镁合金防腐涂层微观形貌及残余应力研究

采用等离子喷涂在镁合金表面制备Al2O3基防腐陶瓷涂层,并对涂层激光重熔和热处理,研究涂层的形貌和表面残余应力。研究表明:激光重熔涂层粗糙度降低、表面致密度大大提高。激光重熔降低Al2O3涂层残余应力幅度44.76%,热处理降低11.12%,激光重熔效果较热处理更为良好。Al2O3、Al2O3-13%Ti O2和Al2O3-40%Ti O2三种等离子喷涂制备态涂层残余应力分别为363.57MPa、304MPa、-202.38MPa,Al2O3-40%Ti O2具有最好的残余应力属性,有利于涂层服役寿命的提高。     

Al2O3-40%TiO2陶瓷涂层残余应力的有限元分析

为分析大气等离子喷涂Al2O3-40%Ti O2复合陶瓷涂层在冷却过程中涂层崩裂的现象,本文采用有限元方法,研究了涂层内部残余应力分布情况,探讨了涂层厚度、孔隙、裂纹等因素对残余应力的影响。结果表明:基体与粘结层和粘结层与涂层的界面边缘处出现了应力集中区域,随着X尺寸(模型水平方向的距离)的增加,涂层及粘结层内部应力由压应力转变为拉应力;涂层厚度只对残余应力值有影响,对应力分布状态影响较小,随着涂层厚度的增加,X向(径向)应力逐渐增加,Y向(轴向)应力及剪切应力在界面边缘处急剧变化;大孔隙、纵向裂纹对涂层残余应力影响较大。有限元模拟分析较好的解释了涂层在冷却过程中涂层层状崩裂的现象。     

等离子喷涂高温涂层残余应力模拟比较研究

本文运用有限元方法对等离子喷涂高温涂层(包括W涂层、Zr C涂层和Zr O2涂层)沉积过程中涂层内部残余应力进行了数值模拟计算,着重对涂层表面及涂层与钛合金基体界面处径向应力进行分析,讨论了这三种高熔点材料及不同的涂层厚度(0.2mm,0.5mm,0.8mm和1.0mm)对残余应力状态及分布的影响。结果表明,涂层表面处,Zr C涂层径向应力值最大;涂层与基体界面处,随着涂层厚度的增加,W涂层径向应力值逐渐超过Zr C涂层;Zr O2涂层在其表面及涂层与基体界面处的径向应力值在三种材料中均为最小。涂层内部径向应力分布均匀,在试样边缘处,W涂层和Zr C涂层应力集中和突变现象较为显著,而边缘效应对Zr O2涂层影响较小。     

热处理对超音速火焰喷涂 NiCoCrAlY 涂层组织性能的影响

采用超音速火焰喷涂制备了NiCoCrAlY合金涂层,采用真空热处理工艺对涂层进行了后处理,研究了热处理前后涂层的结构形貌、界面以及涂层结合强度的变化。研究结果表明:热处理后涂层的缺陷和孔隙由8.3%降低至1.4%;SEM和EDS分析表明,涂层与基材之间发生了元素互扩散,涂层与基体形成了约20μm的扩散层,涂层的结合强度由42.1MPa提高到55.6MPa。热处理后,涂层/基体界面形成的扩散层改善了界面结合状态,有助于消除界面处的残余应力,并形成冶金结合,从而提高涂层的结合强度。     

等离子喷涂NiCrBSi合金涂层的高温性能

根据高温涂层要求,采用等离子喷涂工艺制备NiCrBSi合金涂层试样,对涂层成分、组织、硬度、粘结强度、冷热疲劳性能、抗热震性能及常温和高温摩擦磨损性能进行了检测,对其结果进行了分析讨论.结果表明:等离子喷涂NiCrBSi合金涂层具有良好的粘结强度和抗高温氧化、耐高温磨损性能.     

