等离子熔化—注射制备碳化物增强涂层组织及耐磨性能研究
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摘要
为解决热喷涂、堆焊、熔覆等技术制备碳化物涂层中存在的涂层脱落、碳化物分解、碳化物颗粒沉底或上浮、裂纹等问题,研制开发了等离子熔化-注射技术,实现了涂层与基体冶金结合,显著地提高了涂层与基体结合强度。有效解决了涂层中碳化物颗粒沉底或上浮,碳化物颗粒分解等问题,显著提高涂层的耐磨性能。等离子熔化—注射设备造价低廉,加工效率高,技术更容易实现工业化。
本文采用等离子熔化-注射技术在Q235钢表面注射WC-Co、SiC颗粒制备出成形良好、无宏观缺陷的碳化物涂层。采用SEM、TEM、XRD及EDS对涂层组织结构及成分进行了分析。采用摩擦磨损实验机测量了涂层干滑动摩擦磨损性能。组织分析结果表明,熔化-注射WC-Co涂层由WC、M6C(Fe3W3C、Co3W3C)、Fe和W2C等相组成。熔化-注射20~30μmWC-Co涂层顶部由原始WC颗粒、棒状和十字花状的Fe3W3C、板条状铁基共晶组织和灰色铁基组织构成;中部棒状和十字花状组织比较粗大,灰色铁基共晶组织明显多于涂层顶部;底部棒状及十字花状组织比中部稍多,尺寸较小。熔化-注射200~300μmWC-Co涂层顶部WC基本保持原始形貌,颗粒边缘Fe3W3C形成长竿状的“触角”,远离WC的显微组织为网状碳化物和铁基相;涂层中部和底部均由网状碳化物和铁基相组成。熔化-注射200~300μmSiC涂层中形成Fe、SiC、石墨等相。在涂层表面,注入的SiC颗粒“镶嵌”在基体中,涂层内部组织由石墨、铁素体、珠光体组成。熔化-注射80~120μmSiC时,涂层中除有Fe、Fe3C外,还出现了珠光体和非平衡相。基体预热200℃制备的20~30μmWC-Co涂层,顶部组织包括鱼骨状共晶组织、灰色铁基组织及鱼骨状组织周围的黑带;中部析出比较粗大碳化物,呈白色树枝状;底部由未分解的块状WC、十字花状碳化物及鱼骨状共晶组织构成。
熔化-注射20~30μmWC-Co、200~300μm和80~120μmSiC涂层组织分布均匀,避免了由于碳化物颗粒与基体密度差引起的颗粒沉底和上浮。采用相同工艺制备200~300μmWC-Co涂层中WC-Co分布在涂层的顶部,没有沉底。20~30μmWC颗粒注入到熔池中需要克服的临界速度为0.20m/s、实际注入速度为2.6m/s。200~300μmWC-Co颗粒所需临界速度为0.063m/s。实际注入速度为0.7m/s。基体表面预涂Ni基自熔合金后,改善WC颗粒与液态基体润湿性,200~300μmWC-Co颗粒所需临界速度转变为零,颗粒在熔池中运行初始速度为0.07m/s,200~300μmWC-Co在整个涂层中分布均匀。
随着颗粒粒度增加,涂层中的颗粒分解程度降低,大颗粒200~300μmWC-Co和200~300μmSiC颗粒分解程度均低于小颗粒20~30μmWC-Co、80~120μmSiC。基体温度提高,由于熔池加深及凝固时间变长,涂层中WC-Co颗粒分解和下沉倾向增加。
等离子熔化—注射碳化物涂层磨损机理主要是磨粒磨损,涂层耐磨性有明显提高。注入大颗粒的碳化物涂层中保留大量的原始碳化物,耐磨性能明显高于注入小颗粒碳化物涂层的耐磨性能。干滑动摩擦磨损条件下,等离子熔化-注射200~300μmWC-Co涂层的耐磨性大约为Q235钢的87倍;20~30μmWC-Co涂层的耐磨性为Q235钢的14倍;200~300μmSiC颗粒涂层耐磨性为Q235钢的48倍,80~120μmSiC颗粒涂层的耐磨性为Q235钢的4倍。
To overcome problems of spallation, dissolution of carbides, carbides sinking or rising, and cracking in carbide coatings produced by thermal spraying, hardfacing and cladding, plasma melt injection(PMI) is presented in this thesis. Coatings metallurgically bonded to the substrate with evenly distributed carbides can be synthesized with PMI technology, and bonding strength of the coating is improved greatly. Dissolution of carbides, carbides sinking or rising,and cracking can be minimized with PMI. The wear resistance can be improved. Equipment of PMI is cost-effective and efficient, and the technology is easy to be industrialized.
