基于正交试验设计的电弧喷涂NiAl/3Cr18Mo复合涂层的性能研究

为获得制备NiAl/3Cr18Mo复合涂层综合性能较优的最佳工艺参数,采用正交法设计试验方案,利用电弧喷涂技术制备NiAl/3Cr18Mo复合涂层,系统研究了工作电流、电弧电压、空气压力和工作距离对复合涂层性能稳定性的影响规律.利用超景深三维显微系统对涂层的显微组织进行分析,并以结合强度及硬度为判据,总结了工艺参数与涂层性能的关系.结果 表明:工艺参数中工作电流、工作距离对NiAl/3Cr18Mo复合涂层结合强度的影响程度最大,空气压力和电弧电压影响较小;工作电流、工作距离对NiAl/3Cr18Mo复合涂层硬度的影响程度较大,电弧电压和空气压力影响次之.在工作电流200 A、电压32 V、空气压力0.6 MPa、工作距离170 mm时所制备的涂层综合性能最好.     

秸秆压块机模块电弧喷涂耐磨性的研究

本文针对当前饲料压块机模块磨损失效问题,提出了电弧喷涂3Cr13改善模块表面性能新工艺。通过正交试验和多因素方差分析,研究了电弧电流、电弧电压、喷涂距离及空气压力对模块耐磨性的影响,优化了在饲料压块机模块上喷涂3Cr13的工艺参数:电弧电流200A,喷涂距离180mm,空气压力0.6MPa,电弧电压38V。     

正交试验设计优化等离子喷涂纳米Al2O3-13%TiO2涂层工艺参数

为了深入研究等离子喷涂纳米Al2O3-13%TiO2(质量分数)工艺参数与涂层性能之间的关系,采用正交试验设计法,针对等离子喷涂过程中喷涂距离、喷涂电流、主气压力及辅气压力等4个主要参数,选用L9(34)正交表,以涂层结合强度为指标开展制备工艺参数的优化。结果表明,影响涂层结合强度的因素主次顺序是喷涂电流、喷涂距离、主气压力、辅气压力;等离子喷涂纳米Al2O3-13%TiO2最佳工艺参数为:喷涂距离110mm,喷涂电流870A,主气压力0.31MPa,辅气压力0.97MPa,优化工艺喷涂的涂层结合强度达到31.5MPa。     

结晶器铬锆铜板表面等离子喷涂镍铬-碳化铬涂层的研究

利用等离子喷涂技术在结晶器CrZrCu基体上制备了Cr3C2-30NiCr涂层,采用正交试验法研究了喷涂工艺参数对Cr3C2-30NiCr涂层与基体间结合强度的影响,观察了断口宏观形貌和涂层的显微组织结构,并对涂层进行了显微硬度试验.结果表明,影响涂层与基体结合强度的因素的主次关系为:送粉速率＞主气流量＞喷涂距离＞功率;正交试验得出的最佳工艺参数为:喷涂距离130mm,主气流量120L/min,送粉速率30g/min,功率22kW;涂层与基体间的最高结合强度大于32.86MPa;涂层截面的显微硬度服从正态分布.     

电弧喷涂工艺参数对Fe基涂层组织及耐磨性的影响

为保证大面积施工过程中电弧喷涂涂层质量的稳定性,采用正交设计方法研究了电弧喷涂工艺参数对Fe基耐磨涂层耐磨性的影响.确定最佳电弧喷涂工艺参数为:喷涂电流180 A,喷涂电压32 V,喷涂压力0.55 MPa,喷涂距离100 mm.试验结果表明:采用优化后的最佳工艺参数喷涂,涂层相对耐磨性为Q235钢的15.6倍,比优化前的1号涂层相对耐磨性提高近1倍.涂层中的孔隙率是影响涂层耐磨性的主要因素,采用适中的电弧电压可减少涂层中的孔隙率和氧化物数量,有利于提高涂层的耐磨性,获得具有良好综合性能的涂层.     

