Bimodal distribution characteristic of microstructure and mechanical properties of nanostructured composite ceramic coatings prepared by supersonic plasma spraying

Nanostructured composite ceramic coatings (NCs) were deposited by supersonic plasma spraying (SPS) technique. The microstructures of NCs were characterized using scanning electron microscope (SEM), X-ray diffraction (XRD) and transmission electron microscope (TEM). The results showed that the microstructure of NCs exhibited a bimodal distribution consisting of fully melted regions (FM regions) and partially melted regions (PM regions). With the spray power increasing, the proportions of FM regions and PM regions both increased, but no distinct laws were found. The measured data of elastic modulus, micro-hardness and fracture toughness were analyzed using Weibull statistics. The results showed that these micromechanical properties followed Weibull distribution and presented a characteristic of bimodal distribution.     

Study of the structure and adhesive properties of ceramic coatings prepared by plasma spraying

We study the influence of technological parameters on the formation and structure of ceramic coatings based on Al₂O₃ and deposited by plasma spraying. We present the results of investigations of the adhesive properties of plasma-sprayed coatings based on Al₂O₃ and ZrSiO₄ that form tribological couples with 19,436 and 12,050 steels and polyamide. It is shown that the parameters of an A-160 plasma torch with aqueous plasma stabilization are suitable for the high-quality melting of ceramic materials based on Al₂O₃ if we use powders with particles 40–100 μm in size and perform spraying from a distance of 200–600 mm. Ceramic layers are formed by three types of particles of different shapes with different arrangements. Defects in the structure of the layers (pores, hollows, branched cracks, and large particles) deteriorate the properties of the coatings. The coatings based on Al₂O₃ and ZrSiO₄ exhibit the best properties under the conditions of abrasive wear, and this material, in combination with 19,436 steel, is suitable for application in friction couples. The degree of wear corresponds to the the value of the friction coefficient for the investigated tribocouples determined by the hardness of the material surfaces in the couple. The ceramics-polyamide couple seems to be quite promising due to the low friction coefficient and minimum wear. Published in Fizyko-Khimichna Mekhanika Materialiv, Vol. 44, No. 2, pp. 62–70, March–April, 2008.     

反应等离子喷涂TiC/Fe-Ni复合涂层及其耐冲蚀性能

以TiFe粉、Ni粉和蔗糖(碳的前驱体)为原料,通过蔗糖的热分解碳化制备Ti-Fe-Ni-C系反应热喷涂复合粉末,并利用等离子喷涂制备了TiC/Fe-Ni复合涂层。复合涂层主要由TiC颗粒均匀分布于(Fe、Ni)固溶体中形成的复合强化片层构成,片层中TiC颗粒呈球形或近球形,粒度为亚微米级和纳米级。TiC/Fe-Ni复合涂层的耐冲蚀磨损性能研究表明：涂层冲蚀失重率随攻角的增大而增加,表现出脆性材料冲蚀特性,但冲蚀失重率对攻角不敏感,涂层具有较好的塑性与硬度的配合;复合涂层的耐冲蚀磨损性能优于相同工艺条件下制备的C_r2C₃/Ni-Cr复合涂层,约为20G钢的2倍以上。     

Preparing of nanostructured Al2O3–TiO2–ZrO2 composite powders and plasma spraying nanostructured composite coating

Nanostructured Al₂O₃–TiO₂–ZrO₂ composite powders for plasma spraying were prepared by spray drying granulation technology. The effects of processing parameters on the microstructure and properties of composite powders were investigated. The results show that with increasing the slurry solid content, the particle size of powders increases, and the bulk density of powders increases, and the flowability of powders increases firstly and then decreases. With increasing the binder content, the particle size of powders increases, and the bulk density of powders increases, and the flowability of powders increases firstly and then decreases. With increasing the spray drying temperature, the particle size of powders increases, and the bulk density and flowability of powders increases firstly and then decreases. The most appropriate spray drying parameters are the slurry solid content of 40 wt.%, the binder content of 2.0 wt.% and the spray drying temperature of 250 °C. The nanostructured composite coating was successfully prepared by using the as-prepared nanostructured Al₂O₃–TiO₂–ZrO₂ composite powders as feedstocks. The nanostructured coating possessed higher hardness and toughness compared with the conventional microstructured one, which was attributed to the use of the nanostructured composite powders feedstocks.     

