CN107699859B - 轴瓦用全金属自润滑减摩涂层及其制备方法 - Google Patents
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Abstract
一种轴瓦用全金属自润滑减摩涂层,其特征在于依次包括Ni栅层及磁控溅射的复合沉积层,该复合沉积层由AlSn20Cu层与Ag层交替沉积而成。进一步,每个AlSn20Cu层的厚度为2~3um,每个Ag层的厚度为0.5um~1um。本发明还公开了该涂层的制备方法。Ag/AlSn20Cu纳米多层交替结构设计,不仅使涂层组分多元化且有效的抑制了AlSn20Cu涂层中Sn相成分的长大提高薄膜膜基结合力。同时多层化设计有效缓解了涂层的应力、降低了摩擦系数和磨损率,增强抗疲劳性能。
Description
技术领域
本发明涉及一种轴瓦涂层,属于表面涂层技术领域,本发明还涉及该涂层的制备方法。
背景技术
随着现代高新技术产业的迅猛发展,对于在极端苛刻工况下服役的机械零部件提出了迫切的要求。日前,在高紧凑设计的前提下(如滑动轴承逐渐向高速、高承载、低能耗、大功率发展),对具有低摩擦磨损性能的润滑防护技术也提出了强烈的要求。轴瓦作为发动机的核心部件在极端苛刻的负荷状态下和容易造成润滑油膜破裂,从而导致局部疲劳磨损与咬粘等现象。目前研究较多的第四代PVD轴瓦(如AlSn20Cu)作为一种新型环保轴瓦在承载能力、抗咬合性能方面都具有无可比拟的优势,但该涂层在高速、乏油或干摩擦状态下摩擦系数依然较高,很容易发生高的磨损,具有较低的环境适应性,同时发动机反复启停时润滑油膜不能及时形成很容易降低轴瓦服役寿命,很大程度上限制了该涂层在高速、乏油-干摩擦等苛刻服役环境下的应用。
技术人员作了诸多努力,例如采用喷涂的方法制备聚合物减磨层用以解决轴瓦合金层或镀层经常剥落的问题从而延长轴瓦使用寿命,可以参考参考专利号为ZL201310062249.0的中国发明专利《一种轴瓦及其合金层喷涂MoS2工艺》(授权公告号为CN103122937B)等。然而,聚合物轴瓦在承载、抗疲劳及耐磨性能方面与PVD轴瓦仍然存在一定差距。截止目前,有关提高PVD轴瓦减磨层润滑性能的研究较少。前期我们通过结构设计制备了具有细Sn相的AlSn20Cu涂层,极大的提高了该涂层的抗疲劳性能,见专利号为ZL201410766300.0的中国发明专利《一种用于轴瓦上的细Sn相AlSn20Cu涂层及其制备方法》(授权公告号为CN104532189B)。因此,通过结构与成分设计改善AlSn20Cu涂层自润滑性能具有重要的研究意义。
发明内容
本发明所要解决的技术问题是针对上述的技术现状而另外提供一种低摩擦系数和低磨损率的轴瓦用全金属自润滑减摩涂层。
本发明所要解决的又一个技术问题是针对上述的技术现状而另外提供一种低摩擦系数和低磨损率的轴瓦用全金属自润滑减摩涂层的制备方法。
本发明解决上述技术问题所采用的技术方案为:一种轴瓦用全金属自润滑减摩涂层,其特征在于依次包括Ni栅层及磁控溅射的复合沉积层,该复合沉积层由AlSn20Cu层与Ag层交替沉积而成。
作为优选,于每个AlSn20Cu层的厚度为2~3um,每个Ag层的厚度为0.5um~1um。
作为优选,所述的复合沉积层共有8~12层镀膜涂层,并且,最上面一层为AlSn20Cu层。
一种轴瓦用全金属自润滑减摩涂层的制备方法,制备过程可以在非平衡磁控溅射镀膜设备上完成,其特征在于包括如下步骤:
