HA/ZrO2梯度涂层的制备及其抗冲击性能研究

为了研究梯度结构对HA涂层结合强度和抗冲击性能的影响,采用等离子喷涂在钛合金基体上分别制备纯HA涂层、HA/ZrO2涂层以及HA/HA+ZrO2/ZrO2梯度涂层(分别命名为H1,H2和H3涂层)。利用SEM和拉伸实验机对涂层的截面形貌和结合强度进行分析,采用落球冲击实验机对涂层进行冲击实验,观察涂层的失效形式并分析了涂层的抗冲击性能。结果表明:制备出的HA梯度涂层呈现明显的分层结构,每一层都有相应的厚度分布且层间结合良好。涂层的结合强度随着ZrO2梯度层的增加而增加。与H1涂层和H2涂层相比,H3涂层具有更好的抗冲击性能。H1涂层的冲击失效形式为涂层大面积脱落,H3涂层的失效形式为涂层层间的剥离。     

热喷涂技术在热障涂层制备中的应用

综述了热障涂层研究及应用中的几种热喷涂技术,包括火焰喷涂、爆炸喷涂和等离子喷涂,介绍了上述几种制备技术的原理并分析了各自的特点,认为爆炸喷涂工艺、溶液注入等离子喷涂工艺在新型热障涂层制备中的应用前景广阔．     

热喷涂技术在热障涂层制备中的应用

综述了热障涂层研究及应用中的几种热喷涂技术,包括火焰喷涂、爆炸喷涂和等离子喷涂,介绍了上述几种制备技术的原理并分析了各自的特点,认为爆炸喷涂工艺、溶液注入等离子喷涂工艺在新型热障涂层制备中的应用前景广阔．     

等离子喷涂复合陶瓷涂层及其耐磨性能

用等离子喷涂技术制取了ＭＯ＋Ａｌ２Ｏ３－ＴｉＯ２、ＭＯＳ２＋Ａｌ２Ｏ３、ＴｉＯ２＋Ｃｒ３Ｃ２ＮｉＣｒ和ＭｏＳ２＋Ｃｒ３Ｃ２－ＮｉＣｒ复合涂层．利用ＳＥＭ、ＸＲＤ、和ＸＰＳ等技术．观察和分析了涂层的显微结构和喷涂过程中的物相变化及添加成分对涂层耐磨性能的影响．在ＭＭ－２００型磨损试验机上测定了涂层的滑动摩擦系数和磨损率．结果表明；Ｍｏ、ＭｏＳ２与Ａｌ２Ｏ３－ＴｉＯ２的结合性能较好，ＴｉＯ２、ＭｏＳ２在Ｃｒ３Ｃ２－ＮｉＣｒ涂层的气孔和裂纹处偏聚；添加ＭｏＳ２对Ａｌ２Ｏ３－ＴｉＯ２涂层的物相组成有明显的影响；适量的ＭＯ、ＭＯＳ２加入Ａｌ２Ｏ３－ＴｉＯ２中，可以降低涂层的摩擦系数和磨损率；而ＴｉＯ２、ＭｏＳ２加入Ｃｒ３Ｃ２－ＮｉＣｒ中，对涂层的摩擦磨损性能影响不大     

等离子喷涂羟基磷灰石涂层结晶度的分析

采用大气等离子喷涂技术,在Ti6Al4V基体上制备了羟基磷灰石涂层.利用光学显微镜、SEM和XRD分析技术对涂层形貌、相组成和结晶度进行了研究,分析了不同工艺参数对结晶度的影响.结果表明,在喷涂过程中,晶态HA部分发生分解,形成TCP、TTCP、CaO等杂质相,熔化颗粒激冷产生大量非晶;减小喷涂电流,缩短喷涂距离,降低辅助气体流量,均使涂层结晶度增大,杂质相含量降低;1^#(结晶度为34.8%)涂层横截面呈典型的层状组织、粉末几乎被完全熔化,2^#(结晶度为43.9%)和3^#(结晶度为50.6%)涂层的横截面层状组织不明显且含有较多未熔化颗粒.     

氮气保护对纳米复合涂层组织与性能的影响

采用氮气保护方法改进电弧喷涂技术,制备含纳米陶瓷颗粒的粉芯丝材电弧喷涂层,研究其组织结构和高温冲蚀性能.结果表明,氮气保护提高了涂层的致密性和均匀性,组织的连续性和均匀性得到明显改善,涂层中氧化物显著减少.氮气保护使更多的合金元素熔入Fe中形成Fe基固溶体,纳米陶瓷相在基体相中呈较均匀的弥散分布状态.当氮气保护的涂层受磨粒冲蚀时,不会出现明显的层状形式流失.在本试验条件下,3种氮气保护涂层平均体积冲蚀率比无氮气保护均有显著提高.氮气保护改善了纳米陶瓷相与基体相的结合,更有利于发挥纳米陶瓷颗粒对涂层的弥散强化作用.     