WC-Co, SiC particles were injected into Q235 steel,and carbide coating with good appearance were synthesized using PMI technology. The coatings are without macro defects. Scanning electron microscopy (SEM), transmission electron microscopy (TEM), X-ray diffraction (XRD) and energy diffraction spectrum (EDS) were used to examine the microstructure and composition of the coatings. Wear resistance of the coatings was tested using dry sliding wear tester. The results show that the microstructure consists of WC, M6C(Fe3W3C or Co3W3C), and W2C. In the upper part of the specimen injected with 20~30μm WC-Co particles, the microstructure constists of some original WC particles, white bar-shaped and cross-shaped Fe3W3C, gray ion base and black lath Fe-based eutectic structure. White bar-shapedand crossshaped carbides in the middle part of the coating are bigger, amount of the gray ion base is more than that in the upper. White bar-shaped and cross-shaped carbides in the bottom are smaller, and amount of them is more than that in the middle. In the upper part of the specimen injected with 200~300μm WC-Co paticles, WC-Co particles keep their original block shape basically. Carbides crystallize in long pole shape on the edge of WC particles. The microstructure far from WC particles consists of ion based matrix and reticulate carbides. Microstructure in the middle and the bottom consists of ion based matrix and reticulate carbides. Graphite,Fe,SiC Microstructure of the coating injected with with 200~300μm SiC particles consists of iron, SiC and graphite. The SiC particles are embedded on the top surface of the specimen, and the graphite, ferrite, and pearlite are in the coating. The microstructure of the coating injected with 80~120μm SiC particles consists of Fe and Fe3C, forming pearlite and non-equilibrium phase. In the upper part of the coating injected with 20~30μm WC-Co particles, the microstructureconstists of gray, herringbone structure and black belt around the herringbone structure, when the substrate preheated temperature 200℃. In the middle part, the carbide dendrites are larger. In the bottom part, the carbides are fewer not evenly distributed, and in block shape. Some herringbone structure appeares.
Microstructure of the coatings injected with 20~30μm WC-Co, 200~300μm SiC, and 80~120μm SiC particles is evenly distributed, and carbides sinking or rising due to density differences between the substrate and the carbides is avoided.Large amount of unmelted carbides can be found in the top part of the coating injected with 200~300μm WC–Co particles.
The critical velocity of the 20~30μm WC-Co particles to overcome the melt surface barrier is 0.20m/s, and the injecting velocity is 2.6m/s. The critical velocity of the 200~300μm WC-Co particles is 0.063m/s, and the injecting velocity is 0.7m/s. When the nickel-based self-fluxing alloy is coated on the substrate before injection, wetability of the liquid metal to WC-Co particles is improved. The critical velocity of the 200~300μm WC-Co particles becomes zero. The initial velocity in the molten pool increased to 0.7m/s. The WC paticles are well distributed in the coating.
Dissolution of the carbide particles decreases with increase of the particle’s size. Dissolution of the 200~300μm WC-Co and the 200~300μm SiC is lower than that of the 20~30μm WC-Coand the 80~120μm SiC. With deepening of the molten pool and prolongation of the solidification time, the 20~30μm WC-Co particles tends to sink down, when the substrate is preheated 200℃. Abrasion is the main wearing mechanism for carbides coatings produced by PMI Wear resistance of the coatings increase greatly. Large amount of unmelted carbide particles exist in the coatings injected with large carbide particles, so their wear resistance is much higher than that of the coatings injected with fine carbide particles. Wear resistance of the coatings injected with 200~300μm WC particles, 20~30μm WC particles, 200~300μm SiC particles, and 80~120μm SiC particles are about 87, 14, 48 and 4 times higher than the reference substrate material, respectively.