①轴瓦样件表面清洗,将轴瓦毛坯样件在石油醚、酒精、丙酮中依次清洗后置于镀膜机真空腔室内抽真空至10-3Pa以下,向腔室内通入氩气作为离化气体,基底施加偏压,对轴瓦毛坯表面进行氩离子轰击清洗,除去轴瓦毛坯表面的吸附物;
②Ni栅层制备,清洗完毕后,利用磁控溅射的制备方法,首先在轴瓦毛坯表面沉积一层Ni栅层;
③Ag/AlSn20Cu多层复合涂层制备,选用高纯银靶和铝锡铜合金靶作为溅射靶材,氩气作为溅射气体;通过不断改变溅射靶种类、靶电流大小及沉积时间,实现Ag/AlSn20Cu多层结构交替和周期变化;涂层沉积完毕后待设备冷却至腔室温度小于40℃,释放真空取出样品。
作为优选,步骤①所述的轴瓦样件选自钢/CuPb22Sn4轴瓦毛坯或钢/AlZn4SiPb轴瓦毛坯。
作为优选,步骤①中腔室内气压保持在1.0~3.0Pa,基底偏压为-600~-1200V。
作为优选,步骤②中所述的Ni栅层制备调节如下:腔室气压保持在2╳10-2~4╳10-2Pa,溅射电流1~5A,脉冲偏压-150~-250V,过渡层厚度100~500nm。
作为优选,步骤②中所述的Ni栅层制备采用高纯Ni靶作为溅射靶材,氩气作为溅射气体,加偏压-150-300V用于沉积Ni栅层,沉积时间设为15-25分钟。
作为优选,步骤③中涂层沉积条件如下:腔室气压保持在2╳10-1~4╳10-1Pa,银靶与铝锡铜合金靶靶电流分别设为1~4A、2~10A,脉冲偏压分别设为-100~-600V、-100~-1000V,沉积时间分别为5~10min、20~50min。
作为优选,步骤③中所述的铝锡铜合金靶Al、Sn和Cu重量百分比分别为79%、20%和1%。
与现有技术相比,本发明的优点在于:AlSn20Cu层可以提供承载能力,软金属Ag具有良好的自润滑性能,此外,从Ag金属元素的电子结构和能带填充理论可以看出,Ag金属元素d轨道电子已满,Ag金属处于高能态,不易与其他元素发生化学键合,所以掺杂Ag不会改变AlSn20Cu涂层本来的键合方式,而且Ag纳米粒子的弹性模量较小,可以利用界面强化作用调控涂层的高应力及高脆性;其次,复合薄膜中Ag纳米晶的高比表面积使它具有高的化学活性,在摩擦过程中易于向界面扩散,形成具有低剪切作用的自润滑膜,提高AlSn20Cu涂层在多环境中的减摩抗磨作用。另一方面,制备的轴瓦样件在实际摩擦服役过程中产生的Ag膜屑可以作为润滑油添加剂降低整个固/油复合过程中的摩擦与磨损。
本发明制备的Ag/AlSn20Cu纳米多层交替结构设计,不仅使涂层组分多元化且有效的抑制了AlSn20Cu涂层中Sn相成分的长大提高薄膜膜基结合力。同时多层化设计有效缓解了涂层的应力、增强抗疲劳性能,实现了涂层力学性能和摩擦学性能的双向优化。涂层不仅可在不同油润滑条件(富油、乏油)下降低轴瓦部件的磨损,而且还可在高速、高载等苛刻环境中为滑动部件提供持续润滑。
本发明制备的润滑减摩涂层在多种服役环境(富油、乏油、高速、高载等)中都具有低的摩擦系数与磨损率,可以为以柴油机为代表的轴瓦摩擦部件提供良好的润滑性能。同时所用靶材简单易得,沉积工艺稳定,对获得更高品质轴瓦减摩涂层具有较好的适用性。
附图说明
图1为实施例1制备过程示意图:
图2为实施例1中制备涂层结构示意图。
图3为实施例1中制备涂层在高速、高载及油润滑环境中的摩擦系数变化曲线图。
具体实施方式
以下结合附图实施例对本发明作进一步详细描述。
实施例1,结合图1、图2和图3所示。
