Microstructure and mechanical properties of twin-wire arc sprayed Ni-Al composite coatings on 6061-T6 aluminum alloy sheet

We have systematically studied the microstructure and mechanical properties of Ni-5wt%Al and Ni-20wt%Al composite coatings fabricated on 6061-T6 aluminum alloy sheet by twin-wire arc spraying under different experimental conditions. The abrasive wear behavior and interface diffusion behavior of the composite coatings were evaluated by dry/wet rubber wheel abrasive wear tests and heat treatment, respectively. Experimental results indicate that the composite coatings exhibit features of adhesive wear. Besides, the Vickers microhardness of NiAl and Ni₃Al intermetallic compounds is relatively larger than that of the substrate, which is beneficial for enhancing the wear resistance. With the increase of annealing temperature and time, the interface diffusion area between the Ni-Al coating and the substrate gradually expands with the formation of NiAl₃ and Ni₂Al₃ phases, and is controlled by diffusion of aluminum atoms. The grain growth exponent n of diffusion kinetics of the Ni-Al coating, calculated via a high-temperature diffusion model at 400, 480, and 550℃, is between 0.28 and 0.38. This satisfies the cubic law, which is consistent with the general theoretical relationship of high-temperature diffusion.     

HVOF制备亚微米结构WC-12Co涂层性能研究

采用超音速火焰(HVOF)喷涂工艺制备了亚微米结构WC-12Co涂层,测试了这种亚微米涂层的结合强度、显微硬度及抗磨粒磨损性能,并利用XRD对喷涂粉末及涂层进行相结构分析,用扫描电子显微镜对喷涂粉末、磨粒磨损前后的涂层表面形貌进行观察.研究结果表明:喷涂过程中,亚微米结构WC粒子没有明显的脱碳分解发生,涂层组织结构致密,其显微硬度平均值高达HV1105;在相同的试验条件下,16Mn钢的磨粒磨损量是亚微米WC-12Co涂层的7.8倍,这表明亚微米结构涂层具有优异的抗磨粒磨损性能.     

等离子喷涂铁基非晶/晶体复合涂层的工艺–结构–性能关系

本研究试图通过优化等离子喷涂参数来开发一种Fe基非晶/晶体涂层,该涂层主要成分来自一种贫乏的铁基合金（Fe_92.6C_3.5P_1.4Si₂Mn_0.5）。这种合金是钢铁厂高炉产出的生铁剩余废料。为了经济有效地重新利用这种残留物,这种合金在合成时对成分进行了最少的修改。同时,本研究还探讨了涂层的结构、机械、腐蚀和磨损性能对喷涂参数（等离子功率、主气体流速、送粉速度和间隔距离）的依赖性。X射线衍射表明,在最优的喷涂参数下沉积的涂层存在无定形/晶体相。在较低等离子功率和最高气体流速下沉积的涂层表现出更好的密度、硬度和耐磨性。所有涂层都表现出良好的耐腐蚀性（腐蚀环境:3.5wt% NaCl 溶液）。机械、磨损和摩擦学研究表明,单一的工艺参数优化无法提供良好的涂层性能;相反,所有工艺参数在优化涂层性能都具有独一无二的作用,它们主要通过控制飞行中的颗粒温度和速度分布,以及熔滴撞击基材之前的冷却模式来控制涂层性能。     

Microstructure and high-temperature wear properties of in situ TiC composite coatings by plasma transferred arc surface alloying on gray cast iron

In this work, an in situ synthesized TiC-reinforced metal matrix composite (MMC) coating of approximately 350–400μm thick-ness was fabricated on a gray cast iron (GCI) substrate by plasma transferred arc (PTA) surface alloying of Ti–Fe alloy powder. Microhard-ness tests showed that the surface hardness increased approximately four-fold after the alloying treatment. The microstructure of the MMC coating was mainly composed of residual austenite, acicular martensite, and eutectic ledeburite. Scanning electron microscopy (SEM) and X-ray diffraction analyzes revealed that the in situ TiC particles, which were formed by direct reaction of Ti with carbon originally contained in the GCI, was uniformly distributed at the boundary of residual austenite in the alloying zone. Pin-on-disc high-temperature wear tests were performed on samples both with and without the MMC coating at room temperature and at elevated temperatures (473 K and 623 K), and the wear behavior and mechanism were investigated. The results showed that, after the PTA alloying treatment, the wear resistance of the sam-ples improved significantly. On the basis of our analysis of the composite coatings by optical microscopy, SEM with energy-dispersive X-ray spectroscopy, and microhardness measurements, we attributed this improvement of wear resistance to the transformation of the microstruc-ture and to the presence of TiC particles.     

