CN108588628A - 高速模切刀具表面梯度涂层及其制备工艺 - Google Patents

高速模切刀具表面梯度涂层及其制备工艺 Download PDF

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CN108588628A
CN108588628A CN201810412552.1A CN201810412552A CN108588628A CN 108588628 A CN108588628 A CN 108588628A CN 201810412552 A CN201810412552 A CN 201810412552A CN 108588628 A CN108588628 A CN 108588628A
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简明德
练国富
王人婷
杨宝华
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Fujian University of Technology
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Abstract

本发明提供一种高速模切刀具表面梯度涂层的制备工艺，对模切刀具表面进行预处理；采用等离子喷涂粉末预置方式，在刀具表面依次涂布基底层、第一过渡层、第二过渡层和面层；最后用电子束焊覆，得到梯度涂层；所述梯度涂层包括重量百分数的以下各组成：本发明的涂层致密均匀、孔隙较少、结合强度较高，能显着提高模切刀具表面的高硬度和耐磨性。

Description

高速模切刀具表面梯度涂层及其制备工艺
技术领域
本发明具体涉及一种高速模切刀具表面梯度涂层的制备工艺。
背景技术
目前，刀磨损主要包括磨蚀磨损、粘结磨损、扩散磨损和氧化磨损。在不同的切削条件下，加工不同材料的工件时，其磨损的主要原因可能是其中的一种或两种，总的来说切削温度较低时以磨蚀磨损为主，切削温度较高时以扩散磨损、氧化磨损为主。刀具破损主要是塑性变形破损和脆性破损(崩刃、碎裂、剥落、裂纹破损)。硬质合金刀具硬度高、脆性大，是粉末烧结体，组织可能不均匀和存在缺陷，在切削加工过程中，受到机械和热冲击容易产生脆性破损。在高速高效切削加工或加工耐高温材料时可以达到很高的切削温度，过高的温度会降低刀具材料的屈服强度，在切削力的作用下导致塑性变形而丧失切削能力。为了适应高速高效加工、非连续加工和恶劣条件加工的要求，刀具需要更高的韧性和高温强度。涂层刀具的性能来源于涂层和刀具基体性能的统一，在刀具表面涂覆高硬度的涂层，可减轻刀具的磨蚀磨损、粘结磨损和扩散磨损，增加刀具的耐用度。目前有人采用陶瓷材料在刀具表面制作涂层，陶瓷材料具有许多优异性能，但金属陶瓷涂层有易产生裂纹、与基体结合强度低、易发生脱落等问题。
发明内容
本发明要解决的技术问题之一，在于提供一种高速模切刀具表面梯度涂层的制备工艺。
本发明是这样实现的：一种高速模切刀具表面梯度涂层的制备工艺，包括以下步骤：
步骤1：对模切刀具表面进行预处理，清理掉模切刀具表面的灰尘、油垢和锈蚀；
步骤2：采用等离子喷涂粉末预置方式，在刀具表面依次涂布基底层、第一过渡层、第二过渡层和面层，得到预置涂层；
步骤3：对所述预置层进行电子束焊覆，得到梯度涂层。
进一步地，所述预置层包括以下重量百分数的各组分：
面层WC/NB合金粉末
第二过渡层20％NiCo合金粉末、80％WC/NB合金粉末
第一过渡层60％NiCo合金粉末、40％WC/NB合金粉末
基底层NiCo合金粉末。
进一步地，所述NiCo合金粉末包括重量比为7：3的Ni和Co。
进一步地，所述WC/NB合金粉末包括重量比为1：1的WC和NB。
进一步地，所述NiCo合金粉末和WC/NB合金粉末的粒径均为70～200μm。
进一步地，所述等离子喷涂的工艺参数如下：
加速电压25-100V，电流400～500A，机体预热温度200～400℃，喷枪速度10～100mm/s，粉末流量2～50g/s，保护气体流量1～30l/mm，工作距离2～20cm。
进一步地，所述电子束焊覆的工艺参数如下：
加速电压25-300kV，聚焦电流400-500mA，电子束流50-80mA，焊接速度10-30mm/s，扫描频率100-300Hz，扫描形状为圆形。
