CN108265260A - 一种镍铬硼硅耐磨耐疲劳涂层的制备方法 - Google Patents

一种镍铬硼硅耐磨耐疲劳涂层的制备方法 Download PDF

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CN108265260A
CN108265260A CN201810193536.8A CN201810193536A CN108265260A CN 108265260 A CN108265260 A CN 108265260A CN 201810193536 A CN201810193536 A CN 201810193536A CN 108265260 A CN108265260 A CN 108265260A
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nickel chromium
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李国禄
李亚龙
董天顺
付彬国
郑晓东
李少凡
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Hebei University of Technology
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Abstract

本发明为一种镍铬硼硅耐磨耐疲劳涂层的制备方法。该方法包括以下步骤:第一步,配料:将组分的粉料按照以下配比混合,其中,Cr为15%~18%、B为2%~3%、Si为2%~4%、Mn为1.5%~2.5%、Re为铈(Ce)元素,含量为0.5%~1%,余量为Ni;第二步,制备镍铬硼硅涂层:将基体进行调质处理和喷砂预处理基体表面后,利用超音速等离子喷涂和重熔法制备镍铬硼硅涂层。本发明是得到的耐磨耐疲劳涂层,不仅涂层内部致密,孔隙率较低,而且涂层与基体结合紧密,磨损性能是喷涂层的4~5倍,重熔层疲劳寿命2×106次,喷涂层疲劳寿命1×103次。