Microstructure and mechanical properties of titanium nitride coatings for cemented carbide cutting tools by pulsed high energy density plasma

Hard, wear-resistant and well-adhesive titanium nitride coatings on cemented carbide cutting tools were prepared by the pulsed high energy density plasma technique at ambient temperature. The results of Auger spectra analysis indicated that the interface between the coating and substrate was more than 250 nm. Under optimized deposition conditions, the highest critical load measured by nanoscratch tester was more than 90 mN, which meant that the TiN film was well adhesive to the substrate; the highest nanohardness and Young抯 modulus according to nanoindentation tests were near to 27 and 450 GPa. The results of cutting tests evaluated by turning hardened CrWMn steel in industrial conditions indicated that the wear resistance and edge life of the cemented carbide tools were enhanced dramatically because of the deposition of titanium nitride coatings. These improvements were attributed to the three combined effects: the deposition and ion implantation of the pulsed plasma and the becoming finer of the grain sizes.     

反应等离子喷涂制备原位TiC颗粒增强Fe基金属陶瓷涂层

以钛铁粉、铁粉和蔗糖(碳的前驱体)为原料,采用前驱体热分解复合技术制备了Fe-Ti-C系反应热喷涂粉末,并通过普通等离子喷涂技术原位合成并沉积了TiC/Fe金属陶瓷复合涂层.利用XRD、SEM和EDS研究了喷涂粉末和复合涂层的相组成和显微结构.结果表明:前驱体热分解复合技术制备的Fe-Ti-C反应喷涂粉末粒径均匀,原料粉末颗粒间的结合强度高;所制备的TiC/Fe复合涂层主要由不同含量TiC颗粒分布于金属Fe基体内部而形成的复合片层叠加而成;TiC颗粒大致呈球形,粒径呈纳米级;TiC理论质量分数53%的TiC/Fe金属陶瓷涂层的耐磨粒磨损性能较好,SRV磨损实验中涂层的磨损面积为基体(45钢)的1/25左右.     

氩弧熔敷原位自生WC复合涂层组织及耐磨性

为提高采煤机中截齿的耐磨性能,利用氩弧熔敷技术,在35CrMnSi钢表面制备WC增强Ni基复合涂层。利用OM、SEM、XRD和EDS分析复合涂层的显微组织,采用显微维氏硬度仪测试复合涂层的显微硬度,并测试涂层在室温磨损条件下的耐磨性能。结果表明：氩弧熔敷涂层组织均匀致密,熔敷涂层与基体呈冶金结合,主要由WC、W：C、T—Ni、（Fe,Cr）23,C6等物相组成;WC颗粒呈弥散分布,颗粒尺寸为1txm;熔敷涂层可以改善基体的表面硬度,最高显微硬度可达12．6GPa;熔敷涂层在室温冲击磨粒磨损实验条件下,具有优异的耐磨性,磨损机制主要是磨粒磨桶．其耐磨性较35CrMnSi基体提高近12倍。     

TC4合金氩弧熔覆TiN复合涂层的组织及耐磨性

为提高钛合金表面性能,以TiN粉和Ti粉为原料,利用氩弧熔覆技术,在TC4合金表面成功制备出TiN增强Ti基复合涂层。采用扫描电镜、X射线衍射仪分析了熔覆涂层的显微组织和物相组成;利用显微硬度仪、摩擦磨损试验机测试了复合涂层的显微硬度和室温干滑动磨损条件下的耐磨性能。结果表明:氩弧熔覆涂层组织均匀致密,熔覆层与基体呈冶金结合,熔覆涂层主要由TiN棒状树枝晶和TiN颗粒组成,复合涂层明显改善了TC4合金的表面硬度,涂层的最高显微硬度可达9.5 GPa;复合涂层在室温干滑动磨损实验条件下具有优异的耐磨性,磨损机制主要是磨粒磨损,其耐磨性较TC4合金基体提高近9倍。     

High-temperature frictional wear behavior of MCrAlY-based coatings deposited by atmosphere plasma spraying

Al₂O₃-Cr₂O₃/NiCoCrAlYTa coatings were prepared via atmosphere plasma spraying (APS). The microstructure and phase composition of the coatings were analyzed by X-ray diffraction (XRD), scanning electron microscopy (SEM), laser confocal scanning microscopy (LSCM), and transmission electron microscopy (TEM). The dry frictional wear behavior of the coatings at 500℃ in static air was investigated and compared with that of 0Cr25Ni20 steel. The results show that the coatings comprise the slatted layers of oxide phases, unmelted particles, and pores. The hot abrasive resistance of the coatings is enhanced compared to that of 0Cr25Ni20, and their mass loss is approximately one-fifteenth that of 0Cr25Ni20 steel. The main wear failure mechanisms of the coatings are abrasive wear, fatigue wear, and adhesive wear.     