Ti-Al球磨粉反应等离子喷涂涂层的组织与性能

为制备Ti-Al金属间化合物复合涂层并研究其性能,以机械球磨的Ti-Al混合粉在Q235钢表面进行反应等离子喷涂实验,分别采用X射线衍射、扫描电子显微镜对涂层的成分、显微组织进行了分析,并测试了涂层的结合强度、显微硬度和耐腐蚀性能.结果表明:涂层由Al3Ti、TiN、Al2O3、少量TiAl与Ti3Al、以及残留的Al和Ti组成;球磨可促进喷涂时的反应,但喷涂时Al和Ti仍未完全反应,且在空气环境中喷涂容易氧化和氮化;涂层与基体之间是镶嵌式的机械结合,结合强度平均为30.24 MPa;涂层表面的显微硬度平均为206.1 HV,涂层的耐腐蚀性优于基体.总体上看,当球磨时间较长、电流较大、喷涂距离较大、气流量较小时,喷涂时的反应较充分,且涂层比较均匀、致密,其强度、硬度以及耐腐蚀性能较高.     

纳米陶瓷微米高温合金复合涂层组织与性能

采用溶胶-凝胶化学包覆法制备纳米陶瓷微米高温合金复合粉末,用HVOF喷涂技术制备了复合涂层,采用SEM观察和摩擦磨损实验分析了复合粉末和复合涂层的组织和性能.研究表明:复合粉末是以纳米陶瓷为外壳包覆微米级高温合金颗粒核心的核壳式结构;陶瓷壳在喷涂过程中形成液相与高温合金液相熔合,烧结成致密陶瓷相,部分陶瓷在冷却过程中析出结晶体;复合涂层与基体的结合强度为59.2 MPa,摩擦系数为0.766,磨损率比纯高温合金涂层降低了32%.     

溶液注入热等离子体中直接制备纳米结构热障涂层

采用一种新的方法,将Y2O3稳定的ZrO2前驱体溶液雾化注入直流等离子体中直接制备热障涂层.扫描电镜、透射电镜、X射线衍射分析、激光闪烁法分别观察分析了涂层的显微组织、纳米晶粒、相结构和热导率,排水法、冷热冲击法分别检测了涂层密度和热循环性能.实验结果显示等离子体喷涂液体制备出来的热障涂层不具有层状组织,晶粒尺寸小于100nm,组成相为四方相,硬度为350左右,热导率在1.2～1.5 W/m·K范围,涂层中存在16%左右的孔隙率,具有比常规微米结构热障涂层更优越的热循环性能.分析结果表明液体注入热等离子体中的雾化沉积既区别于物理化学气相沉积,又区别于粉末注入热等离子体中的熔化沉积,属于表面工程技术下的交叉领域.     

低压等离子喷涂316L等轴晶涂层及其性能研究

为研究低压等离子喷涂等轴晶涂层组织性能和形成机理,采用大气等离子喷涂（APS）和低压等离子喷涂（LPPS）,分别制备了316L不锈钢涂层.利用金相显微镜,X射线衍射和显微硬度等方法,分析了2种涂层的金相组织、相结构、显微硬度和耐蚀性.结果表明：一定条件下制备的低压等离子喷涂SUS316L不锈钢涂层明显不同于传统大气等离...     

SHS法制备TiC-Ni(Cr)金属陶瓷复合材料组织与性能

采用自蔓延燃烧合成技术在7A52铝合金表面制备了TiC-Ni(Cr)金属陶瓷复合涂层。利用扫描电镜(SEM)、能谱测试(EDS)、X射线衍射分析(XRD)、显微硬度测量、抗热震性检测等对涂层的组织与性能进行了研究。实验结果表明,涂层主要由陶瓷相TiC和金属相Ni组成,涂层内部各物相之间结合较紧密,涂层与基体结合处为高强度的冶金结合,其显微硬度约为基体的10倍,并通过抗热震性实验进一步验证了涂层与基体之间结合良好。实验证明在过渡层处加入与基体润湿性良好的Cr、Ni可较好地提高涂层与基体之间的结合强度。     

Properties of titania/hydroxyapatite nanostructured coating produced by gas tunnel type plasma spraying

Anatase phase titanium dioxide has a photo-catalytic performance for environmental protection. In this study, titanium dioxide/hydroxyapatite photo-catalytic coating was deposited by gas tunnel type plasma spraying using powders with nano-sized grains. The porous structure coating with high photo-catalytic activity could be prepared to vary the injecting position of powder. The phase compositions and microstructures of the coating were characterized using X-ray diffraction (XRD) and Field Emission Scanning Electron Microscopy (FESEM), etc. The results showed that the porous structure coatings with relatively high anatase content could be obtained by controlling the injecting position of the powder. The bimodal microstructure of the coatings was also controllable.     