Description

一种镍铬硼硅耐磨耐疲劳涂层的制备方法
技术领域
本发明涉及金属材料表面涂层技术领域,具体为一种镍铬硼硅(NiCrBSi)耐磨耐疲劳涂层的制备方法。本发明通过重熔方法使得涂层与基体合为一体,从而制得的涂层具有耐磨,耐疲劳优良的力学性能,可以应用于耐磨、耐疲劳具有很高要求的气缸内壁、柱塞、轧辊等。
背景技术
旋转类零部件广泛应用于机械矿工、石油化工、军事装备、水利工程等领域。这些零部件表面失效的形式主要有磨损和接触疲劳两种,而单个旋转类零部件,如轴承、齿轮、轧辊等的失效,往往会限制整个机组的性能,降低服役可靠性。另外,许多大型机械由于部分零部件表面的失效,导致了整机的报废,极大地浪费了资源。
在材料表面制备耐磨、耐疲劳的涂层是一种增加零件服役性能的便捷、高效的技术方法。而此时涂层作为零部件的保护或修复层,是工件磨损、接触疲劳失效产生的主要部位,决定了磨损和滚动接触状态下的服役性能。喷涂类零部件真实服役工况较为复杂,服役模式多为滚动与滑动两者共存。因此,零件的失效是由磨损和接触疲劳共同作用导致的。
因此,对涂层组分的选择以及对应的喷涂工艺成为了关键。镍铬硼硅(NiCrBSi)涂层因为其具有良好的耐磨损耐腐蚀耐疲劳等优异的性能而被广泛采用,该涂层通过组分中含有的Fe和C元素来实现涂层中形成硬质相等目的。但该方法形成的硬质相脆性大且使涂层的腐蚀性能和疲劳性能下降等不足,而且涂层在制备过程中需要用Ni/Al打底层,使工艺复杂,成本增加。
发明内容
本发明的目的是针对当前技术中存在的不足,提供一种镍铬硼硅(NiCrBSi)耐磨耐疲劳涂层的制备方法。该方法去除了普遍采用的Fe和C元素,调整了涂料组分的组成和配比,利用超音速等离子喷涂和重熔法制备镍铬硼硅(NiCrBSi)涂层。本发明提高了涂层与涂层之间的结合强度,增加了涂层的使用寿命。
本发明的技术方案为:
一种镍铬硼硅耐磨耐疲劳涂层的制备方法,包括以下步骤:
第一步,配料:
将组分的粉料按照以下配比混合,其中,Cr为15%~18%、B为2%~3%、Si为2%~4%、Mn为1.5%~2.5%、Re为铈(Ce)元素,含量为0.5%~1%,余量为Ni,所述的百分比均为质量百分比,粉末粒度为10~60μm;
第二步,制备镍铬硼硅(NiCrBSi)涂层
(1)首先将基体进行调质处理;
(2)喷砂预处理基体表面;
(3)对经过喷砂处理的基体进行等离子喷涂;其中,镍铬硼硅粉的送粉口位置距离喷嘴120~150mm;喷涂电压60V,喷涂电流500A,H2气流量为7~8L/min,送粉气体为Ar气,送粉气流量为60~80L/min;得到厚度为600~800微米镍铬硼硅涂层;
(4)对覆盖有镍铬硼硅涂层进行重熔;其中,镍铬硼硅粉的重熔电流为85~95A,弧长为2~3mm,氩气流量为10~15L/min,行走速度为150mm/min,步长为2.5~3mm,最终得到镍铬硼硅耐磨耐疲劳重熔层。
所述的Re具体为铈元素。
所述的基体为碳素钢或合金钢。
所述的调质处理步骤具体为:首先进行淬火,淬火温度为830~850℃,然后高温回火2~3小时,高温回火温度为550~650℃,调质处理后洛氏硬度达到22~34HRC。
所述的表面喷砂后基体表面粗糙度(Ra)为3.2~6.4μm。
本发明的有益效果为:
本发明自主设计的镍铬硼硅(NiCrBSi)粉末,具有优良的耐磨耐疲劳性能;与现有的镍铬硼硅(NiCrBSi)涂层相比较,本发明是由超音速等离子喷涂和重熔制备而得到的耐磨耐疲劳涂层,因此不仅涂层内部致密,孔隙率较低,而且涂层与基体结合紧密。与常规的等离子喷涂相比,优点具体体现在:
其界面的结合强度更高,界面结合强度为50MPa,镍铬硼硅(NiCrBSi)重熔层界面结合强度可高达200MPa;磨损性能是喷涂层的4~5倍,喷涂层疲劳寿命1×103次,测得重熔层疲劳寿命可达2×106次,可以延长涂层的使用寿命;
由于这种镍铬硼硅(NiCrBSi)耐磨耐疲劳涂层的制备方法不需要Ni/Al打底层,使得工艺喷涂工艺简单。
附图说明
图1为实施例1中的镍铬硼硅(NiCrBSi)喷涂层和重熔层的界面结合处SEM图片;其中,图1a为喷涂层界面结合处SEM图片,图1b为重熔层界面结合处SEM图片;
图2为实施例1中的镍铬硼硅(NiCrBSi)喷涂层和重熔层的界面结合处元素扩散曲线;其中,图2a为喷涂层界面结合处元素曲线,图2b为重熔层界面结合处元素扩散曲线;
图3为实施例1中的镍铬硼硅(NiCrBSi)喷涂层和重熔层的XRD;其中,图3a为喷涂层的XRD,图3b为重熔层的XRD;
图4为实施例1中的镍铬硼硅(NiCrBSi)喷涂层和重熔层的摩擦系数曲线和磨损体积;其中,图4a为喷涂层和重熔层的摩擦系数曲线,图4b为喷涂层和重熔层的磨损体积;
图5为实施例1中的镍铬硼硅(NiCrBSi)喷涂层的表面磨损形貌图片;
图6为实施例1中的镍铬硼硅(NiCrBSi)重熔层的表面磨损形貌图片。
具体实施方式
实施例1
本实施例1采用镍铬硼硅(NiCrBSi)粉末,选用粒径大小为10~60μm的镍铬硼硅(NiCrBSi)粉末。这种粉末成分如表1所示。
表1 NiCrBSi的化学成分(质量分数,%)
Ni、Cr、Mn纯度为99%,Ce、B、Si纯度为99.99%
其主要步骤包括:基体45钢喷砂处理→送入起弧离子气体→喷涂设备送电→等离子喷枪起弧→向等离子流中送入喷涂用金属自熔合金粉末对工件表面进行喷涂形成镍铬硼硅(NiCrBSi)合金层→重熔涂层得到镍铬硼硅(NiCrBSi)重熔层。本方法能有效地制备高结合强度、高耐磨性能的镍铬硼硅(NiCrBSi)涂层,制备涂层厚度为800μm。
镍铬硼硅(NiCrBSi)涂层的制备
第一步,镍铬硼硅(NiCrBSi)原料的配置
按照以上配比称量镍铬硼硅(NiCrBSi)粉料,备用。
第二步,镍铬硼硅(NiCrBSi)涂层的制备
(1)喷刚玉砂处理45钢的表面,使得基体表面粗糙度(Ra)为3.2~6.4μm。
(2)喷涂设备送电→送入等离子气体→喷枪起弧;
(3)向等离子焰内送粉,喷涂镍铬硼硅(NiCrBSi)自熔合金粉,制备800μm镍铬硼硅(NiCrBSi)涂层;
(4)对制备好的涂层进行重熔处理,使得涂层与基体的结合强度高。喷砂、喷涂和重熔参数如表2:
表2 喷砂、喷涂和重熔工艺参数
由图1对比可知涂层经过重熔后,重熔层的界面结合明显好于喷涂层;
由图2对比可知涂层经过重熔后,重熔层的界面处元素发生了扩散,对于界面结合是非常有利的;
由图3对比可知涂层经过重熔后,重熔层的物相比喷涂层更多,对重熔层的磨损性能是有利的;
由图4a可知重熔层的摩擦系数小并且稳定。由图4b可知,重熔层的磨损体积仅仅是喷涂层1/5,磨损体积明显减小。可见,重熔层的磨损性能优于喷涂层的。
由图5、图6对比可知涂层经过重熔后,重熔层的表面出现剥落和分层现象,重熔层表面出现犁沟现象,这就说明了重熔层的磨损性能优于喷涂层。
利用拉伸试验机测量镍铬硼硅(NiCrBSi)喷涂层的界面结合强度为50MPa,镍铬硼硅(NiCrBSi)重熔层界面结合强度可高达200MPa;
采用多功能摩擦磨损试验机,实验条件载荷30N,频率10HZ,进行了对喷涂试样和重熔试样进行耐磨性测试,最终得到重熔层的磨损性能是喷涂层的4~5倍;
采用一种新型疲劳试验机,实验条件为载荷1000N,转速为600r/min,测得喷涂层疲劳寿命1×103次,重熔层疲劳寿命可达2×106次。
实施例2
本实施例2采用镍铬硼硅(NiCrBSi)粉末,选用粒径大小为10~60μm的镍铬硼硅(NiCrBSi)粉末。改变涂层当中的Cr、B、Si、Mn的含量,这种粉末成分如表3所示。
表3 NiCrBSi的化学成分(质量分数,%)
其它步骤与实施例1中相同。得到的涂层性能接近于实施例1。
实施例3
本实施例3采用镍铬硼硅(NiCrBSi)粉末,选用粒径大小为10~60μm的镍铬硼硅(NiCrBSi)粉末。改变涂层当中的Cr、B、Si、Mn的含量,这种粉末成分如表4所示。
表4 NiCrBSi的化学成分(质量分数,%)
其它步骤与实施例1中相同。得到的涂层性能接近于实施例1。
实施例4
本实施例4采用镍铬硼硅(NiCrBSi)粉末,选用粒径大小为10~60μm的镍铬硼硅(NiCrBSi)粉末。此时粉末各个成分配比不变,但是喷涂和重熔的工艺参数改变。这种粉末成分如表1所示。
表1 NiCrBSi的化学成分(质量分数,%)
其主要步骤包括:基体45钢喷砂处理→送入起弧离子气体→喷涂设备送电→等离子喷枪起弧→向等离子流中送入喷涂用金属自熔合金粉末对工件表面进行喷涂形成镍铬硼硅(NiCrBSi)合金底层→重熔涂层得到镍铬硼硅(NiCrBSi)重熔层。本方法能有效地制备高结合强度、高耐磨性能的镍铬硼硅(NiCrBSi)涂层,制备涂层厚度为800μm。
镍铬硼硅(NiCrBSi)涂层的制备
第一步,镍铬硼硅(NiCrBSi)原料的配置
称量一定量的10~60μm镍铬硼硅(NiCrBSi),去除粗颗粒,备用。
第二步,镍铬硼硅(NiCrBSi)涂层的制备
(1)喷刚玉砂处理45钢的表面,露出新鲜的表面;
(2)喷涂设备送电→送入等离子气体→喷枪起弧;
(3)向等离子焰内送粉,喷涂镍铬硼硅(NiCrBSi)自熔合金粉,制备800μm镍铬硼硅(NiCrBSi)涂层;
(4)对制备好的涂层进行重熔处理,使得涂层与基体的结合强度高。喷砂、喷涂和重熔参数如表5:
表5 喷砂、喷涂和重熔工艺参数
得到的涂层性能接近于实施例1。
上述实施例说明,本发明得到镍铬硼硅(NiCrBSi)涂层性能优异。其中,实施例1中配比为Cr17%,B2.5%,Si3%,Mn2%,Ce0.5%,Ni75%,在喷涂距离为150mm、重熔电流为90A,行走速度为150mm/min,步长为3mm条件下,效果最佳。
本发明未尽事宜为公知技术。