喷涂工艺对陶瓷/金属自反应复合涂层组织的影响

用等离子喷涂的方法喷涂自制的Fe2O3 Al自反应复合粉,在金属表面制备了陶瓷-金属多相自反应复合涂层．研究了复合粉和涂层的微观结构,以及喷涂工艺参数对复合粉反应程度及涂层组织的影响．研究发现,喷涂距离是影响复合粉反应程度及涂层组织结构的主要因素,枪距在100mm时,反应最充分,涂层组织最致密．     

900℃加热后热喷涂FeCrAl/AlSi复合涂层组织变化

为开发一种经济可靠的高温防护涂层,采用电弧喷涂方法在低碳钢表面制备FeCrAl/AlSi复合涂层,并对复合涂层试件进行900℃温度下的2400h加热,以考察其高温氧化表现和微观组织变化.实验结果表明：复合涂层中抗氧化元素的相互配合很好地保护了基体金属.900℃加热3h,防护涂层表面以及内部的氧化物以Al2O3为主,涂层/基体界面两侧形成Cr元素的扩散带.经过2400h加热后,复合涂层外表面氧化物层增厚,涂层/基体界面原位生成铬的氧化物,界面基体金属一侧存在约200μm宽的Cr元素扩散带.     

热喷涂FeCrAl/Al复合涂层抗高温硫化的研究

为了提高材料的抗热腐蚀性能,采用电弧喷涂方法在钢铁基体表面施加FeCrAl/Al复合涂层,通过沉积Na2SO4的900℃热腐蚀试验以及二硫化碳生产装置中的现场挂片试验,研究了FeCrAl/Al复合涂层的高温硫化表现。实验结果表明:FeCrAl/Al复合涂层提高了钢铁材料的抗高温硫化腐蚀能力,在高温硫化初期,外表面的Al涂层首先发生氧化,形成连续的Al2O3层,显著地减缓了硫原子向复合涂层内部的扩散速度。随着复合涂层中Cr、Al等有效抗硫化合金元素的相互扩散,形成FeCr金属间化合物层,进一步阻碍硫原子扩散,对钢铁基体材料提供有效的高温硫化防护作用。     

加热扩散对电弧喷涂Al涂层的影响

为了提高Al涂层的抗高温氧化性及硬度,采用电弧喷涂方法在Q235碳钢基体上制备了Al涂层.结果表明,经过加热扩散处理后Al涂层和基体之间形成了扩散层.涂层厚度、加热温度与加热时间对扩散层具有一定影响.当加热温度为800℃和900℃时,Al涂层主要形成相为Fe Al、Fe Al2、Fe Al3和Fe2Al5.经过加热扩散处理后Al涂层具有优良的抗高温氧化性,且平均硬度相比未经加热扩散处理的Al涂层提高了10倍以上,利用扩散系数求出的扩散层深度与实际扩散层深度相近.     

电弧喷涂涂层温度场及应力应变分析

为了分析电弧喷涂层的沉积过程，采用有限元分析软件ANSYS计算不同时刻以及不同位置涂层内的温度场、应力场，在建立传热模型过程中考虑了金属液滴向涂层的传热以及涂层向系统外的热量散失等问题.采用在厚度方向以微小层逐层叠加来模拟涂层的增厚，并以此为基础构造涂层有限元计算模型，应用单元生与死逐层激活层单元参与计算过程.实现移动边界以充分模拟真实的喷涂沉积过程，获得了涂层温度场、应力场的分布情况.并在此计算的基础上，分析了应力分布对涂层失稳的影响.     

Abrasive wear behaviors of high velocity arc sprayed iron aluminum composite coatings

The High Velocity Arc Spraying （HVAS） technology was used to prepare Fe-Al composite coatings by the adding of different elements into cored wires to obtain different Fe-Al coatings. The added compounds do great effect on the properties of the composite coatings. The microstructures and abrasive wear performances of the coatings were assessed by transmission electron microscopy （TEM）, scanning electron microscopy （SEM）, and THT07-135 high temperature wear equipment. It was found that the adding of Cr3C2 can greatly increase the room temperature wear behavior, and Fe-Al/WC coatings have adapting periods at the beginning of wear experiment. With the rise of temperature, the wear resistance of Fe-AI/Cr3C2 coatings becomes bad from room temperature to 250℃, and then stable from 250℃ to 550℃; the wear resistance of Fe-Al/WC becomes well with the rise of temperature. The adding of Cr and Ni can also improve wear performances of Fe-Al composite coatings.     

激光重熔制备TA1表面Ni/Al复合抗高温氧化涂层

为了提高纯钛的高温抗氧化性能,采用电弧喷涂和等离子喷涂方法在纯钛表面制备Ni/Al复合涂层.利用激光重熔使得Ni层与Al层发生冶金反应,对试件进行800℃×40 h连续氧化.根据生成的金属间化合物特征研究纯钛的高温抗氧化行为.结果表明,经过表面改性处理后Ni/Al复合涂层可以显著提高纯钛的高温抗氧化性能.在激光重熔过程中Ni/Al复合涂层中的Al发生熔化扩散并与Ni形成以Ni₂Al₃相为主的扩散层.在氧化过程中Ni/Al复合涂层表面形成连续且致密的α-Al₂O₃氧化膜与大量NiAl相,表面扩散层中的富铝相可为表面提供充足的Al元素,进而对纯钛基体提供有效的高温抗氧化保护作用.     