(1)轴瓦样件表面氩离子清洗:将钢/CuPb22Sn4轴瓦毛坯样件在石油醚、酒精、丙酮中依次清洗后置于镀膜机真空腔室内抽真空至1×10-3Pa以下,向真空腔室内通入高纯氩气使气压保持在1.5Pa。打开脉冲偏压电源,将基底偏压调制-800V,对轴瓦毛坯表面进行氩离子轰击清洗,清洗时间为30分钟,从而除去轴瓦毛坯表面的吸附物;
(2)Ni栅层制备:清洗完毕后,利用磁控溅射的方法首先在轴瓦毛坯表面沉积一层Ni栅层。实验中选用高纯Ni靶(纯度为99.99%)作为溅射靶材,氩气作为溅射气体,调节氩气使腔体内气压保持在2╳10-2Pa,加偏压-150V,靶电流调制3A用于沉积Ni栅层,沉积时间设为20分钟。
(3)Ag/AlSn20Cu多层复合涂层制备:选用高纯银靶(99.99%)和铝锡铜合金靶(Al、Sn和Cu重量百分比分别为79%、20%和1%)作为溅射靶材,氩气作为溅射气体。调节Ar气将腔室内气体保持在4╳10-1Pa,脉冲偏压保持在-200V。间歇打开Ag靶。铝锡铜合金靶交替沉积Ag层与AlSn20Cu层。沉积Ag层时,打开Ag靶溅射电源,调节电流为2A,沉积时间设为10分钟;制备AlSn20Cu层时,关闭银靶,打开铝锡铜合金靶电源,调节溅射电流为8A,沉积时间为30分钟。此循环持续5个周期涂层沉积完毕。待真空腔室冷却至40℃以下,放真空,取出样品。
结合图1所示,1-AlSnCu合金靶;2-Ni靶;3-Ag靶;4-气体。
结合图2所示,1a,2a,3a,4a,5a为AlSn20Cu层;1b,2b,3b,4b为Ag层,2c为Ni栅层,3c为轴瓦样件表面。
实施例1获得的涂层性能指标如表1所示
实施例2
(1)轴瓦样件表面氩离子清洗:将钢/AlZn4SiPb轴瓦毛坯样件在石油醚、酒精、丙酮中依次清洗后置于镀膜机真空腔室内抽真空至1×10-3Pa以下,向真空腔室内通入高纯氩气使气压保持在1.5Pa。打开脉冲偏压电源,将基底偏压调制-800V,对轴瓦毛坯表面进行氩离子轰击清洗,清洗时间为30分钟,从而除去轴瓦毛坯表面的吸附物;
(2)Ni栅层制备:清洗完毕后,利用磁控溅射的方法首先在轴瓦毛坯表面沉积一层Ni栅层。实验中选用高纯Ni靶(纯度为99.99%)作为溅射靶材,氩气作为溅射气体,调节氩气使腔体内气压保持在2╳10-2Pa,加偏压-200V,靶电流调制4A用于沉积Ni栅层,沉积时间设为25分钟。
(3)Ag/AlSn20Cu多层复合涂层制备:选用高纯银靶(99.99%)和铝锡铜合金靶(Al、Sn和Cu重量百分比分别为79%、20%和1%)作为溅射靶材,氩气作为溅射气体。调节Ar气将腔室内气体保持在4╳10-1Pa,脉冲偏压保持在-200V。间歇打开Ag靶。铝锡铜合金靶交替沉积Ag层与AlSn20Cu层。沉积Ag层时,打开Ag靶溅射电源,调节电流为3A,沉积时间设为8分钟;制备AlSn20Cu层时,关闭银靶,打开铝锡铜合金靶电源,调节溅射电流为10A,沉积时间为25分钟。此循环持续8个周期涂层沉积完毕。待真空腔室冷却至40℃以下,放真空,取出样品。
实施例3
(1)轴瓦样件表面氩离子清洗:将钢/AlZn4SiPb轴瓦毛坯样件在石油醚、酒精、丙酮中依次清洗后置于镀膜机真空腔室内抽真空至1×10-3Pa以下,向真空腔室内通入高纯氩气使气压保持在1.5Pa。打开脉冲偏压电源,将基底偏压调制-800V,对轴瓦毛坯表面进行氩离子轰击清洗,清洗时间为30分钟,从而除去轴瓦毛坯表面的吸附物;