工艺参数对超音速电弧喷涂钛-铝涂层表面粗糙度的影响

利用SAS-Ⅱ型超音速电弧喷涂设备、工业级钛、铝丝材在LY12铝合金基体上制备了钛铝复合涂层,通过均匀设计方法实验研究了超音速电弧喷涂工艺参数对涂层表面粗糙度(Ra)的影响规律.结果表明:在一定的雾化条件下,随喷涂电压的增大,涂层的Ra逐渐增大,当电压增至32V时,Ra达到最高值,此后,随喷涂电压的继续增大,Ra逐渐下降;随喷涂距离的增大,涂层的Ra逐渐降低,当喷涂距离增至一定程度时,涂层的Ra降到最小值,随喷涂距离的继续增大,涂层的Ra又逐渐增大;随喷涂电流的增大,涂层的Ra呈线性增大的趋势.涂层Ra最小的超音速电弧喷涂工艺参数:喷涂电压为20V,喷涂电流为20A,喷涂距离为0.242m.     

等离子喷涂工艺参数对FeCrBSi合金涂层结合强度的影响

采用等离子喷涂工艺在Q235钢基体上直接制备了FeCrBSi合金涂层,使用正交试验法研究了喷涂工艺参数对涂层结合强度的影响,并对喷涂工艺参数进行了优化,同时在优化参数的基础上进一步研究了涂层厚度对结合强度的影响。结果表明：等离子喷涂制备FeCrBSi合金涂层的最佳工艺参数为喷涂电流900A,主气流量44．8L·min-1,辅气流量27．8L·min-1,喷涂距离110mm;采用最佳工艺制备的涂层与基体的结合强度为18．2MPa,内聚强度为33．5MPa;随着涂层厚度的增加,涂层与基体的结合强度明显下降,而涂层的内聚强度先上升后下降,较佳的涂层厚度为347．2μm。     

电弧喷涂工艺参数对Zn-Al伪合金制模涂层性能的影响

为了提高电弧喷涂模具的复制精度和使用寿命,研究了喷涂工艺参数变化对电弧喷涂制模中Zn-Al伪合金金属壳的硬度和致密性的影响.试验采用Zn丝作阴极,Al丝作阳极进行电弧喷涂.在固定喷枪移动速度和喷涂角度为90°的条件下,分析得出,送丝速度和喷涂距离对伪合金涂层硬度、孔隙率影响较小,而电弧电压和压缩空气压力对伪合金涂层硬度、孔隙率影响较大,并通过正交分析法得出了电弧喷涂制备Zn-Al伪合金涂层的最佳工艺参数:电弧电压30 V,送丝速度5m/min,喷涂距离200mm,压缩空气压力0.5 MPa.最后分析了不同工艺参数下涂层的金相组织.     

钛-铝双丝超音速电弧喷涂层显微硬度特性研究

利用SAS-Ⅱ型超音速电弧喷涂设备、工业级钛、铝丝材在LY12铝合金基体上制备了钛铝复合涂层,并对其显微硬度进行了测定.根据均匀设计实验方案和二次多项式逐步回归分析,获得了实验范围内,显著水平为0.002、相关系数为0.98的钛铝超音速电弧喷涂涂层显微硬度与喷涂电压、喷涂电流和喷涂距离的关系式.进一步分析表明:当喷涂电流较小时,随喷涂电压的增大,涂层的硬度逐渐下降;当喷涂电流较大时,随电压的增大,涂层的硬度随之增大,而且喷涂电流越大,其硬度的上升速度越快.而喷涂距离对涂层显微硬度的影响呈弱线性递增的关系.     