本文采用等离子熔化-注射技术在Q235钢表面注射WC-Co、SiC颗粒制备出成形良好、无宏观缺陷的碳化物涂层。采用SEM、TEM、XRD及EDS对涂层组织结构及成分进行了分析。采用摩擦磨损实验机测量了涂层干滑动摩擦磨损性能。组织分析结果表明,熔化-注射WC-Co涂层由WC、M6C(Fe3W3C、Co3W3C)、Fe和W2C等相组成。熔化-注射20~30μmWC-Co涂层顶部由原始WC颗粒、棒状和十字花状的Fe3W3C、板条状铁基共晶组织和灰色铁基组织构成;中部棒状和十字花状组织比较粗大,灰色铁基共晶组织明显多于涂层顶部;底部棒状及十字花状组织比中部稍多,尺寸较小。熔化-注射200~300μmWC-Co涂层顶部WC基本保持原始形貌,颗粒边缘Fe3W3C形成长竿状的“触角”,远离WC的显微组织为网状碳化物和铁基相;涂层中部和底部均由网状碳化物和铁基相组成。熔化-注射200~300μmSiC涂层中形成Fe、SiC、石墨等相。在涂层表面,注入的SiC颗粒“镶嵌”在基体中,涂层内部组织由石墨、铁素体、珠光体组成。熔化-注射80~120μmSiC时,涂层中除有Fe、Fe3C外,还出现了珠光体和非平衡相。基体预热200℃制备的20~30μmWC-Co涂层,顶部组织包括鱼骨状共晶组织、灰色铁基组织及鱼骨状组织周围的黑带;中部析出比较粗大碳化物,呈白色树枝状;底部由未分解的块状WC、十字花状碳化物及鱼骨状共晶组织构成。
熔化-注射20~30μmWC-Co、200~300μm和80~120μmSiC涂层组织分布均匀,避免了由于碳化物颗粒与基体密度差引起的颗粒沉底和上浮。采用相同工艺制备200~300μmWC-Co涂层中WC-Co分布在涂层的顶部,没有沉底。20~30μmWC颗粒注入到熔池中需要克服的临界速度为0.20m/s、实际注入速度为2.6m/s。200~300μmWC-Co颗粒所需临界速度为0.063m/s。实际注入速度为0.7m/s。基体表面预涂Ni基自熔合金后,改善WC颗粒与液态基体润湿性,200~300μmWC-Co颗粒所需临界速度转变为零,颗粒在熔池中运行初始速度为0.07m/s,200~300μmWC-Co在整个涂层中分布均匀。
随着颗粒粒度增加,涂层中的颗粒分解程度降低,大颗粒200~300μmWC-Co和200~300μmSiC颗粒分解程度均低于小颗粒20~30μmWC-Co、80~120μmSiC。基体温度提高,由于熔池加深及凝固时间变长,涂层中WC-Co颗粒分解和下沉倾向增加。
等离子熔化—注射碳化物涂层磨损机理主要是磨粒磨损,涂层耐磨性有明显提高。注入大颗粒的碳化物涂层中保留大量的原始碳化物,耐磨性能明显高于注入小颗粒碳化物涂层的耐磨性能。干滑动摩擦磨损条件下,等离子熔化-注射200~300μmWC-Co涂层的耐磨性大约为Q235钢的87倍;20~30μmWC-Co涂层的耐磨性为Q235钢的14倍;200~300μmSiC颗粒涂层耐磨性为Q235钢的48倍,80~120μmSiC颗粒涂层的耐磨性为Q235钢的4倍。
To overcome problems of spallation, dissolution of carbides, carbides sinking or rising, and cracking in carbide coatings produced by thermal spraying, hardfacing and cladding, plasma melt injection(PMI) is presented in this thesis. Coatings metallurgically bonded to the substrate with evenly distributed carbides can be synthesized with PMI technology, and bonding strength of the coating is improved greatly. Dissolution of carbides, carbides sinking or rising,and cracking can be minimized with PMI. The wear resistance can be improved. Equipment of PMI is cost-effective and efficient, and the technology is easy to be industrialized.