Claims (4)

1.一种镍铬硼硅耐磨耐疲劳涂层的制备方法,其特征为该方法包括以下步骤:
第一步,配料:
将组分的粉料按照以下配比混合,其中,Cr为15%~18%、B为2%~3%、Si为2%~4%、Mn为1.5%~2.5%、Re为铈(Ce)元素,含量为0.5%~1%,余量为Ni,所述的百分比均为质量百分比,粉末粒度为10~60μm;
第二步,制备镍铬硼硅(NiCrBSi)涂层
(1)首先将基体进行调质处理;
(2) 喷砂预处理基体表面;
(3) 对经过喷砂处理的基体进行等离子喷涂;其中,镍铬硼硅粉的送粉口位置距离喷嘴120~150 mm;喷涂电压60V,喷涂电流500A,H2气流量为7~8 L/min,送粉气体为Ar气,送粉气流量为60~80 L/min;得到厚度为600~800微米镍铬硼硅涂层;
(4) 对覆盖有镍铬硼硅涂层进行重熔;其中,镍铬硼硅粉的重熔电流为85~95A,弧长为2~3mm,氩气流量为10~15L/min, 行走速度为150mm/min,步长为2.5~3mm,最终得到镍铬硼硅耐磨耐疲劳重熔层;
所述的Re具体为铈元素。
2.如权利要求1所述的镍铬硼硅耐磨耐疲劳涂层的制备方法,其特征为所述的基体为碳素钢或合金钢。
3.如权利要求1所述的镍铬硼硅耐磨耐疲劳涂层的制备方法,其特征为所述的调质处理步骤具体为:首先进行淬火,淬火温度为830~850℃,然后高温回火2~3小时,高温回火温度为550~650℃,调质处理后洛氏硬度达到22~34 HRC。
4.如权利要求1所述的镍铬硼硅耐磨耐疲劳涂层的制备方法,其特征为所述的表面喷砂后基体表面粗糙度(Ra)为3.2~6.4μm。
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