83.5 and 88.6% than that of pure coating. Under a simulated seawater environment, the minimum specific wear rate is 5.44 × 10⁻⁵ mm³/Nm for the platelet-filled composite coatings and 0.84 × 10⁻⁵ mm³/Nm for the whisker-filled composite coatings, respectively, showing a decrease of 90.5 and 98.5% than that of pure coating. The morphologies of worn surfaces, wear debris, and transfer films are analyzed, and the corresponding wear resistance mechanisms are discussed. The electrochemical impedance spectroscopy certifies a remarkably improved corrosion resistance of the composite coatings which have been immersed in 3.5 wt % NaCl solution for 30 days. The composite coating reinforced with 7.5 wt % platelets shows the highest resistance of 256.3 × 10⁶ Ω·cm², approximately two orders of magnitude higher than that of pure coating. © 2020 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2020 , 137, 48936.