WC-Co, SiC particles were injected into Q235 steel,and carbide coating with good appearance were synthesized using PMI technology. The coatings are without macro defects. Scanning electron microscopy (SEM), transmission electron microscopy (TEM), X-ray diffraction (XRD) and energy diffraction spectrum (EDS) were used to examine the microstructure and composition of the coatings. Wear resistance of the coatings was tested using dry sliding wear tester. The results show that the microstructure consists of WC, M6C(Fe3W3C or Co3W3C), and W2C. In the upper part of the specimen injected with 20~30μm WC-Co particles, the microstructure constists of some original WC particles, white bar-shaped and cross-shaped Fe3W3C, gray ion base and black lath Fe-based eutectic structure. White bar-shapedand crossshaped carbides in the middle part of the coating are bigger, amount of the gray ion base is more than that in the upper. White bar-shaped and cross-shaped carbides in the bottom are smaller, and amount of them is more than that in the middle. In the upper part of the specimen injected with 200~300μm WC-Co paticles, WC-Co particles keep their original block shape basically. Carbides crystallize in long pole shape on the edge of WC particles. The microstructure far from WC particles consists of ion based matrix and reticulate carbides. Microstructure in the middle and the bottom consists of ion based matrix and reticulate carbides. Graphite,Fe,SiC Microstructure of the coating injected with with 200~300μm SiC particles consists of iron, SiC and graphite. The SiC particles are embedded on the top surface of the specimen, and the graphite, ferrite, and pearlite are in the coating. The microstructure of the coating injected with 80~120μm SiC particles consists of Fe and Fe3C, forming pearlite and non-equilibrium phase. In the upper part of the coating injected with 20~30μm WC-Co particles, the microstructureconstists of gray, herringbone structure and black belt around the herringbone structure, when the substrate preheated temperature 200℃. In the middle part, the carbide dendrites are larger. In the bottom part, the carbides are fewer not evenly distributed, and in block shape. Some herringbone structure appeares.
Microstructure of the coatings injected with 20~30μm WC-Co, 200~300μm SiC, and 80~120μm SiC particles is evenly distributed, and carbides sinking or rising due to density differences between the substrate and the carbides is avoided.Large amount of unmelted carbides can be found in the top part of the coating injected with 200~300μm WC–Co particles.
The critical velocity of the 20~30μm WC-Co particles to overcome the melt surface barrier is 0.20m/s, and the injecting velocity is 2.6m/s. The critical velocity of the 200~300μm WC-Co particles is 0.063m/s, and the injecting velocity is 0.7m/s. When the nickel-based self-fluxing alloy is coated on the substrate before injection, wetability of the liquid metal to WC-Co particles is improved. The critical velocity of the 200~300μm WC-Co particles becomes zero. The initial velocity in the molten pool increased to 0.7m/s. The WC paticles are well distributed in the coating.
Dissolution of the carbide particles decreases with increase of the particle’s size. Dissolution of the 200~300μm WC-Co and the 200~300μm SiC is lower than that of the 20~30μm WC-Coand the 80~120μm SiC. With deepening of the molten pool and prolongation of the solidification time, the 20~30μm WC-Co particles tends to sink down, when the substrate is preheated 200℃. Abrasion is the main wearing mechanism for carbides coatings produced by PMI Wear resistance of the coatings increase greatly. Large amount of unmelted carbide particles exist in the coatings injected with large carbide particles, so their wear resistance is much higher than that of the coatings injected with fine carbide particles. Wear resistance of the coatings injected with 200~300μm WC particles, 20~30μm WC particles, 200~300μm SiC particles, and 80~120μm SiC particles are about 87, 14, 48 and 4 times higher than the reference substrate material, respectively.
引文
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