Ni基合金—ZrO_2·Y_2O_3倾斜功能材料的研究

本文研究的是一种新型材料——“倾斜功能材料”。在一定实验的基础上利用等离子喷涂法成功地制造了7层过渡的Ni基合金—ZrO_2.Y_2O_8倾斜功能材料,其抗热震性能领先于现有文献报道的同类方法制造的倾斜功能材料。同时,本文利用X射线法对ZrO_2·Y_2O_8涂层的残余应力进行了测量,这也是一种新的探索;实验过程中对本文中的两类试样进行了真空热处理及抗热震性实验。实验结果表明,陶瓷涂层中存在着大的应力梯度并随基体温度的提高,ZrO_2.Y_2O_2涂层中残余压应力的趋势增大;对于倾斜功能材料试样,随着过渡层数的增加,材料抗热震性明显增加,并且经过真空热处理后,材料的抗热震性明显提高。     

基于正交试验的热障涂层性能变化规律研究

热障涂层广泛应用于燃气轮机、飞机发动机等装备上,其性能直接影响装备的使用寿命。本文采用大气等离子喷涂工艺,在GH4169高温合金表面依次制备NiCoCrAlY金属粘结层和ZrO_2-8%wtY_2O_3陶瓷层。采用扫描电镜和残余应力测试仪对样品的表面形貌、孔隙率以及表面的残余应力进行测试。通过正交试验研究喷涂工艺参数对热障陶瓷层厚度、孔隙率以及残余应力的影响,实验结果表明,对陶瓷层厚度的影响因素从大到小顺序依次为氢气流量,电流,氩气流量,喷涂距离;在相同的制备时间内,陶瓷层的厚度随着电流与氢气流量的增大而明显的增大;随着氩气流量与喷涂距离的增大,陶瓷层的厚度随之减小;对陶瓷层孔隙率的影响因素从大到小顺序依次为喷涂距离,氢气流量,电流,氩气流量。当氩气流量从30 slpm/min增加到40 slpm/min时,氢气流量从5slpm/min增加到10 slpm/min时,孔隙率随之增大;当氩气流量从40 slpm/min增加到50 slpm/min时,氢气流量从10 slpm/min增加到15 slpm/min时,孔隙率随之减小。当喷涂距离从5 mm增加到10 mm时,孔隙率随之减小,而当喷涂距离从10 mm增加到15 mm时,孔隙率急剧升高,而随着电流的增大,孔隙率减小。电流、氢气流量以及氩气流量对涂层残余应力造成很大影响,随着电流以及氢气流量的增大,氩气流量的减小,涂层表面的残余应力急剧上升。     

在线热处理钢轨残余应力的测试与分析

文章介绍了包钢热处理钢轨标准残余应力的研究情况,通过贴片法、切口法、X衍射等方法对包钢热处理钢轨进行实验分析,与热轧钢轨进行对比分析了包钢在线热处理钢轨的残余应力状态。贴片法检验结果表明包钢生产的热处理钢轨轨头残余应力大于热轧钢轨,切口法检验表明钢轨整体残余拉应力大于热轧钢轨,X衍射法表明钢轨表面残余应力分布不平均。     

低压等离子喷涂硬质涂层的应用

据“Surface & Coatings Technology”,1989,39/40:127-134报道,低压等离子喷涂(LPPS)作为可改善涂层性能的优良的表面改良技术已得到广泛承认。在生产钢铁的设备领域里,大量需要硬质、耐高温、抗侵蚀及耐腐蚀材料。本文主要讨论了低压     

等离子喷涂镍基封严涂层热性能的研究

研究了镍基可磨耗封严涂层的抗热性能。采用等离子喷涂工艺喷涂镍基复合粉末,并对喷涂后涂层的抗热性能进行研究。结果表明,采用等离子喷涂制备的镍基封严涂层经过500℃不同时间热处理试验,涂层的硬度及显微组织仍能满足涂层的使用要求,涂层的抗热性能良好。     

铈锆酸镧涂层高温时效行为和热震性能研究

采用等离子喷涂制备了铈锆酸镧涂层,采用扫描电子显微镜(SEM)、X射线衍射分析(XRD)、图像分析法等研究了喷涂功率对沉积态涂层表面和截面微观结构、孔隙率等的影响规律,研究了涂层在1200℃、1300℃高温100h时效下相稳定性、微观结构、孔隙率的变化,比较了不同喷涂功率涂层的抗热震性能。研究结果表明:随着等离子喷涂功率的增加,喷涂过程中半熔融颗粒比例减小,涂层的孔隙率减小。涂层经1200℃、1300℃高温保温100 h后仍然具有单一的烧绿石结构,随着热处理温度升高,涂层孔隙率减小。研究了不同功率喷涂的涂层从1250℃到冷水中的热震行为,失效机制分析表明:陶瓷层与粘结层热应力不匹配造成陶瓷层底部产生裂纹是导致涂层失效的主要方式。     