Ti-Al双丝超音速电弧喷涂涂层的滑动磨损特性研究

为了提高铝合金(LY12)的表面耐磨性,采用钛、铝金属丝材和SAS-Ⅰ型超音速电弧喷涂设备,利用二次回归正交试验方法、有润滑滑动磨损试验、涂层显微组织和磨损表面形貌观察、XRD分析,定量分析了喷涂电压和喷涂距离对涂层滑动磨损体积的影响规律,并进行了喷涂工艺参数的优化及其与基体滑动磨损的对比试验.结果表明:在特定的磨损和喷涂条件下,当喷涂距离较小时,随喷涂电压的增大,涂层的体积磨损量逐渐减小;随着喷涂距离的增加,涂层的体积磨损量随喷涂电压的升高逐渐增大,并且喷涂距离越大,涂层的体积磨损量随喷涂电压增大的速率愈大.当喷涂电压比较低时,涂层的体积磨损量随喷涂距离的增大而降低,但是,随喷涂电压的逐渐升高,涂层的体积磨损量随喷涂距离的增大逐渐上升,并且,喷涂电压愈高,其随喷涂距离而增加的速率越快.当喷涂电压和喷涂距离分别为26V和0 236m时,涂层具有最佳的耐滑动磨损性能,根据该工艺参数制成的涂层,其滑动磨损体积仅为LY12铝合金的1/38.84.即在适当的工艺条件下,Ti-Al双丝超音速电弧喷涂涂层对LY12铝合金具有显著的表面耐磨强化作用.     

等离子喷涂制备钢质涂布刮刀陶瓷涂层

以涂层平面度为评价标准,通过正交试验优化等离子喷涂工艺参数,在普通蓝钢刮刀上制备Al2O3-20%TiO2涂层,并对涂层的显微形貌、结合强度和耐磨性进行了研究.结果表明:弧电流550 A,喷涂距离100 mm,走枪速度0.8 m/s时等离子喷涂制备的Al2O3-20%TiO2涂层平面度最优;涂层具有良好的结合强度和耐磨性,结合强度大于30 MPa;磨粒磨损机理为切削和脆性断裂或脱落磨损.     

铝基粉芯线材电弧喷涂工艺参数优化研究

为了使铝基粉芯线材电弧喷涂涂层获得优良的涂层性能,选择涂层孔隙率为判据,通过正交试验和OLYC IA m3金相图像分析系统对铝基粉芯线材电弧喷涂工艺进行了优化,同时采用SprayW atch热喷涂监控系统对喷涂过程中粒子的飞行速度和温度进行了测定.经研究得到了铝基粉芯丝材电弧喷涂的最佳工艺参数.结果表明,影响铝基涂层致密性的工艺因素按主次顺序分别为喷涂气压、喷涂电压和喷涂距离;在所选试验范围内,随气体压力和喷涂电压的增大、喷涂距离的减小,涂层的孔隙率降低;在优化的喷涂工艺参数条件下,铝基涂层最小孔隙率可达1.3%.     

Field Application of Automated Power Arc Spraying System on Steel Bridge Deck

The effective corrosion protection coating and high productive coating equipment for steel bridge deck has been a challenge for bridge engineers for many years. An automated power arc spraying system was first designed and field applied to coating the deck of Wuhan Junshan Yangtze River Bridge in high efficiency. This steel bridge is a continuous orthotropic deck box girder cable-stayed bridge with 962 m in length and 38.8 m in width, whose width is the No. 1 in China. The whole orthotropic deck with over 35,000 m2surface area was arc-sprayed a protective coating of zinc on site, followed by a sealant and SMA paving material. The side face and bottom of box girders were arc-sprayed with aluminum in factory.Field application indicated that the newly designed automated power arc spraying system with fan nozzle and separate primary & secondary atomizing air had some advantages over the conventional arc spraying system, such as automated operation,big arc spray current, high spraying rate, big breadth of each coat, even and small atomized particles, high density and low porosity of sprayed coating, and high adhesive strength to the substrate.Working procedure of surface preparation and automated arc spraying on bridge deck were introduced, and the quality of sprayed coating is controlled strictly. Field tests proved that the application of this automated power arc spraying system is successful and suitable for coating the steel bridge deck.     