SiB6-MoSi2复合涂层显微结构及抗氧化性能的研究

采用脉冲电弧放电法在SiC-C/C复合材料表面制备硼化硅和硅化钼的复相(SiB6-MoSi2)抗氧化涂层.借助X射线衍射、扫描电子显微镜对复合涂层的晶相组成、显微结构和抗氧化性能进行了表征与测试.研究了不同晶相组成(m[MoSi2]/m[SiB6]=Cp)对SiB6-MoSi2涂层显微结构的影响.结果表明:当晶相组成m[MoSi2]/m[SiB6]=1∶4时,制备的涂层致密均匀,在1 773K氧化156h后失重仅为2.12%,复合涂层氧化失效是由于长时间氧化后涂层挥发变薄,不能及时有效的愈合气相(CO和CO2)的逸出产生的氧化孔洞等缺陷导致的.     

石墨配比对钨极氩弧熔敷层TiC增强相含量及分布形态的影响

利用钨极氩弧熔敷预涂在碳钢表面的钛铁和石墨粉末能够在碳钢表面获得性能优异的TiC增强涂层.预涂粉末Ti、C元素配比及含量对增强相的数量、形态和分布方式有重要影响：一方面,随着预涂粉末中含碳量的增加,熔敷层中Fe2Ti有害相降低,但出现了极少量的石墨相;另一方面,熔敷层中原位合成TiC增强相的含量增加,颗粒尺寸也随之增加,TiC颗粒的树枝状分布形态也由细枝状向粗枝状转化.     

Oxidation performance of Fe-Al/WC composite coatings produced by high velocity arc spraying

Fe-Al intermetallics with remarkable high-temperature intensity and excellent erosion, high-temperature oxidation and sulfuration resistance are potential low cost high-temperature structural materials. But the room temperature brittleness induces shape difficult and limits its industrial application. The Fe-Al intermetallic coatings were prepared by high velocity arc spraying technology with cored wire on 20G steel, which will not only obviate the problems faced in fabrication of these alloys into useful shapes, but also allow the effective use of their outstanding high-temperature performance. The Fe-Al/WC intermetallic composite coatings were prepared by high velocity arc spraying technology on 20G steel and the oxidation performance of Fe-Al/WC composite coatings was studied by means of thermogrativmetic analyzer at 450, 650 and 800°C. The results demonstrate that the kinetics curve of oxidation at three temperatures approximately follows the logarithmic law. The composition of the oxidized coating is mainly composed of Al₂O₃, Fe₂O₃, Fe₃O₄ and FeO. These phases distribute unevenly. The protective Al₂O₃ film firstly forms and preserves the coatings from further oxidation. Foundation item: Project(50235030) supported by the National Natural Science Foundation of China; Project(98BK014) supported by the Foundation of State Economy Trade Committee of China     

Effect of electromagnetic stirring on the microstructure and wear behavior of iron-based composite coatings

The effect of electromagnetic stirring on the microstructure and wear behavior of coatings has been investigated. A series of iron-based coatings were fabricated by the plasma-transferred arc cladding process by applying different magnetic field currents. The microstructure and wear resistance of the composite coatings were characterized by scanning electron microscope (SEM), energy dispersive X-ray analysis (EDAX), X-ray diffraction (XRD), and wet sand rubber wheel abrasion tester. The experimental re- sults showed that the microstructure of the coatings was mainly the γ-Fe matrix and (Cr, Fe)7C3 carbide reinforced phase. The coatings were metallurgically bonded to the substrate. With increasing magnetic field current, the amount of the block-like (Cr, Fe)7C3 carbide reinforced phase increased at first, reached a local maximum, and then decreased sharply. When the magnetic field current reached 3 A, the block-like (Cr, Fe)7C3 carbides with high volume fraction were uniformly distributed in the matrix and the coating displayed a high microhardness and an excellent wear resistance under the wear test condition.     

Oxidation performance of Fe-Al/WC composite coatings produced by high velocity arc spraying

Fe-Al intermetallics with remarkable high-temperature intensity and excellent erosion, high-temperature oxidation and sulfuration resistance are potential low cost high-temperature structural materials. But the room tem perature brittleness induces shape difficult and limits its industrial application. The Fe-Al intermetallic coatings were prepared by high velocity arc spraying technology with cored wire on 20G steel, which will not only obviate the problems faced in fabrication of these alloys into useful shapes, but also allow the effective use of their outstanding high-temperature performance. The Fe-Al/WC intermetallic composite coatings were prepared by high velocity arc spraying technology on 20G steel and the oxidation performance of Fe-Al/WC composite coatings was studied by means of thermogrativmetic analyzer at 450, 650 and 800 ℃. The results demonstrate that the kinetics curve of oxidation at three temperatures approximately follows the logarithmic law. The composition of the oxidized coating is mainly composed of Al2 O3, Fe2 O3, Fe3 O4 and FeO. These phases distribute unevenly. The protective Al2 O3 film firstly forms and preserves the coatings from further oxidation.