本发明要解决的技术问题之二，在于提供一种高速模切刀具表面梯度涂层。
本发明是这样实现的：一种高速模切刀具表面梯度涂层，包括基底层、第一过渡层、第二过渡层和面层，各层的具体组分如下，各组成均以重量百分数计：
优选地，所述NiCo合金粉末包括重量比为7：3的Ni和Co；所述WC/NB合金粉末包括重量比为1：1的WC和NB。
本发明具有如下优点：涂层致密均匀、孔隙较少、结合强度较高，能显着提高模切刀具表面的高硬度和耐磨性。
附图说明
下面参照附图结合实施例对本发明作进一步的说明。
图1为本发明中对照组样品的面层的SEM图。
图2为本发明中对照组样品的横剖面的SEM图。
图3为本发明高速模切刀具表面梯度涂层的面层的SEM图。
图4为本发明高速模切刀具表面梯度涂层的横剖面的SEM图。
具体实施方式
一种高速模切刀具表面梯度涂层的制备工艺，包括以下步骤：
步骤1：对模切刀具表面进行预处理，清理掉模切刀具表面的灰尘、油垢和锈蚀；
步骤2：采用等离子喷涂粉末预置方式，在刀具表面依次涂布基底层、第一过渡层、第二过渡层和面层，得到预置涂层；所述等离子喷涂的工艺参数如下：
加速电压25-100V，电流400～500A，机体预热温度200～400℃，喷枪速度10～100mm/s，粉末流量2～50g/s，保护气体流量1～30l/mm，工作距离2～20cm。
步骤3：对所述预置层进行电子束焊覆，得到梯度涂层；所述电子束焊覆的工艺参数如下：
加速电压25-300kV，聚焦电流400-500mA，电子束流50-80mA，焊接速度10-30mm/s，扫描频率100-300Hz，扫描形状为圆形。
所述预置层包括以下重量百分数的各组分：
所述NiCo合金粉末包括重量比为7：3的Ni和Co；所述WC/NB合金粉末包括重量比为1：1的WC(碳化钨)和NB(氮化硼)；所述NiCo合金粉末和WC/NB合金粉末的粒径均为70～200μm。
所述电子束焊覆等离子喷涂预置粉末工艺的类型为：多道轨迹搭接、多层轨迹层叠和封闭曲线轨迹对接，根据模切刀具表面梯度的厚度尺寸确定采用所述等离子喷涂工艺的类型中的一种或复数种。
其中，WC/NB合金粉末的制备方法：以纯度为99.99％的WC和NB为原料，按上述配比称量配料，将称量好的原料放入刚玉坩埚中研磨搅拌，制得复合合金粉末；然后将复合合金粉末置于干燥箱中，于100℃保温2h后冷却至室温，得到WC/NB合金粉末；
NiCo合金的制备方法：以纯度为99.99％的Ni和Co为原料，按上述配比称量，将称量好的原料放入刚玉坩埚中研磨搅拌，制得复合合金粉末；将复合合金粉末置于干燥箱中，于100℃保温2h后冷却至室温，即得。
图3为本发明高速模切刀具表面梯度涂层的面层的SEM图，图4为本发明高速模切刀具表面梯度涂层的横剖面的SEM图。图1为仅采用等离子喷涂粉末工艺得到的梯度涂层的面层的SEM图，图2为仅采用等离子喷涂粉末工艺得到的梯度涂层的横剖面的SEM图，图1和图2为对照组样品，其配方和涂层的各梯度设置与本发明的高速模切刀具表面梯度涂层相同，但是处理工艺不同，仅采用等离子喷涂粉末工艺，未使用电子束焊覆工艺。
从图1和图2中可以看到，对照组样品的涂层不致密不均匀、孔隙较多、结合强度较低，能提高模切刀具表面的高硬度，但不均匀和耐磨性较差，从图2看到，涂层上有很多气孔，粘结底层上还存在部分没熔融的颗粒。从图3和图4中可以看到，本发明的高速模切刀具表面梯度涂层致密均匀、孔隙较少、结合强度较高，能显著提高模切刀具表面的硬度和耐磨性。对照组样品和本发明的高速模切刀具表面梯度涂层的各性指标如下表：
本发明采用等离子喷涂工艺预置粉末方式，通过电子束焊覆工艺，熔覆后互熔呈冶金方式结合，强化模切刀具表面，熔覆层致密，无龟裂及气孔，涂层具有硬度高、抗压强度高及优异的耐磨损等性能，提高刀具表面抗耐磨性和强度韧性，解决了传统刀具表面在长期承受高温、高压及高速切削加工下磨损快速增加的问题。本发明将熔覆层设计为一种具有多层结构的高硬度和耐磨性梯度层，解决了金属陶瓷涂层易产生裂纹、结合强度较低、易发生脱落等问题。本发明方法制备的金属陶瓷梯度热障涂层高硬度和耐磨性效果良好，且和金属基体结合牢固，解决了目前金属陶瓷涂层难以成功应用以及在高速切削加工条件下容易崩刃及热裂纹导致涂层脱落失效的问题，因此，施加表面防护高硬度和耐磨性陶瓷涂层是改善高速模切刀具性能以及拓宽陶瓷材料应用范围的一条有效途径。