铸铁喷涂渗铝工艺和性能

采用线材火焰喷涂制备铝基涂层,随后对涂层进行重熔和扩散处理.利用扫描电镜、X射线衍射仪、能谱仪、摩擦磨损实验仪等对涂层的成分、物相、耐高温氧化性能、耐蚀性能等进行分析测试.结果表明:涂层分为两层,外层的物相主要是Al、FeAl3、内层是Fe2 Al5和少量的FeAl3;显微硬度有了很大程度的提高,峰值可达HV 950;渗铝试样在800、900℃进行高温氧化实验几乎不增重,抗氧化性能较铸铁可提升几十倍;同时试样也兼具良好的耐摩擦磨损和耐腐蚀性能.     

B4C颗粒增强镍基合金喷涂层耐磨性研究

采用化学镀技术在B4C颗粒表面包覆一层镍合金层，并采用亚音速热喷涂技术制备了Ni60-B4C（包覆镍）涂层，在销盘式磨损试验机上进行涂层的磨粒磨损实验，结果表明：镍合金包覆层增大了B4C颗粒与涂层中Ni60基体界面的结合强度，阻止了B4C颗粒在火焰加热过程中的氧化分解，同时Ni60-B4C（包覆镍）复合涂层的耐磨性，随B4C颗粒含量（≤15％）的增加而增加。     

电弧喷涂防磨损涂层性能评价

采用电弧喷涂法在45#钢表面制备了1Cr13,3Cr13,T8三种防磨损涂层,通过硬度、强度、磨损试验性能测试、用碳硫分析仪检测其碳元素含量及在金相显微镜上观察其组织形貌的方法,对3种涂层的性能给出了综合评价。研究结果表明,3Cr13涂层的硬度、强度及耐磨性均大大高于1Cr13涂层和T8涂层。T8涂层的强度及耐磨性均低于1Cr13涂层,而硬度却高于1Cr13涂层。铬元素对改善3Cr13涂层性能比改善1Cr13涂层性能所做贡献大,因此应优先选用3Cr13涂层对轴件进行修复及表面强化。T8涂层中由于碳元素被大量烧损,导致涂层氧化严重,孔隙率高,这是造成涂层硬度和强度不高及耐磨性较差的主要原因。     

化学沉积法制备Ni-P-SiC(C)复合镀层的研究

选择廉价的SiC和石C颗粒作为复合镀层添加物，用化学沉积法在碳钢表面制度Ni-P-SiC(C)复合镀层，研究了复合镀层的制备工艺，镀液配方以及复合镀层的性能等，结果显示：风表面开成的复合镀层厚薄均一，SiC和石墨C颗粒在镀层中分布均匀，镀层开成速度理想，表明本文采用的工艺技术合理可行，与单一的Ni-P镀层相比，Ni-P-SiC和Ni-P-C复镀层耐磨性能均有不同程度的提高，而将2种不同性能的SiC和C颗粒同时加入槽液，形成的Ni-P-SiC－C复合镀层具有最优异的耐磨性能。     

Wear and corrosion resistance of laser-cladded Fe-based composite coatings on AISI 4130 steel

The wear and corrosion resistance of Fe_72.2Cr_16.8Ni_7.3Mo_1.6Mn_0.7C_0.2Si_1.2 and Fe_77.3Cr_15.8Ni_3.9Mo_1.1Mn_0.5C_0.2Si_1.2 coatings laser-cladded on AISI 4130 steel were studied. The coatings possess excellent wear and corrosion resistance despite the absence of expensive yttrium, tungsten, and cobalt and very little molybdenum. The microstructure mainly consists of dendrites and eutectic phases, such as duplex (γ+α)-Fe and the Fe–Cr (Ni) solid solution, confirmed via energy dispersive spectrometry and X-ray diffraction. The cladded Fe-based coatings have lower coefficients of friction, and narrower and shallower wear tracks than the substrate without the cladding, and the main wear mechanism is mild abrasive wear. Electrochemical test results suggest that the soft Fe_72.2Cr_16.8Ni_7.3Mo_1.6Mn_0.7C_0.2Si_1.2 coating with high Cr and Ni concentrations has high passivation resistance, low corrosion current, and positive corrosion potential, providing a better protective barrier layer to the AISI 4130 steel against corrosion.     