Residual stresses in high-velocity oxy-fuel metallic coatings

X-ray based residual stress measurements were made on type 316 stainless steel and Fe₃Al coatings that were high-velocity oxy-fuel (HVOF) sprayed onto low-carbon and stainless steel substrates. Nominal coating thicknesses varied from 250 to 1500 μm. The effect of HVOF spray particle velocity on residual stress and deposition efficiency was assessed by preparing coatings at three different torch chamber pressures. The effect of substrate thickness on residual stress was determined by spraying coatings onto thick (6.4 mm) and thin (1.4 mm) substrates. Residual stresses were compressive for both coating materials and increased in magnitude with spray velocity. For coatings applied to thick substrates, near-surface residual stresses were essentially constant with increasing coating thickness. Differences in thermal expansion coefficient between low-carbon and stainless steels led to a 180 MPa difference in residual stress for Fe₃Al coatings. Deposition efficiency for both materials is maximized at an intermediate (∼600 m/s) velocity. Considerations for X-ray measurement of residual stresses in HVOF coatings are also presented.     

Formation of Aluminide Coatings by a Low Temperature FBCVD Process

The formation of aluminide coatings on Ni, Inconel 738, NiCr23Fe, SS304 and ARMCO Fe by a Fluidised Bed Chemical Vapour Deposition (FBCVD) process at low temperatures (550‐650°C) was studied. Aluminium powder and a HCl activator were used to form precursor halide vapours of Al. This led to the aluminide coating formation on the substrate's surface. The examination of the treated samples by means of optical microscopy and SEM/EDX indicated the deposition of dense and homogeneous coatings over the entire surface even for small treatment times. Coating thickness growth and coating morphology were evaluated for various treatment times and temperatures. The low temperature process has advantages compared to the high temperature process since the mechanical properties of the treated parts are not affected, although the coating thicknesses achieved are smaller.     

Structural changes in the surface layer of plasma coatings with ultrasonic treatment by steel balls

Conclusions Ultrasonic treatment with metal balls provides a reduction in the surface roughness of plasma coatings with a mcirohardness of 5630–7890 MPa by a factor of one and a half, and with a thickness of deposited layer less than 4·10^–4 m the time required in order to achieve the minimum roughness depends considerably on the magnitude of residual compressive stresses and the properties of the base.The shock effect of balls changes the size of mosaic blocks, dislocation density, and the magnitude of microstresses in the surface layer of a coating, and the treatment time required in order to achieve the maximum changes is reduced with a smaller deposited layer thickness.Ultrasonic treatment of plasma coatings provides formation at their surface layer of structures which improve the wear resistance of deposited coatings under fretting conditions by a factor of two to four.Translated from Poroshkovaya Metallurgiya, No. 2(350), pp. 23–28, February, 1992.     

Coatings of nanocrystalline metallic wires on steel substrate: mechanical characteristics of coating layer

Coatings are produced by wire arc spraying on a steel surface and the effect of coating thickness on the coating characteristics in terms of microhardness, residual stress and friction coefficient are examined. The wire used during coating is composed of FeCrBMnSi, which comprises nanocrystalline and amorphous phases. The twin wire arc spray system was incorporated to generate different coating thicknesses on steel substrate. The analytical tools including three-dimensional imaging optical and scanning electron microscopes, energy dispersive spectroscopy and X-ray diffraction (XRD) are used to assess the coating characteristics. It is found that the surface texture and surface roughness of the coatings change with coating thickness. Thus, reducing the coating thickness results in slightly increased texture height and surface roughness. Microhardness is almost 15% higher for the thin coating (300?μm) than the thick coating (550?μm). The residual stress developed in the coatings is tensile and it changes with coating thickness, such that it reduces for thick coating.     

