微缺陷对热喷涂涂层接触疲劳性能的影响

采用超音速等离子喷涂设备在45号钢基体上制备了三种含有不同微缺陷的NiCrBSi合金涂层。使用球盘式接触疲劳实验机对涂层的接触疲劳性能进行了测试,建立了Weibull失效概率图;使用扫描电子显微镜对涂层的微观结构和失效形貌进行了表征;比较了三种涂层的接触疲劳寿命及涂层的主要疲劳失效模式。结果表明,涂层内的微缺陷主要由微孔隙和微裂纹构成,涂层接触疲劳寿命的长短与这些微缺陷含量的多少成反比,涂层的孔隙率为2.5%,1.3%和2.1%,对应的接触疲劳寿命分别为7.77×105,8.99×105,7.81×105周次。同时,涂层微缺陷含量较少时涂层的失效模式主要以剥落失效为主;涂层微缺陷含量较多、结合强度较差时主要以分层失效为主;涂层内存在较大的孔隙可致使涂层的提早失效,同时涂层表面磨损失效的概率增加。     

涂层疲劳损伤声发射特征参数及损伤机理

使用超音速等离子喷涂设备在1045钢基体上制备了铁基合金涂层。以球盘式接触疲劳试验机为平台,研究了涂层接触疲劳损伤过程中声发射特征参数的变化规律,并分析了涂层的接触疲劳损伤机理。结果表明,在转速为2500r/min和应力水平为1.58GPa实验条件下,点蚀是涂层的主要失效形式,表现为在涂层磨痕轨迹范围内出现大量的点蚀坑,点蚀坑深度为20～30μm。涂层表面粗糙的微凸体与轴承球滚压接触产生黏着磨损,以及涂层、磨粒、滚动轴承三者形成三体磨料磨损是点蚀失效产生的主要原因。声发射幅值、有效值(Root Mean Square,RMS)、能量、计数和平均频率对涂层表面粗糙微凸体去除、弹塑性变形、裂纹萌生、裂纹稳定扩展和失稳扩展过程比较敏感,并且在不同的疲劳损伤阶段具有不同的信号反馈特点。     

滚动接触条件下铁基涂层的疲劳磨损寿命实验研究

利用超音速等离子喷涂技术在45钢表面制备了铁基合金涂层,利用球盘式疲劳磨损实验机评价了铁基涂层在两种载荷条件下的疲劳磨损性能,利用两参数Weibull分布表征了涂层的疲劳寿命,采用扫描电子显微镜(SEM)分析了涂层的微观结构和失效形貌,利用有限元方法研究了涂层内部应力分布.实验结果表明,载荷条件可以显著地影响涂层的寿命和失效形貌,高载下涂层的寿命明显降低;随着载荷的增加,主要失效形式由表面磨损失效转换成剥层失效,其中表面磨损是由于粗糙接触引起,而剥层则与应力分布机制有关.     

表面电沉积合金层提高碳钢齿轮的接触疲劳强度研究

 接触疲劳破坏是齿轮的主要失效形式之一． 在45#钢齿轮齿面电沉积Ni-P-Co合金层，可以显著提高其接触疲劳强度．同时，对合金层的表面形貌，表面粗糙度、显微硬度和疲劳点蚀坑形貌特征等进行了分析．     

镁合金预处理对其表面有机涂层耐蚀性的影响

镁合金压铸件上涂覆有机涂层后的耐蚀性能与其涂装前的表面处理状态有着密切关系.采用中性盐雾试验和盐水浸渍法对经喷砂、打磨、无铬化学转化、微弧氧化4种不同表面预处理后的丙烯酸树脂涂层进行了耐蚀性测试.结果表明:采用合适的预处理能显著提高涂层的耐蚀性能,其中微弧氧化涂层耐蚀性最佳,在盐雾和盐水浸渍试验中失效时间分别达96 h和168 h;预处理后基材表面光滑的涂层失效形式以起泡为主,而具有微孔或粗糙表面的涂层则以点蚀为主.     

热处理工艺对支撑辊用钢疲劳剥落形式的影响

采用JPM-1型接触疲劳磨损试验机，对450℃、530℃两个回火温度下支撑辊用Cr5钢的线接触滚动疲劳寿命进行了测定；通过扫描电子显微镜（SEM）、X射线（X—ray）和显微组织观察的方法研究了两种热处理工艺下试验用钢的疲劳剥落形式，并对剥落形式及剥落机理进行了初步探讨。结果表明：450℃回火得到硬度为HRC51的试样失效形式主要为棘齿裂纹和深层剥落，疲劳寿命为1．5～3×10^6；530℃回火得到硬度为HRC45的试样失效形式主要为浅层剥落，疲劳寿命为0．5～2×10^5。     

40CrNiM0齿轮材料点蚀破坏的金相研究

用金相试验方法,对40CrNiMo中等硬度齿轮材料在接触疲劳过程中的表面破坏形态、裂纹的萌生与扩展等问题进行了研究,并从金属学角度对材料失效破坏过程进行了分析.结果表明,经过一定周次的循环后,试验滚轮表面产生的接触疲劳破坏是属点蚀破坏,从滚轮表面产生的塑性变形和金属流变层是表面产生点蚀破坏的重要原因.     