Structural integrity and ferroelectric–piezoelectric properties of PbTiO3 coating prepared via supersonic plasma spraying

In order to prepare the PbTiO₃ coating with high density and excellent piezoelectric properties on all kinds shape surface, the PbTiO₃ coating was prepared by supersonic plasma spraying. The microstructure and mechanical properties were analyzed by scanning electron microscopy (SEM), X-ray diffraction (XRD), and X-ray photoelectron spectrograph (XPS). The dielectric constant and dissipation constant of the PbTiO₃ coating were tested. The results show that the coating has a single ferroelectric phase with perovskite structure, and its surface is smooth and dense. In the course of spraying, about 50% PbTiO₃ is decomposed into PbO and TiO₂ at high temperature. The ferroelectric hysteresis is weak and the ferroelectric hysteresis loop is not completely closed, which indicates that the defects, such as pores and cracks, exist in the coating. Although the defects are inevitable, the PbTiO₃ coating with ferroelectric and piezoelectric properties is successfully prepared.     

等离子熔覆ZrB_2-ZrC/Fe复合涂层组织及耐磨性

采用等离子熔覆技术,以Zr、Fe、B_4C混合粉末为原料,在Q235低碳钢表面原位反应合成了ZrB_2和ZrC增强的Fe基复合涂层,分析了ZrB_2-ZrC/Fe涂层的物相组成和组织结构,并进行了硬度、耐磨性对比试验,探讨了物相和组织结构的形成过程及磨损机制。结果表明:涂层主要物相为ZrB_2、α-Fe、ZrC、Fe_2B和Fe_3C,其中ZrB_2呈现针棒状、花瓣状,ZrC呈现规则的颗粒状;随着原始粉末中(Zr+B_4C)含量的增加,增强相ZrB_2和ZrC含量增多,尺寸变大,ZrB_2-ZrC/Fe涂层与Q235钢基体之间结合紧密,呈冶金结合;与Q235钢基体相比,ZrB_2-ZrC/Fe涂层耐磨性显著提高,最高可达基体的5.45倍,ZrB_2-ZrC/Fe涂层的磨损方式以磨粒磨损为主,断裂方式以穿晶断裂为主。     

Toughening mechanism of in-situ synthesized ZrB2 based composite coating by plasma spraying

Journal of Materials Science - ZrB2-based composite coatings have broad application prospects in hypersonic aircraft, rockets, and re-entry spacecraft. However, poor toughness of the ZrB2 coating...     

Mechanical properties of SiNxCx ceramic films prepared by plasma CVD

The mechanical properties of Si₃N₄-SiC, SiN_x and SiC_y films prepared at a low temperature of 400 °C by plasma chemical vapour deposition are reported. Microhardness, internal stress of the film and adhesive strength between the film and glass or stainless steel substrate were evaluated as principal mechanical properties. Microhardness was measured to be about 10 to 20 G Pa dependent on the film composition in each system. Internal stress of the films on borosilicate glass substrates extensively varied from tensile to compressive with the film composition change from Si₃N₄ to SiC. Adhesive strength, as ascertained by the scratch test, was about 580 to 800 MPa for crown glass substrates, and about 210 to 310 M Pa for 316 stainless steel substrates. It is pointed out that tensile stress in these films brought about more abrupt decreases of the adhesive strength than did compressive stress.     

Wear behaviour of aluminium matrix TiB2 composite prepared by in situ processing

Abstract

The wear behaviour and microstructure of aluminium and Al-12Si alloy (A413) matrix composites containing 1 and 5 vol.-%TiB₂ particles have been investigated. The composites were prepared by an in situ reactive slag technique. The wear surfaces and wear products were studied after reciprocating and rolling - sliding tests. Wear resistance increased with increasing particle content, and the Al-12Si composites were more wear resistant than those with Al matrixes. The wear mechanisms are briefly discussed.     

自反应火焰喷涂梯度过渡陶瓷涂层研究

以Ti-B4C-C和Ni-Al自粘结复合粉为自蔓延反应喷涂体系,采用反应火焰喷涂技术,在金属表面制备了Ti(Cx,Ny)-TiB2-NimAln梯度过渡涂层.整个涂层以Ti(C0.7,N0.3)、TiC、TiN和TiB2构成陶瓷主结构,NimAln金属间化合物作为过渡相连续分布其中,涂层具有沿厚度方向宏观连续分布和微观成分突变的特征,并存在孔隙与夹杂,呈典型的多相非均质结构.涂层经梯度过渡后,与基体的结合强度由14.38 MPa增加到30.27 MPa,抗热震性能由2次增加到16次,孔隙率由原来的32%降至19%,显微硬度由底层的Hv545增加到表层的Hv1253.涂层耐磨损性能是45号钢的14倍.     