制备工艺方法对 NiCrFeMo 涂层组织和性能影响研究

采用等离子喷涂、 超音速火焰喷涂和冷喷涂工艺制备了 NiCrFeMo 涂层, 并对涂层的金相性能、 不同基体 材料下涂层的结合性能、 不同温度下涂层的耐磨性能进行了检测。 实验结果表明： 采用冷喷涂工艺制备的涂层孔 隙率最低, 对应涂层的结合强度最高, 但冷喷涂工艺制备的涂层对基体材料较为敏感, 而超音速火焰喷涂和等离 子喷涂受基体材料影响不大。 在室温下, 冷喷涂涂层显示出较优的耐磨性能, 在高温下超音速火焰喷涂涂层显示 出较优的耐磨性能。     

A model of the interfacial heat-transfer coefficient for the aluminum gravity die-casting process

Interfacial heat-transfer coefficients were measured during the solidification of Al-Si alloys against coated die steel chills with varying chill temperature, coating thickness and coating type. Two principal resistances to heat transfer across the casting-chill interface were identified, namely, (1) the resistance to heat transfer of the coating itself and (2) the resistance to heat transfer of a layer of gas, (assumed to be air), trapped between the coating and casting surfaces by virtue of their roughness. These thermal resistances were evaluated by measurement of the coating thermal conductivity and determination of the thickness of the applied coatings and the thickness of the layer of air between the coating and casting surfaces. This produced a simple equation to predict the interfacial heat-transfer coefficient during the solidification of Al alloy die castings, which produced values that were found to agree well with the experimentally determined results. This equation was used to interpret the experimentally measured heat-transfer coefficients and to explain their variation with the different experimental conditions employed. A simple modification of the equation can also take into account the formation of an air gap, where the casting locally retreats away from the die surface, leading to a local reduction in the heat-transfer coefficient.     

料浆法制备NiCrW基高温合金Al-Si涂层的微观结构与性能

航空发动机涡轮叶片在使用时需加以涂层防护,以提高基体合金的抗高温氧化性能。本研究采用料浆渗铝的制备工艺,以CaCl₂作为活化剂,在NiCrW基高温合金表面制备Al-Si涂层。采用X射线衍射仪(XRD)、扫描电子显微镜(SEM)及能谱仪(EDS)对涂层试样的表面和截面进行分析。结果表明,聚乙烯醇水溶液可作为料浆法制备渗铝/铝硅涂层的有效黏结剂;高温扩散的温度和时间显著影响渗铝涂层的厚度。渗剂成分为5%Si+30%Al(质量分数),制备得到的共渗涂层由外而内依次为富Al层、NiAl层和含Si过渡层三部分,涂层致密无明显缺陷,厚度约为57μm。10%Si+25%Al、15%Si+20%Al与20%Si+15%Al共渗涂层由外而内分为富Al层、富Ni层和含Si过渡层三层。Si元素主要以含Si的沉积相形式存在于含Si过渡层中,少量沉积于外层。而Si的少量添加能明显影响Al、Ni元素的扩散过程,从而减小涂层厚度,并由单一NiAl相向富Al、富Ni的镍铝相转变。     

Characterization of Vacuum Plasma Sprayed Reinforced Hydroxyapatite Coatings on Ti–6Al–4V alloy

Two reinforced hydroxyapatite (HA) coatings with an intermediate layer of zirconia were deposited on Ti–6Al–4V by vacuum plasma spray (VPS) technique. In first coating, HA was reinforced with 10 wt % Al₂O₃ whereas in second coating, HA was reinforced with 10 wt % ZrO₂. The objective of this study was to investigate the microstructure, phase formation and mechanical properties like hardness and bond strength of as-sprayed coatings and the coatings after post coating heat treatment at 700 °C for 1 h. The characterization of the coatings was performed by using SEM/EDAX, XRD, porosity, crystallinity and roughness measurement. The coatings were also evaluated for mechanical properties like hardness and tensile bond strength. It was observed that after post coating heat treatment, crystallinity increased and porosity decreased which indicated recrystallization of amorphous phases of as-sprayed coatings. Heat treatment resulted into improvement in cross-sectional hardness, however sharp decrease in bond strength was observed.