电弧喷涂Al,45CT及其复合涂层的抗高温氧化性能与机理

为获得抗氧化性能优良的涂层,采用电弧喷涂方法制备了Al,45CT及其复合涂层,探讨了3种涂层过渡层的形貌、物相及其相应的作用,分析了3种涂层的组织结构、抗氧化性能与机理。结果表明:Al涂层和复合涂层高温氧化后表面氧化膜有剥落现象,涂层中的抗氧化元素Cr含量很低;45CT涂层中的抗氧化元素Cr含量仍然很高,涂层的自我修复能力很强,表面生成的Cr2O3氧化膜具有优异的抗氧化性能;在涂层与基体结合处有一层过渡层,不仅增强了涂层与基体的结合力,还能进一步阻止氧化性气体向基体入侵,起到二次保护作用。     

Improving the structural quality and adhesion of functional coatings

In this paper a method of improving the structural quality and adhesion of functional coatings due to the pulsed mode of operation of a vacuum arc plasma source is described. The experiments were carried out by producing a carbon-based coating on a molybdenum substrate by spraying a graphite cathode in the benzene vapors. Plasma flow control is provided by alternating connection of two power sources, which allows variable closure of electron and ion currents on the substrate. This mode of operation allows to alternate the mode of heating and active diffusion of particles into the substrate with the mode of their deposition, as well as to provide the process of formation and annealing of the coating layers.     

Low pressure arc spraying of reactive materials

In spite of the introduction of low pressure plasma spraying, disadvantages remain in the case of powdered materials because of their large specific surface area. Thus tantalum, for example, is already embrittled before the spraying operation and the gases adsorbed on the very large surface area of the powder compared with that of a wire limit the purity of the coatings even if high purity gases are employed.Low pressure arc spraying, however, combines the advantages of wire spraying with those of spraying in low pressure chambers in that it yields homogeneous chemically pure coatings of low porosity. At the same time, the process is more economical than low pressure plasma spraying.Stable operation of conventional arc spraying heads at low pressure is not possible because the environmental pressure causes considerable enlargement of the arc between the electrodes being burned off. The result is that, among other things, the arc causes seizure of the contact nozzles and melts them off thereby rendering the spray heads unusable.In low pressure arc spraying the melting process takes place in an antechamber maintained at a pressure above atmospheric to ensure a safe burn-off along with appropriate droplet formation. The low pressure acts on the particles emerging from the nozzle and ensures intense degasification. In this way coatings are produced which are outstanding as regards density and adhesion to the substrate.The arc may burn between two or more current-carrying wires or between one centrally arranged wire and an annular backing electrode, located in the nozzle, or the surface of the substrate. By applying a voltage between an annular metallic electrode insert at the underside of the combustion chamber and the base metal, a transferred arc of selectable polarity can additionally be started and maintained as in low pressure plasma spraying.Coatings of titanium and tantalum prepared by low pressure arc spraying are presented. Optical, electron microscopy, metallographic and electrochemical analyses reveal the properties of the coatings.     

涂布刮刀表面等离子喷涂纳米AI203—13％Ti02涂层的特性

为了深入研究纳米A1203-13％TiO：（ATl3）涂层的组织、性能与喷涂工艺参数之间的关系,采用正交试验法对等离子喷涂工艺的电流、电压、送粉率和喷涂距离等参数进行了优化,在涂布刮刀表面制备了纳米ATl3涂层。采用金相显微镜,SEM,EPMA和XRD等对纳米ATl3涂层的组织、磨粒磨损性能和结合强度进行了分析。结果表...     

引入电弧喷涂氮化锆中间层的钛基PbO2的电催化阳极性能

在钛基体电弧喷涂氮化锆中间层,然后在其上阳极电沉积涂覆β-PbO₂催化表层,制备出Ti/ZrN/PbO₂阳极。对其进行微观结构分析和表面粗糙度测试、中间层附着力评价、电极加速寿命和电化学性能测试以及电氧化苯酚模拟废水实验,并与无中间层的Ti/PbO₂电极对比,研究了有中间层的钛基PbO₂涂层的阳极性能。结果表明,氮化锆中间层使阳极材料的导电性提高,中间层的粗糙表面使PbO₂电沉积层明显细化,表面整平性凸显,涂层与基体结合牢固,PbO₂沉积厚度增加,活性位点的数量增多。有氮化锆中间层的阳极加速寿命显著延长,比Ti/PbO₂电极延长了7倍,对有机污染物的电催化降解活性也有提高。