M_2十4B喷涂层及激光涂覆层的组织与磨损特性

本文对Ｍ２十４Ｂ微晶粉末的喷涂层和激光涂覆层的组织与耐磨性进行了研究．结果表明，喷涂层和激光涂覆展均有各自独特的组织特征，两者的耐磨性均为ＧＣｒ１５钢的６．５倍以上．     

镍基纳米Al2O3粉末复合电刷镀镀层的耐磨性

为了进一步提高刷镀层的耐磨性 ,在 4 5 #钢基体上刷镀含有纳米 Al2 O3粉末的镍基复合镀层。通过光学金相显微镜、扫描电子显微镜对镀层显微组织进行分析 ,用显微硬度计测定了镀层和基体的硬度 ,在 SRV磨损试验机上进行了磨损试验 ,用表面形貌仪测量了镀层磨损量。试验结果表明 ,加入纳米 Al2 O3粉末的复合镀层的硬度要比单纯的致密镍镀层的硬度高。随着纳米 Al2 O3粉末加入量的增加 ,复合镀层硬度逐渐提高。含纳米 Al2 O3粉末的镍基复合镀层与单纯致密镍镀层相比 ,具有更高的耐磨性 ,将有广泛的应用前景。     

爆炸喷涂自敏发光复合涂层组织及性能

采用ADM-4D型气体爆炸喷涂设备,在45^#钢基体上制备高铝青铜/SrAl₂O₄∶Eu²⁺,Dy³⁺磷光粒子耐磨自敏发光复合涂层.分析复合涂层微观形貌及发光强度,并测试了涂层摩擦磨损性能.结果表明:当喷涂的氧燃比值由1.3增大至2.3时,复合涂层中SrAl₂O₄磷光粒子沉积率增加了近78.6%,涂层更加致密,硬度和结合强度分别提高了24%和75%.当氧燃比值为1.3时,复合涂层中沉积的有效发光粒子比率最高,达到9.7%,涂层宏观发光强度也最高,紫外灯激发后的涂层宏观指示效果最好;当氧燃比值为2.3时,复合涂层与304不锈钢对磨时摩擦系数升高近35%,而磨损率降低约47%.     

Cr/WC激光表面改性梯度层组织及磨损行为

用5kWCO2激光器对先后预置不同成分合金粉末的铸造铝硅合金表面进行2次激光扫描，制备了Cr/WC激光表面改性梯度层，并对其显微组织进行了分析，结果表明，在梯度层表面产生了大量的Al9Cr4化合物，且有更多的硅元素固溶在α-Al中，增加了固溶强化的作用，自表面至基体激光改性梯度层的显微硬度呈现明显的连续变化趋势，而单次激光表面改性层与基体之间的显微硬度值则有一突变，微动磨损实验表明，激光改性后的表面抗微动磨损的能力增强，磨损机制不同于铝硅合金基体，而表现出较好的抗粘着损伤性能。     

等离子喷涂纳米和微米Al_2O_3-TiO_2涂层摩擦磨损性能研究

采用大气等离子喷涂的方法制备了纳米和微米Al2O3-TiO2涂层,其中w(TiO2)=13%.分析了涂层组织形貌特征和结合强度等性能,研究了两种涂层在不同载荷下的摩擦磨损性能.结果表明,纳米Al2O3-TiO2涂层是由未熔或半熔纳米颗粒区域与完全熔融粒子铺展区域共同构成的,孔隙率低,显微硬度、结合强度均高于层状结构的微米涂层,且纳米涂层磨损量明显小于微米涂层.高载荷下磨屑均匀细化、圆整,形成微滚珠效应,纳米涂层稳态摩擦系数随载荷增大而下降,而微米涂层摩擦系数随载荷变化不明显.     

反应等离子喷涂TiN涂层电化学腐蚀行为

利用电化学阻抗谱等电化学方法及扫描电镜(SEM)技术,研究了反应等离子喷涂TiN涂层在模拟海水中的电化学腐蚀行为. 研究结果表明:TiN涂层的自腐蚀电位高于基体,涂层对基体能起到良好的腐蚀屏蔽作用;腐蚀介质通过涂层的通孔、微裂纹等缺陷渗入涂层与基体的界面腐蚀基体,从而使涂层电阻下降、电容增加,所产生的腐蚀产物在一定程度上可以抑制腐蚀反应的进行,但不会阻止基体局部腐蚀的继续进行. 涂层的孔隙是造成涂层电化学腐蚀的主要原因.