(2)Ni栅层制备:清洗完毕后,利用磁控溅射的方法首先在轴瓦毛坯表面沉积一层Ni栅层。实验中选用高纯Ni靶(纯度为99.99%)作为溅射靶材,氩气作为溅射气体,调节氩气使腔体内气压保持在3╳10-2Pa,加偏压-150V,靶电流调制4A用于沉积Ni栅层,沉积时间设为25分钟。
(3)Ag/AlSn20Cu多层复合涂层制备:选用高纯银靶(99.99%)和铝锡铜合金靶(Al、Sn和Cu重量百分比分别为79%、20%和1%)作为溅射靶材,氩气作为溅射气体。调节Ar气将腔室内气体保持在4╳10-1Pa,脉冲偏压保持在-150V。间歇打开Ag靶。铝锡铜合金靶交替沉积Ag层与AlSn20Cu层。沉积Ag层时,打开Ag靶溅射电源,调节电流为3A,沉积时间设为10分钟;制备AlSn20Cu层时,关闭银靶,打开铝锡铜合金靶电源,调节溅射电流为10A,沉积时间为30分钟。此循环持续10个周期涂层沉积完毕。待真空腔室冷却至40℃以下,放真空,取出样品。
Claims (8)
1.一种轴瓦用全金属自润滑减摩涂层,其特征在于依次包括Ni栅层及磁控溅射的复合沉积层,该复合沉积层由AlSn20Cu层与Ag层交替沉积而成;
每个AlSn20Cu层的厚度为2~3um,每个Ag层的厚度为0.5um~1um;
所述的复合沉积层共有8~12层镀膜涂层,并且,最上面一层为AlSn20Cu层。
2.一种权利要求1所述的轴瓦用全金属自润滑减摩涂层的制备方法,其特征在于包括如下步骤:
①轴瓦样件表面清洗,将轴瓦毛坯样件在石油醚、酒精、丙酮中依次清洗后置于镀膜机真空腔室内抽真空至10-3Pa以下,向腔室内通入氩气作为离化气体,基底施加偏压,对轴瓦毛坯表面进行氩离子轰击清洗,除去轴瓦毛坯表面的吸附物;
②Ni栅层制备,清洗完毕后,利用磁控溅射的制备方法,首先在轴瓦毛坯表面沉积一层Ni栅层;
③Ag/AlSn20Cu多层复合涂层制备,选用高纯银靶和铝锡铜合金靶作为溅射靶材,氩气作为溅射气体;通过不断改变溅射靶种类、靶电流大小及沉积时间,实现Ag/AlSn20Cu多层结构交替和周期变化;涂层沉积完毕后待设备冷却至腔室温度小于40℃,释放真空取出样品。
3.根据权利要求2所述的制备方法,其特征在于步骤①所述的轴瓦样件选自钢/CuPb22Sn4轴瓦毛坯或钢/AlZn4SiPb轴瓦毛坯。
4.根据权利要求2所述的制备方法,其特征在于步骤①中腔室内气压保持在1.0~3.0Pa,基底偏压为-600~-1200V。
5.根据权利要求2所述的制备方法,其特征在于步骤②中所述的Ni栅层制备调节如下:腔室气压保持在2× 10-2~4× 10-2Pa,溅射电流1~5A,脉冲偏压-150~-250V,过渡层厚度100~500nm。
6.根据权利要求2所述的制备方法,其特征在于步骤②中所述的Ni栅层制备采用高纯Ni靶作为溅射靶材,氩气作为溅射气体,加偏压-150-300V用于沉积Ni栅层,沉积时间设为15-25分钟。
7.根据权利要求2所述的制备方法,其特征在于步骤③中涂层沉积条件如下:腔室气压保持在2× 10-1~4× 10-1Pa,银靶与铝锡铜合金靶靶电流分别设为1~4A、2~10A,脉冲偏压分别设为-100~-600V、-100~-1000V,沉积时间分别为5~10min、20~50min。
8.根据权利要求2所述的制备方法,其特征在于步骤③中所述的铝锡铜合金靶Al、Sn和Cu重量百分比分别为79%、20%和1%。
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