微合金化渗碳齿轮钢的接触疲劳性能

通过滚动接触疲劳试验方法,研究了两种渗碳齿轮钢的接触疲劳性能.结果发现,渗碳齿轮钢接触疲劳试样失效方式主要为渗碳层的点蚀和剥落.氧含量较低的Nb微合金化齿轮钢(含0.04%的Nb)中氧化物夹杂数量少、尺寸小,接触疲劳裂纹起裂较难;同时,Nb微合金化齿轮钢渗碳层晶粒尺寸小、硬度高,提高了疲劳裂纹萌生及扩展阻力,导致Nb微合金化后,齿轮钢的接触疲劳寿命大幅度提高.     

基于统计分析的等离子喷涂层接触疲劳寿命和失效模式

在不同应力水平下考察等离子喷涂镍基合金涂层的滚动接触疲劳寿命和失效模式。以R-3.1.1软件为平台,采用统计分析方法(方差分析、回归分析、判别分析等)对其进行分析和讨论。结果表明:涂层的滚动接触疲劳寿命呈正态分布;随着接触应力的增加,涂层的均值寿命和方差都减小,并且疲劳寿命的分布更加集中;方差分析表明,接触应力对涂层的滚动接触疲劳寿命有显著性影响,且寿命均值与接触应力具有高度的线性相关性;建立了涂层失效模式的判别准则,当指定接触应力和疲劳寿命时可以预测涂层的失效模式,且预测正确率在65%以上;疲劳寿命对失效模式的累积贡献率明显高于接触应力对失效模式的累积贡献率,因此疲劳寿命是决定涂层失效模式的主要因素。     

DZ40M合金铝化物涂层的高温氧化蚀点现象

DZ40M钴基合金铝化物涂层在高温氧化过程中失效特点,晨在氧化膜之上产生隆起的深色蚀点。蚀点的出现标志着涂层局部失效的开始。蚀点增加并长大,则对应着涂层失效面积的扩展。形成的蚀点最终覆盖整个涂层表面,意味着涂层完全失效。     

Stress‐dependent fatigue mechanisms of CrC–NiCr coatings in rolling contact

The rolling contact fatigue (RCF) behaviour of the plasma‐sprayed CrC–NiCr cermet coatings under different tribological conditions of contact stress was investigated. Four sets of fatigue life data of coatings were characterized by Weibull distributions. The failure modes of the coatings were classified on the basis of worn surface observations of the failed coatings. Results showed that the failure mode of the coating was related to the magnitude of contact stress. The RCF life data of the coatings tested at high contact stresses exhibited high scattering, because the bimodal distribution of the fatigue life data was seen in the Weibull plot. Generally, when the contact stress was relatively low, the coatings were prone to fail in spalling and cohesive delamination. However, at high contact stress, the coatings often failed due to interfacial delamination. At different contact stress levels, the maximum shear stress amplitude was the main reason for the generation of spall and delamination.     

Fatigue resistance and failure mechanisms of plasma-sprayed CrC–NiCr cermet coatings in rolling contact

The rolling contact fatigue (RCF) resistance and failure mechanisms of plasma-sprayed CrC–NiCr cermet coatings were experimentally investigated. Fatigue tests were conducted at two different contact stresses. At a given contact stress, thirteen rolling contact tests were performed to obtain the statistical result. The Weibull distribution plots of fatigue life data of the coatings were obtained. At higher contact stress, the bimodal distribution of the fatigue life data of the coatings was observed in the Weibull plot. The fatigue life of the coating decreased with increasing the contact stress. The failure modes of coatings could be classified into two main categories, i.e., spalling and delamination.     

Influence of loading levels on RCF life and failure mode of Ni-based alloy and WC–Ni ceramic composite coatings

This paper studied influence of loading levels on rolling contact fatigue (RCF) performance of NiCrBSi/WC–Ni composite coating. The results showed that abrasion, spalling, delamination, and rolling cracking were four kinds of main failure modes related with contact stress. Under relatively high contact stress, intense deformation of NiCrBSi particles resulted in rolling cracking failure. Furthermore, RCF life can be predicted by established lognormal distribution and σ_max − N model. The study also found that RCF life was closer to expectation E(N), higher failure probability of the coating. And RCF life became more discrete and more difficult to predict as contact stress increased.     