Claims (9)

1.一种高速模切刀具表面梯度涂层的制备工艺，其特征在于：包括以下步骤：
步骤1：对模切刀具表面进行预处理，清理掉模切刀具表面的灰尘、油垢和锈蚀；
步骤2：采用等离子喷涂粉末预置方式，在刀具表面依次涂布基底层、第一过渡层、第二过渡层和面层，得到预置涂层；
步骤3：对所述预置层进行电子束焊覆，得到梯度涂层。
2.根据权利要求1所述的高速模切刀具表面梯度涂层的制备工艺，其特征在于：所述预置层包括以下重量百分数的各组分：
3.根据权利要求2所述的高速模切刀具表面梯度涂层的制备工艺，其特征在于：所述NiCo合金粉末包括重量比为7：3的Ni和Co。
4.根据权利要求2所述的高速模切刀具表面梯度涂层的制备工艺，其特征在于：所述WC/NB合金粉末包括重量比为1：1的WC和NB。
5.根据权利要求2所述的高速模切刀具表面梯度涂层的制备工艺，其特征在于：所述NiCo合金粉末和WC/NB合金粉末的粒径均为70～200μm。
6.根据权利要求1所述的高速模切刀具表面梯度涂层的制备工艺，其特征在于：所述等离子喷涂的工艺参数如下：
加速电压25-100V，电流400～500A，机体预热温度200～400℃，喷枪速度10～100mm/s，粉末流量2～50g/s，保护气体流量1～30l/mm，工作距离2～20cm。
7.根据权利要求1所述的高速模切刀具表面梯度涂层的制备工艺，其特征在于：所述电子束焊覆的工艺参数如下：
加速电压25-300kV，聚焦电流400-500mA，电子束流50-80mA，焊接速度10-30mm/s，扫描频率100-300Hz，扫描形状为圆形。
8.一种高速模切刀具表面梯度涂层，其特征在于：包括基底层、第一过渡层、第二过渡层和面层，各层包括重量百分数的以下各组成：
9.根据权利要求8所述的高速模切刀具表面梯度涂层，其特征在于：所述NiCo合金粉末包括重量比为7：3的Ni和Co；所述WC/NB合金粉末包括重量比为1：1的WC和NB。
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