Microstructure and properties of Nd-Fe-B magnets prepared by spark plasma sintering

Abstract

Anisotropic Nd₁₅.₅Dy₁.₀Fe_BalCo₃.₀B₆.₈Al₁.₀ magnets were produced by the spark plasma sintering (SPS) technique. The effects of processing conditions on the microstructure, magnetic properties, dimensional precision and density of the magnets were studied. The magnetic properties, microstructure and constituents were investigated by means of a magnetic flux density - magnetic field strength (B-H) loopline instrument, scanning electron microscopy and energy dispersive X-ray analysis. The density of the magnets was determined by the Archimedes method, and the dimensional precision of the magnets was measured by micrometer. It was found that the microstructure of SPS processed Nd-Fe-B magnets is unique; the grain size is fine and uniform while distribution of the neodymium rich phase is heterogeneous. The optimal magnetic properties of SPS processed Nd-Fe-B magnets obtained so far are maximum energy product of 240 kJ m^-3 and coercive force of 1260 kA m^-1. The dimensional precision of the magnets is ~ 20 μm, and the density of the magnets reaches 7.58 g cm^-3.     

Microstructure and mechanical characteristics of iron-based coating prepared by plasma transferred arc cladding process

This paper investigated the effect of electromagnetic stirring (EMS) on the microstructure and abrasive wear behavior of iron-based coatings. A series of coatings were prepared by using plasma transferred arc cladding (PTAC) process. The phase and structure of the coatings were characterized by means of SEM, EDXA and X-ray diffraction. The microstructure of the coatings was mainly γ-Fe matrix and (Cr, Fe)₇C₃ carbide reinforced phases. Without EMS, the average size of (Cr, Fe)₇C₃ carbide was about 73 μm, while that of the carbide reached a minimum value of about 20 μm with stirring current of 3 A. The mechanical properties, especially wear resistance, were analyzed in detail. The results showed that the microstructure of the coating plays an important role on abrasive mechanism and the main mechanism is micro-cutting. When the stirring current is 3 A, the coating exhibits excellent wear resistance, which contributes to the good microstructures that hexagonal (Cr, Fe)₇C₃ carbide with the highest volume fraction are uniformly distributed in the matrix. The microhardness of the coatings increase at first, and then decrease as a function of stirring current. The maximum microhardness value of the coating is about 1050 HV.     

Microstructure and mechanical properties of in situ TiB reinforced titanium matrix composites based on Ti–FeMo–B prepared by spark plasma sintering

The in situ synthesized TiB reinforced titanium matrix composites have been prepared by spark plasma sintering at 800–1200 °C under 20 MPa for 5 min. The effects of sintering temperature and reinforcement volume fraction on flexural strength, Young’s modulus and fracture toughness of the composites are investigated. The titanium matrix consists of -Ti and β-Ti phases, and the volume fraction of β-Ti increases with increasing sintering temperatures. The in situ synthesized TiB reinforcements are distributed randomly and uniformly in matrix. The transverse section of TiB has a hexagonal shape aligned along [0 1 0] direction, and the crystallographic planes of the TiB needles are always of the type . The 10 vol% TiB reinforced composite sintered at 1000 °C exhibits excellent mechanical properties. The flexural strength, Young’s modulus and fracture toughness of this composite are 1560 MPa, 137 GPa and 8.64 MPa · m^1/2, respectively.     

n-SiO2/Ni电刷镀复合镀层的组织结构和沉积机理

用SEM和TEM分析了n-SiO2／Ni复合刷镀层的表面形貌和微观组织结构，测定了n-SiO2在快镍刷镀液中的表面Zeta电位和粒度分布，研究了这些因素对复合沉积过程和对镀层组织的影响．结果表明：刷镀液中n-SiO2粒径的分布较广，镀层中n-SiO2粒径在数十纳米范围内；刷镀液中纳米颗粒的粒度越小，刷镀层组织越细小、均匀，结合越致密，而且刷笔运动及溶液对流等因素对进入刷镀层的纳米颗粒粒径有一定选择效应n-SiO2／Ni体系复合共沉积的机理属于力学机理。