Rolling contact fatigue mechanism of a plasma‐sprayed and laser‐remelted Ni alloy coating

The rolling contact fatigue behaviour of the plasma‐sprayed and laser‐remelted Ni‐Cr‐B‐Si alloy coatings under two different tribological conditions of contact pressure was investigated. Two sets of fatigue‐life data of coatings were characterized by Weibull distributions. The failure mode of the coatings was identified on the basis of worn morphologies as observed at the surfaces of the failed coatings. The tribological mechanism leading to the formation of the fatigue spall was discussed on the basis of the subsurface morphologies observed in the failed coating. Experimental results showed that, the mean life and characteristic life of the coating decreased with increasing the contact pressure. The failure of the coatings can be termed as spalling‐type failure. A refined ‘ring‐crack model' was proposed to explain the formation of the fatigue spall. In the refined model, it was postulated that the joining of the ring‐type cracks and subsurface branched cracks was directly responsible for the spall formation.     

某机尾桨轴颈叉耳耳环断裂分析

对某机尾浆轴颈叉耳耳环提前破坏原因进行了全面的检查分析。结果表明：叉耳耳环提前破断是由于耳孔与销子配合不当,而产生滑动磨损（微动）引起疲劳断裂,其磨损特征也不是单一的,而是粘着磨损、磨粒磨损和接触疲劳磨损的复合磨损方式。     

Friction and wear reduction with tribological coatings

The basic requirements for a good tribological surface are (1) low sliding friction, (2) good resistance to scuffing, wear and abrasion, (3) long contact fatigue life and (4) adequate subsurface strength to provide dimensional stability. Coatings have inherent deficiencies. The major problem is failure at the interface between the coating and the substrate, which results in flaking, peeling or spalling of the coating under the repetitively applied contact stresses.Three types of coatings which employ different mechanisms to improve the tribological properties and to maintain coating integrity are described in this paper. Nitrocarburizing represents a class of coatings in which the elements are allowed to diffuse into the surface of the structural material to form an alloy with the substrate. Diffusion provides compositional gradients which result in hard wear-resistant surface and which at low shear strengths avoid the interfaces that frequently exist between coatings and substrates. Chemically vapor-deposited chromium and titanium carbides represent a class of coatings in which a chemically distinct layer is grown on top of the substrate and is bonded to the substrate by diffusion. In the third type of coating, hard particles are suspended in a soft matrix. The hard particles provide the wear and abrasion resistance and the soft matrix both bonds the particles together and provides the low friction. Although the bond strength of this coating to the substrate is lower than that provided by diffusion in the other coatings, the soft matrix will yield without flaking under the shear stresses which are developed at the interface.     

GCr15钢旋压轧辊表面失效原因分析

通过宏观分析、化学成分分析、硬度测试、金相检验、断口分析以及能谱分析等方法对某批GCr15钢旋压轧辊的早期表面崩裂剥落失效原因进行了分析。结果表明:由于旋压轧辊钢材中的碳化物发生了偏聚,呈链状和长条状分布,增加了轧辊的脆性,降低了轧辊的疲劳寿命,从而导致轧辊在使用一轮后就在受力最大区域出现了表面崩裂剥落现象,发生接触疲劳失效。     

n-Al2O3/Ni复合电刷镀层的接触疲劳行为

为研究纳米颗粒复合电刷镀层的接触疲劳行为,通过在镍盐溶液中加入纳米氧化铝(n-Al2O3)颗粒,采用电刷镀技术制备了含n-Al2O3颗粒的镍基复合镀层(n-Al2O3/Ni),采用接触疲劳试验机评价了镀态和热处理态的n-Al2O3/Ni复合镀层的抗接触疲劳性能,并与纯镍刷镀层进行了性能对比.借助SEM和TEM对复合刷镀层的组织进行了分析,探讨了复合刷镀层的接触疲劳失效过程以及纳米颗粒等对刷镀层疲劳失效过程的影响.研究表明:n-Al2O3/Ni复合镀层在镀态下的接触疲劳寿命超过100万周次,明显高于纯镍镀层;退火后n-Al2O3/Ni复合镀层接触疲劳寿命为45.9万次,为纯镍镀层的1.62倍;复合镀层的接触疲劳失效过程分为裂纹萌生、裂纹扩展和镀层断裂3个阶段;纳米颗粒在复合镀层接触疲劳失效过程中起到阻碍位错滑移的作用,从而抑制塑性变形和裂纹扩展,使复合镀层具有较高的接触疲劳寿命.